South Bend Regional Airport, South Bend, IN; Architect: Ken Herceg & Associates, Inc.

; Photo by Abstract Photography, Inc.

High-Performance, Translucent Wall and Skyroof Systems

Jeff Smith Photography

CSI: 08 45 23

What Kalwall is
The most highly insulating daylighting system in the world!
The primary element of the Kalwall System is a flat or curved, structural composite sandwich panel formed by permanently bonding specially formulated, fiberglass-reinforced translucent faces to a grid core constructed of interlocked, structural aluminum/composite, thermally broken I-beams. The natural thermal properties of the sandwich panel can deliver increased energy performance by the inclusion of translucent fiberglass batts or aerogel during the manufacturing process and by specifying a fully thermally broken grid core. U-value options range from .29 to .05 (1.57 to .28 W/m2K) by NFRC for the 2 3/4'' (70 mm) thick panels and .15 or .08 (.83/.45 W/m2K) for 4'' (100 mm) thick panels. Kalwall panels are installed with the efficient, proven ClamptiteTM aluminum system.

Insulation U-value options from .53 to .05 (2.8 to .28 W/m2K) Diffuse-light transmission ranges from 3% to 50% Solar Heat Gain coefficients from 1.0 to under .04 Fiberglass, aerogel or other insulation in various optional densities for extraordinary insulation Lightweight panel and timeproven Clamp-tite installation system installs rapidly

A true sandwich panel for permanency, backed by over 50 years of experience Permanent glass veil erosion barrier architectural face is tough and needs little upkeep Grid core of precision interlocked I-beams may be thermally broken Interior shatterproof faces formulated to meet interior finish, flame and smoke requirements of the toughest codes

BMW Wolverhampton, West Midlands, UK; MDG Architects; Photo by Daniel Hopkins

A Highly Insulated Structural Unit

Outstanding load capacity and structural integrity!

This is NOT possible with competitive systems!

Superior Structural Thermal Break Composite Grid Core 2 5/8'' (68 mm) I-beam 13/4'' (44 mm) Non-conductive break 4'' (100 mm) I-beam 37/8'' (98 mm) Non-conductive break Stronger than aluminum Passes fire testing to 1200F Superior insulation in panels U-values as low as .05 (.30 W/m2K) Stops condensation CRF 80+
Poured and debridged technology does NOT work! And is not Code-approved!

Kalwalls Thermal Break

CRF 80+
South Bend Regional Airport, South Bend, IN; Architect: Ken Herceg & Associates, Inc.

CRF 45-55

www.kalwall.com

Sustainable LEED Contributor

Buckley Army Aviation Support Facility, Aurora, CO; Architect: CH2M Hill; Ron Johnson Photography

University of Alabama Student Recreation Center, Tuscaloosa, AL Architect: TMP Associates, Inc.; Curtis Photographics

Crocker Art Museum, Sacramento, CA; Gwathmey Siegel & Associates Architects Bruce Damonte Photography

www.kalwall.com

8 Daylighting Systems
Wall Systems
1
Structural Sandwich Panels up to 5' x 20' (1.5 m x 6 m), 2 34" (70 mm) or 4" (100 mm) thick are secured to building with simple, Clamp-titeTM aluminum extrusions. System seals panel/panel and building, allowing for expansion/ contraction and proper weepage to channel any moisture to building exterior. May be either flat or curved sandwich panels. Controlled, natural daylight combined with finely tuned thermal and solar controls.
ant Compli

ATFP

Unitized

Curtainwall
2

Sandwich panels, operating/fixed windows, louvers, even opaque panels, factory unitized. Provide rapid installation and permanent weather seal, unlike most stick-built, "frame and glaze" components that are all fieldassembled. Delivered to the job site in large preassembled units up to 5' x 35' (1.5 m x 10.7 m) and larger.

The Single-source Solution!

Window

Replacement
3

Kalwall heavy-duty Window Replacement Systems like our prefabricated Curtainwall Systems are factory-assembled into easily managed building units. Kalwall provides optimum performancecontrolled daylighting and still allows for fulfillment of vision/ventilation requirements. Vandal, graffiti, and impact resistance add up to minimal maintenance expenses with Kalwall.
Chris Cunningham Photography

Standard Unit

Skylights
4

234" (70 mm) and 4" (100 mm) thick flat Skylights up to 5' x 20' (1.5 m x 6 m). 234" (70 mm) Pyramids from 4' (1.2 m) square up to 20' (6 m) square. 234" (70 mm) Geo-Roof units in 17 standard-sized units from 8' to 24' diameter (2.4 m to 7.3 m). Available knocked down or prefabricated.

OSHA Compliant
4
www.kalwall.com

Endless Possibilities
Pre-engineered

Skylights
5
hilliardphoto.com, Photography

Centerline self-supporting ridges with 20, 27, 33, 45, slope to 24' (7.3 m); 234" (70 mm) or 4" (100 mm) Kalcurve 180, Low-Profile 90 in 1' (300 mm) curb width increments, to 25 (7.6 m). Lightweight less than 3 lbs. per square foot (16 kg/m2) means substructure may be minimized. Only thrust-bearing curbs designed to accommodate local live, snow and wind load designs are required.

Custom Skyroof

Skylights
6

Sandwich Panel Systems over substructure designed and installed by others. Flat, curved or combination for design versatility and consistent with all Kalwall Systems. Easy, fast installation, coupled with large-sized panels to speed installations. 234" (70 mm) or 4" (100 mm) possible

Tom Bonner Photography

GREEN LEED

Walkways & Canopies

7

Combinations of sandwich panels and framing components. Standard modular walkways.

NEW!
Fully pre-engineered canopies and walkways, including aluminum structure, are now available!

Clearspan Skyroofs

TM

Taking Kalwall to another dimension... aluminum box beams and Kalwall panels form monolithic, structural enclosures.

Design control, fabrication, delivery and complete installation with singlesource responsibility! Installations completed in weeks not months due to component standardizations and CAD technology. Complete buildings, including Pool Enclosures, featuring built-in non-corrosion and moisture resistance.
www.kalwall.com

Shoji grid variation

Verti-KalTM grid panels

Tuckerman grid panels

Pre-engineered panel units allow for

exceptionally rapid installation, leakproof performance and superior system integrity. Panel Units are factory assembled complete with options such as louvers, fixed or operable windows. Also hurricane-resistant windows to TAS and ASTM standards.

High-performance, Euro-style fixed and operating Kalwall windows with Euro-groove, multi-point locking for maximum safety and security.
6
www.kalwall.com

Designing Panel-Unit Walls

COMPONENTS
Factory-unitized in many combinations up to 5' wide x 35' high (1.5 m x 10.7 m) depending on shipping and handling limitations. Panel-units ready for installation with no additional finishing. Panel-units eliminate superfluous structure required with most other systems.

LOUVERS WALL SYSTEMS

Specify Kalwall fixed-blade louver as required, up to 5' (1.5 m) wide.

THERMAL BREAK SASH

Kalwall-manufactured, projecting sash for top performance up to 5' wide x 4'6'' high (1.5 m x 1.4 m). Fixed and egress units also available. Glazing of all types, 1" (25 mm) thick glazing panels available; factory-installed, if specified. Performance options to AAMA/ANSI PI AW-90.

OPAQUE PANELS
Sandwich panel construction with fiberglass, aluminum or other faces can be combined in the same system for aesthetic value or to fine-tune energy performance.

NOT THIS
THESE

TRANSLUCENT PANEL OPTIONS

STANDARD GRIDS

INSTALLATION
QUICK, LOW-COST, TROUBLE-FREE
Kalwall factory pre-assembled interconnected structural components form rigid, modular units which replace the heavy mullions and floating panels of other curtainwalls. The unique, pre-engineered construction and extreme structural strength of the components permit the largest panel-unit wall sections to be quickly and efficiently installed.

STANDARD PANEL SIZES

Width 4' and 5' (1.2 m and 1.5 m), other widths up to 5' (1.5 m) are optional. Length 3' to 20' (.9 to 6.1 m) standard, 16' (4.9 m) maximum for skyroofs. Thickness 4" (100 mm), 2 3/4" (70 mm). 19/16" (40 mm) and 1" (25 mm) for window glazing only.

STANDARD GRID DESIGNS

SHOJI REVERSE SHOJI

SOME COMMON OPTIONAL GRIDS

Nominal grid size 12" x 24" (300 mm x 600 mm) standard; 8" x 20" (200 mm x 500 mm) optional for flat and curved panels.

OPTIONAL GRID DESIGNS

Other designs and grid sizes available. Please note that spans will vary with different grid patterns. Consult factory.

VERTI-KAL

TUCKERMAN

KAL-TINTS TRANSLUCENT COLORS

White and Crystal are standard but other colors are available. The Kal-tint series and pebble finish are options. Colored translucent insulation inserts are available in an endless palette of colors.
Merry Hill Shopping Centre, Brierley Hill INC Design Associates, Architects

METAL FINISHES
The installation system is available in mill finish or Kalwall Corrosion Resistant Finish, a high-performance coating that meets AAMA 2604, 2605 optional. The finish is highly resistant to acids, alkalis, salt, industrial and moisture-laden atmospheres.

www.kalwall.com

Wall / Panel-Unit Wall System Details

For 23/4'' (70 mm) vertically oriented panels.
These are standard Clamp-tite details. Systems for other conditions, e.g., horizontally oriented, concealed fastener, Kalcurve, Explosion Venting or Blast Resisting, are similar, but do contact Kalwall for specifics. High-performance coatings in Kalwall Corrosion Resistant Finish are standard. CAD versions of these details and more are available at www.kalwall.com.
TM

KALWALL SPAN TABLE 4' (1200 mm) MODULE Maximum Allowable Clearspan
Translucent Panel 2" (51 mm) Batten 31/4" (83 mm) IS-H Silhouette Stiffener Panel Unit Wall Mid-span Joint Nominal Grid Size 12" x 24" (300 mm x 600 mm)

12'-7" (3835 mm) 9'-2" (2794 mm)

23/4" (70 mm) ST+ #4SSSE 16'-2" (4927 mm) 13'-1" (3987 mm) 12" x 24" (300 mm x 600 mm) 19'-7" (5970 mm) 17'-11" (5461 mm) 12" x 24" (300 mm x 600 mm) 24'-6" (7467 mm) 23'-4" (7112 mm) 12" x 24" (300 mm x 600 mm)

Clearspan at 25 p.s.f. (1.2 kPa) wind pressure, L/60 minimum. Spans based on engineering data and tests. Others possible. CAUTION! Spans will vary with panel internal grid core size and orientation. Above based on grid oriented the panel length.

See www.kalwall.com for more complete CAD & Revit Details!

Details 5, 7, and 8 show thermally broken options. All Kalwall windows are thermally broken.

Blue items are field-installed and may require trimming.

www.kalwall.com

Shed/Supported Ridge Skyroof Details

For 23/4'' (70 mm) vertically and horizontally oriented flat panels.
Details for other conditions, e.g., Kalcurve, self-supporting ridge, pyramid, hurricane or blast resistant, are similar, but not identical so be sure to contact Kalwall.

Blue items are field-installed and may require trimming. Factory-sealed perimeter frames.

SPAN GUIDE CHART: 23/4 " (70 mm) Skyroof

5' (1500 mm) module; 8" x 20" (200 mm x 500 mm) grid Live Load Clearspan 30 lb./ft.2 (1.44 kPa) 11'-7" (3530 mm) 40 lb./ft.2 (1.92 kPa) 10'-7" (3225 mm)

5' (1500 mm) module: 12" x 24" (300 mm x 600 mm) grid Clearspan 10'-2" (3098 mm) 9'-0" (2743 mm)

Clearspan @ 25 p.s.f. (1.2 kPa) wind pressure, L/60 minimum. Note: Longer clearspans possible. Contact factory. RECOMMENDED MINIMUM PITCH Skyroofs (field-installed panels) 2":12" (1:6) Note: Exposed metal systems available in mill finish or Kalwall Corrosion Resistant Finish per AAMA 2604. Special finishes available as options.

www.kalwall.com

Dynamic Daylighting
with incredible thermal performance.
Panel options as low as

U-value .05 (0.28 W/m )

2

with 20% diffuse light transmission!

Imagine this Museum-Quality DaylightingTM with thermal performance that also delivers such far superior energy efficiency!

524 lux 630 lux

602 lux 506 lux

967 lux 922 lux

Daylighting Analysis
Take the unpredictability out of your site-specific designs.
Visit www.daylightmodeling.com

Light Transmittance 12% 30-foot room height. Radiance Illuminance for Sept. 21, 12pm Average value for space is 625 lux
Location: Northwest North America

370 lux

912 lux 10
www.kalwall.com

853 lux

Technical Summary
Kalwall is a composite sandwich; various combinations are possible and test data should be interpreted from this point of view. Contact us for further clarification. Listed below are the light transmissions, solar heat gain coefficients, and U-factors for some Kalwall panel face sheet combinations. Others are available. Highlighted values indicate thermally broken panels.

FACE SHEET COMBINATIONS

EXTERIOR COLOR Greenish Blue Aqua Rose Ice Blue White Crystal Crystal INTERIOR COLOR White White White White White White Crystal

% LIGHT TRANSMISSION
2 3/4" (70 mm) thick panels

note 1

SOLAR HEAT GAIN COEFFICIENT @0 < 0.53 U 0.50 0.45 0.46 0.54 0.38 0.52 0.65 0.29 /0.23 0.22 /0.14 0.18 /0.10
U
note 2

note 3

0.53 U 25 29 30 35 20 35 50

0.29 /0.23 0.22 /0.14 0.18 /0.10

U
note 2

0.05
U
note 2

0.05
U
note 2

U
note 2

U
note 2

U
note 2

U
note 2

14 17 18 20 15 20 30

5 6 6 8 8 12 15

3 4 4 6 5 8 10

12 13 14 18 14 20 NA

0.23 0.24 0.24 0.28 0.23 0.28 0.33

0.14 0.14 0.15 0.17 0.15 0.17 0.18

0.10 0.10 0.10 0.12 0.11 0.13 0.13

0.19 0.21 0.21 0.26 0.18 0.25 NA

Kalwall 4'' (100 mm) thick panels U = 0.05 Panel, R-20

NEW Kalwall 100TM Panels for even greater energy performance! FACE SHEET COMBINATIONS
EXTERIOR INTERIOR COLOR COLOR White Crystal Crystal White White Crystal

with...

% LIGHT TRANSMISSION 0.55

U

SOLAR HEAT GAIN COEFFICIENT 0.08

U

0.15
U

0.55
U

0.15
U

0.08
U

The Worlds Most Powerful Daylighting System!

20 35 50
W/m2K = 0.176

12 14 17
Btu/hr/ft2 /F

5 7 8

0.38 0.52 0.65

0.06 0.08 0.10

NA 0.04 0.07

U-value SI conversion: 1.0

1. Approximate values by ASTM E-972. Light transmission values over 30% not recommended for most applications. 2. Panel U-values include grid by NFRC 100 or 102. Certified system U-values vary depending on framing. 3. Shading Coefficient (SC) is equal to 1.15 times the Solar Heat Gain Coefficient (SHGC).

NFRC CERTIFIED SYSTEMS: Kalwall systems provide the best overall U-values as low as .10 (.56 W/m2K)! With light transmission up to 20%. Includes perimeter system.
BOND STRENGTH: Panels and adhesives are tested according to the stringent requirements of Criteria for Sandwich Panels issued by ICC (International Code Council). ES-AC177. Before specifying alternates, insist on actual field proof of bond integrity over a 20-year period.
Caution is urged in accepting look-alikes as equivalents.

WEIGHT: Most panels and systems weigh under 3 p.s.f. (14.65 kg/m2). FIRE TESTS: Although some Kalwall panels contain combustible binder resins (ignition temperature greater than 800F), they will withstand a 1200F flame for one hour with no flame penetration; pass the Class A Burning Brand Test (ASTM E-108), or UL 790 Iisted Class A Roof system. All interior faces are CC-1 by ASTM D-635. Optional flame-spread/smoke developed ratings by UL 723 tunnel tests, including Class A. Kalwall is listed by: ICC #PFC1705 and ATI-CCRR-0173; British Standard 476, Parts 3, 6, 7. NFPA 268 Radiant Panel Test-Exterior Walls.
Whenever reference is made to fire tests, the numerical rating is not intended to reflect hazards presented by this or any other material under actual fire conditions.

DoD and GSA ANTI-TERRORISM COMPLIANT!

UFC 4-010-01
BLAST-RESISTANT CONSTRUCTION
SPECIAL APPROVALS & LISTINGS: FM Explosion Venting Walls standard 4440 FM Wall and Roof Systems standards 4881 and 4471 Hurricane-Resistant Systems NFRC Certified Products Listing UL Listings for Class A Roof System and Faces UFC 4-010-01 DoD Anti-Terrorism Specifications ETA-07/0244 Wall Systems

IMPACT: The shatterproof standard superweathering exterior face will withstand 70 ft.-lbs. (81J) impact. Optional extra-hi-impact faces will withstand 230 ft.-lbs. (311J) impact by UL 972; also small and large missile; resistance even higher.

www.kalwall.com

11

ICC-ES and ATI CCRR

listed for quality assurance and IBC compliance

Metea Valley High School, Aurora, IL; Architect: DLR Group; James Steinkamp Photography

kalwall.com daylightmodeling.com skylightinfo.com

1111 Candia Road, Manchester, NH 03105 U.S.A. 800-258-9777 (N. America) +1-603-627-3861 Inquiries for the UK/EU, contact www.stoakes.co.uk
Kalwall Corporation is engaged in continuing research to improve its products. Therefore, the right is reserved to modify or change material in this brochure without notice. This is descriptive literature and does not constitute warranties, expressed or implied. For statement of warranty contact Kalwall Corporation.

Louis Walker Middleton - Heritage Court, Olympia, WA MSGS Architects; Doug Walker Photo
Kalwall, Kalcurve, and Skyroof are registered trademarks of Kalwall Corporation. Revit is a registered trademark of AutoDesk. LumiraTM aerogel is a trademark of Cabot Corporation.

2012 Kalwall Corporation

5/12 15k

Metea Valley High School, Aurora, IL; Architect: DLR Group; James Steinkamp Photography