Kalzip® Systems
Product information and specification
Content
Page
1.Kalzip aluminium roof and façade systems
4
2. Kalzip innovations
5
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
16
17
17
18
18
18
19
19
20
20
21
21
21
22
22
23
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
24
24
24
25
26
27
28
29
30
31
32
32
32
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
33
33
34
34
35
36
36
37
38
39
40
42
43
43
43
44
44
45
45
45
46
46
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
47
47
48
48
49
50
50
Index
51
Introduction
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.
Karlovy Vary Airport, Czech Republic
Architect: Petr Parolek
4
Kalzip
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.
Innovations
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
Kalzip
5
The system and its components
3. The system and its components
There are many variations in
shape for instance*)
3.1 Dimensions of the profiled sheets
Dimensions mm
Thickness mm
straight
Kalzip 50/333
333
50
Kalzip 50/429
429
50
Kalzip 65/305
305
65
Kalzip 65/333
333
65
Kalzip 65/400
400
65
Kalzip 65/500 **)
500
65
Kalzip AF 65/333 *)
333
65
Kalzip AF 65/434 *)
434
65
Kalzip AS 65/422 *)
422
65
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
convex
curved
tapered-convex
curved
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
tapered
tapered concave
curved
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
concave
curved
elliptically
curved
*) Only in combination with accessible insulation materials or wooden timber lining.
Preferable thicknesses 0.9 to 1.2 mm.
**) Recommended for facade cladding
The nominal thickness is subject to the
tolerances specified by DIN EN 485-4.
As far as the lower tolerances are
concerned, only 50 % of the specified
values will be allowed.
6
Kalzip
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.
hyperbolically
curved
*) Not all shapes are possible for all types of Kalzip
The system and its components
Further shapes***:
XT freeform
***) Not all shapes are possible for all types of Kalzip
3.2 Aluminium clip and
thermal barrier pads
Aluminium clip rods can be used for clip
rods, eaves, gutter brackets and fixed
points. The clips must be fixed to a steel,
aluminium or timber substructure. The
clips are attached to the substructure with
the building authority-approved connecting
elements. To connect the profiled sheets
to concrete substructures, spacer structures made of steel, aluminium or timber
and anchored sufficiently in the concrete
must be placed in-between.
Thermal barrier pad (TK 5 or 15 mm thick)
Kalzip aluminium clip combinations
clip
type
L 10
L 25
L 100
L 140
H
clip
height
66
81
156
196
w1
without
Tk
20
35
110
150
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
Twin thermal barrier pad (DTK 5 or 15 mm thick)
dimensions in mm
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
The system and its components
Kalzip composite clip
The energy-saving clip for attaching Kalzip
profiled sheets. According to the European
energy-saving directives, which are an integral part of building regulations in several
countries, it is now obligatory to take
account of thermal bridges when planning
building projects.
The Kalzip composite clip, which is used to
attach the Kalzip aluminium profiled sheets
to the substructure of the roof, fulfills this
requirement in an exemplary manner. It
prevents thermal bridges and succeeds in
creating a system which is virtually coldbridge free, therefore optimizing the performance and efficiency of the roof. This
creates a roof design with heat transfer
coefficients which are entirely determined
by the thermal insulation. 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. The clip has a PA structure
which is reinforced with steel. E spacer
caps can be connected in between for
varying the required thickness of thermal
insulation.
In principle, the Kalzip composite clip
type E is attached to the substructure
using the same connecting elements as
those used with the aluminium clip.
Technical Data
clip type
E
E
5
20
E
40
E
60
E
80
E 100
E 120
E 140
E 160
E 180
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
clip height
H
66
81
91
101
111
121
131
141
151
161
171
181
191
201
211
221
231
241
Kalzip 50/...
w3
20
35
45
55
65
75
85
95
105
115
125
135
145
155
165
175
185
195
Kalzip 65/...
w3
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.
In order to achieve the desired thermal insulation thicknesses in EnEV 2009-compliant Kalzip roof structures
and to compensate for height tolerances, the Kalzip composite clips can be combined with spacer caps.
Kalzip AF 65/...
w3
5
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
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
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. A combination is thereby
permissible only in following variants.
Correct
Correct
+
+
Composite clip + DK 10
Combination for the desired clip height
Composite clip + DK 10 + DK 5
Max. combination for the desired clip height
and to compensate for height tolerances
Correct
Incorrect
+
Kalzip DuoPlus rotatable clips
and Kalzip DuoPlus rail, 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. This solution
significantly increases ease of installation
and further improves thermal insulation in
comparison to conventional roof designs.
(See diagram page 47).
clip type
D 10
D 25
D 100
D 140
clip height (H)
66
81
156
196
+
Composite clip + DK 5
to compensate for height tolerances
Composite clip with several DKs
– not permissible
After installing the insulant (d = 100 mm),
the rails are aligned according to the calculation and mounted with the fastener
systems of SFS intec SD2-S16-6.0 x L in
the steel trapezoidal profile subshell.
be adapted to the individual circumstances depending on the profile dimension
and/or tolerance. Therefore a customised
and convenient installation is guaranteed
every time.
Sub sequently, the DuoPlus clips are manually screwed in. Although these remain
adjustable, the DuoPlus rail still offers a
secure hold; therefore DuoPlus 100 can
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, 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.
Kalzip
9
The system and its components
Stucco-embossed
Kalzip AluPlusZinc
Kalzip AluPlusPatina
Kalzip AluPlusPatina
Special surface treatment of the preweathered, stucco-embossed profiled sheets
significantly reduces their natural sheen,
thereby creating a new and attractive design with a high-quality appearance. With
characteristics comparable to those of an
aluminium profiled sheet which has been
weathered over years, this elegant and
matt surface provides roofs and facades
with impressive style.
Coil-Coating
Liquid lacquer is rolled onto the aluminium
layer in a coil coating process. These colour
coated coils are then used to roll-form the
Kalzip profiles.
3.3 Different finishes and colours
Stucco-embossed surface
The standard version of Kalzip profiled
sheets is stucco-embossed. The robust
stucco embossed finish is created by treatment with additional embossing rollers.
Due to the special texture of the material
surface, minor dents and accidental damage
is hardly visible. In addition, the surface
diffuses reflected light and minimises the
risk of any dazzling effect.
Kalzip AluPlusZinc
AluPlusZinc from Kalzip GmbH is a fusion
of two of the most established materials
in industry – aluminium and zinc. Manufactured according to the most stringent
quality standards, this is a technically advanced product which sets new standards.
It combines stunning aesthetics with the
highest quality materials to achieve design
perfection.
The patented PEGAL process produces a
durable fusion between aluminium and zinc.
An additional surface treatment creates a
stable patina with exceptionally high resistance to the effects of weathering. Indeed,
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. This surface finish creates an appearance of classic
elegance, which makes it ideal for a wide
range of applications.
Kalzip AluPlusZinc offers unique
product advantages:
• Zinc patina with surface protection
• Sophisticated, traditional impression
• Bright surface
• Longevity due to aluminium core
• UV-resistant
10
Kalzip
The natural ageing process, which the
profile sheets undergo during exposure to
weathering, is not hindered and proceeds
in the usual manner. In addition to the new
and attractive surface finish, and the highly
diverse design opportunities which this
creates for planners and architects, Kalzip
AluPlusPatina offers all the product advantages of the standard, stucco-embossed
design.
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
Kalzip profile boards
with polyester coating
The coating is robust and insensitive to
scratching; it has very good forming characteristics and good resistance to weathering and UV light. Kalzip profiled sheets
in a polyester execution are mainly used
in locations with normal environmental
influences.
Kalzip profiled sheets
with a PVDF coating
This coating is particularly well suited for
aggressive environments and extreme
climatic conditions, e.g. proximity to salt
water. Profiled sheets with a PVDF coating
are characterised by outstanding UV-resistance, have very good forming characteristics and are primarily used for façade
design.
Kalzip ProTect coating
For the protection of the surfaces, Kalzip
additionally offers a high-quality and extraordinarily weather-resistant special highend coating on the basis of a polymer
technology using fluorocarbon (FLP). It is
characterised by extremely high resistance
to scratching, maximum colour and gloss
stability as well as considerably higher
surface hardness and temperature resistance.
The system and its components
Kalzip colours
Characteristics of the ProTect coating:
• Available for RAL, NCS and metallic
shades of colour
• Outstanding long-term characteristics
with minimum chalking tendency
• Very good dirt repulsion due to a
Teflon-like behaviour, 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, 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, Kalzip also offers a wide range of
colour and surface finishes which provides
optimum design freedom and safety. Special colours are available on request.
Controlled colour quality
The aluminium strips coated using the
coil coating process pass through a large
number of elaborate processing steps.
Depending on the type of coating, they
are subjected to different pretreatments
and painted in the desired colour or sealed
with a clear varnish. Aluminium strips with
a single-sided coating are given a coat of
protective varnish on the rear side.
Protective plating
In order to achieve a weather-resistant
and colourfast coating, only high-quality
enamels on a polyester, PVDF or CFTE
basis are used. The coil coating process
is monitored according to the standards
of the ECCA (European Coil Coating Association). Important criteria here are: colour,
degree of gloss, paint coating thickness,
paint hardness, paint adhesion and ductility.
There are additional long-term tests such
as the acid salt spray test, QUV-B test,
condensation climate in an atmosphere
containing SO2 and outdoor weathering
tests in an aggressive environment.
Plating
Plated with a special alloy, the aluminium
core is additionally protected. The thickness of the protective layer is only 4 % of
the material itself. During the rolling process,
a permanent joint between the plating and
the core material is achieved.
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. Corrosion does not attack the core
material but is limited to the plating. This
protection remains effective even if the
surface of the sheets is damaged.
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, surfaces are
protected against possible damage with
an appropriate film. It must be ensured
that the film is removed within two weeks
of delivery in order to prevent increased
effort for its removal.
Metallic enamels
In the case of metallic enamel coating,
variations in colour may occur between
different production batches. For this
reason it is advisable to take care when
planning facades or visible roofs to make
sure that the profiled sheets are roll formed from the same batch of material.
Anti-condensation and
anti-drum coatings
If required the profile sheets can also be
fitted with an anti-condensation or antidrum coating.
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).
Kalzip
11
The system and its components
3.4 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
12
Kalzip
Kalzip vapour barrier
avoids air flow and diffusion
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
The system and its components
3.5 Components for roof superstructures
and safety appliances
SolarClad
14
Kalzip
Step
The system and its components
left to right:
Seam clip aluminium,
Cable clip,
Seam clip (stainless steel)
Snow guard
Kalzip fall arrest system
Soaker frame
Kalzip
15
Kalzip range of applications
4. Kalzip range of applications
Within the context of the amendment of the
German energy saving regulations (EnEV
2009), 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.
The likely effects of snow, wind, humidity
and weathering are fully taken into account.
Kalzip can easily be configured to provide
the highest levels of thermal insulation.
On the basis of newly-developed materials,
Kalzip system components make a significant contribution to EnEV-compliant roof
structures.
Thermal insulation requirements can be
easily fulfilled. The thickness of the insulation can be perfectly adapted to the
individua lrequirements of the building.
In addition, 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.
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 1.5°.
Insulated roof systems are the norm
The main applications for Kalzip roof systems
are insulated roof structures supported by
trapezoidal steel, timber linings, purlins or
concrete elements.
Furthermore it may be combined with any
kind of support or substructure. The system
depends on the special requirements of
the individual application.
• Chemically neutral, fibrous insulating
materials as specified by e.g. the
German DIN 18 165 are recommended
as suitable thermal insulation. The insu-
Non-ventilated Kalzip roof
on a trapezoidal steel deck
R’w = ~ 35 dB (A)*
lation is laid into position and is then
compressed to its required final thickness when are installed the profiled
Kalzip sheets on top. There should be
no cavity between the Kalzip sheets
and the insulation.
• A vapour barrier must be incorporated.
Properly installed it provides the
required air tightness.
• Of course, ventilated roof implementations are also possible
• The sound reduction values of the
standard roof are subsequently
described. Further improvements
can be achieved by including
additional layers.
• Information on U values can be found in
chapter 7, Kalzip dimensioning tables,
starting from page 47.
Non-ventilated Kalzip roof
on a trapezoidal steel deck
This very economical roof system is used
both for industrial and residential buildings.
In order to make sure that there are no air
cavities under the Kalzip roof skin, compressible thermal insulation is used. Incorporated within the roof system the insulation
material is compressed by approx. 20 mm.
The loading on the top skin is not transferred to the inner skin as an evenly distributed
load but rather at set points via the secret
fixing clips. The design roof load must be
increased by 15 % when dimensioning the
trapezoidal steel sheets. The clips must
be staggered on the inner sheet to make
sure that the load is evenly distributed
across all corrugations of the inner
sheet.
* varies depending on thickness and material qualities
16
Kalzip
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 inner sheet has to be oriented parallel to the
top layer. If the module of the inner sheet
does not correspond with the Kalzip elements a top hat section must be installed
to support the clips. If the Kalzip sheets
can span the existing spacing of the purlins, the top hat sections will be positioned
on top of the purlins. By this way the inner
sheet carries only the weight of the insulation.
For larger purlin spans additional top hat
sections are required. In this instance, part
of the load needs to be transferred by the
inner sheet.
Non-ventilated Kalzip roof
on timber rafters with visible timber lining
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. This is advantageous, because:
1. there is a clear separation between
the trades of carpenters, roofers etc.
2. a continuous flat vapour barrier
can be installed.
The clips can only be fixed directly in the
timber lining if this has a minimum thickness of 23 mm. A minimum thickness of
19 mm applies for flat press boards, and
18 mm for OSBs. In both cases the fastener
is visible from below. If the timber lining
is too thin, then a timber purlin must be
installed over the lining and attached to
the rafters. See Kalzip approval No.
Z-14.1-181.
* varies depending on thickness and material qualities
Kalzip
17
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,
the DuoPlus rails can be arranged at a 90°
angle to the Kalzip. The rotary clip rails are
fixed using approved dowels (SFS MBR-XS4-HX-10x160). The dowels are arranged
alternately in the rails. The distance between the rails depends on the static calculation. In the case of slabs made of porous
concrete or non-solid concrete slabs, the
DuoPlus rails are arranged at an angle of
less than 45° to the Kalzip. The dowelling
possibilities must be precisely checked in
each individual case and statically calculated. The choice of approved dowels must be
matched precisely to the concrete material.
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. The
special design is almost cold-bridge free
and has excellent sound absorption properties. An aluminium rail is placed on the
100 mm thick rigid thermal insulation and
is fixed onto the substructure through the
insulation. Special clips are inserted in the
rail and are adjusted to suit the respective
conditions. Connection of the individual
clips to the rail is not necessary. The patented and type-tested system consists of
rigid thermal insulation, DuoPlus rail, DuoPlus clip and connecting elements to secure
the DuoPlus rail, the compressible heat
insulation and the Kalzip profiles sheets.
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, whereby a full layer
of rigid thermal insulation is not necessary.
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. The resulting spaces are filled with
soft heat insulation or low-priced rigid
insulating material. In the case of Kalzip
DuoPlus 100, rigid thermal insulation only
needs to be used in those areas specified
by the statistical requirements. The rigid
thermal insulation is replaced by a layer of
soft insulation in all areas where no reduction in snow loads is required.
* varies depending on thickness and material qualities
18
Kalzip
Kalzip range of applications
Kalzip NatureRoof
All roof designs described above can be
transformed into a Kalzip NatureRoof
providing that the design requirements
are taken into consideration and Kalzip
65/333 is being used. Kalzip NatureRoof
comprises an efficient draining mat to
control the integral water management
and a special substrate supporting a
vegetation layer for extensive landscaping
with sedum plants. All components for the
Kalzip NatureRoof outside Germany are
available only on request.
Kalzip NatureRoof
Technical data:
Min. roof pitch:
1,5°
Max. roof pitch:
15°
Additional weight (wet): 0.9 kN/m2
Shear protection:
from 5°
Kalzip FOAMGLAS® System
as a standard solution
®
Kalzip FOAMGLAS System
as a combination solution
* varies depending on thickness and material qualities
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. The Kalzip
FOAMGLAS® System offers a high level of
energy efficiency as the thermal insulation
is airtight and impervious to water vapour.
What’s more, there is no mechanical attachment between the Kalzip profiled
sheets and the supporting structure. This
means there is no coldbridging. As
FOAMGLAS® is impervious to moisture
penetration the insulation can also act as
a watertight substructure.
The FOAMGLAS® slabs are bonded to
different substructures using either a coldbonding agent or hot bitumen. In order to
attach the composite clips, the galvanized
steel claw plates are inserted under heat
in a fixed installation plan taking into account the respective roof geometry. The
composite clips are installed on the claw
plates using the recommended fastening
elements. The Kalzip profiled sheets are
installed in the usual manner and are friction-fitted together. In order to ensure
economic efficiency, the thickness of the
compressible thermal insulation can be
varied. FOAMGLAS® has a minimum thickness of 80 mm.
The manufacturer’s installation regulations
are to be observed. The installation and dimensioning are governed by the Kalzip approval Z-14.4-475.
Kalzip
19
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, compression-proof,
water repellent mineral wool insulating
board featuring a special fixing system.
Kalzip AF is available in sheet lengths up
to 50 m (longer lengths are available on
request).
The level ribless profile provides a smooth
and attractive appearance. The AF system
offers outstanding thermal as well as
acoustic properties. Kalzip AF profiled
aluminium sheets are not only used in
Kalzip AF with ProDach-insulation
on trapezoidal steel deck
R’w = ~ 42 dB (A)*
* varies depending on thickness and material qualities
20
Kalzip
combination with the ProDach-insulation
system but may also be used with FOAMGLAS® insulation and timber lining.
The twin layer Prorock insulating
board: the ideal base for Kalzip AF
• non combustible
• very efficient thermal insulation
and acoustic properties
• dimensionally stable
• vibration dampening
• open for diffusion
• high accessibility during
installation and maintenance
• safe absorption of pressure
and suction loads
Assembly
The corrosion-proof and weather resistant
Kalzip AF aluminium external skin is fixed
with clips in the usual way. However, and
this is the distinctive feature of the ProDach
insulation system, rather than being fixed
directly to the substructure the skin is
fixed instead to special U-rails embedded
in the insulation material.
The stainless steel system fasteners connecting the U-rails to the substructure of
the roof penetrate the insulation material
only locally. This almost entirely eliminates
the effect of cold/heat and sound bridging.
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. Fixing rails are embedded
in the top-side of the insulation material
and fixed to the trapezoidal steel deck.
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, a timber lining which
remains visible serves as a supporting
element. This structure has proved to be
ideal for residential buildings and other
buildings of similar use. The potential
extends from public buildings to multipurpose halls and sports-arenas. The
rails are invisibly fixed to the rafters.
There are no visible joints or fasteners.
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. It is frequently
used in order to minimise the overall height
of the roof structure. If there is an air gap
under the timber lining adequate ventilation
is essential.
With this in mind, we recommend filling
the total height of the rafters with insulating
material for efficient performance. A vapour
barrier beneath the thermal insulation is
also of critical importance.
For the minimum thickness of timber materials, see Kalzip approval Z-14.1-181.
Kalzip AF on FOAMGLAS® insulation
Kalzip AF on FOAMGLAS® insulation*
Kalzip AF can also be used on the proven
FOAMGLAS® insulation. Various installation
methods are possible. 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.
The composite clips employed allow optimum sliding of the profiles in the case of
a temperature-related change of length.
A thermally stable isolation layer must be
arranged between Kalzip and a bituminous
secondary covering.
* varies depending on thickness and material qualities
Kalzip
21
Kalzip range of applications
Kalzip Solar Power Systems
When referring to photovoltaic systems,
architects make a distinction between
roof-mounted and roof-integrated systems.
Kalzip GmbH offers solar power systems
which are perfectly coordinated with Kalzip
for both options.
Because of the small dead weight and the
lack of structural height, the additional
load on the main support structure remains
very low, which positively affects the costs
of the building. These advantages are particularly effective in the case of renovation
measures. The problem of the existing
support structure not being able to absorb
additional wind and snow loads, which
frequently arises with crystalline systems,
usually does not arise with Kalzip Solar
systems. The necessary static examination
of the existing building can often be omitted due to the low loads.
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. The solar laminates are flexible
and extremely durable. Depending on the
particular roof design, they are permanently
bonded to straight, convex or concave
Kalzip aluminium profiled sheets. The flexibility of Kalzip AluPlusSolar can accommodate barrel vault or monopitch roofs,
as well as customised roof designs.
Kalzip AluPlusSolar is available as a fully
integrated system, including inverter and
accessories, on the AF 65/537/1.0 mm
Kalzip AluPlusSolar
Trapezoidal substructure
profiled sheet in RAL 9006 (other colours
available on request). The solar film, available in two lengths, is laminated in the
factory and then permanently bonded to
the outer surface of the Kalzip profiled
sheets. This film will subsequently generate the power in the photovoltaic system.
Kalzip profiled sheets which have already
been installed cannot be retrofitted with
laminated solar film. However, existing
Kalzip roofs can be retrofitted with Kalzip
SolarClad. In addition to a roof-integrated,
regenerative method of energy production,
Kalzip SolarSystems also offer the opportunity of generating energy in the facade.
We can send you detailed information on
request.
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
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, nom./ blocking diode rating, nom. [A]
Maximum DC system voltage [V]
Connection
Weight in kg per m2 roof size
European regions. The durability of the
Kalzip profiled sheets and the guaranteed
efficiency of the solar modules now make
it possible to create contemporary, modern
buildings which combine maximum freedom
of architectural design with the integration
of ecological concepts.
Planning tips
• Kalzip profiled sheets cannot be retrofitted with laminated thin-film solar
modules. We recommend the use of
Kalzip SolarClad.
• Minimum radius in the area where the
rofiled sheets are fitted with modules 13 m.
• Recommended roof pitch min. 5 % (3°).
Safety Class II, design suitability and
approval in accordance with IEC 61646
TÜV Rheinland, Cologne, Germany
For more information, please visit:
www.aluplussolar.com
PVL-68
PVL-136
PVL-144
> 22.5
> 22
> 20.5
2.85
5.50
5,50
68
136
144
16.50
33
33
4.13
4.13
4.36
23.10
46.20
46.20
5.10
5.10
5.30
8
8
8
1000
1000
1000
reverse side,terminal housing assembly IP65, 50 cm connecting cable MC-FlexSol-XL (4 mm2), male connector MC 4
2.7
2.7
2.7
NOTE: The values specified represent stabilised values (± 5%). During the first 8-10 weeks of operation, power output may be higher
by 15%, operating voltage may be higher than 11% and operating current may be higher by 4%.
22
Kalzip
Kalzip range of applications
Kalzip SolarClad parallel to standing seams,
vertical
Kalzip SolarClad perpendicular to standing seam,
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, nom./ blocking diode rating, nom. [A]
Maximum DC system voltage DC [V]
Connection
Weight in kg per m2 (installation parallel to standing seams)
Kalzip SolarClad
Kalzip SolarClad is a photovoltaic cladding
which has been optimised for use in building envelopes. Its flexibility and versatility
enable solar modules to be integrated into
virtually all standing seam systems made
from a variety of materials. Kalzip SolarClad is a retrofit solar solution which can
be harmoniously integrated into existing
building structures and also used in new
builds.
The system consists of extremely robust
thin-film modules made from amorphous
silicon (a-Si), bonded onto aluminium system rails, which can be installed on any
metal roof system in a non-penetrative
manner. These extremely lightweight module units are suitable for all roof shapes.
Kalzip SolarClad is supplied as a complete
system, including inverters, for different
standing seam designs. The solar film,
available in two different lengths, is laminated onto Kalzip system rails in the factory
to ensure high quality and fast installation.
The solar laminates generate power from
the sun as soon as they are connected.
Kalzip SolarClad is suitable for all roof
shapes with a pitch up to a maximum of
60° from horizontal. As the system is extremely lightweight, this generally means
there are no additional structural requirements for the roof. Kalzip SolarClad is
therefore suitable for all roof structures
and all Kalzip widths.
PVL-68
PVL-136
PVL-144
> 19
> 18.50
> 18
2.85
5.50
5,50
68
136
144
16.50
33
33
4.13
4.13
4.36
23.10
46.20
46.20
5.10
5.100
5.30
8
8
8
1000
1000
1000
reverse side, terminal housing assembly IP65, 50 cm connecting cable MC-FlexSol-XL (4 mm2), male connector MC 4
6.1
6.1
6.1
NOTE: The values specified represent stabilised values (± 5%). During the first 8-10 weeks of operation, power output may be higher
by 15%, operating voltage may be higher than 11% and operating current may be higher by 4%.
Kalzip
23
General data and characteristics
5. General data and characteristics
5.1 Roof pitch
The Kalzip system consisting of self supporting aluminium elements was specially
developed for roofs with pitches down to
1.5° or 2.6 % together with long sheet
lengths. Owing to the attractive appearance of the modular system, architects
often use this system for visible steep
roofs and increasingly for wall claddings.
Continous falling gradient required
All parts of the roof must have a continous
downward gradient towards the draining
system.
Minimum roof pitch
• without horizontal joints 1.5°
respectively 2.6 %
- running from the eaves in one length
- all joints are welded
- factory welded soakers welded into
the roofing skin
• sheets with horizontal joints 2.9° (5%)
- with sealed horizontal joints
- soakers sealed into the roof skin
- Factory welded soakers sealed 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.
5.2 Minimum radii for crimp-,
smooth- and on site curving
Exacting design calls for creative and detailed solutions. Today curved corners or
arched roofs can be easily achieved by
advanced industrial prefabrication. They
provide modern industrial architecture
with a high level of functional and aesthetic quality combined with future oriented
perspectives.
Profiled sheets lengths:
Straight lengths 500 mm min. to 10.000 mm*
max. Depending on radius and transportation limitations
* greater lengths on request
Surface finish:
• stucco-embossed
• AluPlusPatina
• Colour coated with protective foil
• AluPlusZinc with protective foil
The minimum radii for smooth curving
of Kalzip elements are specified on the
following page.
Please take note when ordering:
Please specify the required dimensions in
accordance to the sketch.
5.2.1 Kalzip Convex
Factory crimp-curved
Transportation:
Max. loading height 2.40 m. For any
queries, please contact our logistics
department.
Cover width (BB)
50/333, 50/429, 65/305, 65/333, 65/400,
65/500, AF 65/333, AF 65/434, AS 65/422
Minimum radius: Ri = 450 mm
Installation width is the actual width of
the assembled sheets. If the clips are
pre-installed the installation width must
be increased.
(Installation width = cover width + 3 mm)
If crimp-curved profiled sheets are
connected with straight ones, the rounded
sheet determines the dimension. It is
recommended to carry out the distribution
in accordance with the measured dimension of the rounded profiled sheet.
Minimum length of straight end pieces
min l2
Ri
min l1
[mm]
[mm]
[mm]
l2
150
0
a
C
bis 1000
> 2000
DB
l1
65
Ri
Ra
Ca = Arc length outside
24
Kalzip
150
0
General data and characteristics
5.2.2 Kalzip smooth curved in factory, aluminium
Convex
Sheet thickness
65 / ...
50 / ...
AF 65 / ...
AS 65 / ...
0.8 mm
6
8
10
10
0.9 mm
5
5
8
8
Concave
Sheet thickness
65 / ...
50 / ...
AF 65 / ...
AS 65 / ...
0.8 mm
16
12
15
25
0.9 mm
14
10
14
16
Minimum curving radii in m
1.0 mm
1.2 mm
1.5
1.5
1.3
1.3
3.5
3
3.5
3
1.0 mm
10
7
10
10
1.2 mm
10
6
7
8
Curved and tapered: Please check with our technical department in Koblenz/Germany.
General information
Kalzip AF und AS:
With Kalzip AS and AF profiled sheets, an increase in construction width of up to 20 mm
must be taken into account following curving, so that an overlap with straight sheets
is not possible.
Smooth-curved Kalzip AF profile sheets can
show signs of increased buckling in the
base plate. As it is impossible for technical
production to prevent this buckling, it will
not be accepted as grounds for complaint.
When the optical characteristics of a building are of increased importance, then
smooth-curved Kalzip AS profile sheets
should be used instead.
Standard:
Constant radius with a short (approx. 400
mm) straight segment at the beginning and
the end of the profile sheet. Any radii below
the standard minimum as well as multiple
radii and/or straight elements in one Kalzip
sheet must be agreed with our technical
department in Koblenz.
It is unavoidable that intermediate radii occur
in the transition area of different radii as well
as between curved and straight sectors.
Clips must not be located in these areas.
Transportation:
Maximum loading height 2.4 m. It might be
necessary to coordinate details of transportation with our logistics department.
Tolerance limits. Only after consultation
with our technical department in Koblenz.
Special measures are necessary in order
to reach the tolerance limits.
Transitional area:
If a Kalzip profiled sheet is roll-curved with
several radii, a transitional area is created
in which no clip may be placed (except a
fixed point clip).
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
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, or ± 600 mm (1200 mm in total ) if the
two adjacent radii have different signs, i.e.
from concave to convex or vice versa. It is
necessary to consult the Application Technology Dept. in Koblenz for a more exact
determination of this transitional area.
Length of profiled sheet:
Minimum length 1.5 m. Shorter lengths on
request. The final overall length depends
on the individual radii and possibility of
transport. Minimum length of segment per
radius = 500 mm.
Kalzip
25
General data and characteristics
5.2.3 Kalzip supplied in straight form, curved to radius during installation (naturally curved)
The values given are not standard values. They do not serve as a replacement for project specific consultations.
Convex
Minimum curving radii in m
Kalzip
Type
Sheet thickness
(mm)
Radii
(m)
max. supporting space
(m)
Increase in construction
width (mm)
65/305
65/333
65/400
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2
36
40
48
55
37
37
40
43
50
55
60
70
1.5
1.6
1.8
2.0
1.5
1.5
1.5
1.8
1.5
1.5
1.5
1.8
+3
+3
+3
+3
+2
+2
+2
+2
+2
+2
+2
+2
50/333
50/429
AS 65/422
Kalzip AF Profile cannot be naturally curved. Special forms with beading are available on request.
Concave
Kalzip
Type
Sheet thickness
(mm)
Radii
(m)
max. supporting space
(m)
Increase in construction
width (mm)
65/305
65/333
65/400
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2
40
45
50
60
38
40
42
45
50
55
60
70
1.5
1.6
1.8
2.0
1.5
1.6
1.8
2.0
1.5
1.6
1.8
2.0
+3
+3
+3
+3
+2
+2
+2
+2
+2
+2
+2
+2
50/333
50/429
AS 65/422
Kalzip AF Profile cannot be naturally curved. Special forms with beading are available on request.
General information
Naturally curved:
The profile sheets are supplied in straight
form and are curved by hand to the respective radii during installation.
Accessibility:
Due to the risk of buckling, access to the
sheets must not be gained without load
spreading equipment.
Cover width:
Depending on the radius, the nominal
width (construction width) must be increased to the cover width (installed width).
Finish:
• stucco-embossed
• AluPlusPatina
• coated material with protection foil
• AluPlusZinc with protection foil
• Anti-condensation coating on request
• without protection foil on request
Support spacing:
When the supporting spacings are too
large the supports will appear as polygon
lines.
26
Kalzip
Appearance:
The minimum radii outlined above reflect
current experiences. As it is necessary to
curve the profile sheets to the respective
radius, buckling cannot be ruled out.
Installation tip:
It is advisable to provide a support on the
ridge over which the profile sheets can be
curved. Installation should take place from
the direction of the non-covered side.
Packaging:
If the pitch is greater than 1.70 m, then
this information must be supplied when
ordering. The reason for this is that special packaging may be necessary.
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. A roof can offer more
than just protection: it can enable a building to achieve architectural perfection. In
order to achieve the perfect structure, it
is necessary to take into account several
fundamental considerations. The cover
widths are between 230 and 740 mm. Furthermore, accessibility is limited.
The bottom sheet must be additionally
supported by rigid insulation. Load distributing walkways must be provided. In order
to ensure that the bottom sheet is adequately rigid, it is essential to incorporate
an eaves angle.
The full surface is always covered with foil.
Anti-condensation coating is only subsequently available in the spraying process.
Aquasine coating is not possible. Tapered
Kalzip sheets must be installed on the roof
in accordance with the installation instructions. It is advisable to compare the actual
dimensions of the substructure with the
dimensions stated on the installation in-
Profile types available
Minimum construction width
Maximum width
Minimum length
Maximum length
Plate thicknesses
Curved and tapered
1
structions before production in the factory
begins. Larger building tolerances can
require repartitioning of the area which is
to be covered. The tables on the following
page apply to a sheet width of 500 mm.
Finish:
• stucco-embossed
• AluPlusPatina
• soated material with protection foil
• AluPlusZinc with protection foil
Kalzip 65/… und 50/…
Kalzip AF…
230 mm
170 mm
740 mm1
740 mm1
1500 mm
1500 mm
Dependent on transport
Dependent on transport
0.80 – 1.20 mm
0.80 – 1.20 mm
Possible for construction widths of 230 – 620 mm.
Only following approval from the technical department in Koblenz.
Kalzip AS…
not possible
Applies only to stucco-embossed and colour-coated Kalzip profile sheets. Other material combinations are available on request.
Joint carried out as a welded joint
or step joint
min.
Self-supporting up to a
construction width of 500 mm
max.
For construction widths exceeding 500 mm
only with additional support and clips spaced
at 1.0 m max.
Installation examples with joints
Kalzip
27
General data and characteristics
5.4 Kalzip XT free-form profiled sheets
Kalzip type 65 /… / 1.0 mm
The XT production technology allows difficult roof and wall surfaces, even if they are
free-form surfaces, to be clad with Kalzip
profiled sheets. Different radii, convex and
concave, as well as side radii, bulges and
narrowings can thereby be combined in
one profiled sheet.
The limit values are subjected to constant
changes and improvements. The combination of the various possibilities in particular
has a big influence on the various limit
values.
The following, non-binding limit values
serve as an aid to orientation:
Convex curved
2.50 m
Concave curved 10.0 m
Side radius
20.0 m
Minimum width
275 mm*
Maximum width
740 mm*
Hospital, Emmen (NL)
Architect: A/d Amstel Architecten
28
Kalzip
The maximum length depends on the
transportation possibilities and the basic
material available. The minimum length
depends on the contour and on the production procedure and must be examined
in detail.
For reasons related to production, excess
lengths of at least 400 mm are necessary
at the ends of the XT profiled sheets; these
have to be cut off on the building site. They
offer additional flexibility in the alignment
of the profiled sheets.
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. It must
be adjustable in order to be able to compensate for building tolerances.
The planning and installation of XT profiled sheets requires a great deal of effort.
XT constructions are planned completely
in 3D. A 3D GUI, preferably in the format
.3dm (Rhinoceros), is necessary for editing.
The suitability of other file formats must
be checked.
* Applies only to stucco embossed Kalzip profiled
sheets. Other material/combinations on request.
General data and characteristics
5.5 Accessibility/fall arrest systems
For maintenance and cleaning Kalzip
sheets are accessible both during and after
installation without any load distributing
measures. As far as the installation is concerned this will only be valid if the profiled
sheets are zipped on at least one side. The
following table specifies the critical spans
up to which the profiled sheets are accessible without any additional measures.
It is advisable to install walkways leading
to any units requiring regular maintenance
or operational elements such as daylight
units, chimneys or heating plants. When
exceeding the critical span, load distributing elements such as wooden planks of
a minium cross section of 4 x 24 cm and
a maximum length of 3 m have to be
installed length – or crosswise over the
Kalzip sheets.
In situations where no rigid thermal insulation has been installed along the ridge
and eaves areas, the sheets in these parts
of the roof should not directly be walked
on. The reason being that this might lead
to deformation of the flat area of the Kalzip
sheet resulting in a possible accumulation
of rain water.
The last free sheets along the gable end,
single unzipped sheets and of course
translucent panels should not be walked
on. During the installation of the roof any
areas which are frequently walked on or
used for the transport of materials should
be protected by temporary walkways,
which should be secured with seam clips
to prevent them from sliding down.
The Kalzip fall arrest system is a reliable
solution to secure walkways on the finished roof. It consists of a stainless steel
rope which is fastened to permanently
fixed Kalzip roof anchors and coupled to
the safety harness by means of a guide
link. Project related planning is carried out
by Kalzip GmbH.
Access following installation1
Seamed Kalzip profile sheets with supporting spacings up to the following dimensions
are accessible without the use of load spreading equipment.
Sheet thickness
t/mm
0.8
0.9
1.0
1.2
1
2
65/305
lgr/m
2.90
3.35
3.80
3.80
65/333
lgr/m
2.90
3.35
3.80
3.80
65/400
lgr/m
3.00
3.40
3.80
3.80
50/333
lgr/m
2.50
2.65
2.80
3.00
50/429
lgr/m
2.50
2.60
2.70
2.90
AF 65/3332
lgr/m
2.90
3.20
3.50
3.50
AF 65/4342
lgr/m
3.50
3.55
3.60
3.60
AS 65/4222
lgr/m
3.50
3.55
3.60
3.60
Applies only to stucco-embossed and colour-coated Kalzip profile sheets.
Other material combinations are available on request.
On grounds of final visual appearance, this information is only applicable when rigid thermal insulation is used.
Kalzip
29
General data and characteristics
5.6 Material/corrosion resistance
An essential advantage of Kalzip sheets
is the lightness of the aluminium material.
Seawater proof alloys are used as basic
materials.
Protection by natural oxidation
Due to the natural formation of a protective
coat of oxide, Kalzip profiled aluminium
sheets are reliably protected against corrosion when exposed to normal weathering
by maritime, continental and industrial
atmospheres. With plated material this
effect is even greater, as the plating acts
as a sacrificial anode protecting the core
material against corrosion for many years.
If, however, the roof is exposed to a highly
aggressive atmosphere occurring in the
immediate vicinity of the building, for instance, industrial premises such as copper
plants emitting high levels of aggressive
chemicals; appropriate resin coatings with
a minimum thickness of 25 µm will provide
lasting protection.
Contact corrosion
In contact with other unprotected metals
and under the influence of humidity, aluminium produces an electrochemical contact element, which may lead to corrosion.
The annexed table is the result of extensive
tests and investigations carried out in
Sweden and proves that the Kalzip alloy
can be combined with most of the common materials used for building purposes
without the risk of corrosion.
Protective measures to avoid 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. There
are a number of different protective measures such as plastic foils, intermediate
layers coated with bituminous, zinc chromate or chlorinated rubber paint or the
galvanizing of the contact areas of steel
parts.
Timber:
Timber parts in contact with Kalzip should
be dry. For the protection of timber rafters
and other wooden construction elements
in direct contact with aluminium structures
only compatible (f.i. oil based) wood preservatives must be used. They must not
belong to the group of naphtalenic chlorines
and must not contain any copper, mercury
salts or fluorine compounds.
Concrete and mortar:
Any direct and indirect contact with concrete and mortar must be avoided. The
concrete/mortar must be set and must
not be damp. As dampness can never be
completely ruled out, it is always advisable to separate concrete and aluminium
profiled sheets by means of a suitable
intermediate layer. Do not allow drilling
dust to get onto the aluminium surface;
if this does occur, ensure that the dust is
immediately and carefully removed.
Compatibility with other materials
for common Kalzip system applications*
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, in the case of uncommon applications, must be checked by the
Application Technology Department in Koblenz.
** Only applies to stainless steel self-tapping screws and blind rivets, if a formation of an electrolyte can be
excluded.
30
Kalzip
General data and characteristics
5.7 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. 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. This result in
security and retention of value, in particular
when high demands are placed on the
use of the buildings e.g. at airports or in
demanding locations, e.g. near the coast.
The material for Kalzip has been submitted
to increasingly critical tests over the course
of the time, 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.
Sustainable construction with
aluminium building envelopes
The introduction of certification systems
such as Breeam, Leeds and DGNB has
for the first time provided evaluation criteria for sustainable planning and building,
which urge us to use our resources responsibly and hence to contribute decisively to the protection of the environment.
The building and property business in
particular can make a decisive contribution
to the sustainable development of our
society, 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. The entire lifecycle of the building
must be considered. 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, construction and use to the renovation and demolition. 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.
be recycled any number of times and is
sufficiently abundant: It is the most commonly occurring metallic element on Earth.
Three-quarters of the aluminium ever produced is still in use today. Approximately
95% of aluminium from the roof is recycled. The recycling of Kalzip profiled sheets
and other aluminium products requires
95% less energy than the primary production from bauxite, without loss of quality.
This avoids approx. 80 million tonnes of
greenhouse gases worldwide per year.
Kalzip is a member of the association for
sustainable construction, the DGNB.
Sustainable construction means conscious
planning and construction. A comprehensive quality concept, which is already
applied during product evelopment at
Kalzip, is particularly effective here and
serves both the building industry and our
society. The influence of sustainability is
at its greatest during planning.
The lynchpin of the Kalzip sustainability is
the aluminium itself, a material that can
Zero Emission House, Velux (DK)
Architect: Lars Bo Lindblat, Rubow Architects, Kopenhagen
Photograf: Torben Eskerod
Kalzip
31
General data and characteristics
5.8 Official approvals/design calculations
The use of Kalzip roofing elements is
subject to the official building regulations.
Proof of stability and the suitability for
use must be provided in each individual
case. The basis for the design calculations
is always the German Inspectorate Approval
No. Z-14.1-181 issued by the Institute
for Building Technology. Kalzip is officially
approved by many European building
authorities and is subject to continuous
monitoring.
This includes a description of technical
characteristics, materials and dimensions.
The stipulations for design and measurement contain information on design loads,
static systems and safety values. The stipulations on specification govern, amongst
other things, roof pitch, edge design,
accessibility, technical expertise/training
requirements of the installers. The appendices contain tables relating to standard
details and characteristic values for the
proof of stability and suitability for use.
For frequently recurring applications you
32
Kalzip
5.10 Sheet thickness
will find load-span-tables, from which the
maximum spans under practical windand snow loads can be extracted. So the
proof required by law can be easily provided at any time.
5.9 Transport
When designing unusual special roof
shapes (for instance, long profiled sheets
with small curving radii) the feasablity of
transportation has to be checked with
our logistics department. The dispatch
department at the production factory is
available to advise you here. Permits are
required from the local road authorities
for the transportation of lengths of 18 m
and more. When extreme lengths are to
be transported, it is essential to allow for
the time required to obtain permits from
the local road authorities.
According to the licensing agreement
issued by the building authorities the minimum thickness for Kalzip profiled sheets
is t = 0.7 mm. Although these sheets are
accessible both during as well as after their
installation for maintenance and cleaning
without the need of load distributing
measures, it is however not advisable to
use sheets of this thickness because of
the risk of denting resulting from people
walking on the sheets during installation.
For aesthetic reasons it is advisable to
choose a minimum sheet thickness of 1 mm
on any visible areas.
Design specifications
6. Design specifications
6.1 Moisture proof
6.2 Ice barriers
For insulated roofs and walls it is essential
to provide sufficient protection against
condensation in each and every case. In
this context vapour diffusion (e.g. according
to DIN 4108-3) as well as air flows must
be considered.
In some regions where exceptionally severe
weather conditions can be experienced,
ice barriers can form on metal roofs with
certain structural features. These are blockages or plates formed from snow, melt
water or rainwater which have frozen together and can impede the flow of water on
roofs.
Superficial formation of condensate on
structural components
If the minimum values of heat transition
resistance according to DIN 4108-2 are
observed, a verification of the protection
against condensation 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.
In special cases for instance with permanent high humidity levels it is necessary
to calculate the required heat transition
resistance in relation to the actual internal
climatic conditions.
Formation of condensate inside
multi-layer constructions
A vapour barrier must be installed in order
to prevent vapour from penetrating from
humid internal rooms into the roof construction. In wall structures vapour barriers
are generally not necessary.
To prevent humid internal air from diffusing
into the roofing system, an airtight barrier
must be installed, which is fully sealed at
all joints to the adjacent structures, as
required by the Energy Saving Directive.
A professionally fitted Kalzip vapour barrier
meets these requirements.
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, a multitude
of fittings or structures
• Guttering and downspouts which can
freeze up (bends, no gutter heating)
• Accumulated snow, 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,
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.
Those areas of the roof which are at risk
include, for example, channels, single-skin
roof overhangs, areas which are partially
roofed and shaded areas.
Standing water must be avoided on metal
roofs. For this reason, these roofs must
always be sloping. 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.
For this reason, 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.
Furthermore, metal roofs which have longitudinal and cross joints or overlaps which
have not been welded or soldered, will
not be watertight (against “pressing water”),
but only rainproof. This means that when
accumulated water exceeds a specific level
it will penetrate via the joints and connections. This is another reason why a minimum
pitch must be maintained.
Standing water on roofs may not only be
caused by inadequate roof pitches but also
as a result of other factors. For example,
as a result of blockages in the flanges on
the profiled sheets which carry the water,
in the case of superstructures or projections
which have been incorrectly designed or
installed or when ice barriers have formed.
An essential planning task is to ensure that
ice barriers are avoided. Various measures
can be recommended. However, no list of
recommendations can be regarded as
complete. As the effectiveness of recommended measures depends on local conditions, these measures can only be regarded as suggestions and do not release the
company carrying out the work from the
obligation to check feasibility. No liability
can be accepted for this.
In view of the experiences of the particularly
catastrophic snow conditions experienced
in winter 2006, it should be noted that
absolute safety against ice barriers cannot
be guaranteed.
Kalzip
33
Design specifications
6.4 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, particularly
internal structures
• Bends in downspouts should be
avoided
• Keep downpipes free, 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, use
as an emergency downspout?
• Fall arrest equipment, 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.
The planner must check that individual
measures are adequate or whether the combination of several measures is required in
order to achieve adequate efficiency. If ice
barriers have occurred and these are to
be avoided in the future, then the following
measures can be successful – depending
on the causes. However, there can be no
guarantee of absolute safety here:
• Long joints should be avoided,
e.g. 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.
34
Kalzip
• Accumulated snow should always be
removed as quickly as possible. Snow
and ice should be cleared away.
In the case of each of these measures,
the specific conditions of the individual
building in question must always be taken
into account. For this reason, it is not
possible to make general statements.
6.3 Sound absorption
The demands concerning fire protection
of building materials and structural parts
etc. are specified in the local building regulations. According to DIN 4102-4 aluminium
alloys are classified in category A1 (”not
inflammable“) without special verification.
Kalzip profiled sheets – even with organic
coatings on both sides and with class B
insulation layers underneath – are classified as resistant against flash-over and
radiating heat without any special verification (“hard roof covering“).
Highly efficient sound absorption can be
easily achieved with Kalzip roofs by constructive measures such as incorporating
additional layers, while all benefits of the
lightweight constructions remain unaffected.
Classification of fire behaviour (without floor coverings) according to DIN EN 13501-1
(Appendix 0.2.2 to the Building Regulation List A, Part 1, edition 2002/1)
Building authority
designations
Non-combustible
Flame-retardant
Additional requirements
no
smoke
X
X
X
no burning droppings/drips
X
X
X
X
X
X
Normally flammable
Highly flammable
1)
European class
according to
DIN EN 13501-1
Class
according to
DIN 4102-1
A1
A2 – s1 d0
B, C – s1 d0
B, C – s3 d0
B, C – s1 d2
B, C – s3 d2
D – s3 d0
E
D – s3 d2
E – d2
A1
A2
F
B3
B1
1)
B2
1)
Specifications for strong smoke development and burning drips/droppings in the proof of usability and in
the labelling
Design specifications
6.5 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. The calculated probability
of structurally damaging lightning strikes
is once in every 500 years. Such a strike
hitting a Kalzip clad building would cause,
at worst, no more than a small hole in one
of the sheet seams. 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.
Kalzip as a conductor of lightning
According to the lightning protection
standard BS EN 62305-3 or VDE 0185305-3 ‘Protection against lightning - Part
3: Physical damage to structures and life
hazard’, metal roofs are suitable as ‘natural arresters’ for lightning protection.
Figure 1 Kalzip as a
conductor of lightning
In the table in Supplement 4 of this standard, ‘Use of metallic roofs in lightning protection systems’, 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, mill finish, AluPlusZinc or AluPlusPatina) are suitable for use as a natural component of a lightning protection
system without further requirements.
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. The same applies to
welded profiled sheets. Type testing is required if the flanged or folded roof elements are coated. Kalzip has passed this
examination in accordance with report
BET/Corus 08-06-17-1d issued by the
BET Blitzschutz und EMV Technologiezentrum - OBO Bettermann, D-58710
Menden.
The same applies to standing seam roofs
as well as trapezoidal and corrugated
profiles. The prerequisite for this is that
the roofs are capable of conducting current, e.g. they are connected to ground
via approved lightning conductors from
OBO Bettermann GmbH (www.obo.de).
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:
- a conductive wall cladding (metal)
- a steel or aluminium sub-structure
- any concrete sub-structure must be
reinforced
Construction details relating to these
requirements should be checked with
a lightning protection specialist.
Hence, roofs made of Kalzip profiled
sheets are suitable without further requirements for use as a natural component of a lightning protection system.
Figure 2 Kalzip as
protective screening
Figure 3.
Cross section showing
connection and earthing
across the structure.
Kalzip
35
Design specifications
Kalzip as protective screening
If the complete building envelope consists
of aluminium (Figure 2 on page 35), i.e.
Kalzip systems used for both the roof and
wall cladding, 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.
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.
For optimum screening, 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. Tests on
Kalzip installations have shown that, depending on the design of the screening,
the electromagnetic field inside the system,
corresponding voltages and strength of
current, are reduced by a factor of more
than 100.
Technical requirements for protective
screening
• The envelope of the building must be
completely conductive at all points and
connected to earth (Figure 3).
• Kalzip must have a metal finish (stuccoembossed, AluPlusZinc or mill finish).
• Where coated Kalzip sheets are used:
- the ST Clips must be secured to a
metal substructure
- on timber substructures, the ST Clips
must be connected with aluminium
strips (minimum 60 mm wide and
0.7 mm thick) below the sheeting.
• At the Interface between roof and walls,
each and every profiled sheet must be
connected using short aluminium strips
(minimum 50 mm wide and 1.0 mm thick).
36
Kalzip
• Window openings should not exceed
1.5 m x 1.5 m. 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, in which
case no other conductive structural
connections are required.
Construction details relating to these
requirements should be checked with
a lightning protection specialist.
6.6
Roof systems
6.6.1 Rafter roof:
Kalzip sheets perpendicular to
the trapezoidal steel deck
A supporting trapezoidal deck forming the
substructure of the roof spans from rafter
to rafter running parallel to the eaves. The
clips are either fixed directly to the top
corrugations of the deck or indirectly by
means of spacers. The fixing points are
visible underneath the supporting steel
deck. The clips are diagonally distributed
on top of the steel deck, so that all corrugations of the deck are load bearing. The
clips must be located following a special
pattern to ensure even load distribution on
the trapezoidal steel deck both in the case
of positive loads (due to snow) or negative
loads (due to wind or aerodynamic suction).
Design specifications
• A continous row of clips is to be
fitted along the ridge and the eaves.
• The number and positioning of the
clips as well as the joining elements
are indicated in the assembly plan.
• In between the clips are arranged diagonally. Distances depend on the design
loads, the Kalzip sheet widths, the pitch
of the ribs and the support spacing of
the trapezoidal sheet underneath.
• 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.
6.6.2 Kalzip perpendicular
on timber lining
The clips are fixed directly to the timber
lining. The clips must be positioned on the
timber lining in accordance with positioning
diagram 1 or 2. If the clips are to be positioned next to each other, then the timber
board and its attachment to the substructure
must be statically verified. A carpentry
attachment is not sufficient.
(See dimension tables)
Positioning scheme 2
Clips
Pitch of the supporting deck
clip
Kalzip
TR
Eaves
Ridge
Gable end
Ridge
Gable end
Pitch of the supporting deck
Positioning scheme 1
Clips
Clip
Eaves
Cover width Kalzip
Rafter spacing
d = clip distance
Kalzip
TR
Cover width Kalzip
Rafter spacing
Rafter spacing
TR = trapezoidal profile
Rafter spacing
d = clip distance
TR = trapezoidal profile
Distances not to scale
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).
For the coefficient of wind pressure,
distinction must be made between the
roof form, the position on the roof (zone)
and the load induction area. An example
of distribution according to zones is
shown on the right. More exact details for
the determination of the wind loads are
given in DIN 1055 Part 4.
Rid
area H
ge
Roof areas
Gab
Eav
el en
es
area G
area F
d
Kalzip
37
Design specifications
6.6.3 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. Depending on the design of the
bottom skin, an intermediate section may
be necessary with double skin roofs. The
clips are normally positioned on top of
each purlin.
In re-roofing projects with narrow spaced
purlins it may be sufficient to position the
clips on every second purlin only. With
regard to an even load distribution the clips
are alternately arranged on the purlins.
A design calculation is required. Please
consult our local representative for design
calculations.
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
Gable end
Clip
Clip
Kalzip
Purlin
Kalzip
Purlin
Eaves
Eaves
Cover width Kalzip
Rafter spacing
Rafter spacing
d = clip distance = purlin spacing
Cover width Kalzip
Rafter spacing
Rafter spacing
c = purlin spacing
d = clip distance
Distances not to scale
38
Kalzip
Design specifications
6.6.4 Kalzip DuoPlus 100
and Kalzip Duo 100
The Kalzip DuoPlus 100 system always
consists of a full layer of 10 cm thick, rigid
thermal insulation, the DuoPlus rail, the
DuoPlus clip and the special screws for
fixing the rail onto the substructure.
In contrast to this, the Kalzip Duo 100
system does not contain a full layer of rigid
thermal insulation. Strips of rigid insulation
with a width of 24 cm and a thickness of
10 cm are simply inserted under the Kalzip
DuoPlus 100 rails.
In the case of both systems, only the named
components will be permitted. The arrangement of the rails and the number of connecting elements are outlined in the installation
plan. The DuoPlus clips are secured against
shifting by means of a plastic strip that is
attached in the factory.
The final row of clips, at the end of the
installation surface (gable end), is also
secured into the rail by means of a screw
through the clip base. The compressible
thermal insulation is then placed on top
and pressed over the clips. The Kalzip roof
structure can then be installed as normal.
Rafter spacing
Rafter spacing
Rafter spacing
Panel spacing = Clip spacing
DuoPlus
clips
DuoPlus rail
Ridge
Positioning scheme Kalzip purlin roof
The system requires that the DuoPlus rails are
positioned parallel to the purlins.
Eaves
DuoPlus
clips
45°
Eaves
Gable end
Clip spacing
Ridge
Positioning scheme Kalzip rafter roof
The system requires that the DuoPlus rails are
positioned at an angle of 45°.
Rafter spacing
The DuoPlus rail must be long enough to
cover at least two ribs of the trapezoidal
deck and can be secured in it. If this is
not possible, then a section of adequate
length can be installed next to the first
row (see positioning diagram for rafter
roof and purlin roof).
Gable end
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°).
The first row of clips, at the start of the
installation surface (gable end), is aligned
precisely and fixed into the rail by means
of a screw through the base of the clip.
The remaining clips are inserted into the
rail and positioned parallel to the Kalzip
seam direction. Every tenth row of clips is
fixed with a screw to prevent shifting.
DuoPlus
rail Rail spacing
First of all the rigid thermal insulation is
placed on the substructure. A full layer of
rigid insulation is used in the case of Kalzip
DuoPlus 100. 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. 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.
Distances not to scale
Kalzip
39
Design specifications
6.6.5 Kalzip FOAMGLAS® System
The system always consists of FOAMGLAS® insulating slabs installed and
bonded across the full surface area, the
L-shaped claw plate, the composite clip
with fixing elements and optional compressible thermal insulation.
No compressible thermal insulation is used
with Kalzip AF; in this case, a PE film is
used as a separating layer.
Kalzip FOAMGLAS® slabs are available
in different formats and are suitable for
substructures such as:
• steel trapezoidal profiles
• timber lining
• concrete slabs
In order to attach the Kalzip composite
clips, the newly developed, galvanized
L-shaped steel claw plates are inserted
under heat in a fixed grid, taking into account the respective roof geometry and
wind/suction load. A friction-fit, coldbridgefree connection is created with the insulation layer (in accordance with building
approval Z-14.4-475 issued by the Institute
for Building Technology).
Rafter Spacing
Rafter Spacing
Claw-plates
Ridge
Claw-plates
Clip spacing
Gable end
Eaves
Composite clip
Clip spacing
Gable end
45°
Kalzip AF profiled sheets retain the possibility of free movement due to a durable PE
film as an isolating layer.
Installation pattern for Kalzip FOAMGLAS®
system on concrete slab
The FOAMGLAS® claw plates can be aligned
parallel to the eaves.
Ridge
Positioning scheme Kalzip FOAMGLAS® system
on trapezoidal steel deck or timber lining
The FOAMGLAS® claw plates should be arranged at an
angle of 45°
In addition to this, a layer of bitumen with
polyester fleece should also be applied
above the insulation layer and claw plates.
The Kalzip composite clips are installed
on the claw plates using the recommended
fastening elements.
Eaves Composite clip
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 lower temperatures the
substructure should be prewarmed accordingly. In the case of trapezoidal profiles,
bonding is carried out on the upper flanges.
When the substructure is closed, the entire
surface of the FOAMGLAS® and all joints
are sealed with hot bitumen. The butt
joints of the plates are completely sealed
using the edge dipping process. A hot bitumen top coat seals the surface and creates a prepared base for the subsequent
construction work.
Distances not to scale
40
Kalzip
Design specifications
The Kalzip profiled sheets are installed in
the usual manner. When Kalzip AF is used,
the Kalzip backing strip should be used
during welding. Only components which
have been approved by the building authorities should be used with the FOAMGLAS®
system. The arrangement of the L-shaped
claw plates and fastening components
(type/no.) is specified in the installation
plan.
Curved roofs
All roof shapes are possible. In the case
of large radii, the insulated slabs are connected in a polygonal manner or, in the
case of smaller radii and freely shaped
designs, they are delivered already in the
respective shapes or cut to size at the
construction site. The suppliers have a
team of technical advisors who will be
delighted to advise you on these roof
shapes. We recommend that you seek
their advice at the earliest possible stage.
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.
Fire cannot spread across the foam glass
insulating layer. FOAMGLAS® insulating
materials, 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”).
A roof featuring a design made from
FOAMGLAS® and Kalzip specified by the
manufacturer, is able to meet DIN 18234-1
requirements and can therefore be used
in accordance with the construction standards for industrial buildings.
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®, with L-shaped
claw plate installed above
• 3 mm hot bitumen top coat
• 5 mm bitumen sheeting
• 20 mm air space
• E clips
• Kalzip > 0.9 mm
Depending on the structural design,
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
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
Technical data FOAMGLAS® D slab T4 DS
®
FOAMGLAS is made from 100% pure
glass and is therefore totally inorganic. It
is manufactured from recycled glass products and the natural mineral materials
sand, dolomite and chalk in the thermal
foaming process. It contains no CFCs,
flame retardants or binders, does not
release any emissions and does not shed
any fibres.
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 = 0.04 W/(m·K)
German building material class A1 /
Euro class A (non-combustible)
allowable σ = 0.23 N/mm2
αth = 8.5·10-6 1/K
∞ = (impervious to water vapour)
durable waterproof
minimum +5° C
-260° C to +430° C
Kalzip
41
Design specifications
6.7 Connections
6,1
7,0
6,1
65
Note: The number of connecting elements
depends on the static requirements and
must be determined in each case. At the
edges and corners of roofs as well as at
the edges of walls, 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.
The minimum anchorage depth of the
screw in the wood is 4 x ds. The maximum
accountable anchorage depth is 12 x ds.
(ds = nominal diameter of the screw). The
connecting elements must be made of
stainless steel or aluminium. The use of
galvanised carbon steels is not possible.
36
The Kalzip profiled sheets are connected
to the substructure by clips made of extruded aluminium. The clips have diverse
holes in the baseplate. Special connecting
elements are used, depending on the
substructure.
44
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*, or
composite clip type E respectively, to steel purlin
Aluminium clip with and without TK5 or TK15*, or
composite clip type E respectively, to steel purlin
Aluminium clip with and without TK5 or TK15*, or
composite clip type E respectively, to steel purlin
Aluminium clip with TK5 or TK15*,
to steel purlin
Aluminium clip with TK5 or TK15*
to steel purlin
Appropriate fastener system2)
Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Sealing blind rivet Ø 4.8 x 9,5
Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Self-tapping fastener A Ø 6.5 x 19
Blind rivet Ø 5 x 12 K8 - 10; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Sealing blind rivet Ø 4.8 x 9.5
Bulb tite rivet Ø 5 min. 8 W SFS SL3/2 6.0 x 27
SD2 - S16 - 6.0 x 127 / SDK-S16 6.0 x 167
t = 0.75 - 3.0 mm Bulb tite rivet Ø 5-12W
t = 0.75 - 1.2 mm Screw SFS SDK21)
t = 1.20 - 3.2 mm Screw SFS SDK31)
Self-drilling screw Ø 5.5 x L1)
t = 1.5 - 2.0 mm Self-tapping fastener Ø 6.5 x L1)
Self-tapping fastener Ø 6.3 x L1) 3) 4)
t = 2.0 - 6.0 mm (Self-drilling screws no longer recommended)
Self-tapping fastener Ø 6,3 x L1) 4)
t > 6.0 mm
(Self-drilling screws no longer recommended)
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, aluminium clip and
composite clip type E on timber substructure
2 drilling screws Ø 6.5 x L1)
2 screws A Ø 6.5 x L (pre-drilled)
SFS SDK2 6 x 45 / 60
Timber materials from 19 mm: 2 self-drilling screws SFS SDK 2 6.0 x L
Timber lining from 30 mm: 2 screw A Ø 6.5 x L (pre-drilled)
5 - 15 mm longer fasteners are to be used, depending on the
spacer cap
1)
The length of the rivet or screw must be adapted to the required gripping length.
2)
In the case of blind rivets and sealed blind rivets, aluminium is used for the sleeve and stainless steel for the mandrel.
Stainless Steel is used for the screws. Please observe the information and specifications of the rivet and screw manufacturers.
The application and the structural conditions should be taken into consideration when selecting attachments and material.
3)
On steel purlin with flange thickness < 6 mm.
4)
Be sure to remove drilling swarf.
*
TK = Thermal barrier pads
42
Kalzip
Design specifications
6.10 Ridge, eaves, gable ends
6.8 Thermal expansion
Temperature changes can cause length
variations and these must be taken into
account. The thermal expansion coefficient
of aluminium in the observed temperature
range is approx 24 x 10–6/K. When the profiled sheets are installed at a given temperature of 20°C, there will be an expansion
in sheet length of approx. 1.5 mm/m in
summer (+ 80°C) and a contraction in sheet
length of approx. 1 mm/m in winter (-20°C).
However, as adjacent components are
also subject to variations in temperature,
and the substructure can usually absorb
elongations, a variation in movement of
± 0.5 mm/m may be applied to the sheet
length in practice. If these requirements
are not fulfilled then the maximum values
stated above must be assumed.
6.9 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. Each Kalzip profiled
sheet is to be secured at the fixed point
against displacement.
Fixed points are statically verified and
are to be taken from the installation plan.
The standard ridge consists of three components:
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, the rivet is inserted and the swage head is covered by
the large flange of the next profiled sheet.
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. The foam filler
acts as an additional “sealing” of the end
of the Kalzip sheet preventing rain water
from penetrating into the system. The folding up is the final protection against the
ingress of rain water into the ridge.
Alternatively, the fixed point is manufactured by the insertion of bolts through the
webs of the Kalzip and the fixed point clip.
Sealing washers must be inserted on both
sides (bolt head and nut). If a composite
clip is used for the fixed point, all drilling
swarf must be removed from the profiles,
since the composite clip is made of plasticsheathed steel. Rust stains on the profiled
sheets are thus avoided. For the further
installation of the roof surface, the Kalzip
profiled sheets are placed with the large
flange on the small flange, aligned to the
eaves and only then pressed into the next
row of clips.
If the fixed point is not located directly at
the roof ridge, 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.
Each Kalzip profiled sheet may have only
one fixed point. Kinks in the Kalzip profiled
sheet, fixed lighting elements etc. are likewise fixed points and must be taken into
account. No second fixed point may be
manufactured.
Generally the ridge is also the place where the fixed point is located. If the fixed
point is positioned elsewhere, then the
ridge must be designed as a sliding structure to be able to accommodate the expansion movement of the profiled sheets.
It is a fact that ventilated ridges cannot
be completely sealed against snow. 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.
At the eaves the drip angle stiffens the
bottom sheet and keeps the eaves filler in
position. 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. The gable
end is secured by the gable end hook and
the gable end clamping section.
(see page 13).
Aluminium clip
Fixed point with
Gesipa PolyGrip
Aluminium-Blind rivet
Ø 4.8 x 10 K9,5
45-60°
Composite clip
Fixed point with
Gesipa PolyGrip
Aluminium-Blind rivet
Ø 4.8 x 10 K9,5
Screw M6,
stainless steel
Kalzip
Clip
Note to Blind rivet:
See Kalzip approval and table on page 42.
Kalzip
43
Design specifications
Welded connecting frame
6.11 Skylights/Smoke/heat extractors
6.12 Transverse joints
Specially designed soakers are supplied
for the installation of skylights and smoke
extractors, etc.For arched roofs, special
curved soakers are required. The soakers
can either be welded or sealed (in the
case of a minimum roof pitch of 2.9°) into
the roofing. Welding is the recommended
option.
It is not always possible to produce the
required Kalzip sheet length in one element.
In most cases the length of the sheets is
determined by transport limitations, so that
the sheets must be joined by overlapping.
Especially with arched roofs the maximum
loading height of the trucks must be observed. Obviously, the requirements for absolute tightness of the overlapping joints are
very high. Therefore it is necessary to take
great care when making overlapping joints.
Overlaps are positioned on top of the support, if the joint is located at the fixed point.
Otherwise the profiled sheets have to be
joined directly next to the support. Joints
can be either welded or sealed.
The steel soaker is securely connected to
the substructure. The vapour barrier is installed on the soaker and extends up to
the height of the thermal insulation. The
covering frame is either welded or sealed
to the Kalzip sheets and is able to move
with the Kalzip roof skin. The upper connecting frame securely connects/seals the skylight or smoke extractor in the roof skin.
Skylights and smoke extractors must not
be walked on. As these must be regularly
accessed for servicing and maintenance
work, it is recommended that the area
around the opening is reinforced with rigid
thermal insulation. Large lighting elements
or rows of sky lights can require special
solutions and must be planned in detail.
44
Kalzip
Welded joint
The Kalzip profiled sheets to be joined are
overlapped by approx. 10 - 20 mm. The
welding seams should be supported.
The structure underneath the welding seam
must be secured against fire, e.g. by means
of the Kalzip welding underlay. 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. If necessary, the fire brigade must be
informed before carrying out welding work.
Design specifications
Sealed joints
(only possible with minimum roof pitch of 2.9°)
The profiled sheets are installed in a precise
sequence according to the assembly instructions. The critical tightness of seal is achieved
by three rows of silicone in the joint zone of
the individual profiled sheets plus two rows
of sealing rivets. The overlap is 200 mm.
Kalzip and the substructure, the thermal
barrier pads under the clips provide sufficient separation.
On concrete substructures a suitably
anchored steel section or timber batten
(minimum thickness 40 mm) must be
inserted.
Drilling pattern 2
Drilling pattern 1
6.14 Cantilevers/clip bars
2
1
Direction of assembly
4
2
If the roof is to protrude at the eaves, additional substructures are dispensable providing that the clips are installed as clip bars.
They are fixed to the roof with appropriate
length and serve as support for the Kalzip
sheets as well as a fixing for the gutter
(see table of roof projections and 6.16).
Drilling pattern 2
6.15 Installation rules
Drilling pattern 2
Individual verification is required in each
and every case. Roof projections are not
accessible. The ends of the Kalzip sheets
must be joined with an eaves angle. The
length of the clip bars is outlined in the
diagram opposite.
1
3
eaves angle as
lateral stiffener
Drilling pattern 2
Drilling pattern 1
6.13 Substructures
Kalzip roofs can be installed on all kinds
of substructures. With metal or timber
substructures the clips are directly fixed to
the substructure. With metal substructures
contact corrosion must be taken into consideration. As, with the exception of Kalzip
AF, there is no direct contact between
Drilling pattern 2
b = Fixing distance depends on substructure
Clip bar spacings
Roof projection (a)
over last support
1m
(0.5 m)*
1.5 m
(0.9 m)*
Kalzip 65/... 50/...
305
every
2nd sheet
every
sheet
333
every
2nd sheet
every
sheet
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. The table is applicable for a snow load of 0.75 kN/m2.
*Values apply to clip type L10.
Kalzip
45
Design specifications
a
6.16 Roof projections without
clip bars
An additional substructure can be omitted
in certain conditions where the roof extends
beyond the eaves. This overhang can be
installed without clip bars, 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). The minimum
length of the Kalzip tracks is 5 m.
Clip length
in accordance
with table
Roof projections constructed from Kalzip profile sheets
In this kind of design a short clip piece can
be installed within the seams to secure
the gutter support. The clip is attached by
using either 2 rivets in the clip head or 2
screws. As there is no connection to the
substructure, the Kalzip profile sheets are
able to expand freely. With a sheet length
of greater than 12 m the downpipe must
be designed to accommodate the elongation of the tracks, e.g. by means of moveable pipe laps. The sheets must be connected with the eaves angle in each case.
Line
Please note:
The roof projections are not accessible
during installation or before the seams are
zipped. Please observe and follow all instructions relating to safety measures and
fall arrest equipment. Roof projections
should be fitted with clip bars in the case
of values above 1.0 and up to 1.5 m.
6
1
2
3
4
5
7
8
9
10
The roof projection (a) is calculated from
the spacing between the first clip at the
roof edge and the outer edge of the Kalzip.
When the Kalzip profile sheets are visible
from below, it is advisable to always use
load spreading equipment when gaining
access.
Wind suction
2.00 kN/m2
2.50 kN/m2
1.50 kN/m2
Roof projections (a) in meters
0.90
0.80
0.60
s
s
d
1.00
1.00
0.80
s
s
d
0.80
0.60
0.50
s
d
d
1.00
0.80
0.60
s
d
d
1.00
1.00
0.90
s
s
d
1.00
1.00
1.00
s
s
d
1.00
1.00
0.80
s
s
d
1.00
1.00
1.00
s
s
d
1.00
1.00
0.60
s
d
d
1.00
1.00
0.90
s
d
d
Kalzip type
50/333 x 0.9
Clip length
50/333 x 1.0
Clip length
50/429 x 0.9
Clip length
50/429 x 1.0
Clip length
65/305 x 0.9
Clip length
65/305 x 1.0
Clip length
65/333 x 0.9
Clip length
65/333 x 1.0
Clip length
65/400 x 0.9
Clip length
65/400 x 1.0
Clip length
s: first clip at the roof edge in standard length/d: first clip at roof edge in double length
6.17 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.
Sheet length
> 20 m
> 20 m
F
E
E
E
E
E
E
E
> 20 m
E
> 20 m
> 40 m
E
E
E
E
E
E
F
E
E
E
E
E
E
E = composite clip
F = fixed point
Additional instructions for rafter roofs: in the case of profiled sheets > 20m, the clips
should be placed on supporting top-hat profiles.
46
Kalzip
Dimensioning tables
7. Kalzip dimensioning tables
7.1 Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035.
Thickness of insulation
[mm]
90
100
110
120
130
140
150
160
170
180
WLG 040
U value [W/(m²K)]
0.41
0.38
0.34
0.32
0.29
0.27
0.26
0.24
0.23
0.21
WLG 035
U value [W/(m²K)]
0.37
0.33
0.30
0.28
0.26
0.24
0.22
0.21
0.20
0.19
Related to the calculated value for the thermal conductivity.
7.2 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040)
thickness WD
[mm]
0.3
U value [W/(m2 K)]
160
180
200
0.2
220
240
0.1
0.5
1.5
2.5
3.5
clips per m2
Kalzip
47
Dimensioning tables
7.3 Clip spacings
7.3.1 Rafter roof (multi-span sheets) with composite clips
Clip fixing: directly to trapezoidal steel deck tmin = 0.75 mm. Two fastener systems per clip (Self-tapping screw SFS SDK).
Line
Kalzip
type
Sheet thickness
t in mm
0.80
0.90
1.00
1.20
Pressing loads*
kN/m2
0.75
1.00
2.50
2.40
3.15
2.50
3.30
2.50
3.30
2.50
loads
1.25
2.00
2.00
2.10
2.20
Uplifting
kN/m2
0.90
2.20
2.80
3.15
3.30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
65/333
65/305
1.44
2.00
2.00
2.00
2.00
1.60
1.65
1.80
1.80
1.80
1.98
1.45
1.45
1.45
1.45
2.56
1.10
1.10
1.10
1.10
3.52
0.80
0.80
0.80
0.80
65/400
0.80
0.90
1.00
1.20
2.50
2.95
3.00
3.00
2.30
2.30
2.30
2.30
1.85
1.85
1.85
1.85
2.00
2.60
2.75
2.75
1.70
1.70
1.70
1.70
1.50
1.50
1.50
1.50
1.20
1.20
1.20
1.20
0.95
0.95
0.95
0.95
0.70
0.70
0.70
0.70
50/333
0.80
0.90
1.00
1.20
2.10
2.60
2.80
3.00
1.90
2.00
2.20
2.30
1.80
2.00
2.00
2.00
2.20
2.80
3.15
3.30
1.75
2.00
2.00
2.05
1.55
1.80
1.80
1.80
1.25
1.45
1.45
1.45
0.95
1.10
1.10
1.15
0.70
0.80
0.80
0.80
50/429
0.80
0.90
1.00
1.20
2.00
2.45
2.70
2.80
1.80
1.90
2.10
2.15
1.70
1.70
1.70
1.70
1.85
2.40
2.55
2.55
1.35
1.55
1.55
1.55
1.20
1.40
1.40
1.40
0.95
1.00
1.00
1.00
0.75
0.85
0.85
0.85
0.55
0.65
0.65
0.65
NatureRoof
65/333
0.80
0.90
1.00
1.20
1.80
1.80
1.80
1.80
1.55
1.55
1.55
1.55
1.35
1.35
1.35
1.35
2.20
2.80
3.15
3.30
2.00
2.00
2.00
2.05
1.65
1.80
1.80
1.80
1.45
1.45
1.45
1.45
1.10
1.10
1.10
1.15
0.80
0.80
0.80
0.80
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.
48
Kalzip
100 m.
Dimensioning tables
7.3.2 Purlin roof (multi-span sheets) with composite clips
Clip fixing on steel purlins or steel spacer construction 1.5 mm:
2 fastener systems per clip, screw diameter 5.5 mm or SFS SDK.
Line
Kalzip
type
Sheet thickness
t in mm
0.80
0.90
1.00
1.20
Pressing loads*
kN/m2
0.75
1.00
2.50
2.40
3.15
2.70
3.65
2.70
3.60
2.70
loads
1.25
2.00
2.20
2.20
2.20
Uplifting
kN/m2
0.90
2.20
2.80
3.15
3.30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
65/333
65/305
1.44
2.00
2.50
2.80
2.80
1.60
1.65
2.00
2.50
2.50
1.98
1.45
2.00
2.00
2.15
2.56
1.10
1.50
1.55
1.55
3.52
0.80
1.15
1.45
1.45
65/400
0.80
0.90
1.00
1.20
2.50
2.95
3.00
3.00
2.30
2.30
2.30
2.30
1.85
1.85
1.85
1.85
2.00
2.60
3.00
3.15
1.70
2.30
2.35
2.35
1.50
1.70
2.10
2.10
1.20
1.70
1.70
1.70
0.95
1.30
1.30
1.30
0.70
0.95
0.95
0.95
50/333
0.80
0.90
1.00
1.20
2.10
2.60
2.80
3.00
1.90
2.00
2.20
2.30
1.80
2.00
2.00
2.00
2.20
2.80
3.15
3.30
1.75
2.40
2.80
2.80
1.55
2.00
2.50
2.50
1.25
1.80
2.00
2.05
0.95
1.40
1.55
1.55
0.70
1.00
1.15
1.15
50/429
0.80
0.90
1.00
1.20
2.00
2.45
2.70
2.80
1.80
1.90
2.10
2.15
1.70
1.70
1.70
1.70
1.80
2.40
2.75
2.90
1.35
1.95
2.15
2.15
1.20
1.70
1.95
1.95
0.95
1.40
1.55
1.55
0.75
1.10
1.20
1.20
0.55
0.80
0.85
0.85
NatureRoof
65/333
0.80
0.90
1.00
1.20
1.80
1.80
1.80
1.80
1.55
1.55
1.55
1.55
1.35
1.35
1.35
1.35
2.20
2.80
3.15
3.35
2.00
2.50
2.80
2.80
1.65
1.80
2.50
2.50
1.45
2.00
2.00
2.15
1.10
1.55
1.55
1.55
0.80
1.15
1.15
1.15
Supporting width in [m]
*The supporting widths for snow load also apply to the wind suction load in the normal range for building heights
100 m.
Kalzip
49
Dimensioning tables
7.3.3 Kalzip ProDach (adjacent) with aluminium clips
Clip fixing: directly to ProDach fixing rail.
(fasteners: SFS SDK2-S-377-6.0 x L). 2 fasteners per clip.
Line
1
2
3
4
5
6
7
8
9
Kalzip
type
Sheet thickness
t in mm
Pressing loads*
kN/m2
AF 65/333
0.80
0.90
1.00
1.20
AF 65/434
AS 65/422
0.80
0.90
1.00
1.20
loads
Pressing loads are
transmitted directly
through contact onto
the substructure
Uplifting
kN/m2
0.48
2.40
2.40
2.90
2.90
0.90
2.20
2.60
2.80
2.90
1.44
1.60
1.80
2.00
2.20
1.60
1.40
1.60
1.80
2.00
1.98
1.10
1.30
1.60
1.80
2.56
0.80
0.90
1.20
1.40
3.52
0.50
0.70
0.90
1.10
Pressing loads are
transmitted directly
through contact onto
the substructure
2.30
2.70
2.90
3.00
2.00
2.30
2.50
2.70
1.20
1.40
1.80
2.00
1.00
1.20
1.40
1.80
0.80
0.90
1.20
1.50
0.50
0.70
0.90
1.10
0.30
0.50
0.60
0.70
Supporting width in [m]
Separate design calculations are required for the substructure. Please contact: DEUTSCHE ROCKWOOL MINERALWOLL GMBH & CO. OHG.
Rockwool Straße 37-41. D-45966 Gladbeck. T +49 (0)2043/408-0. F +49 (0)2043/408-444.
The table does not apply to Kalzip DuoPlus.
7.3.4 Kalzip AluPlusSolar*
When using Kalzip aluminium clips. Details on Kalzip composite clips available on request.
Clip fixing: directly onto steel trapezoidal substructure tmin = 0.75 mm.
2 fasteners per clip (SFS SDK2-S-377-6.0 x L).
Line
1
Kalzip
type
Sheet thickness
t in mm
AF 65/537
1.00
Pressing loads*
kN/m2
0.75 1.00 1.25
2.00 1.90 1.80
Uplifting loads
kN/m2
0.90
1.44
1.20
0.90
1.60
0.70
1.93
0.60
2.56
0.50
3.52
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.
If the Kalzip profiled sheets are not fitted with rigid thermal insulation. access is only possible using load spreading equipment. The values stated are guide
values. They do not serve as a replacement for project-specific consultations. Separate design calculations are required for the substructure. The values
50
Kalzip
Index
A
accessibility
accessories
aluminium clip
AluPlusPatina
AluPlusZinc
assembly
26, 29
12
7, 42, 43, 50
10
10
20, 45
B
bituminous coating
building material class
21, 30
41
C
cantilevers
45
chemicals
30
chlorinated rubber paint
30
clip
36 - 40, 42, 43, 46
clip bars
45, 46
clip spacing
48
coil coating
10, 11
colour coating
11
colour qualities
11
composite clip
8, 42, 43
compressible adhesive tape
12
concrete and mortar
30
condensate
33
connecting frame
44
connections
42
contact corrosion
30, 45
corrosion resistance
30
D
design specifications
Duo
DuoPlus
33
18, 39
9, 18, 39, 47
E
eaves
ecological aspects
extreme lengths
12, 43
22, 31
32
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
29
34, 41
43, 46
21
13
12, 13, 43
43
13, 43
13
30
I
insulating materials
installation instructions for long
profiled sheets
installation rules
16, 41
46
45
K
Kalzip
Kalzip
Kalzip
Kalzip
Kalzip
Kalzip
AF
AluPlusSolar
DuoPlus rail
range of applications
SolarClad
Solar Power Systems
20, 21
22, 23, 50
9
16 - 23
23
22
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
43
43
35
6
29, 32
30
11
25 - 27
24
33
26
19
6
16, 17
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
32
24
30
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, 29
31
42
45
25, 26, 29, 32
6, 7
44
44
24
14, 15
48 - 50
15, 24, 44
34, 41
9, 13, 42
16, 20, 29, 30
14
10
16 - 21, 40, 45
T
thermal barrier pad
thermal expansion
thermal transition coefficient
timber
top hat section
transverse joints
trapezoidal steel sheet
transition sheet
transport
7,
41,
41, 43,
17,
42
43
47
21
17
44
16
12
24, 25, 32
U
U-value
14, 22,
37 20, 21,
20,
38,
R
rafter roof
36, 39,
rafter spacing
37 recycling
reinforcing profile for verge flashing
rib filler
ridge profile
rigid insulation
18, 27,
roll forming
roof anchor
15,
roof areas
roof pitch
19, 22,
roof systems
16,
roof projection
45,
rotatable clip
ridge
13, 42,
rivets
10
23
11
10
40
50
21
6
11
49
48
40
31
13
12
13
39
11
29
37
24
36
46
9
43
42
V
vapour diffusion
vapour barrier
ventilated roof
47
33
12, 16, 17, 21, 33
16
W
welded joints
wind suction forces
44
50
Z
zinc chromate coating
zipping machine
30
7
Kalzip
51
www.kalzip.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. From time to time our product range
may alter as a result of our continued commitment to
product innovation and development. Kalzip cannot
guarantee that printed literature will contain the most
recent updates; the latest editions are available to
download at www.kalzip.com.
Copyright 2011
Kalzip GmbH
August-Horch-Str. 20-22 · D-56070 Koblenz
P.O. Box 10 03 16 · D-56033 Koblenz
T +49 (0) 2 61 - 98 34-0
F +49 (0) 2 61 - 98 34-100
E germany@kalzip.com
English
The address of your nearest local sales office
can be found on our website: www.kalzip.com
adhoc media gmbh:901:EN:01/2011
Kalzip GmbH
Part of Tata Steel Europe Ltd.