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Product information and specification
Page 1.Kalzip aluminium roof and façade systems 4
2. Kalzip innovations
3. The system and its components 3.1 Dimensions of the profiled sheets 3.2 Aluminium clip and thermal barrier pads 3.3 Different finishes and colours 3.4 Accessories 3.5 Components for roof superstructures and safety appliances
6 7 10 12 14
4. Kalzip range of applications Non-ventilated Kalzip roof on a trapezoidal steel deck Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet Non-ventilated Kalzip roof on timber rafters with visible timber lining Kalzip DuoPlus® 100 and Kalzip Duo® 100 on a concrete substructure Kalzip DuoPlus 100 Kalzip Duo 100 Kalzip NatureRoof® Kalzip FOAMGLAS® System as a standard and combined solution Kalzip AF Kalzip AF with ProDach-insulation on trapezoidal steel deck Kalzip AF with ProDach-insulation on timber rafters with formwork Kalzip AF with the insulation layer at rafter level Kalzip AF on FOAMGLAS® insulation Kalzip Solar Power Systems Kalzip AluPlusSolar Kalzip SolarClad
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5. General data and characteristics 5.1 Roof pitch 5.2 Minimum radii for crimp-, smooth- and on site curving 5.2.1 Kalzip Convex Factory crimp-curved 5.2.2 Kalzip smooth curved in factory, aluminium 5.2.3 Kalzip supplied in straight form, curved to radius during installation (naturally curved) 5.3 Tapered shapes 5.4 Kalzip XT free-form profiled sheets Kalzip type 65 /… / 1.0 mm 5.5 Accessibility/fall arrest systems 5.6 Material/corrosion resistance 5.7 Sustainable construction 5.8 Official approvals/design calculations 5.9 Transport 5.10 Sheet thickness
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Page 6. Design specifications 6.1 Moisture proof 6.2 Ice barriers 6.3 Sound absorption 6.4 Fire protection 6.5 Lightning protection using Kalzip aluminium profiled sheet envelopes 6.6 Roof systems 6.6.1 Rafter roof: Kalzip sheets perpendicular to the trapezoidal steel deck 6.6.2 Kalzip perpendicular on timber lining 6.6.3 The purlin roof: Kalzip parallel to inner skin 6.6.4 Kalzip DuoPlus 100 and Kalzip Duo 100 6.6.5 Kalzip FOAMGLAS® System 6.7 Connections 6.8 Thermal expansion 6.9 Design of fixed points Kalzip aluminium clip / Kalzip composite clip 6.10 Ridge, eaves, gable ends 6.11 Skylights/Smoke/heat extractors 6.12 Transverse joints 6.13 Substructures 6.14 Cantilevers/clip bars 6.15 Installation rules 6.16 Roof projections without clip bars 6.17 Installation instructions for long profiled sheets
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7. Kalzip dimensioning tables 7.1 Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035 7.2 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040) 7.3 Clip spacings 7.3.1 Rafter roof (multi-span sheets) with composite clips 7.3.2 Purlin roof (multi-span sheets) with composite clips 7.3.3 Kalzip ProDach (adjacent) with aluminium clips 7.3.4 Kalzip AluPlusSolar
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1. Kalzip aluminium roof and façade systems
Kalzip aluminium building envelopes have been setting trends worldwide in contemporary building culture for more than 40 years. The almost unlimited variety of forms and the most diverse intelligent additional functions continually provide architects and planners with impetus for sophisticated architecture More than 80 million square metres of installed Kalzip profiled sheets speak for themselves. Whether for industrial buildings, exhibition halls, airports, public amenities such as sports facilities or the renovation of existing buildings – the outstanding material characteristics and flexibility of aluminium allow an inexhaustible variety of forms and offer durable secure building protection. As a leading manufacturer of aluminium profiled sheets, Kalzip offers with this brochure comprehensive technical information on Kalzip aluminium roof and façade systems. Detailed data on the system provide you with an in-depth insight into the mode of functioning of this unique building product. The economical all-in-one solution In addition to information on the various material surfaces, colours and refinements, you will also find valuable design tips as well as dimensioning tables to support you during the planning phase. Technical drawings and installation examples illustrate the function of the Kalzip system with components and accessories, e.g. clips, on different roof structures. Additive systems for new buildings or existing building fabric are described using examples. The Kalzip Solar Systems offer creative freedom with maximum efficiency for the integration of photovoltaic systems.
Karlovy Vary Airport, Czech Republic Architect: Petr Parolek
2. Kalzip innovations
This page features our new Kalzip products. Kalzip XT – for a new architectural era Kalzip XT profiles enable for the first time the implementation of computer-generated forms and design principles. Evolutionary animations, visualised in 3D objects, give birth to new architectural-organic forms – the fusion of biology and architecture. The advantages in summary: • Horizontal and vertical profiled sheets in convex and concave forms are possible • New variations in the design of geometries thanks to XT free-form profiled sheets • Small bending radii guarantee the roofing of unusual building forms Further information can be found on page 7 and page 28. The integrated Kalzip renovation concept – the durable roof renovation Emergency repairs to the roofs of old existing buildings are connected with risks, since expensive consequential damage can still occur despite that and the costs can rise dramatically when ‘permanent building sites’ are the result. The Kalzip renovation concept for old roofs takes a new, sustainable path: the sloping roof with a roof cladding made of aluminium profiled sheets and adaptation to the latest thermal insulation standards. The advantages of the Kalzip renovation concept: • Maximum corrosion resistance due to salt water-resistant aluminium base material • Permanent, virtually maintenance-free building protection • High creative freedom due to individual roof forms • No interruption of use during renovation • Economical, fast installation The thermal bridge-optimised composite clip for Kalzip profiled sheets for the achievement of EnEV 2009-compliant roof structures The Kalzip composite clip consists of a stable steel core, which is encased by a glass-fibre reinforced plastic. Advantages of the product: • Minimum heat transfer enables a roof structure that is virtually free of thermal bridges • Safe load dissipation into the substructure • In order to achieve the desired thermal insulation thicknesses in EnEV 2009-compliant Kalzip roof structures and to compensate for height tolerances, the new Kalzip composite clips can be combined with spacer pads Further information can be found on page 8.
Sports arena in Porec (HR)
Gymnasium of the Vallendar comprehensive school (D) before renovation
Kalzip composite clip
BMW Head Office in Leipzig (D), winner of the German Architecture Prize 2005. Architect: Zaha Hadid with Patrik Schumacher
Gymnasium of the Vallendar comprehensive school (D) after renovation Architect: Guido Fries Architekten
Kalzip AluPlusSolar installation with composite clips
8 concave curved Kalzip 50/429 429 50 convex curved Kalzip 65/305 305 65 tapered-convex curved Kalzip 65/333 333 65 Kalzip 65/400 400 tapered 65 Kalzip 65/500 **) 500 65 tapered concave curved Kalzip AF 65/333 *) 333 65 Kalzip AF 65/434 *) 434 65 Kalzip AS 65/422 *) 422 65 elliptically curved *) Only in combination with accessible insulation materials or wooden timber lining.9 0.8 1.0 0.2 1.0 0.2 1. Preferable thicknesses 0.8 1.8 1. The length tolerances are: with sheet lengths up to 3 m: + 10 mm / – 5 mm with sheet lengths of more than 3 m: + 20 mm / – 5mm.1 Dimensions of the profiled sheets There are many variations in shape for instance*) Thickness mm straight Dimensions mm Kalzip 50/333 333 50 1.9 0.8 1.2 1.0 0.2 1. The system and its components 3. only 50 % of the specified values will be allowed.8 1.0 0.9 to 1.9 0.9 0.9 0.0 0.8 1.9 0. **) Recommended for facade cladding The nominal thickness is subject to the tolerances specified by DIN EN 485-4.The system and its components 3.2 1.2 1.9 0.8 1.0 0. hyperbolically curved *) Not all shapes are possible for all types of Kalzip 6 Kalzip .2 1.0 0.2 mm.0 0.8 1. As far as the lower tolerances are concerned.2 1.2 1.0 0.9 0.9 0.
The clips are attached to the substructure with the building authority-approved connecting elements. To connect the profiled sheets to concrete substructures. aluminium or timber substructure. spacer structures made of steel. aluminium or timber and anchored sufficiently in the concrete must be placed in-between. eaves. gutter brackets and fixed points.2 Aluminium clip and thermal barrier pads Aluminium clip rods can be used for clip rods.The system and its components Further shapes***: XT freeform ***) Not all shapes are possible for all types of Kalzip 3. The clips must be fixed to a steel. Thermal barrier pad (TK 5 or 15 mm thick) Kalzip aluminium clip combinations Kalzip 50/… w2 with with Tk 5 Tk 15 25 35 40 50 115 125 155 165 Kalzip 65/… w1 w2 without with with Tk Tk 5 Tk 15 only applicable with AF/AS 20 25 35 95 100 110 135 140 150 dimensions in mm clip type L 10 L 25 L 100 L 140 H clip height 66 81 156 196 w1 without Tk 20 35 110 150 Twin thermal barrier pad (DTK 5 or 15 mm thick) Kalzip aluminium clip Kalzip zipping machine H = height of clip without thermal barrier pad w1 = distance between Kalzip bottom and bottom edge of clip foot w2 = distance between Kalzip bottom and bottom edge of thermal barrier pad Kalzip 7 .
. w3 5 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 w3 = distance from Kalzip base to lower edge of clip foot base E Standard version for connecting elements SFS SDK2 or SDK3. E spacer caps can be connected in between for varying the required thickness of thermal insulation. This creates a roof design with heat transfer coefficients which are entirely determined by the thermal insulation. the Kalzip composite clips can be combined with spacer caps.. In principle. E 100 E 120 E 140 E 160 E 180 clip height H 66 81 91 101 111 121 131 141 151 161 171 181 191 201 211 221 231 241 Kalzip 50/. fulfills this Technical Data clip type E E E E E 5 20 40 60 80 in combination with spacer cap (DK) E 20 + DK 10 E 40 + DK 10 E 60 + DK 10 E 80 + DK 10 E 100 + DK 10 E 120 + DK 10 E 140 + DK 10 E 160 + DK 10 DK 10 mm DK 5 mm requirement in an exemplary manner. which are an integral part of building regulations in several countries. The Kalzip composite clip.. In order to achieve the desired thermal insulation thicknesses in EnEV 2009-compliant Kalzip roof structures and to compensate for height tolerances..The system and its components Kalzip composite clip The energy-saving clip for attaching Kalzip profiled sheets.. According to the European energy-saving directives. it is now obligatory to take account of thermal bridges when planning building projects. therefore optimizing the performance and efficiency of the roof.. w3 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Kalzip AF 65/. which is used to attach the Kalzip aluminium profiled sheets to the substructure of the roof. The clip has a PA structure which is reinforced with steel. It prevents thermal bridges and succeeds in creating a system which is virtually coldbridge free. All characteristics and functions relating to the load carrying capacity and attachment are fulfilled and are documented in the approval granted by the German General Bulding Inspecto- rate approval. w3 20 35 45 55 65 75 85 95 105 115 125 135 145 155 165 175 185 195 Kalzip 65/. the Kalzip composite clip type E is attached to the substructure using the same connecting elements as those used with the aluminium clip. dimensions in mm w3 H Spacer cap (DK 10) Kalzip E 10 composite clip Hole pattern for alignment of the fastening systems to the screw arrangement Kalzip composite clip type E 140/160 with spacer cap (DK 10) H = height of clip w3 = distance between Kalzip lower surface and the bottom edge of clip foot 8 Kalzip .
clip type D 10 D 25 D 100 D 140 clip height (H) 66 81 156 196 Kalzip 50/… w4 25 40 115 155 Kalzip 65/… w4 not applicable 25 100 140 dimensions in mm Kalzip DuoPlus rotatable clips in Kalzip DuoPlus rail.The system and its components Use of spacer caps in combination with the Kalzip composite clip The Kalzip composite clips can be combined with spacer caps (DK) in order to compensate for height tolerances. This solution significantly increases ease of installation and further improves thermal insulation in comparison to conventional roof designs. Kalzip 9 . the DuoPlus rail still offers a secure hold. A combination is thereby permissible only in following variants. After installing the insulant (d = 100 mm). combination for the desired clip height and to compensate for height tolerances Correct Incorrect + Composite clip + DK 5 to compensate for height tolerances + Composite clip with several DKs – not permissible Kalzip DuoPlus rotatable clips and Kalzip DuoPlus rail. Therefore a customised and convenient installation is guaranteed every time. Sub sequently. the rails are aligned according to the calculation and mounted with the fastener systems of SFS intec SD2-S16-6. perforated Dimensions: 120 x 6000 length Kalzip DuoPlus rotatable clip H = height of clip w4 = distance between Kalzip lower surface and the bottom edge of DuoPlus rail. (See diagram page 47). therefore DuoPlus 100 can be adapted to the individual circumstances depending on the profile dimension and/or tolerance.0 x L in the steel trapezoidal profile subshell. the DuoPlus clips are manually screwed in. Correct Correct + Composite clip + DK 10 Combination for the desired clip height + Composite clip + DK 10 + DK 5 Max. perforated With the development of the DuoPlus rail and the DuoPlus clip. a solution has been found which makes the installation of the attachment elements for Kalzip profiled sheets even more secure. Although these remain adjustable.
Due to the special texture of the material surface. An additional surface treatment creates a stable patina with exceptionally high resistance to the effects of weathering. tests in accordance with DIN 50017 KFW (cyclic condensate tests) in addition to HCT tests have proven that Kalzip AluPlusZinc outperforms conventional zinc surfaces in terms of resistance to corrosion. stucco-embossed design. it has very good forming characteristics and good resistance to weathering and UV light. Indeed. This surface finish creates an appearance of classic elegance. the surface diffuses reflected light and minimises the risk of any dazzling effect. thereby creating a new and attractive design with a high-quality appearance.The system and its components Stucco-embossed Kalzip AluPlusZinc Kalzip AluPlusPatina 3. Kalzip profiled sheets with a PVDF coating This coating is particularly well suited for aggressive environments and extreme climatic conditions. Advantages of the product: • Resistant to weathering and to aggressive environmental influences • Considerably less light reflection • Matt look due to pre-weathered surface • Decreased glare due to diffuse light reflections • Dirt-repellent surface – insensitive to fingerprints • Available in a stucco embossed or smooth finish • UV-resistant Coil-Coating Liquid lacquer is rolled onto the aluminium layer in a coil coating process. Profiled sheets with a PVDF coating are characterised by outstanding UV-resistance. It combines stunning aesthetics with the highest quality materials to achieve design perfection. Kalzip AluPlusZinc offers unique product advantages: • Zinc patina with surface protection • Sophisticated. It is characterised by extremely high resistance to scratching. minor dents and accidental damage is hardly visible. e. 10 Kalzip . Kalzip additionally offers a high-quality and extraordinarily weather-resistant special highend coating on the basis of a polymer technology using fluorocarbon (FLP). is not hindered and proceeds in the usual manner.3 Different finishes and colours Stucco-embossed surface The standard version of Kalzip profiled sheets is stucco-embossed. proximity to salt water.g. Kalzip AluPlusPatina offers all the product advantages of the standard. The patented PEGAL process produces a durable fusion between aluminium and zinc. These colour coated coils are then used to roll-form the Kalzip profiles. and the highly diverse design opportunities which this creates for planners and architects. traditional impression • Bright surface • Longevity due to aluminium core • UV-resistant Kalzip AluPlusPatina Special surface treatment of the preweathered. this is a technically advanced product which sets new standards. stucco-embossed profiled sheets significantly reduces their natural sheen. have very good forming characteristics and are primarily used for façade design. The natural ageing process. Kalzip AluPlusZinc AluPlusZinc from Kalzip GmbH is a fusion of two of the most established materials in industry – aluminium and zinc. this elegant and matt surface provides roofs and facades with impressive style. which makes it ideal for a wide range of applications. Kalzip profiled sheets in a polyester execution are mainly used in locations with normal environmental influences. Kalzip ProTect coating For the protection of the surfaces. Kalzip profile boards with polyester coating The coating is robust and insensitive to scratching. The robust stucco embossed finish is created by treatment with additional embossing rollers. maximum colour and gloss stability as well as considerably higher surface hardness and temperature resistance. In addition. With characteristics comparable to those of an aluminium profiled sheet which has been weathered over years. Manufactured according to the most stringent quality standards. In addition to the new and attractive surface finish. which the profile sheets undergo during exposure to weathering.
The system and its components Kalzip colours Protective plating Characteristics of the ProTect coating: • Available for RAL. surfaces are protected against possible damage with an appropriate film. Special colours are available on request. Corrosion does not attack the core material but is limited to the plating. paint coating thickness. QUV-B test. Kalzip 11 . For this reason it is advisable to take care when planning facades or visible roofs to make sure that the profiled sheets are roll formed from the same batch of material. variations in colour may occur between different production batches. During the rolling process. The performance of the protective plating has been proved by several tests carried out by “Bundesanstalt für Materialforschung und Prüfung (BAM) in Berlin” (German Federal Institute for material research and testing). Aluminium strips with a single-sided coating are given a coat of protective varnish on the rear side. Kalzip also offers a wide range of colour and surface finishes which provides optimum design freedom and safety. The thickness of the protective layer is only 4 % of the material itself. The advantages in summary: • Reduced surface reflection compared to Alu-Natur • Calm metallic impression • Salt water resistant • Even surface greying • Resistant to weathering and to aggressive environmental influences Protective film At the customer‘s request and/or due to production requirements. Metallic enamels In the case of metallic enamel coating. The coil coating process is monitored according to the standards of the ECCA (European Coil Coating Association). the aluminium core is additionally protected. Controlled colour quality The aluminium strips coated using the coil coating process pass through a large number of elaborate processing steps. they are subjected to different pretreatments and painted in the desired colour or sealed with a clear varnish. It must be ensured that the film is removed within two weeks of delivery in order to prevent increased effort for its removal. The electro-chemical potential of the plating is lower than that of the core material and therefore has the effect of a sacrificial anode in case of exposure to corrosive agents. PVDF or CFTE basis are used. Depending on the type of coating. only high-quality enamels on a polyester. Plating Plated with a special alloy. This protection remains effective even if the surface of the sheets is damaged. paint hardness. condensation climate in an atmosphere containing SO2 and outdoor weathering tests in an aggressive environment. offering effective protection against vandalism • Also available with high gloss surfaces • Corresponds to the test conditions of the Florida test (outdoor storage for over 20 years) Colour range In addition to the diverse range of shape variants. In order to achieve a weather-resistant and colourfast coating. There are additional long-term tests such as the acid salt spray test. thus less cleaning effort necessary • Resistant to chemicals and also to aggressive emissions such as aircraft exhaust gases • An ‘anti-graffiti effect’ is achieved by means of the FLP technology and an additional clear lacquer. Important criteria here are: colour. a permanent joint between the plating and the core material is achieved. paint adhesion and ductility. degree of gloss. Anti-condensation and anti-drum coatings If required the profile sheets can also be fitted with an anti-condensation or antidrum coating. NCS and metallic shades of colour • Outstanding long-term characteristics with minimum chalking tendency • Very good dirt repulsion due to a Teflon-like behaviour.
4 Accessories Gable bar verge Eaves Transition sheet (Al) for rising walls and gable ends Rib filler seals the edge of the eaves Drip angle (Al) stiffens the bottom sheet and makes the water drip into the gutter indispensable for static reasons! Compressible adhesive tape prevents flow-back of rain water Kalzip vapour barrier avoids air flow and diffusion 12 Kalzip .The system and its components 3.
The system and its components Drip angle Ridge Spacer section (Al) compensates height differences to the end plate Form filler ends flush with the ridge Ridge profile (Al) protects the form filler against UV radiation and reduces wind pressure Gable end profile (Al) provides fastening device for joining sheets Gable end hook (Al) secures gable end against storm Reinforcing profile for verge flashing (Al) stiffens the flange Kalzip 13 .
5 Components for roof superstructures and safety appliances SolarClad Step 14 Kalzip .The system and its components 3.
Cable clip.The system and its components left to right: Seam clip aluminium. Seam clip (stainless steel) Snow guard Kalzip fall arrest system Soaker frame Kalzip 15 .
the system offers advanced detailed solutions for effective interior or exterior draining of the roof which means a high degree of reliabilty throughout the long serviceable life of the roof. Thermal insulation requirements can be easily fulfilled. purlins or concrete elements.g.5°. fibrous insulating materials as specified by e. The insulation is laid into position and is then compressed to its required final thickness when are installed the profiled Kalzip sheets on top. Furthermore it may be combined with any kind of support or substructure. compressible thermal insulation is used. humidity and weathering are fully taken into account. • Of course. • Chemically neutral. • Information on U values can be found in chapter 7. The system depends on the special requirements of the individual application. • A vapour barrier must be incorporated. Application specific system build-up Kalzip sheets can be used both for ventilated and non-ventilated roofs as well as for any roof shape or down to a minimum pitch of 1. 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 German DIN 18 165 are recommended as suitable thermal insulation. In addition. ventilated roof implementations are also possible • The sound reduction values of the standard roof are subsequently described. * varies depending on thickness and material qualities 16 Kalzip . Kalzip range of applications Within the context of the amendment of the German energy saving regulations (EnEV 2009). Incorporated within the roof system the insulation material is compressed by approx. Non-ventilated Kalzip roof on a trapezoidal steel deck R’w = ~ 35 dB (A)* Non-ventilated Kalzip roof on a trapezoidal steel deck This very economical roof system is used both for industrial and residential buildings. The likely effects of snow. Further improvements can be achieved by including additional layers. There should be no cavity between the Kalzip sheets and the insulation. The thickness of the insulation can be perfectly adapted to the individua lrequirements of the building. 20 mm. timber linings. Kalzip dimensioning tables.Kalzip range of applications 4. On the basis of newly-developed materials. Kalzip system components make a significant contribution to EnEV-compliant roof structures. Properly installed it provides the required air tightness. Kalzip can easily be configured to provide the highest levels of thermal insulation. The design roof load must be increased by 15 % when dimensioning the trapezoidal steel sheets. the energetic requirements of external structural components are an important component of the new energy saving regulations for improving the sustainable energy efficiency of buildings in the context of economic viability and in accordance with the state of the art. wind. The clips must be staggered on the inner sheet to make sure that the load is evenly distributed across all corrugations of the inner sheet. Insulated roof systems are the norm The main applications for Kalzip roof systems are insulated roof structures supported by trapezoidal steel. In order to make sure that there are no air cavities under the Kalzip roof skin. starting from page 47.
* varies depending on thickness and material qualities Kalzip 17 . the inner sheet has to be oriented parallel to the top layer. 2. Z-14. the top hat sections will be positioned on top of the purlins. roofers etc. In this instance. If the Kalzip sheets can span the existing spacing of the purlins.1-181. a continuous flat vapour barrier can be installed. By this way the inner sheet carries only the weight of the insulation. In both cases the fastener is visible from below. and 18 mm for OSBs. 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. The clips can only be fixed directly in the timber lining if this has a minimum thickness of 23 mm. For larger purlin spans additional top hat sections are required. Non-ventilated Kalzip roof on timber rafters with visible timber lining R’w = ~ 38 dB (A)* 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. If the timber lining is too thin. because: 1. then a timber purlin must be installed over the lining and attached to the rafters. This is advantageous. A minimum thickness of 19 mm applies for flat press boards. part of the load needs to be transferred by the inner sheet. there is a clear separation between the trades of carpenters. See Kalzip approval No.Kalzip range of applications Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet R’w = ~ 35 dB (A)* Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet If the roof is supported on purlins.
The dowelling possibilities must be precisely checked in each individual case and statically calculated. DuoPlus clip and connecting elements to secure the DuoPlus rail. the DuoPlus rails can be arranged at a 90° angle to the Kalzip. Special clips are inserted in the rail and are adjusted to suit the respective conditions. The base for the Kalzip DuoPlus 100 is simply provided by rigid insulation strips with a width of 24 cm and a thickness of 10 cm. whereby a full layer of rigid thermal insulation is not necessary. the compressible heat insulation and the Kalzip profiles sheets. The rotary clip rails are fixed using approved dowels (SFS MBR-XS4-HX-10x160). The special design is almost cold-bridge free and has excellent sound absorption properties.Kalzip range of applications Kalzip DuoPlus 100 and Kalzip Duo 100 on a concrete substructure R’w = mainly dependent on concrete Kalzip DuoPlus 100 and Kalzip Duo 100 on a concrete substructure The Kalzip DuoPlus and Kalzip Duo system can likewise be installed on a concrete substructure. In the case of a solid concrete slab. * varies depending on thickness and material qualities 18 Kalzip . The rigid thermal insulation is replaced by a layer of soft insulation in all areas where no reduction in snow loads is required. The choice of approved dowels must be matched precisely to the concrete material. the DuoPlus rails are arranged at an angle of less than 45° to the Kalzip. The dowels are arranged alternately in the rails. Kalzip Duo 100 R’w = ~ 41 dB (A)* Kalzip Duo 100 If there are no specific sound insulation requirements then the Kalzip Duo 100 system can be used. The resulting spaces are filled with soft heat insulation or low-priced rigid insulating material. Connection of the individual clips to the rail is not necessary. rigid thermal insulation only needs to be used in those areas specified by the statistical requirements. The distance between the rails depends on the static calculation. An aluminium rail is placed on the 100 mm thick rigid thermal insulation and is fixed onto the substructure through the insulation. The patented and type-tested system consists of rigid thermal insulation. DuoPlus rail. In the case of slabs made of porous concrete or non-solid concrete slabs. Kalzip DuoPlus 100 R’w = ~ 43 dB (A)* Kalzip DuoPlus 100 The Kalzip DuoPlus 100 system combines the advantages of rigid insulation with the constructional possibilities offered by the conventional Kalzip roofing system. In the case of Kalzip DuoPlus 100.
The manufacturer’s installation regulations are to be observed. The Kalzip profiled sheets are installed in the usual manner and are friction-fitted together. The Kalzip FOAMGLAS® System offers a high level of energy efficiency as the thermal insulation is airtight and impervious to water vapour. As FOAMGLAS® is impervious to moisture penetration the insulation can also act as a watertight substructure.4-475. Kalzip NatureRoof comprises an efficient draining mat to control the integral water management and a special substrate supporting a vegetation layer for extensive landscaping with sedum plants. The FOAMGLAS® slabs are bonded to different substructures using either a coldbonding agent or hot bitumen. roof pitch: 15° Additional weight (wet): 0. What’s more. In order to attach the composite clips.9 kN/m2 Shear protection: from 5° Kalzip FOAMGLAS® System as a standard solution Kalzip FOAMGLAS® System as a standard and combined solution This roof design and the system components used are particularly suitable for building projects which place high demands on ensuring that the roof system is free from condensation and where there is therefore a permanent risk of condensation formation.5° Max. roof pitch: 1. This means there is no coldbridging.Kalzip range of applications Kalzip NatureRoof Kalzip NatureRoof All roof designs described above can be transformed into a Kalzip NatureRoof providing that the design requirements are taken into consideration and Kalzip 65/333 is being used. Technical data: Min. In order to ensure economic efficiency. there is no mechanical attachment between the Kalzip profiled sheets and the supporting structure. The composite clips are installed on the claw plates using the recommended fastening elements. the thickness of the compressible thermal insulation can be varied. All components for the Kalzip NatureRoof outside Germany are available only on request. FOAMGLAS® has a minimum thickness of 80 mm. Kalzip FOAMGLAS System as a combination solution ® * varies depending on thickness and material qualities Kalzip 19 . the galvanized steel claw plates are inserted under heat in a fixed installation plan taking into account the respective roof geometry. The installation and dimensioning are governed by the Kalzip approval Z-14.
* varies depending on thickness and material qualities 20 Kalzip .Kalzip range of applications Kalzip AF Kalzip AF profiled aluminium sheets are especially designed for installation above rigid support layers. Under the trade mark “ProDach insulating system” Rockwool offers an accessible. water repellent mineral wool insulating board featuring a special fixing system. The level ribless profile provides a smooth and attractive appearance. Kalzip AF is available in sheet lengths up to 50 m (longer lengths are available on request). The AF system offers outstanding thermal as well as acoustic properties. This almost entirely eliminates the effect of cold/heat and sound bridging. The stainless steel system fasteners connecting the U-rails to the substructure of the roof penetrate the insulation material only locally. Fixing rails are embedded in the top-side of the insulation material and fixed to the trapezoidal steel deck. rather than being fixed directly to the substructure the skin is fixed instead to special U-rails embedded in the insulation material. Kalzip AF with ProDach-insulation on trapezoidal steel deck R’w = ~ 42 dB (A)* Kalzip AF with ProDach-insulation on trapezoidal steel deck In order to meet increased demands for sound reduction and to reduce cold/heat bridges it is advisable to install the ProDach Insulation System. 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 Assembly The corrosion-proof and weather resistant Kalzip AF aluminium external skin is fixed with clips in the usual way. Kalzip AF profiled aluminium sheets are not only used in combination with the ProDach-insulation system but may also be used with FOAMGLAS® insulation and timber lining. compression-proof. However. and this is the distinctive feature of the ProDach insulation system.
Kalzip AF with the insulation layer at rafter level Kalzip AF with the insulation layer at rafter level* This structure is comparable to traditional standing seam systems. The rails are invisibly fixed to the rafters. see Kalzip approval Z-14. If there is an air gap under the timber lining adequate ventilation is essential. we recommend filling the total height of the rafters with insulating material for efficient performance. For the minimum thickness of timber materials. a timber lining which remains visible serves as a supporting element. * varies depending on thickness and material qualities Kalzip 21 . A vapour barrier beneath the thermal insulation is also of critical importance. With this in mind. There are no visible joints or fasteners. A thermally stable isolation layer must be arranged between Kalzip and a bituminous secondary covering. The composite clips employed allow optimum sliding of the profiles in the case of a temperature-related change of length. This structure has proved to be ideal for residential buildings and other buildings of similar use. The method shown here using the L-shaped claw plate does entirely without a mechanical connection between the Kalzip profiles and the support skin and is free of thermal bridges. Kalzip AF on FOAMGLAS® insulation Kalzip AF on FOAMGLAS® insulation* Kalzip AF can also be used on the proven FOAMGLAS® insulation.Kalzip range of applications Kalzip AF with ProDach-insulation on timber rafters with formwork R’w = ~ 45 dB (A)* Kalzip AF with ProDach-insulation on timber rafters with formwork With this type of roof. It is frequently used in order to minimise the overall height of the roof structure.1-181. The potential extends from public buildings to multipurpose halls and sports-arenas. Various installation methods are possible.
/ blocking diode rating. 5 % (3°). existing Kalzip roofs can be retrofitted with Kalzip SolarClad.30 8 8 8 1000 1000 1000 reverse side. modern buildings which combine maximum freedom of architectural design with the integration of ecological concepts.36 23.85 5. Because of the small dead weight and the lack of structural height. usually does not arise with Kalzip Solar systems. • Recommended roof pitch min. Kalzip AluPlusSolar is available as a fully integrated system.13 4. Kalzip AluPlusSolar The new Kalzip AluPlusSolar profiled sheets are the first to combine a system of solar power generation using roof-integrated photovoltaics with the maximum freedom of architectural design to create stunning buildings. convex or concave Kalzip aluminium profiled sheets. including inverter and accessories. nom.20 5. The problem of the existing support structure not being able to absorb additional wind and snow loads. design suitability and approval in accordance with IEC 61646 TÜV Rheinland.com Technical Data Surface required per kWp [m2] Module length [m] Maximum Power (Pmax) [Wp] Voltage at Pmax (Vmpp) [V] Current at Pmax (Impp) [A] Open circuit voltage VOC [V] Short-circuit current ISC [A] Series fuse rating. Cologne.10 5. We can send you detailed information on request.13 4. Depending on the particular roof design. Kalzip GmbH offers solar power systems which are perfectly coordinated with Kalzip for both options.7 2. as well as customised roof designs. is laminated in the factory and then permanently bonded to the outer surface of the Kalzip profiled sheets. The durability of the Kalzip profiled sheets and the guaranteed efficiency of the solar modules now make it possible to create contemporary.0 mm Kalzip AluPlusSolar Trapezoidal substructure profiled sheet in RAL 9006 (other colours available on request). please visit: www. 22 Kalzip . 50 cm connecting cable MC-FlexSol-XL (4 mm2). The flexibility of Kalzip AluPlusSolar can accommodate barrel vault or monopitch roofs. [A] Maximum DC system voltage [V] Connection Weight in kg per m2 roof size PVL-68 PVL-136 PVL-144 > 22.50 68 136 144 16. Kalzip SolarSystems also offer the opportunity of generating energy in the facade. These advantages are particularly effective in the case of renovation measures. The silicon thin-film solar cells use triplejunction technology to generate more energy in diffuse light conditions than crystalline solar cells of the same rated power and are therefore ideal for use in European regions. male connector MC 4 2. Safety Class II.5 > 22 > 20. on the AF 65/537/1.5 2. regenerative method of energy production. operating voltage may be higher than 11% and operating current may be higher by 4%. available in two lengths.20 46.aluplussolar. the additional load on the main support structure remains very low.terminal housing assembly IP65.50 33 33 4.10 46. nom. Kalzip profiled sheets which have already been installed cannot be retrofitted with laminated solar film. they are permanently bonded to straight.7 NOTE: The values specified represent stabilised values (± 5%).7 2. power output may be higher by 15%. which positively affects the costs of the building.50 5. During the first 8-10 weeks of operation. The solar film. This film will subsequently generate the power in the photovoltaic system.Kalzip range of applications Kalzip Solar Power Systems When referring to photovoltaic systems. The necessary static examination of the existing building can often be omitted due to the low loads. We recommend the use of Kalzip SolarClad. In addition to a roof-integrated. • Minimum radius in the area where the rofiled sheets are fitted with modules 13 m. The solar laminates are flexible and extremely durable.10 5. However. which frequently arises with crystalline systems. Planning tips • Kalzip profiled sheets cannot be retrofitted with laminated thin-film solar modules. Germany For more information. architects make a distinction between roof-mounted and roof-integrated systems.
vertical Kalzip SolarClad Kalzip SolarClad is a photovoltaic cladding which has been optimised for use in building envelopes.13 4. Kalzip SolarClad is supplied as a complete system.50 33 33 4.10 5.50 > 18 2. bonded onto aluminium system rails.Kalzip range of applications Kalzip SolarClad parallel to standing seams. As the system is extremely lightweight.30 8 8 8 1000 1000 1000 reverse side.85 5. power output may be higher by 15%. Kalzip SolarClad perpendicular to standing seam. 50 cm connecting cable MC-FlexSol-XL (4 mm2).50 68 136 144 16.50 5. is laminated onto Kalzip system rails in the factory to ensure high quality and fast installation. including inverters. available in two different lengths. for different standing seam designs.36 23.100 5.1 6./ blocking diode rating.20 46.20 5.1 NOTE: The values specified represent stabilised values (± 5%). Its flexibility and versatility enable solar modules to be integrated into virtually all standing seam systems made from a variety of materials.13 4. nom. [A] Maximum DC system voltage DC [V] Connection Weight in kg per m2 (installation parallel to standing seams) PVL-68 PVL-136 PVL-144 > 19 > 18. which can be installed on any metal roof system in a non-penetrative manner. horizontal Kalzip SolarClad elevated from roof Technical Data Surface required per kWP (installation parallel to standing seams) [m2] Module length [m] Maximum Power (Pmax) [Wp] Voltage at Pmax (Vmpp) [V] Current at Pmax (Impp) [A] Open circuit voltage VOC [V] Short-circuit current ISC [A] Series fuse rating. The solar film. The solar laminates generate power from the sun as soon as they are connected.10 46. Kalzip 23 . this generally means there are no additional structural requirements for the roof. The system consists of extremely robust thin-film modules made from amorphous silicon (a-Si). operating voltage may be higher than 11% and operating current may be higher by 4%. nom. Kalzip SolarClad is therefore suitable for all roof structures and all Kalzip widths. terminal housing assembly IP65. Kalzip SolarClad is a retrofit solar solution which can be harmoniously integrated into existing building structures and also used in new builds.1 6. male connector MC 4 6. During the first 8-10 weeks of operation. Kalzip SolarClad is suitable for all roof shapes with a pitch up to a maximum of 60° from horizontal. These extremely lightweight module units are suitable for all roof shapes.
loading height 2. to 10. Depending on radius and transportation limitations * greater lengths on request Surface finish: • stucco-embossed • AluPlusPatina • Colour coated with protective foil • AluPlusZinc with protective foil Please take note when ordering: Please specify the required dimensions in accordance to the sketch. The minimum radii for smooth curving of Kalzip elements are specified on the following page. It is recommended to carry out the distribution in accordance with the measured dimension of the rounded profiled sheet. (Installation width = cover width + 3 mm) If crimp-curved profiled sheets are connected with straight ones. If the clips are pre-installed the installation width must be increased. 5.5° or 2.with sealed horizontal joints .1 Kalzip Convex Factory crimp-curved Cover width (BB) 50/333. 65/305.6 % .9° (5%) . Continous falling gradient required All parts of the roof must have a continous downward gradient towards the draining system. 65/333.General data and characteristics 5. the rounded sheet determines the dimension. 65/400. AF 65/434.1 Roof pitch The Kalzip system consisting of self supporting aluminium elements was specially developed for roofs with pitches down to 1. smooth.6 % together with long sheet lengths. 5. General data and characteristics 5. Minimum length of straight end pieces min l2 Ri min l1 [mm] [mm] [mm] l2 bis 1000 > 2000 a 150 0 150 0 C DB l1 65 Ri Ra Ca = Arc length outside 24 Kalzip .2.000 mm* max.all joints are welded . Transportation: Max. please contact our logistics department.soakers sealed into the roof skin . Today curved corners or arched roofs can be easily achieved by advanced industrial prefabrication.factory welded soakers welded into the roofing skin • sheets with horizontal joints 2. 65/500.and on site curving Exacting design calls for creative and detailed solutions. AF 65/333.Factory welded soakers sealed into the roof skin 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.40 m. 50/429. Owing to the attractive appearance of the modular system.running from the eaves in one length . Minimum roof pitch • without horizontal joints 1. architects often use this system for visible steep roofs and increasingly for wall claddings. They provide modern industrial architecture with a high level of functional and aesthetic quality combined with future oriented perspectives.5° respectively 2. For any queries. Profiled sheets lengths: Straight lengths 500 mm min.2 Minimum radii for crimp-. AS 65/422 Minimum radius: Ri = 450 mm Installation width is the actual width of the assembled sheets.
Kalzip 25 .5 3 3.3 3. a transitional area is created in which no clip may be placed (except a fixed point clip).5 3 0. it will not be accepted as grounds for complaint. It might be necessary to coordinate details of transportation with our logistics department. As it is impossible for technical production to prevent this buckling..9 mm 14 10 14 16 1. General information Kalzip AF und AS: With Kalzip AS and AF profiled sheets. Standard: Constant radius with a short (approx. an increase in construction width of up to 20 mm must be taken into account following curving. aluminium Convex Sheet thickness 65 / .9 mm 5 5 8 8 Concave Sheet thickness 65 / . Finish: • stucco-embossed • AluPlusPatina • coated material with protection foil • AluPlusZinc with protection foil • Anti-condensation coating on request Installation width: For pre-installed clips: cover width + 3 mm successive installation of clips: cover width + 0 to + 3 mm Length of profiled sheet: Minimum length 1..e.0 mm 10 7 10 10 1.. 400 mm) straight segment at the beginning and the end of the profile sheet.2 Kalzip smooth curved in factory. It is necessary to consult the Application Technology Dept.... Special measures are necessary in order to reach the tolerance limits.5 m.General data and characteristics 5. then smooth-curved Kalzip AS profile sheets should be used instead.. Transitional area: If a Kalzip profiled sheet is roll-curved with several radii..2. Transportation: Maximum loading height 2. It is unavoidable that intermediate radii occur in the transition area of different radii as well as between curved and straight sectors.. in Koblenz for a more exact determination of this transitional area. from concave to convex or vice versa. 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.. AS 65 / . 50 / . Minimum curving radii in m 1. AF 65 / .0 mm 1. Minimum length of segment per radius = 500 mm. Smooth-curved Kalzip AF profile sheets can show signs of increased buckling in the base plate.....5 1. When the optical characteristics of a building are of increased importance. or ± 600 mm (1200 mm in total ) if the two adjacent radii have different signs.8 mm 16 12 15 25 0. AF 65 / .2 mm 10 6 7 8 Curved and tapered: Please check with our technical department in Koblenz/Germany.. This transitional area can be safely estimated to be ± 300 mm (600 mm in total) if the two adjacent radii both have the same sign has. Shorter lengths on request. so that an overlap with straight sheets is not possible. 50 / . The final overall length depends on the individual radii and possibility of transport..3 1. Clips must not be located in these areas. Tolerance limits. 0.5 1.4 m. AS 65 / .8 mm 6 8 10 10 0.2 mm 1. Only after consultation with our technical department in Koblenz. i.
Special forms with beading are available on request. supporting space (m) 1. General information Naturally curved: The profile sheets are supplied in straight form and are curved by hand to the respective radii during installation.8 2.5 1.5 1.9 1.6 1. Cover width: Depending on the radius.2 Radii (m) 40 45 50 60 38 40 42 45 50 55 60 70 max.8 Minimum curving radii in m Increase in construction width (mm) +3 +3 +3 +3 +2 +2 +2 +2 +2 +2 +2 +2 AS 65/422 Kalzip AF Profile cannot be naturally curved.0 1. then this information must be supplied when ordering.6 1.8 0.2 0.6 1.9 1.70 m. curved to radius during installation (naturally curved) The values given are not standard values.9 1. As it is necessary to curve the profile sheets to the respective radius.0 1. Packaging: If the pitch is greater than 1.5 1.6 1.9 1.General data and characteristics 5. supporting space (m) 1.0 1. Finish: • stucco-embossed • AluPlusPatina • coated material with protection foil • AluPlusZinc with protection foil • Anti-condensation coating on request • without protection foil on request Appearance: The minimum radii outlined above reflect current experiences.8 0. the nominal width (construction width) must be increased to the cover width (installed width). 26 Kalzip .5 1.0 1.0 1.8 2. The reason for this is that special packaging may be necessary. Accessibility: Due to the risk of buckling.0 1.5 1.0 1. Concave Kalzip Type 65/305 65/333 65/400 50/333 50/429 Sheet thickness (mm) 0.3 Kalzip supplied in straight form. access to the sheets must not be gained without load spreading equipment.0 1.9 1. Installation should take place from the direction of the non-covered side. Convex Kalzip Type 65/305 65/333 65/400 50/333 50/429 Sheet thickness (mm) 0.2 0.5 1. Installation tip: It is advisable to provide a support on the ridge over which the profile sheets can be curved.0 1.8 0.5 1.8 0.8 0. Special forms with beading are available on request.2 0. Support spacing: When the supporting spacings are too large the supports will appear as polygon lines.8 1.8 2.8 0.2.2 0.2 Radii (m) 36 40 48 55 37 37 40 43 50 55 60 70 max. They do not serve as a replacement for project specific consultations.5 1.5 1.5 1. buckling cannot be ruled out.9 1.8 2.0 Increase in construction width (mm) +3 +3 +3 +3 +2 +2 +2 +2 +2 +2 +2 +2 AS 65/422 Kalzip AF Profile cannot be naturally curved.
Aquasine coating is not possible. Only following approval from the technical department in Koblenz. Tapered Kalzip sheets must be installed on the roof in accordance with the installation instructions. Load distributing walkways must be provided. It is advisable to compare the actual dimensions of the substructure with the dimensions stated on the installation in- structions before production in the factory begins.80 – 1. Larger building tolerances can require repartitioning of the area which is to be covered. Joint carried out as a welded joint or step joint min.General data and characteristics 5.3 Tapered shapes Tapered Kalzip profile sheets have become increasingly significant for roofing applications as they can be formed into a diverse range of shapes.80 – 1. Kalzip AS… not possible Applies only to stucco-embossed and colour-coated Kalzip profile sheets. The tables on the following page apply to a sheet width of 500 mm. Furthermore. In order to achieve the perfect structure. Self-supporting up to a construction width of 500 mm max. A roof can offer more than just protection: it can enable a building to achieve architectural perfection. Anti-condensation coating is only subsequently available in the spraying process.20 mm Possible for construction widths of 230 – 620 mm. The bottom sheet must be additionally supported by rigid insulation. Other material combinations are available on request. The cover widths are between 230 and 740 mm. it is essential to incorporate an eaves angle. it is necessary to take into account several fundamental considerations. For construction widths exceeding 500 mm only with additional support and clips spaced at 1. The full surface is always covered with foil.0 m max.20 mm 0. Installation examples with joints Kalzip 27 . In order to ensure that the bottom sheet is adequately rigid. Finish: • stucco-embossed • AluPlusPatina • soated material with protection foil • AluPlusZinc with protection foil Profile types available Minimum construction width Maximum width Minimum length Maximum length Plate thicknesses Curved and tapered 1 Kalzip 65/… und 50/… Kalzip AF… 230 mm 170 mm 740 mm1 740 mm1 1500 mm 1500 mm Dependent on transport Dependent on transport 0. accessibility is limited.
Different radii. XT constructions are planned completely in 3D. excess lengths of at least 400 mm are necessary at the ends of the XT profiled sheets. The combination of the various possibilities in particular has a big influence on the various limit values. even if they are free-form surfaces. to be clad with Kalzip profiled sheets.General data and characteristics 5. A 3D GUI. these have to be cut off on the building site. bulges and narrowings can thereby be combined in one profiled sheet. as well as side radii. They offer additional flexibility in the alignment of the profiled sheets. It must be adjustable in order to be able to compensate for building tolerances.0 m Side radius 20.0 m Minimum width 275 mm* Maximum width 740 mm* The maximum length depends on the transportation possibilities and the basic material available. The following.50 m Concave curved 10.4 Kalzip XT free-form profiled sheets Kalzip type 65 /… / 1. Emmen (NL) Architect: A/d Amstel Architecten 28 Kalzip . The quality of the finished Kalzip surface depends to a large extent on the quality of the spacer structure between the support structure and the outer skin. The suitability of other file formats must be checked. The planning and installation of XT profiled sheets requires a great deal of effort. The limit values are subjected to constant changes and improvements. Hospital. is necessary for editing. non-binding limit values serve as an aid to orientation: Convex curved 2. Other material/combinations on request. preferably in the format . The minimum length depends on the contour and on the production procedure and must be examined in detail. convex and concave. For reasons related to production.0 mm The XT production technology allows difficult roof and wall surfaces.3dm (Rhinoceros). * Applies only to stucco embossed Kalzip profiled sheets.
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.60 2 Applies only to stucco-embossed and colour-coated Kalzip profile sheets. It is advisable to install walkways leading to any units requiring regular maintenance or operational elements such as daylight units.60 3.50 3.9 1. Other material combinations are available on request.80 65/400 lgr/m 3.5 Accessibility/fall arrest systems For maintenance and cleaning Kalzip sheets are accessible both during and after installation without any load distributing measures.35 3. which should be secured with seam clips to prevent them from sliding down.90 3. When exceeding the critical span.50 2.90 3. Project related planning is carried out by Kalzip GmbH. In situations where no rigid thermal insulation has been installed along the ridge and eaves areas.0 1. Sheet thickness t/mm 0.80 50/333 lgr/m 2. the sheets in these parts of the roof should not directly be walked on.50 3. 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.60 AS 65/4222 lgr/m 3. The Kalzip fall arrest system is a reliable solution to secure walkways on the finished roof.80 3. this information is only applicable when rigid thermal insulation is used. single unzipped sheets and of course translucent panels should not be walked on. As far as the installation is concerned this will only be valid if the profiled sheets are zipped on at least one side.65 2.90 3.35 3.50 3. Kalzip 29 .80 65/333 lgr/m 2.80 3. The following table specifies the critical spans up to which the profiled sheets are accessible without any additional measures.60 2.80 3.70 2.8 0.00 50/429 lgr/m 2.50 AF 65/4342 lgr/m 3. 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.2 1 65/305 lgr/m 2.General data and characteristics 5.20 3. On grounds of final visual appearance.80 3.50 2.00 3.90 AF 65/3332 lgr/m 2. The last free sheets along the gable end. chimneys or heating plants.55 3.55 3.60 3.40 3. It consists of a stainless steel rope which is fastened to permanently fixed Kalzip roof anchors and coupled to the safety harness by means of a guide link. Access following installation1 Seamed Kalzip profile sheets with supporting spacings up to the following dimensions are accessible without the use of load spreading equipment.
zinc chromate or chlorinated rubber paint or the galvanizing of the contact areas of steel parts.General data and characteristics 5.6 Material/corrosion resistance An essential advantage of Kalzip sheets is the lightness of the aluminium material. as the plating acts as a sacrificial anode protecting the core material against corrosion for many years. however. 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. appropriate resin coatings with a minimum thickness of 25 µm will provide lasting protection. Protective measures to avoid contact corrosion are • plastic coating • neutralizing the steel surfaces for instance by hot-dip galvanizing • interrupting the metallic conductive contact by applying a primer or by incorporating a suitable separation layer Installation in combination with different materials Steel: Direct contact between the profiled aluminium sheets and unprotected steel parts of the substructure must be avoided due to the likely risk of contact corrosion. the roof is exposed to a highly aggressive atmosphere occurring in the immediate vicinity of the building. in the case of uncommon applications. The concrete/mortar must be set and must not be damp. For the protection of timber rafters and other wooden construction elements in direct contact with aluminium structures only compatible (f. continental and industrial atmospheres. There are a number of different protective measures such as plastic foils. ensure that the dust is immediately and carefully removed. Compatibility with other materials for common Kalzip system applications* Timber: Timber parts in contact with Kalzip should be dry. Kalzip profiled aluminium sheets are reliably protected against corrosion when exposed to normal weathering by maritime. ** Only applies to stainless steel self-tapping screws and blind rivets. for instance. Protection by natural oxidation Due to the natural formation of a protective coat of oxide. must be checked by the Application Technology Department in Koblenz. Do not allow drilling dust to get onto the aluminium surface. Seawater proof alloys are used as basic materials. They must not belong to the group of naphtalenic chlorines and must not contain any copper. oil based) wood preservatives must be used. industrial premises such as copper plants emitting high levels of aggressive chemicals. As dampness can never be completely ruled out. if this does occur. Contact corrosion In contact with other unprotected metals and under the influence of humidity. Concrete and mortar: Any direct and indirect contact with concrete and mortar must be avoided. which may lead to corrosion. aluminium produces an electrochemical contact element. mercury salts or fluorine compounds. if a formation of an electrolyte can be excluded. Combination of materials zinc stainless steel lead hot-dip galvanized steel unprotected steel copper Atmospheres rural safe safe safe safe critical critical town/industrial safe safe safe safe critical critical maritime safe safe** critical safe critical critical * This list is not universally applicable and. With plated material this effect is even greater. it is always advisable to separate concrete and aluminium profiled sheets by means of a suitable intermediate layer. 30 Kalzip .i. intermediate layers coated with bituminous. If.
7 Sustainable construction Aluminium – functional and long-lived Aluminium contributes substantially to the effective protection of buildings against external influences over many years and to the retention of their value. in particular when high demands are placed on the use of the buildings e. This result in security and retention of value. The building and property business in particular can make a decisive contribution to the sustainable development of our society. e. is particularly effective here and serves both the building industry and our society. Leeds and DGNB has for the first time provided evaluation criteria for sustainable planning and building. the DGNB. construction and use to the renovation and demolition. at airports or in demanding locations. Kopenhagen Photograf: Torben Eskerod Kalzip 31 . The recycling of Kalzip profiled sheets and other aluminium products requires 95% less energy than the primary production from bauxite.g. Rubow Architects. A comprehensive quality concept.g. The lynchpin of the Kalzip sustainability is the aluminium itself. Kalzip aluminium roof and façade systems have been used for 40 years worldwide as a preferred solution for building envelopes. One of the outstanding characteristics of the material is its resistance to weathering and the associated durability. The material for Kalzip has been submitted to increasingly critical tests over the course of the time. This avoids approx. Sustainable construction means conscious planning and construction. including an examination by the BAM (Federal Institution of Materials Testing and Research) of the improved weather resistance of plated Kalzip profiled sheets after nearly 40 years of exposure. Three-quarters of the aluminium ever produced is still in use today.General data and characteristics 5. All individual measures for the minimisation of the energy consumption and use of resources must be optimally coordinated with one another and external influences must also be considered. which urge us to use our resources responsibly and hence to contribute decisively to the protection of the environment. near the coast. without loss of quality. Sustainable construction aims at a minimisation of the consumption of energy and resources as well as the lowest possible impact on the ecological balance in all phases of the lifecycles of buildings – from the planning. a material that can be recycled any number of times and is sufficiently abundant: It is the most commonly occurring metallic element on Earth. Zero Emission House. Velux (DK) Architect: Lars Bo Lindblat. The influence of sustainability is at its greatest during planning. The entire lifecycle of the building must be considered. because around 40 per cent of worldwide CO2 emissions are caused by buildings (source: DGNB) The planning and construction of buildings will demand integrated solutions in the future. Kalzip is a member of the association for sustainable construction. Approximately 95% of aluminium from the roof is recycled. which is already applied during product evelopment at Kalzip. 80 million tonnes of greenhouse gases worldwide per year. Sustainable construction with aluminium building envelopes The introduction of certification systems such as Breeam.
it is essential to allow for the time required to obtain permits from the local road authorities. 5. Kalzip is officially approved by many European building authorities and is subject to continuous monitoring. When extreme lengths are to be transported. from which the maximum spans under practical windand snow loads can be extracted.General data and characteristics 5. So the proof required by law can be easily provided at any time. 5. amongst other things. The basis for the design calculations is always the German Inspectorate Approval No. Proof of stability and the suitability for use must be provided in each individual case. This includes a description of technical characteristics. Although these sheets are accessible both during as well as after their installation for maintenance and cleaning without the need of load distributing measures. materials and dimensions. accessibility.1-181 issued by the Institute for Building Technology. For frequently recurring applications you will find load-span-tables. The appendices contain tables relating to standard details and characteristic values for the proof of stability and suitability for use. Permits are required from the local road authorities for the transportation of lengths of 18 m and more. roof pitch. The stipulations on specification govern.8 Ofﬁcial approvals/design calculations The use of Kalzip roofing elements is subject to the official building regulations. long profiled sheets with small curving radii) the feasablity of transportation has to be checked with our logistics department.9 Transport When designing unusual special roof shapes (for instance.10 Sheet thickness According to the licensing agreement issued by the building authorities the minimum thickness for Kalzip profiled sheets is t = 0. The dispatch department at the production factory is available to advise you here. For aesthetic reasons it is advisable to choose a minimum sheet thickness of 1 mm on any visible areas. static systems and safety values. edge design. Z-14. 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. technical expertise/training requirements of the installers. The stipulations for design and measurement contain information on design loads.7 mm. 32 Kalzip .
these roofs must always be sloping. Furthermore. Known regions include: • the Alpine region • the Central German Uplands • other areas which have a high snow fall Structural features which have led to ice barriers on roofs: • Shaded areas created by additional fitting or structures • Cold roof overhangs • Complicated roof shapes. In this context vapour diffusion (e. metal roofs which have longitudinal and cross joints or overlaps which have not been welded or soldered. will not be watertight (against “pressing water”). a multitude of fittings or structures • Guttering and downspouts which can freeze up (bends. for example. Superficial formation of condensate on structural components If the minimum values of heat transition resistance according to DIN 4108-2 are observed. no gutter heating) • Accumulated snow. ice barriers can form on metal roofs with certain structural features. Standing water on roofs may not only be caused by inadequate roof pitches but also as a result of other factors. uneven distribution of snow on the roof • Linear snow guard systems • Fall arrest systems with cable connections • Lightning conductors • Walkways • Discontinuities in the thermal insulation effect • Thermal bridging • Poor workmanship (defective connec tions on penetrations or roof edges. these measures can only be regarded as suggestions and do not release the company carrying out the work from the obligation to check feasibility. In view of the experiences of the particularly catastrophic snow conditions experienced in winter 2006. As the effectiveness of recommended measures depends on local conditions. but only rainproof. no list of recommendations can be regarded as complete. an airtight barrier must be installed. 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.Design specifications 6. For this reason. However. Standing water must be avoided on metal roofs. These are blockages or plates formed from snow. channels. A professionally fitted Kalzip vapour barrier meets these requirements. An essential planning task is to ensure that ice barriers are avoided. Design specifications 6. melt water or rainwater which have frozen together and can impede the flow of water on roofs. according to DIN 4108-3) as well as air flows must be considered.g. 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. Those areas of the roof which are at risk include. In wall structures vapour barriers are generally not necessary. areas which are partially roofed and shaded areas. For this reason. single-skin roof overhangs. This means that when accumulated water exceeds a specific level it will penetrate via the joints and connections. in the case of superstructures or projections which have been incorrectly designed or installed or when ice barriers have formed. as required by the Energy Saving Directive. This is to prevent the loading capacity of the roof covering from being exceeded and the roof from collapsing as a result of the load exerted by standing water. defective vapour barriers in the case of warm interior rooms) Exceptional weather conditions experienced in recent winters: • Rapid and frequent alternation between freezing/thawing • Catastrophic snow quantities • Frost coldness and snow at the same time If ice barriers impede or stop the flow of rainwater or melt water above guttering there is a risk that the water will accumulate and enter the attic area and therefore the building through the joint overlap of the profiled sheets. For example. a verification of the protection against condensation in non air-conditioned rooms such as residential premises and offices is generally not required providing that these rooms are adequately heated and ventilated according to the normal standards. Kalzip 33 .2 Ice barriers In some regions where exceptionally severe weather conditions can be experienced. the values given in the standards and in the directives for roof pitches stipulated by the building authorities must be observed on all points of a roof as a minimum. as a result of blockages in the flanges on the profiled sheets which carry the water. 6. To prevent humid internal air from diffusing into the roofing system. it should be noted that absolute safety against ice barriers cannot be guaranteed. Various measures can be recommended. This is another reason why a minimum pitch must be maintained. No liability can be accepted for this.1 Moisture proof For insulated roofs and walls it is essential to provide sufficient protection against condensation in each and every case. which is fully sealed at all joints to the adjacent structures.
particularly internal structures • Bends in downspouts should be avoided • Keep downpipes free. • Accumulated snow should always be removed as quickly as possible. then the following measures can be successful – depending on the causes. According to DIN 4102-4 aluminium alloys are classified in category A1 (”not inflammable“) without special verification. In the case of each of these measures. the specific conditions of the individual building in question must always be taken into account. C – s3 d0 B. C – s1 d0 B. edition 2002/1) Building authority designations Additional requirements European class according to DIN EN 13501-1 Class according to DIN 4102-1 Non-combustible no smoke X X X X Flame-retardant no burning droppings/drips X X X X X Normally flammable Highly flammable 1) A1 A2 – s1 d0 B. Part 1. Snow and ice should be cleared away. it is not possible to make general statements.2 to the Building Regulation List A. The demands concerning fire protection of building materials and structural parts etc. C – s1 d2 B. The planner must check that individual measures are adequate or whether the combination of several measures is required in order to achieve adequate efficiency. C – s3 d2 D – s3 d0 E D – s3 d2 E – d2 F A1 A2 B1 1) B2 1) B3 Specifications for strong smoke development and burning drips/droppings in the proof of usability and in the labelling 34 Kalzip . 6. e.4 Fire protection Planning and constructive measures: • Roof projections should be avoided or at least insulated • Shaded areas should be avoided or heated • Areas at risk should be equipped with roof heating • Substructure should be installed at least 3 mm towards the inside of the roof and connected at the gutter • Flow directions/roof pitch should not be directed into cold roof areas • Gutters should be heated. there can be no guarantee of absolute safety here: • Long joints should be avoided. Classification of fire behaviour (without floor coverings) according to DIN EN 13501-1 (Appendix 0. service gutters and downpipes • Direct gutter heating into the downpipes right through to the frost-free ground area • Be aware of the risk of suspended gutters breaking away • Ensure snow remains evenly distributed on the roof (use a lot of individual snow guards rather than just a few linear systems) • Connect vapour barrier to gutter. walkways and other obstacles should be protected by snow guards to prevent snow and ice from collecting • Thermal bridges should be minimized or completely avoided • Large discrepancies in U-values should be avoided. 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“). For this reason. However. If ice barriers have occurred and these are to be avoided in the future. are specified in the local building regulations. through welding or masking • Panel heating should be installed (gutter heating should always be available) • Linear snow guard systems should be redesigned and either replaced by systems which provide a more even distribution of snow or supplemented by additional systems. use as an emergency downspout? • Fall arrest equipment.2. while all benefits of the lightweight constructions remain unaffected.3 Sound absorption Highly efficient sound absorption can be easily achieved with Kalzip roofs by constructive measures such as incorporating additional layers.Design specifications 6.g.
The same applies to standing seam roofs as well as trapezoidal and corrugated profiles. Hence. Technical requirements for lightning conducting devices: • The Kalzip sheets must be conductively connected to earth • The seams of the Kalzip sheets must be fully zipped to ensure contact • There must be conductive connection of the roof sheets to: . Cross section showing connection and earthing across the structure. Roof elements that are bolted or riveted to one another (trapezoidal and corrugated profiles) for use with and without an organic coating are suitable without further requirements. Such a strike hitting a Kalzip clad building would cause. Kalzip has passed this examination in accordance with report BET/Corus 08-06-17-1d issued by the BET Blitzschutz und EMV Technologiezentrum .Part 3: Physical damage to structures and life hazard’. The prerequisite for this is that the roofs are capable of conducting current.any concrete sub-structure must be reinforced Construction details relating to these requirements should be checked with a lightning protection specialist. ‘Use of metallic roofs in lightning protection systems’.obo.OBO Bettermann. at worst.de). Figure 1 Kalzip as a conductor of lightning Figure 2 Kalzip as protective screening Figure 3.a conductive wall cladding (metal) . The same applies to welded profiled sheets. D-58710 Menden. roofs made of Kalzip profiled sheets are suitable without further requirements for use as a natural component of a lightning protection system. e. Kalzip 35 . no more than a small hole in one of the sheet seams. In the table in Supplement 4 of this standard. mill finish.a steel or aluminium sub-structure . metal roofs are suitable as ‘natural arresters’ for lightning protection. Type testing is required if the flanged or folded roof elements are coated. Kalzip as a conductor of lightning According to the lightning protection standard BS EN 62305-3 or VDE 0185305-3 ‘Protection against lightning .Design specifications 6. AluPlusZinc or AluPlusPatina) are suitable for use as a natural component of a lightning protection system without further requirements. they are connected to ground via approved lightning conductors from OBO Bettermann GmbH (www.5 Lightning protection using Kalzip aluminium profiled sheet envelopes Economic and efficient protection against lightning strikes and their effects can be achieved by using Kalzip systems: • As a lightning arrest or conducting device to prevent lightning strikes affecting the structure • As a protective screen to counter the electromagnetic effect of lightning strikes When installing Kalzip roof or wall cladding systems there is generally no need for dedicated or additional lightning protection devices. it is specified that uncoated metal roofs whose roof elements (profiled sheets) are connected by folding (Kalzip foldable aluminium in the finishes FalZinc and Titansilver) or by flanges (Kalzip profiled sheets in the finishes stucco embossed. Damage of this nature would lie above the line of weathering and could be easily sealed again with no risk of damage to either the sub-structure or to the rest of the Kalzip cladding. The calculated probability of structurally damaging lightning strikes is once in every 500 years.g.
Tests on Kalzip installations have shown that.Design specifications Kalzip as protective screening If the complete building envelope consists of aluminium (Figure 2 on page 35).e. The clips are diagonally distributed on top of the steel deck. the electromagnetic field inside the system. the Kalzip profiled sheets right across the building envelope should each be con-ductively connected to earth and any larger openings in the building should be by-passed.5 m.the ST Clips must be secured to a metal substructure . 36 Kalzip . IT networks and electronic control systems connected to the mains power supplies will be safely protected from damage and in most instances there will be no need for additional protective devices. each and every profiled sheet must be connected using short aluminium strips (minimum 50 mm wide and 1. in which case no other conductive structural connections are required.6 Roof systems 6.0 mm thick). • Kalzip must have a metal finish (stuccoembossed. The fixing points are visible underneath the supporting steel deck. i. the envelope will halt and collect the electrical energy from lightning and safely conduct it to earth thereby preventing dangerous voltages from affecting the power supplies. 6. the ST Clips must be connected with aluminium strips (minimum 60 mm wide and 0.5 m x 1. Larger openings must be by-passed using aluminium strips (minimum 50 mm wide x 1 mm thick) or must be connected to the wall substructure by means of aluminium frames. are reduced by a factor of more than 100.7 mm thick) below the sheeting.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. • Window openings should not exceed 1. AluPlusZinc or mill finish).6. corresponding voltages and strength of current. so that all corrugations of the deck are load bearing. Technical requirements for protective screening • The envelope of the building must be completely conductive at all points and connected to earth (Figure 3). 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 negative loads (due to wind or aerodynamic suction). Construction details relating to these requirements should be checked with a lightning protection specialist. For optimum screening. • Where coated Kalzip sheets are used: . • At the Interface between roof and walls. Kalzip systems used for both the roof and wall cladding.on timber substructures. The clips are either fixed directly to the top corrugations of the deck or indirectly by means of spacers. depending on the design of the screening.
the Kalzip sheet widths. the position on the roof (zone) and the load induction area. • 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. Distances depend on the design loads.6. An example of distribution according to zones is shown on the right. distinction must be made between the roof form. For the coefficient of wind pressure.2 Kalzip perpendicular on timber lining The clips are fixed directly to the timber lining. • The number and positioning of the clips as well as the joining elements are indicated in the assembly plan.Design specifications • A continous row of clips is to be fitted along the ridge and the eaves. (See dimension tables) 6. Positioning scheme 1 Clips Gable end Ridge Positioning scheme 2 Clips Gable end Ridge Pitch of the supporting deck TR Kalzip Pitch of the supporting deck clip Clip TR Kalzip Eaves Cover width Kalzip Rafter spacing Rafter spacing Eaves Cover width Kalzip Rafter spacing Rafter spacing d = clip distance TR = trapezoidal profile d = clip distance Distances not to scale TR = trapezoidal profile Determination of wind loads The wind loads are calculated from the gust velocity pressure and the coefficient of the wind pressure. The gust velocity pressure is determined from the wind load zone and the height above the terrain (location and height of the building). A carpentry attachment is not sufficient. The clips must be positioned on the timber lining in accordance with positioning diagram 1 or 2. • In between the clips are arranged diagonally. the pitch of the ribs and the support spacing of the trapezoidal sheet underneath. Rid ge Roof areas area H area G area F Gab Eav es el en d Kalzip 37 . then the timber board and its attachment to the substructure must be statically verified. More exact details for the determination of the wind loads are given in DIN 1055 Part 4. If the clips are to be positioned next to each other.
Depending on the design of the bottom skin. an intermediate section may be necessary with double skin roofs.Design specifications 6. The clips are normally positioned on top of each purlin.3 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. 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. In re-roofing projects with narrow spaced purlins it may be sufficient to position the clips on every second purlin only.6. Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet Positioning scheme 3 Clips Positioning scheme 4 Clips Clip positions with closer spaced purlins (Refurbishment) Ridge Ridge Clip Gable end Clip Kalzip Purlin Purlin Kalzip Eaves Cover width Kalzip Rafter spacing Rafter spacing Cover width Kalzip Rafter spacing Eaves Rafter spacing d = clip distance = purlin spacing c = purlin spacing d = clip distance Distances not to scale 38 Kalzip .
at the end of the installation surface (gable end). The first row of clips. is aligned precisely and fixed into the rail by means of a screw through the base of the clip.Design specifications 6. The DuoPlus rail must be long enough to cover at least two ribs of the trapezoidal deck and can be secured in it. A full layer of rigid insulation is used in the case of Kalzip DuoPlus 100. the DuoPlus clip and the special screws for fixing the rail onto the substructure. Ridge Positioning scheme Kalzip purlin roof The system requires that the DuoPlus rails are positioned parallel to the purlins. The special DuoPlus clips are inserted into the rail and rotated so that they are positioned parallel to the seam direction (minimum rotation angle = 45°). at the start of the installation surface (gable end). The final row of clips. DuoPlus rail Rail spacing Positioning scheme Kalzip rafter roof The system requires that the DuoPlus rails are positioned at an angle of 45°. the Kalzip Duo 100 system does not contain a full layer of rigid thermal insulation. In contrast to this. The DuoPlus clips are secured against shifting by means of a plastic strip that is attached in the factory. The remaining clips are inserted into the rail and positioned parallel to the Kalzip seam direction. 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. Ridge DuoPlus rail 45° Eaves Rafter spacing Rafter spacing Rafter spacing Rafter spacing Distances not to scale Eaves Kalzip 39 Panel spacing = Clip spacing Clip spacing DuoPlus clips Gable end Gable end DuoPlus clips . In the case of both systems. rigid thermal insulation. Strips of rigid insulation with a width of 24 cm and a thickness of 10 cm are simply inserted under the Kalzip DuoPlus 100 rails. The Kalzip roof structure can then be installed as normal. only the named components will be permitted. is also secured into the rail by means of a screw through the clip base. then a section of adequate length can be installed next to the first row (see positioning diagram for rafter roof and purlin roof). If this is not possible. The compressible thermal insulation is then placed on top and pressed over the clips. First of all the rigid thermal insulation is placed on the substructure. the DuoPlus rail.6. Strips of rigid insulation are used in the Kalzip Duo 100 system and any spaces between these strips are filled with soft thermal insulation or rigid insulation.4 Kalzip DuoPlus 100 and Kalzip Duo 100 The Kalzip DuoPlus 100 system always consists of a full layer of 10 cm thick. The arrangement of the rails and the number of connecting elements are outlined in the installation plan. Every tenth row of clips is fixed with a screw to prevent shifting.
The Kalzip composite clips are installed on the claw plates using the recommended fastening elements. In lower temperatures the substructure should be prewarmed accordingly. Kalzip FOAMGLAS® slabs are available in different formats and are suitable for substructures such as: • steel trapezoidal profiles • timber lining • concrete slabs The slabs are bonded to the substructure using either a cold-bonding agent or hot bitumen and the bonding process can be carried out in an external temperature as low as +5° C. in this case. A hot bitumen top coat seals the surface and creates a prepared base for the subsequent construction work. taking into account the respective roof geometry and wind/suction load. a PE film is used as a separating layer. the entire surface of the FOAMGLAS® and all joints are sealed with hot bitumen. Ridge Clip spacing Distances not to scale Eaves Composite clip Gable end Claw-plates Clip spacing Gable end 45° Rafter Spacing Rafter Spacing 40 Kalzip Eaves Composite clip Claw-plates .6. the composite clip with fixing elements and optional compressible thermal insulation. Positioning scheme Kalzip FOAMGLAS® system on trapezoidal steel deck or timber lining The FOAMGLAS® claw plates should be arranged at an angle of 45° Ridge Installation pattern for Kalzip FOAMGLAS® system on concrete slab The FOAMGLAS® claw plates can be aligned parallel to the eaves. the newly developed. No compressible thermal insulation is used with Kalzip AF. In the case of trapezoidal profiles. the L-shaped claw plate. A friction-fit. bonding is carried out on the upper flanges. The butt joints of the plates are completely sealed using the edge dipping process. In order to attach the Kalzip composite clips. In addition to this. a layer of bitumen with polyester fleece should also be applied above the insulation layer and claw plates. Kalzip AF profiled sheets retain the possibility of free movement due to a durable PE film as an isolating layer.4-475 issued by the Institute for Building Technology). When the substructure is closed. coldbridgefree connection is created with the insulation layer (in accordance with building approval Z-14.Design specifications 6.5 Kalzip FOAMGLAS® System The system always consists of FOAMGLAS® insulating slabs installed and bonded across the full surface area. galvanized L-shaped steel claw plates are inserted under heat in a fixed grid.
When Kalzip AF is used. is able to meet DIN 18234-1 requirements and can therefore be used in accordance with the construction standards for industrial buildings. In the case of large radii. It is manufactured from recycled glass products and the natural mineral materials sand. the L-shaped claw plate and the Kalzip profiled sheets are non-combustible and as so-called “hard roofing” are resistant to flying sparks and radiating heat (“fire from the outside”). Sound insulation The weighted apparent sound reduction index R’w for the roof design outlined below is approx 36 dB • Steel trapezoidal profile 106/250-1.0 unperforated • Adhesive • 100 mm FOAMGLAS®. flame retardants or binders.5·10-6 1/K ∞ = (impervious to water vapour) durable waterproof minimum +5° C -260° C to +430° C Kalzip 41 . Fire cannot spread across the foam glass insulating layer. ® Density Thermal conductivity Fire protection Compressive strength Coefficient of thermal expansion Resistance to water vapour transmission Water impermeability Installation temperature Temperature resistance ρ = 110 kg/m3 λ = 0. Only components which have been approved by the building authorities should be used with the FOAMGLAS® system. The reference values for the radii (r) are: r 12 m: slabs installed in a polygonal manner (grind edges if necessary) 6 m: half slabs installed in a r polygonal manner 6 m: special roof shape with r formed parts from factory Fire protection FOAMGLAS® is non-combustible and when used in combination with the fixing system and the Kalzip aluminium profiled sheets contributes towards fire protection.9 mm Depending on the structural design. the insulated slabs are connected in a polygonal manner or. The arrangement of the L-shaped claw plates and fastening components (type/no. dolomite and chalk in the thermal foaming process. We recommend that you seek their advice at the earliest possible stage. FOAMGLAS® insulating materials. does not release any emissions and does not shed any fibres. with L-shaped claw plate installed above • 3 mm hot bitumen top coat • 5 mm bitumen sheeting • 20 mm air space • E clips • Kalzip > 0. the Kalzip backing strip should be used during welding. the roof system can achieve a sound reduction value R’w of up to 56 dBa Dimensions and delivery forms: Formats: 600 x 450 mm 300 x 450 mm 600 x 600 mm 600 x 300 mm Slab thickness: 80–180 mm Technical data FOAMGLAS® D slab T4 DS FOAMGLAS is made from 100% pure glass and is therefore totally inorganic. It contains no CFCs. A roof featuring a design made from FOAMGLAS® and Kalzip specified by the manufacturer. in the case of smaller radii and freely shaped designs.) is specified in the installation plan. The suppliers have a team of technical advisors who will be delighted to advise you on these roof shapes.Design specifications The Kalzip profiled sheets are installed in the usual manner. they are delivered already in the respective shapes or cut to size at the construction site.04 W/(m·K) German building material class A1 / Euro class A (non-combustible) allowable σ = 0.23 N/mm2 αth = 8. Curved roofs All roof shapes are possible.
The clips have diverse holes in the baseplate.5 x L1) 2 screws A Ø 6. 3) 4) On steel purlin with flange thickness < 6 mm. The connecting elements must be made of stainless steel or aluminium. to steel purlin Aluminium clip with and without TK5 or TK15*. aluminium clip and composite clip type E on timber substructure 1) 2) Appropriate fastener system2) Blind rivet Ø 5 x 12 K9.0 mm (Self-drilling screws no longer recommended) Self-tapping fastener Ø 6.8 x 9.8 x 10 Blind rivet Ø 5 x 12 K9.75 .6. Please observe the information and specifications of the rivet and screw manufacturers. At the edges and corners of roofs as well as at the edges of walls.0 mm Bulb tite rivet Ø 5-12W t = 0.3.0 x 167 t = 0. depending on the substructure. depending on the spacer cap The length of the rivet or screw must be adapted to the required gripping length.0 x 27 SD2 . to steel purlin Aluminium clip with TK5 or TK15* to steel purlin Clip on timber substructure Aluminium clip and composite clip type E to timber purlin Aluminium clip and composite clip type E to timber lining E clip with spacer cap.5 Bulb tite rivet Ø 5 min.8 x 10 Blind rivet Ø 5 x 12 K9. the connecting elements must be dimensioned for increased wind suction loads. The anchorage depth of the screws in wooden substructures is determined according to DIN 1052 T2. Note: The number of connecting elements depends on the static requirements and must be determined in each case.5 x L1) Self-tapping fastener Ø 6. or composite clip type E respectively.1 44 65 36 65 The following fastener systems are recommended for the Kalzip system: Fixing position Eaves angle to Kalzip Ridge closure to seam Spacer to seam Ridge flashing to ridge closure Gable end channel to seam Gable end hook to aluminium clip and composite clip type E Fixed point: aluminium clip and composite clip type E to Kalzip seam Sealing joints Kalzip or soaker connection Top-hat section to trapezoidal sheet Kalzip DuoPlus 100 rail / rotatable clip Clip on steel substructure Aluminium clip with and without TK5* to steel purlin Aluminium clip with and without TK5 or TK15*.3 x L1) 3) 4) t = 2. The maximum accountable anchorage depth is 12 x ds. In the case of blind rivets and sealed blind rivets.2.5 .2 mm Screw SFS SDK31) Self-drilling screw Ø 5. Be sure to remove drilling swarf. Special connecting elements are used.1.5 x L (pre-drilled) SFS SDK2 6 x 45 / 60 Timber materials from 19 mm: 2 self-drilling screws SFS SDK 2 6.5 x L1) t = 1.10.5 x L (pre-drilled) 5 . Gesipa PolyGrip Alu/Nirosta Ø 4.20 .3 x L1) 4) t > 6. Gesipa PolyGrip Alu/Nirosta Ø 4. or composite clip type E respectively. to steel purlin Aluminium clip with and without TK5 or TK15*.5 Blind rivet Ø 5 x 12 K9.0 x L Timber lining from 30 mm: 2 screw A Ø 6.8 x 10 Self-tapping fastener A Ø 6. The application and the structural conditions should be taken into consideration when selecting attachments and material. 8 W SFS SL3/2 6. or composite clip type E respectively.15 mm longer fasteners are to be used.75 .3. 6.0 mm Self-tapping fastener Ø 6.8 x 9. Gesipa PolyGrip Alu/Nirosta Ø 4.6.1 7. The minimum anchorage depth of the screw in the wood is 4 x ds. Gesipa PolyGrip Alu/Nirosta Ø 4. Stainless Steel is used for the screws. (ds = nominal diameter of the screw). aluminium is used for the sleeve and stainless steel for the mandrel.Design specifications 6.0 6. The use of galvanised carbon steels is not possible.8 x 10 Sealing blind rivet Ø 4. TK = Thermal barrier pads * 42 Kalzip .8 x 10 Sealing blind rivet Ø 4.0 x 127 / SDK-S16 6.S16 .5 x 19 Blind rivet Ø 5 x 12 K8 . Gesipa PolyGrip Alu/Nirosta Ø 4.0 mm (Self-drilling screws no longer recommended) 2 drilling screws Ø 6. to steel purlin Aluminium clip with TK5 or TK15*.7 Connections The Kalzip profiled sheets are connected to the substructure by clips made of extruded aluminium.2 mm Screw SFS SDK21) t = 1.0 .
stainless steel Kalzip Clip Note to Blind rivet: See Kalzip approval and table on page 42.5 45-60° Composite clip Fixed point with Gesipa PolyGrip Aluminium-Blind rivet Ø 4. However. If the fixed point is not located directly at the roof ridge. a variation in movement of ± 0. 1 mm/m in winter (-20°C). No second fixed point may be manufactured. The folding up is the final protection against the ingress of rain water into the ridge. Alternatively. 6. then the ridge must be designed as a sliding structure to be able to accommodate the expansion movement of the profiled sheets. If the fixed point is positioned elsewhere. the rivet is inserted and the swage head is covered by the large flange of the next profiled sheet. Each Kalzip profiled sheet may have only one fixed point. If these requirements are not fulfilled then the maximum values stated above must be assumed. Fixed points are statically verified and are to be taken from the installation plan. since the composite clip is made of plasticsheathed steel. The thermal expansion coefficient of aluminium in the observed temperature range is approx 24 x 10–6/K. If a composite clip is used for the fixed point. Each Kalzip profiled sheet is to be secured at the fixed point against displacement. gable ends The standard ridge consists of three components: The ridge closure with its chamber reduces the wind pressure and at the same time fixes and protects the foam filler against UV radiation and birds. fixed lighting elements etc. (see page 13). On extremely low pitch roofs both the eaves filler and the folding down of the bottom sheet ensures that no water can flow back towards the building. A hole for the blind rivet is drilled through the small flange into the head of the clip at an angle of 45-60° degrees. For the further installation of the roof surface.8 x 10 K9. the Kalzip profiled sheets are placed with the large flange on the small flange. there will be an expansion in sheet length of approx. Kinks in the Kalzip profiled sheet.8 Thermal expansion Temperature changes can cause length variations and these must be taken into account. Aluminium clip Fixed point with Gesipa PolyGrip Aluminium-Blind rivet Ø 4. Rust stains on the profiled sheets are thus avoided. When the profiled sheets are installed at a given temperature of 20°C. then the elongation of the Kalzip profiled sheets from the fixed point to the roof ridge must be taken into account when forming the covering of the roof ridge.5 mm/m may be applied to the sheet length in practice. 1.Design specifications 6. Kalzip 43 . 6. It is a fact that ventilated ridges cannot be completely sealed against snow. aligned to the eaves and only then pressed into the next row of clips. and the substructure can usually absorb elongations. Generally the ridge is also the place where the fixed point is located. In case of high sealing demands or direct exposure to strong wind additional measures such as the installation of wind deflector plates or similar devices will be neccessary.5 Screw M6. eaves. as adjacent components are also subject to variations in temperature. The foam filler acts as an additional “sealing” of the end of the Kalzip sheet preventing rain water from penetrating into the system. The gable end is secured by the gable end hook and the gable end clamping section. Sealing washers must be inserted on both sides (bolt head and nut).9 Design of fixed points Kalzip aluminium clip / Kalzip composite clip The fixed point prevents slippage of the profiled sheets and is the point of each Kalzip profiled sheet that is not subject to a change of length. At the eaves the drip angle stiffens the bottom sheet and keeps the eaves filler in position. the fixed point is manufactured by the insertion of bolts through the webs of the Kalzip and the fixed point clip. all drilling swarf must be removed from the profiles.5 mm/m in summer (+ 80°C) and a contraction in sheet length of approx. are likewise fixed points and must be taken into account.8 x 10 K9.10 Ridge.
Joints can be either welded or sealed. The vapour barrier is installed on the soaker and extends up to the height of the thermal insulation. The welding seams should be supported.g. the requirements for absolute tightness of the overlapping joints are very high. Therefore it is necessary to take great care when making overlapping joints. special curved soakers are required. Overlaps are positioned on top of the support. The structure underneath the welding seam must be secured against fire. it is recommended that the area around the opening is reinforced with rigid thermal insulation. Welding is the recommended option. Welding seams must maintain a minimum distance of 100 mm to the Kalzip composite clip in order to avoid the clip being damaged by heat. etc.Design specifications Welded connecting frame 6. if the joint is located at the fixed point. Skylights and smoke extractors must not be walked on. The soakers can either be welded or sealed (in the case of a minimum roof pitch of 2.20 mm.For arched roofs.11 Skylights/Smoke/heat extractors Specially designed soakers are supplied for the installation of skylights and smoke extractors. Large lighting elements or rows of sky lights can require special solutions and must be planned in detail.9°) into the roofing. 10 . the fire brigade must be informed before carrying out welding work. Otherwise the profiled sheets have to be joined directly next to the support. As these must be regularly accessed for servicing and maintenance work. If necessary.12 Transverse joints It is not always possible to produce the required Kalzip sheet length in one element. The covering frame is either welded or sealed to the Kalzip sheets and is able to move with the Kalzip roof skin. 6. by means of the Kalzip welding underlay. Especially with arched roofs the maximum loading height of the trucks must be observed. e. 44 Kalzip . The upper connecting frame securely connects/seals the skylight or smoke extractor in the roof skin. Welded joint The Kalzip profiled sheets to be joined are overlapped by approx. In most cases the length of the sheets is determined by transport limitations. so that the sheets must be joined by overlapping. Obviously. The steel soaker is securely connected to the substructure.
As. The overlap is 200 mm.9 m)* 305 every 2nd sheet every sheet 333 every 2nd sheet every sheet Kalzip 65/.5 m (0. On concrete substructures a suitably anchored steel section or timber batten (minimum thickness 40 mm) must be inserted. With metal or timber substructures the clips are directly fixed to the substructure. the thermal barrier pads under the clips provide sufficient separation.13 Substructures Kalzip roofs can be installed on all kinds of substructures.9°) The profiled sheets are installed in a precise sequence according to the assembly instructions. Drilling pattern 2 1 3 eaves angle as lateral stiffener Drilling pattern 1 Drilling pattern 2 6.. Drilling pattern 2 Drilling pattern 1 6. 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. with the exception of Kalzip AF. there is no direct contact between Drilling pattern 2 b = Fixing distance depends on substructure Clip bar spacings Roof projection (a) over last support 1m (0.16).Design specifications Sealed joints (only possible with minimum roof pitch of 2. The length of the clip bars is outlined in the diagram opposite.15 Installation rules Individual verification is required in each and every case. *Values apply to clip type L10.5 m)* 1. 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 projections and 6. 400 every 2nd sheet every sheet 422 every sheet impossible 429 every sheet impossible 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. additional substructures are dispensable providing that the clips are installed as clip bars.. The table is applicable for a snow load of 0.. Drilling pattern 2 2 4 6. Kalzip and the substructure..14 Cantilevers/clip bars 2 1 Direction of assembly If the roof is to protrude at the eaves. 50/.75 kN/m2. With metal substructures contact corrosion must be taken into consideration. Roof projections are not accessible. Kalzip 45 . The ends of the Kalzip sheets must be joined with an eaves angle.
With a sheet length of greater than 12 m the downpipe must be designed to accommodate the elongation of the tracks.90 s s d 1.9 Clip length 65/333 x 1. The clip is attached by using either 2 rivets in the clip head or 2 screws.80 0.80 s s d 0. it is advisable to always use load spreading equipment when gaining access.50 kN/m2 Roof projections (a) in meters 0.00 0.16 Roof projections without clip bars An additional substructure can be omitted in certain conditions where the roof extends beyond the eaves.0 and up to 1.0 Clip length 50/429 x 0.00 0.00 0. Please observe and follow all instructions relating to safety measures and fall arrest equipment. 46 Kalzip .00 1. The roof projection (a) is calculated from the spacing between the first clip at the roof edge and the outer edge of the Kalzip.60 s s d 1. In this kind of design a short clip piece can be installed within the seams to secure the gutter support.9 Clip length 65/305 x 1. When the Kalzip profile sheets are visible from below.5 m.00 1.00 s s d 1.60 0.90 s d d 1 2 3 4 5 6 7 8 9 10 s: first clip at the roof edge in standard length/d: first clip at roof edge in double length 6.00 1.50 s d d 1.17 Installation instructions for long profiled sheets Kalzip composite clips should be installed (composite clip type E) in the case of profiled sheets with spacings from the fixed point of more than 20m.Design specifications a 6.00 0. Roof projections should be fitted with clip bars in the case of values above 1. As there is no connection to the substructure.00 1.00 1.60 s d d 1. the clips should be placed on supporting top-hat profiles.00 kN/m2 2.80 0.9 Clip length 50/429 x 1. whereby the roof projection without clip bars and subsequent accessibility is adjusted to comply with the respective building height and material thickness (see also table).9 Clip length 50/333 x 1. The sheets must be connected with the eaves angle in each case. Clip length in accordance with table Roof projections constructed from Kalzip profile sheets Line Kalzip type 50/333 x 0.00 1.80 0.g. Please note: The roof projections are not accessible during installation or before the seams are zipped.0 Clip length 65/400 x 0.00 0. Sheet length > 20 m > 20 m F E E E E E E E E > 20 m > 20 m > 40 m E E = composite clip F = fixed point E E E E E F E E E E E E Additional instructions for rafter roofs: in the case of profiled sheets > 20m.00 0.0 Clip length 65/333 x 0.00 s s d 1.50 kN/m2 1.00 1. The minimum length of the Kalzip tracks is 5 m.90 0.9 Clip length 65/400 x 1. by means of moveable pipe laps.00 1. the Kalzip profile sheets are able to expand freely.60 s d d 1. e.00 1.80 s s d 1. This overhang can be installed without clip bars.0 Clip length Wind suction 2.0 Clip length 65/305 x 0.
5 Kalzip 47 .5 1.5 clips per m2 2.21 0.26 0.29 0.21 WLG 035 U value [W/(m²K)] 0.24 0.23 0.22 0.19 Related to the calculated value for the thermal conductivity.41 0.30 0. Thickness of insulation [mm] 90 100 110 120 130 140 150 160 170 180 WLG 040 U value [W/(m²K)] 0. 7.27 0.37 0.38 0. Kalzip dimensioning tables 7.5 3.1 0.2 220 240 0.2 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040) thickness WD [mm] 0.34 0.32 0.Dimensioning tables 7.3 160 U value [W/(m2 K)] 180 200 0.24 0.26 0.28 0.1 Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035.33 0.20 0.
35 1.20 0.70 0.80 1.50 1.80 0.45 1.80 0.70 1.55 1.80 3.40 1.80 2.80 1.65 1.45 2.30 1.45 1.85 1.25 1.95 0.15 2.30 loads 1.98 1.20 1.80 1.80 1.00 1.45 1.75 2.85 1.80 0.55 1.90 1.20 1.20 2.30 2.80 0.10 1.10 2.60 1.80 0.00 2.10 1.10 1.75 1.35 1.90 2.1 Rafter roof (multi-span sheets) with composite clips Clip fixing: directly to trapezoidal steel deck tmin = 0.50 1.00 1.10 2.30 2.Dimensioning tables 7.00 2.75 mm.55 1.55 0.05 1.80 0.15 3.3 Clip spacings 7.20 0.00 1.90 2.00 2.80 1.00 1.35 1.70 2.00 2.40 1.85 2.90 2.70 0.60 2.20 0.80 0.75 2.45 1.95 0.50 2.00 1.70 0.30 1.20 1.70 1.80 0.80 65/400 50/333 50/429 NatureRoof 65/333 Supporting width in [m] *The supporting widths for snow load also apply to the wind suction load in the normal range for building heights The clip spacing must not exceed half the supporting width of the supporting trapezoidal steel deck.10 1.56 1. Two fastener systems per clip (Self-tapping screw SFS SDK).00 2.15 1.45 1.3.85 0.85 1.50 1. 48 Kalzip .55 2.50 3.35 1.80 0.65 0.40 2.10 1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1.20 2.30 2.55 2.95 1.95 0.85 0.35 1.90 1.00 2.00 1.75 2.00 2.70 0.90 1.85 1.70 1.52 0.45 1.00 1.85 1.45 0.10 1.05 100 m.80 1.30 1.00 1.80 0.00 2.15 3.55 1.80 3.70 0.80 2.00 2.70 1.20 1.45 1.70 1.65 0.10 2.55 1.25 2.20 0. Line Kalzip type 65/333 65/305 Sheet thickness t in mm 0.90 1.65 0.00 2.20 1.00 3.80 0.80 1.00 1.30 2.20 Pressing loads* kN/m2 0.55 2.30 2.20 2.55 1.00 2.50 2.80 3.00 2.70 1.70 1.40 1.20 1.50 1.45 1.80 1.55 Uplifting kN/m2 0.10 0.80 1.00 2.80 0.10 1.15 3.95 3.00 2.65 1.15 3.00 1.45 2.00 2.95 0.40 3.80 0.00 2.10 1.50 2.30 2.80 1.95 1.80 1.70 1.80 1.80 0.20 2.75 0.00 2.90 1.45 1.80 3.80 1.44 2.00 2.80 1.80 0.50 3.15 0.60 2.
80 1.15 3.70 1.20 1.45 2.30 1.30 2.80 0.50 2.10 1.00 2.00 1.80 2.80 1.80 2.00 2.50 1.00 2.80 2.80 1.60 2.35 1.35 1.10 2.55 1.55 0.45 1.00 2.70 2.50 2.60 3.45 2.80 1.70 1.15 2.00 1.55 Uplifting kN/m2 0.95 1.85 1.15 2.00 2.45 2.20 0.15 2.75 2.20 0.50 1.20 2.00 2.70 3.15 1.20 2.70 1.55 1.10 1.95 2.55 0.25 1.55 3.55 1.80 2.50 2.00 1.85 0.85 1.98 1.50 1.15 2.70 1.55 1.80 3.20 Pressing loads* kN/m2 0.Dimensioning tables 7.15 2.75 2.75 1.80 0.20 1.15 65/400 50/333 50/429 NatureRoof 65/333 Supporting width in [m] *The supporting widths for snow load also apply to the wind suction load in the normal range for building heights Kalzip 49 .80 3.05 0.45 0.44 2.95 0.55 0.00 2.50 2.90 1.00 2.60 1.50 2.70 1.70 1.10 2.00 1.90 2.70 1.15 1.90 1.00 2.30 2.20 1.2 Purlin roof (multi-span sheets) with composite clips Clip fixing on steel purlins or steel spacer construction 1.80 1.80 0.95 0.55 1.35 loads 1.15 0.70 2.20 2.00 2.00 1.70 2. Line Kalzip type 65/333 65/305 Sheet thickness t in mm 0.15 1.90 2.85 1.00 2.15 1.3.30 2.55 1.70 0.00 2.80 2.80 3.20 2.95 1.80 0.80 0.60 2.95 1.35 1.55 1.00 1.80 1.20 2.52 0.90 1.20 1.40 3.10 1.80 3.10 1.40 2.90 1.00 2.55 2.95 0.70 3.00 2.30 1.65 2.95 3.30 1.85 0.90 1.50 1.30 0.70 2.00 3.00 2.15 1.40 1.30 2.15 3.50 2.50 1.65 1.80 2.20 0.10 2.00 1.00 2.00 2. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1.56 1.00 2.5 mm or SFS SDK.35 2.40 2.40 1.55 1.75 1.95 1.55 1.80 2.90 2. screw diameter 5.30 1.35 1.15 3.20 0.70 1.35 1.80 100 m.50 2.20 2.95 1.25 2.35 1.30 2.80 1.70 1.85 1.15 1.00 3.90 2.80 0.65 2.80 1.20 1.5 mm: 2 fastener systems per clip.80 1.80 2.30 1.
44 1.00 1.90 1. The values stated are guide values.50 0.20 0.50 3. T +49 (0)2043/408-0.3 Kalzip ProDach (adjacent) with aluminium clips Clip fixing: directly to ProDach fixing rail.20 2.90 1. They do not serve as a replacement for project-specific consultations.60 0. 2 fasteners per clip (SFS SDK2-S-377-6.90 1.20 1.40 1.40 3.3.3.00 2.30 2. Line Kalzip type AF 65/333 Sheet thickness t in mm 0.80 0.90 loads 0.60 1.30 1.60 2.80 2.75 mm.52 0.00 1.98 1.4 Kalzip AluPlusSolar* When using Kalzip aluminium clips.56 0.60 1.20 1.70 2. Rockwool Straße 37-41.40 1.90 3.50 0.10 1.00 1.44 1.20 1.40 1. D-45966 Gladbeck.80 Uplifting loads kN/m2 0.00 2.80 2.60 1.30 2.25 2.00 1.80 0.90 1 1.48 2.10 0.0 x L).80 2.90 1.90 1.90 1.56 0. OHG.90 1. 7. Line Kalzip type AF 65/537 Sheet thickness t in mm 1. The values 50 Kalzip . Please contact: DEUTSCHE ROCKWOOL MINERALWOLL GMBH & CO.50 2.60 0.90 1.00 2.20 Pressing loads are transmitted directly through contact onto the substructure 2.52 0. Clip fixing: directly onto steel trapezoidal substructure tmin = 0.80 0.20 Pressing loads* kN/m2 Pressing loads are transmitted directly through contact onto the substructure Uplifting kN/m2 0.40 2.30 0.50 0.70 0.00 Pressing loads* kN/m2 0.Dimensioning tables 7.60 2.80 0.40 *in accordance with DIN 1052 *The supporting widths for snow load also apply to the wind suction load in the normal range for building heights 100 m.93 0.90 2. 2 fasteners per clip.90 1.80 2.40 2. The table does not apply to Kalzip DuoPlus. If the Kalzip profiled sheets are not fitted with rigid thermal insulation. access is only possible using load spreading equipment.20 1.60 1.00 1.80 0.90 2.70 Supporting width in [m] Separate design calculations are required for the substructure. Details on Kalzip composite clips available on request.70 1.80 2.75 1. Separate design calculations are required for the substructure. (fasteners: SFS SDK2-S-377-6. F +49 (0)2043/408-444.00 1.00 1.0 x L).20 1.70 1.10 1 2 3 4 5 6 7 8 9 AF 65/434 AS 65/422 0.70 0.50 0.
45 corrosion resistance 30 D design specifications Duo DuoPlus E eaves ecological aspects extreme lengths F fall arrest systems fire protection fixed point FOAMGLAS® insulation form filler G gable end gable end clamping section gable end hook gable end profile galvanizing L length change length expansion lightening protection length tolerance M maintenance and cleaning material compatibility metallic enamels minimum curving radii minimum roof pitch moisture proof N natural curving NatureRoof nominal sheet thickness non-ventilated roof O official approval on site curving oxide coating P PVDF coating photovoltaics plating polyester coating positioning schemes ProDach ProDach insulating system profile sheet dimensions protective film purlin roof 43 43 35 6 29. 40. 10 23 11 10 40 50 21 6 11 49 V vapour diffusion vapour barrier ventilated roof W welded joints wind suction forces Z zinc chromate coating zipping machine 33 12. 29. 43 22. 43. 42 16. rotatable clip ridge 13. rivets 48 40 31 13 12 13 39 11 29 37 24 36 46 9 43 42 30 7 Kalzip 51 . 45 K Kalzip Kalzip Kalzip Kalzip Kalzip Kalzip AF AluPlusSolar DuoPlus rail range of applications SolarClad Solar Power Systems 20. 21. 43 13 30 I insulating materials installation instructions for long profiled sheets installation rules 16. 12. 47 47 14. 31 32 37 20. 24.40. 25.50 15. 42. 41 9. 32 7. 29 34.21. 27. 42. 41 43. 30 14 10 16 . 11 colour coating 11 colour qualities 11 composite clip 8. 17 32 24 30 T thermal barrier pad thermal expansion thermal transition coefficient timber top hat section transverse joints trapezoidal steel sheet transition sheet transport U U-value 42 43 47 21 17 44 16 12 24. 50 9 16 . 42. 21. 41. roof projection 45. 32 6. 29 31 42 45 25. 39. 20. 50 10 10 20. 13. 22. 43 compressible adhesive tape 12 concrete and mortar 30 condensate 33 connecting frame 44 connections 42 contact corrosion 30. 20. 45 21. 29 12 7. rafter spacing 37 recycling reinforcing profile for verge flashing rib filler ridge profile rigid insulation 18. 39. 7 44 44 24 14. 44 34. 42. 43. 46 clip bars 45. 26. 15 48 . 29.27 24 33 26 19 6 16. roof systems 16. 41 46 45 R rafter roof 36. 39 9.Index A accessibility accessories aluminium clip AluPlusPatina AluPlusZinc assembly B bituminous coating building material class 26.23 23 22 S safety appliances safety system saving resources screws sealed joint sheet thickness shape variations skylights smoke extractors smooth curving snow guard snow load soaker sound absorption spacer steel step stucco-embossed substructures 14 14. 33 18. roof areas roof pitch 19. 41. 46 21 13 38. 16. 46 clip spacing 48 coil coating 10. 32 30 11 25 . roll forming roof anchor 15. 33 16 44 50 12. 21 22. 43. 23. 13. 17. 43 43 13. 22. 30 41 C cantilevers 45 chemicals 30 chlorinated rubber paint 30 clip 36 . 18. 17.
Kalzip cannot guarantee that printed literature will contain the most recent updates.www.com English The address of your nearest local sales ofﬁce can be found on our website: www. the latest editions are available to download at www.kalzip. From time to time our product range may alter as a result of our continued commitment to product innovation and development.com.O.98 34-100 E germany@kalzip. Box 10 03 16 · D-56033 Koblenz T +49 (0) 2 61 .com adhoc media gmbh:901:EN:01/2011 . 20-22 · D-56070 Koblenz P. Copyright 2011 Kalzip GmbH Part of Tata Steel Europe Ltd.kalzip.98 34-0 F +49 (0) 2 61 .com The product and technical information contained in this document is accurate according to our knowledge at the time of publication. Details do not refer to any specific application and cannot give rise to any claim for compensation.kalzip. Kalzip GmbH August-Horch-Str.
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