Kalzip® systems

Products and applications

1 Kalzip GmbH 2020

Kalzip Systems
Office building Messchenveld (NL)
Profile type 65/400, RAL 9007
Architect: Axes Architecten, Assen

Content

Kalzip roof and façade systems

The future of building 3
Sustainable building 4

Kalzip Products
All systems in one view 6
Kalzip Liner roof system 12
Kalzip structural deck system 14
Kalzip Deck roof construction 16
Kalzip low U-value system 20
Kalzip DuoPlus and Kalzip Duo 22
Kalzip roof systems for residentials 26
Kalzip ProDach 30
Kalzip Vario LB roof refurbishment system 34
Kalzip + Foamglas®  40
Kalzip FlexiCon RR 80 42

Kalzip Additive Systeme

Kalzip NatureRoof  44
Kalzip AluPlusSolar  48
Kalzip SolarClad 50
Additive systems and materials 52

Colours and surfaces54

Rollforming60

System components and accessories62

Kalzip Service63

2 Kalzip GmbH 2020

 Products & Application

Railway station Newport (UK), Profile type: 65/xtail, stucco-embossed

Architect: Grimshaw Architects

Innovative performance and proven

system solutions for creative
architectural design
Creative people all over the world are opting Kalzip building systems meet the highest cons-
for it, to implementable visionary high-tech truction physical and design requirements for
architecture with Kalzip. Roofs and facades are the realisation of roofs and facades that are
impressively set in scene through puristically functionally inspiring and visually appealing.
elegant restraint or as a design element - Kalzip fascinate.
creates solitaires, giving every building its own
character. The result is buildings that set new Building with Kalzip also means being able to
standards and are trend-setting in form and draw on many years of know-how.
function. For 50 years Kalzip has been the model for
creative feasibility, guarantees well-founded
Perfect system solutions and state-of-the-art technological experience and provides
production technology, highest product architects and contractors with comprehensive
quality and innovative material symbioses as planning aids. The aim is to relieve the building
well as the harmony of form, colour and sur- contractor so that he is left with what
face merge into a new determines the value of his work - space for the
architectural dimension - as functional and essential.
economical as the task requires.
Discover the innovative and creative possibili-
ties of Kalzip building envelopes and be inspi-
red by the versatile, durable system solutions
that Kalzip offers.

Kalzip GmbH 2020 3

Kalzip Systems

Sustainable building
with positive ecological balance

Kalzip is constantly developing new solutions environmental product declaration in

with sustainability in mind. Reliability, safety, accordance with ISO 14025 and are recognized
consistency and innovation are the guiding and verified by independent auditors.
principles in every phase of product develop-
ment. As a result, buildings are no longer desi- The trend in international construction is
gned as energy consumers, but as certified moving even further in the direction of intelli-
"green buildings"; should make an active gent buildings. The further development of the
contribution to achieving climate targets. "green building"; aims to create high-tech buil-
dings with the greatest possible claim to susta-
The demand for environmentally friendly buil- inability - the use of building materials such as
dings with sustainability certificates and qua- Kalzip is more than obvious.
lity seals is constantly increasing. This seal of
approval evaluates the ecological, economic So the future belongs to the "blue technologies".
and socio-cultural aspects of building. In addi- Together with all involved companies in the
tion, technology, processes, site quality and life construction process, Kalzip buildings is striving
cycle costs are also included in the evaluation to develop new international building technolo-
criteria. gies. Not only meet national sustainability stan-
dards, but also set global standards themselves.
With the BRE, ECO* and FDES Environmental The Kalzip material is the perfect choice to
Declarations, Kalzip offers the relevant Euro- achieve this goal.
pean programmes which support certification
of the construction project. You make a Type III

* European EPD,
carried out by the Institute for Building and Environ-
ment (IBU e. V. ) in accordance with prEN 15804.

4 Kalzip GmbH 2020

 Products & Application

Stoke Bus Station (UK), Profile type : 65/400, stucco-embossed

Architect: Grimshaw Architects

Aluminium -
functional and durable
Kalzip sustainability focuses on aluminium One of the outstanding properties of the mate- Why aluminium?
itself - a material that can be recycled as often rial is its resistance to weathering and the asso- ■ Third most common element of the earth's
as required and which can be recycled over a ciated durability. This creates security, espe- crust - in combination with other elements it
long period of time has abundant deposits. It cially when there are high demands on the use is present everywhere in nature
contributes significantly to protecting buil- of buildings, e. g. B. at airports, or in aggressive ■ Aluminium, once produced, delivers pro-

dings effectively and for decades against exter- Environment, as near the coast. ducts for generations through recycling
nal influences and to maintaining their value. ■ It can be dismantled without restriction

The material used for Kalzip has been subjec- ■ Up to 95 % of the energy used for production

Due to its enormous durability and excellent ted to critical tests time and again over the required energy are generated during the
recycling properties, three-quarters of the alu- years. Among other things, the Recycling saved
minium produced worldwide to date is still in Federal Institute for Material Testing and ■ Roof and façade products are durable, main-

use. -research - after almost 40 years of exposure - tenance-free, deconstructable and therefore
the improved weather resistance of plated sustainable
Kalzip profiled sheets. ■ Very corrosion resistant and causes

a very low load potential through

worn metal parts.

Spazio Zoetermeer (NL), Profile type 65/... tapered, stucco-embossed

Architect: De Architekten Cie, Amsterdam

Kalzip GmbH 2020 5

Kalzip Systems

The systems at a glance -

the right solution for every requirement
System Roof design Advantages*

Kalzip - Kalzip Liner systems provide a fast installation

Liner roof system - Allows other trades to work below once the non
fragile walkable liner is installed
Page 12 - The liner and Kalzip outer sheet are laid
perpendicular to the purlins across the purlins
- Steel or aluminium options available

Kalzip - Similar to the Liner system but with a top hat for
Structural deck roof system enhanced thermal performance
- Allows other trades to work below once the non
Page 12 fragile liner is installed
- The liner deck and Kalzip outer sheet are laid
perpendicular to the purlins across the purlins
- Steel or aluminium options available

Kalzip - For all roof shapes, roof pitches, all

Deck roof system Substructures and supporting structures
- High design freedom - convex, concave,
Page 12 conical, elliptical, hyperbolic and XT free-form
- Economical due to standard system components
- Low weight
- Variable in thermal insulation
- Roof construction with minimized thermal bridges

Kalzip - Cost effective and technical feasible, because it will

Low U-value roof likely survive the life of the building without
requiring an upgrade
Page 12 - Reducing heat loss by improving U-values
- Will contribute to the regime of improvements which
will ultimately result in delivering net zero emissions for
the UK by 2050
- System options: Liner deck system, structural deck and
liner systems.

Kalzip DuoPlus - High insulation thicknesses possible, thus optimised

and Kalzip Duo building and thermal protection
- Virtually free of thermal bridges, therefore extremely
Page15 low heat transfer coefficient
- Low weight
- Excellent sound insulation values

Kalzip Aluminium- - Economical alternative to bitumen and plastic sheets/

Roof system for resdential sealings, traditional roofing materials such as bricks or
slate
Page 21 - Low maintenance and no maintenance costs
- Cost-effective overall package due to standardized
web lengths, surface and components
- High safety due to durable aluminium-
alloy

Standard Particularly suitable Outstanding

6 Kalzip GmbH 2020

 Products & Application

Formability / high- Thermal insula- Energy efficiency

Examples Purpose* Soundproofing Sustainability
creative freedom tion/ U-Value according to EnEV

- Is predominantly used for new build construction,

although they can also be used for refurbishment
- Ideal for covering complete building envelopes
- For normal acoustic requirements

- For enhanced acoustic absorption

- Ideal for covering complete building envelopes for
rigorous acoustics specifications

- For building projects with high creative

requirements
- Ideal for covering complete building envelopes
- For normal acoustic requirements

- For building projects with with technical sound

solutions and low U-value requirements.

- Ideal for construction projects with high acoustic

requirements, e. g. B. Airports and multi-purpose
halls
- Suitable for the energetic refurbishment of buildings
in order to comply with the EnEV

- For flat roof landscapes in housing

- Refurbishment of damaged flat roofs -
sustainable and safe

* This system overview serves merely as an orientation for choosing the best possible system for your building project.

Kalzip GmbH 2020 7

Kalzip Systems

The systems at a glance -

the right solution for every requirement
System Roof design Advantages*

Kalzip ProRoof - Suitable for new construction and renovation

- Virtually free of thermal bridges, therefore extremely
Page 25 low heat transfer coefficient
- Meets the requirements of the EnEV
- Can be adapted exactly to object-specific requirments
due to insulation board thicknesses of up to 220 mm
- Excellent sound insulation values

Kalzip Vario LB - Sustainable and durable refurbishment solution for

Refurbishment system damaged flat roofs from 1. 5
- Low structural weight, also suitable for statically critical
Page 28 roof structures
- In most cases, no interruption of use during
rehabilitation
- Saving of disposal costs for old roof cladding and
insulation layer depending on condition
- Improvement of the energetic standard

Kalzip Foamglas® - For high thermal and acoustic requirements

- Absolutely water- and vapour-proof (suitable as
Page 33 emergency sealing)
- No additional vapour barrier required
- Highest functional reliability due to additional
water-bearing layer
- Alternative roof concept if mechanical connecting
means are not possible

System Roof design Advantages*

Kalzip FlexiCon RR 80 - Economical and favourable solution as substructure for

freeform structures
Page 35 - Quick adjustment of the spatial position of the pipe
substructure segments by means of three measuring
points
- Height compensation of on-site tolerances
- Higher insulation thicknesses

Standard Particularly suitable Outstanding

8 Kalzip GmbH 2020

 Products & Application

Formability / high- Thermal insula- Energy efficiency

Examples Purpose* Soundproofing Sustainability
creative freedom tion/ U-Value according to EnEV

- Especially suitable for construction projects with

high acoustic requirements, e. g. B. Airports,
Multipurpose halls
- For use with Kalzip AF profiled sheets
- Suitable for the energetic refurbishment of buildings
in order to comply with the EnEV

- For permanent architectural and structural

upgrading of buildings
- Ideal for deconstruction and construction in existing
buildings
- For the sustainable rehabilitation of ailing Flat roofs
- For the visual enhancement of buildings worthy of
preservation
- Improvement of summer forest protection

- For construction projects with high thermal and phy

sical requirements, e. g. B. for swimming pools,
swimming pools for swimming pools swimming
pools and ice stadiums
- For the construction of production halls for high-
valuable goods and industrial buildings with high
thermal requirements
- For high-quality administrative and school buildings

Formability / high- Thermal insula- Energy efficiency

Examples Purpose* Soundproofing Sustainability
creative freedom tion/ U-Value according to EnEV

Ideal for substructures and substrates such as:

- Single-shell roof structures for industry and Sports
facilities
- Double-shell roof structures with normal heat
transfer coefficients (U-values)
- Sophisticated building geometries such as Large
containers, domed roofs
- Renovation of existing roof areas

* This system overview serves merely as an orientation for choosing the best possible system for your building project.

Kalzip GmbH 2020 9

Kalzip Systems

The systems at a glance -

the right solution for every requirement
Additive Systeme Roof design Advantages*

Kalzip NatureRoof - Installation directly on the Kalzip profiled sheets

without additional sealing measures
Page 38 - High efficiency with fast assembly
- Environmentally compatible and decomposable
- Year-round improvement of thermal insulation and
indoor climate, thereby increasing the value of living
- Improvement of the microclimate. - Slowing down of
the water drain

Kalzip AluPlusSolar - Maximum freedom of design for sophisticated object

architecture through a roof-integrated photovoltaic
Page 41 System without additional fastening elements
- High safety and performance, a fully IEC-certified
glassless, semi-flexible and ultra-lightweight light
module based on silicon solar cells
- Optimal use of solar energy even in low light conditions
due to the micro-lens-shaped surface of ETFE
(ethylene tetrafluoroethylene) foil

Kalzip SolarClad - Retrofitting existing Kalzip roofs for all building widths
- Building authority approved fixing clamps for maximum
Page 43 safety
- Low weight - incl. solar modules - usually no additional
strengthening of the roof structure necessary
- Optimal use of solar energy even in low light conditions
due to the micro-lens-shaped surface made of ETFE
(ethylene tetrafluoroethylene) foil
- Ideal for all roof shapes, for barrel-shaped roofs contour
following up to 13 m radius

Kalzip combinations, - Ideally suited for the attachment of additive,

e.g. Composite shape-supporting building materials
Composite panels - High design freedom
- Penetration-free mounting on the flanges
Page 46 - Separation of the water-bearing layer from the visual
appearance

Standard Particularly suitable Outstanding

10 Kalzip GmbH 2020

 Products & Application

Formability / high- Thermal insula- Energy efficiency

Examples Purpose* Soundproofing Sustainability
creative freedom tion/ U-Value according to EnEV

- All building projects with a requirement for additinal

use of the roof areas
- Creation of compensation areas

- All building projects with a requirement for

additional use of the roof areas

- All building projects with a requirement for

vadditional use of the roof areas

- Aesthetically sophisticated architecture

- Complete building envelopes

* This system overview serves merely as an orientation for choosing the best possible system for your building project.

Kalzip GmbH 2020 11

Kalzip Systems

Kalzip liner roof system

Form and functionality
Kalzip liner roof systems are predominantly The Kalzip liner roof system has the outer Advantages:
used for new build construction, although Kalzip standing seam roof sheet and the n Kalzip Liner systems provide a fast installation

they can also be used for refurbishment in internal Kalzip liner trapezoidal profiled liner n Allows other trades to work below once the

the event of other failed roofing systems or sheet laid in the same direction across roof pur- non fragile walkable liner is installed
building enhancements. lins acting as the primary support. Typical pur- n The liner and Kalzip outer sheet are laid

lin centres would be approximately 1.4 to 1.8 perpendicular to the purlins across the
The Kalzip liner roof system is ideal metres. purlins
where speed of installation on a project n Purlin centres are typically between 1.0m to

is of utmost importance. A non-fragile The Kalzip standing seam roof sheets are sup- 1.8m
walkable Kalzip liner sheet can be ported directly off the roof purlins via the sup- n Perforated options available for acoustic

quickly installed to provide a weather port clips/halters (aluminium clips or E clips) so enhancement
cover to allow other trades to work therefore act independently of the Kalzip liner n Steel or aluminium options available

below. The remainder of the roofing sheet. When lightweight quilt type insulation is
components can then be installed used, the external loads (wind suction, snow,
without affecting the critical path of the access etc.) are transferred direct to the sup-
construction programme. port purlins and not the liner [Link]
affecting the critical path of the construction
programme.

Standard liner roof configuration Liner with top hat spacer system for increased U-values

Kalzip standing seam sheet

Kalzip insulation Kalzip standing seam sheet
Kalzip E clip Kalzip insulation
Kalzip vapour control layer Kalzip E clip
Trapeziodal liner sheet Kalzip vapour control layer
Purlin Trapeziodal liner sheet
Purlin
Top hat sub purlin
Top hat saddle bracket

12 Kalzip GmbH 2020

Products & Application

Kalzip GmbH 2020 13

Kalzip Systems

Kalzip structural deck system

Form and functionality
Kalzip structural decking provides an economi- Where structural decking is installed there is a Advantages:
cal solution for long span installations and eli- reduced requirement for secondary steelwork. n This is a long span solution which negates the

minates the need for purlins. For enhanced The Kalzip structural decking sheet is generally need for roof purlins
acoustic absorption, decking sheets can be laid transverse to the direction of the Kalzip n The deck is installed directly onto the steel

perforated and can support mass, such as standing seam roof sheet and spans between rafters
increased insulation or board, which may be the main steel rafters. Typical rafter centres n I t allows other trades to work below once th

introduced for more rigorous acoustic specifi- would be approximately 3 to 8 metres. edeck is installed
cations. n The deep section deck profiles can support

The Kalzip clips are installed in a diagonal lay- additional mass such as those needed for
With a choice of steel or aluminium, a selection out so that all external roof loads can be evenly acoustic systems
of profiles, gauges and sheet lengths – this distributed to the structural decking sheet. The n The deck sheet and Kalzip outer sheet are

range of products has been developed to frequency of clips may be increased at the typically laid perpendicular to each other
extend the versatility of Kalzip, making it suita- perimeter of the building where higher wind n Perforated options available for acoustic

ble for a wide range of applications. loads occur. enhancement

n Steel or aluminium options available

As a general rule, steel is cost effective and pro- The gauge and profile of the Kalzip structural
vides the optimum in loading and spanning decking sheet is therefore determined by the
capability; whereas aluminium offers exceptio- rafter centres, all external roof loads, internal
nal durability in buildings with high humidity wind loads, service loads (e.g. lighting) and the
levels such as swimming pools and wet indust- dead weight of the construction components.
rial process plants, e.g. paper mills.

14 Kalzip GmbH 2020

 Products & Application

Kalzip standing seam on Kalzip structural decking Kalzip standing seam on perforated Kalzip structural decking with
acoustic insulation slab

Kalzip standing seam on Kalzip structural decking with top hat sub
purlins
Kalzip standing seam sheet
Kalzip insulation
Kalzip E clip
Kalzip vapour control Layer
Structural decking
Acoustic insulation slab
Top hat sub purlins

Kalzip GmbH 2020 15

Kalzip Systems

Kalzip Deck roof system

Statically exactly adjustable and highly flexible

Kalzip is a flexible, weather-resistant, Advantages trial building guideline and DIN 18234-1 for
easy-to-install, lightweight construction n Applicable for all substructures industrial roofs and the DIN EN 13984
system which can be used to bridge even large n Fast, largely weather-stand-alone installation n Durable and sustainable through the use of

spans without difficulty. Through extensive n Individual design variations from aluminium recycling alloy
system components and accessories, Kalzip Geometries through XT free-form profiles for n No lightning protection is necessary in the

becomes a complete solution for building unusual building shapes area, as the aluminium standing seam roof
envelopes, easily combined with other n Penetration-free roof cladding, therefore no serves as a natural catchment device.
building materials. This always results in again weak points due to fasteners Superstructures of any kind must be tested
unique buildings, which are visually and n Complies with the requirements of the indus- separately.
technically convincing.

16 Kalzipparish
Protestant GmbHhall,
2020
Heddesheim (DE)
Profile type: 65/400, AluPlusPatina Champagne G 12
Architect: motorplan Architektur + Stadtplanung
 Products & Application

Office building Eurofleurs Kevelaer (D)

Profile type: 65/422, RAL 9006
Architect: TBP Generalplaner, Düsseldorf

The application determines the design

The unique flexibility of the standard roof The standard roof structure is predominantly
structure with a variety of profile construction designed as a warm roof structure and it is, like
widths makes it possible to combine the all other Kalzip roof structures, generally
demand for form and function with technical suitable for all roof pitches from 1. 5 ° and for all
perfection. The spectrum of convex, concave or substructures and supporting structures. The
elliptical and hyperbolically rounded shapes constructive design depends on the respective
opens up interesting variations for creative application. It takes into account loads caused
architecture. by snow, wind, temperature and humidity.

The Kalzip XT free-form profiles enable the Thermal insulation requirements can be met
implementation of computer-generated shape flexibly. The roof structure can be adapted
languages and construction principles made exactly to the requirements of the building by
possible. Evolutionary animations, visualized in selecting the thickness of the insulation
3-D objects, bring forth new organic material. In addition, sophisticated detailed
architectural forms - the fusion of biology and solutions for interior and exterior drainage are
architecture. available.

Kalzip GmbH 2020 17

Kalzip Systems

The advanced lightweight construction system

High safety over the entire service life Vorzügliche bauphysikalische Werte Durability and economic efficiency
n The profiled panels are connected to the sub- n High thermal insulation requirements are ■ Corrosion-resistant, weatherproof

structure by means of special clips that snap easily met. The roof structure can be adapted Aluminium alloy as base material
into the seams and are covered by the next exactly to the requirements of the building ■ Insensitive to UV rays, resistant to

element. The roof cladding will not be by selecting the thickness of the insulation microorganisms and to aging
penetrated n High quality sound insulation is made ■ Particularly quick installation, mostly

n Pressure and suction loads become safe possible by constructive measurements independent of weather conditions
added n K alzip profiled sheets are optionally available ■ Economical due to pre-manufactured system

n The possibly existing residual moisture of the with an anti-condensation coating (Kalzip components
insulation layer can escape through the Aquasine®) available
seams All these advantages can be applied to all
n Sophisticated and detailed solutions for roof Kalzip systems and features.
penetrations, connections and terminations
for roof edges
n Non-flammable, resistant to flying sparks and

radiant heat ("hard roofing")

n K alzip assumes the function of a Collecting

device according to DIN VDE V 0185-3 for

lightning protection

Unlimited application possibilities

n Suitable for warm and cold roof

constructions in all shapes, substructures,

supporting structures and roof pitches
from 1.5 °
n High stability and low self-weight - very well

suited for large spans and the refurbishment

of old roofs
n Lengths without joints over 100 m and more

metres, when production takes place on-site.

n Adapts flexibly to any floor plan, building

geometry and size

Martin Community Frankfurt-Schwanheim (DE)

Profile type: 50/429, HPC 7016 3%
Architect: Reuter + Werr Architekten BDA

18 Kalzip GmbH 2020

 Products & Application

Eurowheel, Vorchdorf (AT)

Profile type: 65/333, bronze
Architect: Kienesberger Schrökenfuchs Architeture

Non-ventilated Kalzip roof on a trapezoidal steel deck Non-ventilated Kalzip roof on purlins with trapezoidal inner sheet

Non-ventilated Kalzip roof on timber rafters with visible timber lining Non-ventilated Kalzip roof on concrete with purlins

Kalzip standing seam sheet

Compressible thermal insulation felt
Kalzip vapour control layer
Kalzip composite clip
Hat profile

Kalzip GmbH 2020 19

Kalzip Systems

Kalzip low U-value system

The cost effective and technically sound solution
Kalzip’s low U-value roof system provides a cost The low U-value system is primarily based on a Advantages:
effective and technically sound solution for standard Kalzip standing seam roof build and n Kalzip standing seam roof sheets are
roof U-values as low as 0.10 W/m2/K by as such is subject to the same basic set of supported directly off the roof purlins
combining rigid insulation boards with glass criteria and properties for materials, finishes, n Supported directly off the roof purlins

mineral fibre layers. geometries, accessories and components as via the support clips/halters
outlined in the Kalzip systems brochure. (aluminium clips or E clips)
It is the symbiosis of the two insulation types n The profile of the Kalzip liner sheets

that gives the system its high performance and will be determined by its dimensional
uniqueness in achieving extremely low compatibility with the Kalzip standing
U-values, allowing a significantly greater seam roof sheet
overall thermal resistance to be achieved n K alzip liners are available as standard

compared to that of any one single layer of in high grade steel or aluminium.
insulation of the same total thickness. n Standard finishes include a galvanised,

or white enamel finish to suit the internal

application.

Liner-deck roof system Structural deck roof system

Timber deck roof system

Kalzip top sheet

Kalzip E clips fixed to inverted channel
Mineral fibre quilt insulation
SFS Iso-Tak fastener system
Kalzip insulation 23 (2400 mm x 1200 mm)
Kalzip vapour control layer
Inverted liner sheet over purlins
Timber decking

20 Kalzip GmbH 2020

Products & Application

Kalzip GmbH 2020 21

Kalzip Systems

Kalzip DuoPlus and Kalzip Duo

EnEV compliant roof systems

The Kalzip DuoPlus and Kalzip Duo Roofing systems offer a complete Advantages
construction system without thermal bridging, which easily meets the n Nearly free of thermal bridges - due to an extremely low heat

new energy requirements for new buildings. transmission coefficient

n High thermal insulation - meets the requirements of current EnEV

The permissible annual primary energy requirement was reduced by an n Variable thermal insulation thicknesses up to 345 mm

average of 25 percent and the permissible heat transfer coefficient n Suitable for all E clip types and heights

degreased by an average of 20 percent. Depending on the type of use, n Excellent sound insulation ratings up to R'w = 50 dB (A),

the maximum heat transfer coefficients that may be achieved during depending on the roof structure
refurbishment are those specified in attachment 3 of the current EnEV n Low weight - ideal for large spans

(for example U = 0.20 W/(m²-K). Kalzip DuoPlus and Kalzip Duo show n A complete System from one source

what perfect solutions look like in terms of the EnEV, which save energy n Functional and harmonic coordinated system components

and yet offer individual design versatility. n Adjustable fastening system

n High economic efficiency and short installation times through

prefabricated system components

n For substructures of trapezoidal steel profiles, concrete,

cellular concrete and wood

Grand Canal Theatre Dublin (IRE)

Profile type: 65/400, stucco-embossed
Architect: Daniel Libeskind, New York

22 Kalzip GmbH 2020

 Products & Application

The perfect roof system to fullfill the current

Energy Saving Regulation
Kalzip DuoPlus Kalzip Duo
The construction principle of the Kalzip thermal insulation and the substructure below. Kalzip Duo is a particularly economical system
DuoPlus and Kalzip Duo roof systems is based Through their special design, it serves as an variant. This more cost-effective option has no
on the thermal separation of the external roof economical and secure fixing surface for the need for a full-surface step-resistant thermal
and the inner supporting shell. The most new Kalzip roatable clip rail with E-clips. These insulation. Only approx. 240 mm wide
common constructions are used for the are then screwed in manually and can be adap- step-resistant mineral wool insulation strips or
load-bearing shell to which a suitable vapour ted during installation depending on the PIR/PUR insulation boards of 100 or 140 mm
barrier is attached. A layer of step-resistant profile dimensions and/or tolerance to the thickness are required as underlays for the
mineral wool or PIR/PUR insulation boards in respective conditions. DuoPlus clip-on rotating clip-on rail.
thicknesses of 100 or 140 mm is used The height of the E-clips determines the The gaps are filled with mineral fibre insulation
as continuous thermal separation. second insulation layer of mineral fibre felt. Due to the height of the E-clips, total
The specially developed DuoPlus clip-on rotary insulation felt, which allows total insulation insulation thicknesses of up to 345 mm are also
rail type E is attached to this thermal insulation thicknesses of a current maximum of 330 mm possible as for the DuoPlus roof construction.
by means of approved connecting elements, at 65 profile standing seam height, 345 mm at
e.g. on a trapezoidal steel substructure. This 50 profile standing seam height.
roatable clip rail has the function of transfer-
ring the external force from the clip to the

Kalzip DuoPlus on a trapezoidal steel profile Kalzip Duo on a trapezoidal steel profile

Kalzip standing seam sheet Mineral wool insulation felt (compressible)

Connecting element SFS intec SD2-S16-6,0 x L Mineral wool insulation felt
DuoPlus clip-on rotary rail type E Thermal insulation, step-resistant (mineral wool or PIR/PUR insulation boards
DuoPlus rotary clip adapter Vapour barrier
Kalzip E clip Substructure

Kalzip GmbH 2020 23

Kalzip Systems

The system for excellent thermal insulation and

high acoustic insulation
Kalzip DuoPlus or Kalzip Duo n  ressure-resistant mineral wool insulation
P n  otary clip adapter E for the attachment of
R
on trapezoidal steel profile according to DIN EN 13162 Kalzip E-clips
Euroclass A1 - non-flammable Clip height depends on the
n Subshell Application type WD as per DIN 18165 requirements of the EnEV
Thermal conductivity level WLS 037
Fischer Trapezoidal Profiles Compressive strength: 60 kN/m2 n  onnecting elements for
C
Panel thicknesses t = 0,88 mm Thickness: 100/140 mm Rotary clip rail E
Kalzip DuoPlus – fully laid Fastener suitable for the fixing base and
Cross sections: FI   90/305 Kalzip Duo – in 24 cm wide strips clamping length e.g. SFS intec SD2-6,0 x L
FI 100/275 (With Kalzip Duo installations the spaces are
FI 135/310 n  ressure-resistant PIR/PUR thermal insula-
P filled with mineral wool insulation felt
FI 144/287 tion according to DIN EN 13165 beween the 24 cm wide strips.)
FI 150/280 Euroclass E - normal flammability
FI 165/250 Application type WD as per DIN 4102/1 n  ineral wool insulation felt according to
M
Thermal conductivity level WLS 024 DIN EN 13162
Optional Fischer acoustic profiles Compressive strength: 60 kN/m² Euroclass A1 - non-flammable
perforated: AK 100/275 Thickness: 100/140 mm Application type WL as per DIN 18165
AK 135/310 Kalzip DuoPlus – fully laid Thermal conductivity level WLS 040
AK 150/280 Kalzip Duo – in 24 cm wide strips Thickness depends on the requirements of
AK 165/250 the EnEV
n Rotary clip rail E with plug-in connector
n Kalzip vapour barrier FR self-adhesive with a hole average of 7 and 10,5 mm n Kalzip aluminium profiled sheets
pre-punched

Combination of insulating materials with different heat transfer coefficients

Insulation thickness U-value U-value *

Variant Basic insulation Insulation felt
compressed (mm) (undisturbed) (rated value)
100 + 100 0,135 0,141
1 WLS 024 WLS 032
140 + 180 0,086 0,092
100 + 100 0,173 0,186
2 WLS 037 WLS 035
140 + 190 0,106 0,118
100 + 100 0,195 0,205
3 WLS 040 WLS 040
140 + 180 0,123 0,131

*U-values in W/(m2 x K) for the combination of thermal insulation materials with different heat transfer coefficients
and insulation thicknesses for a number of clips of 2 clips/m²

24 Kalzip GmbH 2020

 Products & Application

Kalzip DuoPlus and Duo as a rafter roof construction on a timber Kalzip DuoPlus and Duo as a rafter roof construction on a timber
material with rotary clip rail type E parallel to the eaves frame fabric with diagonal clip rail type E

Kalzip DuoPlus and Duo as a truss roof construction with trapezoidal

steel underlay and rigid PIR/PUR insulation boards Swivel clip rail E with thermal insulation

Kalzip standing seam sheet Mineral wool insulation felt (compressible)

Connecting element SFS intec SD2-6,0 x L Thermal insulation, step-resistant (mineral wool or PIR/PUR insulation boards
Clip-on rotary rail E Vapour barrier
Rotary clip adapter Substructure
Kalzip E-clip

Kalzip GmbH 2020 25

Kalzip Systems

Housing area Joseph-Seliger, Ottobrunn (D)

Profile type: 65/434, RAL 9006
Architect:
26 Kalzipgoergens
GmbH 2020 + miklautz Architekten
 Products & Application

Kalzip aluminium roof system

for residentials

Sustainability and profitability in housing construction - which

means energy efficiency, longevity, safety and no maintenance
required! The metal roof from Kalzip was specially developed for
these requirements. With the price-optimized construction con-
cept you can use all roof forms on your new building or renovate
old flat roofs. The noble Aluminium surface additionally lends the
building a new aesthetic value.

Flexible planning: A great advantage -

Design freedom for new buildings the roof system from Kalzip
More than 100 million square metres of the The Kalzip roof cladding with its natural, pre-
Kalzip roof system have already been laid. weathered and matt aluminium plus patina
Thanks to this wealth of experience, the roofs surface is low-reflective and almost
can be installed extremely flexibly, quickly, maintenance-free. It not only contributes to
easily and safely - even with very flat roof the long-term maintenance of the value of the
pitches from 1.5°. This means that the height property, but also increases its value through
on the top floor can also be fully utilised. Our its attractive appearance. At the same time, the
Kalzip technical advisors will provide you with metal roof offers natural lightning protection
concrete support in the planning and tende- and, thanks to the "hard roofing", further
ring of your projects. We have a comprehen- protection against flying sparks and radiant
sive collection of detailed solutions at our dis- heat. Even after its long service life, the metal
posal. roof complies with the principle of
sustainability: it can be completely recycled
In terms of building physics, the diffusion-open and is therefore particularly environmentally
roof cladding made of aluminium standing friendly.
seam panels offers maximum safety. The
special construction of the two flanges allows
moisture to escape from the thermal insula-
tion.

Kalzip GmbH 2020 27

Kalzip Systems

Sustainable and value-enhancing

An alternative for renovation: system elements is firmly connected to the
A new roof for existing buildings substructure. In most cases, the old
Wind, weather and UV rays cause conventional waterproofing and insulation structure can
flat roof sealings to "age". Wrinkles and remain on the roof and does not have to be
tensions arise in sensitive seam areas and for disposed of at great expense.
connections to rooflights and walls. Flat roofs
that become dilapidated over time ultimately The new roof cladding made of aluminium
pose a danger to the building structure. The standing seam panels is then installed on the
virtually maintenance-free Kalzip pitched roof flexible stud frame. In the ventilated
offers you a cost-effective alternative to intermediate space, a mineral fibre insulation
renovation. You also save long-term mainte- layer can be laid loosely on the floor slab in
nance costs, which would otherwise be accordance with the requirements of the EnEV.
maintenance and repairs would have to be All work can often be carried out without dis-
included. To convert a flat roof into a pitched turbing the residents. The ventilation of the
roof, a lightweight framework of Vario RT new cold roof construction helps to avoid heat
accumulation in summer and ensures a plasant
living climate.

Anderson Street residential area, Inverness (UK)

Profile type: 65/400, stucco-embossed
Architects: Keppie Design Ltd.

28 Kalzip GmbH 2020

 Products & Application

Technical data
Profile type AF 65/537 (seamless profile)

Thickness (mm) 0,8

Material Aluminium EN AW 3004/3005

Profile panel shape Straight profiled sheets

Maximal length 20 m* (longer panels on request)

Surface AluPlusPatina natural aluminium

System fastener Kalzip E-clips: E 5 – E 180

Roof Pitch from 1.5° according to approval Z-14.1-181

Anti-condensate coating DripStop (optional)

Insulation Compressible mineral wool,

rigid insulation materials
Weight incl. approx. 3 kg
Housing area Bonlanden with green roof, Filderstadt (D) system fastener (m²)
Profile type: 65/333, stucco-embossed
*Measured from the fixing point to the end of the Kalzip profiled sheet
Architect: Thomas Baur

Kalzip residential standing seam roof WF 65/537 in aluminium

Back ventilation level Kalzip WF 65/537

Wood counter battening

Undercarriage track

Interior room cladding

with e.g. plasterboard
Timber rafter
Insulation between rafters Wooden formwork
Kalzip E-clip type E5 24 mm

Vapour barrier Vapour permeable underlay

sd > = 100 m

Kalzip GmbH 2020 29

Kalzip Systems

German Football Museum Dortmund

Profile type: 65/434, RAL 9010
Architect: HPP Hentrich-Petschnigg & Partner

© HGEsch Photography

30 Kalzip GmbH 2020

 Products & Application

Kalzip ProDach

Functionality and design

The Kalzip ProDach is the combination of The areas of application
seamless Kalzip AF profiled sheets and the Kalzip ProDach is suitable for all standard
step-resistant Prorock thermal insulation substructures or load-bearing structures made
boards from the manufacturer Rockwool. of steel, concrete and timber, and for all
Visually, this roof construction is impressive due applications in building construction and for
to its elegant and discreet surface effect, which the renovation of old roofs.
is based on the traditional standing seam roof.
Even smaller buildings obtain a proportionally The static design can be adapted exactly to the
balanced, well-designed roof cladding with this object requirements by the number and
system. Kalzip ProDach is a complete solution arrangement of the fixing points. Suction loads
for high-quality, visually attractive, rational are safely transferred to the supporting
roofing. structure via the Kalzip fixing clips.
Special system fasteners are available for all
Advantages types of substrate. The insulation board offers a
n Suitable for new buildings and roof high level of slip resistance during installation
renovation and maintenance work.
n Diffusion-open insulating material; water

vapour diffusion resistance factor µ = 1.0

n The insulating material is non-flammable,

highly heat and sound insulating,

dimensionally stable and vibration damping
n The roof structure can be adapted exactly to

the requirements of the building with insula-

tion board thicknesses of up to 220 mm;
calculated thermal
conductivity = 0.036 W/(m-K)
n High-quality sound insulation due to an

open-pored insulating material structure -

with this roof structure, sound insulation
values of 38 to 42 dB can be easily achieved
n The insulation board transfers the ballast

from the roof covering to the substructure.

Kalzip GmbH 2020 31

Kalzip Systems

The result of the innovative performance of two major

brands - outstanding sound and thermal insulation
The Installation
Technical data insulating felt Prorock 036*
The corrosion-resistant, weatherproof alumi-
nium top layer is attached using the usual Kal- Fire behaviour Euroclass A1, non-flammable
zip processing technique with clips, but - and
Thermal conductivity 0,036 W/(m · K)
this is the special feature of the Kalzip ProRoof
- not directly to the supporting structure but to Temperature characteristics melting point of rock wool: > 1000 °C
a corrosion-resistant steel U-rail embedded in
the insulation layer. The system fasteners, Steam diffusion resistance μ = 1,0
which connect the U-rail with the supporting
Compressive stress at 10 % compression σ10 ≥ 50 kPa
structure only penetrate the insulating mate-
rial at certain points. This results in advantages Tensile strength vertical to the panel plane (tear strength) σMT ≥ 7,5 kPa
for sound and heat insulation.
Point-load with 5 mm compression Fp ≥ 550 N

* The exact thickness of the insulation layer depends on the requirements of the current EnEV.

Fixing the rail with expanding rivets Attached clips on mounting rails

32 Kalzip GmbH 2020

 Products & Application

Roof construction Kalzip ProDach on a truss roof construction Roof construction Kalzip ProDach on rafter roof construction

Roof construction Kalzip ProDach on concrete/ aerated concrete

Kalzip AF profiled sheets

Kalzip composite clip
Mounting rail steel
System fastener according to substructure
Thermal insulation
Vapour barrier

Remark:
The roof structures shown are application examples. The roof structure must be adapted to the structural conditions in each individual
case.

Kalzip GmbH 2020 33

Kalzip Systems

Kalzip Vario LB
Roof refurbishment system
The foundation for an economical and safe The Kalzip refurbishment service includes: n Cost calculation
refurbishment concept is an exact survey and n Non-binding project-related advice on site n Provision of bases for the Call for tender
analysis of the building condition, the bearing from Kalzip refurbishment experts n Cost comparison conventional refurbish-

capacity and the planned scope of n Stocktaking by qualified roof experts (e.g. ment vs. Kalzip
refurbishment. For buildings of the 1970s and inspection of the insulation and sealing n Supervision of the execution work with

1980s, updated plans, static proofs and the construction)* extended warranty*
documentation and specification of the n Recommendation of independent n Calculations for anchors, fasteners and

building materials used at that time are often engineering offices for condition monitoring dowels*
missing. The Kalzip refurbishment options n Calculation and evaluation of the n Heat and moisture protection certificates*

therefore offer a comprehensive solution from load-bearing ceiling structure and inclusion n Lightning protection*

planning and tendering to the provision of all of trusses and columns*. n Parts lists and installation plans*

necessary materials for substructure, roofing n Development of a planning process capable

and drainage. of making decisions with a property-specific

renovation proposal *These services are charged.

Vor der Sanierung

Berufsbildende Schulen Meppen (D
Planer: Stefan
34 Kalzip Hölscher,
GmbH 2020Geeste
 Products & Application

After the refurbishment

Vocational school Meppen (DE)
Profile type: 65/400 , RAL 9007
Planner: Stefan Hölscher, Geeste

Refurbishment of flat roofs (from 1.5°)

with the Vario LB roof renovation system
Kalzip offers various systems for the such a way that it determines the roof pitch
sustainable refurbishment of flat roofs which while sitting on the round tube and can
have proven themselves over the years. With accommodate the newly developed rail clips.
these solutions, flat roofs can be converted
particularly economically into a safe pitched The system is stiffened by stiffening profiles
roof (cold roof construction). which are installed from the eaves to the ridge
after the LB purlin has been attached. Bracing
In the constructional design, any existing and coupling rods are also installed to stabilise
gravel fill is usually removed first. This weight the structure. The LB clips are then simply scre-
saving provides load reserves that are suitable wed into the LB purlin, the Kalzip® profiled
for safely accommodating additional sheets are snapped into the clips as usual with
superstructures. This is followed by a careful the small flange and covered by the larger
inspection of the sealing (cutting open existing flange of the next profiled sheet and finally
perforations, bubbles, etc.). For the connected together mechanically with a
construction of a cold roof, a flexible positive fit. The system includes all the connec-
lightweight substructure is firmly connected to tion and end details.
the building. Special inclination-flexible
troughs serve as anchoring base, into which
the variable supports are adjusted and
screwed. A T-shaped component with a round
tube is inserted and fastened into these
supports vertical to receive the inclination-
flexible purlin. The flexible purlin is designed in

Kalzip GmbH 2020 35

Kalzip Systems

For the highest building physics and architectural

requirements
Usually, the existing supporting structure can the profiled sheets are prefabricated to exact Advantages
continue to be used without additional measu- dimensions in roll formers. As a result, barrels, n Low, additional structural weight - suitable

res. The new substructure can be easily and vaults and rounded eaves solutions can also be for statically critical roof structures
safely adapted to the building geometry and realised cost-effectively and accurately. This n Activation of payload and safety reserves by

structure. refurbishment variant is preferably suitable for removing the gravel layer
all flat roof constructions made of bitumen or n High rigidity and stability

Kalzip refurbishment offer the opportunity to foil. n Simple determination of the new roof geo-

permanently increase the value of the property metry

through contemporary roof architecture. n Economical, fast assembly

In accordance with the architectural concept, n Old insulation materials can continue to be

used, depending on their condition, and new

insulation materials provide additional ther-
mal protection

12
11 10

6
9 13

4
5
3
2

Kalzip Vario LB System structure

Old inventory Kalzip renovation solution

  1) Top storey ceiling (rigid substructure) e.g.   5) Vario LB basic profile

concrete or trapezoidal profiles   6) Vario LB support profile
  2) Vapour barrier   7) Vario LB thermal cap 145/200
  3) Flat roof insulation   8) Kalzip LB tubular purlin 80
  4) Existing bitumen or membrane sealing   9) Vario LB rotary clip
10) Fixed point clip
11) Vario LB fork profile
12) Vario LB support plate
13) Vario LB joint profile 80
14) Eave angle

36 Kalzip GmbH 2020

 Products & Application

Vallendar comprehensive school (DE) before and after renovation; profile type: 50/429, stucco-embossed
Architect: Guido Fries Architekten, Vallendar

Trust in aluminium! Cost-effective over the entire service life

In the medium to long term, the virtually maintenance-free Kalzip metal roof made of aluminium profiled sheets saves you hard cash. A roof cladding
made from Kalzip aluminium profiled sheets offers significantly better protection: the roof is installed without penetration and is classified as a hard
roofing material which is not flammable.

Sample calculation: Flat pitched roof, 1.500 m2

Bitumen roof deck: 18 mm, rigid mineral wool insulation. Kalzip: 65/500, 0,8 mm soft fibreglass insulation.

Bitumen Kalzip standing seam Savings with Kalzip

Construction 90.000 € 99.000 € –9.000 €
Maintenance
In 10 years 22.000 € 5.000 € 17.000 €
In 25 years 35.000 € 10.000 € 25.000 €
In 50 years 80.000 € 30.000 € 50.000 €
Renovation
In 10 years 0€ 0€ 0€
In 25 years 22.500 € 0€ 22.500 €
In 50 years 44.500 € 0€ 44.500 €
Disposal 5.000 € –3.571 € 8.571 €
Total
In 10 years 112.000 € 104.000 € 16.571 €
In 25 years 152.500 € 105.429 € 47.071 €
In 50 years 219.500 € 125.429 € 94.071 €

Kalzip roof construction

Building type: Chart

Industrial or commercial hall with a roof area of 1,500 m² in double-shell
construction 250.000 €

Roof shape: 200.000 €

Saddle roof, 3° roof pitch
150.000 €
Drainage:
exterior
100.000 €

Number of rooflights/RWAs and other penetrations: approx. 8

50.000 €
Insulating material mineral WLG 040:
U-value: approx. 0.24 W/(m² x K) 0€
Thickness approx. 160 mm 0 10 25 50
years years years years

Legend

Bitumen Kalzip

Kalzip GmbH 2020 37

Kalzip Systems

38 Kalzip GmbH 2020

 Products & Application

Sanitation Miele & Cie KG , Warendorf

Architect: Bauabteillung Miele & Cie. KG

Kalzip GmbH 2020 39

Kalzip Systems

Kalzip + Foamglas®

The key element for safe roof concepts

The Kalzip Foamglas® system is a roof Advantages The area of application
construction which, due to the diversity of the n Absolutely water- and vapour-proof (suitable The system is particularly suitable for construc-
insulation material, occupies a technically as emergency sealing) tion projects in which high demands are
exceptional position and thus leads to an n Non-capillary suction placed on the components of the roof system
absolutely safe, damage and maintenance-free n Non-flammable (Building material class A1/ due to building physics conditions and where
building envelope. Euro class A) there is a permanent risk of condensate forma-
n Free of thermal bridges tion. Sensitive production areas, e.g. pure areas
n Wind and airtight for the production or storage of electronic
n Pest proof components, where a perfect tightness of the
n Stable to size (does not swell, shrink or building envelope is essential, are also an ideal
deform) area of application for this construction
n Resistant to rotting method.
n Suitable as secondary sealing

n Extremely temperature-resistant and

equipped with the best sound insulation

properties
n Alternative roof concept if mechanical

fasteners are not possible

Grundschule Mülheim-Kärlich
Profiltyp 65/434), RAL 9007
Architekten: VG Weißenthurm

40 Kalzip GmbH 2020

 Products & Application

The perfect roof system for highest

constructional requirements
Kalzip and Foamglas® offer double safety, because the Standard roof construction Kalzip FOAMGLAS® system
Insulation also has a sealing effect. This means that
roof edges and connections are also made durable and free of thermal
bridges. With Foamglas® almost all roof shapes can be realized, since the
foam glass sheets are easy to process and adapt.

Kalzip with FOAMGLAS® additionally stands out through

n High energy efficiency due to air- and vapour-tight thermal insulation

and thermal bridge-free mounting

n Few functional layers in the roof structure

n No additional vapour barrier

n No mechanical fixation in the supporting structure

n Additional safety through a waterproof subroof

(moisture-proof system)
n Additional load-bearing effect via the insulation layer
Roof construction Kalzip with FOAMGLAS® as a combined solution
n Eignung für Kalzip Falzbares Aluminium in handwerklicher

Klempnertechnik geeignet
n Ideal conditions for the renovation of roofs even with

minimal tendency
n High degree of safety against water accumulation, e.g. in the event of

ice jumps

Technical data Foamglas® insulation board T4 WDS

Bulk density ρ = 110 kg/m3 Roof construction Kalzip AF on FOAMGLAS® insulation
Thermal conductivity λ = 0,04 W/(m·K)
Building material class A1/Euro
Fire behaviour
class A (non-flammable)
Pressure resistance tn. σ = 0,23 N/mm2

Thermal expansion coefficient αth = 8,5·10-6 1/K

Vapor diffusion resistance ∞ = vapour-tight

Water resistance permanently waterproof

Application temperature at least +5 °C

Temperature resistance -260 °C to +430 °C

Kalzip aluminium profiled sheet Polymer bitumen sealing (1-layer) Kalzip Foamglas® panel Optional: 20 mm soft thermal insulation
Compressible thermal insulation Claw plate L Bitumen bonding Kalzip AF profiled sheet
Kalzip composite clip Hot bituminous pavement swab Trapezoidal profile PE foil

Kalzip GmbH 2020 41

Kalzip Systems

Kalzip
FlexiCon RR 80

The flexible
substructure
The Kalzip FlexiCon system is a flexible substructure which can be used
to compensate for large differences in height in the substructure for
receiving and installing Kalzip system fasteners and can be adjusted to
the required level. A further area of application is three-dimensional
structures or complete building envelopes which, due to their
demanding building geometry, have limitations in the design of the
substructure.

This particularly includes tank construction, such as digestion towers or

domed roofs. This system is also excellently suited for refurbishment, as
the pipe construction can be fastened to all substrates. For clip
mounting, the clip can be aligned three-dimensionally on the specially
designed saddle. This means that the Kalzip profiled sheets fit perfectly
and the length can change without restriction due to temperature
changes.

Digestion tower sewage treatment plant Fredrichshafen (DE)

Profile type: 65/500, RAL 5012
42 Kalzip GmbH 2020
 Products & Application

For sophisticated architectural geometries

Advantages
n T hree-dimensional alignment of Kalzip clips The area of application
n Economical and low-cost solution for free- is possible The Kalzip FlexiCon substructure is ideal for all
form structures substructures with standing
n Adaptation of the profiled panels to the ideal substructures and substrates such as:
seam profiled panels building geometry n Single-shell roof structures for industry and

n High safety due to corrosion-resistant alumi-

n Undisturbed temperature-related linear sports facilities
nium alloy expansion via perfectly installed Kalzip clips n Double-shell roof structures with normal

n Quick adjustment of the spatial position of

n Complete engineering and project-related heat transfer coefficients (U-values)
the pipe substructure segments using three production of the components n Free-form roof surfaces or building envelo-

measuring points
n Higher insulation thicknesses pes
n Height compensation of on-site tolerances n Sophisticated building geometries such as

n Simple installation of Kalzip free-form pro- large containers, domed roofs

filed sheets n Renovation of existing roof surfaces on all

substrates
n Compensation of height differences

Kalzip FlexiCon RR 80
Tecnical dataKalzip FlexiCon RR 80

Material Aluminium AlMgSi 0,5

Diameter 80 mm

Thickness 3 mm

Length 6.000 mm

Radii several radii possible

U-angle on site

Kalzip aluminium profiled sheet Distance angle

Mineral wool insulating felt (compressible) Vapour barrier
Kalzip clip on clip saddle Trapezoidal profile
FlexiCon RR 80

Kalzip GmbH 2020 43

Kalzip Systems

Kalzip NatureRoof
Ecologically valuable roof greening
The Kalzip NatureRoof meets high ecological, Advantages easily retrofittable to a natural roof
structural and design expectations. n The assembly takes place without additional (only Kalzip 65/333)
The heat-insulating and resource-saving Sealing measures directly on the n The Kalzip aluminium profiled sheets offer a

lightweight construction of the Kalzip Kalzip profiled sheets high level of protection against mechanical
construction system is a benchmark and a n A compact solution in modular design damage to the roof waterproofing when the
prerequisite for sustainable, intelligent n Permanently resistant to root penetration NaturDach components are applied
constructing. Environmentally friendly and and moisture penetration n After removing the vegetation, Kalzip

aesthetic requirements are equally fulfilled and n High economic efficiency due to easy, fast remains as a full roof covering
technical planning reliability is guaranteed. installation n K alzip is resistant to flying sparks and radiant

n Thrust protection enables a Greening with heat. This attribute is retained if the relevant
The Kalzip NatureRoof enables a safe green inclined and curved roofs requirements of the FLL guidelines and the
roof with minimal maintenance - low-growing, n The function as a catchment device for state building regulations are met.
self-regenerating, drought-resistant sedum lightning protection is maintained.
plants transform grey roof landscapes into n All components are environmentally friendly

flowering oases. Sedum plants are and can be dismantled

undemanding, they tolerate smoke and n The planning is homogeneous, even if only

exhaust fumes and are resistant to frost and partial areas are greened
wind. n With the appropriate static load Kalzip is

Administration building Kalzip GmbH Koblenz (D)

Profile type: 65/333, stucco-embossed
Architect: Architektengruppe Voss Naujack von Canal, Koblenz
44 Kalzip GmbH 2020
 Products & Application

Cofi Roc Café Caernarfon, Gwynedd, Wales (UK)

Profile type: 65/333, stucco-embossed
Architect: Aegis Architects

Compensating green areas with the Kalzip NatureRoof

The water retention effect is particularly high humidity, high dust formation, pollution and Kalzip NatureRoof additionally impresses
on flat roofs. The greening measures of roof overheating can be effectively counteracted by with
areas is a sustainable enrichment for plants, green roofs. Material pollution from the air in n Considerable pressure relief for the sewerage

animals and people. The Kalzip NatureRoof undissolved and particulate form, e.g. "acid system and delayed discharge of excess
makes a valuable contribution to rainwater rain" and soot, is reduced to a high proportion rainwater into the local and communal
management and to the improvement of the when seeping through the root area of the drainage facilities
air quality. NaturDach structure. n Improvement of the oxygen content,

microclimate and humidity in the building

With a Kalzip Nature Roof which has a runoff environment
coefficient of Ψ = 0.5 (up to 5 % slope), 50 % of n Binding of dust and air pollutants, e.g. CO²

the precipitation is retained by the n Thermal and mechanical protection against

storage capacity of the NatureRoof structure. Reduction of pollutants with extensive temperature, radiation and weathering
According to experiments at the School for roof greening: influences
Technology and Architecture in Bonn, about 33 Cd Zn Cu Pb N n Year-round improvement of thermal

% of the precipitation returns to the natural 96 % 16 % 99 % 99 % 97 % insulation and indoor climate

rainwater cycle through evaporation. n Value enhancement for the building

n Creation of ecological compensation areas as

Renaturation as a compensation for a countermeasure to progressive soil sealing

urbanisation contributes significantly to the
preservation of our environment and the
improvement of living conditions. Low air

Kalzip GmbH 2020 45

Kalzip Systems

The Kalzip NatureRoof is unique in its constellation and

technical design
The components of the Kalzip NatureRoof sys- sheets 65/333 used in a length of 30 m. It is a The Kalzip planting substrate is a quality
tem are delivered to the construction site as a linear drainage system in accordance with DIN assured natural product with a test certificate.
separate unit. The functional layers are 4095 with drainage holes and water storage Consisting of lava and pumice gravel, the pH
matched to one another in their mode of troughs - a Recycled product, biologically value of the Kalzip Plant Substrate is well
action and form a single unit in terms of execu- neutral, weather resistant and recyclable again. matched to the aluminium base material. It is
tion. DIN 4095 "Drainage for the protection of The Water storage troughs hold back up applied to the drainage mat and has a layer
structures" as well as the roof greening to 3.2 l/m2 of precipitation. This serves the thickness of 6 cm when set (approx. 15 to 20 %
guidelines of the FLL, Forschungsgesellschaft planting as a nutrient and the natural cycle as a settlement must be taken into account).
Landschaftsentwicklung Landschaftsbau, are valuable evaporation reservoir. The filter fleece
complied with. prevents finer soil and substrate particles from
the vegetation layer from being slurried into
The Kalzip drainage mat is supplied in rolls the drainage layer.
with a filter fleece coating. The width
corresponds to the Kalzip aluminium profiled

Roof structure Kalzip NatureRoof

Kalzip sedum planting, low-growing, self-regenerating, drought-resistant,

frost-resistant

Kalzip plant substrate, a natural product with a test certificate

Kalzip drainage mat with filter fleece coating, supplied in rolls

Kalzip aluminium profiled sheets, the root-resistant and moisture-proof


basis for natural roof constructions.

Thermal insulation layer, exactly adaptable to object-related requirements

Kalzip composite clip

Vapour and air barrier, permanently protects against diffusion moisture


from above and below

Trapezoidal profile, the durable and lightweight load-bearing shell for truss

and purlin roof construction; wooden formwork is also possible

46 Kalzip GmbH 2020

 Products & Application

Extensive roof greening with minimal construction effort

and maintenance
333 mm

Kalzip aluminium profiled sheets 65/333 Kalzip NDS 60

Thickness: 1,0 mm Natural roof substrate, pH = 5 - 7 65
Basis weight: approx. 4.0 kg/m2 Lava and pumice gravel
Construction thickness: 6 cm
Kalzip NatureRoof Construction Surface load: approx. 75 kg/m2 Kalzip aluminium profiled sheets 65/333
Surface load: water saturated approx. 90 kg/m2
Discharge coefficient up to 5 % roof pitch: Ψ = 0.5 Loose goods, available by truck or
Discharge rate with precipitation donation in a silo vehicle for approx. 380 m2,
0.03 l/sec/m2 and roof slope 3 %: 2.41 l/sec/m2 in Big-Bag (1000 l capacity) for approx. 14 m2

Kalzip KD 33 linear drainage system Kalzip flat root plants Sedum

Construction width: 333 mm 9 common plant species/varieties
Thickness: approx. 2,5 cm depending on the season,
Surface load: 4.5 kg/m2 50 pieces each in plates

Drainage mat Kalzip Sedum sprouts Kalzip KD 33 linear drainage system

Polystyrene, compressive strength: 383 kN/m2 5 - 7 common plant species/varieties
Outflow rate: 4 l/sec/m2 depending on the season,
Water storage volume: 3.2 l/m2 in bags with a capacity of 2 - 10 kg

Filter fleece Kalzip Nerotec 60 Erosion protection adhesive

Polypropylene staple fibre fleece (when using rungs)
Punching force (CBR test): 1400 N in bags of 60 litres capacity
Pore opening width (Dw): 0.14 mm 1 bag is sufficient for 25 m2 (requirement 0.4 kg/m²)

Kalzip NDS 60 Natural roof substrate

Sedum acre, Sharp stonecrop Sedum album "Coral Carpet", Red Moossedum Sedum floriferum "Weihenstephan Gold", Gold sedum;
Height: 5 cm, Flowering: June to August Height: 5 cm, Flowering: June to August Height: 15 cm, Flowering: July to August

Sedum hybridum, "evergreen" Sedum reflexum, Tripmadam Sedum reflexum ssp. rupestre, rock stonecrop
Height: 10 cm, Flowering: June to August Height: 15 cm, Flowering: June to August Height: 10 cm, Flowering: June to August

Sedum spurium "Album Superbum", Caucasian Sedum spurium, "Fuldaglut" Sedum sexangulare, Mild stonecrop
stonecrop Height: 10 cm, Flowering: July to August height: 5 cm, flowering: June to August
Height: 10 cm, Flowering: July to August

Kalzip GmbH 2020 47

Kalzip Systems

Kalzip AluPlusSolar

Aesthetic solar architecture

Kalzip AluPlusSolar profiled sheets of the The micro-lens-shaped surface, consisting of The advantages
second generation enable roof-integrated an ETFE (ethylene tetrafluoroethylene) foil, n Aesthetic, roof-integrated photovoltaics
generation of regenerative energy using which leads to the so-called light trap effect without additional fastening elements
photovoltaics, with maximum creative f and thus to better absorption of the sun's rays, n High safety and efficiency due to the first

reedom for sophisticated architectural ensures higher yields. By using the ETFE film, fully IEC-certified glassless, semi-flexible and
projects. the surface is not only dirt-repellent but also ultra-light module based on silicon solar cells
glare-free. n Optimal use of solar energy even in low light

The ultra-light and flexible, extremely robust conditions due to the micro-lens-shaped
solar module is based on silicon solar cells and The module is applied to polyester-coated Kal- surface made of ETFE foil
is the world's first fully IEC-certified solar zip profiled sheets in RAL 9006 and is available (ethylene tetrafluoroethylene)
module without glass, which embeds the PV in straight or convex rounded profile shapes. n Can be connected with standard DC connec-

cells in glass fibre reinforced plastic (GRP). The Integrated into the surface without the need tion boxes and controlled with conventional
patented glass fiber reinforced plastic core for an elevation, the solar modules are visually inverters
together with state-of-the-art front and back unobtrusive but retain their own expressive n Economical due to high performance gua-

sides and EVA films guarantee strength, robust character. The combination of the advantages rantee (25 years)
design, flexibility, quality and durability - and of aluminium with those of a photovoltaic n Dirt-repellent and glare-free surface - there-

all in one module. system results in a perfect synthesis of design fore minimal maintenance
and function. n Suitable as cold and warm roof version

The modules are permanently and firmly n Ideal for sophisticated object architecture

laminated onto the Kalzip surface. The internal With Kalzip AluPlusSolar a wide range of roof n High system safety due to internal

connection system of the roof-integrated shapes can be achieved. Barrel, shed or pitched connection technology
Kalzip AluPlusSolar solution protects the plug roofs can be designed as energy roofs just as n Efficient plant design and profitability

connections and cables securely against easily as individually curved shapes. Kalzip calculation with Kalzip
moisture, snow, ice, UV rays and animals. A AluPlusSolar can also be used for the entire n K alzip AluPlusSolar profiled sheets are

further visual advantage is that no disturbing building envelope and facade surfaces can be optionally available with an
cable ducts or connections are visible on roof "solarised" up to a maximum inclination of 90 anti-condensation coating (Kalzip Aquasine)
surfaces. degrees. Kalzip offers architects planning n On request also available as

options for designing environmentally friendly façade-integrated solar solution

solar living spaces - economically, sustainably
and aesthetically.

48 Kalzip GmbH 2020

 Products & Application

Electrical characteristics High reliability

Description 12 x 2 25 years performance guarantee according to DAS Energy warranty conditions
Output (Wp) 110 10 years product warranty
Isc (A) 9,15 Maximum system voltage: 1000 V
Voc (V) 16,01 Maximum current: 20 A
Imp (A) 8,63 All data under STC/standard test conditions (1000 W/m², 25 °C)
Vmp (V) 13,04
Certifications
Technical data IEC 61215:2005 IEC 61730-1&2:2007
Solar panels 24 5BB Monocrystalline solar cells Fire protection class II EN 13501-5:2007 Euroclass B (ROOF) t1
Solar panel characteristics 156 mm x 156 mm, 3 Busbars
Frontage Polymer foil with high permeability Temperature characteristics
Upper embedding foil Proprietary fibre-reinforced plastic Operating temperature range –40 to 85 °C
Cell embedding EVA Environmental temperature range –45 to 45 °C
TÜV-certified (IP 67) with a Thermal coefficient of Pmpp –0,393 %/°C
Junction box
Bypass diode (12 A) Thermal coefficient of Voc –0,310 %/°C
Output cable 2 x 400 mm TThermal coefficient of Isc 0,051 %/°C
Connector PV-compatible connector
Dimensions (L x W x H) 2052 mm x 355 mm x 2 mm
Weight of laminate 2,5 kg

Kalzip AluPlusSolar

Planning information
n Minimum radius in the area of the profiled panel covered with

modules: convex > 10 m, concave: 10 m

n Roof pitch: from 1.5° upwards

n Application in complete building envelope or façade after

consultation with the application technology department

n Design (electrics and fastening) according to Kalzip SolarSystems Powered by
installation guidelines

PV Laminate Thermal insulation (compressible)

Kalzip aluminium profiled sheet 65/537 Kalzip vapour barrier MH
Kalzip composite clip type E

Kalzip GmbH 2020 49

Kalzip Systems

Kalzip SolarClad

Lightweight and flexible

Kalzip SolarClad is a solar cladding system Advantages silicon solar cells
optimised for use on metal roofing n PV retrofit solution laminated onto flat sheets n  ptimum use of solar energy even in low
O
Photovoltaic system which, thanks to its for all Kalzip widths light conditions through the
flexibility and versatility, allows the integration n Fixing clamps approved by the building microlens-shaped surface of ETFE film
of solar modules into almost all standing seam authorities for maximum safety (ethylene tetrafluoroethylene)
systems with different materials. n Low weight - including solar modules only n With standard DC connection boxes and to
approx. 7 kg/m², usually no additional roof be connected with conventional Control
The ultra-light and flexible, extremely robust construction is necessary inverters
solar module is based on silicon solar cells and n For maximum power density and optimized n Economical due to high performance
is the world's first fully IEC-certified without yields, SolarClad can be mounted vertically, guarantee (10 years)
glass, which embeds the PV cells in glass fibre horizontally, parallel to the roof or as an n Dirt-repellent and glare-free surface -
reinforced plastic (GRP). The patented glass elevation therefore minimal maintenance
fibre reinforced plastic core together with the n Retrofitting of existing Kalzip roofs n Ideal for all roof shapes, for barrel-shaped
most modern front and rear backs and EVA n High efficiency and safety due to fast, roofs contour-following up to 13 m radius
films guarantee Strength, robust design, penetration-free installation n High system safety due to rear connection
flexibility, Quality and durability - all in one n Simple structural analysis of Kalzip roofs technology
module. n Improvement of summer thermal insulation n Efficient plant design and profitability
through façade and roof shading calculation with Kalzip
The very light modular units are suitable for all n High safety and performance through the n Also available as a façade-integrated solar
roof shapes. Kalzip SolarClad stands for a har- first fully IEC-certified glassless, semi-flexible solution on request
monious solar solution that can be integrated and ultra-light module based on
into the building structure.
As a retrofit solution for existing Kalzip roof
landscapes, Kalzip SolarClad can be installed
vertically parallel to the roof or parallel to the
roof, horizontally, following the contours of the
roof, or mounted on Kalzip standing seam
using Kalzip fastening clamps approved by the
building authorities. Existing roof landscapes
can therefore be transformed into solar power
stations.

Residential house Oordegem (B)

Profile type: 65/400, stucco-embossed

50 Kalzip GmbH 2020

 Products & Application

The retrofit solution for all metal roofs

Kalzip SolarClad is offered as a complete system including Kalzip fixing High reliability
clamps and various standing seam variants. The solar modules are 25 years performance guarantee according to our warranty conditions
permanently laminated onto Kalzip system supports at the factory ready
10 years product warranty
for connection and can be installed on any metal roof system without
Maximum system voltage: 1000 V
penetration using the fastening clamps approved by the building
Maximum current: 20 A
authorities.
All data according to STC/standard test conditions (1000 W/m², 25 °C)

The areas of application

Kalzip SolarClad is ideally suited for all roof shapes up to complete Certifications
building envelopes and façade applications. Due to its low dead weight, IEC 61215:2015 IEC 61730-1&2:2007
there are generally no additional structural requirements for the roof or Fire protection class II EN 13501-5:2007 Euroclass B (ROOF) t1
façade, making Kalzip SolarClad suitable for all roof/facade structures
and Kalzip building widths. Temperature characteristics
Operating temperature range –40 to 85 °C
Planning information Environmental temperature –45 to 45 °C
n Recommended roof pitch from 1.5° upwards
Thermal coefficient of Pmpp –0,393 %/°C
n Application in a complete building envelope or façade after
Thermal coefficient of Voc –0,310 %/°C
consultation with the application technology
Thermal coefficient of Isc 0,051 %/°C
n Design (electrics and fastening) according to Kalzip SolarSystems

installation guidelines

Electrical characteristics Kalzip SolarClad

Description 12 x 2P
Output (Wp) 100
Isc (A) 8,41
Voc (V) 15,03
Imp (A) 8,02
Vmp (V) 12,47

Technical data
Solar panels 24 polycrystalline silicium cells Powered by
Solar panel characteristics 156 mm x 156 mm, 3 Busbars
Frontage Polymer foil with high permeability
Upper embedding foil Proprietary fibre-reinforced plastic
Cell embedding EVA
TÜV-certified (IP 67) with a PV Laminate
Junction box
bypass diode (12 A) Kalzip flat sheet with rear connection box and plug connections
Kalzip fixing clamp type FA
Output cable 2 x 400 mm
Kalzip standing seam profiled sheets 65/... or 50/...
Connector MC4-compatible connector
Dimensions (L x W x H) 2052 mm x 355 mm x 2 mm
Weight of laminate 2,5 kg

Kalzip GmbH 2020 51

Kalzip Systems

Additive systems and

materials
The standing seam system as a water-bearing layer
The possible applications of the additive Kalzip example, with an intermediate construction Advantages
systems can be extended infinitely by made of extruded aluminium profiles. These n Wide range of design options with all the
combining them with a wide range of covering are attached to the tried-and-tested Kalzip roof advantages of the selected Kalzip roof
materials such as slate, wood or large-format covering by means of fixing clamps without structure
composite composite panels. There are no any penetration. In this way, even with n Penetration-free mounting of the fastening

creative limits - aesthetic claddings in a wide complicated details and large-format roofing of additive systems
range of design variants can be implemented materials, reliable water drainage and n High load capacity of the system

permanently and safely. functional reliability is always guaranteed. The n Can be dismantled at any time to change or

selected design variant essentially depends on modernise the appearance

The Kalzip standing seam system serves as a the shape of the building and the structural n Particularly economical and permanently

water-bearing layer to which the visible conditions. safe

material of the building envelope is applied.
The outer shell or the system is fixed, for

Hotel Kameha Grand Bonn (DE)

Profile type: 50/429, stucco-embossed
Architect: Architekturbüro
Karl-Heinz Schommer, Bonn

52 Kalzip GmbH 2020

 Products & Application

Fan Wold, Dortmund (DE)

Profile type: 50/429, RAL 9006
Architect: osd office for structural design

The areas of application Combination materials

The wide range of applications depends on n Wood

the intended use, shape, material combina- n Natural stone

tions and statics. It is important to consider the n Composite panels etc.

choice of Kalzip roof construction in advance. n Ceramics

Exemplary roof structures with composite panels in two design variants

Kalzip aluminium profiled sheet Vapour barrier

Composite panels Hat profile
Kalzip composite clip Trapezoidal profile
Fixing clamp Fastening the composite panels
Thermal insulation

Kalzip GmbH 2020 53

Kalzip Systems

Constructive colours
and surfaces
Discover the freedom of design in form, colour and surface, which opens up architectural horizons.
Whether cool, pure aluminium aesthetics or hip trend colours for façades or roofs. Kalzip offers even
more inspiration now. And for those who prefer a more purist and clear metallic look, there is a wide
range of surfaces to choose from. Kalzip goes its own way right up to Kalzip CC Tec EcoClean. The self-
cleaning surface with high-tech coating makes aluminium roof and façade systems a real ecological
specialist.

CC Classic CC Trend resistance and colour stability. We are pleased

to present our exclusive CC Trend colours
Colour system for coloured accents in The high-performance colour system with which we have developed in collaboration with
architecture - Polyester or PVDF coated long-term guarantee a renowned paint manufacturer. Whether
The polyester or PVDF coatings are applied to Color high performance: Iceberg White, Mediterranean Blue, Sea Green,
the aluminium in the coil coating process and Our own Kalzip high-tech polymer resin colour Black Grey, Brown Grey or Aluminium Grey:
represent an extremely durable, system enables new structures and colours. these colours are only available from Kalzip.
abrasion-resistant product. The combination of The high UV stability prevents changes in the
resistance and flexibility ensures that the colour image. Kalzip recommends HPC colours
profiled sheets and panels are very easy to for locations with extreme climatic conditions
form. We recommend the polyester coating for and high levels of sunlight.
locations with normal climatic conditions. The new CC Trend shades are particularly
Many variations in colour design are possible aesthetically appealing. With a gloss level of 15 Jahre
here: from a completely matt surface to a gloss only 3 %, this colour system promises the high- HPC Garantie

level of 80%. PVDF-coated profiled panels are est mattness and thus noble surfaces in a
suitable for use close to seawater; they are also fascinating quality.
particularly UV-resistant. This gives them the Kalzip offers a 15 year guarantee on chalking
highest possible resistance to loss of gloss,
chalking and colour changes - for perfect
protection and maximum durability. Standard colours:

Mediterranean
Iceberg White blue Sea green
HPC M353 HPC M353 HPC M353
Standard colours:

Anthracite grey White aluminium Grey aluminium Chacoral Grey Brown Grey Aluminium Grey
RAL 7016 RAL 9006 RAL 9007 HPC M353 HPC M353 HPC M353

54 Kalzip GmbH 2020

 Products & Application

Nya Nordiska Textiles GmbH, Dannenberg (D), Deichhalle Ettelbrück (L)

Profiktyp: 50/429, Selon Ech 2111/09 Profiltyp: 50/333, AluPlusPatina Gold G 30, RAL 9005
Architekt: Staab Architekten, Berlin Architekt: Besch da Costa Architectes, Luxembourg
BDA Architekturpreis Niedersachsen 2012

CC Pure AluPlusPatina The advantages

n Noble and matt appearance due to
Metallic - from elegant to noble The matt metallic version of AluPlusPatina with pre-weathered surface
Puristic, clear and timeless - our metallic a stucco-embossed surface or fine mill finish, n Reduced glare due to diffuse light reflections

surfaces that have made us famous - we can i.e. rolled smooth, conveys calm elegance. It n Dirt-repellent surface - insensitive to

offer you a wide range of different surface fini- radiates sovereign timelessness like an alumi- fingerprints
shes. nium that has been weathered for years with n UV-resistant

an even surface greying. n Suitable for large spans due to high inherent

Stucco-embossed strength
AluPlusPatina is also available in the colours n Available for all Kalzip widths

The classic natural aluminium stucco design champagne or bronze - these are applied n Available in stucco-embossed or smooth

reflects only slightly and is therefore hardly electrolytically as a toning and thus provide a finish
dazzling. With its robust surface it is also further protective layer that increases the
insensitive to slight mechanical damage. already long service life. Another advantage of The areas of application
this treatment is that this surface treatment Kalzip AluPlusPatina is the ideal solution for
does not affect the workability of the material building projects in which architects and plan-
in any way. All tints are provided with a 5 µm ners wish to give roofs and facades a special
thick passivation layer as standard. expression by means of their discreet matt
The thickness of the surface layer is the result appearance, while at the same time avoiding
Standard colours and Surfaces: of an optimal combination of highest colour the typical light reflections which often occur.
quality and mechanical suitability for cold roll
forming techniques.
Natural AluPlusPatina AluPlusPatina
aluminium Natural alumi- Natural
stucco- nium, stucco- aluminium,
embossed embossed mill-finish

AluPlusPatina AluPlusPatina
Champagne Light Bronze
G 12 B 20

AluPlusZinc

Kalzip GmbH 2020 55

Kalzip Systems

56 Kalzip GmbH 2020

 Krakow WasteProducts & Application
Incineration Plant (PL)
Profile type 50/429, RAL 3031, 6011, 6018, 6019, 6021
Architects: Architectural office Teller Architekci ,
Architectural office Lapinski Architekci,
Architectural office Manufaktura nr 1,
Prochem S.A.

Kalzip GmbH 2020 57

Kalzip Systems

Biological Institute of the University Hospital Dijon (F)

Profile type: 65/400, AluPlusZinc
Architect: AIA Atelier de la Rize Architectes - Albert Constantin, Lyon

AluPlusZinc Advantages and North Sea climate confirm an above-ave-

AluPlusZinc combines the many positive cha- n Excellent corrosion behaviour due to the rage Weathering behaviour of AluPlusZinc.
racteristics of aluminium and zinc. Light, matt applied Zinc patina in the PEGAL process
grey, which can change further due to n The weather-related removal rate is

weathering, is a building material full of cha- considerably lower than with conventional
racter for roofs and façades. zinc
n Even surface

Contemporary technology and a material that n High inherent strength - therefore suitable

ages with dignity were combined in a patented for large spans

process. As a symbiosis of aluminium and zinc, n Smooth appearance and colour uniformity

which combines the classic zinc look with the over the entire surface
low weight and high corrosion resistance of n Efficient and cost-saving due to low weight,

the established Kalzip standing seam profiles, 3.5 - 4.5 kg/m²

we have developed this manufacturing process n Resource-saving reduction of the material

within the Group and had it protected as a input for the load-bearing structural parts
PEGAL process. n Unjointed web lengths over 100 m possible

In a special process, a permanent bond is The areas of application

created between the aluminium carrier Kalzip AluPlusZinc is suitable for the
material and the zinc surface. The new product construction of high-quality roofs and walls on
has an additional surface treatment that new buildings as well as for the renovation of
creates a stable patina and makes it resistant to existing buildings. Especially in inner-city areas,
weathering. This protective layer resists when integration is required, AluPlusZinc is Simplified representation
harmful weathering very well and gives Kalzip predestined for representative buildings. Kalzip AluPlusZinc (PEGAL)
AluPlusZinc outstanding characteristics Kalzip AluPlusZinc is characterised by its very
Aluminium Zinc Patina
compared to conventional zinc surfaces. good corrosion behaviour.
When manufactured in the patented PEGAL
Measurements of the weather-induced process, a permanent bond is created between
removal rate are hardly verifiable. This is proven aluminium and zinc. An additional surface
by extensive scientific studies. The laboratory treatment creates a stable patina which is
tests have been fully confirmed by outdoor highly resistant to weathering. Outdoor
weathering tests in urban and industrial weathering tests in an urban atmosphere and
environments as well as in a maritime climate. in a very aggressive combination of industrial

58 Kalzip GmbH 2020

 Products & Application

Residential complex The Iceberg (DK),

Profile type: 50/400, RAL 9010
Architects: Cebra, JDS Architects, SeARCH and Louis Paillard

CC Tec EYou can obtain a selection of possible colour

shades directly from your customer advisor or
ProTect - the effective protection against from the Kalzip customer service team in our
anti-graffiti contamination plant in Koblenz.
To protect the surfaces, Kalzip also offers a
high-quality and exceptionally weather- Further information and application examples
resistant high-end special coating based on a can be found in our book on constructive
polymer technology using colours and surfaces, which we will be pleased
fluorocarbon (FLP). to send you free of charge on request.

It is characterised by high scratch resistance,

best colour and gloss stability as well as a signi-
ficantly higher surface hardness and tempera-
ture resistance.

Characteristics of coil coating paint systems

Coating system Coating thickness Balance of hardness Chemical resistance Excretion behaviour Weather Resistance Gloss level in %
range (μm) and flexibility
Polyester
25 +/- 5 + + + + 10–80
2-layer

PVDF
25 +/- 5 + ++ ++ ++ 10–30
2-layer

HPC
35 +/-5 + ++ ++ ++ 3–80
2-layer

+ good ++ excellent

Kalzip GmbH 2020 59

Kalzip Systems

Perfection in
Rollforming Technology

Flexibility in unexpected dimensions

The high-precision Kalzip elements can be Perfection in production technology -
manufactured both on the most modern fac- anywhere in the world - just in time
tory machinery as well as on mobile rollformers A large number of mobile rollformers in use all
which can be used anywhere on earth - over the world ensure a cost-effective solution
wherever it makes economic and ecological with minimal logistical effort. There are no
sense to do so. The relief of road traffic and limits even for unusual roof shapes.
short distances from the production site to the
place of use are time-saving, just like the The unique advantages of on-site production
typical Kalzip lightweight construction. are particularly impressive when covering large
roof areas with impressive lengths of panels.
Numerous patents and utility models prove the
uniqueness and technological advantage of
this system.

60 Kalzip GmbH 2020

 Products & Application

Kalzip shapes, widths and dimensions

Kalzip 50/333*** 333
1) straight 5) conical-concave
roll-rounded
50

Kalzip 50/429 429

50
2) convex 6) cocave
roll-rounded roll-rounded
Kalzip 65/305*** 305

65

7) elliptic
3) conical-convex Kalzip 65/333*** 333
roll-rounded
roll-rounded
65

Kalzip 65/400 400

4) conical 8) hyperbolic
roll-rounded 65

Kalzip 65/500 500

65

9) Examples XT-Free form

Kalzip AF 65/333*/*** 333

65

Kalzip AF 65/434* 434

65

Kalzip WF 65/537/0,8** 537

65

Kalzip AS 65/422*/*** 422

65

* Only in conjunction with rigid insulation materials or wooden formwork.

** Only as straight profiled sheets in lengths of 20 m (longer sheets on request).
Measured from the fixed point to the end of the profiled panel.
*** Availability of shapes, widths, quantities, surfaces, colours and dimensions on
request!

Kalzip GmbH 2020 61

Kalzip Systems

System components and

accessories
Exactly matching system components and Intelligent and technologically mature for a n Kalzip standing seam clamps for the penetra-
useful accessories complete the wide range of complete roof structure: tion-free fastening of additive systems
design options offered by Kalzip. The technical n Supporting shells made of steel or n Lightning protection components

requirements for a long service life, easy hand- aluminium n and much more

ling, safe installation and the recyclability of n Kalzip vapour barriers

the materials are given the highest priority. n Insulating materials (compressible or Comprehensive information on all system
The accustomed demand for excellent Kalzip step-resistant on request) components and all accessories is available at:
quality is consistently maintained - perfect and n K alzip system holder E-clips, RT clips [Link]
reliable right down to the last detail. Of course, n System fastener for all substrates

the current regulations relating to the n K alzip tread grates/ continuous gratings and

structural thermal insulation of the building railing systems for pitched roofs
envelope, the required fire protection class and n Latchways CFP - approved cable-guided fall

the applicable European standards are also protection system for Kalzip® standing seam
fulfilled. roofs
n K alzip snow guard system

62 Kalzip GmbH 2020

 Products & Application

Kalzip Service
What applies to Kalzip products also describes construction system available under the Our technical service for you:
our service: tailor-made, competent, flexible, globally registered trademark Kalzip turns n Tender documents adapted to your building

reliable and of the highest quality, in a word: visions into reality. Impressive, futuristic, f project
perfect. With maximum product and unctional, aesthetically pleasing ecologically n Technical support in solving detailed

consultancy services, Kalzip pursues the goal of outstanding buildings from the seemingly questions
realising only the very best solutions. limitless possibilities of roofing and building n Advice and assistance with all questions

envelopes. Architects and building owners relating to Kalzip

You will benefit from over 50 years of prefer Kalzip. We have set and continue to set
experience. With perfection and technical trends. Our own seminars:
know-how, experienced engineers accompany n Practice-oriented architect seminars

your construction project - whether new An international network of assembly n Assembly training courses

construction or renovation - from the idea to companies, system partners and suppliers n Courses on aluminium thin sheet welding

the realisation on site. Kalzip customers benefit guarantees our customers perfect complete (WIG) in cooperation with local chambers of
from our comprehensive consulting and solutions including all accessories in an trade
planning services, right through to project extraordinarily high manufacturing and service
management. quality. You are welcome to ask for our techni-
cal advice!
Since the first Kalzip roof was produced in
Germany in 1968, the lightweight aluminium
system has been conquering the world. More
than 100 million square metres of Kalzip
profiled sheets have now been installed. The

Kalzip GmbH 2020 63

[Link]

Kalzip is a registered trademark.

While care has been take to ensure that the
information contained in this publication is accurate,
neither Kalzip GmbH, nor its agents, accept
responsibility or liability for errors or for information
which is found to be misleading. Before using
products or services supplied or manufactured by
Kalzip GmbH, customers should satisfy themselves as
to their suitability.

Copyright ©2020
Kalzip GmbH

Kalzip is a Donges Group Company

[Link]

Kalzip GmbH
August-Horch-Str. 20-22
D-56070 Koblenz
PO 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@[Link]

English 01/20