Kalzip® Systems

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 6
3.2 Aluminium clip and thermal barrier pads 7
3.3 Different finishes and colours 10
3.4 Accessories 12
3.5 Components for roof superstructures and safety appliances 14
4. Kalzip range of applications
Non-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 23
5. General data and characteristics
5.1 Roof pitch 24
5.2 Minimum radii for crimp-, smooth- and on site curving 24
5.2.1 Kalzip Convex Factory crimp-curved 24
5.2.2 Kalzip smooth curved in factory, aluminium 25
5.2.3 Kalzip supplied in straight form, curved to radius during installation (naturally curved) 26
5.3 Tapered shapes 27
5.4 Kalzip XT free-form profiled sheets Kalzip type 65 /… / 1.0 mm 28
5.5 Accessibility/fall arrest systems 29
5.6 Material/corrosion resistance 30
5.7 Sustainable construction 31
5.8 Official approvals/design calculations 32
5.9 Transport 32
5.10 Sheet thickness 32

Page
6. Design specifications
6.1 Moisture proof 33
6.2 Ice barriers 33
6.3 Sound absorption 34
6.4 Fire protection 34
6.5 Lightning protection using Kalzip aluminium profiled sheet envelopes 35
6.6 Roof systems 36
6.6.1 Rafter roof: Kalzip sheets perpendicular to the trapezoidal steel deck 36
6.6.2 Kalzip perpendicular on timber lining 37
6.6.3 The purlin roof: Kalzip parallel to inner skin 38
6.6.4 Kalzip DuoPlus 100 and Kalzip Duo 100 39
6.6.5 Kalzip FOAMGLAS ® System 40
6.7 Connections 42
6.8 Thermal expansion 43
6.9 Design of fixed points Kalzip aluminium clip / Kalzip composite clip 43
6.10 Ridge, eaves, gable ends 43
6.11 Skylights/Smoke/heat extractors 44
6.12 Transverse joints 44
6.13 Substructures 45
6.14 Cantilevers/clip bars 45
6.15 Installation rules 45
6.16 Roof projections without clip bars 46
6.17 Installation instructions for long profiled sheets 46
7. Kalzip dimensioning tables
7.1 Thermal conductivity coefficients when using Kalzip composite clips for WLG 040 and WLG 035 47
7.2 Thermal conductivity coefficients for Kalzip DuoPlus 100 roof (WLG 040) 47
7.3 Clip spacings 48
7.3.1 Rafter roof (multi-span sheets) with composite clips 48
7.3.2 Purlin roof (multi-span sheets) with composite clips 49
7.3.3 Kalzip ProDach (adjacent) with aluminium clips 50
7.3.4 Kalzip AluPlusSolar 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.
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 com -
ponents and accessories, e.g. clips, on
different roof structures. Additive systems
for new buildings or existing building fabric
are described using examples. The Kalzip
Solar Systems offer creative freedom with
maximum efficiency for the integration of
photovoltaic systems.
Karlovy Vary Airport, Czech Republic
Architect: Petr Parolek
4 Kalzip

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
geo me tries 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
3.1 Dimensions of the profiled sheets
There are many variations in
shape for instance*)
Dimensions mm
Kalzip 50/333
333
50
Thickness mm
1.2
1.0
0.9
0.8
straight
Kalzip 50/429
429
50
1.2
1.0
0.9
0.8
convex
curved
Kalzip 65/305
Kalzip 65/333
305
333
65
65
1.2
1.0
0.9
0.8
1.2
1.0
0.9
0.8
tapered-convex
curved
Kalzip 65/400
400
65
1.2
1.0
0.9
0.8
tapered
Kalzip 65/500 **)
500
65
1.2
1.0
0.9
0.8
tapered concave
curved
Kalzip AF 65/333 *)
333
65
1.2
1.0
0.9
0.8
Kalzip AF 65/434 *)
434
65
1.2
1.0
0.9
0.8
concave
curved
Kalzip AS 65/422 *)
422
65
1.2
1.0
0.9
0.8
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.
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
6 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
Kalzip 50/…
Kalzip 65/…
H w1 w2 w1 w2
clip
type
clip
height
without
Tk
with
Tk 5
with
Tk 15
without
Tk
with
Tk 5
with
Tk 15
L 10 66 20 25 35 only applicable with AF/AS
L 25 81 35 40 50 20 25 35
L 100 156 110 115 125 95 100 110
L 140 196 150 155 165 135 140 150
dimensions in mm
Twin thermal barrier pad (DTK 5 or 15 mm thick)
Kalzip aluminium clip
Kalzip zipping machine
H = height of clip without thermal barrier pad
w1 = distance between Kalzip bottom
and bottom edge of clip foot
w2 = distance between Kalzip bottom
and bottom edge of thermal barrier pad
Kalzip 7

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
pre vents 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 Inspectorate
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.
Technical Data
clip type
in combination with
spacer cap (DK)
clip height
H
Kalzip 50/...
w3
Kalzip 65/...
w3
E 5 - 66 20 - 5
E 20 - 81 35 20 20
E 20 + DK 10 91 45 30 30
E 40 - 101 55 40 40
E 40 + DK 10 111 65 50 50
E 60 - 121 75 60 60
E 60 + DK 10 131 85 70 70
E 80 - 141 95 80 80
E 80 + DK 10 151 105 90 90
E 100 - 161 115 100 100
E 100 + DK 10 171 125 110 110
E 120 - 181 135 120 120
E 120 + DK 10 191 145 130 130
E 140 - 201 155 140 140
E 140 + DK 10 211 165 150 150
E 160 - 221 175 160 160
E 160 + DK 10 231 185 170 170
E 180 - 241 195 180 180
DK 10 mm
DK 5 mm
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
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
Composite clip + DK 10
Combination for the desired clip height
+
Correct
Composite clip + DK 10 + DK 5
Max. combination for the desired clip height
and to compensate for height tolerances
Correct
Incorrect
+
+
Composite clip + DK 5
to compensate for height tolerances
Composite clip with several DKs
– not permissible
Kalzip DuoPlus rotatable clips
and Kalzip DuoPlus rail, 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).
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.
Sub sequent ly, the DuoPlus clips are manually
screwed in. Although these remain
adjustable, the DuoPlus rail still offers a
secure hold; therefore DuoPlus 100 can
be adapted to the individual circumstances
depending on the profile dimension
and/or tolerance. Therefore a customised
and convenient installation is guaranteed
every time.
Kalzip 50/… Kalzip 65/…
clip type clip height (H) w4 w4
D 10 66 25 not applicable
D 25 81 40 25
D 100 156 115 100
D 140 196 155 140
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
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
out performs 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
Kalzip AluPlusPatina
Special surface treatment of the pre weathered,
stucco-embossed profiled sheets
significantly reduces their natural sheen,
thereby creating a new and attractive design
with a high-quality appearance. With
charac teristics comparable to those of an
aluminium profiled sheet which has been
weathered over years, this elegant and
matt surface pro vides roofs and facades
with impressive style.
The natural ageing process, which the
profile sheets undergo during exposure to
weathering, is not hindered and pro ceeds
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
Coil-Coating
Liquid lacquer is rolled onto the alumi ni um
layer in a coil coating process. These colour
coated coils are then used to roll-form the
Kalzip profiles.
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.
10 Kalzip

The system and its components
Kalzip colours
Protective plating
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.
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 SO 2
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 performance of the protective plating
has been proved by several tests carried
out by “Bundes anstalt für Materialforschung
und Prüfung (BAM) in Berlin” (German
Federal Institute for material research and
testing).
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.
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
Kalzip vapour barrier
avoids air flow and diffusion
12 Kalzip

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
Step
14 Kalzip

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.
On the basis of newly-developed materials,
Kalzip system components make a significant
contribution to EnEV-compliant roof
structures.
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°.
Furthermore it may be combined with any
kind of support or substructure. The system
depends on the special requirements of
the individual application.
The likely effects of snow, wind, humidity
and weathering are fully taken into account.
Kalzip can easily be configured to provide
the highest levels of thermal insulation.
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.
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.
• Chemically neutral, fibrous insulating
materials as specified by e.g. the
German DIN 18 165 are recommended
as suitable thermal insulation. The insulation
is laid into position 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
R’w = ~ 35 dB (A)*
Non-ventilated Kalzip roof
on a trapezoidal steel deck
This very economical roof system is used
both for industrial and residential buildings.
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 insu -
lation.
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.
* varies depending on thickness and material qualities
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.
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 sub -
structure. 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-X-
S4-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, Duo-
Plus 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
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 sup porting a
vegetation layer for extensive landscaping
with sedum plants. All components for the
Kalzip NatureRoof outside Germany are
available only on request.
Technical data:
Min. roof pitch: 1,5°
Max. roof pitch: 15°
Additional weight (wet): 0.9 kN/m 2
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
combination with the ProDach-insulation
system but may also be used with FOAM-
GLAS ® 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. How ever, and
this is the distinctive feature of the ProDach
insulation system, rather than being fixed
directly to the substruc ture 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
R’w = ~ 42 dB (A)*
Kalzip AF with ProDach-insulation
on trapezoidal steel deck
In order to meet increased demands for
sound reduction and to reduce cold/heat
bridges it is advisable to install the ProDach
Insulation System. Fixing rails are embedded
in the top-side of the insulation material
and fixed to the trapezoidal steel deck.
* varies depending on thickness and material qualities
20 Kalzip

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 multipur
pose 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 tradi tional
standing seam systems. It is frequently
used in order to minimise the overall height
of the roof structure. If there is an air gap
under the timber lining adequate ventilation
is essential.
With this in mind, we recommend filling
the total height of the rafters with 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.
Kalzip AluPlusSolar
Trapezoidal substructure
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 par -
ticularly 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 permanent ly
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
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,
regenera tive 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
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
Technical Data PVL-68 PVL-136 PVL-144
Surface required per kWp [m 2 ] > 22.5 > 22 > 20.5
Module length [m] 2.85 5.50 5,50
Maximum Power (P max ) [W p ] 68 136 144
Voltage at P max (V mpp ) [V] 16.50 33 33
Current at P max (I mpp ) [A] 4.13 4.13 4.36
Open circuit voltage V OC [V] 23.10 46.20 46.20
Short-circuit current I SC [A] 5.10 5.10 5.30
Series fuse rating, nom./ blocking diode rating, nom. [A] 8 8 8
Maximum DC system voltage [V] 1000 1000 1000
Connection
reverse side,terminal housing assembly IP65, 50 cm connecting
cable MC-FlexSol-XL (4 mm 2 ), male connector MC 4
Weight in kg per m 2 roof size 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
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 Solar-
Clad is a retrofit solar solution which can
be harmo niously 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 com plete
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 extrem
ely 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.
Technical Data PVL-68 PVL-136 PVL-144
Surface required per kWP (installation parallel to standing seams) [m 2 ] > 19 > 18.50 > 18
Module length [m] 2.85 5.50 5,50
Maximum Power (P max ) [W p ] 68 136 144
Voltage at P max (V mpp ) [V] 16.50 33 33
Current at P max (I mpp ) [A] 4.13 4.13 4.36
Open circuit voltage V OC [V] 23.10 46.20 46.20
Short-circuit current I SC [A] 5.10 5.100 5.30
Series fuse rating, nom./ blocking diode rating, nom. [A] 8 8 8
Maximum DC system voltage DC [V] 1000 1000 1000
Connection
reverse side, terminal housing assembly IP65, 50 cm connecting
cable MC-FlexSol-XL (4 mm 2 ), male connector MC 4
Weight in kg per m 2 (installation parallel to standing seams) 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 conti nous
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 with out 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.
The minimum radii for smooth curving
of Kalzip elements are specified on the
following page.
5.2.1 Kalzip Convex
Factory crimp-curved
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.
l 2
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
Please take note when ordering:
Please specify the required dimensions in
accordance to the sketch.
Transportation:
Max. loading height 2.40 m. For any
queries, please contact our logistics
department.
Minimum length of straight end pieces
Ri min l 1
min l 2
[mm] [mm] [mm]
bis 1000 150 150
> 2000 0 0
C
a
DB
l 1
65
R i
R a
C a
= Arc length outside
24 Kalzip

General data and characteristics
5.2.2 Kalzip smooth curved in factory, aluminium
Convex
Minimum curving radii in m
Sheet thickness 0.8 mm 0.9 mm 1.0 mm 1.2 mm
65 / ... 6 5 1.5 1.5
50 / ... 8 5 1.3 1.3
AF 65 / ... 10 8 3.5 3
AS 65 / ... 10 8 3.5 3
Concave
Sheet thickness 0.8 mm 0.9 mm 1.0 mm 1.2 mm
65 / ... 16 14 10 10
50 / ... 12 10 7 6
AF 65 / ... 15 14 10 7
AS 65 / ... 25 16 10 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 in -
crease 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 tech nical
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 inter mediate 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.
Tolerance limits. Only after consultation
with our technical department in Koblenz.
Special measures are necessary in order
to reach the tolerance limits.
Finish:
• stucco-embossed
• AluPlusPatina
• coated material with protection foil
• AluPlusZinc with protection foil
• Anti-condensation coating on request
Installation width:
For pre-installed clips:
cover width + 3 mm
successive installation of clips:
cover width + 0 to + 3 mm
Length of profiled sheet:
Minimum length 1.5 m. Shorter lengths on
request. The final overall length depends
on the individual radii and possibility of
transport. Minimum length of segment per
radius = 500 mm.
Transportation:
Maximum loading height 2.4 m. It might be
necessary to coordinate details of transportation
with our logistics department.
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).
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.
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
Kalzip
Type
Sheet thickness
(mm)
Radii
(m)
max. supporting space
(m)
65/305 0.8 36 1.5 +3
65/333 0.9 40 1.6 +3
65/400 1.0 48 1.8 +3
1.2 55 2.0 +3
50/333 0.8 37 1.5 +2
50/429 0.9 37 1.5 +2
1.0 40 1.5 +2
1.2 43 1.8 +2
AS 65/422 0.8 50 1.5 +2
0.9 55 1.5 +2
1.0 60 1.5 +2
1.2 70 1.8 +2
Kalzip AF Profile cannot be naturally curved. Special forms with beading are available on request.
Minimum curving radii in m
Increase in construction
width (mm)
Concave
Kalzip
Type
Sheet thickness
(mm)
Radii
(m)
max. supporting space
(m)
65/305 0.8 40 1.5 +3
65/333 0.9 45 1.6 +3
65/400 1.0 50 1.8 +3
1.2 60 2.0 +3
50/333 0.8 38 1.5 +2
50/429 0.9 40 1.6 +2
1.0 42 1.8 +2
1.2 45 2.0 +2
AS 65/422 0.8 50 1.5 +2
0.9 55 1.6 +2
1.0 60 1.8 +2
1.2 70 2.0 +2
Kalzip AF Profile cannot be naturally curved. Special forms with beading are available on request.
Increase in construction
width (mm)
General information
Naturally curved:
The profile sheets are supplied in straight
form and are curved by hand to the respective
radii during installation.
Cover width:
Depending on the radius, the nominal
width (construction width) must be increased
to the cover width (installed width).
Support spacing:
When the supporting spacings are too
large the supports will appear as polygon
lines.
Accessibility:
Due to the risk of buckling, access to the
sheets must not be gained without load
spreading equipment.
Finish:
• stucco-embossed
• AluPlusPatina
• coated material with protection foil
• AluPlusZinc with protection foil
• Anti-condensation coating on request
• without protection foil on request
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.
26 Kalzip

General data and characteristics
5.3 Tapered shapes
Tapered Kalzip profile sheets have become
increasingly significant for roofing appli ca -
tions 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 distri buting
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 instructions
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
Profile types available Kalzip 65/… und 50/… Kalzip AF… Kalzip AS…
Minimum construction width 230 mm 170 mm
Maximum width 740 mm 1 740 mm 1
Minimum length 1500 mm 1500 mm
Maximum length Dependent on transport Dependent on transport
not possible
Plate thicknesses 0.80 – 1.20 mm 0.80 – 1.20 mm
Curved and tapered
Possible for construction widths of 230 – 620 mm.
Only following approval from the technical department in Koblenz.
1
Applies only to stucco-embossed and colour-coated 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*
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.
Hospital, Emmen (NL)
Architect: A/d Amstel Architecten
28 Kalzip

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 con -
cerned 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 installation 1
Seamed Kalzip profile sheets with supporting spacings up to the following dimensions
are accessible without the use of load spreading equipment.
Sheet thickness 65/305 65/333 65/400 50/333 50/429 AF 65/333 2 AF 65/434 2 AS 65/422 2
t/mm lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m lgr/m
0.8 2.90 2.90 3.00 2.50 2.50 2.90 3.50 3.50
0.9 3.35 3.35 3.40 2.65 2.60 3.20 3.55 3.55
1.0 3.80 3.80 3.80 2.80 2.70 3.50 3.60 3.60
1.2 3.80 3.80 3.80 3.00 2.90 3.50 3.60 3.60
1
Applies only to stucco-embossed and colour-coated Kalzip profile sheets.
Other material combinations are available on request.
2
On grounds of final visual appearance, this information is only applicable when rigid thermal insulation is used.
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 cor rosion
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.
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, interme diate
layers coated with bituminous, zinc chromate
or chlorinated rubber paint or the
galvanizing of the contact areas of steel
parts.
Timber:
Timber parts in contact with Kalzip should
be dry. For the protection of timber rafters
and other wooden construction elements
in direct contact with aluminium structures
only compatible (f.i. oil based) wood preservatives
must be used. They must not
belong to the group of naphta lenic 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.
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.
Compatibility with other materials
for common Kalzip system applications*
Atmospheres
Combination of materials rural town/industrial maritime
zinc safe safe safe
stainless steel safe safe safe**
lead safe safe critical
hot-dip galvanized steel safe safe safe
unprotected steel critical critical critical
copper critical critical critical
* 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.
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
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.
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 Inspec torate 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
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 pro duction 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.
5.10 Sheet thickness
According to the licensing agreement
issued by the building authorities the minimum
thickness for Kalzip profiled sheets
is t = 0.7 mm. Although these sheets are
accessible both during as well as after their
installation for main tenance and cleaning
without the need of load distributing
measures, it is however not advisable to
use sheets of this thickness because of
the risk of denting resulting from people
walking on the sheets during installation.
For aesthetic reasons it is advisable to
choose a minimum sheet thickness of 1 mm
on any visible areas.
32 Kalzip

Design specifications
6. Design specifications
6.1 Moisture proof
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. accor ding
to DIN 4108-3) as well as air flows must
be considered.
Superficial formation of condensate on
structural components
If the minimum values of heat transition
resistance according to DIN 4108-2 are
observed, a verification of the protection
against condensation 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 perma -
nent 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.
6.2 Ice barriers
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.
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 experien ced
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:
• 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
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.
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“).
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
Normally flammable
Additional requirements
European class
according to
DIN EN 13501-1
no
smoke
no burning droppings/drips
X X A1 A1
X X A2 – s1 d0
A2
X X B, C – s1 d0
X
B, C – s3 d0
X
B, C – s1 d2
B, C – s3 d2
X
D – s3 d0
E
D – s3 d2
E – d2
Highly flammable F B3
Class
according to
DIN 4102-1
B1 1)
B2 1)
1)
Specifications for strong smoke development and burning drips/droppings in the proof of usability and in
the labelling
• 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

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 0185-
305-3 ‘Protection against lightning - Part
3: Physical damage to structures and life
hazard’, metal roofs are suitable as ‘natural
arresters’ for lightning protection.
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 Alu-
PlusPatina) 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.
Hence, roofs made of Kalzip profiled
sheets are suitable without further requirements
for use as a natural component
of a lightning protection system.
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.
Figure 1 Kalzip as a
conductor of lightning
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).
• 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).
36 Kalzip

Design specifications
• A continous row of clips is to be
fitted along the ridge and the eaves.
• In between the clips are arranged diagonally.
Distances depend on the design
loads, the Kalzip sheet widths, the pitch
of the ribs and the support spacing of
the trapezoidal sheet underneath.
• The number and positioning of the
clips as well as the joining elements
are indicated in the assembly plan.
• Depending on the likely loads it may
be necessary to halve the spacing of
the clips at the corners and along the
edges of the roof.
(See dimension tables)
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.
Positioning scheme 1
Clips
Positioning scheme 2
Clips
Pitch of the supporting deck
Gable end
TR
Ridge
clip
Kalzip
Eaves
Pitch of the supporting deck
Gable end
TR
Ridge
Clip
Kalzip
Eaves
Cover width Kalzip
Rafter spacing
Rafter spacing
Cover width Kalzip
Rafter spacing
Rafter spacing
d = clip distance
TR = trapezoidal profile
d = clip distance
Distances not to scale
TR = trapezoidal profile
Determination of wind loads
The wind loads are calculated from the
gust velocity pressure and the coefficient
of the wind pressure. The gust velocity
pressure is determined from the wind load
zone and the height above the terrain
(location and height of the building).
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.
Gabel end
Ridge
Eaves
Roof areas
area H
area G
area F
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 inter mediate 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
Clip
Gable end
Purlin
Kalzip
Purlin
Clip
Kalzip
Eaves
Eaves
Cover width Kalzip
Rafter spacing
Rafter spacing
Cover width Kalzip
Rafter spacing
Rafter spacing
d = clip distance = purlin 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.
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 connec ted
to the substructure through the thermal
insulation.
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.
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.
The DuoPlus rail must be long enough to
cover at least two ribs of the trape zoidal
deck and can be secured in it. If this is
not possible, then a section of adequate
length can be installed next to the first
row (see positioning diagram for rafter
roof and purlin roof).
Positioning scheme Kalzip rafter roof
The system requires that the DuoPlus rails are
positioned at an angle of 45°.
Clip spacing
Gable end
45°
Rafter spacing
Rafter spacing
Ridge
DuoPlus
clips
Eaves
Rail spacing
DuoPlus
rail
Positioning scheme Kalzip purlin roof
The system requires that the DuoPlus rails are
positioned parallel to the purlins.
Gable end
Rafter spacing
Rafter spacing
Ridge
Eaves
DuoPlus rail
DuoPlus
clips
Panel spacing = Clip spacing
Distances not to scale
Kalzip 39

Design specifications
6.6.5 Kalzip FOAMGLAS ® System
The system always consists of FOAM-
GLAS ® 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
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 subse quent
construction work.
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, cold bridgefree
connection is created with the insulation
layer (in accordance with building
approval Z-14.4-475 issued by the Institute
for Building Technology).
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.
Kalzip AF profiled sheets retain the possibility
of free movement due to a durable PE
film as an isolating layer.
Positioning scheme Kalzip FOAMGLAS ® system
on trapezoidal steel deck or timber lining
The FOAMGLAS ® claw plates should be arranged at an
angle of 45°
Installation pattern for Kalzip FOAMGLAS ®
system on concrete slab
The FOAMGLAS ® claw plates can be aligned
parallel to the eaves.
Clip spacing
Gable end
45°
Rafter Spacing
Rafter Spacing
Ridge
Composite clip
Eaves
Claw-plates
Clip spacing
Gable end
Eaves Composite clip Ridge
Claw-plates
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.
The reference values for the radii (r) are:
r 12 m: slabs installed in a polygonal
manner
(grind edges if necessary)
r 6 m: half slabs installed in a
polygonal manner
r 6 m: special roof shape with
formed parts from factory
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.
Fire protection
FOAMGLAS ® is non-combustible and
when used in combination with the fixing
system and the Kalzip aluminium profiled
sheets contributes to wards 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 stan -
dards for industrial buildings.
Technical data FOAMGLAS ® D slab T4 DS
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
Density ρ = 110 kg/m 3
Thermal conductivity
λ = 0.04 W/(m·K)
Fire protection German building material class A1 /
Euro class A (non-combustible)
Compressive strength allowable σ = 0.23 N/mm 2
Coefficient of thermal expansion α th = 8.5·10 -6 1/K
Resistance to water vapour transmission ∞ = (impervious to water vapour)
Water impermeability
durable waterproof
Installation temperature
minimum +5° C
Temperature resistance
-260° C to +430° C
Kalzip 41

Design specifications
6.7 Connections
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.
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.
44
65
6,1
7,0
6,1
36
65
The following fastener systems are recommended for the Kalzip system:
Fixing position Appropriate fastener system 2)
Eaves angle to Kalzip Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Ridge closure to seam Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Spacer to seam Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Ridge flashing to ridge closure Sealing blind rivet Ø 4.8 x 9,5
Gable end channel to seam Blind rivet Ø 5 x 12 K9; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Gable end hook to aluminium clip and composite clip type E Self-tapping fastener A Ø 6.5 x 19
Fixed point: aluminium clip and composite clip type E to Kalzip seam Blind rivet Ø 5 x 12 K8 - 10; Gesipa PolyGrip Alu/Nirosta Ø 4.8 x 10
Sealing joints Kalzip or soaker connection Sealing blind rivet Ø 4.8 x 9.5
Top-hat section to trapezoidal sheet Bulb tite rivet Ø 5 min. 8 W SFS SL3/2 6.0 x 27
Kalzip DuoPlus 100 rail / rotatable clip SD2 - S16 - 6.0 x 127 / SDK-S16 6.0 x 167
Clip on steel substructure
Aluminium clip with and without TK5*
to steel purlin t = 0.75 - 3.0 mm Bulb tite rivet Ø 5-12W
Aluminium clip with and without TK5 or TK15*, or
composite clip type E respectively, to steel purlin t = 0.75 - 1.2 mm Screw SFS SDK2 1)
Aluminium clip with and without TK5 or TK15*, or
composite clip type E respectively, to steel purlin t = 1.20 - 3.2 mm Screw SFS SDK3 1)
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
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
t = 1.5 - 2.0 mm
t = 2.0 - 6.0 mm
t > 6.0 mm
Self-drilling screw Ø 5.5 x L 1)
Self-tapping fastener Ø 6.5 x L 1)
1) 3) 4)
Self-tapping fastener Ø 6.3 x L
(Self-drilling screws no longer recommended)
1) 4)
Self-tapping fastener Ø 6,3 x L
(Self-drilling screws no longer recommended)
2 drilling screws Ø 6.5 x L 1)
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
6.8 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.
Aluminium clip
Fixed point with
Gesipa PolyGrip
Aluminium-Blind rivet
Ø 4.8 x 10 K9,5
Fixed points are statically verified and
are to be taken from the installation plan.
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.
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.
6.10 Ridge, eaves, gable ends
The standard ridge consists of three components:
The ridge closure with its chamber reduces
the wind pressure and at the same time
fixes and protects the foam filler against
UV radiation and birds. The foam filler
acts as an additional “sealing” of the end
of the Kalzip sheet preventing rain water
from pene trating into the system. The folding
up is the final protection against the
ingress of rain water into the ridge.
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 accom modate 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).
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
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.
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 con necting
frame securely connects/seals the sky -
light 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.
6.12 Transverse joints
It is not always possible to produce the
required Kalzip sheet length in one element.
In most cases the length of the sheets is
determined by transport limitations, so that
the sheets must be joined by overlapping.
Especially with arched roofs the maximum
loading height of the trucks must be observed.
Obviously, the requirements for absolute
tightness of the overlapping joints are
very high. Therefore it is necessary to take
great care when making over lapping 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.
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.
44 Kalzip

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 in struc -
tions. 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
6.14 Cantilevers/clip bars
Drilling pattern 1
1
2
Direction of assembly
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
2
4
6.15 Installation rules
Drilling pattern 2
1
3
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.
eaves angle as
lateral stiffener
Drilling pattern 2
6.13 Substructures
Drilling pattern 1
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 con -
sideration. 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
1 m
(0.5 m)*
1.5 m
(0.9 m)*
Kalzip 65/... 50/...
305 333 400 422 429
every every every every every
2nd sheet 2nd sheet 2nd sheet sheet sheet
every every every impossible impossible
sheet sheet sheet
Depending on the construction width of the Kalzip sheets and the desired roof projection the clip bars
must be fitted to each or every second seam. The table is applicable for a snow load of 0.75 kN/m 2 .
*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.
Roof projections constructed from Kalzip profile sheets
Clip length
in accordance
with table
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.
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.
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.
Line Wind suction
1.50 kN/m 2 2.00 kN/m 2 2.50 kN/m 2
Kalzip type Roof projections (a) in meters
1 50/333 x 0.9 0.90 0.80 0.60
Clip length s s d
2 50/333 x 1.0 1.00 1.00 0.80
Clip length s s d
3 50/429 x 0.9 0.80 0.60 0.50
Clip length s d d
4 50/429 x 1.0 1.00 0.80 0.60
Clip length s d d
5 65/305 x 0.9 1.00 1.00 0.90
Clip length s s d
6 65/305 x 1.0 1.00 1.00 1.00
Clip length s s d
7 65/333 x 0.9 1.00 1.00 0.80
Clip length s s d
8 65/333 x 1.0 1.00 1.00 1.00
Clip length s s d
9 65/400 x 0.9 1.00 1.00 0.60
Clip length s d d
10 65/400 x 1.0 1.00 1.00 0.90
Clip length s d d
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 E
> 40 m
> 20 m > 20 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 WLG 040 WLG 035
[mm] U value [W/(m²K)] U value [W/(m²K)]
90 0.41 0.37
100 0.38 0.33
110 0.34 0.30
120 0.32 0.28
130 0.29 0.26
140 0.27 0.24
150 0.26 0.22
160 0.24 0.21
170 0.23 0.20
180 0.21 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
160
U value [W/(m 2 K)]
0.2
180
200
220
240
0.1
0.5
1.5 2.5 3.5
clips per m 2
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 t min
= 0.75 mm. Two fastener systems per clip (Self-tapping screw SFS SDK).
Line Kalzip
type
Sheet thickness
t in mm
Pressing loads*
kN/m 2
Uplifting loads
kN/m 2
0.75 1.00 1.25 0.90 1.44 1.60 1.98 2.56 3.52
1 65/333 0.80 2.50 2.40 2.00 2.20 2.00 1.65 1.45 1.10 0.80
2 65/305 0.90 3.15 2.50 2.00 2.80 2.00 1.80 1.45 1.10 0.80
3 1.00 3.30 2.50 2.10 3.15 2.00 1.80 1.45 1.10 0.80
4 1.20 3.30 2.50 2.20 3.30 2.00 1.80 1.45 1.10 0.80
5
6 65/400 0.80 2.50 2.30 1.85 2.00 1.70 1.50 1.20 0.95 0.70
7 0.90 2.95 2.30 1.85 2.60 1.70 1.50 1.20 0.95 0.70
8 1.00 3.00 2.30 1.85 2.75 1.70 1.50 1.20 0.95 0.70
9 1.20 3.00 2.30 1.85 2.75 1.70 1.50 1.20 0.95 0.70
10
11 50/333 0.80 2.10 1.90 1.80 2.20 1.75 1.55 1.25 0.95 0.70
12 0.90 2.60 2.00 2.00 2.80 2.00 1.80 1.45 1.10 0.80
13 1.00 2.80 2.20 2.00 3.15 2.00 1.80 1.45 1.10 0.80
14 1.20 3.00 2.30 2.00 3.30 2.05 1.80 1.45 1.15 0.80
15
16 50/429 0.80 2.00 1.80 1.70 1.85 1.35 1.20 0.95 0.75 0.55
17 0.90 2.45 1.90 1.70 2.40 1.55 1.40 1.00 0.85 0.65
18 1.00 2.70 2.10 1.70 2.55 1.55 1.40 1.00 0.85 0.65
19 1.20 2.80 2.15 1.70 2.55 1.55 1.40 1.00 0.85 0.65
20
21 NatureRoof 0.80 1.80 1.55 1.35 2.20 2.00 1.65 1.45 1.10 0.80
22 65/333 0.90 1.80 1.55 1.35 2.80 2.00 1.80 1.45 1.10 0.80
23 1.00 1.80 1.55 1.35 3.15 2.00 1.80 1.45 1.10 0.80
24 1.20 1.80 1.55 1.35 3.30 2.05 1.80 1.45 1.15 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 100 m.
The clip spacing must not exceed half the supporting width of the supporting trapezoidal steel deck.
48 Kalzip

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
Pressing loads*
kN/m 2
Uplifting loads
kN/m 2
0.75 1.00 1.25 0.90 1.44 1.60 1.98 2.56 3.52
1 65/333 0.80 2.50 2.40 2.00 2.20 2.00 1.65 1.45 1.10 0.80
2 65/305 0.90 3.15 2.70 2.20 2.80 2.50 2.00 2.00 1.50 1.15
3 1.00 3.65 2.70 2.20 3.15 2.80 2.50 2.00 1.55 1.45
4 1.20 3.60 2.70 2.20 3.30 2.80 2.50 2.15 1.55 1.45
5
6 65/400 0.80 2.50 2.30 1.85 2.00 1.70 1.50 1.20 0.95 0.70
7 0.90 2.95 2.30 1.85 2.60 2.30 1.70 1.70 1.30 0.95
8 1.00 3.00 2.30 1.85 3.00 2.35 2.10 1.70 1.30 0.95
9 1.20 3.00 2.30 1.85 3.15 2.35 2.10 1.70 1.30 0.95
10
11 50/333 0.80 2.10 1.90 1.80 2.20 1.75 1.55 1.25 0.95 0.70
12 0.90 2.60 2.00 2.00 2.80 2.40 2.00 1.80 1.40 1.00
13 1.00 2.80 2.20 2.00 3.15 2.80 2.50 2.00 1.55 1.15
14 1.20 3.00 2.30 2.00 3.30 2.80 2.50 2.05 1.55 1.15
15
16 50/429 0.80 2.00 1.80 1.70 1.80 1.35 1.20 0.95 0.75 0.55
17 0.90 2.45 1.90 1.70 2.40 1.95 1.70 1.40 1.10 0.80
18 1.00 2.70 2.10 1.70 2.75 2.15 1.95 1.55 1.20 0.85
19 1.20 2.80 2.15 1.70 2.90 2.15 1.95 1.55 1.20 0.85
20
21 NatureRoof 0.80 1.80 1.55 1.35 2.20 2.00 1.65 1.45 1.10 0.80
22 65/333 0.90 1.80 1.55 1.35 2.80 2.50 1.80 2.00 1.55 1.15
23 1.00 1.80 1.55 1.35 3.15 2.80 2.50 2.00 1.55 1.15
24 1.20 1.80 1.55 1.35 3.35 2.80 2.50 2.15 1.55 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
Kalzip
type
Sheet thickness
t in mm
Pressing loads*
kN/m 2
Uplifting loads
kN/m 2
0.48 0.90 1.44 1.60 1.98 2.56 3.52
2.40 2.20 1.60 1.40 1.10 0.80 0.50
1 AF 65/333 0.80 Pressing loads are
2
3
4
0.90
1.00
1.20
transmitted directly
through contact onto
the substructure
2.40
2.90
2.90
2.60
2.80
2.90
1.80
2.00
2.20
1.60
1.80
2.00
1.30
1.60
1.80
0.90
1.20
1.40
0.70
0.90
1.10
5
6 AF 65/434 0.80 Pressing loads are 2.30 2.00 1.20 1.00 0.80 0.50 0.30
7 AS 65/422 0.90 transmitted directly 2.70 2.30 1.40 1.20 0.90 0.70 0.50
8 1.00 through contact onto 2.90 2.50 1.80 1.40 1.20 0.90 0.60
9 1.20 the substructure 3.00 2.70 2.00 1.80 1.50 1.10 0.70
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.
Supporting width in [m]
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 t min
= 0.75 mm.
2 fasteners per clip (SFS SDK2-S-377-6.0 x L).
Line Kalzip
type
Sheet thickness
t in mm
Pressing loads*
kN/m 2
Uplifting loads
kN/m 2
0.75 1.00 1.25 0.90 1.44 1.60 1.93 2.56 3.52
1 AF 65/537 1.00 2.00 1.90 1.80 1.20 0.90 0.70 0.60 0.50 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 26, 29
accessories 12
aluminium clip 7, 42, 43, 50
AluPlusPatina 10
AluPlusZinc 10
assembly 20, 45
B
bituminous coating 21, 30
building material class 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 33
Duo 18, 39
DuoPlus 9, 18, 39, 47
E
eaves 12, 43
ecological aspects 22, 31
extreme lengths 32
F
fall arrest systems 29
fire protection 34, 41
fixed point 43, 46
FOAMGLAS ® insulation 21
form filler 13
G
gable end 12, 13, 43
gable end clamping section 43
gable end hook 13, 43
gable end profile 13
galvanizing 30
I
insulating materials 16, 41
installation instructions for long
profiled sheets 46
installation rules 45
K
Kalzip AF 20, 21
Kalzip AluPlusSolar 22, 23, 50
Kalzip DuoPlus rail 9
Kalzip range of applications 16 - 23
Kalzip SolarClad 23
Kalzip Solar Power Systems 22
L
length change 43
length expansion 43
lightening protection 35
length tolerance 6
M
maintenance and cleaning 29, 32
material compatibility 30
metallic enamels 11
minimum curving radii 25 - 27
minimum roof pitch 24
moisture proof 33
N
natural curving 26
NatureRoof 19
nominal sheet thickness 6
non-ventilated roof 16, 17
O
official approval 32
on site curving 24
oxide coating 30
P
PVDF coating 10
photovoltaics 14, 22, 23
plating 11
polyester coating 10
positioning schemes 37 - 40
ProDach 20, 21, 50
ProDach insulating system 20, 21
profile sheet dimensions 6
protective film 11
purlin roof 38, 49
R
rafter roof 36, 39, 48
rafter spacing 37 - 40
recycling 31
reinforcing profile for verge flashing 13
rib filler 12
ridge profile 13
rigid insulation 18, 27, 39
roll forming 11
roof anchor 15, 29
roof areas 37
roof pitch 19, 22, 24
roof systems 16, 36
roof projection 45, 46
rotatable clip 9
ridge 13, 42, 43
rivets 42
S
safety appliances 14
safety system 14, 29
saving resources 31
screws 42
sealed joint 45
sheet thickness 25, 26, 29, 32
shape variations 6, 7
skylights 44
smoke extractors 44
smooth curving 24
snow guard 14, 15
snow load 48 - 50
soaker 15, 24, 44
sound absorption 34, 41
spacer 9, 13, 42
steel 16, 20, 29, 30
step 14
stucco-embossed 10
substructures 16 - 21, 40, 45
T
thermal barrier pad 7, 42
thermal expansion 41, 43
thermal transition coefficient 41, 43, 47
timber 17, 21
top hat section 17
transverse joints 44
trapezoidal steel sheet 16
transition sheet 12
transport 24, 25, 32
U
U-value 47
V
vapour diffusion 33
vapour barrier 12, 16, 17, 21, 33
ventilated roof 16
W
welded joints 44
wind suction forces 50
Z
zinc chromate coating 30
zipping machine 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
Part of Tata Steel Europe Ltd.
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
The address of your nearest local sales office
can be found on our website: www.kalzip.com
adhoc media gmbh:901:EN:01/2011
English