Kalzip flat roofing systems

Kalzip Ltd
Kalzip flat roofing systems
product review
High performance, cost effective solutions
for flat / low pitched roofs
Kalzip aluminium roof system is BBA approved (Agrément Certificate No 98/3481)*
for use on flat/low pitched roofs down to 1.5º, making it a robust and cost effective
alternative to single ply membrane.
Kalzip is a proven solution offering complete versatility across every kind of roofing
application and its many advantages can eliminate the concerns often associated with
single ply flat roofing products.
Benefits
• Roof sheets are secret-fixed to the substructure by means of non-penetrative
clips – there are no through fixings and therefore no leaks
• Mechanical design of Kalzip eliminates the need for sealants and bonding as a
method of weathering making the system reliably weathertight
• Buildings can be made watertight far sooner than would be possible using
alternative single ply roofing methods
• High standing seam eliminates potential for ingress at joints
• Unlimited sheet lengths with on-site production means no end laps
• Aluminium is more resistant to damage (e.g. punctures, tears) than other single
ply materials and its properties are not compromised by temperature cycling
• No hot processes on-site
*Certificate number may change pending the issue of a new BBA certificate.

Proven benefits, new opportunities
Architects, designers and specifiers
have long recognised the creative
possibilities afforded by the Kalzip
standing seam roofing system, with
millions of square metres now installed
on roofs of every shape and size.
The success of any roof is measured
by its long term performance and this
is just one area in which Kalzip offers
substantially improved performance –
and whole life cost – compared with
traditional flat roof materials.
Inherently strong and watertight
With its ease of installation, inherent
water-tightness, durability and 40 year
guarantee, Kalzip makes sense from a
financial as well as aesthetic point of
view.
Kalzip is renowned for its visual
impact and performance on numerous
landmark and prestigious buildings
around the world, and for its ability to
accommodate the most complex of
geometries, both angular and organic
in form.
As an aluminium product, Kalzip combines strength with lightness. It is durable,
corrosion-resistant and essentially maintenance-free. In short, it offers the best of
both worlds: aesthetic appeal and ultimate practicality.
The design of the Kalzip system builds on these qualities, enabling quick and easy
installation with techniques that maintain the robustness of the material.
Kalzip’s weather-tightness is based on its mechanical properties as opposed to
manual finishing or the application of sealants. As an aluminium product it is also
far more resistant to damage (e.g. punctures, tears) than other materials and its
properties will not be compromised by temperature cycling.
It is also a system as well suited to
flat/low pitch roofs as it is to the more
elaborate curved and/or tapered roofs
for which it has earned its outstanding
reputation.
Kalzip is a proven solution offering
complete versatility across every kind
of roofing application and is available
in a multitude of standard Kalzip
configurations to cater for all designs
and the most exacting performance
requirements.
Examples of standard Kalzip configurations for flat roof applications
Kalzip liner system Kalzip liner deck system Kalzip acoustic build
Profile Filler
sealed top and
bottom
Butyl seal
Butyl seal
Boundary wall composite gutter
THE MAIN AREAS OF POTENTIAL LEAKAGE ARE
AT JUNCTION DETAILS. CONSIDERATION SHOULD BE GIVEN
TO COMPONENT JUNCTIONS TO ACHIEVE AIRTIGHTNESS
6
Composite insulated gutter
Above Gutter - Patent Pending
5 3
2
Profile fillers sealed top
and bottom to liner
4
1
KALZIP SHEET
THERMAL INSULATION
VAPOUR CONTROL LAYER
STRUCTURAL DECKING
ROOF BEAM
FLASHING SUPPORT
Clip Size
E-120
VERGE FLASHING
GABLE END CLIP
GABLE END
CHANNEL
KALZIP CLIP INTERNAL
FLASHING
RIDGE FLASHING
Z-SECTION RIDGE SUPPORT
U-TYPE RIDGE FILLER
U-TYPE RIDGE CLOSURE
E-CLIP
Typical double skin parapet detail
E Clip
Spacer
E-100
Clip Size
Spacer
APRON FLASHING SEALED UNDER PARAPET
INSULATION
KALZIP SHEET
LINER SHEET
VAPOUR CONTROL LAYER
Double skin abutment verge detail to parapet
STRAP
FLASHING
TREATED TIMBER

Cost-effective solution for flat/low pitched roofs
The durability, ease of installation and maintenance-free
nature of Kalzip also means it offers a cost-effective alternative
to single ply membrane. In fact, a whole life comparison (WLC)
report published by the Building Research Establishment (BRE)
concluded that:
“… in the longer term, the predicted
cumulative life cycle costs show that the
Kalzip liner roof actually provides the
most economical option …”
The low operational cost associated with Kalzip is one of its
key advantages. Where other roof types tend to require regular
cleaning, maintenance and overhaul of failed areas, a Kalzip
roof is essentially maintenance-free, Agrément Certificate No
98/3481 states that, depending on the environment, Kalzip “will
have a minimum service life of 40 years” and this is reflected in
the Kalzip XL Guarantee, a forty year performance guarantee
that covers the full system build from the outer sheet through
to the internal liner.
Fast, quality-assured installation
Installation of Kalzip roofing is carried out to a high level of
predetermined standard details by fully trained and approved
members of the Teamkal installer network. Indeed, the
Agrément Certificate specifically links site working practices
with system details, providing further assurances of the highest
standard of installation.
The mechanical nature of the fix, combined with a system
of integrated, prefabricated components and accessories,
minimises installation time and ensures that the building is
watertight far sooner than would be possible using alternative
roofing methods. Another important benefit is Kalzip’s ability to
be installed in virtually all conditions, substantially reducing the
risk of delays due to adverse weather.
Excellent thermal and acoustic
insulation
Once installed, a Kalzip roof provides excellent performance in
terms of minimising heat transfer and sound levels.
The use of aluminium helps to reduce heat transfer and this
property can be enhanced with surface treatments, enabling
energy flow through the roof to be cut from 340 to 50 W/m 2 .
The qualities of heat reflection in summer and heat retention in
winter enable energy saving and associated cost reduction.
Kalzip also offers good acoustic performance, with tests
demonstrating the ability to reduce noise levels by as much
as 53dB (typically 38-40dB). Insulants or acoustic mat can be
incorporated to further enhance this performance if required.

www.kalzip.com
Care has been taken to ensure that this
information is accurate, but Tata Steel Europe
Limited – including its subsidiaries – does not
accept responsibility for information which is
found to be misleading.
Copyright 2010
Corus
Kalzip Ltd
Haydock Lane
Haydock
St Helens
Merseyside WA11 9TY
England
T: +44 (0) 1942 295500
F: +44 (0) 1942 295508
Email: enquiries.uk@kalzip.com
English
Outstanding sustainability
Aluminium is inherently sustainable. The raw material that contains aluminium, bauxite,
is the third must abundant element in the earth’s crust with at least 300 years of
reserves left at the current rate of usage. Furthermore, the power used in its production
is predominantly hydroelectric, which is clean, CO 2 free and renewable.
Once it has been produced, it then offers extraordinary recyclability: it can be reused
again and again – with no loss of performance – and up to 95% of the energy used in
initial manufacture is saved through recycling.
Kalzip takes this recyclability a stage further with a system that provides decades of
total building protection, and can then be unzipped and reused or recycled when a
building reaches the end of its working life.
If reuse is not possible, then Kalzip, as an aluminium product, offers an extremely high
residual value compared with other roofing products, eliminating the cost and adverse
environmental impact associated with disposal by landfill.
This level of recyclability, together with its long term performance, means a Kalzip
system can provide A+ ‘Green Rating’ for BREEAM accreditation.
Another green benefit of using a Kalzip roof is the opportunity to incorporate either of
Kalzip’s two photovoltaic solar solutions – AluPlusSolar and Solarclad – or the advanced
Kalzip Nature Roof system with its low growing, self-regenerating, drought-resistant
plant cover.
Kalzip AluPlusSolar Kalzip Nature Roof
A fully tested and certified system
Kalzip benefits from extensive 3rd party certification including:
• ASTM (USA)
• Avis Technique (France)
• BBA (UK)
• Factory Mutual (France)
• Zulassung (Germany)