AP Systems AP P.1-17(21-7) - Kalzip

Kalzip Asia Pacific 

Kalzip ® Systems 

Products and applications

Kalzip ® 

innovative 

performance 

and proven 

system solutions 

for creative 

architectural 

design.


Contents 

Introduction 4 

Kalzip ® Standing seam roof systems 6 

Kalzip ® Solar Power Solutions AluPlusSolar and SolarClad 18 

Kalzip ® Facade Solutions Innovative building envelope technology 22 

Kalzip ® Bespoke Solutions Aesthetics and proven performance 32 

Kalzip ® Acoustic Systems Solutions for auditory applications 34 

Kalzip Nature Roof ® Green roof system 38 

Components and accessories 40 

Materials and finishes 52 

Facing page: 

Guangzhou Asian Games Town Gymnasium, China 

System design guidelines 56 

and performance characteristics


Project: Taipei Arena, Taiwan 

Architect: Lo Hsing Hua Architect & Associates


Innovation is 

our strength 

Our research and 

development work is based 

on one aim: to provide you the 

customer with the very best 

solutions everytime. 

Kalzip ® will transform your ideas and dreams into 

reality – without making any compromises in quality and 

with a true passion for detail. 

Kalzip ® is the source of inspiration for planners and 

architects throughout the world. And there are very good 

reasons for this: Kalzip ® offers perfect system solutions, 

limitless design potential, state-of-the-art production technology, 

ultimate product quality, innovative material combinations and 

harmonious integration of shapes, 

colours and surfaces. 

Kalzip ® aluminium standing seam profiles are able to 

meet even the most demanding construction and design 

requirements, enabling you to create roofs and facades which 

successfully combine outstanding functionality 

with stunning aesthetics. The design potential is virtually 

limitless – from the discreet to the elaborate; combining 

sophisticated elegance with contemporary design. 

Intelligent additional features such as Kalzip ® SolarSystems or 

the Kalzip NatureRoof ® provide the perfect finishing touches to 

the unique Kalzip ® range. Spectacular aesthetics are skillfully 

integrated into contemporary architectural design. And, as if this 

were not enough, Kalzip ® also offers significant economic and 

ecological advantages. 

For more than 40 years we have remained at the very forefront 

of architectural design, constantly pushing the boundaries of 

creative potential. We are extremely proud of this achievement. 

The experience we have gained over many years, together 

with our highly-specialised technical expertise, guarantees the 

ultimate in quality and reliability – right down to the very last 

detail. Kalzip ® is a highly sophisticated, light weight building 

system, which is extremely flexible and can be precisely 

adapted to suit the static requirements of a building. Even large 

spans can be accommodated without a problem. Kalzip ® can 

be easily combined with other construction materials to create 

stunning and inspirational buildings. 

05


Kalzip ® – the sophisticated, 

lightweight building system 

Highly flexible and can be adapted to suit the 

precise static requirements of the building. 

Unlimited application potential 

• Suitable for ventilated and nonventilated 

roof designs and all shapes 

and pitches of roof from 1.5°. Suitable for 

all substructures and supporting 

structures. 

• Can be flexibly adjusted to suit the 

layout, geometry and dimensions of any 

building. 

• Extremely strong and lightweight. 

Therefore ideal for large spans and for 

renovating old roofs. 

• Continuous lengths of 100 m and more, 

when production takes place on-site. 

Superior thermal and acoustic insulation 

• Fulfills strict thermal insulation 

requirements. By choosing the 

appropriate thickness of insulating 

material, the roof structure can be 

adapted to suit the precise requirements 

of the building. 

• Highly efficient thermal insulation can be 

achieved by means of constructive 

measures. 

• A series of acoustic tests and 

appreciation of the demanding 

requirements for noise control within 

buildings helps to create optimum 

internal conditions. 

A high level of safety throughout the 

entire service life 

• A non-penetrative patented clip attaches 

the sheets to the substructure. These 

clips are locked into the seam to ensure 

smooth thermal cycling of the external 

sheet over the clip head whilst facilitating 

outstanding spanning capacity under 

high wind loading. 

• The mechanical zipping of the seams 

produces a load bearing, permanent 

connection. 

• Pressure and suction loads are safely 

absorbed. 

• The weather tight seam permits any 

residual moisture in the insulating layer 

to evaporate through the seam allowing 

the roof to breathe naturally. 

• Sophisticated detailed solutions for roof 

penetrations, joints and gable ends. 

• Non-flammable. Resistant to flying 

sparks and radiant heat. 

• Kalzip ® can be used as a lightning 

conductor in conformity with 

requirements of EN62305-3 in 

conjunction with DIN V VDE V0185- 600. 

Durability and economy 

• Corrosion-resistant, weather-resistant 

aluminium alloy base material. 

• Non-sensitive to UV rays, resistant to 

microorganisms, resistant to ageing. 

• Installation is particularly quick and 

largely independent of weather. Cost 

savings through pre-fabricated 

components. 

Valuable ecological and 

sustainable properties 

• The raw material that contains 

aluminium - bauxite - is the third most 

commonly occurring element in the 

earth’s crust with at least 300 years of 

current reserves left at the present rates 

of usage – a figure that is improved 

by the increasing amount of aluminium 

that is being recycled. 

• Over 60% of all aluminium is produced 

using hydroelectric power, which is 

clean, CO 2 

free and renewable. 

• Aluminium is a closed loop process; 

once produced - it can be recycled 

infinitely with no loss of performance. 

• Kalzip is a fully demountable system 

which, at the end of the buildings 

life, can be unzipped and reused or 

recycled without limitation. 

• Up to 95% of the energy required to 

manufacture the original aluminium 

material is saved through recycling. 

• A study by Delft University, supported 

by the European Aluminium Association 

through the Aluminium for Future 

Generations programme, found that 

the general collection rates of aluminium 

from individual buildings was between 

93 and 98 percent – almost total 

recovery. 

• An insulated Kalzip roof structure 

contributes significantly to emissions 

reduction. 

Right: 

Lien Khuang,Vietnam 

06


Available shapes 

Widths of Kalzip ® profiled sheets 

Kalzip ® dimensions 

333 

straight 

Kalzip ® 50/333 

50 

429 


50 

convex 

curved 


305 

65 

333 


65 

tapered-convex 

curved 

400 


65 

500 

tapered 


65 

333 

Kalzip ® AF 65/333* 

65 

tapered-concave 

curved 

434 

Kalzip ® AF 65/434* 

65 

concave 

curved 

* only when used with rigid thermal insulation or timber lining 

07


BMW central building Leipzig 

Winner of the German Architecture 

Award 2005 

Architect: Zaha Hadid 

with Patrik Schumacher 

Perfection in roll-forming technology 

Flexibility and freedom of design 

The unique formability of Kalzip ® aluminium profiled sheets enables design and functionality 

to be combined with technical perfection. The range of shapes available – convex, concave, 

elliptically or hyperbolically curved – opens up a whole variety of fascinating options for 

creating stunning architectural designs. 

Perfection in production 

The high-precision Kalzip components 

can be produced using the very latest 

equipment both in the factory and also 

on mobile roll formers to create a variety 

of complex shapes and geometric 

options. Numerous patents and utility 

models are clear evidence of the unique 

features and technological preeminence 

of this system. Even unconventional 

roof shapes are subject to no restriction. 

In addition to aluminium, it is also 

possible to process other materials 

such as stainless steel, copper and 

AluPlusZinc. The large number of mobile 

roll formers which are in operation 

throughout the world, guarantees an 

economical and sophisticated complete 

solution with minimum logistical costs 

and without having to compromise on 

creative architectural design. The unique 

advantages of on-site production are 

clearly evident when continuous sheet 

lengths in excess of 150 metres are used 

to cover large spans. 

Above: 

Cite Shopping Mall, Germany 

Above: 

Basketball Sports Hall, Croatia 

08


Available shapes 

Kalzip XT Profiles 

The advent of a new architectural era 

Malleable, pliable, foldable and flexible, 

Kalzip XT profiled sheets make it possible 

to transform computer-generated designs 

and structural principles into reality. These 

evolutionary animations, visualized in 3D 

objects, enable new architectural shapes 

and forms to be created. 

Revolutionary in its field this computer 

controlled patented roll forming 

technology allows three dimensional 

contouring to be combined with a 

standing seam system to achieve 

technical perfection in the creation 

of free flowing shapes. The ability to 

achieve extremely tight radii guarantees 

unusual shapes of buildings, including: 

ellipses, cones, semi-spheres, prisms, 

pyramids, as well as classic geometrical 

shapes –both horizontal and vertical. 

Left top: 

Emmen Hospital, The Netherlands 

elliptically 

curved 

hyperbolically 

curved 

XT Freeform 

XT Freeform 

Left bottom: 

Vigo University, Spain 

XT Freeform 

09


Form and functionality 

Kalzip standing seam roof systems are available 

in a multitude of configurations to cater to the most 

challenging architectural design or most exacting 

performance requirements. 

Kalzip liner roof system 

Kalzip liner roof systems are predominantly 

used for new build construction, although 

they can be used for refurbishment 

especially where the existing roofing system 

has been completely removed. 

The Kalzip liner roof system is ideal where 

speed of installation on a project is of utmost 

importance. A non-fragile walkable Kalzip 

liner sheet can be quickly installed to provide 

a weather cover to allow other trades to work 

below. The remainder of the roofing 

components can then be installed without 

affecting the critical path of the construction 

programme. 

The Kalzip liner roof system has the outer 

Kalzip standing seam roof sheet and the 

internal Kalzip liner trapezoidal profiled liner 

sheet laid in the same direction across roof 

purlins acting as the primary support. Typical 

purlin centres would be approximately 1.0 to 

2.0m. This type of roof construction can also 

be known as a purlin roof construction. 

The Kalzip standing seam roof sheets are 

supported directly off the roof purlins via the 

support clips/halters (aluminium clips or E 

clips) so therefore act independently of the 

Kalzip liner sheet. When lightweight quilt 

type insulation (compressed by 

approximately 15% to 20%) is used, the 

external loads (wind suction, snow, access, 

etc.) are transmitted direct to the support 

purlins and not the liner sheet. 

The profile and thickness of the Kalzip 

standing seam roof sheet will be 

determined by the external loads and 

the purlin centres. 

The profile of the Kalzip liner sheets will be 

determined by its dimensional compatibility 

with the Kalzip standing seam roof sheet 

and its thickness will be determined by the 

internal wind pressure, the purlin centres, 

dead weight of the construction 

components, its walkability requirement 

and its non-fragility rating. 

Left to right: 

Supreme Court, Singapore 

Mumbai Terminal T1B, India 

10


Liner roof system 

Kalzip standing seam sheet 

Rockwool insulation 

Aluminium ST clip with thermal barrier pad 

Vapour control layer 

Trapezoidal liner sheet 

Purlin 

Structural cassette roof system 



Aluminium ST Clip with thermal barrier pad 



Top hat 

Structural cassette 

Structural deck roof system 





Structural deck 

11


Project: Spencer Street Station, Australia 

Architect: Grimshaw Jackson Joint Venture


Outstanding and proven performance 

An impressive list of project references stand 

testament to Kalzip’s ability to perform in a wide 

array of applications and conditions 

With over 80 million square metres of 

Kalzip roofing and façade systems installed 

across the last 40 years, Kalzip’s superior 

performance in the most trying conditions 

have met and often exceeded specifiers’ 

needs for durability, versatility, design 

flexibility and corrosion-resistance. 

Transport facilities 

Passenger transport facilities, whether air, 

rail, road or sea, requires easy accessibility, 

the capacity to handle high human traffic 

and a welcoming environment. 

Terminals are designed to insulate 

passengers from the noise and pollution 

associated with busy transport facilities and 

it entails that the construction materials used 

will be exposed to the harsh external 

environment. Kalzip’s proven durability and 

versatility would fulfill the key requirements 

of any transport terminal, including: high 

wind loading capabilities, superior acoustic 

reduction/absorption and low radar 

signature. 

International transport hubs are icons of 

national identity and the gateway for visitors 

from the world over. Kalzip Building Systems 

have the resource to work as an effective 

and supportive partner on major projects 

from conception right through 

to completion. 

Sporting facilities 

Whether dedicated to one sport like the 

Qizhong International Tennis Centre in 

Shanghai or a multi-purpose stadium like the 

Taipei Arena in Taiwan, sports facilities have 

much in common architecturally. 

Easy accessibility, ample and safe 

seating capacity, adequate facilities for 

support staff and optimized views of the 

action are hallmarks of a well-designed 

sporting facility. 

Convention and exhibition facilities 

Convention and exhibition centres are often 

amongst the most extensive installations of 

Kalzip in the world. From the 200,000 square 

metres Munich Exhibition Centre in Germany 

to the AsiaWorld Expo spanning 90,000 

square metres in Hong Kong, Kalzip is a truly 

cost-effective solution for such large projects. 

The system offers high performance with 

minimal maintenance requirements and high 

residual value (at the end of the building’s life 

span) – a critical consideration when such 

large areas are specified. 

Kalzip has the flexibility and capability to 

meet the complex and stringent 

requirements of the modern sports facility, 

not withstanding the high loadings 

associated with the “open roof” 

configurations of many stadiums 

worldwide. 


AsiaWorld Expo, Hong Kong 

Republic Polytechnic Sports Complex, 

Singapore 

13



Structural 

Deck system 

14


Kalzip structural decking provides an 

economical solution for long span 

installations and eliminate the need for 

purlins. For enhanced acoustic adsorption, 

decking sheets can be perforated and can 

support mass, such as increased insulation 

or board, which may be introduced for more 

rigorous acoustic specifications. 

Decking sheets can be supplied in 

galvanised or polyester-coated in any RAL 

colour. For buildings with extreme 

temperature variations, a very effective 

anti-condensation coating can also be 

applied. With a choice of steel or 

aluminium, a selection of profiles, gauges 

and sheet lengths – this range of products 

has been developed to extend the 

versatility of Kalzip, making it suitable for a 

wide range of applications. 

As a general rule, steel is cost effective and 

provides the optimum in loading and 

spanning capability; whereas aluminium 

offers exceptional durability in buildings with 

high humidity levels such as swimming pools 

and wet industrial process plants, e.g. paper 

mills. 

Where structural decking are installed there 

is a reduced requirement for secondary 

steelwork – the sheets span between main 

steel rafters with the Kalzip outer sheet 

being fixed either directly to the decking or 

onto top hat sub-purlins riveted to the 

decking. 

Kalzip structural decking sheets are 

manufactured from high grade steel to BS 

EN 10346 or from aluminium alloy. 

Standard finishes for decking sheets, 

available on a short lead time are: 

• Hot-dip galvanized, natural finish, ideal 

for situations where the deck is not 

visible or where visual appearance is 

not critical. 

• White polyester coated on hot-dip 

galvanized substrate. This finish is 

highly durable, resists scratching and 

has good formability, suitable for 

exterior soffits. 

Alternative coatings such as PVDF or 

double-side polyurethane are available to 

suit particular specifications 


Jurong West Sports Complex, Singapore 

Kalzip structural decking sheets are 

available perforated to provide sound 

absorption performance. Alternative 

perforation patterns and sizes are available 

to suit specific requirements. 

Perforated decking will improve the acoustic 

conditions within a building by helping to 

optimise reverberation times. Furthermore, 

the decking sheets can contribute to noise 

reduction and noise containment within the 

building by the inclusion of mass above the 

decking sheet such as cement board or 

calcium silicate and the inclusion of air 

spaces within the system. If the application 

requires, the system can be configured for 

both acoustic absorption and noise 

reduction. To obtain the correct specification 

for precise acoustic requirements, please 

contact our technical department. 

Product advantages 

• Capable of spanning up to 8m 

between trusses 

• Eliminates the need for purlins 

• Reduced construction time 

• Can be used as stress skin 

design to reduce the requirement 

for bracing 

• Perforated options provide good 

acoustic absorption 

15



Structural 

Cassette 

system 

16


Suitable for both roof and wall applications, 

Kalzip structural cassette are available in 

both aluminium and steel and are available 

as a tested and proven alternative lining 

element for the Kalzip standing seam 

system. With good strength and stability, 

cassette are suitable for long span 

applications and there is also a reduced 

requirement for structural steelwork. 

Once in position the interior face of 

the cassette provides a clean and pleasing 

appearance with no visible fixings. 

For increased spanability a special 

section can be inserted into the side lap of 

the cassette. 

Structural cassette materials and 

finishes 

Kalzip structural cassette are manufactured 

from high grade steel to BS EN 10346 or 

from aluminium alloy. 

Perforated versions are available where 

acoustic absorption is required. The sheets 

also have the strength to support the 

introduction of additional mass such as 

cement board or calcium silicate where 

there is a requirement for good sound 

reduction. For further details, please refer to 

the acoustic section on page 34, or contact 

out technical department. 

Standard finishes for cassette, available on 

a short lead time are: 

• Hot-dip galvanized, natural finish. Ideal 

for situations where the cassette is not 

visible or where visual appearance is 

not critical. 

• White polyester coated on hot-dip 

galvanized substrate. This finish is 

highly durable, resists scratching and 

has good formability, suitable for 

exterior soffits. 

A wide range of special colours can be 

supplied subject to order quantity and 

extended delivery. Alternative coatings such 

as PVDF or double-side polyurethane are 

available to suit particular specifications, e.g. 

swimming pools and wet industrial processes. 


Wieland Factory, Singapore 

Kalzip structural cassette are available 

perforated to provide sound absorption 

performance. 

Alternative perforation patterns and sizes 

are available to suit specific requirements. 

Perforated cassette will improve the 

acoustic conditions within a building by 

helping to optimise reverberation times. 

Furthermore, the cassette can contribute to 

noise reduction and noise containment 

within the building by the inclusion of mass 

above the cassette such as particle board 

or plaster board and the inclusion of air 

spaces within the system. If the application 

requires, the system can be configured for 

both acoustic absorption and noise 

reduction. To obtain the correct 

specification for precise acoustic 

requirements, please contact our technical 

department. 



between trusses 

• Eliminates the need for purlins 

• Concealed fixing 

• Provides smooth internal finish 

eliminating the need for a seperate 

ceiling 

17



Solar Power 

Solutions 

AluPlusSolar 

and SolarClad 

18


Sustainable architectural aesthetics 

A roof-integrated source of renewable energy 

The solar laminates are flexible and 

extremely durable. Depending on the 

particular roof design, they are permanently 

bonded to straight, convex or concave 

Kalzip ® aluminium profiled sheets. The 

flexibility of Kalzip ® AluPlusSolar can 

accommodate barrel vault or mono-pitch 

roofs, as well as individual roof designs. 

The combination of thin-film solar 

cells with the characteristics of Kalzip ® 

profiled sheets guarantees the architects 

and planners of photovoltaic systems 

a truly integrated solar solution, 

which optimises both roof design and 

energy generation. 

Kalzip ® AluPlusSolar is available as a fully 

integrated system, including inverter and 

accessories, on the AF 65/537/1.0 mm 

profiled sheet with an RAL 9006 coating 

(other colours available on request). 

The solar film, available in two lengths, 

is laminated in the factory and then 

permanently bonded to the outer surface of 

the Kalzip ® profiled sheets. This film 

will subsequently generate the power in 

the photovoltaic system. Kalzip ® profiled 

sheets which have already been installed 

cannot be retrofitted with laminated solar 

film. However, existing Kalzip ® roofs can be 

retrofitted with Kalzip ® SolarClad. 

In addition to a roof-integrated, regenerative 

method of energy production, Kalzip ® solar 

systems also offer the opportunity of 

generating energy in the facade. We can 

send you detailed information on request. 

The silicon solar cells use triple-junction 

technology to generate more energy in 

diffuse light conditions than crystalline solar 

cells of the same rated power and are 

therefore ideal for use. 

The durability of the Kalzip ® profiled 

sheets and the guaranteed efficiency of the 

solar modules now make it possible to 

create contemporary, modern buildings 

which combine maximum freedom of 

architectural design with the integration 

of ecological concepts. 


• Attractive, roof-integrated 

photovoltaics without additional 

fixing elements 

• Optimum utilization of solar energy 

even in weaker light conditions 

through triple-junction technology 

• Greater shade tolerance than 

crystalline modules through narrowmeshed 

bypass circuit 

• Economical – supplied with a 20- 

year performance guarantee 

• Self-cleaning surface – therefore 

low-maintenance 

• Suitable for use as an insulated or 

non-insulated roof 

• Ideal for the most challenging 

architectural design 

• Available as a complete system 

inclusive of inverter and accessories 

• Advice and planning support 

provided by Kalzip, also project 

management support on request 


Auguste Bozon Ochestra training room, France 

Mastershausen Town Hall, Germany 

Versatile photovoltaic solutions 

Flexibility in sustainable development 

The ideal retrofitting solution for all 

metal roofs Kalzip ® SolarClad is a 

photovoltaic cladding which has been 

optimised for use in building envelopes. Its 

flexibility and versatility enables the solar 

modules to be fixed onto all standing seam 

systems made from a variety of materials. It 

can be retrofitted to existing installations or 

used in new builds. 

The system consists of extremely 

robust thin-film modules made from 

amorphous silicon (a-Si), bonded onto 

aluminium carrier plates, which can be 

installed on any metal roof system in a 

non-penetrative manner. 

These extremely lightweight module 

units are suitable for all roof shapes and 

guarantee maximum freedom of design for 

planners and architects. 

Kalzip ® SolarClad is supplied as a 

complete system, including inverters, 

for different standing seam designs. The 

solar film, available in two different lengths, 

is laminated onto Kalzip ® carrier plates 

in the factory to ensure high quality and fast 

installation. The solar laminates generate 

power from the Sun as soon as they are 

connected. 

19


Triple-junction technology 

The solar cells used in amorphous silicon thin-film laminates consist 

of three silicon layers applied one after the other. The different 

layers are optimized so that each layer can optimally convert a 

different range of the light spectrum to electrical energy. This 

enables greater efficiency in diffuse light conditions, which 

constitute the predominant form of daylight in central and northern 

Europe. The specific yields of a Kalzip ® AluPlusSolar or Kalzip ® 

SolarClad system are thus, depending on local conditions, 10-20% 

higher than yields from a regular crystalline system in identical 

conditions. 

Relative Intensity 

1,0 

0,8 

0,6 

0,4 

0,2 

0 

300 400 500 600 700 800 900 

Wavelength in µm 

Tight bypass circuitry 

When partially or temporarily shaded, amorphous thin-film 

laminates have at their disposal a bypass circuit so that the system 

power is not significantly reduced or affected. This is in contrast to 

a similarly shaded crystalline system which, in the event of partial 

shading, would deactivate much larger areas. 

Temperature performance 

The temperature coefficient describes the output reductions 

exhibited by solar cells when exposed to heat. For regular 

monocrystalline or polycrystalline modules, this coefficient is around 

-0.5%/K. For the PV laminates used in Kalzip ® Solar Power 

Systems, it is only -0.2%/K. 

Amorphous module 

(e.g. Kalzip ® AluPlusSolar) 

Crystalline module 

Output [%] 

105 

100 

95 

90 

85 

80 

75 

70 

65 

60 25 30 35 40 45 50 55 60 65 70 75 80 

Cell temperature [°C] 

Environmentally friendly 

The low energy demands during the manufacture and the 

high yields result in an energy payback time of approximately 3 

years. This is a fraction of the required energy payback times 

for crystalline modules. 

Cumulative energy consumption and energy payback time of 

frameless PV modules 

Areas of use 

Kalzip ® AluPlusSolar is suitable for all roof designs with a 

pitch of up to 60°. In case of a combined roof and facade via a 

curved or continuous eaves detail, advice should be obtained from 

your local office. 

Kalzip ® AluPlusSolar is available with a choice of two different 

photovoltaic thin-film solar modules PVL-68 and PVL-136, each 

with different performance characteristics. Roof and facade 

surfaces can therefore be used to their optimum potential. 

0 2 4 6 8 10 12 14 

CEE [GJ/m] and EPT [a] 

Ranges from different studies for calculation of: 

Cumulative expenditure of energy (CEE) in gigajoules per m 

Energy payback time (EPT) in years 

(Data source: Möller, Jochen. 1998. 

Integrierte Betrachtung der Umweltauswirkungen 

von Photovoltaik -Technologien.) 

20


Technical Data 

Surface required per kWp 

(installation parallel to standing seams) [m 2 ] 

Module length [m] 

Rated power [W] 

Operating voltage V MPP [V] 

Operating current I MPP [A] 

Open-circuit voltage V OC [V] 

PVL-68 

> 18.50 

2.85 

68.00 

16.50 

4.13 

23.10 

PVL-136 

> 18.50 

5.50 

136.00 

33.00 

4.13 

46.20 

Planning guidance 

• In addition to SolarClad, the Kalzip 

AluPlusSolar roof integrated 

photovoltaic system is also suitable for 

new Kalzip roofs 

• Recommended roof pitch min. of 

3°(5%) 

Open-circuit voltage V OC at 

-10 °C and 1250 W/m 2 [V] 

Short-circuit current I SC [A] 

Short-circuit current I SC bei 75 °C 

and 1250 W/m 2 [A] 

Series fuse rating/blocking 

26.30 

5.10 

6.70 

52.70 

5.10 

6.70 

• Kalzip profiled sheets cannot be 

laminated once installed with 

thin-film solar modules, for retrofitting 

we recommend the use of Kalzip 

SolarClad 

diode rating [A] 

Maximum system voltage DC [V] 

8.00 

1000.00 

8.00 

1000.00 

• Minimum radius in the area of the 

profiled sheets fitted with modules 

Pleae note: The values specified ± 5 % represent stabilised values. During the first 8-10 weeks of operation, 

power output may be higher by 15 %, operating voltage may be higher by 11% and operating current may be 

higher by 4 %. 

Design suitability and approval in accordance 

with IEC 61646 

TÜV Rheinland, Cologne, Germany 

Possible methods of installation 

Kalzip SolarClad parallel to 

standing seams 

Kalzip SolarClad perpendicular to 

standing seams 

Kalzip SolarClad elevated from roof 

Day Nursery for the Companies Sodeb'O, France 

Arnold Lodge Phase 2, United Kingdom 

Sports hall Frechen, Germany 

Schiller School Bretten, Germany 

21



Facade Solutions 

Innovative 

building envelope 

technology 

22


Unique building envelopes 

Complementing contemporary architectural design 

with stunning aesthetics 

Designers and architects throughout 

the world use Kalzip ® roof and facade 

systems to create stunning buildings. The 

combination of traditional materials such as 

glass and wood with Kalzip ® aluminium 

profiles is already an established approach 

to leading-edge architectural design. 


• Durability 

• Lightweight 

• High bearing capacity 

• Saltwater-resistant aluminium alloy 

In this respect, a facade becomes so 

much more than a building envelope – 

it highlights the unique individuality and 

character of a building. Kalzip ® facade 

systems provide architects with the ideal 

scope for creating contemporary and 

individual designs. 

The wide range of shapes, surface finishes 

and colours available provides virtually 

unlimited opportunities for enhancing 

architectural design – functionality is 

complemented by stunning aesthetics. 

The flexibility of Kalzip ® facade systems 

creates exciting potential for pushing the 

boundaries of contemporary architectural 

design even further. Individual and 

future-oriented solutions highlight the unique 

nature of a building. 

23

Louisiana Superdome, USA 

Kalzip FC rainscreen system 

Ingenious, attractive, 

innovative and economical 

Kalzip FC rainscreen is a non-penetrative 

facade system that incorporates a 

fast-to-install lightweight flat rainscreen 

panel, suitable for both new build and 

refurbishment projects. 

The main feature of the system is its 

flexibility which allows the installation of the 

profiles to be carried out in two directions, 

either from the top down or from the bottom 

up. 

This choice of panel mounting direction is a 

unique benefit which enables not only easier 

and faster installation compared to 

conventional panel systems but also allows 

scaffolding or subsequent construction work 

to be coordinated independently from the 

installation process. 

The system's innovative design and technical 

capabilities also allow individual sheets to be 

removed and installed without compromising 

the adjoining panels or the overall integrity of 

the facade system. 


• Contemporary, visually stunning 

aesthetics 

• Several different standard profile 

widths 

• Simple and fast installation 

techniques 

• Optimised panel geometry 

• Variable acoustic and thermal 

insulation options 

• A wide range of colour and surface 

finishes 

• High structural performance 

• Creation of fixed point 

Profile options and dimensions 

Materials and finishes: 

FC rainscreen panels are available in stucco 

embossed aluminium EN AW 6025 

(AIMg2.5SiMnCu) and painted aluminium EN 

AW 3004 (AIMn1Mg1) or EN AW 3005 

(AIMn1Mg0.5) The profiles are available as 

standard in a range of RAL / PVDF colours. 

Other surface finishes are available on 

request including stucco-embossed, 

AluPlusPatina, micro-ribbed, perforated and 

with integrated recessed seams. 

Protective foil: 

All material is provided with protective film. 

Please contact us for further information. 

24

Technical information 

Installation and fixing 

The Kalzip FC rainscreen system has been 

designed for horizontal installation and for 

use with all common substructures. 

The panels are fixed into either proprietary 

individual clips or continuous modular rails 

which feature integrated plastic inlays that 

lock the panels securely into place. The 

individual mono-click brackets can also be 

used for creating special details. 

The modular click rail is typically supplied in 

three to four metre lengths. This is not only 

for practical handling reasons but also 

where a break in the facade 

sub-construction is required to allow 

expansion between floors. A specially 

designed setting out tool is available to 

ensure the correct spacing and alignment 

between adjacent rails. The same tool can 

be adjusted to accommodate all standard 

profile cover widths. 

The system components have been 

optimised to enable the system to be 

adjusted and aligned solely via the 

substructure. Fully integrated corner panels 

add a subtle yet harmonious detail to the 

building geometry and enhance the overall 

aesthetics of the facade. 

Installation from the bottom upwards 

Installation from the top downwards 

Individual rainscreen panel demounting 

A particular advantage of this rainscreen system is that, in case of damage to the facade panels, individual panels can be exchanged 

without having to dismount entire facade areas. Please contact us for further information. 

25


Kalzip ® TF facade systems 

Combining a unique facade design with 

optimum functionality 

The sleek profiling of this facade system 

enhances the sophisticated interplay of 

light and shade across all elevations, at the 

same time creating a distinct and unique 

overall appearance with a real sense of 

clarity. The Kalzip ® TF facade system not 

only enhances the individual character of 

the building but also offers optimum 

functional benefits such as outstanding 

thermal insulation characteristics. This is a 

system which is both aesthetically 

appealing and highly practical. 

The Kalzip ® TF facade system is so much 

more than a building envelope – it provides 

planners and architects with a wealth of 

scope to create stunning buildings with a 

highly individual character. This is a 

perfectly systemised solution which is 

available in a range of colours and 

combines sophisticated, appealing 

aesthetics with optimum practicality. 

Special system components are available 

which have been developed specifically for 

the Kalzip ® TF facade system. These 

components provide perfect interfaces with 

other building elements and systems. They 

also add the ultimate finishing touches to 

the optics of the building, creating a 

perfectly integrated overall appearance 

which is distinctive and sophisticated. 

Assembly and installation 

The Kalzip ® TF facade system is suitable 

for horizontal or slightly pitched building 

elevations. Fixing takes place within the 

narrow lower brace between the ribs – 

either inside each rib or in line with the 

longitudinal joints. 

Attachment 

Fastener with JT3-FR-6-5.5xL E10 internal 

Torx drive, or irius ® drive system 

SX-L12-A10-5.5xL. 


• Unique, aesthetic design with a 

distinct “long view” visual appeal 

• Lightweight and therefore 

economical in terms of both cost and 

materials 

• Wide range of acoustic and thermal 

insulation options 

• Harmonised system components 

and interfaces 

• Available in a wide range of colours 

Technical data 

TF800R 


TF800R 

Material: 

EN AW-3004 or EN AW-6025 

Dimensions: 

Thickness 

Constructional width 

Profile length 

Profile height 

Load bearing capacity: 

Surface finishes: 

0.9mm, 1.0 mm and 1.2 mm 

800 mm 

max. 6000 mm 

37 mm 

Load bearing capacity values in accordance with BS EN 

1999-1-4:2007 

Polyester and PVDF 

66.7 200 66.7 200 

800 

Colours: 

RAL standard colours in accordance with the Kalzip ® colour 

chart, special colours available on request. 

200 

Sub-structure: 

Vertical girders or spacer elements 

37 

26


Kalzip Structural cassette facade system 

Economical facade solution offering a combination 

of durability and performance 

Kalzip facade cassette systems 

comprises a variable system of supporting 

coffers in different designs, dimensions and 

lengths. It enables a simple and 

economical construction with very 

good insulation values. 

Perforated facade cassettes offer 

high sound absorption values in technically 

important frequency ranges and are 

used very successfully to ensure 

economical compliance with noise 

protection stipulations. 

The Kalzip facade cassette system 

can span up to 6m between supports, 

eliminating the need for purlins. This 

smooth finish of the cassette provides a 

durable and maintenance free facade, 

without the need for additional sealant. 

The fixings for the cassette system can 

be concealed with the flanges of the tray to 

further enhance the aesthetics of 

the system. 



without supports 

• Provides a smooth, maintenancefree 

facade 

• Concealed fixing system 

• Can be supplied in coated steel or 

aluminium 

• Acoustic and thermal performance 

can be customised to suit specific 

requirements 

Kalzip structural cassette facade system-Typical build up 

Kalzip standing seam on Kalzip structural 

cassette with top hat 

Kalzip TF on Kalzip structural cassette 

without top hat 

1 

2 

3 

4 

5 

6 

Kalzip 65/400 

Vapour barrier 

Insulation 


Top hat to cassette 

E-clip or ST clip with thermal barrier 

1 

2 

3 

4 

TF800R (Applicable for W18/76 & TR35/200) 

Vapour barrier 

Insulation 


* The above are just typical build-up. All the profiles can be lay vertically, horizontally or diagonally. 

27


Kalzip trapezoidal and corrugated profiles 

A variety of profiles - a diversity of designs for roofs 

and facades 

Metal and glass building envelopes 

characterise contemporary architectural 

design for all kinds of buildings. Metal 

building envelopes have not only 

become a striking feature in the design 

of functional industrial and commercial 

properties, but also in public and private 

residential developments. 

Kalzip ® trapezoidal and corrugated 

profiles offer tremendous scope for design. 

The variety of different profiles available – 

ranging from different trapezoidal sections 

to classic corrugated designs - provides 

planners and designers with a wealth of 

scope to create fascinating, unique 

designs. 

Whichever Kalzip ® profiles you decide 

to use, this facade system creates stunning 

buildings with a highly individual and 

unique character. The highest quality of 

manufacture and the functional reliability of 

all components create a solution which is 

not only strong and durable but also 

aesthetically pleasing. 

All elements – the facade and roof 

sheets, the corresponding connecting 

flanges, the end plates of the substructure, 

the transition sheets and the pilaster 

strips – are designed and manufactured for 

complete compatibility and fulfill the most 

demanding requirements stipulated by 

architects and planners. 

In addition to the diverse selection of 

profiles available, there is also a wide range 

of Kalzip ® colour and surface finish options 

which provides maximum freedom of 

design and maximum peace of mind. 

Only high-quality PVDF or polyester-based 

paints are used for coating Kalzip ® 

trapezoidal and corrugated profiles as 

this ensures our products meet the high 

performance requirements of modern 

building methods. 


• Lightweight 

• High strength 

• Excellent acoustic and thermal 

insulation properties 

• Easy installation 

• Long life expectancy 

• Economical solution 

• Ideal for refurbishment project; 

suitable for all types of existing 

cladding and sub-structures 


Seagate Building, Singapore 

Tradeport Logistics Centre, Hong Kong 

28

Kalzip Kalzip ® Systems 

® Intelligent fixing systems 

The system has been developed with 

careful attention to every single component 

– aesthetics, efficiency, performance and 

safety are of critical importance in every 

case. For instance, a special drill fastener 

has been developed to either blend 

harmoniously into coloured facades or, 

alternatively, to provide stylish accentuating 

colour contrasts. What’s more, the new drill 

fastener offers many functional benefits. 

Developed by SFS exclusively for use on 

the Kalzip ® system, the drill 

fastener joins two thin metal sheets load 

bearing and securely. In comparison to the 

riveting process, the drill fastener saves a 

considerable amount of time during 

installation work. 

Fixing systems 

Substructure 

Maximum Sheet Length 

Fixing Method 

Fastener 

Aluminium 

Steel 

16m (horizontal 6m) 

in bottom flange 

Stainless steel self-tapping fasteners, disc with seal. 

Dimensions 

Kalzip ® W 18/76 

(recommended) 

Thickness: 

1.0 mm 

1.2 mm 

18 

76,2 

Constructional width 

13 x 76.2 = 991 

Side A 

Side B 

13 

Kalzip ® TR 35/200 

Thickness: 

0.9 mm 

1.0 mm 

1.2 mm 

35 

200 

Constructional width 1000 

35 Side A 

90 110 

Side B 

Load bearing capacity: 

Surface finishes: 

Colours: 

Load bearing values: in accordance with BS EN 1999-1-4:2007 (see calculation tables) 

Stucco-embossed 

RAL standard colours in accordance with the Kalzip® colour chart, special colours available on request. 

29


Steba Industria Building, Austria 

Kalzip ® perforated facade systems 

A fascinating interplay of light and shade 

Kalzip ® perforated facade systems 

provide an inspirational and highly creative 

extension to the range of Kalzip ® aluminium 

profiled sheets already available. 

Architects continue to conceive new ways 

of using light to create new and exciting 

effects for enhancing their architectural 

designs. However, the most inspirational 

design can only be successfully 

accomplished with the right materials. 

It requires the perfect combination of 

appealing aesthetics with the highest 

standards of quality and functionality. 

Kalzip ® perforated facade systems provide 

planners and architects with virtually 

unlimited design potential – allowing them 

to turn their visions into a reality. 

A perforated facade solution provides 

immense scope for design creativity and 

the interplay of light and shade. Creating 

aesthetics which change with the light. At 

night, the introduction of lighting adds a 

totally new dimension. An inspirational 

building envelope can totally transform 

a building, making it come alive. The range 

of different hole diameters available means 

that the scope for design is virtually 

limitless. Kalzip ® perforated facade 

systems are a simple, cost-effective and 

elegant solution for creating striking and 

sophisticated designs. 

The strength and quality of Kalzip ® is 

combined with the design flexibility of a 

perforated solution. 


• Ideal for solar shading on transparent 

facades 

• Sophisticated accentuation of facade 

surfaces 

• Differentiates between public and 

semi-public areas 

• Ideal for enhancing the appearance 

of unsightly facades 

• Economic refurbishment of facades 

30


Kalzip ® perforated facade systems offer a wide variety of surface finishes and are available in all standard Kalzip ® widths and lengths. 

Technical data 

Material 

EN AW-3004 or EN AW-6025 

Thickness (mm) 0.8, 0.9, 1.0, 1.2 

Perforation 

Ao 

Rv 3-5 

32% 

Rv 5-8 

35% 

Profile Dimensions 

Kalzip ® 50/333, 50/429, 65/305, 65/333, 65/400,FC30/400 

AF65/333, AF65/434 

TF800R, TR35/200,W18/76 

Kalzip perforated profiles 

Kalzip 


Kalzip FC30/400 

Kalzip TF800R 

In lower flange 

In wide flange 


Trapezoidal & corrugated 

Kalzip TR35/200 Kalzip W18/76 


Full surface 

31



Bespoke 

Solutions 

Aesthetics 

and proven 

performance 

32


Kalzip Bespoke Solutions 

Guaranteed watertightness for open panel systems 

Kalzip cladded systems were developed to 

satisfy the increasing demand for open joint 

systems on complex roof geometry. The 

architecture of the roof is becoming 

increasingly important, requiring more 

sophisticated cladding solutions to be 

developed. The Kalzip Cladded System 

allows the architect complete freedom to 

use any panel or louvre system on the roof 

without the need to penetrate the 

waterproof layer of the roof system. 

The Kalzip system can be designed and 

installed in the normal manner. An 

additional cladding system can be installed 

on top of the Kalzip system by using unique 

Kalzip seam clips and an extruded 

Aluminium framework to mount the panels 

on top of the Kalzip without having to make 

a single penetration through the roof. The 

Aluminium framework is designed to allow 

final adjustments of the support structure to 

guarantee the perfect alignment of the 

external clad panels. 

The joints between the external panels are 

normally left open with a gap of 10 to 

15mm between the panels. The rainwater 

will drain between these gaps onto the 

Kalzip system, and then to the gutter and 

rainwater disposal system. The system 

does not require any silicone joints between 

the panels which eliminates the 

requirement of maintenance and avoids 

any streaking or dirt accumulation between 

the panels. 


• Attachment of the external panel of 

louvre system with no penetrations 

through the waterproof layer 

• Open joints between the panels or 

louvres eliminating maintenance and 

reducing cleaning requirements 

• Adjustable system allowing perfect 

alignment of the external panels or 

louvre system 

• Minimal maintenance other than 

cleaning of the external panels 

• Improved acoustics due to the air 

gap between the external panels and 

the Kalzip 

• Complete flexibility to use any 

external panel 

• Able to meet any acoustic or thermal 

performance requirement 


China Central Academy of Fine Arts, 

China 

Supreme Court, 

Singapore 

33



Acoustic Systems 

Solutions for 

auditory 

applications 

34


Tailored to high acoustic performance 

Combining Kalzip’s proven durability and versatility 

with effective acoustic insulation 

Kalzip roof constructions can be modified 

to accommodate various acoustic 

performance requirements, by 

incorporating other layers such as high 

density insulation, acoustic boards and 

flexible membranes to provide increased 

sound reduction performance and by 

perforating the liner to provide improved 

sound absorption performance. 

Acoustic performance is an important 

consideration in the design of buildings, 

especially within the education sector. 

Multi-layer forms of construction achieve 

better results and the built-up Kalzip 

system allows for many combinations to 

address various acoustic requirements 

within a building. By using its different 

system variations Kalzip can assist in 

achieving the right sound reduction 

and/or absorption levels required for 

specific applications. 

Over 80 tests have been conducted 

on Kalzip roof constructions for air-bourne 

sound reduction and sound 

absorption levels. 

Air-bourne sound reduction 

A standard insulated Kalzip roof 

construction will have an approximate 

weighted sound reduction (Rw) of 33dB 

with an aluminium trapezoidal liner and 36 

dB with a steel trapezoidal liner. 

The Rw can be increased by varying the 

number and the densities of the insulation 

layers as well as adding additional mass 

into the construction e.g. through the 

incorporation of high density Kalzip 

insulation, Kalzip acoustic board or Kalzip 

acoustic membrane, etc. 

In situations with overt external noise near 

a railway or airport, for instance there is 

high density Kalzip acoustic board to help 

reduce incoming sounds. 

Recent tests carried out incorporating 

varying types and levels of mass have 

recorded sound reduction rates of between 

33dB and 52dB depending on the product 

combinations applied. 

A valid consideration is Kalzip Nature Roof 

which adds weight and therefore ‘mass’ to 

a Kalzip system build up especially when 

fully saturated. This solution can be a 

natural way of providing dB reduction and a 

number of additional benefits. 

Sound absorption 

Sound absorption is achieved by 

perforating the metal liner sheet and 

incorporating a ‘soft’ absorbing material 

behind it. Different combinations of 

perforations and levels of insulation will 

give varying results of sound absorption. 

Impact noise due to rainfall 

In all Kalzip roof construction the top layer 

of insulation is typically a low density 

mineral fibre insulation which is slightly 

compressed to the underside of the Kalzip 

outer sheet. The Kalzip anti-drumming 

membrane is highly effective and inhibits 

the build up of resonant vibrations. 

National Convention Centre, Hanoi 

35


Liner roof system 





Cement board 


Purlin 

Structural cassette roof system 






Top hat 


Structural deck roof system 





Cement board 


Top hat 

Structural decking 

36


Project: Foshan lignan Pearl Stadium, China 

Architect:Pan Weijiang, Architectural Design & 

Research Institute of Guangdong Province 

37



Nature Roof ® 

A robust and 

sustainable 

green roof 

system 

38


The Kalzip Nature Roof ® is unique 

both in terms of its construction and design 

There is nothing to compare with 

the fascinating wonders of nature. In 

this day and age, the preservation of our 

natural environment has become more 

important that ever before. Kalzip ® offers a 

perfectly balanced and complete solution – 

it not only enhances the aesthetic appeal of 

a building, but also provides important 

environmental benefits. 

The Kalzip Nature Roof ® meets high 

environmental, technical and design 

requirements. This lightweight roofing 

system improves thermal insulation and 

is kind on resources – essential features for 

intelligent and environmentally-friendly 

architecture. 

The Kalzip Nature Roof ® provides 

extensive greening and is 

low-maintenance. This roofing system 

successfully combines environmental 

benefits with stunning architectural design. 

The Nature Roof provides almost total plant 

cover – a natural carpet of colours which 

changes with the seasons. 

Low-growing, self-regenerating, 

drought-resistant sedum plants transform 

dreary roofscapes into an oasis of colour. 

Sedums are extremely hardy, they can 

withstand smoke and exhaust fumes 

and are resistant to both frost and wind. 

The additional features of the Kalzip 

Nature Roof ® are certainly impressive: 

• Significant reduction in the load placed 

on the drainage system and time 

delayed release of excess rainwater 

into the local and domestic drainage 

systems. 

• Reduced load placed on the drainage 

culverts, storage tanks, sewage plants 

and rivers. 

• Considerable reduction in waste water 

and sewage costs. 

• Approximately 50% of the rainwater is 

stored. 

• Approximately 30% of the rainwater 

retained by Kalzip Nature Roof ® is 

returned to the natural cycle by 

evaporation. 

Left to Right: 

Universal Studio, Singapore 

• Improved oxygen levels, improved 

microclimate and air humidity in the 

area surrounding the building. 

• Absorption of dust and pollution 

such as CO 2 . 

• Thermal and mechanical protection 

against the effects of temperature, 

weather and radiation. 

• Improvement of sound insulation, 

internal and external noise is reduced. 

• Improved thermal insulation and 

room climate throughout the year. 

• Temperature peaks are levelled out and 

temperature variations caused by 

temperature fluctuations are reduced. 

• Creates a more attractive and 

comfortable place in which to live 

and work. 

• Reduced temperature-related 

deformation processes which affect 

components. 

• Increases the value of the building. 

• Provides an ecological balance in the 

face of increasing urbanisation. 


• The Nature Roof is constructed 

directly onto the Kalzip ® profile 

panels without the need for 

additional sealing work. 

• The aluminium surface offers lasting 

protection against rooting and 

moisture penetration. 

• The complete modular package 

features a highly economical, 

modular design, guaranteeing 

quick and easy installation. 

• Nature Roof offers the same level 

of planning security, ease of handling 

and recognised performance 

characteristics as you would expect 

from the Kalzip ® building system. 

• Anti-slip devices ensure that even 

sloping or curved roofs can be 

landscaped. 

• The roof still acts as a lightening 

conductor. 

• All components are environmentally 

friendly and can be recycled. 

• Uniform planning – even if only 

sections of a roof are to be 

landscaped. 

• Kalzip ® can be easily converted into 

a Nature Roof, by taking into account 

the static requirements. 

• When the greenery has been 

removed, Kalzip ® makes an 

excellent, attractive roof covering. 

• The Kalzip ® aluminium profiles offer a 

high level of protection against 

mechanical damage of the roof during 

installation of the Nature Roof 

components. 

• Kalzip ® is resistant to flying sparks 

and radiant heat. These properties 

are maintained if the corresponding 

installation requirements and local 

construction regulations are 

followed. 

39


Project: Jalan Besar Stadium, Singapore 

Architect: SAA Partnership


Components and 

accessories 

Kalzip components and accessories are specially 

designed to meet the exacting requirements of 

discerning architects and planners. Perfectly 

matched system components and a comprehensive 

range of accessories provide the ideal complement 

to Kalzip's unlimited design potential. 

Visible elements can be adapted to match the 

individual hue of the profiles or the surface of the 

profiled sheets to produce a synergistic harmony 

with the roof and wall cladding surfaces. The 

materials are manufactured according to the most 

stringent technical standards, with regards to 

longevity, ease of handling, installation safety 

and recyclability. 

Kalzip components and accessories feature the 

renowned and outstanding quality of Kalzip 

products - performance and reliability right through 

to the very last detail. Coupled with compliance with 

the current regulations and relating to the thermal 

insulation of building envelopes, the required fire 

protection class and the relevant industrial norms. 

41


Kalzip Clips 

Advanced E Clip 

The Advanced new E Clip is a steel 

reinforced Polyamide clip (Patent pending) 

which is designed to further enhance the 

performance of the overall Kalzip system 

by improving the thermal, acoustic and 

movement performance of the Kalzip 

System. The metal insert guarentees the 

strength of the clip, while the polyamide 

case completely eliminates and thermal 

bridging between the substructure and the 

Kalzip roof, and prevent any concers 

regarding dissimilar metals. 


• No thermal bridging between the 

substructure and the Kalzip roof. 

• Reduced frictional resistance 

between the clip and the roof 

• Improved sound reduction across 

the roof 

• Removal of Bi-metallic corrosion 

concerns 

• Full range of advanced E Clip heights 

Thermal Bridging 

The Advanced new E Clip virtally eliminates 

any thermal bridging between the substructure 

and the Kalzip roof. For a typical 

roof which uses 2.5 clips per square metre, 

the U Value with 140mm of rockwool will 

reduce by approximately 20% when using 

Heat transfer coefficients Kalzip ® clips 

U value [W/(m 2 K)] 

0.4 

0.3 

0.2 

0.1 

Aluminium 

0 0.5 1 1.5 2 2.5 3 

Clips per m 2 

the new E140 when compared to the 

traditional ST140 clip. The reduction in U 

Value across the roof can lead to significant 

savings in the amount of rock wool required 

to achieve the required U Value, 

140 

150 

160 

170 

Kalzip ® E 140 



Kalzip ® E 170 

N o t e : 

It is clearly apparent that when Kalzip ® 

compound clips are used, the U values 

are not dependent on the number of 

clips. The heat transfer is related to the 

thickness of the heat insulation. 

Acoustic Performance 

The polyamide shell used in the advanced 

E Clip eliminates the acoustic bridging 

which is prevalent when the Aluminium ST 

Clips are used. By replacing standard 

Aluminium ST Clips with the advanced E 

Clip, the acoustic performance of the 

overall roof can be improved by 2dB. 

In Plane Movement 

The forces incurred when the roof sheets 

move over an Aluminium clips on a roof are 

significant, particularly when the length of 

the Kalzip sheet if longer than 40m. The 

movement of the roof occurs on a daily 

basis primarily due to thermal expansion 

and contraction of the roof. With perfect 

alignment of the clips the in plane forces 

transmitted through the clips on a 40m long 

sheets using an Aluminium clip is 1,200N. 

By replacing the Aluminium ST Clip with the 

advanced E Clip the force is reduced to 

350N, approximately 30% of the load. 

The reduction in force induces less load 

into the fixings and substructure, resulting 

in smaller or fewer fastenings required for 

the fixing of the clips. A further signficant 

benefit is the elimination of all noise due to 

the movement of the Aluminium roof sheets 

over the Aluminium clips. 

For all roofsheets with a length greater than 

40m the use of advanced E Clips is highly 

recommended. 


• Reduced in-plane forces between 

the Clip and the roof sheet. 

• Elimination of any potential noise 

between the roof sheet and the clip 

• Reduced number of fixings required 

• Quicker to install 

Advanced E Clip 

42


E clip dimensions 

The range of E clips is E5, E20, E40, E60, 

E80, E100, E140, E160 and E180 with clip 

heights and working dimensions as shown 

in the table below. 

All clips can be installed to structural 

decking and top-hat sub-purlins e.g. Kalzip 

deck roof system. Kalzip liner-deck roof 

system and Kalzip acoustic roof system 

requires top hats to pick up the hole 

centres. 

Clip type 

E-5 

E-20 

E-40 

E-60 

E-80 

E-100 

E-120 

E-140 

E-160 

E-180 

Spacer 5 

Spacer 10 

Combination 

- 

- 

E-20 + Spacer 10 

- 


- 


- 


- 

E-100 + Spacer 10 

- 

E-120 + Spacer 10 

- 

E-140 + Spacer 10 

- 

E-160 + Spacer 10 

- 

- 

- 

Mass (g) 

118 

130 

157 

146 


166 

193 


205 

194 

221 


240 

228 

255 

246 

273 

263 

17 

27 

Overall 

clip height 

H (mm) 

66 

81 

91 

101 

111 


131 

141 

151 

161 


181 

191 

201 



231 

241 

W (mm) 

65/ * 50/ * AF65/* 

N/A 

20 

30 

40 

50 

60 

70 

80 

90 

100 

110 

120 

130 

140 

150 

160 


180 

20 

35 

45 

55 

65 

75 

85 

95 

105 

115 

125 

135 

145 

155 

165 


185 

195 

5 

20 

30 

40 

50 

60 

70 

80 

90 

100 

110 

120 

130 

140 

150 

160 


180 

Spacer 10 

Note: 

The values quoted for W do not take account of any reduction in the cavity as a result of fixing in the troughs 

of trapezodial liner sheets. 

Spacer Pads 

In addition, there are two thickness of 

spacer pads available which can be added 

either individually to the base of the clip 

giving height increments of 5mm and 

10mm respectively, or combined to give an 

overall maximum 15mm increment. 

The spacer pads are not supplied 

pre-fitted, they are site-applied only. The 

spacer pads can be used to provide 

tolerance for minor discrepancies in the 

underlying substructure. 

Advanced E-clip dimensions 

Spacer 5 

Note: 

When using two spacers, the 10mm pad must be 

fitted to the clip before the 5mm and a maximum of 

two spacer pads only is permitted to increase the 

height of the clips. 

(a) View from top 

(b)View from bottom 

Advanced E Clip dimensions (plan) 

Note: All dimensions in mm. 

43

Kalzip Systems 

ST Clips 

The ST clip is a aluminium clip which is also designed to secure the Kalzip profiled 

sheets. The installation of ST clip should be accompanied by pdyamide thermal barrier 

for thermal insulator purpose.Difference profile height can be achieve as presented in below 

table. 

ST clips - Kalzip self-supporting sheet 

ST clip 

type 

L10 

L25 

L50 

L60 

L80 

L90 

L100 

L110 

L120 

L130 

L140 

L150 

L190 

Clip 

height 

H 

66 

81 

106 

116 

136 

146 

156 

166 


186 

196 

206 

246 

Kalzip 65/* 

W1 W2 

(TK5) 

Not possible 

20 25 

45 50 

55 60 

75 80 

85 90 

95 100 

105 110 

115 120 

125 130 

135 140 

145 150 

185 190 

W2 

(TK15) 

35 

60 

70 

90 

100 

110 

120 

130 

140 

150 

160 

200 

Kalzip 50/* 

W1 W2 

(TK5) 

20 25 

30 40 

60 65 

70 75 

90 95 

100 105 

110 115 

120 125 

130 135 

140 145 

150 155 

160 165 

200 205 

Note: ST clip type number refers to W2 depth of insulation cavity assuming TK5 barrier pad. 

W2 

(TK15) 

35 

50 

75 

85 

105 

115 

125 

135 

145 

155 

165 



H = height of clip without thermal barrier pad 

W1=distance between underside of Kalzip sheet 

and underside of ST Clip 

W2=distance between underside of Kalzip sheet 

and underside of ST Clip with thermal barrier 

pad 

ST Clip base dimensions 

Standard L type ST clip base T type ST clip base for fixing to Timber Double Length (DL) type ST clip 

Please note that special length clips and clip bars are available on request. 

Thermal barrier pads 

Polyamide thermal barrier pads for standard length ST clips 

Polyamide thermal barrier pads for double length ST clips 

Thermal barrier pad 

TK5: 5mm depth 

TK15: 15mm depth 

Thermal barrier pad 

DTK5: 5mm depth 

DTK15: 15mm depth 

Note: All dimensions in mm. 

44

Kalzip Systems 

Project: Supreme Court, Singapore 

Architect: Foster & Partner 

45


Vapour control layer (VCL) 

It is good practice to enhance the 

performance of a roofing system by 

incorporating a suitable vapour control layer 

(VCL). 

A VCL will reduce the movement of water 

vapour from inside the building through the 

roof construction (thereby reducing the risk 

of condensation) and also assists in limiting 

air permeation through the system. 

Kalzip VCLs are available as standard in 

either a clear 3 layer membrane for mid 

range applications (with humidity classes of 

4 or below) or a foil encapsulated 5 layer 

membrane suitable for high humidity 

applications where a greater vapour 

resistance performance is required. 

The VCL should always be installed on the 

warm side of the construction and should 

be continous across its surface. It must be 

fully sealed at all laps, perimeters and 

penetrations in order to ensure its 

effectiveness. 

The type of VCL to be specified would be 

dependent upon the use of the building and 

therefore the condensation risk. 

Recommended Kalzip vapour control layer (VCL) for Kalzip roofing and cladding systems 

Humidity 

Class 3 

Typical building type 

Kalzip VCL 1 

Liner/decking configuration 

Solid liner 

1 Very low Storage areas Kalzip VCL clear with one row of 

Kalzip VCL sealing tape 2 

2 Low Offices, shops Kalzip VCL clear with one row of 

Kalzip VCL sealing tape 

3 Medium Dwellings with low occupancy Kalzip VCL clear with one row of 


Perforated liner sheet and solid or 

perforated decking 

Kalzip VCL clear with one row of 


Kalzip VCL clear with one row of 


Kalzip VCL foil with one row of 


4 High Dwellings with high occupancy, 

sports halls, kitchens, canteens: 

buildings heated with unflued 

gas heaters 





5 Very high Special buildings, e.g. laundry, 

brewery, swimming pool 

Kalzip VCL foil sealed with two 

rows of Kalzip VCL sealant tape 

Kalzip VCL foil sealed with two 

rows of Kalzip VCL sealant tape 

Notes: 

1. The Kalzip VCL must be fully sealed at all side and end laps, penetrations and perimeter detaills to ensure the required level of air-tightness for the building 

envelope. 

2. On humidity class 1 (very low) buildings where there is limited flashing details and penetrations it may be feasible to omit the Kalzip VCL. The Kalzip liner 

sheet should be fully sealed at all side and end laps, penetrations and perimeter in this instance. 

3. Humidity Class of buildings taken from BS EN ISO 1378:2002 - Hygrothermal performance of building components and building elements - internal surface 

temperature to avoid critical humidity and interstitial condensation - calculation methods. 

46


Kalzip insulation 

Kalzip insulation products are fully 

compliant with the harmonized 

European Standard BS EN 13162:2001 

Thermal insulation products for 

buildings – factory made mineral wool 

products – specification. 

The most common insulation used is a quilt 

or flexible slab type of a non-hygroscopic 

material (for example the Kalzip range of 

mineral fibre insulations) in that they will not 

absorb any moisture, but simply retain it on 

the surface of their fibres thus encouraging 

evaporation to take place. 

The insulation is oversized to allow 

compression, reducing any air space 

between the top of the insulation and the 

underside of the Kalzip sheet. A major 

design feature of the Kalzip roof system is 

that no sealants are used in the formation 

of the standing seam, therefore making 

then outer skin of the roof build-up 

permeable to the passage of moisture 

vapour and allowing the Kalzip system 

to breathe. 

The Kalzip standing seam is weathertight 

by virtue of the anti-capillary groove 

situated within the formed seam, but is 

not air tight. 

The use of a compressed insulation, 

completely filling the roof void above the 

vapour control layer, together with the 

breathability of the Kalzip sheet seams, 

negates the need for a breather membrane 

material within the Kalzip roof system. 

Kalzip offers a wide range of insulation 

products for use as fully integrated 

components of Kalzip roofing and cladding 

systems. The range includes glass and 

rockfibre quilt, semi-rigid slab and 

high density slab. 

At the heart of the range are Kalzip 

insulation Plus 35, Plus 37 and Plus 40, 

which are high performance mineral fibre 

quilts offering extremely efficient thermal 

performance. ( 90/90 = 0.035, 0.037 and 

0.040 W/mK respectively). 

To complete the range, further glass and 

rockfibre insulants are available offering a 

wide variety of thermal performance values 

( 90/90 = 0.032 to 0.044 W/mK) together 

with the flexibility of use where additional 

acoustic performance is required, or where 

a rigid insulation material is necessary 

to support the forming of details and 

interfaces at soaker positions, welded laps 

and ridge position of curved sheets. The 

details can be found by referral to the 

Kalzip standard and typical details brochure 

and CAD compatible CD ROM. 

Sample U-value calculation for liner roof system 

Description 

Thickness (mm) 

K-value (W/mK) 

R-value (m 2 K/W) 

Outside air film 

- 

- 

0.055 


0.9 


0.000 

Bitumen Felt 

1.0 

1.298 

0.770 

Rockwool (60 kg/m 3 ) 

50 

0.034 

1.471 

Aluminium Foil 

0.5 

- 

0.000 

Cement Board 

12 

0.533 

0.023 

Kalbau TR 35/200 liner 

0.7 

47.6 

0.000 

Inside air film 

- 

- 

0.162 

Total Thermal Resistance (R-value) 

2.689 

Thermal Transmittance (U-value) (W/m 2 K) 

0.372 


Aluminium Foil 




Cement board 


Purlin 

47


Kalzip fall arrest systems 

Kalzip fall arrest systems (for straight and 

tapered Kalzip sheets) have been 

specifically designed using advanced 

technology and has been fully tested and 

proven for use on the Kalzip standing seam 

system. The constant force post and base 

are manufactured from zinc coated mild 

steel with the domed cap of the post and all 

internal performance components made 

from 316S marine grade stainless steel. 

Workers wearing a full body harness 

lanyard attach themselves to the Kalzip 

safety systems using a Transfastener which 

slides smoothly along the stainless steel 

cable enabling the person to operate 

handsfree. 

In performance terms the post has an 

integral high capacity energy absorbing coil 

which is designed to reduce loads in a fall 

situation to a maximum of 10kN. 

This means that the post nearest to the 

incident absorbs the impact without 

transferring the load across the rest of the 

fall arrest system or onto the roof structure 

itself. This advanced capability allows up to 

three people to be linked to the system at 

any one time. 

The neat cylindrical design is unobtrusive 

and both the post and the base plate can 

be colour coated to match the Kalzip sheet. 

Installation and fixing is via special clamps 

that fix the post to the standing seam; no 

penetrative fixings are required and the 

integrity of the roof is preserved. 

Kalzip fall arrest systems are custom 

designed for each project, using computer 

design software. This unique Windows ® 

software package models and calculates 

loadings to determine optimum spacing for 

the posts. 

Kalzip fall arrest system's installation, 

maintenance and routine certification is 

carried out only by our approved Kalzip 

height safety specialist network. 

Product advantage: 

• Neat, unobtrusive appearance 

• Available colour coated 

• Integral load absorbing capacity 

• 3 users at any one time 

• Non-penetrative fixings 

• Tested and approved for use on 

Kalzip aluminium standing seam 

• CE marked 

• Conforms to BS EN795 

48


Kalzip grillage walkway and handrail system 

The Kalzip grillage walkway and handrail 

system is a modular system manufactured 

from extruded aluminium components. It 

offers a lightweight, durable, self-draining, 

low maintenance construction for simple 

and quick installation to the Kalzip standing 

seam roof system. 

Extruded aluminium seam clips ensure a 

secure fixing method to the Kalzip seams 

without penetrating the sheets. 

Walkway grillage 

The walkway grillage is supplied in modular 

lengths to suit the cover width of the Kalzip 

sheet and consists of 25 mm deep non-slip 

load bearing extruded aluminium bars 

joined using the unique swage lock method 

of construction. 

The bars-in a nominal 30 x 100 mm mesh 

pattern spanning transversely across 

the width of the walkway-are set into 65 

mm deep side 'z' section members. 

The walkway grillage is available in 600 

mm and 900 mm wide panels with other 

widths available if required. Lengths of the 

walkway grillage can be easily cut to suit, 

on or off site, if size adjustment is required 

without any detriment to the walkway 

construction. 

The Kalzip grillage walkway can be 

installed with handrails to both sides, one 

side only or without handrails. 

Roof pitch 

The system can be installed in plane to the 

roof at pitches up to 10°. Above this can 

be accommodated by stepped units. 

Where a flat and level surface is required 

special clip extension pieces are utilised to 

counter the roof pitch. 

Kalzip suregrip walkway 

The Kalzip Suregrip UPVC roof 

walkway system provides anti-slip 

walkways across roofs, for access 

and maintenance traffic. The system 

consists of an assembly of extruded 

PVC-U, moulded PVC-U and stainless 

steel components. The plank 

components are manufactured with 

a patterned surface to give improved 

slip resistance in dry and wet weather 

and meet the requirements of the 

following: 

• HSG33 Health and safety in roofwork 

• The Construction (Health, Safety 

and Welfare) Regulations 1996 

-Regulations 5 and 6 

• Workplace (Health, Safety and 

Welfare) Regulations 

-Regulation 13 

• Scotland - Regulation 27, 

Standard P2.8 

Tests to BS 476 : Part 7 : 1987 Fire Tests 

on Building Materials and Structures 

- Method for classification of the surface 

spread of flame of products show that the 

PVC compound used to manufacture the 

Kalzip Suregrip Walkway System is 

classified: 

• Class 1Y 

Durability 

The Kalzip Suregrip walkway system, 

when subjected to normal conditions of 

exposure and use, will retain integrity for a 

period in excess of 25 years. The white 

PVC compound is UV stabilised and will 

remain colour stable over an extended 

period of time. 

Finish 

Available in white and grey. 

Further details on Kalzip walkways are 

available on request. 

49


Fasteners 

Kalzip recommends Austenitic Stainless 

Steel grade 304 A2 & grade 316 A4 

fasteners for use with Kalzip Standing 

Seam Roof Systems, Facade Systems, 

liners, cassette and structural decks. 

Our range of purpose-designed fastening 

solutions for metal roof and cladding sheets 

include self drilling and self tapping 

fasteners manufactured to the highest 

quality and tolerances. 

Available in a wide range of RAL colours to 

suit the cladding profile, special colours can 

be matched on request. 

Kalzip Standing Seam 

Kalzip facade cladding profiles 

Applications Fastener Type Drive System 

Applications Fastener Type Drive System 

Kalzip ST clip with 

TK5 thermal pad to 

cold rolled purlin 

Kalzip ST clip 

with TK5 thermal 

pad to purlin 

Kalzip ST clip 

with TK5 thermal 

pad to timber 

Kalzip ST clip to 

structural deck 

(2 x 0.63 - 2 x 1.25mm) 

Kalzip ST clip to 


(2 x 1.25 - 2 x 1.50mm) 

or over lining sheet onto 

purlins max 3.2mm 

Kalzip gable end 

clip to ST clip 

Kalzip fixed point 

Drip angle to Kalzip 

Flashing to 

Kalzip ridge 

Self-Drill 

1.2 - 2.0mm 

Self-Drill 

1.5 - 3.5mm 

Self-Drill 

1.5 - 6.0mm 

Self-Tap, Type A 

1.5 - 3.5mm 

Self-Tap, Type B 

3.1 - 12.0mm 

Self-Tap, Type A 

Self-Drill 

(Installed with special 

torque controlled 

setting tool) 

Bulb-Tite Rivet 

Self-Drill 

(Installed with special 

torque controlled 

setting tool) 

Self-Tap 

Type A 

Rivet 

Rivet 

Rivet 

Bulb-Tite Tivet 

8mm Hex 

8mm Hex 

8mm Hex 

8mm Hex 

8mm Hex 

8mm Hex 

8mm Hex 

Rivet 

8mm Hex 

8mm Hex 

8mm Hex 

Rivet 

Rivet 

Rivet 

Kalzip facade 

cladding to cold 

rolled rail 


cladding to hot 

rolled rail 


cladding side lap 

stitching 

Low Profile Head, 

Self-Drill 

1.2 - 3.5mm 


Self-Drill 

1.5 - 6.0mm 


Self-Drill 

4.0 - 12.5mm 

Low Profile, 

Self-Drill 

2 x 0.63 - 2 x 1.25mm 

Kalzip lining sheet / Kalzip structural deck profiles 

Lining sheet / 

structural deck to 

cold rolled purlin 


structural deck to 

hot rolled steel 



side lap stitching 

Hex head, 

Self-drill 

1.2 - 3.5mm 

Hex head, 

Self-drill 

1.5 - 6.00mm 

Hex head, 

Self-drill 

4.0 - 12.5mm 

Hex head, 

Self-drill 

2 x 0.63 - 2 x 1.25mm 

Rivet (Alu/SS) 

DS25 Recess 

DS25 Recess 

DS25 Recess 

DS25 Recess 

8mm Hex 

8mm Hex 

8mm Hex 

8mm Hex 

Rivet 

Steel top hat 

section to 


Bulb-Tite Tivet 

Rivet 

50


Liners 

The TR35/200 is a high spanning 

trapezoidal steel profile suitable for use 

in wall cladding or as a steel liner system 

for roofing systems. TR35/200 is available 

in two thickness, 0.47mm and 0.7mm, and 

in two finishes, hot dipped galvanized and 

white polyester, other finishes including 

PVDF paint finishes are available on 

request. The 1 metre coverwidth of the 

steel profile makes installation fast and 

requires less fixings when compared with 

other steel profiles. 

The liner has excellent spanning 

characteristics, this enable free spans 

of over 2.0m to be adopted. 

The steel liner can be both smooth 

curved and crimped curved to suit 

most requirements. The liner can also 

be perforated to improve acoustic 

performance. 

Liner to Kalzip 65/400 

The TR35/200 Steel liner is particularly 

efficient when used with the Kalzip 65/400 

cladding system. The 200mm pitch of the 

steel liner compliments the 400mm pitch of 

Kalzip 65/400, this can allow the roofing 

system to be constructed without the 

requirement for additional top hat sections. 

In addition to saving the costs, the 

TR35/200 steel liner also dramatically 

increases installation speed, the 200mm 

pitch acts as a perfect template for the 

Kalzip fixing clips. 

35 Side A 

35 

200 

90 110 

Side B 

1000 


Bedok Market and Hawker Centre, Singapore 

Mumbai Terminal T1B, India 

51


Project: Tung Chung Cable Car, Hong Kong 

Architect: Aedas LPT Architects


Materials and 

finishes 

Kalzip roof and cladding systems are available 

in a host of finishes and materials. In 

aluminium, the system is offered in clad or 

non-clad alloys, as well as, special finishes like 

AluPlusZinc or AluPlusPatina, in addition to the 

industrial standard stucco-embossed finish. 

Modern building technology and design makes 

great demands on the weather and corrosion 

resistance of the materials involved, with 

regards to, colour fastness, adhesion and 

resistance against aggressive substances. 

Colour-coated Kalzip aluminium products meet 

these stringent demands and are available in a 

wide variety of standard RAL colours with a 

choice between high quality polyester or PVDF 

coatings. On demand, special colours can be 

supplied too. 

Together with aluminium, Kalzip in stainless 

steel and copper give even more choices to the 

discerning architect or planner. 

53


Materials and finishes 

Natural aluminium 

Kalzip standing seam and profiled cladding 

sheets are available as standard in a 

stucco embossed finish which is achieved 

by processing the natural mill finish material 

through embossing rollers. This provides a 

surface which diffuses light reducing 

reflectivity and glare. 

As aluminium is both stable and durable 

material, it provides excellent service as a 

roofing or cladding without the need for any 

protective coating. 

After prolonged exposure to the elements, 

the original highly reflective surface of 

aluminium will dull down to a uniform patina 

finish and changes in appearance will be 

consistent along any elevation. 

The weathering effect is particularly well 

illustrated on the City of Manchester 

Stadium. In the space of just 12 months the 

original roof had dulled down. Once the 

new North Stand was installed it too will 

start to lose much of its high reflectivity and 

over the coming months will tone down to 

match the original Kalzip material. 

For specifications that can not wait for 

nature to take its course and want an 

instant matt grey appearance, such as 

buildings close to airports or roads, there is 

a pre-weathered finish available in the form 

of AluPlusPatina. 

Colour coated aluminium 

Although, in the majority of cases, 

aluminium provides excellent service 

without the need for any protective coating, 

there are applications where the metal 

requires protection against a particularly 

aggressive environment or the client simply 

requires colour. 

Reasons why a user may choose to specify 

a coating on their systems is that colour 

may be required to match existing 

buildings, to comply with building 

requirements or to conform with the 

customer’s visual expectations or it may be 

that the use of infra-red paint may be 

required to aid reflectivity. 

Kalzip profiled sheets are available in 

three standard pre-coated systems: 

• Polyester coil coated 

• Abrasion resistant coated (ARS) 

• Polyvinylidene flouride (PVDF) 

AluPlusZinc 

Kalzip AluPlusZinc offers all the performance 

benefits of traditional aluminium together with 

the aesthetic appeal of zinc. The unique 

patented PEGAL process produces a highly 

durable fusion between the aluminium 

substrate and the thin zinc layer eliminating 

most of the corossion problems associated 

with zinc roofing and allowing simpler and 

more cost effective roof constructions to be 

created. 


• Lightweight yet strong material 

• Speed of installation compared with 

traditional systems 

• Non-ventilated, warm roof 

construction 

• Complimentary associated flashings 

• Trained installer network 

AluPlusPatina 

Kalzip AluPlusPatina provides an attractive 

metallic design option with a high quality, 

matt appearance. 

The pre-weathered profile sheets are made 

from resistant stucco embossed aluminium 

with additional surface treatment. With this 

treatment, the aluminium surface loses its 

natural shine and significantly reduces 

reflection - by up to 20% in some cases. 

In addition, Kalzip is available in a variety of 

materials and finishes including zinc, 

stainless steel and copper, providing the 

specifier with unrivalled aesthetic and 

performance options. 

54


Copper 

Copper Kalzip combines the aesthetic and 

durable properties of copper with the added 

benefit of low costs over the material’s 

lifespan. 

It is an exceptionally strong, anti-corrosive 

and virtually maintenance-free material with 

an initial bright appearance that weathers 

gradually to mellow bronze tones through 

to a rich green patina in roofing and 

anthracite brown in vertical applications. 

Copper Kalzip can also be offered partially 

or fully pre-weathered. 

Stainless steel 

The Kalzip standing seam roofing and 

cladding system can now be supplied in 

austenitic stainless steel - a long life, low 

maintenance and corrosion resistant 

building material available in more than one 

finish. 

A wide range of stainless steel fabrications 

is available to fully support a roof or wall 

specification. 

Galvanised steel 

Available across the entire Kalzip range 

of liner sheets, liner trays and structural 

decks - galvanised steel offers both utility 

and economy. 

In applications where increased 

corrosion-resistance is required, together 

with the strength of steel, hot-dip galvanised 

(HDG) steel would often be specified. The 

zinc coating on HDG steel preferentially 

corrodes rather than the steel, so the onset 

of rust at exposed edges and surfaces is 

delayed, in some cases indefinitely.The 

natural mill finish is characterised by 

crystallisation patterns on the surface, a 

result of the hot-dip galvanisation process. 

The standard zinc coating weight for 

HDG steel in mill finish is 275 g/m 2 , tested to 

ASTM A 653 (M). 

AlZn steel 

The aluminium/zinc alloy coating 

on AlZn ® steel imparts corrosion resistance 

of up to four times the life of 

galvanised steel. 

Superior impact resistance, low 

maintenance and high durability makes 

AlZn ® steel an attractive choice as part of a 

Kalzip roof or facade system. 

Colour-coated steel 

Hot-dip galvanised (HDG) steel is also 

available in colour-coated options for use in 

the Kalzip range of liner sheets, liner trays 

and structural decks. 

Colour coating would provide added 

corrosion protection to the HDG steel 

substrate and, at the same time, offer a 

wide array of standard RAL colours to suit 

different aesthetic requirements. On 

demand, special colours can be 

supplied too. 

Colour-coated HDG steel products 

are available in two standard pre-coated 

systems: 

- Polyester coil coated 

- Polyvinylidene fluoride (PVDF) 

It is available as an option for Kalzip 

trapezoidal and corrugated profiles, Kalzip 

Structural decking profiles and Kalzip 

Structural cassette profiles. 

55

Kalzip ® Systems


Project: AsiaWorld Expo, Hong Kong 

Architect: Ronald Lu & Partners (HK) Ltd. 

and Aedas LPT Architects 

System design 

guidelines and 

performance 

characteristics 

Kalzip has developed system design, specification and 

product innovation to guarantee compliance with the latest 

Building Regulations without compromising the overall 

performance capabilities or aesthetic potential. 

With proven durability and high performance, Kalzip has the 

capacity to meet the complex and rigorous requirements of 

the most challenging buildings. Being a multi-component 

built up system, Kalzip can be precisely tailored to meet the 

needs of the individual project – addressing prime concerns, 

such as corrosion resistance, sound reduction/absorption, 

thermal performance or condensation control – in addition to 

other fundamental performance requirements such as load 

span capability. 

Performance of the system was established by the unique 

‘zip’ technology – ensuring a weather tight seam which also 

allows the roof to breathe naturally. 

A non-penetrative, patented clip ensures smooth thermal 

cycling of the external sheet over the clip head whilst at the 

same time facilitating outstanding spanning capacity under 

high wind loading. Combined with Kalzip’s pioneering 

on-site roll-forming capability we can provide continuous 

single sheet lengths in excess of 150 metres without end 

laps or surface penetration by fasteners. 

57


Clip Set Out 

Setting-out tolerances 

Kalzip is manufactured to high 

engineering tolerances because of the 

critical nature of the side lap arrangement 

and engagement over the head of the clip. 

The tolerances outlined are recommended 

to enable Kalzip elements to accommodate 

full thermal movement over the clips 

without locking and introducing unwanted 

“fixed points”. It is assumed that the Kalzip 

element when fixed in place will follow a 

straight line or single curve over their entire 

length. Multiple curves resulting in dips or 

sudden changes in slope may cause a 

transfer of “fixed points”. For help 

and advice consult the Kalzip Technical 

Department. 

Variations in one line of clips 

Clips must be vertical on the line of the roof pitch. Structural 

steelwork must allow for the installation of the clips within the 

stated tolerances. 

Variations between lines of clips-plan variations 

It is recommended that lines of clips are set-out to the system 

dimension. 

Cover width 

+ 3mm 

- 0mm* 

Clips must not be set-out skewed. 

Vertical variation of clips heads in line (over any 3 purlins). 

Structural support must not vary in level between purlins. 

* 1mm will be acceptable if limited to a small area of Kalzip sheets, e.g. when 

“closing” to a predetermined finishing point, gable etc. 

Variations between lines of clips-plan variations 

It is recommended that lines of clips are set-out to the system 

dimension. 

Plan variations of clip heads in line (over any 3 purlins). 

NB Applies to complete line of clips only. 

* ± 1 mm when the line of clips is set-out at the system dimension - 1mm 

** Under no circumstances should the distance between adjacent clips be less 

than the system dimension - 2mm 

58


Project: Mabletree @ Anson Road, Singapore 

59


Product parameters 

The flexibility and ductility of aluminium makes Kalzip the perfect 

roofing sheet for beautifully curved and tapered designs. 

Kalzip roof sheets can be produced with a convex or concave 

radius utilising 3 methods: 

• Natural curved 

- minimum convex radii 40m to 52m subject to gauge & 

cover width 

• Machine curved (smooth curved) 

- minimum radii 1.5m to 40m, subject to gauge and finish 

• Crimp curved 

- minimum radii 0.485m - convex only 

Natural curving 

Factory curved 

The following applies to all forms of machine curved profiles: 

• Curves can be produced with, one or two straight legs 

- min leg 400mm 

• Maximum sheet length subject to handleability/transportation 

• Minimum sheet length 1.5m 

Concaved curving 

Kalzip profile 

65 std profiles 


AF std profiles 

AS std profiles 

0.9mm 

16.0 

12.0 

16.0 

18.0 

1.0mm 

12.0 

9.0 

12.0 

16.0 

1.2mm 

16.0 

8.0 

10.0 

12.0 

Parameters 


Profile 

(mm) 

305 

up to 

500 

Gauge 

(mm) 

0.9 

1.0 

1.2 

Support 

spacing 

L(M) 

1.6 

1.8 

2.0 

Convex 

radius 

Ri(M) 

40 

45 

52 

Concave 

radius 

Ri(M) 

45 

50 

60 

Convex curving 




AF std profiles 

AS std profiles 

0.9mm 

7.0 

7.0 

10.0 

10.0 

1.0mm 

3.0 

2.0 

6.0 

6.0 

1.2mm 

2.5 

2.0 

5.0 

5.0 

Waveform - Concave / Convex or Convex / Concave 

Combination of convex / concave parameters as above and 

transition distances as per notes below: 

• Transition distance between two convex or two concave radii 

is a maximum of 600mm. 

• Transition distance between a convex and concave multi-wave 

curve is a maximum of 1200mm 

NB - For radii outside the above parameters please contact the 

Kalzip Technical Department. 

Tapering 

Tapered convex 




0.9mm 

10.0 

10.0 

1.0mm 

6.0 

7.0 

1.2mm 

5.0 

7.0 

Tapered concave 




0.9mm 

12.0 

10.0 

1.0mm 

10.0 

9.0 

1.2mm 

10.0 

9.0 

Site curving 

Site curving is also possible subject to space availability. 

Please contact the Kalzip Technical Department for further details. 

60


Nanjing Olympic Stadium, China 

Tapered sheets 

Tapered Kalzip profile sheets have become 

increasingly significant for roofing 

applications as they can be formed into a 

diverse range of shapes. A roof can offer 

more than just protection: it can give the 

building architectural perfection. For a 

perfect construction some fundamental 

aspects have to be observed. The 

minimum and maximum cover widths are 

between 230mm and 740mm. 

Tapered Kalzip sheets have to be installed 

on the roof by following the precise 

instructions laid down in the relevant 

installation plan. 

It is advisable to check the actual 

dimensions of the substructure against the 

dimensions on the installation plan before 

the production is started. 

The bottom sheet must be supported by an 

insulation material of sufficient compressive 

strength if the taper size exceeds 400mm. 

To achieve the required stiffness of the 

bottom sheet at the eaves end of the sheet, 

the incorporation of an eaves angle is 

essential. The sheets are delivered with a 

standard extra length of 50mm on both 

ends and have to be cut to the required 

actual length on site. 

Minimum construction width 

Maximum width 

Minimum length 

Maximum length 

Gauge 

Curved and tapered 

1 

Kalzip 65 and 50 Kalzip AF 

240mm 

170mm 

700mm 1 

700mm 1 

1500mm 

1500mm 

Dependent on transport Dependent on transport 

0.9 - 1.2mm 

0.9 - 1.2mm 

Possible for construction widths of 230mm to 

620mm max. Only following approval from the 

Technical Department. 

Applies only to stucco-embossed and colour-coated Kalzip ® profile sheets. 

Other material combinations are available on request. 

min. 

Sheet layout example with joints 

Self-supporting up to a pan width of 400mm 

Finishes: 

• Stucco-embossed 

• AluPlusPatina* 

• Coated material (with protection foil) 

• AluPlusZinc (with protection foil)* 

• Stainless Steel* 

• Copper* 

max. 

For construction widths exceeding 

400mm only with additional support 

and clips spaced at 1.0m max. 

* Maximum width for AluPlusZinc, AluPlusPatina, 

stainless steel and copper is 400 mm. 

61


Transverse joints 

It is not always possible to produce the 

required Kalzip ® sheet length in one 

element. In most cases the length of the 

sheets is determined by transport 

limitations, so that the sheets must be 

joined by overlapping. Especially with 

arched roofs the maximum loading height 

of the trucks must be observed. Obviously, 

the requirements for absolute tightness of 

the overlapping joints are very high. 

Therefore it is necessary to take great care 

when making overlapping joints. Overlaps 

are positioned on top of the support, if the 

joint is located at the fixed point. Otherwise 

the profiled sheets have to be joined 

directly next to the support. Joints can be 

either welded or sealed. 

Welded joints 

The Kalzip ® sheets to be joined must 

have an overlap of approx. 10-20 mm. The 

welding seams should be supported (for 

instance by a Z-section or a rigid thermal 

insulation with an intermediate layer of 

aluminium foil). 

Sealed joints 

(only possible with minimum roof pitch of 2.9°) 

The profiled sheets are installed in a 

precise sequence according to the 

assembly instructions. The critical tightness 

of seal is achieved by three rows of silicone 

in the joint zone of the individual profiled 

sheets plus two rows of sealing rivets. The 

overlap is 200 mm. 

2 

2 

4 

Direction of 

assembly 

1 

1 

3 


Mount Stromlo Technology Centre, 

Australia 

BCA College Architecture, 

Singapore 

62


Long length Kalzip 

The Budget Terminal, Singapore 

Kalzip sheets are commonly used in long lengths (with continous lengths in excess of 150 metre being achieved) therefore the 

understanding and control of thermal movement is a prime consideration. 

Thermal movement 

The colour and finish of a roof will also play an important role in determining the anticipated thermal movement. As a rule of thumb the 

following thermal movement rates are adopted for aluminium. It is recommended that on roof areas with sheet lengths exceeding 40m the 

Kalzip reinforced polyamide E clip is used. 

Advanced E clips 

The new Kalzip Reinforced Polyamide 

Clips (E clip) which connect the Kalzip 

standing seam sheets direct to a support 

structure and act as an insulation spacer 

within a Kalzip insulated system, gives 

minimal thermal impairment allowing 

thermal-bridge free roofing and wall 

cladding constructions to be built and the 

necessary regulations to be met with ease. 

The range of Kalzip E clips is manufactured 

and reinforced with a galvanised steel core 

and has been fully tested for structural 

performance in terms of wind suction 

attachment and load compression as 

well as durability. 

When reinforced polyamide E clips are 

used within a Kalzip roof system the 

in-plane forces (friction forces) at the head 

of the clip resulting from thermal movement 

of the Kalzip standing seam sheet are 

dramatically reduced when compared with 

extruded alumimium clips. 

This more efficient accommodation of 

thermal movement is particularly relevant 

when designing the structure, sub-structure 

and fasteners to accommodate long 

lengths of standing seam sheets potentially 

allowing thinner structural material and 

fewer fasteners to be used. 

The Kalzip E clip is the standard 

recommendation for use on roof areas with 

effective sheet lengths over 40 metres 

(length from the fixed point). 

Fixed points and clip tolerances 

To control thermal movement and avoid 

creepage of the sheet down-slope, a 

‘fixed-point’ is introduced into the system. 

Fixed points are usually installed at the 

ridge position, thus allowing thermal 

movement to take place at the eaves 

position. According to the design there 

will always be exceptions to this rule, and 

instances of ‘fixed points’ occurring at 

the eaves position or mid-slope are 

not uncommon. 

The design of the fixed point is based on 

a number of given criteria, such as intensity 

of snow loading, roof pitch and length, 

width and weight of sheeting. 

By using standard formulae with the above 

criteria, the in-plane forces can be 

determined and the correct ‘fixed point’ can 

be adopted. 

Anticipated thermal movement 

in alumimium 

Finish 

Stucco/mill 

Light colour 

Dark colour 

Approx. 

temp 

attained 

40° - 50°C 

40° - 50°C 

70° - 80°C 

Movement 

per metre 

length (mm) 

1.0 

1.0 

1.5 


• Minimal heat transfer allowing 

thermal-bridge free roofing and 

cladding constructions 

• Complies with the requirement of 

National, European and International 

energy conversation regulations and 

standards 

• Excellent properties in the 

accommodation of thermal 

movement, which is particularly 

important where very long sheet 

lengths are used 

• Improved sound reduction 

performance 

• Guaranteed to withstand the rigors 

of UV, live and dead loads, thermal 

cycling etc 

• Safe load transmission from the 

Kalzip standing seam sheeting to 

the structure or sub-structure 

• Quickly and simply installed using 

SFS intec SDK fastener system 

63


Loyang Marine Coast Guard HQ, Singapore 

Lightning protection 

Lightning Conduction 

The Kalzip system offers safe and effective 

protection against lightning strikes and their 

electro-magnetic effect on both plant and 

equipment, by acting as: 

• A lightning arrest or conducting device 

to prevent lightning strikes affecting 

the structure 

• A protective screen to counter the 

electromagnetic effect of lightning 

strikes 

When installing Kalzip roof or wall cladding 

systems there is generally no need for 

dedicated or additional lightning protection 

devices. The calculated probability of 

structurally damaging lightning strikes is 

once in every 500 years. Such a strike 

hitting a Kalzip clad building would cause, 

at worst, no more than a small hole in one 

of the sheet seams. 

Kalzip as a conductor of 

lightning 

Kalzip aluminum profiled sheets can be 

regarded as natural components of a 

lightning conducting system, as per the 

International Standard ENV 61024-1 

“Protection of structures against lightning - 

Part 1: General Principles”, because the 

crimped seams of the sheets give a 

permanent electric connection. 

Technical requirements for 

lightning conducting devices 

• The Kalzip sheets must be conductively 

connected to earth 

• The seams of the Kalzip sheets must 

be fully zipped to ensure contact 

• There must be conductive connection 

of the roof sheets to: 

- a conductive wall cladding (metal) 

- a steel or aluminium sub-structure 

- any concrete sub-structure must be 

reinforced 

Kalzip as a protective 

screening 

If the complete building envelope consists 

of aluminium, i.e. Kalzip systems used for 

both the roof and wall cladding, the 

envelope will halt and collect the electrical 

energy from lightning and safely conduct it 

to earth thereby preventing dangerous 

voltages from affecting the power supplies. 

IT networks and electronic control systems 

connected to the mains power supplies will 

be safely protected from damage and in 

most instances there will be no need for 

additional protective devices. 

64


Skylights, gutters and ridge 

Skylights 

skylight 

Aluminium ridge flashing 

Flashing 


Ridge closure & filler 


Aluminium Clip with 

thermal barrier pad 

Sur purlin 


Purlin 

Gutters 


Aluminium drip angle 

Eaves flashing 






Gutter 

Flashing 

Zed spacer 



Sur purlin 

Ridge 

Ridge decoration panel 

Ridge flashing 

Zed spacer 






Sur purlin 



Purlin 

65


On-site requirements 

Where site or local access restrictions 

apply, Kalzip have the equipment, 

personnel and expertise to manufacture 

on-site. Mobile roll former machines with 

integral generators offer a flexible and 

effective solution. On-site roll-forming can 

be done at either ground, ground to eaves 

or eaves levels, and in the case of the 

latter, 

Requirements for on-site 

production of Kalzip 

• Secure compound to keep coils in 

during production 

• Access to stacker truck capable of 

lifting 3 tonne coils. Dependant where 

coils are stored on site. 

• Material handlers, recommend one 

operative every 6 metres. 

Ground level production 

• Hard ground foundation, capable of 

accommodating tractor unit and trailer 

with roll former. Combined weight of 

38 tonnes (Approx. size 20 m long by 

5 m wide). 

the fully-integrated production facility 

(roughly 6m long) needs to be mounted on 

scaffolding or a similar type of platform. 

It is possible to reposition the mobile rollformer 

during the manufacturing process,so 

that the finished sheets are as close 

aspossible to where they will be required. 

Eaves level production 

• A certified scaffold platform at eaves 

level capable of accommodating the 

roll former, generator and 3 tonne coil. 

Total weight: 15 tonne. (Approx. 12 m 

long by 6 m wide) 

• A copy of the scaffold certification, 

prior to the roll former being loaded 

onto the scaffold. 

• A crane to lift the roll former, generator 

on and off the platform. (First and last 

day of proposed production run) 

• A crane to lift the 3 tonne coils up to 

the platform during the production run 

(Intermediate days during 

production run) 

Appropriate lifting beams can also be 

supplied to carry the sheets into position. 

Kalzip’s professional team produces a full 

operations document, detailing 

requirements, safe working procedures and 

risk assessment. 

Quality control 

• ISO 9002 now applies to all on-site 

production. 

• All quality tests and samples are now 

undertaken on site in keeping with our 

factory tests. 

• All on-site production has same 

dimensional quality as factory 

production. 



The Budget Terminal, Singapore 

• No lapping: The on-site production 

eliminates virtually all requirements 

for lap joints 

• No maintenance 

• Reduced transport costs: Up to 5000 

m 2 of coil can be delivered on a 

single trailer, dramatically reducing 

transport time and costs. 

• Reduced handling on-site: 

Aluminium sheets are half the weight 

of steel, which in turn, reduces 

the amount of labour required 

on site. 

• Reduced crane requirements: Roof 

sheets can be roll-formed straight 

onto the roof, reducing the 

dependency on cranes. 

• Flexible manufacturing: any 

damaged sheets can be replaced 

immediately. 

66


Load span details 

Aluminium Kalzip 65/305, 65/400 and 65/500 with aluminium clips 

The following tables give the allowable loading of various Kalzip 65 profiles with Kalzip extruded aluminium clips. 

All values are for multiple span conditions and are given in kN/m 2 . 

305 

65 

Kalzip 65/305 with aluminium clips 

Gauge (mm) 

Span (m) 

1.0 

1.2 

1.4 

1.6 

1.8 

2.0 

2.2 

2.4 

2.6 

2.8 

Wind suction load case (maximum deflection = span/90) - maximum unfactored load (kN/m 2 ) 

0.8 

4.845 

4.041 

3.428 

2.746 

2.252 

1.881 

1.597 

1.373 

1.194 

1.044 

0.9 

6.728 

5.611 

4.813 

4.185 

3.386 

2.798 

2.351 

2.005 

1.730 

1.495 

1.0 

8.606 

7.176 

6.155 

5.389 

4.344 

3.576 

2.996 

2.548 

2.194 

1.910 

1.2 

10.032 

8.365 


6.282 

5.588 

4.667 

3.885 

3.287 

2.817 

2.442 

Snow load case (maximum deflection = span/200) - maximum unfactored load (kN/m 2 ) 

0.8 

7.027 

5.851 

5.011 


3.294 

2.665 

2.198 

1.842 

1.460 

1.162 

0.9 

7.024 

5.848 

5.007 

4.377 

3.887 

3.232 

2.666 

2.098 

1.642 

1.307 

1.0 

7.020 

5.844 

5.004 

4.374 

3.884 

3.492 

3.037 

2.330 

1.824 

1.452 

1.2 

7.013 

5.837 

4.996 

4.366 

3.876 

3.484 

3.163 

2.798 

2.190 

1.743 

400 

65 


Gauge (mm) 

Span (m) 

1.0 

1.2 

1.4 

1.6 

1.8 

2.0 

2.2 

2.4 

2.6 

2.8 


0.8 

3.730 

3.111 

2.669 

2.311 

1.898 

1.588 

1.350 

1.162 

1.011 

0.889 

0.9 

5.443 

4.539 

3.894 

3.410 

2.878 

2.380 

2.002 

1.709 

1.476 

1.285 

1.0 

6.956 

5.801 

4.976 

5.833 

5.108 

4.544 

3.996 

3.329 


2.415 

1.2 

8.155 

6.801 

5.833 

5.108 

4.544 

3.996 

3.329 


2.415 

2.095 


0.8 

5.354 

4.457 

3.816 

3.336 

2.757 

2.228 

1.836 


1.190 

0.946 

0.9 

5.350 

4.453 

3.813 

3.332 

2.959 

2.660 

2.233 

1.712 

1.339 

1.065 

1.0 

5.347 

4.450 

3.809 

3.329 

2.955 

2.656 

2.412 

1.902 

1.488 

1.183 

1.2 

5.340 

4.443 

3.802 

3.322 

2.948 

2.649 

2.405 

2.201 

1.786 

1.420 

500 

65 


Gauge (mm) 

Span (m) 

1.0 

1.2 

1.4 

1.6 

1.8 

2.0 

2.2 

2.4 

2.6 

2.8 


0.8 

2.962 

2.472 


1.858 

1.535 

1.287 

1.096 

0.946 

0.825 

0.728 

0.9 

4.106 

3.425 

2.939 

2.574 

2.291 

1.933 

1.629 

1.392 

1.204 

1.052 

1.0 

5.245 

4.375 

3.753 

3.287 

2.924 

2.493 

2.093 

1.783 

1.538 

1.341 

1.2 

6.164 

5.142 

4.411 

3.863 

3.437 

3.096 

2.736 


1.988 

1.725 


0.8 

4.279 

3.562 

3.049 

2.632 

2.074 

1.675 

1.380 

1.155 

0.981 

0.793 

0.9 

4.276 

3.558 

3.046 

2.662 

2.363 

2.123 

1.791 

1.435 

1.122 

0.891 

1.0 

4.273 

3.555 

3.043 

2.658 

2.359 

2.120 

1.925 

1.597 

1.248 

0.992 

1.2 

4.266 

3.549 

3.036 

2.652 

2.353 

2.114 

1.918 

1.755 

1.495 

1.188 

67


Aluminium Kalzip 50/333 and 50/429 with aluminium clips 

The following tables give the allowable loading of various Kalzip 50 profiles with Kalzip extruded aluminium clips. 


333 


Gauge (mm) Span (m) 

1.0 1.2 1.4 1.6 1.8 2.0 2.2 


0.8 

0.9 

1.0 

1.2 

3.624 

5.004 

6.384 

6.913 

3.023 


5.323 

5.765 

2.593 

3.579 

4.566 

4.944 

2.271 

2.964 

3.997 

4.329 

2.006 

2.391 

3.318 

3.568 

1.628 

1.970 

2.714 

2.984 

1.349 

1.653 

2.262 

2.535 


0.8 

0.9 

1.0 

1.2 

5.818 

6.433 

6.430 

6.423 

4.138 

5.003 

5.353 

5.346 

3.092 

3.747 

4.410 

4.576 

2.395 

2.909 

3.430 

3.999 

1.907 

2.322 

2.742 


1.539 

1.858 

2.061 

2.474 

1.231 

1.387 

1.539 

1.847 

2.4 

1.137 

1.407 

1.810 

2.182 

0.941 

1.060 


1.412 

2.6 

0.972 


1.432 

1.898 

0.734 

0.827 


1.101 

2.8 

- 

1.057 

1.154 

1.634 

- 

0.655 

0.727 

0.872 

50 

429 



1.0 1.2 1.4 1.6 1.8 2.0 2.2 


0.8 

0.9 

1.0 

1.2 

2.816 

3.887 

4.959 

5.370 

2.349 

3.242 

4.135 

4.479 

2.016 

2.781 

3.547 

3.842 

1.765 

2.429 

3.106 

3.364 

1.571 

1.960 

2.713 

2.923 

1.304 

1.616 

2.220 

2.446 

1.111 

1.356 

1.850 

2.078 


0.8 

0.9 

1.0 

1.2 

4.992 

4.989 

4.985 

4.979 

3.836 

4.152 

4.149 

4.143 

2.873 

3.487 

3.552 

3.545 

2.230 

2.713 

3.104 

3.097 

1.780 

2.103 

2.329 

2.749 

1.354 

1.524 

1.688 

2.023 

1.010 

1.137 

1.259 

1.509 

2.4 

0.937 

1.155 

1.542 

1.789 

0.771 

0.868 

0.962 

1.152 

2.6 

0.801 

0.996 

1.220 

1.557 

0.600 

0.676 

0.749 

0.987 

2.8 

- 

- 

- 

1.369 

- 

- 

- 

0.709 

50 

Notes: 

1. All loads are in kN/m 2 and are assumed to be applied uniformly 

2. The following shading denotesthe limiting criteria: 

support clips deflection stress 

3. The self-weight of the Kalzip sheeting has been taken into account in the above loadings 

4. The following load factors have been taken into account in the design capacity of the sheeting: 

Dead load = 1.4 

Dead load (restraining wind uplift) = 1.0 

Snow load = 1.6 

Attachment resisting wind uplift = 2.0 

Wind load = 1.4 

5. All spans are assumed to be equal or within 15% of largest span 

6. The above snow loadings are applicable for Kalzip sheets with aluminium clips type 190 or below 

7. For loading conditions outside of the above please contact the Kalzip Technical Department 

68


Aluminium Kalzip 65/305, 65/400 and 65/500 with E clips 

The following tables give the allowable loading of various Kalzip 65 profiles with Kalzip reinforced polyamide E clips. 


305 

65 

Kalzip 65/305 with E clips 

Gauge (mm) 

Span (m) 

1.0 

1.2 

1.4 

1.6 

1.8 

2.0 

2.2 

2.4 

2.6 

2.8 


0.8 

0.9 

1.0 

1.2 

3.029 


5.328 

7.125 

2.527 

3.485 

4.443 

5.942 

2.168 

2.990 

3.812 

5.096 

1.899 

2.619 

3.338 

4.463 

1.690 

2.330 

2.969 

3.970 

1.523 

2.099 

2.675 

3.575 

1.386 

1.910 

2.433 

3.252 

1.272 

1.752 

2.232 

2.984 


1.619 

2.062 

2.756 

1.044 

1.495 

1.910 

2.442 

Impose load case (maximum deflection = span/200) - maximum unfactored load (kN/m 2 ) 

0.8 

0.9 

1.0 

1.2 

5.919 

5.916 

5.912 

5.904 

4.928 

4.924 

4.920 

4.913 

4.220 



4.205 

3.688 

3.685 

3.681 

3.674 

3.275 

3.272 

3.268 

3.260 

2.665 

2.941 

2.937 

2.930 

2.198 

2.666 

2.667 

2.660 

1.842 

2.235 

2.442 

2.434 

1.565 

1.899 


2.244 

1.345 

1.633 

1.907 

2.080 

400 

65 


Gauge (mm) 

Span (m) 

1.0 

1.2 

1.4 

1.6 

1.8 

2.0 

2.2 

2.4 

2.6 

2.8 


0.8 

2.312 

1.929 

1.656 

1.451 

1.292 

1.164 

1.060 

0.973 

0.899 

0.836 

0.9 

3.189 

2.660 

2.283 

2.000 

1.780 

1.603 

1.459 

1.339 

1.237 

1.150 

1.0 

4.066 

3.392 

2.910 

2.549 

2.268 

2.043 

1.859 

1.706 

1.576 

1.465 

1.2 

5.437 

4.535 

3.890 

3.407 

3.031 

2.730 

2.484 

2.279 

2.106 

1.957 

Imposed load case (maximum deflection = span/200) - maximum unfactored load (kN/m 2 ) 

0.8 

4.509 

3.753 


2.808 

2.493 

2.228 

1.836 

1.539 

1.307 

1.123 

0.9 

4.505 

3.749 

3.209 

2.804 

2.489 

2.237 

2.031 

1.859 

1.595 

1.371 

1.0 

4.502 

3.746 

3.206 

2.801 

2.486 

2.234 

2.028 

1.856 

1.710 

1.586 

1.2 

4.495 

3.739 

3.199 

2.794 

2.479 

2.227 


1.849 

1.703 

1.579 

500 

65 


Gauge (mm) 

Span (m) 

1.0 

1.2 

1.4 

1.6 

1.8 

2.0 

2.2 

2.4 

2.6 

2.8 


0.8 

0.9 

1.0 

1.2 

1.852 

2.554 

3.255 

4.353 

1.546 

2.131 

2.716 

3.631 

1.327 

1.829 

2.331 

3.115 

1.163 

1.602 

2.042 

2.729 

1.035 

1.426 


2.428 

0.933 

1.285 

1.637 

2.187 

0.850 


1.490 

1.991 

0.780 

1.074 

1.367 

1.827 


0.992 

1.263 

1.688 

0.671 

0.923 


1.569 


0.8 

0.9 

1.0 

1.2 

3.603 

3.600 

3.597 

3.590 

2.998 

2.995 

2.992 

2.985 

2.566 

2.563 

2.560 

2.553 

2.242 

2.239 

2.236 

2.229 

1.990 

1.987 

1.984 

1.977 

1.675 

1.785 

1.782 

1.776 

1.380 

1.620 


1.611 

1.155 

1.483 

1.480 

1.473 

0.981 

1.274 

1.363 

1.357 

0.842 

1.094 

1.264 

1.257 

69


Aluminium Kalzip 50/333 and 50/429 with E clips 

The following tables give the allowable loading of various Kalzip 50 profiles with Kalzip reinforced polyamide E clips. 


333 



1.0 1.2 1.4 1.6 1.8 2.0 2.2 


0.8 

0.9 

1.0 

1.2 

- 

3.433 

4.420 

6.526 

- 

2.864 

3.687 

5.442 

- 

2.457 

3.163 

4.668 

- 

2.152 

2.770 

4.087 

- 

1.915 

2.464 

3.568 

- 

1.725 

2.220 

2.984 

- 

1.570 

2.020 

2.535 


0.8 

0.9 

1.0 

1.2 

- 

4.672 

4.668 

4.662 

- 

3.888 

3.885 

3.878 

- 

3.328 

3.325 

3.318 

- 

2.908 

2.905 

2.898 

- 

2.322 

2.578 

2.572 

- 

1.895 

2.240 

2.310 

- 

1.571 

1.863 

2.097 

2.4 

- 

1.407 

1.853 

2.182 

- 

1.315 

1.561 

1.766 

2.6 

- 


1.643 

1.898 

- 

1.116 

1.325 

1.499 

2.8 

- 

1.057 

1.426 

1.668 

- 

0.958 

1.067 

1.281 

50 

429 



1.0 1.2 1.4 1.6 1.8 2.0 2.2 


0.8 

0.9 

1.0 

1.2 

- 

2.668 

3.434 

5.069 

- 

2.226 

2.865 

4.228 

- 

1.910 

2.458 

3.627 

- 

1.673 

2.153 


- 

1.489 

1.916 

2.826 

- 

1.342 

1.726 

2.446 

- 

1.222 

1.571 

2.078 


0.8 

0.9 

1.0 

1.2 

- 


3.618 

3.612 

- 

3.013 

3.010 

3.003 

- 

2.578 

2.575 

2.569 

- 

2.252 

2.249 

2.243 

- 

1.999 

1.996 

1.989 

- 

1.773 

1.793 

1.787 

- 

1.475 

1.627 


2.4 

- 


1.442 

1.789 

- 

1.245 

1.406 

1.483 

2.6 

- 

0.996 

1.332 

1.557 

- 

0.991 

1.098 

1.316 

2.8 

- 

0.868 

1.168 

1.369 

- 

0.787 

0.872 

1.045 

50 

Notes: 

1. All loads are in kN/m 2 and are assumed to be applied uniformly 

2. The following shading denotes the limiting criteria: 

Kalzip Clips Stress Deflection 

3. The self-weight of the Kalzip standing seam sheeting has been taken into account in the above loadings 

4. The following load factors have been taken into account in the design capacity of the Kalzip standing seam sheeting: 

Dead load = 1.4 

Dead load (restraining wind suction) = 1.0 

Imposed load = 1.6 

Attachment (resisting wind suction) = 2.0 

Wind load = 1.4 

5. All spans are assumed to be equal or within 15% of largest span 

6. The above imposed loadings are applicable for Kalzip standing seam sheets with E.180 clips or below 

7. For loading conditions outside of the above please contact the Kalzip Technical Department 

70


India 

Hong Kong 

China 

Taiwan 

Singapore 

Take advantage of our 

wealth of experience and the 

comprehensive range of 

Kalzip ® services available 

Australia 

The installation of more than 80 million 

square metres of Kalzip ® profiled sheets 

worldwide speaks for itself. 

Renowned architects throughout the 

world greatly value the advantages and 

virtually limitless design opportunities 

offered by the Kalzip ® system. 

Our technical service department can 

provide you with: 

• Tender documentation relating 

specifically to your project 

• Technical support in finding detailed 

solutions 

• Help and support in all matters 

relating to Kalzip ® 

71

www.kalzip.com 

While care has been taken to ensure that the 

information contained in this brochure 

is accurate, neither Tata Steel Europe Limited 

nor its subsidiaries accept responsibility or 

liability for errors or information which is found 

to be misleading. 

Copyright 2012 

Kalzip Asia Pte Ltd 

Singapore 


25 Pioneer Crescent 

Singapore 628554 

T : +65 6768 9081 

F : +65 6898 9374 

sales.sg@kalzip.com 

China 

Kalzip (Guangzhou) Limited 

Suite 2310, North Tower The Hub 

1068 Xin Gang East Road 

Haizhu District 

Guangzhou, China 510335 

T : +86 20 8904 7408 

F : +86 20 8923 1863 

sales.cn@kalzip.com 

India 

Kalzip India Pvt. Ltd 

310, 3rd Floor, Vipul Agora, 

M.G. Road, Gurgaon 

Haryana - 122002 

India 

T: +91 124 4848 800 

F: +91 124 4848 801 

sales.in@kalzip.com 

Hong Kong 


Unit 17-18, 7/F., Delta House 

3 On Yiu Street, Siu Lek Yuen 

Shatin, N.T. 

Hong Kong 

T : +852 2887 5277 

F : +852 2234 6739 

sales.hk@kalzip.com 

Taiwan 


5F., No.1-10, Lane 174 

Huaide St., Banqiao City 

Taipei County 220 

Taiwan (R.O.C.) 

T : +886 2 2257 1418 

F : +886 2 2257 9458 

sales.tw@kalzip.com 

English

AP Systems AP P.1-17(21-7) - Kalzip

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