Kalzip Installation Guideline
84Pages

Kalzip® Installation Guideline Date 05/2011

This Kalzip Installation Guideline provides the company with the "Installation Instructions" required by the building reg- ulations for installing the profiled sheets. It provides information, general notes and explanations, as well as detailed instruc- tions for installing Kalzip aluminium roof The present Guideline provides a basis for the correct, professional installation of Kalzip profiled sheets. It deals with the usual cases of processing and use. Supplementary guidelines are available for special applications, such as the installation of Kalzip solar power systems or the inclusion...

Overview of contents Introduction 1.0 The System 2.0 Transport · Storage · Inspection 3.0 Clip installation 4.0 Installing Kalzip · renovating with Kalzip 5.0 Connections 6.0 Installations 7.0 Welding · cutting · bending 8.0 Useful hints and advice 9.0 Special tools 10.0 10.0 System components and accessories 11.0 11.0

Overview Page 2.1 Kalzip range of applications 10 2.1.1 Kalzip non-ventilated roof on trapezoidal steel deck 11 2.1.2 Kalzip non-ventilated roof on purlin with trapezoidal sheets inner skin 11 2.1.3 Kalzip non-ventilated roof on timber rafters with visible timber lining 12 2.1.4 Kalzip ventilated roof with common rafter insulation 12 2.2 Kalzip DuoPlus® 100 and Kalzip Duo® 100 13 2.2.3 Kalzip DuoPlus 100 or Kalzip Duo 100 on steel trapezoidal deck 15 2.2.4 Kalzip DuoPlus 100 or Kalzip Duo 100 on timber 16 2.2.5 Kalzip DuoPlus 100 or Kalzip Duo 100 on concrete 17 2.2.6 Kalzip DuoPlus 100 or...

Overview Page 5.0 Installing Kalzip • renovating with Kalzip 5.5 Fixed point design: Kalzip aluminium clip/Kalzip composite clip 38 5.7 Renovating existing roofs with Kalzip profiled sheets 42 6.1.4 Spacer section/sliding element 44 6.1.5 Ridge cover plate 44 6.2.3 Gable end support rail 46 6.2.4 Gable end profile 50/65 (option) only for flat roofs 46 6.3 Eaves closure and static edge reinforcement 48 7.3 Kalzip roof anchor 52 7.4 Fall arrest systems 52 7.7 Seam clamps (Cable clip, Seam clip stainless steel) 53

Overview Page 8.0 Welding • cutting • bending 8.2 Welding backing strip 54 9.0 Useful hints and advice 9.1 Installation template for installing clips 56 9.2 Preassembly of the clips on top hat profiles 56 9.3 Storing long profiled sheets 56 9.4 Installation with several installation groups 57 9.5 Protection when drilling through U disc 57 9.6 Roof projections with clip bars 58 9.7 Roof projections without clip bars 59 9.8 Roof projections constructed from Kalzip profile sheets 60 11.0 System components and accessories Kalzip composite clip type E 63 Fixed point clip bar including fastening...

Overview Page 11.0 System components and accessories Kalzip flashing sheet with large sheet upstand 67 Seam clip stainless steel 68 Seam clip aluminium 68 Compressed adhesive tape 71 Expansion compensating ribbon 71 Repair cover strip 72 Comb-profiled jointing sheet 72 Kalzip welding backing strip 73 Kalzip snow guard system 75 Snow guard bracket 75 Aluminium snow guard pipe 75 Roof step - short grid 76 Roof step - standing grid 76 Aluminium continuous access grid 76 Bracket for aluminium access grid 77 Kalzip vapour and convection barrier 77 Kalzip vapour and convection barrier H 77 Kalzip...

This Installation Guideline specifies the correct method for installing Kalzip pro- filed sheets, the fasteners and accesso- Installing the profiled sheets The profiled sheets may only be installed by skilled workers employed by the ma- nufacturer or by companies who have been properly instructed and authorized or whoever is responsible for laying the profiled sheets, must prepare installation instructions describing how the elements are to be laid, and must give them to the installation companies. In accordance with building regulations Kalzip can only be installed by companies approved...

The System 2.0 The System Kalzip is a system of aluminium sheets designed for low pitched roofs to a minimum of 1.5 degrees when running from ridge to eaves as well as for steeper pitches. Kalzip profiled sheets are available in a variety of construction widths and can be manufactured in different shapes such as straight, convex, concave, convex and concave curved, as well as XT freeform shapes to suit the roof geometry. The aluminium sheets are fixed with clips which are locked into the seam and concealed by the adjacent sheet. This means that the fixings are positioned beneath the roof...

2.1 Kalzip range of applications The application determines the design Kalzip aluminium profiled sheets are suit- able both for non-ventilated and ventilat- ed roofs of any shape or pitch from 1.5° and with any type of substructure or The construction design depends on the individual application. It must take into account the likely effects of snow, wind, heat, humidity and weathering. High thermal insulation requirements can be easily fulfilled. The roof design can be adapted to suit the precise requirements of each individual building by selecting the appropriate thickness of thermal...

2.1.1 Kalzip non-ventilated roof on trapezoidal steel deck This very economical roof system is used both for industrial and residential build- ings. In order to make sure that there are no air cavities under the Kalzip roof skin, compressible thermal insulation is used. Incorporated within the roof system the insulation material is compressed by The loading on the top skin is not trans- ferred to the inner skin as an evenly dis- tributed load but rather at set points via the secret fixing clips. The design roof load must be increased by 15 % when dimensioning the trapezoidal steel sheets....

2.1.3 Kalzip non-ventilated roof on timber rafters with visible timber lining In residential buildings the roof system is frequently built-up using wooden rafters with visible timber lining. This is advan- tageous, because: 1. there is a clear separation between the trades of carpenters, roofers etc. 2. a continuous flat vapour and convec- tion barrier can be installed. The clips can only be fixed directly in the timber lining if this has a minimum thickness of 23 mm. A minimum thick- ness of 19 mm applies for flat press boards, and 18 mm for OSBs. In both cases the fastener is visible from...