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Corus Bausysteme

Kalzip sets standards

Architectural highlights

Kalzip vorbildlich und richtungsweisend

CONTENTS

East Terminal, Frankfurt on Main (D), 1993.


Kalzip special grey colour, partly barrel-vaulted.
Architects: JSK Perkins & Partner, Frankfurt.

Oberhausen Arena (D), 1996.


Kalzip stucco embossed and RAL 8004 Polyester.
Architects: DLA-Ellerbe Becket, Wakefield (UK).

Leisure and recreation centre Magdeburg (D), 1999.


Kalzip stucco embossed, tapered and pre-curved.
Architects: Edenne von der Brelie, Hryniewicki &
Partner, Paris; Roschke & Partner, Hamburg;
Dipl.-Ing. H. Baas & J. Schulte, Hamburg.

Solar cell factory Gelsenkirchen of Deutsche Shell AG


(D), 1999. Kalzip stucco embossed. Architects:
Dipl.-Ing. Uwe Hohaus & Partner, Hamburg.

H10 Airbus Hangar, Toulouse/Blagnac Airport (F),1991.


Kalzip stucco embossed.
Architects: M. Laborie, Toulouse.

Lightweight and environmentally


friendly

4-5

Flexible shapes

6-7

Functional elementary system

8-9

A well-conceived system

10

Various colours and finishes

11

Proven technical construction

12

Totally convincing

13

Advantages of rigid insulation

14-15

Elegant surface structure

16-17

Sound-proofing and heat-insulation

18-19

Guaranteed corrosion-proof

20

Long-lasting function

21

Range of well-proven products

22

Mature complementary products

23-24

Trend-setting innovations

25

Excellent for renovation

26-28

Manufacturing on-site

29

Saves resources

30

Geesthacht College (D), 1995 (see also cover


photograph). Kalzip RAL 9006, partly tapered.
Architects: Hchel Engelken + Partner Beinhoff,
Buxtehude.

Architektur ganz oben

Yesterday - just a vision. Today Kalzip.

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

A new architectural dimension


There are visionaries amongst our
customers. We complement them with
technical collaboration. The result are
buildings which set the standard and lead
the way in terms of shape and function.
High demands for safety and quality of
construction merge into a new architectural dimension as demanding, functional
and economic as the task requires.
Aluminium is the material
Lightweight yet strong, corrosion-resistant,
durable, easy to work with, can be welded
and combined with other materials.

It is non-flammable, conducts heat and


electricity, is non-toxic, can be recycled
and used again.
Kalzip is the product
The result is something which is often
exceptional and unique in its technology.
We admire the creativity and far-sighted
planning of our customers. We appreciate the confidence placed in us as
manufacturers and reciprocate by
providing corresponding products and
services. It is our aim to unburden the
designer, leaving him free to concentrate
on what is important the room
for the essential.

Retractable roofing construction with Kalzip


stucco embossed sheets.

Leicht und umweltgerecht

The environmental friendly building envelope with a lightweight


structure. Thats Kalzip.

Sports Centre, Annemasse (F), 1992. Kalzip stucco embossed, concave-convex. Architects: Richard Plotter, Annemasse.
Photograph right:
New Exhibition Centre, Munich (D), 1998.
Kalzip stucco embossed.
Architects: BBP Arkitekter A/S, Copenhagen.
(Competition design/Artistic direction);
Architects: BDA/DWB Prof Kaup, Dr. Ing. Scholz,
Dipl.-Ing. Jesse + Partner, Mnchen;
Obermeyer Planen + Beraten, Mnchen.

Lightweight structure using Kalzip


The lightweight Kalzip roof structure
can easily bridge large spans, even with
curved lines.
Kalzip is a well-proven, environmentally
friendly building system: lightweight,
strong, weather-proof, can be precisely
adapted and is flexible in shape. Whats
more, it is ideal for combining with other
building materials such as those used in
the roof build-up which create what we
consider indispensible, comfort and safety.

Saving energy and resources by utilising


re-usable building materials in lightweight structures are important factors
when planning building work. Kalzip
does this very simply. Because it is light
weight, only 3-5 kg/m2, the amount of
material used in the supporting structure
is reduced, thus saving resources.
Installing large sheets instead of layers
of small components saves time. High
costs on-site are replaced by more
efficient industrial production techniques.

Living in harmony with nature that is


both our aim and our challenge.

Flexibel in der Formgebung

You conceive the designs. We supply the protective shell.

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

Your imagination is our challenge


Every day, we work for innovative
building shapes. So every day we rise to
new challenges. The result is often more
than just a building shell in the normal
sense because, with Kalzip, there
are many buildings which have a strong
visual impact.

A multitude of shapes and colours


can be used
Kalzip is flexible and can be adapted
to suit the requirements of progressive
architects, both in terms of building
geometry and size. Planning details are
computer-controlled and transferred to
production using CAD/CAM systems.
Dimensional accuracy of manufacture
guarantees the maximum precision and
consequently, fast, trouble-free
installation.
As experienced advisers, we can give
you all the support you need right from
the early planning stages.

Raab Tennis Hall, Fischbach (D), 1993.


Kalzip RAL 6033, partly smooth curved and tapered.
Architects: Ing. Bro Uwe Erbach, Illingen.

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

Creativity Centre of shoe factory Rhode, Schwalmstadt


(D), 1999. Kalzip stucco embossed, factory curved
incorporating 3 different radii. Architects and overall
planers: Koschany, Zimmer & Assozierte, Essen.

Hot springs Xanten (D), 1999. Kalzip coralred poly coated. Architects: IPP Ingenieurbro fr Bauwesen,
Prof. Dr. Ing. Polony u. Partner, Kln.

Funktionell im Baukastenprinzip

Attention to detail. Youll recognise this in Kalzip.

Kalzip is much more than just an


industrial prefabricated metal roofing
system
Precision, functionality and great shapes
in regards to both detail and fixing thats
Kalzip.
The Kalzip system offers proven
accessories:

For roof openings


Komplementery items for verge,
ridge and eaves areas

Translucent elements including


accessories

Soakers
Cover strips
Seam clips
Specially made components, e.g. for
walkways, solar equipment etc.
Kalzip is a building system which has
been continually developed over more
than three decades. All components
complement each other both functionally
and visually.
This allows the user to ensure that he has
made the right decision.

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

Audi Development Centre, Ingolstadt (D), 1987.


Kalzip stucco embossed, smooth curved.
Architects: Henn + Hann, Mnchen.

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

Westbad Mnchen, Munich (D), 1999. Kalzip stucco embossed and tapered. Architect: Herbert Killinger, Mnchen.

Administration Building, Corus Bausysteme, Koblenz (D). Extension 1996.


Kalzip stucco embossed, smooth curved. Group of architects: Voss, Naujack, von Canal, Koblenz.

Airport Office Centre, Munich Riem Airport (D), 1988.


Kalzip stucco embossed, smooth curved.
Architects: Mhlmeier + Scheller, Mnchen.

Durchdacht im System

The Kalzip system the result of great innovative effort.

Kalzip the complete solution

Lightweight and quick to install

Durable, maintenance-free

Special aluminium clips have to be used


for joining the Kalzip profiled sheets
with the substructure of the roof. They
are locked into the seam and will be
overlapped by the following Kalzip
element, so that the fixing elements are
hidden under the roofing. This ensures
that the roofing elements need not to be
punctured for fastening.

In its standard form, Kalzip has a


stucco embossed finish with a protective
plating on both sides.

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3

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5
6

A typical Kalzip roof structure:


1
2

Kalzip profiled sheet


Kalzip aluminium
secret fix clip
Thermal-insulation
(compressible)

4
5

Thermal barrier pad


Vapour control barrier
and air-lock layer
Trapezoidal sheet

This helps to make the material


impervious to external influences.
Plating

Core material

Kalzip

is a flexible, weather-proof,
easy-to-install system made of aluminium
profiled sheets and well co-ordinated
accessories.
Installed using the modular design principle, Kalzip is the complete solution for
high quality shape and function
throughout the buildings entire life.

Rolled on both sides, Kalzip protective


plating increases the strength and
service-life of the buildings aluminium
shell. Colour coating fulfills a purely
visual function.
The newly developed sliding clip even
improves the as such excellent sliding
properties of the Kalzip roofing.

Physical construction aspects such as


sound-proofing, heat-insulation and
moisture-protection, as well as climatic
and health requirements, are taken into
consideration in the layers of the roof
structure.
If produced on site the lightweight sheets
can be supplied in lengths of 80 metres
and more and allow a particularly fast and
economical installation.
The mechanical zipping of the seams
produces a load bearing connection.
Vapor diffusion, however, is still possible
in this area enableing residual moisture
to evaporate after the installation.

Kalzip meets current-day


requirements in a special way:

Lightweight
Great strength
Resistance
Corrosion-proof
Practically maintenance-free
Resistant to atmospheric effects
Flexible shape
Non combustible
Can be used as lightning conductor
Can be re-usable
High quality material
Can be recycled
Can be re-used, maintaining full
functional quality

10

Variabel in Farbe und Oberflche

You decide how it looks.

Kalzip AluPlusZinc symbiosis


of two well-established, timeless
materials
Kalzip AluPlusZinc is a fine, technically
demanding product manufactured by
Corus Bausysteme GmbH featuring a
matt zinc patinated surface. The timeless
aesthetic character of the pre-zinc patina
weathered opens a wide field of application for prestigious buildings especially
in cities, where integration is required
and where a high quality appearance
and a harmonic design are fundamental
features. The patina on both sides of the
profiled sheets develops its appearance
under external influences it is alive.
Klazip AluPlusZinc is a suitable
cladding for roofs and walls of new
buildings and for the refurbishment of
existing structures as well.

11

The fusing of the two well matching


materials aluminium and zinc is effected
in a patented process (PEGAL). Combined with the industrial production and
our strict rules of quality management
this process leads to a new product
setting new standards. The well-known,
world-wide appreciated advantages of
our aluminium building system are of
course guaranteed with Kalzip
AluPlusZinc as well.
Colour finishes have become
increasingly popular for Kalzip
over the last decade
You decide whether to use RAL or a
special colour shade. We do the rest.
For Kalzip, we only use high-quality,
weather-proof paint systems. You can
choose between a polyester- or PVF2based paint. Ask for the Kalzip
colour chart.

Oberhausen Arena (D), 1996. Kalzip stucco


embossed. Architects: DLA-Ellerbe Becket,
Wakefield (UK).

Bewhrt im technischen Aufbau

Also safe to construct.

Kalzip profiled sheet


Thermal-insulation (compressible)

Kalzip aluminium secret fix clip with


thermal barrier pad
Vapour control barrier and air-lock layer
Trapezoidal sheet
Kalzip
truss roof
construction

Truss

Kalzip profiled sheet


Thermal-insulation (compressible)
Kalzip aluminium secret fix clip with
thermal barrier pad
Top hat section
Vapour control barrier and air-lock layer
Trapezoidal sheet
Kalzip
purlin roof
construction

Purlin

Kalzip profiled sheet

Thermal-insulation (compressible)
Kalzip aluminium secret fix clip with
thermal barrier pad
Timber support
Vapour control and air-lock layer
Kalzip
rafter roof
construction

Wooden supporting substructure


Rafter

12

berzeugend als Ganzes

A building system with no "ifs and buts.

Kalzip truss roof construction

Kalzip is convincing because:

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3

Kalzip purlin roof construction


1

It offers unlimited possibilities, high quality construction and flexibility


As a ventilated and non-ventilated roof design, it is suitable for all roof shapes and pitches
from 1.5 degrees and is suitable for all sub-structures and supporting structures.
It is flexible and can be adapted to suit the requirements of private and public sector clients
whatever the buildings basic shape, geometry or size.
Its light weight makes it particularly suitable for renovating old roofs. Kalzip AF and
"Rockwool Prodach insulation systems are particularly suitable for renovating corrugated
asbestos roofs. Approval from the professional control board is required in each case.
Continuous sheets can be produced in lengths of 80 m and more.
It has a neutral colour, timeless aluminium stucco embossed finish with a discreet surface
which is appreciated by knowledgeable experts.
Available in a multitude of colours. RAL and special colours, all of high-quality and
weather-proof.
Kalzip AluPlusZinc has a matt zinc-patinated smooth surface (PEGAL process) and excels
by its high natural strength, its increased resistance against abrasion due to weathering and
its fine appearance.
It allows a wide scope of different shapes: straight, convex or concave roll-formed, crimpcurved, tapered, tapered-convex curved ... Our growing know-how of the ductility of the base
metal aluminium again and again opens new design aspects.

Excellent construction qualities

High thermal-insulation requirements can be easily fulfilled. The roof structure can be easily
adapted to suit the buildings exact requirements by selecting the appropriate thickness of
insulation material.
The construction makes high-quality sound-proofing easy and simple.

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4
5

Durable and economic

Corrosion-resistant aluminium alloy.


Increased resistance against acid rain and industrial emissions due to the protective

plating on both sides.

Non-sensitive to UV rays, resistant to micro-organisms, longlive expectancy.


Extremely fast installation being to a large extent independent of the prevailing

weather conditions ergonomic and cost saving due to prefabricated components.

Kalzip rafter roof construction

Extremely safe throughout its entire life

Special aluminium clips have to be used for joining the Kalzip profiled sheets with the

substructure of the roof. They are locked into the seam and will be overlapped by the
following Kalzip element, so that the fixing elements are hidden under the roofing.
The mechanical zipping of the seams produces a load bearing connection.
Positive and negative loads will be safely absorbed.
Vapour diffusion, however, is still possible in this area enableing residual moisture to
evaporate after the installation.
Tried and tested detailed solutions for roof penetrations as well as for joints and gable ends.
Non-flammable. Resistant to airborne-fire and radiant heat.
Kalzip can act as a part of the air termination network.

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3

4
10

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1
2

3
4
5
6

Kalzip profiled sheet


Kalzip aluminium
secret fix clip with
thermal barrier pad
Thermal-insulation
Vapour control and
air-lock layer
Trapezoidal sheet
Truss

13

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8
9

10

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Top hat section


Purlin
Timber support and
thermal-insulation
Wooden supporting
substructure
Rafters

Excellent ecological characteristics


Aluminium, combined with other elements, is the third most common element in the earths
crust and is available everywhere in nature.
Once produced, aluminium can be recycled to provide products for generations.
The Kalzip roof covering can easily be re-used.
Recycled aluminium material can be re-used again for the manufacture of other products.
The aluminiums beneficial properties remain intact.
Only 5 % of the original manufacturing power is required for recycling.
An insulated Kalzip roof contributes significantly to reducing air pollution and so to
preserving our environment.

Vorteilhaft auf trittfester Dmmung

PRO-ZIP-Roof: Kalzip AF aluminium profiled sheets without


stiffening ribs on rigid insulation.

A new generation of profiled sheets


Kalzip AF aluminium profiled sheets
were designed for roofing with a rigid
insulation board or a wooden supporting
substructure.
Using Kalzip AF profiled sheets in
conjunction with a load-transmitting layer
of insulation simplifies installation considerably. Under the name Prodach
insulating system, Rockwool offer a
rigid, water-repellent rockwool insulation
board with a special fixing system.

The insulation board is very suitable as


a base for Kalzip AF profiled sheets.
It is non-flammable, highly thermallyinsulating, sound absorbing, dimensionally stable, diffusible and absorbs
vibration. In its top layer, the double-layer
Prorock insulation board is extremely
strong and resistant to mechanical stress.
Its high load-transmitting capabilities
contribute considerably to the roofings
static function.

PRO-ZIP-Roof is the complete solution


for high quality in shape, function and
safety
PRO-ZIP-Roof is the combination of
Kalzip AF aluminium profiled sheets
without stiffening ribs and rigid Prorock
insulation board optimised in both
safety and long-life. Aluminium fixing
rails and stainless steel self-tapping
screws are included in the supply
package.

Kalzip AF profiled sheets


Kalzip secret fix clip
Fixing rail, aluminium
Self-tapping screw, stainless steel
Prorock insulation board (rigid)
Vapour control and air-lock layer

Trapezoidal sheet as substructure


PRO-ZIP-Roof
as truss roof structure

Kalzip AF profiled sheets


Kalzip secret fix clip
Fixing rail, aluminium
Self-tapping screw, stainless steel
Prorock insulation board (rigid)
Vapour control and air-lock layer

Wooden rafters with wooden supporting


substructure
PRO-ZIP-Roof
as rafter roof
structure

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PRO-ZIP-Roof on a structural steel decking


system as substructure

Discreet surface appearence


The flat trough shape of Kalzip AF
profiled sheets produces a discreet, quietly
elegant surface finish. Even small buildings
can have a proportional, well constructed
Kalzip AF aluminium roof covering.

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5

Kalzip AF profiled sheets can


also be used with the FOAMGLAS
insulation system

Always right and quite safe


7

PRO-ZIP-Roof on wooden rafters with a wooden


supporting substructure
1
2

The PRO-ZIP-Roof is suitable for all


commenly used substructures or structures in steel, concrete and timber, for all
structural engineering applications and
for the renovation of old roofs. Special
system fixings are manufactured for all
types of substructures.
The Prorock insulating board offers a
high degree of walkability during installation and maintenance. Concentrated
loads are transferred to the substructure
as spread load.

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5

Installation

Kalzip

Example: Renovation of corrugated asbestos roof


using PRO-ZIP-Roof
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6

With the usual


technique, the
corrosion-resistant, weather-proof aluminium outer sheet is fixed using secret fix
clips, but and this is whats special
about the PRO-ZIP-Roof it is not fixed
directly to the supporting structure but to
an aluminium U-rail inserted in the
insulation layer. The system fixings which
connect the U-rail to the supporting
structure only penetrate the insulating
material in points. This system almost
entirely eliminats sound and heat bridging.

10

Renovation of corrugated asbestos roofs


11

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3
4
5
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Kalzip AF profiled sheet


Kalzip secret fix clip
Prodach fixing rail, aluminium
System fixings, depending on substructure
Prorock insulation board (rigid)
Vapour control and air-lock layer
Structural steel decking system
Wooden supporting substructure
Rafter
Corrugated asbestos roofing
Bottom layer of insulation

15

The PRO-ZIP-Roof is also suitable for


renovating corrugated asbestos roofs.
Various processes are possible. In each
case, approval must be obtained from the
professional control board. Depending on
the local situation, its possible to
dispense with the dismantling of existing
corrugated asbestos roofing (see page
28).

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8

Kalzip AF profiled sheets


Kalzip secret fix clip
Secondary seal (1st position)
Claws or metal rails
Molten bitumen topcoat (only when claws are used)
FOAMGLAS insulation layer (rigid)
Bitumen bonding
Structural steel decking, wooden supporting
substructure or solid base

Filigran strukturiert in der Flche

Gentle contours create space and dimension.

Thomson Administration Building, Elancourt (F), 1993. Kalzip RAL 9010, smooth curved to five different radii. Architects: R. Taillibert, Paris.

The lines of Kalzip roofing fit well into


the design concept for this building.
Its rich use of light and shadow emphasises the particularly striking architecture.
Curves are gentle but also full of character, visually emphasising the dimension
and width of the building.

The elegant surface structure of the


Kalzip roof covering contrasts richly
with the deliberately practical finish of
the facades and glazing. The colour of
the durable, protective Kalzip
aluminium roof covering blends harmoniously with the other architecturally
important parts of the building.

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This building is a good example of how


the combination of different building material complement each other in shape
and function. With its almost unlimited
shapes and applications, it also shows
how the highly flexible Kalzip roofing
system has developed to match the
architectural and aesthetic demands of
our time.

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The visual lines of the roof covering can


be determined by selecting an appropriate width of Kalzip profiled sheet.
Weather-proof, totally flat Kalzip AF
aluminium profiled sheets for rigid and
continious types of substructure enrich
the scope of construction.

Schall- und wrmedmmend

Lightweight, self-supporting and good sound-proofing.


In this instance, Rw = 53 dB(A).

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

Wide spans

Excellent acoustics

Technical and shape constraints

The Oberhausen Arena is currently one


of the most modern of its type in Europe.
Its architecture and technical construction
change a simple visit into an unforgettable experience.

The hall has a capacity of over 12,500


seats. Its technical layout enables it to be
re-arranged very quickly and provides a
great degree of flexibility. The acoustics
are particularly important for large events.
At the Oberhausen Arena, with a soundreflection of 1.8 seconds, it is particularly
remarkable that this measurement is
achieved even though the hall has a very
open interior design. The architects,
DLA-Ellerbe Becket, produced an
ambitious roof structure, using wide-span
steel trusses with support-work which is
visible internally.

Must be as lightweight as possible


because of the wide spans

The wide-span, self-supporting domed


roof is covered with Kalzip aluminium
profiled sheets in lengths up to 42 m.

High demands for sound-proofing and


acoustics
Very flexible because of the dome
shaped roof structure at the entrance
Lightweight. Self-supporting. Well soundproofed. Good acoustics. Flexible shape.
Kalzip roofing is all these.

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Cross-section

Longitudinal section

Example: Kalzip roof structure for special


sound-proofing requirements
1

2
3
4

............................

5
4
6

............................

3
7
8

1
2
3
4

Kalzip profiled sheets


Kalzip secret fix clip
with thermal barrier pad
Thermal-insulation
(compressible)
Plaster fibreboard

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6
7
8

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Top hat profile and


thermal-insulation (rigid)
Vapour control and
air-lock layer
Perforated structural steel
decking
Top hat profile on intermediate rubber layer

Strict accoustic requirements were met

Kalzip has no static problems

Tests proved this before the roof was


installed. The result: Rw = 53 dB(A).

The Kalzip roof covering can be


precisely adapted to suit the buildings
requirements by selecting the appropriate
number and position of fixing points.

Insulating layers inside the roofing


structure enabled the thermal-insulation
requirements to be met easily.
The Kalzip roof structure also fulfilled
the highest economical expectations.

Lightweight Kalzip roof structures are


suitable for large buildings of all kinds:
for gymnasiums, multi purpose halls,
swimming pools, leisure centres, airport
terminals, railway stations, office
buildings, industrial and administration
buildings...

Sicher im Korrosionsschutz

Kalzip gives long-lasting protection, even under massive


corrosion attack.

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

Protective plating, a sure thing

Plating

Core material

The whole composting process, starting


with the delivery of compost waste right
up to storage of the end-product, takes
place in enclosed halls. The climate in
these halls is extremely aggressive; the
gases, temperatures and air-humidity are
extremely high. The building materials
used to construct the roof and rooms
must withstand massive corrosion attack.
These high demands are met by
Kalzip because of its protective
plating on both sides.

Through its protective plating on both


sides, Kalzip offers a particularly
long-lasting resistance to corrosion.
Kalzip is the ideal solution for the
use under the effects of marine and
industrial atmosphere. The material used
is one of the so-called saltwater-resistant
alloys. Special surface protection offers
a suitable solution for use directly next
to copper-works or industries which use
large quantities of aggressive chemicals.
Ask us and well advise you.

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Dauerhaft in der Funktion

Kalzip is long-lasting.

Kalzip: Over 30 years on the


worlds roofs.
Over 30 million square meters of
Kalzip profiled sheets have been
manufactured.
In 1968, Kalzip was used for the
Conference Centre in Nuremberg.
Economic studies have confirmed it:
both visually and functionally, the roof is
still as good as new today.
The durability of the material is particularly impressive on the dome of Romes
San Gioacchino Church, which was
covered in aluminium in 1897. Although
the aluminium used then was by no
means up to modern day quality, the roof
covering is still in very good condition.
Perhaps future generations will stand
and wonder at a 100 year old Kalzip
roof. Certainly, at the end of its useful life,
the Kalzip aluminium roof covering with
its ever-increasing material value will always sell well and be used again after
recycling.

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

Kalzip is non-flammable
Aluminium alloys are non-flammable and
so, without proof, are building materials
Class A1 according to DIN 4102.
Even with an organic coating on both
sides and with insulation layers on the
underside in building materials Class B2,
Kalzip is, without proof, resistant to
air-borne fire and radiant heat according
to DIN 4102 Part 4, Section 8.7.

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Kalzip assumes the function of a


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

Praxisbewhrt die Produktpalette

The Kalzip range.

Kalzip aluminium profiled sheets

Many shapes are possible, e.g.:

Dimensions
mm

Gauge
mm

Kalzip 50/333

333
50

Kalzip 65/305

305
65

Kalzip 65/333

333
65

400

Kalzip 65/400
65

Kalzip 65/500

65
Kalzip AF 65/333 *)

333
65

Kalzip AF 65/434 *)

1,2
1,0
0,9
0,8
0,7
1,2
1,0
0,9
0,8
0,7

smooth curved
(convex)

smooth curved
(concave)

1,2
1,0
0,9
0,8
0,7

tapered

1,2
1,0
0,9

600

Kalzip 65/600

1,2
1,0
0,9
0,8
0,7

1,2
1,0
0,9

500
65

straight

434
65

1,2
1,0
0,9
0,8
0,7

tapered and smooth


curved (convex)

1,2
1,0
0,9
0,8
0,7

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


layer.
Thicknesses from 0.9 to 1.2 mm are to be preferably used.

22

Proven accessories complete the Kalzip roofing system.

The Kalzip system includes an


extensive range of accessories which
has grown out of demand.
Shown here are some components with
durable functions.
The Kalzip price list contains
complete details.

Walk weys are fixed to the seam using clumping


sections. The roof covering is not punctured.

Folding tools make it easier to bevel the ridge of the


Kalzip profiled sheets.

Roof assemblies such as walkways, absorbers and


solar systems are firmly fixed to the seam using
Kalzip clamping sections in stainless steel or
aluminium. The roof covering is not punctured.

Top closure on a Kalzip profiled sheet with a


locking plate, shape-filler and bevel. Small-radius
crimped curved Kalzip as an attractive variant for
a fascia.

Rooflight unit systems (PVC) are available for


single-skin roofs.

Gable clip and cap to reinforce and secure the


edge flange.

Snow and ice bars in aluminium are fixed to the


seam of the Kalzip profiled sheets using clamping
sections. The roof covering is not punctured.

The bevelling tongs for the eaves produce a


uniform, functional edge line.

A special folding technique enables gable end


flashing to be nicely shaped, even on curved roofs.

Vent-pipes are welded into the roof covering.

Soakers for rooflight domes or smoke extractor


fans are produced to building requirement and are
welded or sealed into the Kalzip layer
(depending on the requirements).

23

Kalzip supports the worlds largest photo-voltaic roof system.

New Exhibition Centre, Munich (D), 1998.


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

Small details with a big effect


The Kalzip clamping sections fitted
on the seam of the Kalzip roof
covering support Siemens photo-voltaic
system.
656,208 solar cells were fitted. The outer
roof covering wasnt punctured. The roof
can be walked on in order to maintain
the solar system.

1000 light domes were easily built-into


the roof using prefabricated Kalzip
soakers.
The eaves consist of prefabricated
sandwich units. Together with Kalzip,
they mould the architectural appearance
of the exhibition halls. The Kalzip
covered roof measures 160,000 m2.

24

Kalzip innovations set standards.

Kalzip NatureRoof is the safe way of


landscaping unique in its conception
and technical design
The Kalzip Natural Roof elements are
mounted direct to the profile sheets without any additional sealing measures.
This combines the technical advantages
of Kalzip with the ecological requirements of a green roof.

Streamline drainage installations, joints and end pieces


can be manufactured to project requirements.
Kalzip NatureRoof though incorporating a planted
area is still considered a lightweight construction.

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

The Kalzip mounting system for a


fast and safe clip-fixing on trapezoidal
steel decks

Kalzip secret fix clips, fitted in


seconds, even on thin trapezoidal
steel profiles.

Drill/screw technique: one process


for drilling and fixing.

High strength.
This new fixing system was developed
by the Swiss company SFS, the leading
manufacturer of mechanical fixing
systems for industrial light engineering.
Together with Corus, this technique has
been adapted to the Kalzip system.
Ordinary drills are suitable for the
Kalzip drill/screw technique.
Please ask for information about
Kalzip drill/screw technique.
Accident prevention regulations are compulsory for work
on the roof. The Kalzip fall-prevention system offers the
necessary protection.

25

Hervorragend als Sanierungskonzept

Renovating with Kalzip is more than just a facelift.

Kalzip is ideal for renovating roofs


Its light weight, great strength, longevity,
considerable installation advantages,
high economics as well as good thermalinsulation and sound-proofing, make roof
renovation a special field of application
for Kalzip.

Whether sloping shallow or steep, the


existing roof covering does in most
cases not have to be removed. Also roof
structures need generally not be
reinforced.

Bitumenous felt and membrane roofs,


with and without gravel ballast and even
corrugated asbestos roofs can be
quickly, safely and above all, economically renovated using Kalzip.

During installation, the building can


continue to be used in the normal way,
usually without any interruption.

Visual aspects and unusual shapes can


be accommodated.

The Kalzip system is suitable for


renovating all types of roofs.

26

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

Long-lasting increase in value


In many cases, the corrosion-resistant
material and its ability to withstand the
effects of the environment endorse
Kalzip as the ideal system for
renovation.
A new Kalzip outer shell offers a
building long-lasting protection. In addition, the renovation clearly enhances the
building visually.

27

Savings on thermal-insulation and soundproofing are very positive, not only for the
buildings users:

The costs of operating and maintaining


the building are clearly reduced.

Increasing environmental demands


are met.

The building as a whole increases


in value.

Hervorragend als Sanierungskonzept

KalzipAF and the Rockwool Prodach insulation system


are ideal for roof renovation.

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

19,500 m2 roof was renovated in about 2 months

Milling grooves for fixing rails

Fixing rails using a rivet gun

No dismantling and removing of the


asbestos layer

Because of the light weight of the


Kalzip system, it wasnt necessary to
reinforce the roofs substructure.

The result of an expert report on the


subject Drilling asbestos-cement
products formed the start of this renovation concept. Drilling dust was sucked
away using special suction equipment
connected to the drilling machines.
A copy of the report is available on
request.

In Landau/Isar, a building complex comprising of six steel halls with a roof area
of about 190 x 120 m, received a new,
long-lasting Kalzip AF aluminium roof
covering. Following installation, the roof
can be walked on without restriction.
Renovation work took about two months.
The client continued to operate,
un-interrupted.

2
3
4

1
2
3
4
5
6
7
8

Kalzip AF profiled sheets


Kalzip aluminium secret fix clip
Fixing rail
System fixing, depending on substructure
Prorock insulating board (rigid)
Vapour control and air-lock layer
Corrugated asbestos roofing
Bottom layer of insulation

28

Produktiv auch vor Ort

We can produce Kalzip anywhere in the world.

On-site production
For the suspended, tent-like roof structure
of the Stadio di Torino (I), Kalzip
profiled sheets, partly smooth curved,
were manufactured on-site.
Transportable Kalzip profiling and
bending machines can be used anywhere in the world - particularly where it
is economically and ecologically sensible.
Relieving traffic congestion and finding
the best route from the point of manufacture to the point of use, as well as providing a lightweight construction method,
are very important considerations today.

29

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

Ressourcenschonend im Einsatz

Partner of the environment.

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

Once produced, aluminium is at our


disposal for evermore, thus saving
resources
Aluminium, combined with other elements, is the third most common element
in the earths crust and is available
everywhere in nature.
From the initial material, recycling over
and over again produces valuable new
aluminium products.

Up to 95% of the power used to produce


aluminium can be saved when it is
re-smelted. The smelting process can be
repeated as often as required.
Aluminiums beneficial material properties
remain intact.
The product characteristics of the
Kalzip system meet high ecological
demands.

An insulated Kalzip building


contributes significantly to reducing
air pollution and preserving our
environment.
After a long service-life, Kalzip can be
continually re-used.
Ecology and economy complement
each other. The circle is complete.

The lightweight construction of Kalzip


enables a resource-saving reduction in
the amount of materials used to create
the supporting structure.

30

Our experts with their knowledge of


many applications are at your disposal
We hold installation training courses at
our in-house seminar centre and for
architects, the schedule includes planning
seminars.
For further advice and information,
please contact one of our sales offices
(see overleaf).

www.kalzip.com
Europe:
The Netherlands
HAFKON B.V.
Postbus 46
NL-3140 AA Maasluis The Netherlands
Phone +31 (0) 1059 15300
Fax
+31 (0) 1059 15125
Belgium
Corus Building Systems NV
Part of Corus Group plc
A. Stocletlaan 87
B-2570 Duffel Belgium
Phone +32 (0) 15 30 29 21
Fax
+32 (0) 15 30 29 20
Austria
Robert Pfisterer
Bautechnische Beratung
Keplerstrae 16
A-4222 Luftenberg Austria
Phone +43 (0) 7237 5123
Fax
+43 (0) 7237 2123
United Kingdom and Ireland
Corus Building Systems Ltd.
Part of Corus Group plc
Haydock Lane, Haydock
GB-Haydock/Merseyside WA11 9TY
United Kingdom
Phone +44 (0) 19 42 29 55 00
Fax
+44 (0) 19 42 27 21 36

Denmark
A.E. Stlmontage a/s
P.O. Box 70
Hagensvej 54
DK-9530 Stvring Denmark
Phone +45-98 37 32 88
Fax
+45-98 37 32 79
Switzerland
Bro Dach & Wand, Jrg Senteler
P.O. Box 247
CH-7302 Landquart Switzerland
Phone +41 (0) 8 13 22 38 38
Fax
+41 (0) 8 13 22 38 39
Cyprus
Phanos N Epiphaniou Ltd.
21 Markou Drakou Avenue
Pallouriotissa
P.O. Box 9078
CY-1621 Nicosia Cyprus
Phone +357 (0) 2 438 991
Fax
+357 (0) 2 431 534
Greece
Phanos N. Epiphaniou Ltd.
82 Grammou Str.
GR-18345 Moschato Greece
Phone +301 9 405 941
Fax
+301 9 412 465

France
Corus Building Systems SAS
Part of Corus Group plc
8, Avenue Desclers
B.P. 20
F-77515 Faremoutiers France
Phone +33 (0) 1 64 65 30 56
Fax
+33 (0) 1 64 03 98 55

Overseas:

Spain
IBER-AIS, S.L.
Avda. de la Plata, 67
E-46006 Valencia Spain
Phone +34 (9) 6 374 56 85
Fax
+34 (9) 6 374 04 33

Kuwait
Ali Alghanim & Sons
Trading & Contracting Group Co. W.L.L.
P.O. Box 21540 KW-Safat 13076 Kuwait
Phone +965 4 822190
Fax
+965 4 821669

Middle East
Dubai
Corus Building Systems
P.O. Box 9217 Dubai United Arab Emirates
Phone +971 4 3388586
Fax
+971 4 3389970

Corus Bausysteme GmbH Part of Corus Group plc


August-Horch-Str. 20-22 D-56070 Koblenz Pf. 10 03 16 D-56033 Koblenz Phone +49 (0) 261 8 91-0 Fax +49 (0) 261 820 38
Kalzip@corusgroup.com www.kalzip.com
The information and product descriptions contained in this publication are provided to the best of our knowledge and based on our experience and studies.
They do not refer to any specific application and cannot give rise to any claims for compensation.
We reserve the right to make any changes to the construction or product range which seem technical sensible in view of our high demands for quality and progress.
We have endeavoured to reproduce colours accurately. However, colour deviations due to printing constraints whilst regrettable cannot be excluded.