Product information and specification - Kalzip

1 Kalzip SystemsProduct information and aluminium roof and fa ade systems 42. Kalzip innovations 53. The system and its components Dimensions of the profiled sheets 6 Aluminium clip and thermal barrier pads 7 Different finishes and colours 10 Accessories 12 Components for roof superstructures and safety appliances 144. Kalzip range of applicationsNon-ventilated Kalzip roof on a trapezoidal steel deck 16 Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet 17 Non-ventilated Kalzip roof on timber rafters with visible timber lining 17 Kalzip DuoPlus 100 and Kalzip Duo 100 on a concrete substructure 18 Kalzip DuoPlus 100 18 Kalzip Duo 100 18 Kalzip NatureRoof 19 Kalzip FOAMGLAS System as a standard and combined solution 19 Kalzip AF 20 Kalzip AF with ProDach-insulation on trapezoidal steel deck 20 Kalzip AF with ProDach-insulation on timber rafters with formwork 21 Kalzip AF with the insulation layer at rafter level 21 Kalzip AF on FOAMGLAS insulation 21 Kalzip Solar Power Systems 22 Kalzip AluPlusSolar 22 Kalzip SolarClad 235.

2 General data and characteristics Roof pitch 24 Minimum radii for crimp-, smooth- and on site curving 24 Kalzip Convex Factory crimp-curved 24 Kalzip smooth curved in factory, aluminium 25 Kalzip supplied in straight form, curved to radius during installation (naturally curved) 26 Tapered shapes 27 Kalzip XT free-form profiled sheets Kalzip type 65 /.. / mm 28 Accessibility/fall arrest systems 29 Material/corrosion resistance 30 Sustainable construction 31 Official approvals/design calculations 32 Transport 32 Sheet thickness 32 Content Page6. Design specifications Moisture proof 33 Ice barriers 33 Sound absorption 34 Fire protection 34 Lightning protection using Kalzip aluminium profiled sheet envelopes 35 Roof systems 36 Rafter roof: Kalzip sheets perpendicular to the trapezoidal steel deck 36 Kalzip perpendicular on timber lining 37 The purlin roof: Kalzip parallel to inner skin 38 Kalzip DuoPlus 100 and Kalzip Duo 100 39 Kalzip FOAMGLAS System 40 Connections 42 Thermal expansion 43 Design of fixed points Kalzip aluminium clip / Kalzip composite clip 43 Ridge, eaves, gable ends 43 Skylights/Smoke/heat extractors 44 Transverse joints 44 Substructures 45 Cantilevers/clip bars 45 Installation rules 45 Roof projections without clip bars 46 Installation instructions for long profiled sheets 467.

3 Kalzip dimensioning tables Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035 47 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040) 47 Clip spacings 48 Rafter roof (multi-span sheets) with composite clips 48 Purlin roof (multi-span sheets) with composite clips 49 Kalzip ProDach (adjacent) with aluminium clips 50 Kalzip AluPlusSolar 50 Index 51 Page4 KalzipKalzip aluminium building envelopes have been setting trends worldwide in contemporary building culture for more than 40 almost unlimited variety of forms and the most diverse intelligent additional functions continually provide architects and planners with impetus for sophisti-cated architecture More than 80 million square metres of installed Kalzip profiled sheets speak for for industrial buildings, exhibition halls, airports, public amenities such as sports facilities or the renovation of existing buildings the outstanding material char-acteristics and flexibility of aluminium allow an inexhaustible variety of forms and offer durable secure building protection.

4 As a leading manufacturer of aluminium profiled sheets, Kalzip offers with this brochure comprehensive technical information on Kalzip aluminium roof and fa ade systems. Detailed data on the system provide you with an in-depth insight into the mode of functioning of this unique building economical all-in-one solutionIn 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 dra-wings and installation examples illustrate the function of the Kalzip system with com -ponents and accessories, 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 Vary Airport, Czech RepublicArchitect: Petr Parolek1. Kalzip aluminium roof and fa ade systemsIntroduction Kalzip 5 InnovationsKalzip XT for a new architectural eraKalzip XT profiles enable for the first time the implementation of computer-generated forms and design principles.

5 Evolutionary animations, visualised in 3D objects, give birth to new architectural-organic forms the fusion of biology and advantages in summary: Horizontal and vertical profiled sheets in convex and concave forms are possible New variations in the design of geo me tries thanks to XT free-form profiled sheets Small bending radii guarantee the roofing of unusual building formsFurther information can be found on page 7 and page integrated Kalzip renovation concept the durable roof renovationEmergency 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 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 installationThe thermal bridge-optimised composite clip for Kalzip profiled sheets for the achievement of EnEV 2009-compliant roof structuresThe Kalzip composite clip consists of a stable steel core, which is encased by a glass-fibre reinforced of the Product .

6 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 padsFurther information can be found on page page features our new Kalzip Kalzip innovationsSports arena in Porec (HR) Kalzip AluPlusSolar installation with composite clipsKalzip composite clipBMW Head Office in Leipzig (D), winner of the German Architecture Prize 2005. Architect: Zaha Hadid with Patrik SchumacherGymnasium of the Vallendar comprehensive school (D) after renovationArchitect: Guido Fries ArchitektenGymnasium of the Vallendar comprehensive school (D) before renovation6 Kalzip3. The system and its componentsThe system and its componentsThe nominal thickness is subject to the tolerances specified by DIN EN 485-4.

7 As far as the lower tolerances are concerned, only 50 % of the specified values will be length tolerances are:with sheet lengths up to 3 m: + 10 mm / 5 mmwith sheet lengths of more than 3 m:+ 20 mm / Dimensions of the profiled sheets*) Only in combination with accessible insulation materials or wooden timber lining. Preferable thicknesses to mm.**) Recommended for facade claddingDimensions mm Thickness 50/333 Kalzip 50/429 Kalzip 65/305 Kalzip 65/333 Kalzip 65/400 Kalzip 65/500 **) Kalzip AF 65/333 *) Kalzip AF 65/434 *) Kalzip AS 65/422 *)50333504296530565333654005006565333654 3465422 There are many variations in shape for instance*)straightconvex curvedtapered-convex curvedtaperedtapered concave curvedconcave curvedellipticallycurvedhyperbolicallycu rved*) Not all shapes are possible for all types of Kalzip Kalzip 7 The system and its Aluminium clip and thermal barrier padsAluminium clip rods can be used for clip rods, eaves, gutter brackets and fixed points.

8 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 struc-tures made of steel, aluminium or timber and anchored sufficiently in the concrete must be placed barrier pad (TK 5 or 15 mm thick)Twin thermal barrier pad (DTK 5 or 15 mm thick) Kalzip zipping machineKalzip aluminium clip combinationsKalzip 50/.. Kalzip 65/..Hw1w2w1w2clip typeclip heightwithoutTkwith Tk 5with Tk 15without Tkwith Tk 5with Tk 15L 1066202535only applicable with AF/ASL 2581354050202535L 10015611011512595100110L 140196150155165135140150dimensions in mmKalzip aluminium clipH = height of clip without thermal barrier padw1 = distance between Kalzip bottom and bottom edge of clip footw2 = distance between Kalzip bottom and bottom edge of thermal barrier padFurther shapes**:XT freeform**) Not all shapes are possible for all types of Kalzip8 KalzipThe system and its componentsTechnical Dataclip typein combination with spacer cap (DK)clip heightH Kalzip 50/.

9 W3 Kalzip 65/..w3 Kalzip AF 65/..w3 E 5-6620 -5E 20-81352020E 20 + DK 1091453030E 40-101554040E 40 + DK 10111655050E 60-121756060E 60 + DK 10131857070E 80-141958080E 80 + DK 101511059090E 100-161115100100E 100 + DK 10171125110110E 120-181135120120E 120 + DK 10191145130130E 140-201155140140E 140 + DK 10211165150150E 160-221175160160E 160 + DK 10231185170170E 180-241195180180DK 10 mmDK 5 mmw3 = distance from Kalzip base to lower edge of clip foot base EStandard version for connecting elements SFS SDK2 or 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 in mmKalzip composite clipThe energy-saving clip for attaching Kalzip profiled sheets. According to the European energy-saving directives, which are an inte-gral part of building regulations in several countries, it is now obligatory to take account of thermal bridges when planning building projects.

10 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 pre vents thermal bridges and succeeds in creating a system which is virtually cold-bridge free, therefore optimizing the per-formance 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 insu lation. 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. 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 footKalzip E 10 composite clipHole pattern for alignment of the fastening systems to the screw arrangementSpacer cap (DK 10)w3H Kalzip 9 The system and its componentsKalzip DuoPlus rotatable clips in Kalzip DuoPlus rail, perforatedDimensions: 120 x 6000 lengthKalzip 50/.