UK TechnBrosch

8/10/2019 UK TechnBrosch

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Kalzip Systems

Product information and specification


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Introduction

1a

Roofs and walls are the main factors

marking the external appearance

of buildings. The fundamental rule

applying to architectural design is:

form follows function.

As far as the realisation of an architec-

tural design is concerned the costs

for building, operating and maintaining

the building are crucial factors for

any decision maker. This is why high

quality building materials requiringonly little maintenance are more

economical in the long run. In addition,

the increasing shortage of resources

is raising awareness of the need for

energy saving construction methods.

The beneficial characteristics of

aluminium as a building material go

a long way towards meeting these

requirements.

Corus Bausysteme is the leading

manufacturer of profiled aluminium

sheets and in the form of Kalzip

offers a mature system for covering

both roofs and walls. This brochure

offers detailed product information

and demonstrates various fields of

application.

Planning specifications and dimensio-

ning tables are also included to provide

a comprehensive guide to the design

of Kalzip roofs and walls for a wide

range of building types. Fashion centre Almere (NL)

Architect: KOW Stedenbouw & Architectuur

Primary school Hille (D)

Architect: Brinkmeier, Kraus, Stanczus, Lbbecke

Offices Wrth Den Bosch (NL)

Architect: De Twee Snoeken

Roofs and walls

Exhibition hall 3, Frankfurt trade fair (D)

Architect: N icholas Grimshaw & Partners


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1b

1. Introduction Site

Contents 1bKalzip the economical all-round solution 1cLightweight building envelopes 1d

2. The construction system and its components

2.1 Dimensions of the profiled sheets 2a2.2 Clips and thermal barrier pads 2b2.3 Different finishes and colours 2e2.4 Accessories 2g2.5 Structural components for roof superstructures and safety devices 2i

3. Kalzip range of applications

Kalzip non ventilated roof on trapezoidal steel deck 3aKalzip non venti lated roof on purl in with trapezoidal sheets inner skin 3bKalzip non ventilated roof on timber rafters with visible timber lining 3bKalzip ventilated roof with common rafter insulation 3bKalzip DuoPlus 3cKalzip Duo 3c

Kalzip NatureRoof

3cKalzip AF 3dKalzip AF with Prodach-insulation on trapezoidal steel deck 3dKalzip AF with Prodach-insulation on timber rafters with timber lining 3eKalzip AF with common rafter insulation 3eKalzip AF on FOAMGLAS insulation 3e

4. General data and characteristics

4.1 Roof pitch 4a4.2 Minimum radii for crimp, smooth and on-site curving 4b4.2.3 Natural curving 4d4.3 Tapered shapes 4e4.4 Walkability/fall arrest system 4f4.5 Material/corrosion resistance 4g4.6 Ecological aspects 4h4.7 Approval by surveyor's office/design calculation 4i

4.8 Transport 4i4.9 Sheet thickness 4i

5. Design specifications

5.1 Thermal insulation 5a5.2 - 5.4 Moisture proof, Acoustic performance, fire/lightning protection 5b5.5 Constructional features 5c5.5.1 Rafter roof: Kalzip perpendicular to the trapezoidal steel deck 5c5.5.2 Purlin roof : Kalzip parallel to inner skin 5d5.5.3 Kalzip Duo and Kalzip DuoPlus 5e5.6 Connections 5g5.7 Thermal expansion 5h5.8 Fixed point 5h5.9 Ridge, eaves, gable ends 5h5.10 Skylights/smoke extractors 5i

5.11 Transverse joints 5j5.12 Substructures 5j5.13 Roof projections with cantilevers/clip bars 5j5.14 Instructions for the installation of cantilevers/clip bars 5j5.15 Roof projections without clip bars 5k5.16 Installation rules 5k

6. Dimensioning tables for Kalzip multi-span sheets

6.1 Thermal conductivity coefficents for TK 15 6a6.1.1 Thermal conductivity coefficents for Kalzip DuoPlus 6b6.2 Clip spacings 6c6.2.1 Rafter roof with aluminium clips 6c6.2.2 Rafter roof with compound clips 6d6.2.3 Purlin roof with aluminium clips 6e6.2.4 Purlin roof with compound clips 6f6.2.5 Kalzip ProDach with aluminium clips 6g

6.2.6 Stainless Steel with aluminium clips and compound clips 6h

Index


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Introduction

1c

Kalzip the economical all-round solution

Highly flexible and proven

For more than 35 years Kalzip has been

used in the design and construction of

buildings all over the world. Developed

upon the basic principles of the classic

handmade standing seam roof Kalzip

is perfectly suitable for roofs featuring a

very low pitch. Due to the great variety

of different designs and its attractive

appearance, the Kalzip system is the

first choice when it comes to combining

architectural design and function. The

proven modular Kalzip system offers a

great variety of different shapes and

includes all the accessories needed to

construct a beautiful building envelope.

Quality at its best

The standard version of the Kalzip

aluminium sheets is stucco-embossed

and plated on both sides with a specialalloy providing the surface with an

effective additional protection.

Designed to fit any architectural

style of roof or building

Kalzip offers economical solutions for

almost all requirements of advanced

architecture no matter what shape

or size the building may be. Despite

its low structural weight the Kalzip

roof is able to span large widths and

can achieve the most elegant, filigree

constructions. Kalzip profiled sheets

are perfectly suitable for the lining oflarge areas of facades and roofs.

Introducing colour into architectural

design

Kalzip is a highly diverse product and

is also available in a variety of colours.

A colour chart illustrates the range of

standard and special colours available.

Only top quality coatings are used on

a polyester, PVDF and CFTE base.

The colour range includes:

RAL colours

RAL special colours

SoftColor

TitanColor

AntGraffiti

This diverse range of options increases

the freedom of design even further

and guarantees the highest level of

resistance to weathering and corrosion.

Kalzip

colour products are the resultof the very latest surface refinement

techniques.

Innovative material combinations for

exclusive surfaces

In addition to the standard stucco-

embossed option, Kalzip also creates

exclusive architectural designs through

the use of innovative material combi-

nations and surface treatments. Kalzip

sheets in AluPlusPatina, AluPlusZinc,

AluPlusTitan and Stain less Steel

provide the perfect finishing touches,

adding individuality to elegant buildingdesign.

Innovation with international appeal:

Kalzip with zinc plated surface

This innovative product developed by

Corus Bausysteme combines two highly

approved materials: aluminium and zinc.

Zinc is a classic roofing material noted for

its timeless appearance. The intrinsic ad-

vantages of the Kalzip system combined

with the distinctive pre-aged zinc look

make this product an attractive option

for those applications where aesthetic

appearance or visual compatiblity with

surrounding structures is desired.

Kalzip AluPlusZinc offers unique

advantages:

Zinc patina with surface protection

Impressive, authentic visual appeal

Dynamic surface effects with

changing light conditions

Durability thanks to aluminium core

Kalzip AluPlusTitan

This combination of aluminium and titani-

um offers architects yet more interesting

design potential. The symbiosis of these

two materials each in themselves high

quality/high performance metals brings

quite unique advantages. Titanium not

only guarantees long-term resistance to

corrosion but also provides exceptionally

high mecha-nical and thermal stability.

For roofs and facades exposed to

particu-larly harsh conditions, Kalzip

AluPlusTitan will provide reliable andlong-lasting protection.


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Introduction

1d

Lightweight building envelopes

Kalzip AluPlusTitan offers the following

benefits:

Durable, exceptionally weather-

resistant combination

Outstanding mechanical and

thermal stability

Exclusive metallic appearance

Kalzip Stainless Steel

Where an architectural design is

characterised by the use of stain-less

steel both for decorative and functio-

nal purposes both on the interior and

the exterior of the structure; the effect

can now be extended to the facade and

roof with use of Kalzip Stainless Steel

profile sheets.

Available in a characteristic metal lic

surface, stainless steel provides a

striking visual effect whilst offeringoutstanding durability.

Kalzip Stainless Steel

product advantages:

Durable, weather-resistant

Striking metallic finish

Hi-tec facade appearance

Proven experience

To date more than 65 million square

metres of Kalzip elements have been

installed all over the world. This level

of expertise and the experience gained

over more than 30 years offers theoptimum guarantee to planners and

design engineers for this reason

Corus Bausysteme is the leading

producer of prefabricated aluminium

standing seam systems in the world.

Material Aluminium

light and strong

corrosion-resistant

durable

good workability

weldable

high compatibility in combination with

different materials

nonflammable

suitable as a part of air termination

network

nontoxic

recyclable

reusable

stable in value

valuable

Kalzip variants in shape

precurved

tapered

concave-convex

convex-curved

tapered-curved

smooth curved

crimped curved

Quick and precisely fitting assembly

Kalzip profiled sheets are joined onsite

by mechanical seaming. The roof is fixed

by means of special flanged-in clips,so that the roof surface is not penetrated

by any fixing elements. The clips transfer

the forces of aerodynamic pressure and

uplift to the supporting structure. The

special design of the clips and also of

the flanging allows unrestricted linear

expansion even across long Kalzip

profiled sheets.

Economical reconstruction

Kalzip profiled sheets allow a quick

and easy refurbishment of deckings,

pitch roofs and even steep roofs.

Due to the low weight of approximately

7 kg of the Kalzip elements, there is

in most cases no need either to remove

the existing roof or to reinforce the

supporting structure. The assembly

of the Kalzip system is a speedy

process and usually there is little or

no disruption to either the occupantsof the building or to its function.

Kalzip features and benefits

long lasting durability

high economy

ideal for efficient thermal insulation and

acoustic performance

compatible with any kind of roof

design and supporting structures

ideal for roof refurbishment bitumen,

foil or corrugated asbestos sheet roofs

requires only minimum maintenance

no painting required

comprehensive range of advancedaccessories


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The system and its components

2a

2. The system and its components

The standard version is stucco-embossed

and coated with a protective plating on

both sides. The minimum thickness ofthis plating is 4 per cent of the nominal

sheet thickness.

The nominal thickness is subject to the

tolerances specified by DIN EN 485-4.

As far as the lower tolerances areconcerned, only 50 per cent of the

specified values will be allowed.

The length tolerances are:

with sheet lengths up to 3 m:

+ 10 mm / 5 mmwith sheet lengths of more than 3 m:

+ 20 mm / 5mm.

2.1 Dimensions of the profiled sheets

*) Only in combination with accessible insulation materials or wooden timber lining.

Preferable thicknesses 0.9 to 1.2 mm.

**) recommended for facade cladding

Dimensions mm Thickness mm

1,2

1,0

0,9

0,8

1,2

1,0

0,9

0,8

1,2

1,0

0,9

0,8

1,2

1,0

0,9

0,8

1,2

1,0

0,9

0,8

1,2

1,0

0,9

0,8

1,2

1,0

0,9

0,8

1,2

1,0

0,90,8

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 *)

1,2

1,0

0,9

0,8

Kalzip AS 65/422 *)

There are many variations in shape

for instance

hyperbolically

curved

elliptically

curved

tapered-convex

curved

tapered

concave

curved

convex

curved

straight

65

65

65

65

65

65

50

50

333

429

305

333

400

500

333

434

65

422


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2b

2.2 Clips and thermal barrier pads

Kalzip aluminium clip

Special aluminium clips have to be

used for securing the Kalzip profiled

sheets to the substructure of the roof.

They are locked into the seam and will

be overlapped by the following Kalzip

sheet, so that the fixing elements are

hidden under the roofing.

This ensures that the roofing elements

need not be punctured for fastening

and therefore provide a perfect seal.

The clips allow the sheets to move

lengthwise sliding freely to accommodate

thermal expansion.

The clip head has a special shape

which has been designed to ease this

longitudinal expansion of the profiled

sheets enabling the use of very long

sheets.

Movement generally occurs from the

fixed point towards the eaves.

The movement of the sheets must not

be restricted by rigid joints with other

constructional elements.

The clips have to be directly fixedto the steel, aluminium or wooden

substructure by means of approved

fasteners.

When fixing the profiled sheets to concrete

substructures; steel, aluminium or wooden

spacers, firmly anchored in the concrete

must be used for mounting the profiled

Kalzip sheets.

When installing Kalzip sheets on roofs

with a very low pitch special care has

to be taken to see that the clips are

positioned at the correct height both at

the eaves and at the ridge of the roof in

order to avoid an inverse pitch.

At the ridge the head of the clip should

be positioned slightly higher and at the

eaves preferably slightly lower.

Kalzip zipping machineKalzip aluminium clip


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2d


Kalzip DuoPlus rotatable clips and

Kalzip DuoPlus rail, perforated

The DuoPlus rail along with the DuoPlus

clip create a total solution for secure

and convenient installation of the

mounting elements for Kalzip profile

sheets.

After install ing the insulant, the rails are

aligned according to the calculation and

mounted with the fixing elements of

SFS intec SD2-S16-6.0 x L in the

steel trapezoidal profile subshell.

Subsequently, the DuoPlus clips are

manually screwed in.

Although these remain adjustable, the

DuoPlus rail still offers a secure hold;

therefore DuoPlus can be adapted to

the individual circumstances depending

on the profile dimension and/or toleran-

ce. Therefore a customised and conve-

nient installation is guaranteed every

time.

Kalzip E 140/160

compound clips

According to the European heating

requirements, which has been an inte-

gral part of building regulations in

several countries, it is now obligatory

to take account of thermal bridges

when planning building projects.

The new Kalzip compound clip, which

is used to connect Kalzip aluminium

standing seam to the substructure ofthe roof, fulfils this requirement in an

exemplary manner, prevents thermal

bridges (see diagrams) and succeeds

in creating a system which is virtually

cold-bridge free therefore optimizing

the performance & efficiency of the

roof. All characteristics and functions

relating to the load carrying capacity

and attachment to structure or decking

are fulfilled and are documented in the

approval granted by the state con-

struction supervisors. The clip has a

PA structure which is reinforced witha steel core.

Kalzip E 140/160

compound clips

Kalzip DuoPlus rotatable clip

Kalzip DuoPlus rotatable clips in

Kalzip DuoPlus rail, perforated

Dimensions: 120 x 6000 length

Kalzip 50/ Kalzip 65/

clip type clip height (H) w3 w3

E 140 201 155 140

E 160 221 175 160

dimensions in mm

Kalzip 50/ Kalzip 65/

clip type clip height (H) w4 w4

D 60 116 75 60D 80 136 95 80

D 100 156 115 100

D 120 176 135 120

D 140 196 155 140

dimensions in mm

H = height of cl ip

w3 = distance between Kalzip bottom

and bottom edge of clip foot type E

w4 = distance between Kalzip bottom

and bottom edge of DuoPlus rail


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2f

Alumin ium strips with single-sided

coating are also given a coat of pro-

tective varnish on the reverse side.

In order to achieve a weather resistant

and colourfast coating, only high

quality stove enamels have been

used on a polyester, PVDF or CFTE

base.

The coil-coating process is monitored

in accordance with the standards of

the ECCA (European Coil-Coating

Association).

These standards relate to the following

important criteria: colour tone, degree

of lustre, thickness of finish) coating,

hardness of finish, bonding and consi-

stency of finish.

Long-duration tests are also carried

out, for example, acid salt spray tests,

QUV B tests, tests carried out in a

saturated atmosphere in the presence

of SO2 and outdoor exposure tests

conducted in a hostile environment.

Kalzip SoftColor

This coating has a soft textured

appearance, which reduces reflection

and provides the architectural design

with a distinctive appearance. Softcolor

contains a special polyester laquer

that is added during a separate pre-

treatment process.

Kalzip TitanColor

TitanColor features a special, unbrus-

hed aluminium base with a tough,

UV-resistant, single-layer polyurethane/

polyamide coating, which effectivelygives the appearance of high quality

titanium.

KalzipAntiGraffiti

The multi-layer AntiGraffiti system is

designed to remove graffiti using speci-

ally approved cleaning agents and the

associated cleaning technology. When

correctly used, the system will remove

all traces of graffiti. The colour structure

is not affected.

The AntiGraffiti coating provides a

combined colour structure of PVDF

and CTFE, and has similar properties

to Teflon.

Surface finishes and colours

In addition to the diverse range of

shape variants, Kalzip also offers a

wide range of colour and surface

finishes which provides optimum design

freedom and safety. Only high-quality

coatings on a PVDF or polyester base

are used for Kalzip sheets and these

coatings meet the extreme demands

of modern building technology.

The coloured coating is applied in the

quality-monitored coil coating procedurein accordance with the strict standards

of the ECCA (European Coil Coating

Association). A wide range of RAL

colours is also available as standard

for the fittings.

Coil-Coating

Liquid lacquer is rolled onto the

aluminium layer in a coil coating

process. These colour coated coils

are then used to roll-form the Kalzip

profiles. Coil coating is the most

economical, environmentally friendly

and safest way of fabricating largequantities of coated semi-finished

products of uniform quality.

The coating materials used for coil coa-

ted Kalzip profiled sheets offer outs-

tanding resistance to weathering and

also to the effects of high levels of air

pollution.

These excellent performance characte-

ristics ensure a long decorative life for

coil coated profiles. Profiled sheets in

standard colours shown in our colour

chart are kept in stock. Special colours

in small quantities have to be individu-

ally coated piece by piece either by

powder coating or by wet coating.

Protective foil

On request the whole surface or just

the flanges will be protected against

damage by a self-adhesive foil.

Metallic enamels

In the case of metallic enamel coating,

variations in colour may occur between

different production batches. For this

reason it is advisable to take care when

planning facades or visible roofs to

make sure that the profiled sheets areroll formed from the same batch of

material.

Anti-condensation and

anti-drum coatings

If required the profile sheets can also

be fitted with an anti-condensation or

anti-drum coating.

Continuous

coil coating

Roll forming


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Rib fillerseals the edge of the eaves

Drip angle (Al)

stiffens the bottom sheet and

makes the water drip into the gutter

indispensable for static reasons!

Compressible adhesive tape

prevents flow-back of rain

water

Kalzip vapour barrier

avoids air flow and

diffusion


2g

2.4 Accessories

gable bar verge Eaves

Transition sheet (Al)

for rising walls and gable ends


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2h

Drip angle Ridge

Reinforcing profile for

verge flashing (Al)

stiffens the flange

Gable end hook (Al)

secures gable end against storm

Ridge profile (Al)

protects the form filler against UV radiati-

on and reduces wind pressure

Form filler

ends flush with the ridge

Spacer section (Al)

compensates height differences

to the end plate

Gable end profile (Al)

provides fastening device for

joining sheets


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2i

2.5 Components for roof superstructuresand safety appliances

Photovoltaics Step


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2j

Seam clips Snow guard


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Kalzip range of applications

3a

3. Kalzip range of applications

Non-ventilated Kalzip roof

on a trapezoidal steel deck

Rw = ~ 35 dB (A)*

* varies depending on thickness and material qualities

Appl icat ion specific system build-upKalzip sheets can be used both for

ventilated and non ventilated roofs as

well as for any roof shape or down to

a minimum pitch of 1.5.

Furthermore it may be combined with

any kind of support or substructure.

The system depends on the special

requirements of the individual application.

The likely effects of snow, wind,

humidity and weathering are fully

taken into account. Kalzip can easily

be configured to provide the highestlevels of thermal insulation.

The thickness of the insulation can be

perfectly adapted to the individua lre-

quirements of the building.

In addition, the system offers advanceddetailed solutions for effective interior or

exterior draining of the roof which means

a high degree of reliabilty throughout the

long serviceable life of the roof.

Insulated roof systems are the norm

The main applications for Kalzip roof

systems are insulated roof structures

supported by trapezoidal steel, timber

linings, purlins or concrete elements.

Because of the generally very long pro-

filed sheets and the low pitch of most

of the roofs a non ventilated roof is

recommended.

Chemically neutral, fibrous insulating

materials as specified by e.g. the

German DIN 18 165 are recommended

as suitable thermal insulation.

The insulation is laid into position andis then compressed to its required

final thickness when are installed the

profiled Kalzip sheets on top. There

should be no cavity between the

Kalzip sheets and the insulation.

A vapour barrier must be incorporated.

Properly installed it provides the

required air tightness.

Ventilated roofs are also an option.

The sound reduction values of the

standard roof are subsequentlydescribed. Further improvements

can be achieved by including

additional layers.

Non-ventilated Kalzip roof on a

trapezoidal steel deck

This very economical roof system is

used both for industrial and residential

buildings. In order to make sure that

there are no air cavities under the

Kalzip roof skin, compressible thermal

insulation is used. Incorporated within

the roof system the insulation material

is compressed by approx. 20 mm. The

loading on the top skin is not transferred

to the inner skin as an evenly distributed

load but rather at set points via the

secret fixing clips. The design roof load

must be increased by 15 per cent when

dimensioning the trapezoidal steel

sheets. The clips must be staggered

on the inner sheet to make sure that

the load is evenly distributed across allcorrugations of the inner sheet.


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3b

Non-ventilated Kalzip

roof on purlinswith trapezoidal inner sheet

If the roof is supported on purlins, the

inner sheet has to be oriented parallel

to the top layer. If the module of the

inner sheet does not correspond with

the Kalzip elements a top hat section

must be installed to support the clips.

If the Kalzip sheets can span the exi-

sting spacing of the purlins, the top

hat sections will be positioned on top

of the purlins. By this way the inner

sheet carries only the weight of the

insulation. For larger purlin spans

additional top hat sections are required.In this instance, part of the load needs

to be transferred by the inner sheet.

Non-ventilated Kalzip roof on timber

rafters with visible timber lining

In residential buildings the roof system

is frequently built-up using wooden

rafters with visible timber lining. This

is advantageous, because:

1. there is a clear separation between

the trades of carpenters, roofers etc.

2. a continuous flat vapour barrier

can be installed.

The clips can only be fixed directly to a

timber lining that has a minimum thick-

ness of 30 mm. If the lining is too thin

an additional wooden purlin connected

to the rafters must be mounted on top

of the lining.

Ventilated Kalzip roof with thermal

insulation of the rafter levelWith roofs featuring a structure as shown

on the left it is quite often impossible to

design the roof as a non-ventilated version

because the distances are too great bet-

ween the vapour barrier and the roof skin.

Therefore such a roof must be designed

as a ventilated roof. Consequently perfect

functioning of the vapour barrier is a pre-

requisite condition. Sufficient ventilation

is essential for efficient dispersal of any

condensation that might occur. If there

are any risks of wind driven snow it may

be necessary to install a foil barrier to

prevent snow from coming into contactwith the insulating material.

Non-ventilated Kalzip roof on timber rafters

with visible timber lining

Rw = ~ 38 dB (A)*

Ventilated Ka lzip

roof with thermalinsulation of the rafter level

Rw = ~ 35 dB (A)*


Non-ventilated Kalzip roof

on purlins with trapezoidal inner sheet

Rw = ~ 35 dB (A)*


20/52


3c

Kalzip DuoPlus

The Kalzip DuoPlus system combines

the advantages of rigid insulation with

the constructional possibilities offered by

the conventional Kalzip roofing system.

The special design is almost cold-bridge

free and has excellent sound absorption

properties. An aluminium rail is placed

on the 100 mm thick rigid thermal insu-

lation and is fixed onto the substructure

through the insulation. Special clips are

inserted in the rail and are adjusted to

suit the respective conditions. Connection

of the individual clips to the rail is not

necessary. The patented and type-testedsystem consists of rigid thermal insu-

lation, DuoPlus rail, DuoPlus clip and

connecting elements to secure the

DuoPlus rail, the compressible heat in-

sulation and the Kalzip profiles sheets.

Kalzip Duo

If there are no specific sound insulation

requirements then the Kalzip Duo

system can be used, whereby a full

layer of rigid thermal insulation is not

necessary. The base for the Kalzip

DuoPlus is simply provided by rigid

insulation strips with a width of 24 cm

and a thickness of 10 cm. The resulting

spaces are filled with soft heat insula-

tion or low-priced rigid insulating

material.

In the case of Kalzip DuoPlus, rigid

thermal insulation only needs to be

used in those areas specified by the

statistical requirements. The rigid

thermal insulation is replaced by a

layer of soft insulation in all areas

where no reduction in snow loads

is required.

Kalzip NatureRoof

All roof designs described above can be

transformed into a Kalzip NatureRoof

providing that the design requirements

are taken into consideration and Kalzip

65/333 is being used.

Kalzip NatureRoof comprises an efficient

draining mat to control the integral water

management and a special substratesupporting a vegetation layer for exten-

sive landscaping with sedum plants (see

special brochure Kalzip NatureRoof).

Kalzip NatureRoof

Kalzip Duo

Rw = ~ 41 dB (A)*

Kalzip DuoPlus

Rw = ~ 43 dB (A)*


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3d


Kalzip AF

Kalzip

AFprofiled aluminium sheets

are especially designed for installation

above rigid support layers. Under

the trade mark Prodach insulating

system Rockwool offers an accessible,

compression-proof, water repellent

mineral wool insulating board featuring

a special fixing system. Kalzip AF

is available in sheet lengths up to

50 m (longer lengths are available

on request).

The level ribless profile provides a

smooth and attractive appearance.

The AF system offers outstandingthermal as well as acoustic properties.

Kalzip AF profiled aluminium sheets

are not only used in combination withthe Prodach-insulation system but

may also be used with FOAMGLAS

insulation and timber lining.

The twin layer Prorock insulating

board: the ideal base for Kalzip AF

non combustible

very efficient thermal insulation

and acoustic properties

dimensionally stable

vibration dampening

open for diffusion

high accessibility during

installation and maintenance safe absorption of pressure

and suction loads

AssemblyThe corrosion-proof and weather resi-

stant Kalzip AF aluminium external

skin is fixed with clips in the usual way.

However, and this is the distinctive

feature of the Prodach insulation

system, rather than being fixed directly

to the substructure the skin is fixed

instead to special U-rails embedded in

the insulation material.

The stainless steel system fasteners

connecting the U-rails to the substruc-

ture of the roof penetrate the insulation

material only locally. This almost entirelyeliminates the effect of cold/heat and

sound bridging.

Kalzip AF with Prodach-insulation

on trapezoidal steel deck

Rw = ~ 42 dB (A)*


on trapezoidal steel deck

In order to meet increased demands

for sound reduction and to reduce

cold/heat bridges it is advisable to

install the Prodach Insulation System.

Fixing rails are embedded in the top-

side of the insulation material and

fixed to the trapezoidal steel deck.



22/52

Kalzip AF

on FOAMGLAS

insulationKalzip AF can also be installed on the

proven FOAMGLAS insulation. There

are different ways of building up the

roof structure.

The method with claw plates shown in

the drawing on the left does not require

any mechanical connection between the

Kalzip sheets and the supporting layer

thus making it completely free of thermal

bridges.

Kalzip AF with the insulation layer

at rafter level

This structure is comparable to tradi-

tional standing seam systems. It is

frequently used in order to minimise

the overall height of the roof structure.

If there is an air gap under the timber

lining adequate ventilation is essential.

With this in mind, we recommend filling

the total height of the rafters with insu-

lating material for efficient performance.

A vapour barrier beneath the thermal

insulation is also of critical importance.


3e


on timber rafters with formwork

Rw = ~ 45 dB (A)*

Kalzip AF with the insulation

layer at rafter level

Kalzip AF

on FOAMGLAS insulation

Kalzip

AFwith Prodach-insulationon timber rafters with formwork

With this type of roof a 30 mm timber

lining, which remains visible, serves as

a supporting element. This structure

has proved to be ideal for residential

buildings and other buildings of similar

use. The potential extends from public

buildings to multi-purpose halls and

sports-arenas. The rails are invisibly

fixed to the rafters. There are no visible

joints or fasteners.



23/52

General data and characteristics

4a

4. General data and characteristics

Minimum roof pitch

without horizontal joints 1.5

respectively 2.6 per cent

- running from the eaves in one length

- all joints are welded

- factory welded soakers welded into

the roofing skin

sheets with horizontal

joints 2.9 (5%)

- with sealed horizontal joints

- soakers sealed into the roof skin

- Factory welded soakers sealed intothe roof skin

Roof pitch in degrees ... in per cent

45 100%

83,9%

70,0%

57,8%

46,6%

36,4%

26,8%

17,5%

10,5%5,2%

40

35

30

25

20

15

10

63

1,5 2,6%

4.1 Roof pitch

The Kalzip system consisting of self

supporting aluminium elements was

specially developed for roofs with

pitches down to 1.5 degrees or 2.6 per

cent together with long sheet lengths.

Owing to the attractive appearance of

the modular system, architects often

use this system for visible steep roofs

and increasingly for wall claddings.

Continous falling gradient required

All parts of the roof must have a conti-

nous downward gradient towards thedraining system.

Anomalies

The specification limiting the minimum

roof slope is not applicable along the

ridge area where roof elements run

without joints from eaves to eaves

over the ridge. Wherever the roof is

penetrated, for instance by light domes

etc., the requirement for minimum roof

pitch may also be by-passed under the

following conditions:

Completely welded soakers are used

Soakers or any other elements pene-trating the roof are tightly welded into

the external skin in order to achieve a

leakproof connection

The local rules and regulations must

be strictly observed for any welding

carried out on aluminium elements

and profiled sheets on the roof.


24/52

Minimum length of straight end piecesRi min l1 min l2

[mm] [mm] [mm]

up to 1000 150 150

1000-2000 75 350

over 2000 0 0

4.2 Minimum radii for crimp-,smooth- and on site curving

Exacting design calls for creative

and detailed solutions. Today curved

corners or arched roofs can be easily

achieved by advanced industrial

prefabrication. They provide modern

industrial architecture with a high level

of functional and aesthetic quality

combined with future oriented

perspectives. The minimum radii for

smooth curving of Kalzip elements

are specified on the following page.

4.2.1 Kalzip Convex

Factory crimp-curved

Cover width (BB) nominal width:

50/333 Ri = 450 mm

50/429 Ri = 450 mm

65/305 Ri = 400 mm

65/333 Ri = 400 mm

65/400 Ri = 400 mm

AF 65/333 Ri = 450 mm

AF 65/434 Ri = 450 mm

AS 65/422 Ri = 450 mm

Installation width (DB):

Installation width is the actual width

of the assembled sheets. If the clips

are pre-installed the installation width

must be increased. (Installation width

= cover width (BB) + 3 mm) respectively

BB + 3 mm for pre-installed clips.

Profiled sheets lengths:

Straight lengths 500 mm min.

to 10.000 mm* max. Depending on

radius and transportation limitations

* greater lengths on request

Surface finish:

stucco-embossed

AluPlusPatina

Colour coated with protective foil

AluPlusZinc with protective foil

AluPlusTitan

Stainless Steel

Please take note when ordering:

Please specify the required dimen-

sions in accordance to the sketch.

Transportation:

Max. loading height 2.40 m.

For any queries, please contactour logistics department.


4b


25/52


4c

4.2.2 Kalzip

smooth curved in factory, aluminium

General information

Kalzip AF:

Smooth-curved Kalzip AF profile sheets

can show signs of increased buckling

in the base plate. As it is impossible

for technical production to prevent

this buckling, it will not be accepted

as grounds for complaint. When the

optical characteristics of a building are

of increased importance, then smooth-

curved Kalzip AS profile sheets should

be used instead.

Standard:

Constant radius with a short (approx.

400 mm) straight segment at the

beginning and the end of the profile

sheet. Any radii below the standard

minimum as well as multiple radii and/or

straight elements in one Kalzip sheet

must be agreed with our technical

department in Koblenz. It is unavoidable

that intermediate radii occur in the

transition area of different radii as well

as between curved and straight sectors.

Clips must not be located in these areas.

Limit:

Tolerance limits. Only after consultation

with our technical department in

Koblenz. Special measures are necessary

in order to reach the tolerance limits.

Finish:

stucco-embossed

AluPlusPatina

coated material with protection foil

AluPlusZinc with protection foil

Anti-condensation coating on request AluPlusTitan

Stainless Steel

Installation width:

For pre-installed clips:

cover width + 3 mm

successive installation of clips:

cover width + 0 to + 3 mm

Length of profiled sheet:

Minimum length 1.5 m. Shorter lengths

on request. The final overall length

depends on the individual radii and

possibility of transport. Minimum length

of segment per radius = 500 mm.

Transportation:

Maximum loading height 2.4 m. It

might be necessary to coordinate

details of transportation with our

logistics department.

Validity:

With the publication of this issue any

previously published data becomes

invalid. Any deviations from the limiting

values quoted above depend on the

constant further development and can

be only granted after consultation with

our technical department.

Convex Minimum curving radii in m

Sheet thickness 0,8 mm 0,8 mm 0,9 mm 0,9 mm 1,0 mm 1,0 mm 1,2 mm 1,2 mm

Kalzip Standard Limit Standard Limit Standard Limit Standard Limit

65 / ... 8 6 7 5 3 1,5 2,5 2

50 / ... 10 8 7 5 2 1,3 2 1,3

AF 65 / ... 12 10 10 8 6 3,5 5 3

AS 65 / ... 30 25 20 16 14 10 10 8

Concave

Sheet thickness 0,8 mm 0,8 mm 0,9 mm 0,9 mm 1,0 mm 1,0 mm 1,2 mm 1,2 mm

Kalzip Standard Limit Standard Limit Standard Limit Standard Limit

65 / ... 18 16 16 14 12 10 16 1450 / ... 16 12 12 10 9 7 8 6

AF 65 / ... 17 15 16 14 12 10 10 7

AS 65 / ... 30 25 20 16 18 14 14 10

Curved and tapered: For Kalzip 65/260-480. Please check with our technical department in Koblenz/Germany.

Kalzip smooth curved in factory, stainless steel Minimum curving radii in m

Kalzip 65/400, Sheet thickness 0,6 mm

Convex Concave Tapered convex Tapered concave

1.4301 6 10 10 10

1.4401 6 10 10 10


26/52

4.2.3 Kalzip

supplied in straight form, curved to radius during installation

The values given are not standard values. They do not serve as a replacement for project specific consultations.

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

General information

Naturally curved:

The profile sheets are supplied in

straight form and are curved by hand to

the respective radii during installation.

Cover width:

Depending on the radius, the nominal

width (construction width) must be increa-

sed to the cover width (installed width).

Support spacing:

When the supporting spacings are too large

the supports will appear as polygon lines.

Accessibi lity :

Due to the risk of buckling, access to

the sheets must not be gained without

load spreading equipment.

Finish:

stucco-embossed

AluPlusPatina

coated material with protection foil AluPlusZinc with protection foil

Anti-condensation coating on request

without protection foil on request

AluPlusTitan

Stainless Steel

Appearance:

The minimum radii outlined above reflect

current experiences. As it is necessary to

curve the profile sheets to the respective

radius, buckling cannot be ruled out.

Installation tip:

It is advisable to provide a support on

the ridge over which the profile sheets

can be curved. Installation should takeplace from the direction of the non-

covered side.

Validity:

All prior issues become inval id wi th

the publication of this document. Any

deviations from the limiting values

outlined above can only be approved

following consultation with our technical

department within the context of conti-

nuous product development.


4d

Convex Minimum curving radii in m

Kalzip Sheet thickness Radii max. Supporting space Increase in

Sheet thickness (mm) (m) (m) construction width (mm)*

65/305 0,8 36 1,5 +3

65/333 0,9 40 1,6 +3

65/400 1,0 48 1,8 +3

1,2 55 2,0 +3

50/333 0,8 37 1,5 +2

50/429 0,9 37 1,5 +2

1,0 40 1,5 +2

1,2 43 1,8 +2AS 65/422 0,8 50 1,5 +2

0,9 55 1,5 +2

1,0 60 1,5 +2

1,2 70 1,8 +2

Concave

Kalzip Sheet thickness Radii max. Supporting space Increase in

Sheet thickness (mm) (m) (m) construction width (mm)*

65/305 0,8 40 1,5 +3

65/333 0,9 45 1,6 +3

65/400 1,0 50 1,8 +3

1,2 60 2,0 +3

50/333 0,8 38 1,5 +2

50/429 0,9 40 1,6 +2

1,0 42 1,8 +2

1,2 45 2,0 +2

AS 65/422 0,8 50 1,5 +2

0,9 55 1,6 +2

1,0 60 1,8 +2

1,2 70 2,0 +2

* Not when sliding clips are used


27/52


4e

max.

min.

For construction widths exceeding500 mm only with additional supportand clips spaced at 1.0 m max.

Self-supporting upto a constructionwidth of 500 mm

Sheet layout example with joints

Joint executed as a welded seam

or step joint

4.3 Tapered shapes

Tapered Kalzip profile sheets have

become increasingly significant for

roofing applications as they can

be formed into a diverse range of

shapes. A roof can offer more than

just protection: i t can give the building

architectural perfection. For a perfect

construction some fundamental

aspects have to be observed. The

cover widths are between 230 and

740 mm.

Tapered Kalzip sheets have to be installed

on the roof by following the precise instruc-

tions 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. Larger toleran-

ces of the building may call for a newpartition of the areas to be covered. The

tables on the following page apply to a

cover width of up to 500 mm. With larger

widths the accessibility is limited.

The bottom sheet must be supported

by an insulation material of sufficient

compressive strength. Load distributing

walkways must be provided. 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 delieverd with

a standard extra length of 50 mm on

both ends and have to be cut to the

required actual length on site.

Finish:

stucco-embossed

AluPlusPatina

coated material

with protection foil

AluPlusZinc

with protection foil

AluPlusTitan Stainless Steel

The full surface is always covered with

foil. Anti-condensation coating only

available subsequently in the spraying

process. Aquasine coating is not possible.

Kalzip 65/ and 50/ Kalzip AF

Minimum construction width 230 mm 170 mm

Maximum width 740 mm1 740 mm1

Minimum length 1500 mm 1500 mm

Maximum length Dependent on transport Dependent on transport

Plate thicknesses 0,80 1,20 mm 0,80 1,20 mmCurved and tapered Possible for construction widths of 230 620 mm.

Only following approval from the technical

department in Koblenz.1 Applies only to stucco-embossed and colour-coated Ka lzip profile sheets.

Other material combinations are available on request.


28/52

4.4 Accessibility/fall arrest systems

For maintenance and cleaning Kalzip

sheets are accessible both during and

after installation without any load

distributing measures. As far as the

installation is concerned this will only

be valid if the profiled sheets are zipped

on at least one side. The following table

specifies the critical spans up to which

the profiled sheets are accessible with-

out any additional measures.

It is advisable to install walkways leading

to any units requiring regular mainten-ance or operational elements such as

daylight units, chimneys or heating

plants. When exceeding the critical

span, load distributing elements such

as wooden planks of a minium cross

section of 4 x 24 cm and a maximum

length of 3 m have to be installed

length or crosswise over the Kalzip

sheets.

In situations where no rigid thermal

insulation has been installed along the

ridge and eaves areas, the sheets in

these parts of the roof should not directly

be walked on. The reason being that

this might lead to deformation of the

flat area of the Kalzip sheet resulting in

a possible accumulation of rain water.

The last free sheets along the gable

end, single unzipped sheets and of

course translucent panels should not

be walked on.

During the installation of the roof any

areas which are frequently walked on or

used for the transport of materials should

be protected by temporary walkways,

which should be secured with seam clips

to prevent them from sliding down.

The Kalzip fall arrest system is a reliable

solution to secure walkways on the

finished roof. It consists of a stainless

steel rope which is fastened to perma-

nently fixed Kalzip roof anchors and

coupled to the safety harness by meansof a guide link. Project related planning

is carried out by Corus Bausysteme.


4f

Access following installation1

Seamed Kalzip profile sheets with supporting spacings up to the following dimensions are accessible without the use of load

spreading equipment.

Sheet thickness 65/305 65/333 65/400 50/333 50/429 AF 65/333* AF 65/434* AS 65/422*

t/mm lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m

0,8 2,90 2,90 3,00 2,50 2,50 2,90 3,50 3,50

0,9 3,35 3,35 3,40 2,65 2,60 3,20 3,55 3,55

1,0 3,80 3,80 3,80 2,80 2,70 3,50 3,60 3,60

1,2 3,80 3,80 3,80 3,00 2,90 3,50 3,60 3,60

1

Applies only to stucco-embossed and colour-coated Ka lzip

profile sheets.Other material combinations are available on request.

2 On grounds of final visual appearance, this information is only applicable when rigid thermal insulation is used.


29/52


4g

4.5 Material/corrosion resistance

An essential advantage of Kalzip

sheets is the lightness of the aluminium

material. Seawater proof alloys are used

as basic materials.

Protection by natural oxidation

Due to the natural formation of a protective

coat of oxide, Kalzip profiled aluminium

sheets are reliably protected against

corrosion when exposed to normal

weathering by maritime, continental

and industrial atmospheres. With plated

material this effect is even greater, asthe plating acts as a sacrificial anode

protecting the core material against

corrosion for many years. If, however,

the roof is exposed to a highly aggressive

atmosphere occurring in the immediate

vicinity of the building, for instance,

industrial premises such as copper

plants emitting high levels of aggressive

chemicals; appropriate resin coatings

with a minimum thickness of 25 will

provide lasting protection.

Contact corrosion

In contact with other unprotected metals

and under the influence of humidity,

aluminium produces an electrochemical

contact element, which may lead to

corrosion. The annexed table is the result

of extensive tests and investigations

carried out in Sweden and proves that

the Kalzip alloy can be combined with

most of the common materials used for

building purposes without the risk of

corrosion.

Protective measures to avoid contactcorrosion are

colour coating

neutralizing the steel surfaces for

instance by hot-dip galvanizing

interrupting the metallic conductive

contact by applying a primer or by

incorporating a suitable separation

layer

Installation in combination with

different materials

Steel:

Direct contact between the profiledaluminium sheets and unprotected steel

parts of the substructure must be avoided

due to the likely risk of contact corrosion.

There are a number of different protective

measures such as plastic foils, interme-

diate layers coated with bituminous,

zinc chromate or chlorinated rubber

paint or the galvanizing of the contact

areas of steel parts.

Timber:Timber parts in contact with Kalzip

should be dry. For the protection of timber

rafters and other wooden construction

elements in direct contact with aluminium

structures only compatible (f.i. oil

based) wood preservatives must be

used. They must not belong to the

group of naphtalenic chlorines and

must not contain any copper, mercury

salts or fluorine compounds.

Concrete and mortar:

Any direct contact with concrete and

mortar must be avoided.

Compatibility with other materials

Atmospheres

Combination of materials rural town/industrial maritime

zinc safe safe safe

stainless steel safe safe safe*

lead safe safe critical

hot-dip galvanized steel safe safe safe

unprotected steel critical critical critical

copper critical critical critical

* Only applies to stainless steel self-tapping screws and blind rivets, if a formation of an electrolyte

can be excluded.


30/52

4.6 Ecological aspects

It is a fact, that aluminium, just like any

other material cannot be produced with-

out the use of energy and emissions

resulting from the production process.

However, the industry has achieved

considerable progress in the field of

advanced production technologies

and the considerable investment in

environmental protection is now having

a notable effect. Today the energy

required for the electrolytic production

of aluminium amounts only 60 per cent

of the energy required 40 years ago.

Special advantage:

high strenghts/low weight

Due to the fairly high strength of Kalzip

profiled sheets they can fulfill important

structural demands such as enclosing

and sealing a building off, protecting it

from the weather thereby retaining its

value with relatively low material expen-

diture. This saving of resources meets

one of the most important ecological

demands in a truly exemplary way.

100 per cent recyclable after a long

environmentally friendly service life

Throughout the long service life there

is nearly no erosion of the aluminium

surface at all. At the end of use, the

structural elements can be recycled.

Aluminium is especially suitable for

this procedure, because it is available

in large and relatively homogenous

quantities. Only 5 per cent of the ener-

gy initially used for the production of

alumimium is required for remelting.

And, in additon, this low energy recyclingprocess can be repeated again and

again without impairing the intrinsic

qualities of the material. Aluminium

structures have a constantly increasing

proportion of recycled aluminium.

Today virtually all the scrap aluminium

resulting from construction industry is

recycled.


4h


31/52


4i

4.7 Official approvals/

design calculation

The use of Kalzip roof elements is sub-

ject to the offic ial building regulations.

Correspondingly the stabilty and fitness

for use must be proved in each and

every individual case. The basis for

any design calculation is always the

No. Z-14.1-181 issued by the Institute

for Building Technology. Kalzip is

officially approved by many European

Building authorities.

For further details please contact ourexport department. The appendix of the

licensing agreement contains tables

concerning standard details, value cha-

racteristic figures for the proof of the

stability and fitness for use.

For frequently recurring applications you

will find load-span-tables, from which the

maximum spans under practical wind-

and snow loads can be extracted. So

the proof required by law can be easily

provided at any time.

4.8 Transport

When designing unusual special roof

shapes (for instance, long profiled

sheets with small curving radii) thefeasablity of transportation has to be

checked with our logistics department.

For sheets of extreme length it is essen-

tial to allow for the time required to gain

permits from the local road authorities.

4.9 Sheet thicknesses

According to the licensing agreement

issued by the building authorities the

minimum thickness for Kalzip profiled

sheets is t = 0.7 mm. Although these

sheets are accessible both during as

well as after their installation for main-

tenance and cleaning without the need

of load distributing measures, it is

however not advisable to use sheets

of this thickness because of the risk of

denting resulting from people walking

on the sheets during installation. Foraesthetic reasons it is advisable to

choose a minimum sheet thickness

of 1 mm on any visible areas.


32/52

5. Design specifications

Determination of the U-value of a roof build-up

The thickness of the installed thermal insulation is predetermined.

The diagram above indicates actual thermal conductivity of the roof

structure depending on the number of clips used.

Example based on the use of 15 mm thick thermal barrier pads (red):

Thermal insulation compressed to a final thickness of 120 mm results in a

calculated thermal coefficient (k-value) of 0.315 W/m2K.

Number of clips installed per m 2 1.5 nos/m2.

According to the d iagram the actual k-value is 0,342 W/m2K.

Example based on the use of Kalzip E140 plastic compound (green):

In the case of the Type E clip, the number of clips/m 2 is not important.

The reading is always taken on the 0-axis (0 clips/m 2). Heat insulation

compressed to a thickness of 140 mm gives a value of 0,272 W/m 2K.

Determination of the required insulation thickness

in order to achieve a specific U-value

A cer tain k-value is specified. The final thickness of the compressed

thermal insulation depends on the number of clips used.

Example with 15 mm thick heat thermal barrier pads (red):

Required k-value: 0.32 W/m2K

Number of clips used: 2.0 per m 2

Minimum thickness of insulation to be installed 136 mm.

Supply thickness chosen: 150 mm.

Example based on Kalzip E140 compound clips (green):

Required U-value = 0,28 W/m2K.

Minimum thickness of heat insulation to be installed: (reading)

approx. 135 mm. Thickness chosen: 140 mm in compressed condition.

Thermal transmission coefficient is dependent on the insulation thickness and the number of clips (reading example)

5.1 Thermal insulation

The main applications of the Kalzip

system are non-ventilated, insulated

roof structures on trapezoidal decks,

timber lining or concrete. Where there

are low roof pitchs which lead to

insufficient ventilation velocity, it is not

advisable to construct a ventilated roof.

The thermal insulation is supplied with

approx. 20 mm excess thickness and

will be compressed by the inner surface

of the Kalzip sheets to the required

final thickness during installation. The

clips securing the Kalzip sheets to the

substructure penetrate the thermal

insulation and have the effect of heat

bridges. This effect increases the heat

transmission coefficient (k-value).

Influential parameters are among others

the thickness of the insulation and the

number of clips used. This phenomenon

has been experimentally investigated

with insulation materials of the thermal

conductivity group 040. The diagrams

below are derived from the results of

this study.They illustrate the dependen-

ce of the heat transmission coefficient

from the number of clips per area unit

in the specific range for normal con-

structional applications.

Design specifications

5a


33/52


5b

5.2 Moisture proof

For insulated roofs and walls it is es-

sential to provide sufficient protection

against condensation in each and every

case. In this context vapour diffusion

(e.g. according to DIN 4108-3) as well

as air flows must be considered.

Superficial formation of condensate

on structural components

If the minimum values of heat transition

resistance according to DIN 4108-2

are observed, a verification of the

protection against condensation innon air-conditioned rooms such as

residential premises and offices is

generally not required providing that

these rooms are adequately heated

and ventilated according to the normal

standards.

In special cases for instance with

permanent high humidity levels it is

necessary to calculate the required

heat transition resistance in relation to

the actual internal climatic conditions.

Formation of condensate inside

multi-layer constructions

A vapour barrier must be installed

in order to prevent vapour from

penetrating from humid internal

rooms into the roof construction.

In wall structures vapour barriers

are generally not necessary.

To prevent humid internal air from

diffusing into the roofing system,

an airtight barrier must be installed,

which is fully sealed at all joints to

the adjacent structures, as requiredby the Energy Saving Directive. A

professionally fitted Kalzip vapour

barrier meets these requirements.

5.3 Sound absorption

Highly efficient sound absorption can

be easily achieved with Kalzip roofs

by constructive measures such as

incorporating additional layers, while

all benefits of the lightweight construc-

tions remain unaffected.

5.4 Fire/lightning protection

Fire protection

The demands concerning fire protection

of building materials and structural parts

etc. are specified in the local buildingregulations. According to DIN 4102-4

aluminium alloys are classified in cate-

gory A1 (not inflammable) without

special verification. Kalzip profiled

sheets even with organic coatings on

both sides and with class B insulation

layers underneath are classified as

resistant against flash-over and radiating

heat without any special verification

(hard roof covering).

Lightning protection

With a minimum thickness of 0.7 mm

the Kalzip aluminium roof and wall

cladding is classified by ENV 61024-1

as a natural part of the air termination

network when it is not necessary to

avoid the melting of sheets at the point

of impact or the ignition of inflammable

material under the covering surface.

Colour coating or 1 mm thick coats of

bitumen or 0.5 mm thick coats of PVC

are not considered as an isolation in

the sense of lightning protection.The

seaming at the flange is considered as

a electrical conductor, as the distanceof the sheets is less than 1mm. This

allows in many cases to avoid extensive

lightning protection measures.

Building Official

mater ial class classif icat ion

A non- inflammable

materials

A 1

A 2

B inflammable

materials

B 1 flame resistant

materials

B 2 normal flammabiltymaterials

B 3 highly Inflammable

materials

Fire- Duration of

resistance- fire resistance

class in minutes

F 30 -> 30

F 60 -> 60

F 90 -> 90

F 120 -> 120

F 180 -> 180

Kalzip roof

Lightning protection with Kalzip

Kalzip wall

Break

Earthing

Connection

roof/wall

Connection to

the earthing


34/52

Positioning scheme 1

Alumin ium clips/Compound clips



d = clip distance d = clip distance

Distances not to scale

5.5 Roof systems

5.5.1 Rafter roof:

Kalzip sheets perpendicular

to the trapezoidal steel deck

A supporting trapezoidal deck forming

the substructure of the roof spans from

rafter to rafter running parallel to the

eaves. The clips are either fixed directly

to the top corrugations of the deck or

indirectly by means of spacers. The

fixing points are visible underneath the

supporting steel deck. The clips are

diagonally distributed on top of the steeldeck, so that all corrugations of the

deck are load bearing. The clips must

be located following a special pattern

to ensure even load distribution on the

trapezoidal steel deck both in the case

of positive loads (due to snow) or nega-

tive loads (due to wind or aerodynamic

suction).

A continous row of clips is to be

fitted along the ridge and the eaves.

In between the clips are arranged

diagonally. Distances depend

on the design loads, the Kalzip sheet

widths, the pitch of the ribs and the

support spacing of the trapezoidal

sheet underneath.

The number and positioning of the

clips as well as the joining elements

are indicated in the assembly plan.

Depending on the likely loads it

may be necessary to halve the

spacing of the clips at the corners

and along the edges of the roof.

(See dimension tables)

Kalzip perpendicular on timber lining

(see upper diagram on page 3d)

5.5.1 Applies accordingly.

The clips are fixed directly to the

timber lining. The clips must be

positioned on the timber lining in

accordance with positioning diagram

1 or 2. If the clips are to be positioned

next to each other, then the timber

board and its attachment to the

substructure must be statically verified.

A carpentry attachment is not sufficient.


5c


35/52


5d




d = clip distance = purlin spacing d = clip distance

Roof areas:For buildings up to a total width (a) of

30 m and closed walls the width of the

corner and edge areas can be reduced

to 2 m. Buildings with a total width

exceeding 30 m the width of the corner

and edge areas is one eight (a/8) of the

total width of the building. (reference:

DIN 1055 T-4 tables 11 and 12).

5.5.2 The purlin roof:

Kalzip parallel to inner skin

The clips are fixed to the purlins or the

inner skin spans parallel to the Kalzip

sheet. Depending on the design of the

bottom skin, an intermediate section

may be necessary with double skin

roofs. The clips are normally positioned

on top of each purlin.

In re-roofing projects with narrow spaced

purlins it may be sufficient to position

the clips on every second purlin only.

With regard to an even load distribution

the clips are alternately arranged on the

purlins.

A design calculation is required.

Please consult our local representative

for design calculations.


Aluminium clips/Compound clips

Clip positions with closer spaced purlins (re-roofing)

Central area

Edge area

Corner area

max. 2,0 m to a = 30 m

Roof areas


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5e

5.5.3 Kalzip DuoPlus

and Kalzip DuoPlus

The Kalzip DuoPlus system always

consists of a full layer of 10 cm thick,

rigid thermal insulation, the DuoPlus

rail, the DuoPlus clip and the special

screws for fixing the rail onto the sub-

structure.

In contrast to this, the Kalzip Duo

system does not contain a full layer of

rigid thermal insulation. Strips of rigid

insulation with a width of 24 cm and a

thickness of 10 cm are simply insertedunder the Kalzip DuoPlus rails.

In the case of both systems, only the

named components will be permitted.

The arrangement of the rails and the

number of connecting elements are

outlined in the installation plan. The

DuoPlus clips are secured against

shifting by means of a plastic strip

that is attached in the factory.

First of all the rigid thermal insulation is

placed on the substructure. A full layer

of rigid insulation is used in the case

of Kalzip DuoPlus. Strips of rigid

insulation are used in the Kalzip Duo

system and any spaces between these

strips are filled with soft thermal insula-

tion or rigid insulation. The DuoPlus

rails are then arranged on the thermal

insulation in accordance with the

installation plan and are connected to

the substructure through the thermal

insulation.

The special DuoPlus clips are inserted

into the rail and rotated so that they arepositioned parallel to the seam direction

(minimum rotation angle = 45o).


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5f

The first row of clips, at the start ofthe installation surface (gable end), is

aligned precisely and fixed into the rail

by means of a screw through the base

of the clip. The remaining clips are

inserted into the rail and positioned

parallel to the Kalzip seam direction.

Every tenth row of clips is fixed with a

screw to prevent shifting.

The final row of clips, at the end of the

installation surface (gable end), is also

secured into the rail by means of a screw

through the clip base. The compressible

thermal insulation is then placed on topand pressed over the clips. The Kalzip

roof structure can then be installed as

normal.

The DuoPlus rail must be long enough

to cover at least two ribs of the trape-

zoidal deck and can be secured in it.

If this is not possible, then a section of

adequate length can be installed next

to the first row (see positioning diagram

for rafter roof and purlin roof).

Positioning scheme Kalzip

Rafter roofThe system requires that the DuoPlus rails are positioned at an angle of 45 .

Positioning scheme Kalzip purlin roof

The system requires that the DuoPlus rails are positioned parallel to the purlins.

Ridge

Railspacing

Eav

es

Rafter spacing Rafter spacing

DuoPlusrail

DuoPlusclip

45

Eaves

Rafter spacing Rafter spacing

Stainlesssteelscrew

Gableend

Clip

spacing

Panelspacing=

Clip

spacingR

idge

DuoPlusrail

Stainlesssteelscrew

Gableend


DuoPlusclip


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5g

The following fixing elements are recommended for the Kalzip system:

5.6 Connections

The Kalzip profiled sheets are fixed to

the substructure by means of extruded

aluminium clips. The bottom flange of

each clip is fitted with several bore holes.

Depending on the substructure special

fixing elements are used. Note: The

number of the fixing elements required

depends on the static requirements and

must be determined in each and every

case. Both in the edge and corner areas

of roofs as well as in the edge areas of

walls the fixing elements must be

dimensioned for increased wind suction.

The anchoring depth for screws in timber

substructures is to be calculated according

to DIN 1055 T2. The minimum anchoring

depth (sg) for screws in timber is four times

their diameter (4xds). The maximum

anchoring depth is 12xds. (ds = nominal

diameter of the screw). The fixing ele-

ments must be made either of aluminium

or stainless steel. The use of galvanized

carbon steel is excluded. Regarding the

correct application of the fixing elements,

the manufacturers recommendations

must be strictly observed.

Fixing position Appropriate fixing element**

Eaves angle to Kalzip Blind rivet 5 x 12

Ridge closure to seam Blind rivet 5 x 8

Spacer to seam Blind rivet 5 x 8

Ridge flashing to ridge closure Sealing blind rivet 4,8 x 9,6

Gable end channel to seam Blind rivet 5 x 8

Gable end hook to clip Self-tapping screw A 6,5 x 19

Fixed point: Clip to Kalzip seam Blind rivet 5 x 12 K9

Sealing joints Kalzip or soaker connection Sealing blind rivet 4,8 x 9,6

Top-hat section to trapezoidal sheet Bulb tite rivet 5 W*

Kalzip DuoPlus rotatable clip/Kalzip DuoPlus rail SD2 - S16 - 6,0 x 127

Clip on steel substructure

Clip with and without TK5 Bulb tite rivet 5 W*

to steel purlin t = 0,75 - 3,0 mm

Clip with and without TK5 or TK 15, Screw SFS SDK2*

or E clip respectively, to steel purlin t = 0,75 - 1 ,2 mm

Clip with and without TK5 or TK 15, Screw SFS SDK3*

or E clip respectively, to steel purlin t = 1,20 - 3 ,2 mm

Clip with and without TK5 or TK 15 Self-drilling screw 5,5 x L*

to steel purlin t = 1,5 - 2,0 mm Self-tapping screw 6,5 x L*

Clip with and without TK5 or TK 15 Self-drilling screw 5,5 x L*

to steel purlin t = 2,0 - 6,0 mm Self-tapping screw 6,25 x L*Clip with and without TK5 or TK 15 Self-tapping screw 6,25 x L*

to steel purlin t > 6 mm

Clip on timber substructure

Clip to timber purlin 2 Drilling screws 6,5 x L*

2 Screws A 6,5 x L (vorbohren)

Clip to timber lining Timber materials from 24 mm onwards: 2 Drilling screws SFS

SDK2 timber lining, 30 mm: 2 Screws A 6,5 x L (pre-drilled)

E- Clip to timber lining Timber materials from 24 mm onwards: 2 Drilling screws SFS

SDK2 timber lining, 30 mm: 2 Screws A 6,5 x L (pre-drilled)

All dimensions in mm

** In the case of blind rivets and sealed blind rivets, aluminium is used for the sleeve and stainless steel for the mandrel.

Stainless Steel is used for the screws. Please observe the information and specifications of the rivet and screw manufacturers.

The application and the structural conditions should be taken into consideration when selecting attachments and material.

* The length of the rivet or screw must be adapted to the required gripping length.


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5i

5.10 Skylights/Smoke/heat extractors

Corus Bausysteme supply complete

units in a variety of dimensions for

the installation of skylights, smoke

extractors, etc. These units consist

of a steel soaker with skylight and

a multipart, welded aluminium

connecting frame.

For arched roofs, special curved soakers

are required. The soakers can either

be welded or sealed (in the case of a

minimum roof pitch of 2.9) into the

roofing. Welding is the recommendedoption.

The right drawing shows a welded

connecting frame. For more detailed

information on installation please refer

to the assembly instructions which are

supplied with the skylights.

Skylights and smoke extractors must

not be walked on. As these must be

regularly accessed for servicing and

maintenance work, it is recommended

that the area around the opening is

reinforced with rigid thermal insulation.

Welded connecting frame

Thermal separation

Connecting frame

Soaker

frame

Covering frame

Rigid thermal insulation

Static exchange Trapezoidal profile

Kalzip

Vapour barr ier


41/52

5j


5.12 Substructures

Kalzip roofs can be installed on all

kinds of substructures. With metal or

timber substructures the clips are directly

fixed to the substructure. With metal

substructures contact corrosion must

be taken into consideration. As, with

the exception of Kalzip AF, there is

no direct contact between Kalzip and

the substructure, the thermal barrier

pads under the clips provide sufficient

separation.

On concrete substructures a suitablyanchored steel section or timber batten

(minimum thickness 40 mm) must be in-

serted.

5.13 Cantilevers/clip bars

If the roof is to protrude at the eaves,

additional substructures are dispensable

providing that the clips are installed as

clip bars. They are fixed to the roof with

appropriate length and serve as support

for the Kalzip sheets as well as a fixing

for the gutter (see table of roof projec-

tions and 5.14).

5.14 Installation rules

Individual verification is required in

each and every case. Roof projections

are not accessible. The ends of the

Kalzip sheets must be joined with an

eaves angle. The length of the clip bars

is outlined in the diagram opposite.

5.11 Transverse joints

It is not always possible to produce

the required Kalzip sheet length in one

element. In most cases the length of

the sheets is determined by transport

limitations, so that the sheets must be

joined by overlapping. Especially with

arched roofs the maximum loading

height of the trucks must be observed.

Obviously, the requirements for abso-

lute tightness of the overlapping joints

are very high. Therefore it is necessary

to take great care when making over-

lapping joints. Overlaps are positionedon top of the support, if the joint is

located at the fixed point. Otherwise

the profiled sheets have to be joined

directly next to the support. Joints can

be either welded or sealed.

Welded 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.

1

3

42

Direction of assembly

1

2

Clip bar spacings

Roof projection (a) Kalzip 65/... 50/...

over last

support 305 333 400 422 429

1 m every every every every every

(0,5 m)* 2nd sheet 2nd sheet 2nd sheet sheet sheet

1,5 m every every every impossible impossible

(0,9 m)* sheet sheet sheet

Depending on the construction width of the Kalzip sheets and the desired roof projection the clip bars

must be fitted to each or every second seam. The table is applicable for a snow load of 0.75 kN/m2.

*Values apply to clip type L10.


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43/52

Kalzip Dimensioning tables

5j

6. Kalzip Dimensioning tables

6.1 Thermal conductivity coefficients

with 15 mm thick thermal barrier pads (black) and E-Clip (green)

For example reading please refer to page 5a.


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6a

6.1.1 Thermal conductivity coefficientsKalzip DuoPlus roof (WLG 040)

0,3

0,25

0,150 0,5 1 1,5 2 2,5 3 3,5 4

160

Thickness WD

[mm]

180

200

220

240

0,2

Clips per m2

U-value[W/(m2K)]


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6b

Line Kalzip Sheet Snow load Wind suction

type thickness kN/m2

t/mm building heights

0 - 8 m 8 - 20 m 20 - 100 m

0,75 1,00 1,25 RB* EB* RB* EB* RB* EB*

1 65/305 0,80 2,50 2,40 2,00 2,20 1,65 2,00 1,10 1,45 0,80

2 65/333 0,90 3,15 2,50 2,00 2,80 1,80 2,00 1,10 1,45 0,80

3 1,00 3,30 2,50 2,10 3,15 1,80 2,00 1,10 1,45 0,804 1,20 3,30 2,50 2,20 3,30 1,80 2,00 1,10 1,45 0,80

5

6 65/400 0,80 2,50 2,30 2,00 2,00 1,50 1,70 0,95 1,20 0,70

7 0,90 2,95 2,50 2,00 2,60 1,50 1,70 0,95 1,20 0,70

8 1,00 3,30 2,50 2,00 2,75 1,50 1,70 0,95 1,20 0,70

9 1,20 3,30 2,50 2,00 2,75 1,50 1,70 0,95 1,20 0,70

10

11 50/333 0,80 2,10 1,90 1,80 2,20 1,65 2,00 1,15 1,45 0,80

12 0,90 2,60 2,00 2,00 2,80 1,80 2,00 1,15 1,45 0,80

13 1,00 2,80 2,20 2,00 3,15 1,80 2,05 1,15 1,45 0,80

14 1,20 3,00 2,30 2,00 3,30 1,80 2,05 1,15 1,45 0,80

15

16 50/429 0,80 2,00 1,80 1,70 1,85 1,40 1,55 0,85 1,02 0,65

17 0,90 2,45 1,90 2,00 2,40 1,40 1,55 0,85 1,02 0,65

18 1,00 2,70 2,10 2,00 2,55 1,40 1,55 0,85 1,02 0,65

19 1,20 2,90 2,20 2,00 2,55 1,40 1,55 0,85 1,02 0,65

20

21 NatureRoof 0,80 1,80 1,55 1,40 2,20 1,65 2,00 1,15 1,45 0,80

22 65/333 0,90 1,80 1,55 1,40 2,80 1,80 2,00 1,15 1,45 0,80

23 1,00 1,80 1,55 1,40 3,15 1,80 2,05 1,15 1,45 0,80

24 1,20 1,80 1,55 1,40 3,30 1,80 2,05 1,15 1,45 0,80

Supporting width in [m]

Separate design calculation for substructure is required. In the values under snow loads the wind suction forces under normal

conditions are already taken into consideration.

The clip spacing must not exceed half the supporting width of the supporting trapezoidal steel deck.

Area of app lication: enclosed buildings, roofs w ithout roof l ights and additiona l loads that need to be accepted by the roof skin.

* EB = corner area / * RB = edge area

The table does not apply to Kalzip DuoPlus .

6.2 Clip spacings

The values given are not standard values. They do not serve as a replacement for project specific consultations.

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

Clip fixing: directly to trapezoidal steel deck tmin = 0.75 mm. Two fixing elements per clip

Self-tapping screw SFS SDK or bulb tite rivet


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6c

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

Clip fixing: directly to trapezoidal steel deck tmin = 0.75 mm. Two fixing elements per clip

(Self-tapping screw SFS SDK).

Line Kalzip Sheet Snow load1) Wind suction

type thickness kN/m2

t/mm building heights

0 - 8 m 8 - 20 m 20 - 100 m

0,75 1,00 1,25 RB* EB* RB* EB* RB* EB*

1 65/333 0,80 2,50 2,40 2,00 2,20 1,65 2,00 1,10 1,45 0,80

2 65/305 0,90 3,15 2,50 2,00 2,80 1,80 2,00 1,10 1,45 0,80

3 1,00 3,30 2,50 2,10 3,15 1,80 2,00 1,10 1,45 0,804 1,20 3,30 2,50 2,20 3,30 1,80 2,00 1,10 1,45 0,80

5

6 65/400 0,80 2,50 2,30 1,85 2,00 1,50 1,70 0,95 1,20 0,70

7 0,90 2,95 2,30 1,85 2,60 1,50 1,70 0,95 1,20 0,70

8 1,00 3,00 2,30 1,85 2,75 1,50 1,70 0,95 1,20 0,70

9 1,20 3,00 2,30 1,85 2,75 1,50 1,70 0,95 1,20 0,70

10

11 50/333 0,80 2,10 1,90 1,80 2,20 1,55 1,75 0,95 1,25 0,70

12 0,90 2,60 2,00 2,00 2,80 1,80 2,00 1,10 1,45 0,80

13 1,00 2,80 2,20 2,00 3,15 1,80 2,00 1,10 1,45 0,80

14 1,20 3,00 2,30 2,00 3,30 1,80 2,05 1,15 1,45 0,80

15

16 50/429 0,80 2,00 1,80 1,70 1,85 1,20 1,35 0,75 0,95 0,55

17 0,90 2,45 1,90 1,70 2,40 1,40 1,55 0,85 1,00 0,65

18 1,00 2,70 2,10 1,70 2,55 1,40 1,55 0,85 1,00 0,65

19 1,20 2,80 2,15 1,70 2,55 1,40 1,55 0,85 1,00 0,65

20

21 NatureRoof 0,80 1,80 1,55 1,35 2,20 1,65 2,00 1,10 1,45 0,80

22 65/333 0,90 1,80 1,55 1,35 2,80 1,80 2,00 1,10 1,45 0,80

23 1,00 1,80 1,55 1,35 3,15 1,80 2,00 1,10 1,45 0,80

24 1,20 1,80 1,55 1,35 3,30 1,80 2,05 1,15 1,45 0,80

Supporting width in [m]

* EB = corner area / * RB = edge area

1) The supporting widths for snow load also apply to the wind suction load in the normal range for building heights 100 m.


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Kalzip Dimensioning tab

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