Kal Zip Image

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Corus Bausysteme

Kalzip ® sets standards

Architectural highlights


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Kalzip ® – vorbildlich und richtungsweisend

2

CONTENTS

Lightweight and environmentallyfriendly 4-5

Flexible shapes 6-7

Functional elementary system 8-9

A well-conceived system 10

Various colours and finishes 11

Proven technical construction 12

Totally convincing 13

Advantages of rigid insulation 14-15

Elegant surface structure 16-17

Sound-proofing and heat-insulation 18-19

Guaranteed corrosion-proof 20

Long-lasting function 21

Range of well-proven products 22

Mature complementary products 23-24

Trend-setting innovations 25

Excellent for renovation 26-28

Manufacturing on-site 29

Saves resources 30

Solar cell factory Gelsenkirchen of Deutsche Shell AG (D), 1999. Kalzip ® stucco embossed. Architects:Dipl.-Ing. Uwe Hohaus & Partner, Hamburg.

East Terminal, Frankfurt on Main (D), 1993.Kalzip ® special grey colour, partly barrel-vaulted.Architects: JSK Perkins & Partner, Frankfurt.

Leisure and recreation centre Magdeburg (D), 1999.Kalzip ® stucco embossed, tapered and pre-curved.Architects: Edenne von der Brelie, Hryniewicki &Partner, Paris; Roschke & Par tner, Hamburg;Dipl.-Ing. H. Baas & J. Schulte, Hamburg.

H10 Airbus Hangar, Toulouse/Blagnac Airport (F),1991.Kalzip ® stucco embossed.Architects: M. Laborie, Toulouse.

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

Geesthacht College (D), 1995 (see also coverphotograph). Kalzip ® RAL 9006, partly tapered.Architects: Höchel Engelken + Partner · Beinhoff,Buxtehude.


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Architektur ganz oben

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Yesterday - just a vision. Today Kalzip ® .

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

It is non-flammable, conducts heat andelectricity, is non-toxic, can be recycledand used again.

Kalzip ® is the product

The result is something which is oftenexceptional and unique in its technology.We admire the creativity and far-sightedplanning of our customers. We appreci-ate the confidence placed in us asmanufacturers and reciprocate byproviding corresponding products andservices. It is our aim to unburden thedesigner, leaving him free to concentrateon what is important – the room

for the essential.

A new architectural dimension

There are visionaries amongst our

customers. We complement them withtechnical collaboration. The result arebuildings which set the standard and leadthe way in terms of shape and function.

High demands for safety and quality ofconstruction merge into a new architectur-al dimension – as demanding, functionaland economic as the task requires.

Aluminium is the material

Lightweight yet strong, corrosion-resistant,durable, easy to work with, can be welded

and combined with other materials.

Retractable roofing construction with Kalzip ®

stucco embossed sheets.


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Leicht und umweltgerecht

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The environmental friendly building envelope with a lightweightstructure. That’s Kalzip ® .

Lightweight structure using Kalzip ®

The lightweight Kalzip® roof structure

can easily bridge large spans, even withcurved lines.

Kalzip® is a well-proven, environmentallyfriendly building system: lightweight,strong, weather-proof, can be preciselyadapted and is flexible in shape. What’smore, it is ideal for combining with otherbuilding materials such as those used inthe roof build-up which create what weconsider indispensible, comfort and safety.

Living in harmony with nature – that isboth our aim and our challenge.

Saving energy and resources by utilisingre-usable building materials in light-weight structures are important factors

when planning building work. Kalzip®does this very simply. Because it is lightweight, only 3-5 kg/m2, the amount ofmaterial used in the supporting structureis reduced, thus saving resources.

Installing large sheets instead of layersof small components saves time. Highcosts on-site are replaced by moreefficient industrial production techniques.

Sports Centre, Annemasse (F), 1992. Kalzip ® stucco embossed, concave-convex. Architects: Richard Plottìer, Annemasse.

Photograph right:New Exhibition Centre, Munich (D), 1998.Kalzip ® stucco embossed.Architects: BBP Arkitekter A/S, Copenhagen.

(Competition design/Artistic direction);Architects: BDA/DWB Prof Kaup, Dr. Ing. Scholz,Dipl.-Ing. Jesse + Partner, München;Obermeyer Planen + Beraten, München.


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Flexibel in der Formgebung

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You conceive the designs. We supply the protective shell.

Your imagination is our challenge

Every day, we work for innovative

building shapes. So every day we rise tonew challenges. The result is often morethan just a building shell in the normalsense because, with Kalzip®, thereare many buildings which have a strongvisual impact.

Raab Tennis Hall, Fischbach (D), 1993.Kalzip ® RAL 6033,partly smooth curved and tapered.Architects: Ing. Büro Uwe Erbach, Illingen.

A multitude of shapes and colours

can be used

Kalzip®

is flexible and can be adaptedto suit the requirements of progressivearchitects, both in terms of buildinggeometry and size. Planning details arecomputer-controlled and transferred toproduction using CAD/CAM systems.Dimensional accuracy of manufactureguarantees the maximum precision andconsequently, fast, trouble-freeinstallation.

As experienced advisers, we can giveyou all the support you need – right from

the early planning stages.

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


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Creativity Centre of shoe factory Rhode,Schwalmstadt (D), 1999. Kalzip ® stucco embossed, factory curved incorporating 3 different radii. Architects and overall planers: Koschany, Zimmer & Assozierte, Essen.

Hot springs Xanten (D), 1999. Kalzip ® coralred poly coated. Architects: IPP Ingenieurbüro für Bauwesen,Prof. Dr. Ing. Polony u. Partner, Köln.

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


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Funktionell im Baukastenprinzip

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Attention to detail. You’ll recognise this in Kalzip ® .

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

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

Audi Development Centre, Ingolstadt (D), 1987.Kalzip ® stucco embossed, smooth curved.Architects: Henn + Hann, München.

Kalzip ® is much more than just an

industrial prefabricated metal roofing

system

Precision, functionality and great shapes –in regards to both detail and fixing – that’sKalzip®.

The Kalzip ® system offers proven

accessories:

• For roof openings

• Komplementery items for verge,

ridge and eaves areas

• Translucent elements includingaccessories

• Soakers

• Cover strips

• Seam clips

• Specially made components, e.g. forwalkways, solar equipment etc.

Kalzip® is a building system which hasbeen continually developed over more

than three decades. All componentscomplement each other both – functionallyand visually.

This allows the user to ensure that he hasmade the right decision.


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Administration Building, Corus Bausysteme, Koblenz (D). Extension 1996.Kalzip ® stucco embossed, smooth curved. Group of architects: Voss, Naujack, von Canal, Koblenz.

Airport Office Centre, Munich Riem Airport (D), 1988.Kalzip ® stucco embossed, smooth curved.Architects: Mühlmeier + Scheller, München.

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


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Durchdacht im System

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The Kalzip ® system – the result of great innovative effort.

Kalzip ® – the complete solution

In its standard form, Kalzip® has astucco embossed finish with a protectiveplating on both sides.

This helps to make the materialimpervious to external influences.

Plating

Core material

Rolled on both sides, Kalzip® protectiveplating increases the strength andservice-life of the building’s aluminiumshell. Colour coating fulfills a purelyvisual function.

Kalzip ® meets current-day

requirements in a special way:

• Lightweight

• Great strength

•

Resistance• Corrosion-proof

• Practically maintenance-free

• Resistant to atmospheric effects

• Flexible shape

• Non combustible

• Can be used as lightning conductor

• Can be re-usable

• High quality material

• Can be recycled

• Can be re-used, maintaining full

functional quality

Kalzip® is a flexible, weather-proof,easy-to-install system made of aluminiumprofiled sheets and well co-ordinatedaccessories.

Installed using the modular design princi-ple, Kalzip® is the complete solution forhigh quality shape and function –throughout the building’s entire life.

Physical construction aspects such assound-proofing, heat-insulation andmoisture-protection, as well as climaticand health requirements, are taken intoconsideration in the layers of the roofstructure.

If produced on site the lightweight sheetscan be supplied in lengths of 80 metresand more and allow a particularly fast andeconomical installation.

The mechanical zipping of the seamsproduces a load bearing connection.Vapor diffusion, however, is still possiblein this area enableing residual moisture

to evaporate after the installation.

The newly developed sliding clip evenimproves the as such excellent slidingproperties of the Kalzip® roofing.

Special aluminium clips have to be usedfor joining the Kalzip® profiled sheetswith the substructure of the roof. Theyare locked into the seam and will beoverlapped by the following Kalzip®

element, so that the fixing elements arehidden under the roofing. This ensuresthat the roofing elements need not to bepunctured for fastening.

A typical Kalzip® roof structure:

Kalzip ® profiled sheet

Kalzip ® aluminium ‘secret fix’ clip

Thermal-insulation(compressible)

1

2

3

4

5

6

Thermal barrier pad

Vapour control barrier and air-lock layer

Trapezoidal sheet

1

2

3

4

5

6

Lightweight and quick to install Durable, maintenance-free


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Variabel in Farbe und Oberfläche

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Kalzip AluPlusZinc ® – symbiosis

of two well-established, timeless

materials

Kalzip AluPlusZinc® is a fine, technicallydemanding product manufactured byCorus Bausysteme GmbH featuring amatt zinc patinated surface. The timelessaesthetic character of the pre-zinc patinaweathered opens a wide field of applica-tion for prestigious buildings – especially

in cities, where integration is requiredand where a high quality appearanceand a harmonic design are fundamentalfeatures. The patina on both sides of theprofiled sheets develops its appearanceunder external influences – it is alive.

Klazip AluPlusZinc® is a suitablecladding for roofs and walls of newbuildings and for the refurbishment ofexisting structures as well.

You decide how it looks.

Oberhausen Arena (D), 1996. Kalzip ® stuccoembossed. Architects: DLA-Ellerbe Becket,Wakefield (UK).

The fusing of the two well matchingmaterials aluminium and zinc is effectedin a patented process (PEGAL). Com-bined with the industrial production andour strict rules of quality managementthis process leads to a new productsetting new standards. The well-known,world-wide appreciated advantages ofour aluminium building system are ofcourse guaranteed with KalzipAluPlusZinc® as well.

Colour finishes have become

increasingly popular for Kalzip ®

over the last decade

You decide whether to use RAL or aspecial colour shade. We do the rest.

For Kalzip®, we only use high-quality,weather-proof paint systems. You canchoose between a polyester- or PVF2-based paint. Ask for the Kalzip®

colour chart.


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Bewährt im technischen Aufbau

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Also safe to construct.

Kalzip ®

truss roofconstruction

Kalzip ®

purlin roofconstruction

Kalzip ®

rafter roofconstruction


Thermal-insulation (compressible)

Kalzip ®aluminium ‘secret fix’ clip with thermal barrier pad

Trapezoidal sheet

Top hat section

Purlin





Wooden supporting substructure

Vapour control and air-lock layer

Rafter

Timber support





Trapezoidal sheet

Truss


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Überzeugend als Ganzes

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A building system with no "ifs and buts”.

Kalzip ® is convincing because:

It offers unlimited possibilities, high quality construction and flexibility

• As a ventilated and non-ventilated roof design, it is suitable for all roof shapes and pitchesfrom 1.5 degrees and is suitable for all sub-structures and supporting structures.

• It is flexible and can be adapted to suit the requirements of private and public sector clientswhatever the building’s basic shape, geometry or size.

• Its light weight makes it particularly suitable for renovating old roofs. Kalzip® AF and"Rockwool Prodach” insulation systems are particularly suitable for renovating corrugatedasbestos roofs. Approval from the professional control board is required in each case.

• Continuous sheets can be produced in lengths of 80 m and more.

• It has a neutral colour, timeless aluminium stucco embossed finish with a discreet surfacewhich is appreciated by knowledgeable experts.

• Available in a multitude of colours. RAL and special colours, all of high-quality and

weather-proof.• Kalzip AluPlusZinc® has a matt zinc-patinated smooth surface (PEGAL process) and excels

by its high natural strength, its increased resistance against abrasion due to weathering andits fine appearance.

• It allows a wide scope of different shapes: straight, convex or concave roll-formed, crimp-curved, tapered, tapered-convex curved ... Our growing know-how of the ductility of the basemetal aluminium again and again opens new design aspects.

Excellent construction qualities

• High thermal-insulation requirements can be easily fulfilled. The roof structure can be easilyadapted to suit the building’s exact requirements by selecting the appropriate thickness ofinsulation material.

• The construction makes high-quality sound-proofing easy and simple.

Durable and economic

•Corrosion-resistant aluminium alloy.

• Increased resistance against acid rain and industrial emissions due to the protectiveplating on both sides.

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

• Extremely fast installation being to a large extent independent of the prevailingweather conditions – ergonomic and cost saving due to prefabricated components.

Extremely safe throughout its entire life

• Special aluminium clips have to be used for joining the Kalzip® profiled sheets with thesubstructure of the roof. They are locked into the seam and will be overlapped by thefollowing Kalzip® element, so that the fixing elements are hidden under the roofing.

• The mechanical zipping of the seams produces a load bearing connection.

• Positive and negative loads will be safely absorbed.

• Vapour diffusion, however, is still possible in this area enableing residual moisture toevaporate after the installation.

•Tried and tested detailed solutions for roof penetrations as well as for joints and gable ends.

• Non-flammable. Resistant to airborne-fire and radiant heat.

• Kalzip® can act as a part of the air termination network.

Excellent ecological characteristics

• Aluminium, combined with other elements, is the third most common element in the earth’scrust and is available everywhere in nature.

•Once produced, aluminium can be recycled to provide products for generations.

• The Kalzip® roof covering can easily be re-used.

• Recycled aluminium material can be re-used again for the manufacture of other products.The aluminium’s beneficial properties remain intact.

•Only 5 % of the original manufacturing power is required for recycling.

• An insulated Kalzip® roof contributes significantly to reducing air pollution and so topreserving our environment.

Kalzip ® truss roof construction


Kalzip ® aluminium ‘secret fix’ clip with thermal barrier pad

Thermal-insulation

Vapour control andair-lock layer

Trapezoidal sheet Truss

1

2

3

4

5

Top hat section

Purlin

Timber support and thermal-insulation


Rafters 6

7

8

9

10

11

1

2

3

4

5

6

Kalzip ® purlin roof construction

1

2

3

4

5

7

8

Kalzip ® rafter roof construction

1

2

3

4

9

10

11


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Vorteilhaft auf trittfester Dämmung

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PRO-ZIP-Roof: Kalzip ® AF aluminium profiled sheets withoutstiffening ribs on rigid insulation.

Kalzip ® AF profiled sheets

Kalzip ® ‘secret fix’ clip

Fixing rail, aluminium

”Prorock” insulation board (rigid)

Self-tapping screw, stainless steel


Trapezoidal sheet as substructure


Fixing rail, aluminium



Wooden rafters with wooden supporting substructure


A new generation of profiled sheets

Kalzip® AF aluminium profiled sheetswere designed for roofing with a rigidinsulation board or a wooden supportingsubstructure.

Using Kalzip® AF profiled sheets inconjunction with a load-transmitting layerof insulation simplifies installation con-siderably. Under the name ”Prodach”insulating system, Rockwool offer arigid, water-repellent rockwool insulationboard with a special fixing system.

The insulation board is very suitable asa base for Kalzip®AF profiled sheets.It is non-flammable, highly thermally-insulating, sound absorbing, dimension-ally stable, diffusible and absorbsvibration. In its top layer, the double-layer”Prorock” insulation board is extremelystrong and resistant to mechanical stress.Its high load-transmitting capabilitiescontribute considerably to the roofing’sstatic function.

PRO-ZIP-Roof is the complete solution

for high quality in shape, function and

safety

PRO-ZIP-Roof is the combination ofKalzip® AF aluminium profiled sheetswithout stiffening ribs and rigid ‘Prorock’insulation board – optimised in bothsafety and long-life. Aluminium fixingrails and stainless steel self-tappingscrews are included in the supplypackage.

PRO-ZIP-Roofas truss roof structure

PRO-ZIP-Roofas rafter roofstructure

Self-tapping screw, stainless steel


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PRO-ZIP-Roof on a structural steel deckingsystem as substructure

Example: Renovation of corrugated asbestos roofusing PRO-ZIP-Roof

Kalzip ® AF profiled sheet


”Prodach” fixing rail, aluminium

System fixings, depending on substructure



Structural steel decking system


Rafter

Corrugated asbestos roofing

Bottom layer of insulation

1

2

3

4

5

6

7

8

9

10

11



Secondary seal (1st position)

Claws or metal rails

Molten bitumen topcoat (only when claws are used)

FOAMGLAS ® insulation layer (rigid)

Bitumen bondingStructural steel decking, wooden supporting substructure or solid base

1

2

3

4

5

6

7

8

1

2

3

4

5

6

10

11

1

2

3

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5

6

7

PRO-ZIP-Roof on wooden rafters with a woodensupporting substructure

1

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Kalzip ® AF profiled sheets can

also be used with the FOAMGLAS ®

insulation system

Discreet surface appearence

The flat trough shape of Kalzip® AF profiled sheets produces a discreet, quietlyelegant surface finish. Even small buildingscan have a proportional, well constructedKalzip® AF aluminium roof covering.

Always right and quite safe

The PRO-ZIP-Roof is suitable for allcommenly used substructures or struc-tures in steel, concrete and timber, for allstructural engineering applications andfor the renovation of old roofs. Specialsystem fixings are manufactured for alltypes of substructures.

The ”Prorock” insulating board offers ahigh degree of ”walkability” during instal-lation and maintenance. Concentratedloads are transferred to the substructureas spread load.

Installation

With the usual Kalzip® technique, thecorrosion-resistant, weather-proof alumini-um outer sheet is fixed using ‘secret fix’clips, but – and this is what’s specialabout the PRO-ZIP-Roof – it is not fixeddirectly to the supporting structure but toan aluminium U-rail inserted in theinsulation layer. The system fixings whichconnect the U-rail to the supportingstructure only penetrate the insulatingmaterial in points. This system almostentirely eliminats sound and heat bridging.

Renovation of corrugated asbestos roofs

The PRO-ZIP-Roof is also suitable forrenovating corrugated asbestos roofs.Various processes are possible. In eachcase, approval must be obtained from theprofessional control board. Depending onthe local situation, it’s possible todispense with the dismantling of existingcorrugated asbestos roofing (see page28).


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Filigran strukturiert in der Fläche

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Gentle contours create space and dimension.

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

The lines of Kalzip® roofing fit well intothe design concept for this building.Its rich use of light and shadow empha-sises the particularly striking architecture.Curves are gentle but also full of charac-ter, visually emphasising the dimensionand width of the building.

The elegant surface structure of theKalzip® roof covering contrasts richlywith the deliberately practical finish ofthe facades and glazing. The colour ofthe durable, protective Kalzip®

aluminium roof covering blends harmo-niously with the other architecturallyimportant parts of the building.


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This building is a good example of howthe combination of different building ma-terial complement each other in shapeand function. With its almost unlimitedshapes and applications, it also showshow the highly flexible Kalzip® roofingsystem has developed to match thearchitectural and aesthetic demands ofour time.

The visual lines of the roof covering canbe determined by selecting an appropri-ate width of Kalzip® profiled sheet.Weather-proof, totally flat Kalzip® AF aluminium profiled sheets for rigid andcontinious types of substructure enrichthe scope of construction.


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Schall- und wärmedämmend

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Lightweight, self-supporting and good sound-proofing.In this instance, R’w = 53 dB(A).

Wide spans

The Oberhausen Arena is currently one

of the most modern of its type in Europe.Its architecture and technical constructionchange a simple visit into an unforget-table experience.

The wide-span, self-supporting domedroof is covered with Kalzip® aluminiumprofiled sheets in lengths up to 42 m.

Excellent acoustics

The hall has a capacity of over 12,500

seats. Its technical layout enables it to bere-arranged very quickly and provides agreat degree of flexibility. The acousticsare particularly important for large events.At the Oberhausen Arena, with a sound-reflection of 1.8 seconds, it is particularlyremarkable that this measurement isachieved even though the hall has a veryopen interior design. The architects,DLA-Ellerbe Becket, produced anambitious roof structure, using wide-spansteel trusses with support-work which isvisible internally.

Technical and shape constraints

– Must be as lightweight as possible

because of the wide spans– High demands for sound-proofing and

acoustics

– Very flexible because of the domeshaped roof structure at the entrance

Lightweight. Self-supporting. Well sound-proofed. Good acoustics. Flexible shape.Kalzip® roofing is all these.

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


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Strict accoustic requirements were met

Tests proved this before the roof was

installed. The result: R’w = 53 dB(A).Insulating layers inside the roofingstructure enabled the thermal-insulationrequirements to be met easily.

The Kalzip® roof structure also fulfilledthe highest economical expectations.

Cross-section

Kalzip ® has no static problems

The Kalzip® roof covering can be

precisely adapted to suit the building’srequirements by selecting the appropriatenumber and position of fixing points.

Lightweight Kalzip® roof structures aresuitable for large buildings of all kinds:for gymnasiums, multi purpose halls,swimming pools, leisure centres, airportterminals, railway stations, officebuildings, industrial and administrationbuildings...

Longitudinal section

Kalzip ® profiled sheets

Kalzip ® ‘secret fix’ clip with thermal barrier pad

Thermal-insulation(compressible)

Plaster fibreboard

1

2

3

4

5 Top hat profile andthermal-insulation (rigid)

Vapour control and

air-lock layerPerforated structural steel decking

Top hat profile on interme- diate rubber layer

6

7

8

Example: Kalzip ® roof structure for specialsound-proofing requirements

1

2

3

5

3

4

4

6

7

8

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

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


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Sicher im Korrosionsschutz

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Kalzip ® gives long-lasting protection, even under massivecorrosion attack.

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

Protective plating, a sure thing

The whole composting process, starting

with the delivery of compost waste rightup to storage of the end-product, takesplace in enclosed halls. The climate inthese halls is extremely aggressive; thegases, temperatures and air-humidity areextremely high. The building materialsused to construct the roof and roomsmust withstand massive corrosion attack.These high demands are met byKalzip® because of its protectiveplating on both sides.

Through its protective plating on bothsides, Kalzip® offers a particularlylong-lasting resistance to corrosion.

Kalzip® is the ideal solution for theuse under the effects of marine andindustrial atmosphere. The material usedis one of the so-called saltwater-resistantalloys. Special surface protection offersa suitable solution for use directly nextto copper-works or industries which uselarge quantities of aggressive chemicals.Ask us and we’ll advise you.

Plating

Core material


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Dauerhaft in der Funktion

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Kalzip ® is long-lasting.

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

Kalzip ® : Over 30 years on the

world’s roofs.

Over 30 million square meters ofKalzip® profiled sheets have beenmanufactured.

In 1968, Kalzip® was used for theConference Centre in Nuremberg.Economic studies have confirmed it:both visually and functionally, the roof isstill as good as new today.

The durability of the material is particu-larly impressive on the dome of Rome’sSan Gioacchino Church, which wascovered in aluminium in 1897. Althoughthe aluminium used then was by nomeans up to modern day quality, the roofcovering is still in very good condition.

Perhaps future generations will standand wonder at a 100 year old Kalzip®

roof. Certainly, at the end of its useful life,the Kalzip® aluminium roof covering withits ever-increasing material value will al-

ways sell well and be used again afterrecycling.

Kalzip ® is non-flammable

Aluminium alloys are non-flammable and

so, without proof, are building materialsClass A1 according to DIN 4102.

Even with an organic coating on bothsides and with insulation layers on theunderside in building materials Class B2,Kalzip® is, without proof, resistant toair-borne fire and radiant heat accordingto DIN 4102 Part 4, Section 8.7.

Kalzip ® assumes the function of a

lightning conductor

When connected and earthed correctly,Kalzip® roofing can be used as alightning receiver and lightning conduc-tor in accordance with DIN 57 185,Part 1, Lightning Protection.


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Praxisbewährt die Produktpalette

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The Kalzip ® range.

smooth curved (concave)

tapered and smooth curved (convex)

smooth curved (convex)

tapered

Kalzip ® aluminium profiled sheets

Dimensions Gaugemm mm

Kalzip®AF 65/333 *)

65

333

Kalzip® 50/333 1,21,00,90,80,7

1,21,00,9

1,21,00,90,80,7

1,21,00,9

1,21,00,90,80,7

1,21,00,9

1,21,00,90,80,7

1,21,00,9

1,21,00,90,80,7

1,21,00,9

1,21,00,9

1,21,00,9

1,21,00,90,80,7

1,2

1,00,9

Kalzip® 65/305

Kalzip® 65/333

Kalzip® 65/400

Kalzip® 65/500

Kalzip® 65/600

Kalzip ® AF 65/434 *)

65 434

333

65

305

65

333

65

400

65

500

65

600

50

333

Many shapes are possible, e.g.:

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

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

straight


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A special folding technique enables gable end flashing to be nicely shaped, even on curved roofs.

Soakers for rooflight domes or smoke extractorfans are produced to building requirement and are

welded or sealed into the Kalzip ®

layer(depending on the requirements).

Vent-pipes are welded into the roof covering.

Top closure on a Kalzip ® profiled sheet with a locking plate, shape-filler and bevel. Small-radius crimped curved Kalzip ® as an attractive variant fora fascia.

Walk weys are fixed to the seam using clumping sections. The roof covering is not punctured.

Folding tools make it easier to bevel the ridge of the Kalzip ® profiled sheets.

Rooflight unit systems (PVC) are available forsingle-skin roofs.

The bevelling tongs for the eaves produce auniform, functional edge line.

Gable clip and cap to reinforce and secure theedge flange.

Snow and ice bars in aluminium are fixed to theseam of the Kalzip ® profiled sheets usingclamping

sections. The roof covering is not punctured.

Proven accessories complete the Kalzip ® roofing system.

Roof assemblies such as walkways, absorbers and solar systems are firmly fixed to the seam usingKalzip ® clamping sections in stainless steel oraluminium. The roof covering is not punctured.

The Kalzip® system includes anextensive range of accessories whichhas grown out of demand.

Shown here are some components withdurable functions.

The Kalzip® price list containscomplete details.


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Kalzip ® supports the world’s largest photo-voltaic roof system.

Small details with a big effect

The Kalzip® clamping sections fittedon the seam of the Kalzip® roofcovering support Siemens’ photo-voltaicsystem.

656,208 solar cells were fitted. The outerroof covering wasn’t punctured. The roofcan be walked on in order to maintainthe solar system.

New Exhibition Centre, Munich (D), 1998.Kalzip ® stucco embossed.Architects: BBP Architekter A/S. Copenhagen.(Competition design/Artistic direction);Architects: BDA/DWB Prof. Kaup, Dr. Ing. Scholz,Dipl.-Ing. Jesse + Partner, München;Obermeyer Planen + Beraten, München.(see also page 5).

1000 light domes were easily built-intothe roof using prefabricated Kalzip®

soakers.

The eaves consist of prefabricatedsandwich units. Together with Kalzip®,they mould the architectural appearanceof the exhibition halls. The Kalzip®

covered roof measures 160,000 m2.


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Accident prevention regulations are compulsory for work on the roof. The Kalzip ® fall-prevention system offers the

necessary protection.

Streamline drainage installations, joints and end pieces can be manufactured to project requirements.Kalzip NatureRoof ® though incorporating a planted area is still considered a lightweight construction.

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

The Kalzip ® mounting system for a

fast and safe clip-fixing on trapezoidal

steel decks

• Kalzip® ‘secret fix’ clips, fitted inseconds, even on thin trapezoidalsteel profiles.

• Drill/screw technique: one processfor drilling and fixing.

• High strength.

This new fixing system was developedby the Swiss company SFS, the leadingmanufacturer of mechanical fixingsystems for industrial light engineering.Together with Corus, this technique hasbeen adapted to the Kalzip® system.

Ordinary drills are suitable for theKalzip® drill/screw technique.

Please ask for information aboutKalzip® drill/screw technique.

Kalzip ® innovations set standards.

Kalzip NatureRoof ® is the safe way of

landscaping – unique in its conception

and technical design

The Kalzip® Natural Roof elements aremounted direct to the profile sheets with-out any additional sealing measures.This combines the technical advantagesof Kalzip® with the ecological require-ments of a green roof.


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Hervorragend als Sanierungskonzept

26

Renovating with Kalzip ® is more than just a facelift.

Kalzip ® is ideal for renovating roofs

Its light weight, great strength, longevity,

considerable installation advantages,high economics as well as good thermal-insulation and sound-proofing, make roofrenovation a special field of applicationfor Kalzip®.

Whether sloping shallow or steep, theexisting roof covering does in mostcases not have to be removed. Also roof

structures need generally not bereinforced.

During installation, the building cancontinue to be used in the normal way,usually without any interruption.

The Kalzip® system is suitable forrenovating all types of roofs.

Bitumenous felt and membrane roofs,with and without gravel ballast and evencorrugated asbestos roofs can be

quickly, safely and above all, economi-cally renovated using Kalzip®.

Visual aspects and unusual shapes canbe accommodated.


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

Long-lasting increase in value

In many cases, the corrosion-resistant

material and its ability to withstand theeffects of the environment endorseKalzip® as the ideal system forrenovation.

A new Kalzip® outer shell offers abuilding long-lasting protection. In addi-tion, the renovation clearly enhances thebuilding visually.

Savings on thermal-insulation and sound-proofing are very positive, not only for thebuilding’s users:

• The costs of operating and maintainingthe building are clearly reduced.

• Increasing environmental demandsare met.

• The building as a whole increasesin value.


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Hervorragend als Sanierungskonzept

Kalzip ® AF and the Rockwool ”Prodach” insulation systemare ideal for roof renovation.

No dismantling and removing of the

asbestos layer

In Landau/Isar, a building complex com-prising of six steel halls with a roof areaof about 190 x 120 m, received a new,long-lasting Kalzip®AF aluminium roofcovering. Following installation, the roofcan be walked on without restriction.

Renovation work took about two months.

The client continued to operate,un-interrupted.

Because of the light weight of theKalzip® system, it wasn’t necessary toreinforce the roof’s substructure.

The result of an expert report on thesubject ”Drilling asbestos-cementproducts” formed the start of this renova-tion concept. Drilling dust was suckedaway using special suction equipmentconnected to the drilling machines.A copy of the report is available onrequest.

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


Kalzip ® aluminium ‘secret fix’ clip

Fixing rail

System fixing, depending on substructure

”Prorock” insulating board (rigid)


Corrugated asbestos roofing

Bottom layer of insulation

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

Fixing rails using a rivet gun Milling grooves for fixing rails 19,500 m 2 roof was renovated in about 2 months


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Produktiv auch vor Ort

29

We can produce Kalzip ® anywhere in the world.

On-site production

For the suspended, tent-like roof structure

of the Stadio di Torino (I), Kalzip®

profiled sheets, partly smooth curved,were manufactured on-site.

Transportable Kalzip® profiling andbending machines can be used any-where in the world - particularly where itis economically and ecologically sensible.Relieving traffic congestion and findingthe best route from the point of manufac-ture to the point of use, as well as provid-ing a lightweight construction method,are very important considerations today.

25,000 m 2 of Kalzip ® profiled sheets were produced on-site. Not that we had to move our factory to Turin.Much smaller mobile units, built specially for this type of use, ensured that whatever was needed could bemanufactured on-site, on time, correctly co-ordinated in an economic and environmentally friendly way.The installation professionals weren’t the only ones to be astonished.


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Ressourcenschonend im Einsatz

30

Partner of the environment.

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

Up to 95% of the power used to producealuminium can be saved when it isre-smelted. The smelting process can be

repeated as often as required.Aluminium’s beneficial material propertiesremain intact.

The product characteristics of theKalzip® system meet high ecologicaldemands.

The lightweight construction of Kalzip®

enables a resource-saving reduction inthe amount of materials used to createthe supporting structure.

Once produced, aluminium is at our

disposal for evermore, thus saving

resources

Aluminium, combined with other ele-ments, is the third most common elementin the earth’s crust and is availableeverywhere in nature.

From the initial material, recycling overand over again produces valuable newaluminium products.

An insulated Kalzip® buildingcontributes significantly to reducingair pollution and preserving our

environment.

After a long service-life, Kalzip® can becontinually re-used.

Ecology and economy complementeach other. The circle is complete.


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Our experts with their knowledge of

many applications are at your disposal

We hold installation training courses atour in-house seminar centre and forarchitects, the schedule includes planningseminars.

For further advice and information,please contact one of our sales offices(see overleaf).


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www.kalzip.com

Corus Bausysteme GmbH · Part of Corus Group plcA H h S 20 22 D 56070 K bl Pf 10 03 16 D 56033 K bl Ph 49 (0) 261 891 0 F 49 (0) 261 820 38

Europe:

The NetherlandsHAFKON B.V.Postbus 46NL-3140 AA Maasluis · The Netherlands

Phone +31 (0) 1059 15300Fax +31 (0) 1059 15125

BelgiumCorus Building Systems NVPart of Corus Group plcA. Stocletlaan 87B-2570 Duffel · BelgiumPhone +32 (0) 15 30 29 21Fax +32 (0) 15 30 29 20

AustriaRobert PfistererBautechnische BeratungKeplerstraße 16A-4222 Luftenberg · AustriaPhone +43 (0) 7237 5123

Fax +43 (0) 7237 2123

United Kingdom and IrelandCorus Building Systems Ltd.Part of Corus Group plcHaydock Lane, HaydockGB-Haydock/Merseyside WA11 9TYUnited KingdomPhone +44 (0) 19 42 29 55 00Fax +44 (0) 19 42 27 21 36

FranceCorus Building Systems SASPart of Corus Group plc8, Avenue DesclersB.P. 20

F-77515 Faremoutiers · FrancePhone +33 (0) 1 64 65 30 56Fax +33 (0) 1 64 03 98 55

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

DenmarkA.E. Stålmontage a/sP.O. Box 70Hagensvej 54

DK-9530 Støvring · DenmarkPhone +45-98 37 32 88Fax +45-98 37 32 79

SwitzerlandBüro Dach & Wand, Jürg SentelerP.O. Box 247CH-7302 Landquart · SwitzerlandPhone +41 (0) 8 13 22 38 38Fax +41 (0) 8 13 22 38 39

CyprusPhanos N Epiphaniou Ltd.21 Markou Drakou AvenuePallouriotissaP.O. Box 9078CY-1621 Nicosia · Cyprus

Phone +357 (0) 2 438 991Fax +357 (0) 2 431 534

GreecePhanos N. Epiphaniou Ltd.82 Grammou Str.GR-18345 Moschato · GreecePhone +301 9 405 941Fax +301 9 412 465

Overseas:Middle East

DubaiCorus Building Systems

P.O. Box 9217 · Dubai · United Arab EmiratesPhone +971 4 3388586Fax +971 4 3389970

KuwaitAli Alghanim & SonsTrading & Contracting Group Co. W.L.L.P.O. Box 21540 · KW-Safat 13076 · KuwaitPhone +965 4 822190Fax +965 4 821669

Documents

Kal Zip Image