Kalzip sets standards

Architectural highlights
 ®

Kalzip – vorbildlich und richtungsweisend

CONTENTS

Lightweight and environmentally

friendly 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

East Terminal, Frankfurt on Main (D), 1993. Solar cell factory Gelsenkirchen of Deutsche Shell AG
Kalzip® special grey colour, partly barrel-vaulted. (D), 1999. Kalzip® stucco embossed. Architects:
Architects: JSK Perkins & Partner, Frankfurt. Dipl.-Ing. Uwe Hohaus & Partner, Hamburg. 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
Oberhausen Arena (D), 1996. H10 Airbus Hangar, Toulouse/Blagnac Airport (F),1991.
Kalzip® stucco embossed and RAL 8004 Polyester. Kalzip® stucco embossed. Excellent for renovation 26-28
Architects: DLA-Ellerbe Becket, Wakefield (UK). Architects: M. Laborie, Toulouse.
Manufacturing on-site 29

Saves resources 30

Leisure and recreation centre Magdeburg (D), 1999.
Kalzip® stucco embossed, tapered and pre-curved.
Architects: Edenne von der Brelie, Hryniewicki &
Partner, Paris; Roschke & Partner, Hamburg;
Dipl.-Ing. H. Baas & J. Schulte, Hamburg.
Geesthacht College (D), 1995 (see also cover
photograph). Kalzip® RAL 9006, partly tapered.
Architects: Höchel Engelken + Partner · Beinhoff,
Buxtehude.

2
Architektur ganz oben
Yesterday - just a vision. Today Kalzip®.
Millenium Stadion Cardiff (GB), 1999. Kalzip® stucco embossed. Architects: Hok & Cobb Sports Architecture.
A new architectural dimension
There are visionaries amongst our
customers. We complement them with
technical collaboration. The result are
buildings which set the standard and lead
the way in terms of shape and function.
High demands for safety and quality of
construction merge into a new architectur-
al dimension – as demanding, functional
and 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.
3
It is non-flammable, conducts heat and
electricity, is non-toxic, can be recycled
and used again.
Kalzip® is the product
The result is something which is often
exceptional and unique in its technology.
We admire the creativity and far-sighted
planning of our customers. We appreci-
ate the confidence placed in us as
manufacturers and reciprocate by
providing corresponding products and
services. It is our aim to unburden the
Retractable roofing construction with Kalzip®
designer, leaving him free to concentrate stucco embossed sheets.
on what is important – the room
for the essential.
Leicht und umweltgerecht
The environmental friendly building envelope with a lightweight
structure. That’s Kalzip®.
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.
Lightweight structure using Kalzip® Saving energy and resources by utilising
re-usable building materials in light-
The lightweight Kalzip® roof structure
weight structures are important factors
can easily bridge large spans, even with
when planning building work. Kalzip®
curved lines.
does this very simply. Because it is light
Kalzip® is a well-proven, environmentally weight, only 3-5 kg/m2, the amount of
friendly building system: lightweight, material used in the supporting structure
strong, weather-proof, can be precisely is reduced, thus saving resources.
adapted and is flexible in shape. What’s
Installing large sheets instead of layers
more, it is ideal for combining with other
of small components saves time. High
building materials such as those used in
costs on-site are replaced by more
the roof build-up which create what we
efficient industrial production techniques.
consider indispensible, comfort and safety.
Living in harmony with nature – that is
both our aim and our challenge.
4
Flexibel in der Formgebung
You conceive the designs. We supply the protective shell.
Conference Centre, SECC, Glasgow (GB), 1997. Kalzip® stucco embossed. Architects: Foster & Partners, London.
Your imagination is our challenge
Every day, we work for innovative
building shapes. So every day we rise to
new challenges. The result is often more
than just a building shell in the normal
sense because, with Kalzip®, there
are many buildings which have a strong
visual impact.
A multitude of shapes and colours
can be used
Kalzip® is flexible and can be adapted
to suit the requirements of progressive
architects, both in terms of building
geometry and size. Planning details are
computer-controlled and transferred to
production using CAD/CAM systems.
Dimensional accuracy of manufacture
guarantees the maximum precision and
consequently, fast, trouble-free
installation.
Raab Tennis Hall, Fischbach (D), 1993.
As experienced advisers, we can give Kalzip® RAL 6033, partly smooth curved and tapered.
you all the support you need – right from Architects: Ing. Büro Uwe Erbach, Illingen.
the early planning stages.
6
Congress Palace Valencia (E), 1998. Kalzip® stucco embossed and curved. Architects: Foster & Partners, London (GB).

Creativity Centre of shoe factory Rohde, Schwalmstadt Hot springs Xanten (D), 1999. Kalzip® coralred poly coated. Architects: IPP Ingenieurbüro für Bauwesen,
(D), 1999. Kalzip® stucco embossed, factory curved Prof. Dr. Ing. Polony u. Partner, Köln.
incorporating 3 different radii. Architects and overall
planers: Koschany, Zimmer & Assozierte, Essen.

7
Funktionell im Baukastenprinzip

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

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’s
Kalzip®.
The Kalzip® system offers proven
accessories:

• For roof openings

• Complementery items for verge,
ridge and eaves areas
• Translucent elements including
accessories
• Soakers
• Cover strips
• Seam clips
• Specially made components, e.g. for
walkways, solar equipment etc.
Kalzip® is a building system which has
been continually developed over more
than three decades. All components
complement each other both – functionally
and visually.
This allows the user to ensure that he has
made the right decision.

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

Audi Development Centre, Ingolstadt (D), 1987. Primary school Hille (D), 1999. Kalzip® stucco embossed, tapered. Architects: Brinkmeier, Kraus, Stanczus,
Kalzip® stucco embossed, smooth curved. Lübbecke.
Architects: Henn + Henn, München.

8
Westbad München, Munich (D), 1999. Kalzip® stucco embossed and tapered. Architects: Reichert-Pranschke-Maluche, München.

Administration Building, Corus Bausysteme, Koblenz (D). Extension 1996. Airport Office Centre, Munich Riem Airport (D), 1988.
Kalzip® stucco embossed, smooth curved. Group of architects: Voss, Naujack, von Canal, Koblenz. Kalzip® stucco embossed, smooth curved.
Architects: Mühlmeier + Scheller, München.

9
 Durchdacht im System

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

Kalzip® – the complete solution Lightweight and quick to install Durable, maintenance-free

3 Special aluminium clips have to be used In its standard form, Kalzip® has a
for joining the Kalzip® profiled sheets with stucco embossed finish with a protective
4
the substructure of the roof. They are plating on both sides.
5
locked into the seam and will be over-
This helps to make the material
6
lapped by the following Kalzip®
impervious to external influences.
element, so that the fixing elements are
hidden under the roofing. This ensures Plating
A typical Kalzip® roof structure: that the roofing elements need not to be
punctured for fastening.
1 Kalzip® profiled sheet 4 Thermal barrier pad
2 Kalzip® aluminium 5 Vapour control barrier
‘secret fix’ clip and air-lock layer
3 Thermal-insulation 6 Trapezoidal sheet
(compressible)
Core material

Kalzip is a flexible, weather-proof,

®

easy-to-install system made of aluminium Rolled on both sides, Kalzip® protective

profiled sheets and well co-ordinated plating increases the strength and
accessories. service-life of the building’s aluminium
shell. Colour coating fulfills a purely
Installed using the modular design princi- visual function.
ple, Kalzip® is the complete solution for
The newly developed sliding clip even Kalzip® meets current-day
high quality shape and function –
improves the as such excellent sliding requirements in a special way:
throughout the building’s entire life.
properties of the Kalzip® roofing.
Physical construction aspects such as • Lightweight
sound-proofing, heat-insulation and • Great strength
moisture-protection, as well as climatic • Resistance
and health requirements, are taken into • Corrosion-proof
consideration in the layers of the roof
• Practically maintenance-free
structure.
• Resistant to atmospheric effects
If produced on site the lightweight sheets • Flexible shape
can be supplied in lengths of 80 metres • Non combustible
and more and allow a particularly fast and
• Can be used as lightning conductor
economical installation.
The mechanical zipping of the seams
• Can be re-usable
produces a load bearing connection. • High quality material
Vapor diffusion, however, is still possible • Can be recycled
in this area enableing residual moisture • Can be re-used, maintaining full
to evaporate after the installation. functional quality

10
Variabel in Farbe und Oberfläche

You decide how it looks.

Storage unit for high-bay warehouse M-Preis, Völs (A) 2000/2001, Kalzip AluPlusZinc®. Architects: Heinz, Mathol & Streli ZT Innsbruck (A).

Kalzip AluPlusZinc® – symbiosis The fusing of the two well matching

of two well-established, timeless
materials
Kalzip AluPlusZinc® is a fine, technically
demanding product manufactured by
Corus Bausysteme GmbH featuring a
matt zinc patinated surface. The timeless
aesthetic character of the pre-zinc patina
weathered opens a wide field of applica-
tion for prestigious buildings – especially
in cities, where integration is required
and where a high quality appearance
and a harmonic design are fundamental
features. The patina on both sides of the
profiled sheets develops its appearance
under external influences – it is alive.
Klazip AluPlusZinc® is a suitable
cladding for roofs and walls of new
buildings and for the refurbishment of
existing structures as well.
materials aluminium and zinc is effected
in a patented process (PEGAL). Com-
bined with the industrial production and
our strict rules of quality management
this process leads to a new product
setting new standards. The well-known,
world-wide appreciated advantages of
our aluminium building system are of
course guaranteed with Kalzip
AluPlusZinc® as well.
Colour finishes have become
increasingly popular for Kalzip®
over the last decade
Oberhausen Arena (D), 1996. Kalzip® stucco
You decide whether to use RAL or a
embossed and RAL 8004 Poly.
special colour shade. We do the rest. Architects: DLA-Ellerbe Becket, Wakefield (UK).
For Kalzip®, we only use high-quality,
weather-proof paint systems. You can
choose between a polyester- or PVdF-
based paint. Ask for the Kalzip®
colour chart.

11
Bewährt im technischen Aufbau

Also safe to construct.

Kalzip profiled sheet

Thermal-insulation (compressible)

Kalzip aluminium ‘secret fix’ clip with

thermal barrier pad

Vapour control barrier and air-lock layer

Trapezoidal sheet

Kalzip®
truss roof Truss
construction

Kalzip profiled sheet

Thermal-insulation (compressible)

Kalzip aluminium ‘secret fix’ clip with

thermal barrier pad
Top hat section

Vapour control barrier and air-lock layer

Trapezoidal sheet
Kalzip®
purlin roof Purlin
construction

Kalzip profiled sheet

Thermal-insulation (compressible)
®

Kalzip aluminium ‘secret fix’ clip with

thermal barrier pad

Timber support

Vapour control and air-lock layer

Kalzip® Wooden supporting substructure

rafter roof
construction
Rafter

12
 Überzeugend als Ganzes

A building system with no "ifs and buts”.

Kalzip® truss roof construction Kalzip® is convincing because:

1

It offers unlimited possibilities, high quality construction and flexibility

2
• As a ventilated and non-ventilated roof design, it is suitable for all roof shapes and pitches
from 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 clients
3

whatever the building’s basic shape, geometry or size.

4
• Its light weight makes it particularly suitable for renovating old roofs. Kalzip® AF and
"Rockwool Prodach” insulation systems are particularly suitable for renovating corrugated
5 asbestos 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 surface
which is appreciated by knowledgeable experts.
6
• 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 and
Kalzip® purlin roof construction its fine appearance.
1 • 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 base
metal aluminium again and again opens new design aspects.
2

3
Excellent construction qualities
• High thermal-insulation requirements can be easily fulfilled. The roof structure can be easily
adapted to suit the building’s exact requirements by selecting the appropriate thickness of
7
insulation material.
4
• The construction makes high-quality sound-proofing easy and simple.
5

Durable and economic

• Corrosion-resistant aluminium alloy.
8 • Increased resistance against acid rain and industrial emissions due to the protective
plating 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 prevailing
weather conditions – ergonomic and cost saving due to prefabricated components.
Kalzip® rafter roof construction
Extremely safe throughout its entire life
• Special aluminium clips have to be used for joining the Kalzip
1 ®
profiled sheets with the
substructure of the roof. They are locked into the seam and will be overlapped by the
2
following Kalzip® element, so that the fixing elements are hidden under the roofing.
3 • 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 to
evaporate 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.
9

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

10
Excellent ecological characteristics
• Aluminium, combined with other elements, is the third most common element in the earth’s
11 crust 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.
®

1 Kalzip profiled sheet

®
7 Top hat section • Recycled aluminium material can be re-used again for the manufacture of other products.
2 Kalzip® aluminium 8 Purlin The aluminium’s beneficial properties remain intact.
‘secret fix’ clip with
thermal barrier pad
9 Timber support and • Only 5 % of the original manufacturing power is required for recycling.
3 Thermal-insulation
thermal-insulation • An insulated Kalzip roof contributes significantly to reducing air pollution and so to
®

4 Vapour control and

10 Wooden supporting preserving our environment.
air-lock layer substructure
5 Trapezoidal sheet 11 Rafters
6 Truss

13
 ®
Kalzip ProDach: Kalzip® AF aluminium profiled sheets without
stiffening ribs on rigid insulation.
A new generation of profiled sheets
Kalzip® AF aluminium profiled sheets
were designed for roofing with a rigid
insulation board or a wooden supporting
substructure.
Using Kalzip® AF profiled sheets in
conjunction with a load-transmitting layer
of insulation simplifies installation con-
siderably. Under the name ”Prodach”
insulating system, Rockwool offer a
rigid, water-repellent rockwool insulation
board with a special fixing system.
Kalzip® ProDach
as truss roof structure
Kalzip ProDach
®
as rafter roof
structure
The insulation board is very suitable as
a base for Kalzip® AF profiled sheets.
It is non-flammable, highly thermally-
insulating, sound absorbing, dimension-
ally stable, diffusible and absorbs
vibration. In its top layer, the double-layer
”Prorock” insulation board is extremely
strong and resistant to mechanical stress.
Its high load-transmitting capabilities
contribute considerably to the roofing’s
static function.
Kalzip® ProDach is the complete
solution for high quality in shape,
function and safety
Kalzip® ProDach is the combination of
Kalzip® AF aluminium profiled sheets
without stiffening ribs and rigid ‘Prorock’
insulation board – optimised in both
safety and long-life. Aluminium fixing
rails and stainless steel self-tapping
screws are included in the supply
package.
Kalzip AF profiled sheets
®
Kalzip ‘secret fix’ clip
Fixing rail, aluminium
Self-tapping screw, stainless steel
”Prorock” insulation board (rigid)
Vapour control and air-lock layer
Trapezoidal sheet as substructure
Kalzip AF profiled sheets
®
Kalzip ‘secret fix’ clip
Fixing rail, aluminium
Self-tapping screw, stainless steel
”Prorock” insulation board (rigid)
Vapour control and air-lock layer
Wooden rafters with wooden
supporting substructure
14
 Kalzip® ProDach on a structural steel decking Discreet surface appearence Kalzip® AF profiled sheets can
system as substructure
also be used with the FOAMGLAS®
1
The flat trough shape of Kalzip® AF
insulation system
2 profiled sheets produces a discreet, quietly
3 elegant surface finish. Even small buildings
4 can have a proportional, well constructed
5 Kalzip® AF aluminium roof covering.
6

Always right and quite safe

7

The Kalzip® ProDach is suitable for all

commenly used substructures or struc-
tures in steel, concrete and timber, for all
structural engineering applications and
Kalzip® ProDach on wooden rafters with a
wooden supporting substructure
for the renovation of old roofs. Special
system fixings are manufactured for all
1
2 types of substructures.
3 The ”Prorock” insulating board offers a
4
high degree of ”walkability” during instal-
5
lation and maintenance. Concentrated
1 Kalzip® AF profiled sheets
6 loads are transferred to the substructure 2 Kalzip® ‘secret fix’ clip
8
as spread load. 3 Secondary seal (1st position)
4 Claws or metal rails
5 Molten bitumen topcoat (only when claws are used)
9 Installation 6 FOAMGLAS ® insulation layer (rigid)
7 Bitumen bonding
With the usual Kalzip technique, the
®
8 Structural steel decking, wooden supporting
corrosion-resistant, weather-proof alumini- substructure or solid base
um outer sheet is fixed using ‘secret fix’
clips, but – and this is what’s special
Example: Renovation of corrugated asbestos roof
using Kalzip® ProDach about the Kalzip® ProDach – it is not fixed
1
directly to the supporting structure but to
2 an aluminium U-rail inserted in the
3
insulation layer. The system fixings which
4 connect the U-rail to the supporting
5 structure only penetrate the insulating
6 material in points. This system almost
entirely eliminats sound and heat bridging.
10

Renovation of corrugated asbestos roofs

11

The Kalzip® ProDach is also suitable for

renovating corrugated asbestos roofs.
1 Kalzip® AF profiled sheet
Various processes are possible. In each
2 Kalzip® ‘secret fix’ clip case, approval must be obtained from the
3 ”Prodach” fixing rail, aluminium professional control board. Depending on
4 System fixings, depending on substructure
5 ”Prorock” insulation board (rigid)
the local situation, it’s possible to
6 Vapour control and air-lock layer dispense with the dismantling of existing
7 Structural steel decking system corrugated asbestos roofing (see page
8 Wooden supporting substructure
9 Rafter
28).
10 Corrugated asbestos roofing
11 Bottom layer of insulation

15
Filigran strukturiert in der Fläche
Avant-garde architecture with compelling appearance and function.
Exhibition Hall 3, Frankfurt (D) 2001 – Kalzip® 50/333, stucco patterned; architects: Nicholas Grimshaw & Partners.
Following the natural flow of power,
the undulating roofing construction of
exhibition hall 3 in Frankfurt rises in its
metallically shimmering elegance. The
exceptional architecture and technology
creatively fit in between the gatehouse
of Martin Unger and hall 1 of Helmut
Jahn. It is the embodiment of a new
form of aesthetics: the aesthetics of
modern times, of simple and pure
structures, of lightness and trans-
parency. The design of the curves is
soft yet distinctive. The enduringly
protective Kalzip® aluminium sectional
panels merge harmoniously with the
high-tech architecture designed by
Nicholas Grimshaw & Partners. The
striking, self-supporting roof arches
16
span the upper level of this building system combine visual perfection
over a length of 165 m, which shows with technical excellence, and make
just how well the highly flexible roof a decisive contribution to the timeless
and wall system with the partially elegance of modern architecture.
conical, convex and concave sectional
sheets can be adapted to the require-
ments of the design architects. The
virtually unlimited design possibilities
and the high functionality of the Kalzip®

17
Schall- und wärmedämmend
Lightweight, self-supporting and good sound-proofing.
In this instance, R’w = 53 dB(A).
Oberhausen Arena (D), 1996. Kalzip® stucco embossed and RAL 8004 Polyester, smooth curved. Architects: DLA-Ellerbe Becket, Wakefield (UK).
Wide spans
The Oberhausen Arena is currently one
of the most modern of its type in Europe.
Its architecture and technical construction
change a simple visit into an unforget-
table experience.
The wide-span, self-supporting domed
roof is covered with Kalzip® aluminium
profiled sheets in lengths up to 42 m.
Excellent acoustics Technical and shape constraints
The hall has a capacity of over 12,500 – Must be as lightweight as possible
seats. Its technical layout enables it to be because of the wide spans
re-arranged very quickly and provides a
– High demands for sound-proofing and
great degree of flexibility. The acoustics
acoustics
are particularly important for large events.
At the Oberhausen Arena, with a sound- – Very flexible because of the dome
reflection of 1.8 seconds, it is particularly shaped roof structure at the entrance
remarkable that this measurement is
Lightweight. Self-supporting. Well sound-
achieved even though the hall has a very
proofed. Good acoustics. Flexible shape.
open interior design. The architects,
Kalzip® roofing is all these.
DLA-Ellerbe Becket, produced an
ambitious roof structure, using wide-span
steel trusses with support-work which is
visible internally.
18
 Cross-section

Longitudinal section

Example: Kalzip® roof structure for special Strict accoustic requirements were met Kalzip® has no static problems
sound-proofing requirements
1 Tests proved this before the roof was The Kalzip® roof covering can be
installed. The result: R’w = 53 dB(A). precisely adapted to suit the building’s
2 requirements by selecting the appropriate
Insulating layers inside the roofing
3 number and position of fixing points.
structure enabled the thermal-insulation
4 ............................
requirements to be met easily. Lightweight Kalzip® roof structures are
suitable for large buildings of all kinds:
5
The Kalzip® roof structure also fulfilled
for gymnasiums, multi purpose halls,
4 the highest economical expectations.
6
............................ swimming pools, leisure centres, airport
3 terminals, railway stations, office
7 buildings, industrial and administration
8 buildings...
1 Kalzip® profiled sheets 5 Top hat profile and
2 Kalzip® ‘secret fix’ clip thermal-insulation (rigid)
with thermal barrier pad 6 Vapour control and
3 Thermal-insulation air-lock layer
(compressible) 7 Perforated structural steel
4 Plaster fibreboard decking
8 Top hat profile on interme-
diate rubber layer

19
Sicher im Korrosionsschutz
Kalzip® gives long-lasting protection, even under massive
corrosion attack.
PURVA Composting plant, Purmerend (NL), 1996. Kalzip® RAL 5009. Architect: Haskoning, Nijmegen.
Plating Protective plating, a sure thing
The whole composting process, starting
with the delivery of compost waste right
up to storage of the end-product, takes
place in enclosed halls. The climate in
these halls is extremely aggressive; the
Core material
gases, temperatures and air-humidity are
extremely high. The building materials
used to construct the roof and rooms
must withstand massive corrosion attack.
These high demands are met by
Kalzip® because of its protective
plating on both sides.
Through its protective plating on both
sides, Kalzip® offers a particularly
long-lasting resistance to corrosion.
Kalzip® is the ideal solution for the
use under the effects of marine and
industrial atmosphere. The material used
is one of the so-called saltwater-resistant
alloys. Special surface protection offers
a suitable solution for use directly next
to copper-works or industries which use
large quantities of aggressive chemicals.
Ask us and we’ll advise you.
20
Dauerhaft in der Funktion

Kalzip® is long-lasting.

Kalzip®: Over 30 years on the

world’s roofs.
Over 65 million square meters of
Kalzip® profiled sheets have been
manufactured.
In 1968, Kalzip® was used for the
Conference Centre in Nuremberg.
Economic studies have confirmed it:
both visually and functionally, the roof is
still as good as new today.
The durability of the material is particu-
larly impressive on the dome of Rome’s
San Gioacchino Church, which was
covered in aluminium in 1897. Although
the aluminium used then was by no
means up to modern day quality, the roof
covering is still in very good condition.
Perhaps future generations will stand
and wonder at a 100 year old Kalzip®
roof. Certainly, at the end of its useful life,
the Kalzip® aluminium roof covering with
its ever-increasing material value will al-
ways sell well and be used again after
recycling.

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

Kalzip® is non-flammable Kalzip® assumes the function of a

lightning conductor
Aluminium alloys are non-flammable and
so, without proof, are building materials When connected and earthed correctly,
Class A1 according to DIN 4102. Kalzip® roofing can be used as a
lightning receiver and lightning conduc-
Even with an organic coating on both
tor in accordance with DIN 57 185,
sides and with insulation layers on the
Part 1, Lightning Protection.
underside in building materials Class B2,
Kalzip® is, without proof, resistant to
air-borne fire and radiant heat according
to DIN 4102 Part 4, Section 8.7.

21
Praxisbewährt die Produktpalette

The Kalzip® range.

Kalzip® aluminium profiled sheets

Dimensions mm Thickness mm There are many variations in shape

for instance

Kalzip® 50/333 1,2 straight

333
1,0
0,9
50 0,8

Kalzip® 50/429 1,2

429
1,0 convex
0,9 curved
50 0,8

Kalzip® 65/305 1,2

305
1,0
0,9
65 0,8
concave
curved
Kalzip 65/333
®
1,2
333
1,0
0,9
65 0,8

Kalzip® 65/400 1,2

400
1,0 tapered
0,9
65 0,8

Kalzip® 65/500 **) 1,2

500
1,0 tapered-convex
0,9 curved
65 0,8

Kalzip® AF 65/333 *) 1,2

333
1,0
0,9
65 0,8
elliptically
Kalzip® AF 65/434 *) 1,2 curved
434
1,0
0,9
65 0,8

Kalzip® AS 65/422 *) 1,2

422
1,0 hyperbolically
0,9 curved
65 0,8

*) Only in conjunction with rigid insulating materials or on a continous wooden support layer
Thicknesses from 0.9 to 1.2 mm are to be preferably used
**) recommended for facade cladding

22
Proven accessories complete the Kalzip® roofing system.

The Kalzip® system includes an

extensive range of accessories which
has grown out of demand.
Shown here are some components with
durable functions.
The Kalzip® price list contains
complete details.

Walk weys are fixed to the seam using clumping Folding tools make it easier to bevel the ridge of the
sections. The roof covering is not punctured. Kalzip® profiled sheets.

Roof assemblies such as walkways, absorbers and Top closure on a Kalzip® profiled sheet with a locking Rooflight unit systems (PVC) are available for
solar systems are firmly fixed to the seam using plate, shape-filler and bevel. Small-radius crimped single-skin roofs.
Kalzip® clamping sections in stainless steel or curved Kalzip® as an attractive variant for
aluminium. The roof covering is not punctured. a fascia.

Gable clip and cap to reinforce and secure the Snow and ice bars in aluminium are fixed to the The bevelling tongs for the eaves produce a
edge flange. seam of the Kalzip® profiled sheets using clamping uniform, functional edge line.
sections. The roof covering is not punctured.

A special folding technique enables gable end Vent-pipes are welded into the roof covering. Soakers for rooflight domes or smoke extractor
flashing to be nicely shaped, even on curved roofs. fans are produced to building requirement and are
welded or sealed into the Kalzip® layer
(depending on the requirements).

23
Kalzip® supports the world’s largest photo-voltaic roof 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).
Small details with a big effect 1000 light domes were easily built-into
the roof using prefabricated Kalzip®
The Kalzip clamping sections fitted
®
soakers.
on the seam of the Kalzip® roof
covering support Siemens’ photo-voltaic The eaves consist of prefabricated
system. sandwich units. Together with Kalzip®,
they mould the architectural appearance
656,208 solar cells were fitted. The outer
of the exhibition halls. The Kalzip®
roof covering wasn’t punctured. The roof
covered roof measures 160,000 m2.
can be walked on in order to maintain
the solar system.
24
Kalzip® innovations set standards.

Kalzip NatureRoof® is the safe way of

landscaping – unique in its conception
and technical design

The Kalzip® Natural Roof elements are

mounted direct to the profile sheets with-
out any additional sealing measures.
This combines the technical advantages
of Kalzip® with the ecological require-
ments of a green roof.

Streamline drainage installations, joints and end pieces The Kalzip NatureRoof ® is an expansive roof greenery with minimum installation and maintenance requirements.
can be manufactured to project requirements. The water retaining capacity is 50 %. Approx. 33 % of the precipitation volume returns into the ecological cycle.
Kalzip NatureRoof ® though incorporating a planted The Kalzip NatureRoof ® elements are delivered to the building-site as a complete package.
area is still considered a lightweight construction.

The Kalzip® mounting system for a

fast and safe clip-fixing on trapezoidal
steel decks
• Kalzip® ‘secret fix’ clips, fitted in
seconds, even on thin trapezoidal
steel profiles.
• Drill/screw technique: one process
for drilling and fixing.
• High strength.
This new fixing system was developed
by the Swiss company SFS, the leading
manufacturer of mechanical fixing
systems for industrial light engineering.
Together with Corus, this technique has
been adapted to the Kalzip® system.
Ordinary drills are suitable for the
Kalzip® drill/screw technique.
Please ask for information about
Kalzip® drill/screw technique.
Accident prevention regulations are compulsory for work
on the roof. The Kalzip® fall-prevention system offers the
necessary protection.

25
Hervorragend als Sanierungskonzept
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 roof
renovation a special field of application
for Kalzip®.
Whether sloping shallow or steep, the
existing roof covering does in most
cases not have to be removed. Also roof
structures need generally not be
reinforced.
During installation, the building can
continue to be used in the normal way,
usually without any interruption.
The Kalzip® system is suitable for
renovating all types of roofs.
Bitumenous felt and membrane roofs,
with and without gravel ballast and even
corrugated asbestos roofs can be
quickly, safely and above all, economi-
cally renovated using Kalzip®.
Visual aspects and unusual shapes can
be accommodated.
26
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 the
effects of the environment endorse
Kalzip® as the ideal system for
renovation.
A new Kalzip® outer shell offers a
building long-lasting protection. In addi-
tion, the renovation clearly enhances the
building visually.
27
Savings on thermal-insulation and sound-
proofing are very positive, not only for the
building’s users:
• The costs of operating and maintaining
the building are clearly reduced.
• Increasing environmental demands
are met.
• The building as a whole increases
in value.
Hervorragend als Sanierungskonzept
Kalzip® AF and the Rockwool ”Prodach” insulation system
are ideal for roof renovation.
Einhell AG, Landau/Isar (D), Renovation. Kalzip® AF stucco embossed.
Milling grooves for fixing rails
No dismantling and removing of the
asbestos layer
In Landau/Isar, a building complex com-
prising of six steel halls with a roof area
of about 190 x 120 m, received a new,
long-lasting Kalzip® AF aluminium roof
covering. Following installation, the roof
can be walked on without restriction.
Renovation work took about two months.
The client continued to operate,
un-interrupted.
Fixing rails using a rivet gun 19,500 m2 roof was renovated in about 2 months
1
Because of the light weight of the
2
Kalzip® system, it wasn’t necessary to
3
reinforce the roof’s substructure.
4
The result of an expert report on the 5
subject ”Drilling asbestos-cement 6
products” formed the start of this renova-
7
tion concept. Drilling dust was sucked
away using special suction equipment 8
connected to the drilling machines.
A copy of the report is available on 1 Kalzip® AF profiled sheets
request. 2 Kalzip® aluminium ‘secret fix’ clip
3 Fixing rail
4 System fixing, depending on substructure
5 ”Prorock” insulating board (rigid)
6 Vapour control and air-lock layer
7 Corrugated asbestos roofing
8 Bottom layer of insulation
28
Produktiv auch vor Ort

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 and bend-
ing machines can be used anywhere in
the world - particularly where it is eco-
nomically and ecologically sensible. Re-
lieving traffic congestion and finding the
best route from the point of manufacture
to the point of use, as well as providing a
lightweight construction method, are very 25,000 m2 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 be
important considerations today. manufactured 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.

29
Ressourcenschonend im Einsatz
Partner of the environment.
Town House, Melsbach (D), 1993. Kalzip® RAL 6003 / RAL 1019. Architects: Karl-Heinz Müller, Neuwied.
Once produced, aluminium is at our
disposal for evermore, thus saving
resources
Aluminium, combined with other ele-
ments, is the third most common element
in the earth’s crust and is available
everywhere in nature.
From the initial material, recycling over
and over again produces valuable new
aluminium products.
Up to 95% of the power used to produce An insulated Kalzip® building
aluminium can be saved when it is contributes significantly to reducing
re-smelted. The smelting process can be air pollution and preserving our
repeated as often as required. environment.
Aluminium’s beneficial material properties
After a long service-life, Kalzip® can be
remain intact.
continually re-used.
The product characteristics of the
Ecology and economy complement
Kalzip® system meet high ecological
each other. The circle is complete.
demands.
The lightweight construction of Kalzip®
enables a resource-saving reduction in
the amount of materials used to create
the supporting structure.
30
Our experts with their knowledge of
many applications are at your disposal
We hold installation training courses at
our in-house seminar centre and for
architects, the schedule includes planning
seminars.
For further advice and information,
please contact one of our sales offices
(see overleaf).
www.kalzip.com
Europe:
Austria
Corus Bausysteme
Bruckner Büro Center
Honauerstraße 2
A-4020 Linz
Austria
T +43 - 7 32 78 61 14
F +43 - 7 32 78 61 15
kalzip.austria@corusgroup.com
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
Cyprus
Phanos N. Epiphaniou Ltd.
21 Markou Drakou Avenue
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 Sanovcová
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
Corus ByggeSystemer A/S
Kaarsbergsvej 2
Box 136
DK-8400 Ebeltoft
Denmark
T +45 - 8953 2000
F +45 - 8953 2001
dk@cbsnordic.com
France
Corus Building Systems SAS
8, Avenue Desclers · B.P. 20
F-77515 Faremoutiers
France
T +33 - 1 64 65 30 56
F +33 - 1 64 03 98 55
cbsfr@corusgroup.com
Corus Bausysteme GmbH
August-Horch-Str. 20-22 · D-56070 Koblenz
P.O. Box 10 03 16 · D-56033 Koblenz
T +49 (0) 2 61 - 98 34-0
F +49 (0) 2 61 - 98 34-100
kalzip@corusgroup.com
English
Greece
Phanos N. Epiphaniou Ltd.
82 Grammou Str.
GR-18345 Moschato
Greece
T +30 - 21 09 40 59 41
F +30 - 21 09 41 24 65
fanos@otenet.gr
The Netherlands
HAFKON BV
Postbus 46
NL-3140 AA Maassluis
The Netherlands
T +31 - 105 91 53 00
F +31 - 105 91 51 25
info@hafkon.nl
Norway
Corus Bygg Systemer AS
Røraskogen 2
N-3739 Skien
Norway
T +47 - 3591 5200
F +47 - 3591 5201
norge@cbsnordic.com
Poland
A-B Space
Lukasz Lomozik
Ul. Stawowa 31 B
PL-43-250 Pawlowice SI.
Poland
T +48 - 32 47 25 110
F +48 - 32 47 57 010
kalzip@wp.pl
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
Spain
Corus Sistemas
Constructivos S.L.U.
Calle Guatemala, 1
Bajos 3 y 4
E-28016 Madrid
Spain
T +34 - 9 13 43 03 43
F +34 - 9 13 59 94 73
kalzip.spain@corusgroup.com
Overseas: Near East
Sweden Lebanon
Corus ByggSystem AB Naggiar Agencies SCS
Sliparegatan 5 · Box 4003 P.O. Box 175415 Beirut
S-300 04 Halmstad Negib Hobeika Street
Sweden LB-Saifi-Beirut 20296406
T +46 - 3510 0110 Lebanon
F +46 - 3515 9200 T +961 - 1 56 26 52
se@cbsnordic.com F +961 - 1 44 83 91
roy.naggiar@naggiar.com.lb
Switzerland www.naggiar.com.lb
Büro Dach & Wand
Jürg Senteler
P.O. Box 247 Overseas: Middle East
CH-7302 Landquart
Switzerland Dubai
T +41 (0) 81 3 22 38 38 Corus Building Systems
F +41 (0) 81 3 22 38 39 P.O. Box 18294 · UAE-Dubai
info@kalzip.ch United Arab Emirates
T +971 - 43 38 85 86
Turkey F +971 - 43 38 99 70
Tür Group azad@corusmiddleeast.com
Architectural Materials
Mahmut Sk. No: 8 Kuwait
TR-81200 Kosuyolo-Istanbul Ali Alghanim & Sons
Turkey Trading & Contracting
T +90 - 216 327 4720 Group Co. W.L.L.
F +90 - 216 327 4724 P.O. Box 21540
sahikakutsal@tur-group.com KT-Safat 13076 · Kuwait
T +965 - 4 84 22 23
United Kingdom F +965 - 4 84 18 12
and Ireland
Corus Building Systems
Haydock Lane, Haydock Overseas: Far East
GB-St. Helens, Merseyside
WA11 9TY China
United Kingdom Corus Building Systems
T +44 - 19 42 29 55 00 Guangzhou Representative Office
F +44 - 19 42 27 21 36 Suite 1208, West Tower
kalzip-uk@corusgroup.com Yangcheng International
Commercial Centre
Tian He Ti Yu Dong Road
Guangzhou
PRC Postal Code 510620
T +86 - 20 38 87 01 91
F +86 - 20 38 87 02 65
Hong Kong
Corus Building Systems
6/F Jardine Engineering House
260 King’s 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:101:GB:03/2004
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 2004
Corus Bausysteme GmbH · Part of Corus Group plc