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Facade Systems TF 800 R

Technical, design and construction manual

Kalzip Facade Systems

Table of contents

Page

1.

Introduction

1.1

Aluminium building envelope

1.2

New emphasis on object architecture

1.3

Safety combined with quality

2.

Kalzip Facade Systems

2.1

Colours

2.2

System overview

3.

Construction principles

3.1

Kalzip Facade Systems on walling and concrete

3.2

Kalzip Facade Systems on cassettes

4.

General data/properties

10

4.1

Material/corrosion resistance

10

4.2

Ecology

11

4.3

Static proof

11

4.4

Transport/storage and fitting

11

4.5

Sheet metal thicknesses

11

4.6

Thermal protection

12

4.7

Moisture protection/ventilation at rear

12

4.8

Air tightness of the building envelope

12

4.9

Fire protection

12

4.10

Lightning protection

13

4.11

Temperature-dependent change of length

13

4.12

Tolerances

13

5.

Design notes

14

5.1

Substructure made of concrete, walling

14

5.2

Substructure made of cassettes, trapezoidal profile sheets, post frame constructions

15

5.3

Intermediate construction in case of cassettes

16

6.

Kalzip Facade System TF 800 R

17

6.1

System components

17

6.2

Connections

17

6.3

Construction detail inside, outside

17

6.4

Construction detail pilaster strips

18

6.5

Construction detail window (top, sides, window cill)

20

6.6

Construction detail door (top, sides)

21

6.7

Construction detail wall junction top/bottom (bracing angle, drip tray)

21

6.8

Load span tables

22

6.9

Placement of screws

30

Index

31

Left:
Storage Electro Helfrich Viernheim (D)
Architects: Fischer Architekten, Viernheim

Kalzip Facade Systems

1. Introduction
1.1 Aluminium building envelope

1.2 New emphasis on architecture

Visually exquisite, technically well conceived aluminium

For over 30 years Corus has developed, produced and

facades in distinctive and clear-cut profiles have become

marketed innovative aluminium roof and wall cladding

an important design element in architecture. The desire

systems. Todate more than 65 million m2 of Kalzip have

of clients and architects to present a building of indivi-

been manufactured and installed. The introduction of

dual aesthetic quality which is also technically perfect

the innovative Kalzip Facade Systems concides with

in shape and function, requires integrated solutions

both clients and architects placing a new emphasis on

that combine architecture and technology. As a material

architecture. Kalzip opens up almost limitless possi-

which retains its value, aluminium offers not only many

bilities in the individual language of shapes and helps

technical advantages but also the ideal prerequisites for

to characterise decisively the functional aesthetics of

an aesthetically appealing and stable building envelope.

the structure. As a safe, low maintenance system, Kalzip


is also a truly economic solution.

To allow unusual design concepts to be realised economically and yet to optimum effect, there is a special
demand for building systems with low operating and

1.3 Safety combined with quality

maintenance expenditure, which also fulfil the requirements with regard to energy-saving building. Kalzip

Standardised production processes combined with

Facade Systems are compatible with various substruc-

an efficient and advanced quality management system

tures for both new building and also refurbishment

from raw material procurement right up to final inspec-

projects, with their versatile profile and surface variants

tion of the finished products guarantee optimum quality

providing a long lasting and high-quality outer skin.

of the finished components.

This brochure serves as a planning aid for the design

Underpinning this production process there is a safety

and execution of facades. It shows areas of application,

management system regulated according to the standards

contains detailed product information and also the

of Det Norske Veritas (DNV). It has been proven that there

necessary design notes and rating tables. The rating

is close interaction between quality and safety.

is calculated in accordance with the rules and regulations applicable at present in the Federal Republic of

Corus was assessed by DNV in 2001 according to the

Germany.

requirements of the INTERNATIONAL SAFETY RATING


SYSTEMS (ISRS) and classed in level 7, which is

Other country-specific requirements must be checked

regarded as a high grade achievement. Corus shares

and adapted to the requirements of the local/national

this classification with leading companies of the

regulations and standards.

chemical industry and other hi-tec companies.


The certification is used at the same time for the
integration of other management systems, e.g.
DIN EN ISO 14001, DIN EN 9001:2000.

Kalzip Facade Systems

2. Kalzip Facade Systems

2.1 Colours*

As part of the exterior building envelope, metal facades

The comprehensive spectrum of colours available for

characterise the appearance of modern functional

Kalzip Facade Systems offers planners and architects

buildings and help to present a contemporary and

extensive scope for the realisation of modern architec-

innovative image of the company. In addition to realising

tural designs. High-quality coating processes in

the design concept; the system offers many functional

polyurethane/polyamide, polyester or PVDF ensure

benefits which contribute to the overall quality and

highly durable exterior life and colour stability.

performance of the structure. Above all, system design


must take into consideration diverse additional require-

Besides standard RAL colours and RAL special colours

ments of technical design and structural engineering.

according to the Kalzip and Kalbau colour range,


Kalzip facade sheets are offered in the following

Kalzip Facade Systems offer architects and clients

exclusive finishes:

new perspectives for individualistic building design


and construction. All elements are perfectly compatible

- TitanColor

with each other and are available in many colour varia-

- SoftColor

tions. Efficient production processes combined with

- AntiGraffiti

an economic and thereby ecologically sound use of


materials allow the systems to fulfil all the requirements

These new finishes offer the benefits of specific

of modern construction. System advantages include:

performance characteristics and impart an individual


visual effect to the building (for further information refer

Unique, aesthetic design with a distinct long view

to the Kalzip Colours and Surfaces brochure).

visual appeal
Economic efficiency and conservation of resources
Low weight
Wide range of acoustic and thermal insulation

*Colour variance: Due to the different coating processes (conveyor


or piece coating), colour differences between the profile panels and
the extruded system components, even with similar RAL colours,
cannot be ruled out.

configurations
System components. Fully integrated and

2.2 System overview

interchangeable
For a perfectly integrated overall appearance; additional

Kalzip Facade System TF 800 R

system components are available that have been specifically designed and manufactured for compatibility with

20,5

Kalzip facades. These components can be used to help


create a distinctive appearance and a visual interesting

Right:
Dimensions of the profile panel

267

Building width 800

67

166

arrangement of complete elevation.

37

Kalzip Facade Systems

3. Construction principles
3.1 Kalzip Facade Systems on walling and concrete

Top:
Wall construction
Kalzip Facade Systems
Detail: Section door

Right:
Wall construction
Kalzip Facade Systems
Detail: Window

Kalzip Facade Systems

Left:
Wall construction
Kalzip Facade Systems
Detail: Roof parapet

Top:
Wall construction
Kalzip Facade Systems
Detail: Door

Left:
Wall construction
Kalzip Facade Systems
Detail: Inside and outside corner

Kalzip Facade Systems

3.2 Kalzip Facade Systems on cassettes

Top:
Wall construction
Kalzip Facade Systems
Substructure cassette
Detail: Section door

Right:
Wall construction
Kalzip Facade Systems
Substructure cassette
Detail: Window

Kalzip Facade Systems

Left:
Wall construction
Kalzip Facade Systems
Substructure cassette
Detail: Roof parapet

Top:
Wall construction
Kalzip Facade Systems
Substructure cassette
Detail: Door

Left:
Wall construction
Kalzip Facade Systems
Substructure cassette
Detail: Inside and outside corner

Kalzip Facade Systems

4. Allgemeine Angaben/Eigenschaften
4.1 Werkstoff/Korrosionsbestndigkeit
An essential advantage of using Kalzip profile sheets

Contact corrosion

lies in the low dead weight of aluminium. Seawater-

In the presence of moisture, aluminium forms a contact

resistant alloys are used as base materials. Kalzip

element in connection with other metals. This may lead

aluminium profile sheets are reliably protected against

to corrosion. Placing non-conductive materials (e.g.

corrosion in normal marine, urban or industrial condi-

plastic coatings) in between the metals provides reliable

tions, by the formation of a natural oxide layer. With

protection against this effect.

clad plated material this effect is further reinforced,


because the plating layer protects the core material

The table below has been established on the basis of

for many years against corrosion by acting as a

very extensive scientific investigations in Sweden and

sacrificial anode. There is increased corrosion risk

demonstrates that in normal building applications, the

in the immediate vicinity of industrial works which

aluminium alloy from Kalzip can be combined with most

emit large quantities of aggressive chemicals - for

commonly used metals in a corrosion-proof manner.

example near copper mines. In such cases, suitable


plastic coatings (minimum thickness 25 m) are
recommended for additional protection.

Compatibility of aluminium with other materials


Atmosphre
Material pairing

Country

Town/industry

Near the sea

Zinc

no cause for concern

no cause for concern

no cause for concern

Stainless steel

no cause for concern

no cause for concern

no cause for concern*

Lead

no cause for concern

no cause for concern

cause for concern

Hot galvanized steel

no cause for concern

no cause for concern

no cause for concern

Unprotected steel

cause for concern

cause for concern

cause for concern

Copper

cause for concern

cause for concern

cause for concern

* This only applies to thread-forming screws and blind rivets made of stainless steel, when an electrolyte formation is to be excluded.

Fitting with other materials


Steel:

Concrete and mortar:

Direct contact between aluminium profile sheets and

Direct contact with fresh concrete and mortar is to

unprotected steel elements of the substructure must

be avoided, e.g. when applying mortar around other

be prevented on a permanent basis. For this purpose,

construction elements, e.g. windows.

plastic foils and intermediate layers with bituminous or


zinc chromate or chlorinated-rubber paint, can be used
or steel parts in the contact zones can be galvanised.

10

Kalzip Facade Systems

4.2 Ecology
In common with all other materials, aluminium cannot

Additionally, for the fixings, the proof Tearing out of

be manufactured without energy expense and associated

the substructure e.g. according to approval Z-14.1-4

emissions. However, the industry has succeeded in

Connection elements or DIN 18807 has to be

achieving remarkable reductions in this area by means

furnished. Furthermore, possible reductions in the

of process developments and environmental investment.

number of screw fixings in unsymmetrical thin-walled

Today, the amount of energy for the production of

substructures are to be taken into consideration.

aluminium by electrolysis is just 60% of the amount


required 40 years ago.

4.4 Transport/storage and fitting


During the useful life of the material (typically several
decades) hardly any corrosion of the aluminium surface

The transportation of the profile sheets is generally

occurs. At the end of the buildings life, building compo-

effected from the works of the manufacturer direct to

nents are preferably recovered for recycling process.

the building site by lorry or railway transport. During

Aluminium is ideally suited for recycling because it is

transport, the material must be protected against

available in large quantities and is relatively pure in terms

weather, particularly against rain. For this, tarpaulins,

of grading. The recycling process uses just 5% of the

oil papers or foils may be used. Rubbing of the indivi-

energy required for original production. The melting

dual sheets against each other MUST be avoided.

process can be repeated as often as required with no


loss of the intrinsic properties and performance of the

Care must be taken to ensure that Kalzip Facade

metal. Aluminium constructions, therefore, contain an

Systems are transported and stored in dry and venti-

ever-increasing proportion of recycled material. Today,

lated conditions. Open transport in changeable weather

all aluminium scrap from construction is supplied to the

is to be avoided. Storage must be carried out in such

recycling process.

a way that formation of condensation within the stacks


is avoided. Storage is to be avoided in damp and warm

The relatively high strength of Kalzip allows important

rooms or where frequent temperature changes occur.

structural requirements such as room surround, weather

Building site stores must covered and ventilated.

protection and retaining value to be fulfilled at compara-

Walking on the stacks without sufficient protection of

tively low material cost. This conservation of resources

the surface must be avoided. The protective foil must

corresponds to one of the most important ecological

be left on and then removed immediately after installation.

demands.
Mechanical damage of the surface causes optical impairment but does not initiate corrosion processes in the

4.3 Static proof

aluminium. Every chemical attack on the surface leads


to visible changes and therefore accumulations of dirt

Because the use of Kalzip Facade Systems as wall

must not be treated with abrasive or caustic substances.

cladding is subject to the requirements of the buildings

Unloading at the building site is to be carried out with

regulations law, the proof of stability and fitness for

appropriate lifting gear.

use has to be furnished for the profile sheets and their


connections in each individual case.

4.5 Sheet metal thicknesses


For this the table printed in section 6 is to be used. It
is based on the calculated determination of the load

The sheet metal thicknesses of the Kalzip facade

bearing values according to DIN 18897 and is officially

profile sheets are 1.0 and 1.2 mm. The load bearing

tested as type static.

values are determined according to DIN 18807.

11

Kalzip Facade Systems

4.6 Thermal protection

4.8 Air tightness of the building envelope

The required proof for thermal and moisture protection

Avoidance of heat loss due to air flow is important.

must be furnished, taking the interaction of all building

For this an air barrier, which must be taken into

materials and structural components into consideration,

consideration at the planning stage, must be designed

according to the current rules and regulations in

and installed.

Germany (DIN 4108, DIN 18807, DIN 18516, Energy


Buildings are to be erected in such a way that the

saving regulation).

heat transferring surround surface, including the joints,


Due to the thermal conductivity of metals, the profile

is permanently impermeable to air in accordance with

sheets and their connections make no contribution to

the state of the art. Any existing joints in walls made

the heat insulation effect of the wall construction. This

of concrete, cellular concrete or walling must be sealed,

depends essentially on the layer construction and the

before fitting the substructure for the facade profile

insulation materials used. Existing thermal bridges

sheets.

must be taken into consideration.


If the load bearing wall consists of trapezoidal sheets,
According to DIN 18516 only such heat insulation

then either their joints are to be sealed (inserting

materials must be used, which can be exposed to

sealing tapes into the longitudinal and transverse

moisture influence, without their volume stability and

joints or pasting over in case of obtuse transverse

insulating ability being essentially impaired. They

joints) or a vapour thermal barrier has to be applied

are to be installed permanently, without gaps, and

to act as an air barrier (Bonding of the overlaps on

be dimensionally stable.

the flanges of the trapezoidal profiles, or on inserted


sheet metal strips, close connections to the structure
and other construction parts, particularly in the case

4.7 Moisture protection/


ventilation at rear

of penetrations, windows, doors etc.).


When using cassettes as a load bearing wall, their

For effective ventilation to the rear of external wall

longitudinal joints are to a sealed by inserting sealing

cladding, the following prerequisites are to be fulfilled

tapes and (obtuse) transverse joints are either to be

(if more precise proof is not furnished):

sealed by pasting over the joints from inside the


cassettes or by inserting of sealing tapes between

- The ventilation space is to be arranged immediately


behind the facade profile sheets.
- The gap between the inner surface of the facade
profile sheets and the internal wall or the insulation

the broad cassette flange and the bearing supports.


In the case of refurbishment of existing buildings, the
disposition of the level impermeable to air must be
separately assessed.

material lying behind it should be at least 20 mm.


- The total cross-section of the ventilation space must
be at least 200 cm2/m (i.e. for a load span of 1 m the

4.9 Fire protection

gap must be at least 2 cm wide).


- Even for a non-vertical arrangement of the

Requirements regarding fire protection of building

substructure, the total cross-section of the ventilation

materials, building elements etc. are defined in the

space must be adhered to.

official building regulations. Aluminium alloys are in

- The ventilation and exhaust vents at the base of the

accordance with DIN 4102-4 without proof, building

building and at the roof edge must have minimum

materials of the classification A1 (not flammable).

cross-sections of 50 cm /m each.
2

- If protective grids or perforated plates are installed,


the above requirements relate to the free crosssection.

12

Kalzip Facade Systems

4.10 Lightning protection


Lightning protection is a necessary protection to preventing

In addition, in terms of design, the length tolerances

damage to buildings and injury to persons. Metal facades,

arising from the manufacture of the profile sheets are

contrary to the widely held view, do not attract lightning

to be taken into consideration. For these reasons,

flashes. The conductive facade of Kalzip facade sheets

on pilaster strips, window embrasures, door frames

can serve, in case of a lightning strike, according to DIN EN

or the like, for the recommended sheet length of 6 m,

V 61024-1 both as lightning arrester (if melting is permitted)

a minimum distance of the profile sheet ends to the

and also path to earth, provided that the profile sheets are

other building elements of 5 mm is to be provided.

conductively connected (e.g. screwed to each other or to a


metal substructure) and are connected at a distance of less
than 10 m to an earth conductor.

4.12 Tolerances

For building heights up to 60 m the amperages of the

For the profile sheets the tolerances, having also to be

lightning flashes which may hit the facades are too low

adhered to on the finished building, are determined in

to cause damage to the profile sheets. Even in a building

DIN 18807. If higher demands are made on the building

with an external lightning protection system installed

construction, these values may be too large, e.g. in case

according to standard it is possible that due to the

of clearly visible pilaster strips or shadow joints. According

induced electromagnetic field in the interior, owing to

to standard, a 6 m long facade profile sheet may be 20 mm

the flash current flowing away on the outside, electronic

longer or 5 mm shorter than the nominal dimension,

installations (e.g. communications, or process control)

in addition from the permitted deviation from the right

can be damaged or destroyed. The most practical and

angle, an offset of 4 mm to the adjacent sheet metal

economic protective measure is screening. By this

(triangular toothing) is possible.

means the flash current is distributed over as many


conduction paths as possible. With an appropriate design

Both phenomena may be more or less clearly visible

specification, the profile sheets can be used as a screen.

depending on the distance of the viewer and the bright-

Details must be discussed with a specialist company for

ness or colour of the background.

lighting protection technology.


Kalzip facade profile sheets are used in prestigious
building constructions. Where required, it is possible to

4.11 Temperature-dependent change


of length

manufacture the profile sheets on request and according


to tighter tolerances. These measures, however, require
additional input during both manufacture and inspection

Temperature-dependent changes of length are to be taken

leading to higher costs. Therefore, the aspects mentioned

into consideration. The thermal coefficient of the expansion

below should be considered:

of aluminium in the considered temperature range is


approx. 24 x 10-6/K. For an assumed temperature of

It is recommended to agree the tolerances between the

20C during installation of the profile sheets, in the

installer and the supplier.

summer (+ 80C) an extension of approx. 1.5 mm/m

For the installer it is particularly important,

sheet length and in the winter (- 20C) a shortening of

- to thoroughly check the substructure prior to fitting,

approx. 1 mm/m sheet length results. However, as the

- to report reservations, if their deviations from the

adjacent building elements are also exposed to tempe-

basic size are too great,

rature fluctuations and the substructures as a rule are

- to have necessary compensation measures for the

able to absorb deformations, from a building practice

correction of the substructure carried out by the

point of view, a motion tolerance of 0.5 mm/m sheet


length may be assumed. If these prerequisites are not

previous trades, before starting with the fitting,


- to claim additional costs from the start, if he carries

met, one must calculate in line with the maximum

out the compensation measures himself or installs

values stated above.

adjustable substructures.

13

Kalzip Facade Systems

Right:
CMT Zeiss Oberkochen (D)
Architect:
SIAT Bauplanung und
Ingenieurleistungen GmbH

5. Design notes
5.1 Substructure made of
concrete, brickwork
The Kalzip Facade System offers extensive design

They may consist of short or long rails and have the ability

possibilities for aesthetic/technical architecture. At the

to compensate for the inaccuracies of the external wall

same time it offers a truly economic solution because

materials such as concrete or brickwork. This frame and

the low dead weight leads to considerable cost savings

spacer section system must have correspondingly low

with regard to the substructure.

tolerances, in order to permit a construction free of tension


and dents on the outer shell. Attention must be paid to

For the substructure, generally multi-part, adjustable

the fulfilment of the requirements of DIN 18516 regarding

sections made of steel or aluminium are used.

materials and corrosion resistance characteristics.

14

Kalzip Facade Systems

Right:
Industrial hall Marxer Friedberg (D)
Architect: Dieter W. Hoppstaedter
Page 16:
Storage Electro Helfrich Viernheim (D)
Architects: Fischer Architekten, Viernheim
Page 17:
Kalzip TF 800 R system components

5.2 Substructure made of cassettes,


trapezoidal profile sheets, posts/frames
Steel cassettes

Trapezoidal sheets

This space surround is frequently employed in industrial

The fitting onto trapezoidal sheets is a typical refurbish-

construction. By selecting the cassette depth (= max.

ment situation. Horizontal hat section are screwed onto

thickness of the insulation material) and the appropriate

the existing external wall profiles. This is followed by the

insulation material it is possible to achieve the required

fastening of a vertical multi-part and adjustable frame

insulating effect. At close intervals, the cassettes are

and spacer construction made of cold-formed steel

braced by vertical running frames (e.g. flat steel) for

profiles.

static conditions.
Post and frame system
Subsequently the fastening of multi-part, adjustable

With this variant, lie lateral U-sections between the

sections made of steel and aluminium allows for the

structural supports on which wall frames with angle

compensation of inaccuracies and variable tolerances.

profiles are fitted vertically.

Following this, the Kalzip Facade System can be fitted

free of tension and dents.

15

Kalzip Facade Systems

5.3 Intermediate construction


for cassettes
Vertical spacer sections made of steel or aluminium
are required between the horizontally laid Kalzip
facade profile sheets and also horizontal cassettes
as a substructure for the Kalzip facade profile sheets
and as bracing for the small flanges and webs of the
cassette. Therefore, their intervals are determined by
both criteria. If the permissible load spans of Kalzip
facade profile sheets are greater than the permissible
intervals of the cassette bracings, further spacer
sections must be installed, if the load spans of the
cassettes are to be fully utilised. The spacer sections
are to be connected to other fixed points, e.g. base
rail or eaves frame. If flat steels or sheet metal strips
are used as spacer sections, they have to be connected to fixed points at both ends.

Kalzip Facade Systems

6. Kalzip Facade System TF 800 R


6.1 System components
The system is suitable only for horizontal or slightly

The use of irius SX-L12-A10-5.5xL screws produced

inclined installation on the faade elevation. Profiles

by SFS intec, is recommended. Then the maximum

for outside corners, pilaster strips, inside corners and

possible load spans can be taken from the type-tested

intrados (reveals) are available as system components.

design tables in section 6. The installation instructions


of the connection element manufacturer are to be
adhered to, e.g. the essential use of a bit stop.

6.2 Connections
For connecting the profile sheets with the substructure

6.3 Construction detail inside, outside

all building regulations approved screws and blind rivets


may be used which are judged suitable for this applica-

All subsequent detail cross-sections can also be

tion. In doing so, their intervals are determined by statical

obtained from Corus on CD-ROM.

requirements.

Kalzip TF 800 R system components


Dimensions

maximum profile length 6000mm

Kalzip outside corner profile A-S2

Kalzip joining detail L-S2

Kalzip inside corner profile I-S1

Kalzip reveal profile LA-S2

Kalzip outside corner profile A-S1

Kalzip reveal profile LA-S1

Kalzip joining detail L-S1

Kalzip F profile F-S1

17

Kalzip Facade Systems

6.4 Construction detail: Pilaster strips

Continuous L-profile
Bracket
Thermal insulation

Continuous L-profile
Bracket
Thermal insulation
Thermal barrier pad

Kalzip profile sheet TF 800 R


Pilaster strip profile outer corner

Box section

Kalzip profile sheet TF 800 R


Outer corner profile TF

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Outer corner with outer corner profile TF

Outer corner with flashing

Thermal barrier pad


Bracket
Continuous L-profile
Thermal insulation

Thermal barrier pad


Bracket
Continuous L-profile
Thermal insulation

Kalzip profile sheet TF 800 R


Internal angle

Inner corner profile TF


Kalzip profile sheet TF 800 R
Cornered
flashing

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Inner corner with inner corner profile TF

Inner corner with flashing

18

Diagonal
flashing

Kalzip Facade Systems

Thermal barrier pad


Bracket
Continuous T-profile
Thermal insulation

Thermal barrier pad


Bracket
Continuous T-profile
Thermal insulation

Kalzip profile sheet TF 800 R

Kalzip profile sheet TF 800 R

Pilaster strip flashing

Pilaster strip profile TF


Top heat section
as a pilaster strip

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Lap joint with pilaster strip TF

Lap joint with flashing

Thermal barrier pad


Bracket
Continuous L-profile
Thermal insulation

Kalzip profile sheet TF 800 R

No rivets due to longitudinal extension

Kalzip Facade System TF 800 R


Lap joint with thermal extension possibility

19

Kalzip Facade Systems

6.5 Construction detail: Window (top, side, window sill)

Window sill
Retainer angle
Perforated sheet

Thermal insulation border

Final flashing sheet

Thermal barrier pad


Bracket
Thermal insulation

Self adhesive tape


F-profile
Window framing profile sheet
Window framing profile TF

Thermal barrier pad


Bracket
Thermal insulation

Continuous support element


Kalzip profile sheet TF 800 R

Front edge window sill


Continuous L-profil
Kalzip profile sheet TF 800 R

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Window sill

Window jamb with framing profile TF

Thermal insulation border


Thermal insulation border

Bracket

Bracket

Thermal barrier pad

Thermal barrier pad

Thermal insulation

Thermal insulation

Self adhesive tape

Self adhesive tape


F-profile
Window framing profile sheet

F-Profile
Window framing profile sheet

Front edge window sill

Front edge window sill


Kalzip profile sheet TF 800 R
Continuous T-profile

Continuous L-profile
Kalzip profile sheet TF 800 R

Pilaster strip profile TF

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Window jamb with pilaster strip TF

Window frame with flashing

20

Kalzip Facade Systems

6.6 Construction detail: Door (top, side)


Kalzip profile sheet TF 800 R
Continuous support element
Bracket
Thermal insulation
Thermal barrier pad

Kalzip profile sheet TF 800 R


Continuous support element
Bracket
Thermal insulation

Window framing profile TF


Perforated sheet

Thermal insulation border


F-profile

Slanted window
framing profile

Self adhesive tape

Window framing profile


Perforated sheet

Thermal insulation border


F-profile
Self adhesive tape

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Lintel with window framing profile TF

Lintel with flashing

6.7 Construction detail: Wall connection


(top, bottom, bracing angle(s), drip tray)
Kalzip profile sheet TF 800 R
Kalzip profile sheet TF 800 R

Continuous support element

Continuous support element

Bracket

Bracket

Thermal insulation

Thermal insulation

Thermal barrier pad

Thermal barrier pad

Window framing profile


Perforated sheet

Thermal insulation border


Base sheet

Slanted window
framing profile
Window framing profile
Perforated sheet

Thermal insulation border


Base sheet

Observe required ventilation area according to national standards

Kalzip Facade System TF 800 R

Kalzip Facade System TF 800 R

Base with framing profile TF

Base with flashing

21

Kalzip Facade Systems

6.8 Load spans Kalzip TF 800 R


Load bearing capacity of Kalzip TF 800 R

22

Kalzip Facade Systems

Translation of the official test report No. 1-08/01 produced in Germany


Kalzip TF 800
Aluminium trapezoidal profile
Cross section and diaphragm action values according to DIN 18807, part 6
Trapezoidal sheeting in buildings / structural engineering (Aluminium trapezoidal profiles and their
connections: Determination of the load bearing capacity values by calculation)
Profile sheets in positive position
Measurements in mm

Enclosure 1
Tested as type-design table
tested in terms of static
see test report No. 1-08/01*
with validity until: 30.04.2006
Darmstadt: 07.02.2002
Examining Office for structural
analysis of the Land of Hessen
*and amendment notification
dated 07.02.2002

Radius R = 3 mm
Nominal value of yield strength at 0.2% proof stress: Rp0,2 = 185 N/mm2
Cross-section properties
Thickness
of sheet
metal

Dead
weight

Normal force

Moment of inertia 1)

non-reduced cross-section

t
mm

g
kN/m2

l +ef
cm4/m

l efcm4/m

1.0
1.2

0.0405
0.0486

17.96
21.56

13.45
16.69

Ag
cm2/m

ig
cm

zg
cm

Limit spans 3)

effective cross-section 2)

Aef
cm2/m

ief
cm

singlecontinuous
span beam
beam

zef
cm

lgr
m

lgr
m

Shear field values


T3,k = GS /750 [kN/m]
GS = 104/(k/1+k/2/LS)
t
mm

1)
2)
3)
4)

5)

6)

LS
m

4)

T1,k
kN/m
4)

k/1
m/kN

k/2
m2/kN

k*1 5)
kN

-1

k*2 5)
m2/kN

k3 6)
-

Effective moments of inertia for downward load direction (+) or upward (-).
Effective cross-section for a constant compressive stress = Rp0,2
Maximum spans, up to which the trapezoidal profile may be walked on without load distributing measures.
For single spans LSi LR T1,k may be taken from the table or increased with (L R/LSi)2;
for LSi > LR T1,k (LR/LSi)2 must be reduced. For single-span beams T1,k = 2 x table value.
If necessary, the total deformation of a diaphragm may be determined as follows:
f=[ ( k/1+k*1 e L ) + ( k/2+k*2 ) /LS ]10-1avorhT (existing T)
with eL = Distance of the connection in the longitudinal joint in m
a = Diaphragm width in m, vertical to the profile direction
T = Existing diaphragm in kN/m
Tx k3+A RA,k/M with T= F-times shear action.

State: 04 February 2002

23

Kalzip Facade Systems

Load bearing capacity of Kalzip TF 800 R

24

Kalzip Facade Systems

Translation of the official test report No. 1-08/01 produced in Germany


Aluminium trapezoidal profile sheet

Kalzip TF 800

Enclosure 2
Tested as type-design table tested in terms of static
see test report No. 1-08/01*
with validity until: 30.04.2006
Darmstadt: 07.02.2002
Examining Office for structural analysis of the
Land of Hessen
*and amendment notification dated 07.02.2002

Characteristic load bearing capacity according to DIN 18807, part 6

Profile sheets in positive position

Load bearing values for downward loading 1)


As partial safety coefficient is to be set M = 1.1.
Thickness
of sheet
metal

Field
moment

t
mm

MF,k
kNm/m

End
support
reaction

Combined bending moment and support reaction at intermediate supports

0
MB,k
kN/m

RA,k
kN/m
bA= 40
mm 2)

1.0
1.2

1.196
1.454

7.34
10.8

0
RB,k
kN/m

Max.
support
moment

Max.
support force
reaction

max MB,k
kNm/m

max RB,k
kN/m

Intermediate bearing (support) width


bB 0 mm, = 2
1.039
1.284

13.17
19.31

1.039
1.284

0
MB,k
kNm/m

R0B,k
kN/m

5)

Max.
support
moment

Max.
support force
reaction

max MB,k
kNm/m

max RB,k
kN/m

Intermediate bearing (support) width


bB 40 mm, = 2

3)

11.78
17.27

1.039
1.284

16.41
24.07

1.039
1.284

4)

14.68
21.53

Load bearing values for uplift loading 1)


As partial safety coefficient is to be set M= 1.1.
Thickness
of sheet
metal

Field
moment

Connection in each adjacent flange

end
support

1)

2)
3)

4)

5)

t
mm

MF,k
kNm/m

RA,k
kN/m

1.0
1.2

1.039
1.284

28.95
38.49

Intermediate support
0
MB,k
kN/m

0
RB,k
kN/m

Connection in each 2nd adjacent flange

end
support

5)

max MB,k
kNm/m

max Vk
kN/m

RA,k
kN/m

1.196
1.454

28.95
38.49

14.47
19.25

Intermediate support
0
MB,k
kNm/m

0
RB,k
kN/m

5)

max MB,k
kNm/m

max Vk
kN/m

0.598
0.727

14.47
19.24

At the areas of line loads perpendicular to the tension direction and of single loads, the proof is not to be furnished with the field
moment MF,k, but with the moment at support max MB,k for the opposite load direction.
bA = end support width. In case of a profile overhang (projection) > s w/t the RA values may be increased by 20%.
For smaller support widths bB than stated, the absorbable load bearing capacity values must be reduced linear in
the relevant ratio. For bb< 10 mm, e.g. in case of pipes bb = 10 mm may be inserted.
In case of support widths lying between the values stated, the absorbable load bearing capacity values can be
linear interpolated in each case.
Interaction relationship between M and R
Interaction relationship for M and V
M
M
V
+(
+ ( R )2 1
) 1,3
0 /
0 /
max MB,k
RB,k
max MB,k/M max Vk/M
M
M

State: 04 February 2002

25

Kalzip Facade Systems

Load bearing capacity of Kalzip TF 800 R

26

Kalzip Facade Systems

Translation of the load bearing capacity of Kalzip TF 800 R


Aluminium trapezoidal profile sheet

Kalzip TF 800

Enclosure 3
Tested as type-design table tested in terms of static
see test report No. 1-08/01*
with validity until: 30.04.2006
Darmstadt: 07.02.2002
Examining Office for structural analysis of the
Land of Hessen
*and amendment notification dated 07.02.2002

Characteristic load bearing capacity for fasteners DIN 18807, part 6

Profile sheet in positive position

Characeristic tensile force Zk in kN per connection element, dependent on the sheet metal thickness t in mm and
the washer diameter d in mm. 1) 2)
As partial safety value is to be set M= 1.33. Tensile stress: Rm = 220 N/mm2.
Connection

1)

2)

t = 1.00

t = 1.20

t=

d= 10

d= 14

d= 10

d= 14

0.964

1.14

1.16

1.37

d= 10

t=
d= 14

d= 10

d= 14

ZkI = L M E Zk
with
L = Coefficient to take into account of the bending tensile stress in the connected flange according to DIN 18807, part 6.
Table 2 (L = 1.0 in case of fastening at the end support)
M = Coefficient of the material of the sealing washers according to DIN 18807, part 6, table 3.
E = Coefficient of the arrangement of the connections according to DIN 18807, part 6, table 4.
The characteristic tensile force for the connection with the relevant substructure and
for the connection element itself must be taken into consideration.

State: 06 February 2002

27

Kalzip Facade Systems

28

Kalzip Facade Systems

Design tables WALL


Maximum possible load spans in m
According to German DIN 1055, part 4 (wind loading). For a safe rating the national valid standard for wind loading
must be taken into consideration in each case. According to wind load distribution stated below.
Kalzip TF 800

Height of building

Connection in
every 2nd small
lower flange, sealing washer
made of steel 10

Single-span beam

4) 5)

Double-span beam

Triple-span beam

1)

2)

3)
4)
5)

4)

4)

0-8
m

> 8 - 20
m

> 20 - 100
m

t
mm

1.0
1.2

2.34
2.49

3.79
4.22

1.81
2.11

2.00
2.13

3.00
3.33

1.13
1.36

1.80
1.92

2.35
2.83

0.82
0.99

1.0
1.2

3.08
3.34

1.92
2.20

0.72
0.87

2.39
2.71

1.29
1.55

0.45
0.55

2.01
2.29

0.94
1.13

0.33
0.40

1.0
1.2

2.90
3.08

2.11
2.40

0.81
0.93

2.48
2.63

1.47
1.71

0.51
0.62

2.23
2.37

1.07
1.29

0.37
0.45

1)

NB

2)

RB

2) 3)

1)

NB

2)

RB

2) 3)

1)

NB

2)

RB

2) 3)

D: Permissible spans taking the profile load bearing capacity and the deflection limitation
f L/150 for pressing-on loading into consideration. Support widths bA 40 mm, bB 0 mm
Wind suction for walls according to DIN 1055 part 4 (NB = normal area, RB = edge area).
Permissible spans taking the profile load bearing capacity and the load bearing capacity of the connections regarding failure
in the building component pulling through into consideration. The proof of the connection load bearing capacity regarding failure in the
building component (tearing out of the substructure) is also to be furnished. In case of thin-walled unsymmetrical substructures
(Reduction of the connection tensile forces to 70%), the connections are to be proven in the individual case. In order to
simplify matters, the permissible spans may be reduced by 30%.
For connection in every small lower flange, the spans stated in the column Edge area may be doubled.
Design recommendation: Sheet length L 6 m m or special measures provided for absorbing the temperature deformations.
The table applies to single-span beams without overlapping for itself connected with the substructure. If single-span beams are constructed
successively overlapping with a common connection with the substructure, then proof for the connections must be furnished separately.
In order to simplify matters, the load bearing width may be halved or, if possible from a design point of view, the number of connection
elements doubled.
State: 04 February 2002

Type-design table prooved in terms of static see test report No. 1-08/01*
with validity until: 30.04.2006
Darmstadt: 07.02.2002
Examining Office for structural analysis of the Land of Hessen
*and amendment notification dated 07.02.2002

- 0,5
Height of building
0-

Wind pressure

8m

q = 0,5 kN/m2

> 8 - 20 m

q = 0,8 kN/m2

> 20 - 100 m

q = 1,1 kN/m2

- 0,7
- 2,0

- 0,7
Load coefficents cp:
Wind loading: w = q cp
- 2,0
0,8

29

Kalzip Facade Systems

6.9 Screw arrangement


Structural module 6 m for height of building 8 - 20 m

Structural module 6 m for height of building 0 - 8 m

Structural module 5 m for height of building 8 - 20 m

Structural module 5 m for height of building 0 - 8 m

M 1:100
Load span widths and screw spacing according to static requirements (see design table)
At the profile sheet ends fastening at every small flange (spacing 267 mm)

30

Kalzip Facade Systems

Index
A
Abrasion
Adjustable profiles
Air barrier
Air tightness
Angle profiles
Anti-Graffiti
Approval
B
Back(ed) butt-joint
Base rail
Base
Basic sizes
Bearing supports
Bit gauge
Blind rivets
Building regulations law
Butt-joint

11
14
12
12
15
5
11

19
16
21
13
12
17
17
11
19

C
Cassette bracings
Cassette flange
Cassette depth
Construction detail inside,
Outside
Construction detail door
Cassettes
Chemicals
Coating processes
Cold-formed steel profiles
Colour deviations
Colour differences
Colours
Concrete
Conductive routes
Connections
Construction detail door
Contact corrosion
Contact zones
Corrosion resistance

17
21
12, 15
10
5
15
5
5
5
10, 14
13
17
21
10
10
10

D
Dead weight
Dent-free construction
Design tables
Det Norske Veritas (DNV)
Detail: Door
Detail: In- & outside corner
Detail: Roof parapet
Detail: Sectional gate
Detail: Window
Dimensions
DIN 18516
DIN 18807
DIN 4102-4
DIN EN ISO 14001
DIN V EV V 61024-1

11
14
17, 28
4
7, 9
7, 9
7, 9
6, 8
6, 8
5
14
11
12
4
13

16
12
15

E
Eaves cross-frame member
16
Ecology
11
Edge part
18, 19, 20, 21

Electrolysis
Electromagnetic field
Energy-saving regulation
Environmental protection Investments
Expansion coefficient

11
13
12
11
13

F
Fire protection
Fixed points
Flanges
Flat steel
Foils
Frame and spacing profile

12
16
16
15
11
14

H
Heat losses
Height of building

12
30

I
Inaccuracies
Inside corner profile
Inside corner
Inside corners
Insulation effect
Insulation material thickness
Intermediate construction
International Safety
Rating System

15
18
18
17
15
15
16

13
13
13
21
11
22
16

M
Material pairing
Material properties
Minimum cross-sections
Moisture influence
Moisture protection
Mortar
Mounting instructions

10
11
12
12
12
10
17

P
Perforated sheet metals
Performance capability
Pilaster strip profile
Pilaster strips
Plastic foils
Porous (cellular) concrete
Post and frame system
Previous trades
Protective grid

R
Recycling
Resource conservation
Reveal profile
Reveals

11
11
20, 21
17

S
Safety Management System
Screening
Screw arrangement
Screws
Sealing tapes
SFS intec
Sheet metal thicknesses
SoftColor
Space surround
Spacing profiles
Stability
Statical analyses
Steel cassettes
Steel
Structural module
Substructure
Surround area
System components

4
13
30
17
12
17
11
5
15
16
11
11
15
10
30
14
12
17

T
Tarpaulins
Temperature fluctuations
Tension and dent-free
Thermal insulation materials
Thermal bridges
Thermal conductivity
Thermal insulation effect
Thermal protection
Titancolor
Tolerances
Top-hat profiles
Transport
Trapezoidal profiles
Triangular toothing
Type static

11
13
15
12
12
12
12
12
5
13
15
11
12, 15
13
11

L
Length change
Lengths tolerances
Lightning protection
Lintel
Load bearing capacity values
Load span widths
Load spans

O
Oil papers
Outside corner
Outside corner profile

Q
Quality Management System

11
18
18

12
11
19
17, 18
10
12
15
13
12

U
U-profiles
Utilization period
V
Vapour barrier
Ventilation and exhaust vents
Ventilation at rear
W
Walling (brickwork)
Weather influences
Webs
Window reveal
Window cill
Windows

15
11

12
12

12, 14
11
16
20
20
20

31

www.kalzip.com
The product information and technical
details contained in this brochure are
accurate, according to our research and
technical programme, at the point of going
to press. They do not refer to any specific
application and cannot give rise to claims
for compensation. We reserve the right to
make any changes to the construction or
product range which seem technically
appropriate, in view of our high standards
for product advancement and development.
Copyright 2003

Corus Bausysteme GmbH


Part of Corus Group plc

Europe:
Poland
A-B Space
Lukasz Lomozik
Ul. Stawowa 31 B
PL-43-250 Pawlowice SI.
Poland
T/F +48 - 324 72 51 10
kalzip@wp.pl

Belgium
Corus Building Systems NV
A. Stocletlaan 87
B-2570 Duffel
Belgium
T +32 - 15 30 29 21
F +32 - 15 30 29 20
cbsbe@corusgroup.com

Portugal
Corus Sistemas
Constructivos Lda.
Av. dos Combatentes 76
Abrunheira
P-2710-034 Sintra
Portugal
T +35 - 12 19 15 88 00
F +35 - 12 19 15 88 09
info@corusportugal.com

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Pallouriotissa
P.O. Box 9078
CY-1621 Nicosia
Cyprus
T +35 - 722 79 35 20
F +35 - 722 43 15 34
phanos@epiphaniou.com
Czech Republic and Slovakia
Engineering Office
Eva Sanovcov
Cejl 20
CZ-60200 Brno
Czech Republic
T +42 - 05 45 11 74 40
F +42 - 05 45 11 74 55
kalzip@ok.cz
Denmark
A.E. Stlmontage a/s
P.O. Box 70
Hagensvej 54
DK-9530 Stvring
Denmark
T +45 - 96 86 87 20
F +45 - 98 37 32 79
ae@kal-zip.dk
France
Corus Building Systems SAS
8, Avenue Desclers
B.P. 20
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France
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F +33 - 1 64 03 98 55
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Corus Bausysteme GmbH


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P.O. Box 10 03 16
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T +49 (0) 2 61 - 98 34-0
F +49 (0) 2 61 - 98 34-100
kalzip@corusgroup.com
English

Overseas: Near East

Austria
Corus Bausysteme sterreich
Honauerstrae 2
A-4020 Linz
Austria
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F +43 (0) 70 78 61 15
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Greece
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82 Grammou Str.
GR-18345 Moschato
Greece
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F +30 - 21 09 41 24 65
fanos@otenet.gr
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Postbus 46
NL-3140 AA Maassluis
The Netherlands
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F +31 - 105 91 51 25
info@hafkon.nl

Lebanon
Naggiar Agencies SCS
P.O. Box 175415 Beirut
Negib Hobeika Street
LB-Saifi-Beirut 20296406
Lebanon
T +961 - 1 56 26 52
F +961 - 1 44 83 91
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www.naggiar.com.lb
Overseas: Middle East
Dubai
Corus Building Systems
P.O. Box 9217
UAE-Dubai
United Arab Emirates
T +971 - 43 38 85 86
F +971 - 43 38 99 70
azad@corusmiddleeast.com

Scandinavia
Corus Bygge Systemer A/S
Kaarsbergsvej 2
Postbox 136
DK-8440 Ebeltoft
Denmark
T +45 - 89 53 20 00
F +45 - 89 53 20 01
mail@corusgroup.com
Spain
Corus Sistemas
Constructivos S.L.U.
Avda. Aragn no 4 - Bajo
Poligono Industrial
Puebla de Farnals
E-46139 Puebla de Farnals
Valencia Espaa
T +34 (9) 61 45 23 40
F +34 (9) 61 45 21 11
kalzip.spain@corusgroup.com
Switzerland
Bro Dach & Wand,
Jrg Senteler
P.O. Box 247
CH-7302 Landquart
Switzerland
T +41 (0) 81 3 22 38 38
F +41 (0) 81 3 22 38 39
info@kalzip.ch
Turkey
Tr Group
Architectural Materials
Mahmut Sk. No: 8
81200 Kosuyolo-Istanbul
TR-Turkey
T +90 - 216 327 4720
F +90 - 216 327 4724
sahikakutsal@tur-group.com
United Kingdom and Ireland
Corus Building Systems
Haydock Lane, Haydock
GB-St. Helens, Merseyside
WA11 9TY
United Kingdom
T +44 - 19 42 29 55 00
F +44 - 19 42 27 21 36
kalzip-uk@corusgroup.com

Kuwait
Ali Alghanim & Sons
Trading & Contracting
Group Co. W.L.L.
P.O. Box 21540
KT-Safat 13076
Kuwait
T +965 - 4 84 22 23
F +965 - 4 84 18 12
Overseas: Far East
China
Corus Building Systems
Guangzhou Representative Office
Suite 1208, West Tower
Yangcheng International
Commercial Centre
Tianhe Ti Yu Dong Road
Guangzhou
P.R. China 510620
T +86 - 20 38 87 01 90/91
F +86 - 20 38 87 02 65
Hong Kong
Corus Building Systems
6/F Jardine Engineering House
260 Kings Road North Point
Hong Kong
T +852 - 28 07 01 96
F +852 - 22 34 67 39
Singapore
Corus Building Systems Pte. Ltd.
41 Gul Circle
Singapore 629576
T +65 - 67 68 90 87
F +65 - 68 98 93 74
sales@corus.com.sg
www.corus.com.sg

adhoc media gmbh:1202:GB:10/2003

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