KAL-Zlp®

Designs for a Lifetime

The KAL·Zlp· contemporary designs are extremely attractive,

but its beauty is more than skin deep. It is tough and durable,
After 25 years, sacrificial outer layer
and manufactured to the most exacting quality standards for of KAL-ALLO'f9 has protected the
maximum strength and longevity, without the need for constant inner core.
maintenance.

All illustration showing the KAL-ALLO~

manufacturing process unique to
KAL-SYSTEMS.

Any small abrasions to the

surface during installation or use
are disguised by the stucco
embossed finish so it retains its
ENVIRONMENTALLY
exceptional good looks for longer.
FRIENDLY
The care taken during
KAL-Zlp· is made to withstand the Increasingly, aluminium used
construction by TEAMKAL·,
ravages of wind, rain, worldwide is produced using safe,
Hoogovens approved, fully
and airborne pollution. environmentally friendfy hydro
trained installer network, ensures
The KAL-ALLOY· . from which electric power. KAL-ALLOY·,
that KAL-Zlp· lasts a lifetime.
KAL-Zlp· and KAL-BAU· sheeting which has a proven long lifespan
and cladding sheets are can be unzipped once the
KAL·Zlp· • AN IMPRESSIVE
produced· has a unique building has served its purpose
ALL·ROUND PERFORMANCE
sacrificial outer layer which and re-used on new buildings.
prevents acid rain and industrial Or the entire material can be fully KAL-Zlp· meets and exceeds
emissions trom reaching the and safely recycled for only 5% of the most stringent quality and
high-grade aluminium core. the original energy consumption. performance requirements.
Its standard stucco-embossed Our in·house Quality Assurance
When it comes to life in service
finish weathers to provide an Programme ensures that the
KAL-Zlp· is an equally convincing
attractive even grey patina over highest standards are maintained
proposition. Once installed, the
the whole roof area. Hoogovens from ingot to finished product.
system requires virtually no
Aluminium uses high grade cfad As a result, KAL·Zlp· is accredited .
maintenance throughout the life of
and unclad alloys, including a with BBA Certification, French
the building. Unlike less durable
high percentage of recycled D'Avis Technique and German
systems, it will not rust - even on
material, together with BS and Zulassung with Hoogovens
the cut edges - and there are no
RAL colour coatings in a variety ot Aluminium Building Systems,
fixing holes to corrode or leak.
paint systems, known as Haydock, being accredited
KAL-KOLOR '" . ISO 9002.

4
KAL-Zlp®
Features and Performance

KAL-Zlp·, the original Standing Seam Roofing and Cladding MULTIPLE DESIGN OPTIONS
System, has many advantages to the building designer and owner.
From concept to completion and beyond Hoogovens help with Straight Sheets
their full in-house design and tabrication service known as
KAL-FORM·. Backed by their TEAMKAL· national network ot Cranked Sheets
approved Installers, with over 500 trained personnel, you can expect
'right tirst time' trom Hoogovens Aluminium Building Systems. Crimp Curved Sheets

Smooth Curved Sheets

KAL-Zlp·, OFFERS ALL THE FOLLOWING FEATURES:
Tapered Sheets
WEATHER TIGHT LONGEVITY
Curved and Tapered Sheets
No externally drilled holes Proven exceptionally
tor tasteners to control thermal long life highly
HEAT RESISTANT
movement and corrosion-resistant alloy
wind sucl/on around the KAL·ALLOY· minimises the
Surface plated for
building perimeters. overheating effect that occurs
protection against acid rain
when the envelope material of
Fully Zipped seams irrespective and industrial emissions
a building fails to reflect away
ot the shape
Ideal for most environments strong sunlight - contributing to
ot the building.
a pleasant working environment
Proven design tor integrated LIGHT BUT STRONG in hot weather.
roof openings and lightning
Light, cost-efficient
protection systems FIRE PERFORMANCE
construction
Capable of withstanding A double skin of KAL-L1NER'"
Ideal for refurbishments
the highest wind suction aluminium liner sheet with
and wind pressures while Resists high wind KAL-ZIP' standing seam outer
maximising 'spannability.' suction pressures will provide rapid venting in the
event of a fire.
EFFICIENCY This can, on occasion, save the
integrity of the structure. leaving
Durable and versatile
only a local repair 10 the affected
No maintenance required area necessary.

Exceptional spanning
characteristics

Recyclable

U/limate high recycle value

Exceptionally low cost in use

Natwesl Ufe Assurance. Btistol.

5
KAL-Zlp®
System

On new-build applications, a built-up insulated system is the

most common option. The KAL-LINER'· aluminium liner sheet
provides an allractive, functional interior finish to the roof.
KAL-DEKo structural deck profile range can be used to provide
large span characteristics, reducing the need for purlins.

The unique KAL-Zlpo range of

clips, complete wilh thermal
barrier pad. enables varying
thicknesses of mineral tibre
insulation to be used in order to
achieve the relevant 'U' value.

Perforated lining sheets and

decks allow for good acoustic
performance from the infinite
number of potential variables
available with the KAL-SYSTEM
range ot decks, liners, clips and
outer sheets.

FINISHING DETAIL NlKE Building, Sunderland.

Internally, self-finish liners may be Imaginative trimming of roofing or

required for both roof and walls. wall cladding can be achieved by
A wide range of colours from the using Hoogovens KAL-FORMo
KAL-KOLOR ,. brochure are bespoke seNice which may be
available to ensure that the right used to fabricate natural or
finish is achieved. Alternatively, a KAL-KOLOR ,. coated material to
natural aluminium or galvanised achieve a wide variely of designs
steel deck may be sufficient including bull nosed fascia,
where suspended ceilings are to shadow line flashing, or large
accessories manufactured from
be installed. recessed feature band details.
high-grade aluminium extrusions
Our fast. accurate seNice is
- flat sheet in numerous gauges
designed to ensure the correct
- or from stainless steel
co-ordination of our wide
components.
component and accessory range.
Even the fixings can be specified
Defailing at ridge, eaves. verge,
to Hoogovens standards.
dormers. soakers, access
KAL-FIX ,. is a range of screws
hatches, internal valley gutters.
and tools specifically selected in
changes in level, parapets,
Guiness Building, DundalJ<. partnership with SFS Stadler for
lightning protection are all
KAL-SYSTEMS.
achieved using proven

6
Point North, Merryhill. A.nnemasse Sports Centre, France.

WEATHER PROTECTION As part of the performance

specification for KAL-SYSTEMS,
From the Outer Hebrides to
air permeability, thermal bridging,
central London, and from the Far
span requirements, live and dead
East to the Antarctic, KAL-ZIJ>8 is
loads, insulation properties and
capable of functioning perfectly,
acoustic performance are taken
irrespective of the climate and
into account.
prevailing weather conditions. lannahill Centre, Paisley.

While purposefully nol employing LONG SPANS

The liner, vapour control layer,
any joint sealants or mastic strips,
and thermally broken ST-Clip are The high quality of aluminium
the design of the KAL-ZIJ>8 seam
also specially designed, so that used for KAL-ZIJ>8, combined
remains completely weather tight.
when installed they will keep warm with the various sizes and gauges
But it allows any entrapped
air leakage into the roofing system means that KAL-SYSTEMS can
moisture from the construction
to an absolute minimum, while span considerable distances
stage, or trom an existing failed
good detailing ensures drainage between structural supports -
roof beneath, to vent through to
01 the system to the eaves. while coping with the high suction
atmosphere via the unsealed
loads often associated with low
raised seam. There is no water
pitched roofing.
ingress from rain, sleet, snow,
and ice which remain on the
outside of the sheet.

7
KAL-Zlp®
Applications

KAL-Zlp· offers an Ideal and highly cost-effective solution In all NEW BUILD
roofing and walling situations. KAL·SYSTEMS can provide
Double skin insulated
exceptional strength while remaining lightweight. These systems
constructions are normal
can be installed quickly and easily for new build construction,
tor new build.
re-cladding and the over-roofing of failed roofs.

The roof construction comprises

REFURBISHMENT OVER· ROOFING the KAL-Zlp· outer sheet,
mineral fibre insulation, a vapour
Single skin KAL-Zlp· is primarily Over-roofing is where KAL-Zlp·
control layer, KAL-L1NER '" liner
used in re-cladding or over- is fixed over an existing flat roof
sheet or KAL-DEK· structural
roofing. (ie felt, ashphalt). A pitched
decking. By selecting from a
substructure is designed to shed
Re-cladding is where KAL-Zlp· range of clip heights, the insulation
water away, preferably to an
is fixed over an existing asbestos depth is accommodaled between
external gutter. This comprises
cement, or metal sheeted roof, the two skins.
a purlin system supported by a
supported on a sub-purlin system
lightweight frame or stub columns,
fixed to spacer brackets, which
fixed back to the existing support
are positioned into the troughs of
structure. It must be designed to
the existing sheeting. Insulation is
distribute all roof loads evenly. .
normally added to upgrade the
To upgrade the thermal
roofing thermal performance.
performance, additional insulation
is normally added.

In both refurbishment and over-

roofing, the new sheeting and
substructure is lightweight, adding
.. J
a minimal additional dead load of
.~/":.->
approximately 6-15kg/m' to the
existing structure.
Typical Over-foofing construction.

Typical over-foofing construction

on 10 existing deck.

Western Morning News Headquarters, Plymouth

8
KAL-Zlp® Technical Information
Profiles and Clips

PROFILES AND WEIGHTS (Kg/m')

GAUGE (mm)
Depth Cover Width Fig No 0.8 0.9 1.0 1.2
65 300 65/300 3.47 3.88 4.31 5.17 Self Supporting Sheet
65 1 305 r 65/305 3.45 3.86 4.28 5.14 Self Supporting Sheet
65 1 333 r 65/333 3.34 3.74 4.15 4.98 Self Supporting Sheet
50 1 333 r 50/333 3.16 3.54 3.92 Self Supporting Sheet
65 1 400 r 65/400 3.19 3.57 3.96 4.76 Self Supporting Sheet
65 1 500 65/500 3.38 3.75 4.50 Fully Supported Sheet
65 1 600 65/600 3.22 3.58 4.30 FUlly Supported Sheet
65 1 600 65/600 5 rib 3.26 3.61 4.34 Fully Supported Sheet

MINIMUM ROOF PITCH

Continuous Sheet Ridge to Eaves 1.5' *

Continuous Sheet Eaves to Eaves 1.5' *
Welded Lap Joints 1.5'
Welded Roof Penetrations 1.5'
Mastic and Rivet Sealed Lap Joinls 3'
Mastic and Rivel Sealed Roof Penetrations 3'
'Minimum pitch requirement must be maintained at sheet ends

RANGE OF ST·CLIPS
KAL- ZIP sheet

TYPE H W1 W2
25 81 20 25
50 106 45 50
60 116 55 60
80 136 75 80
90 146 85 90 W2
100 156 95 100
110 166 105 110
120 176 115 120
Thermal --~!!o.:l#
130 186 125 130 barrier
pad
140 196 135 140
150 206 145 150 60

190 246 185 44 CAS 60

190
11 3eCRS t1"

.~~:+
5.5diCl
Standard dip t.' Type 'E' Type dip
Base detail Base detail
(Fa ftxrtg 10 ffWl. 75 mm WIde IIfT/bef putllns)
9
KAL-Zlp® Technical Information
Structural and Movement

KAL-Zlp· 305 LOAD SPAN GRAPHS ROOF APPLICATION THERMAL MOVEMENT

AND FIXED POINTS
5.0
n

..*
As KAL-ZIP- sheets are commonly
iT :t , +l
~ used in long lengths, the
4.0
I:i+~; understanding and control
~ .t:t ~ of Ihermal movement is a prime
~ 30 ErE !:to
.
.1 .• Z
"- consideration. In general,
"- z
0 0
<i aluminium expands at
9 25 ~ @ Jf;\C
. tE! .-.+ 1\· :=. "
(j
:::> approximately twice the rate ot
~z
<n

<n
20 4-rrr h 9' ~\ 0
z sleel and the same rate as GRP
+. : .~' §
,~ PVC will expand at approximately

o. 2 or 3 times the rate of aluminium.

1.0 1.0

The colour and finish of a roof

o 3.0 1.0 2.0 3.0
will also play an important role in
1.0 2.0
SPAN (m) SPAN (m)
determining the anticipated

~
thermal movement. Dark colours
~ will allain temperatures of
approximately 70°C during hot
KAL·Zlp· 400 LOAD SPAN GRAPHS ROOF APPLICATION
summer days, whereas lighl
5.0 ftFIFf-{"!f;-;- colours and plain mill or stucco
embossed finishes will only reach
40° to 50°C.
4.0
2
~ ~.
~ f 1'.
I STANDARD
~ 3.0
Z 3.0 0.9 "'
"- "-
z ~ >l'. Fixed point
Movement
0
<i 2.5
O. g o. ,
9 \_~-
(j
:::> Cl'
,
~z 2.0 , <n
0 2.0
<n
O. Z RADIUSED EAVES
§
M<Nement
Fixed points
1.0 1.0

CRANKED EAVES
Mtwement
o1.0 o Fixed painlS
2.0 3.0 1.0 2.0 3.0

SPAN (m) SPAN (m)

~ ~
FtXED SOAKER
Fixed point
Movement
Movement
GENERAL NOTES 7 For wmd SUCllOrl cond'lion, pull out values ot tix,ngs
I The above grnphs relote to the U56 of KAL-Zlpe In to 9lfUCluro 10 be determined in accordance with
muWpIe span condition only. foong manufacturers lest data.
8. The above snow laadlngs are epphcable lor
2. AI loads aro kN,rn' ond ore assumed to be applied
KAL-2Ipe sheeting with ST-CIips type L60 or beloW.
BOWED RIDGE
unirormly.
3. MallmLOm detlectiorl is takerl at fTlId-span For c~ps type L80 or above cheCk ST-C~p Fixed point
4. The self weight of the K,Al·Zjpe fool sheelWlQ has lOAOlSPAN DATA SHEET Ior possible load reducll()l'l. Movement Movemenl
been laken InlO account in \he aboYe Ioadings. These can be Iound in !he KAL-21pe Io8dJspan
5. All spans are assumed 10 be equal or within 15'llo of graPhS Md Iables brOChure.
!he IarQeSl span. 9. For Ioad.'spen oond'bOolS 0\.II5Ide Iho6e shown
6. The IoIIowwlg load ladOfS t\8vc been taken onto &bOYe range please contacl Hc:logoYeI'lS AJo..nwwm Fixed point Fixed painl
8CCOU'lI in !he 00Sign capacity 01 the sheebng ~Systems.
Dead Load· 1 4
Dead Load (re9I$IInQ \Wld uplift) - 1.0
Snow l.o9cl • 1.6 FIXed poWll
---J-I~ Fixed paint
WndLoad-14
12
KAL-Zlp®
Technical Information

ANTICIPATED THERMAL MOVEMENT IN ALUMINIUM As KAL-ZIf>8 accommodates for

thermal movement by moving
Finish Approx Temp. Movement
over the head of the ST-Clips, this
Attained per metre Length (mm)
will create a metal-to-metal friction
Stucco/Mill 40· - 50·C 1.0
force that will try to overturn the
Light colour 40· - 50·C 10
ST-Clip. This effect is greatly
Dark colour 70· - ao·c 1.5
increased when high clips and
long length sheets are used.
As a rule of thumb, for aluminium to the design, there will always be
the above thermal movement exceptions to this rule, and Therefore, wihere long length
rates are adopted. instances of 'fixed points' sheets are used, consideration
occurring at the eaves position or should be given to the positioning
KAL-ZIP" accommodates
mid-slope are nof uncommon. of the 'fixed point' at the centre ot
movement by moving over the
the roof slope. This minimises
heads of the ST-Clips which are The design of the 'fixed point'
the friction force and reduces the
installed within stated tolerances. is based on a number of given
effective length ot the KAL-ZIP"
criteria, such as intensity of snow
sheet.
FIXED POINT loading, roof pitch and length, ~=:;:::::;=3;-'n-PIatle force
aclllQ on head 01
width and weight of sheeting. KAl-ZIP' ST-C~p
To control thermal movement
By using standard formulae with
and avoid creepage of the sheet
the above criteria, the movement
down-slope, a 'fixed point' is
forces can be determined and the
introduced into the system.
correct 'fixed point' can be Fixings ~ 1 Purlin
'Fixed poinls' are usually installed
adopted. The following tables give
at the ridge position, thus allowing
the recommended 'fixed point' for
thermal movement to take place
various KAL-ZIP" widths under
at the eaves position. According Over-turning of ST-Clips due to
various intensities of snow loading.
thermal movement of KAL-ZIP"
RECOMMENDED FIXED POINTS resisted by pull-out strength of
KAL·Zlp· 300 and 305
Snow load - 0.6 kN/m' Snow load = 0.75 kN/m' fixings from purlins.
30 30
\ \ 11
C 25 25
\ 4 C \ 1\ 4
Key 10 recommended fixed points
I 20 I
20
Ua.'= 1\ 3 "- f2
15
~ ......
- 0: 15
~ 1"- 3 ....... 1 = 1 rivet
- fP
~ ~

~ 10
5
1 .......
- 0
0
'"
10
5
1 I.......
2 = 2 rivets
o o

bOIt~ ~
5 10 15 20 25 30 35 40 5 10 15 20 25 30 35 40
Effective KAL·Zlp· sheet length (m) Effeclive KAL-Zlp· sheellenglh (m)
KAL·Zlp· 333 and 400 3 = nut and
Snow load = 0 6 kN/m" Snow load'" 0 75 kN/m'
30
I1 30 I 4 = Please consult Hoogovens
25 25
C
I
\ 4 C
I
\ 4
Aluminium Building Systems
20 3\ 20
~ ~ \\ 3
15 \~ 15
~ r-.... ~ ~ ....... Effective length", length of sheet acting on
8 10 1 r- 0
0 10 1
...... r- single roof pilch.
~ r:::::- ~ i-
'" 5 '" 5 Snow load to be taken as average intensity
acting on silgIe roof pitch area.
0 0
5 10 15 20 25 30 35 40 5 10 15 20 25 30 35 40 Snow load intensity 10 be determined from
Effective KAJ....ZI". sheet length (m) EffectIVe KAL-Zlp· sheellenglh (m) as 6399 Part 3.
13
KAL-Zlp® Technical Information
Structural and Movement

RECOMMENDED MINIMUM Stadler 6.3mm diameter stainless KAL-Zlp· sheet length is the
PURLIN GAUGES steel self tapping fasteners fixed length of the sheet from the fixed
into galvanised mild steel purlins point.
The tables below give the
of minimum grade FeE280g
recommended minimum gauges The partnership of Hoogovens
(minimum yield strength =
based on effective KAL-ZIP" sheet Aluminium Building Systems and
280N/mm'). The purlin top flange
length and height of ST-Clip. The SFS STADLER has produced
width is assumed to be 60mm
tables are based on the use of the several innovations. The latest of
minimum and the ST-Clips are to
KAl:ZIP" Sl'Clip fixed with SFS these is a stainless steel self
be fixed centrally. The effective
tapping screw with an aluminium
MINIMUM PURLlN GAUGES washer. The need for this product
was highlighted in the Hoogovens
STUCCO EMBOSSED ALUMINIUM OR Aluminium Building Systems
LIGHT COLOUR COATED SHEET training school. Several trainees
(Approximate Thermal Movement 1mm per metre length) pointed out the benefits that
could be gained from a suitable
STRAIGHT AND PRE-CURVEO SHEETS NATURAl CURVEO SHEETS
stainless steel, self drill and tap
EFFECTIVE KAL-ZIP'S EFFECTIVE KAhZIP" fastener to improve the speed
SHEET LENGTH (m) SHEET LENGTH (m)
o 5 101520253035404550 05101520253035404550 of fixing the ST-Clips. The result is
, , , ,
- -~-~r~ W- a four-fold improvement in clip

~f
25
- I
25 I 11.5 I
1.6 2.0
25
- ~ 25
fixing and a 28% overall time
60 -~
- I,
1.8
2.0
2.3
60 - 15 _. 1.7
2.0
2.2
2.5 improvement in installing the full
80 80
90
----+---'.-1-·
2.0 2.5 90 _~l· 2.2 3.1 KAL-Zlp· system. This helps
~ 100 _ 1~ - 2.1 2.9 ~ 100 2.3 3.3
~ 110 , , 2.2 3.2 ~ 110 , 2.5 3.5 to keep the KAl:Zlp· system
U) U)
. r--: --
120
130
-
-- --- c-
- T
2.4
2.5
3.4
3.6
120
130
- - ;
2.9
3.2
3.7
3.9
cost effective and competitive.
140
150
190
-- 2.9
3.1
3.7
3.7
3.9
4.6
140
150
190
--I·
- 1 ---·1- -
3.3
3.5
4.1
4.1
4.2
4.9
This special screw is unique to
the TEAMKAL· contractor
network together with the
purpose designed nozzle.
DARK COLOUR COATED SHEETS

(Approximate Thermal Movement 1.5mm per metre length)

STRAJGHT ANO PRE-CURVED SHEETS NATURAl CURVED SHEETS

EFFECTIVE KAL_Zlpa EFFECTIVE KAl·ZIP-

SHEET LENGTH (m) SHEET LENGTH (m)
o 5101520253035404550 05101520253035404550
, , , , , , , ,
,,
,
-
25
-- .. - 1151 I 25 I I 1151 I
25
- - - 1.8 25 --1=' 1.6 2.0
60
80
-- .-
1.8
2.0
2.3
60
80
-l 1.7
2.0
2.2
2.5
-
2.0 2.5 90 2.2 3.1
90 - - "- - !.E
~ 100 15 2.1 2.9 d 100 - 2.3 3.3
~ 110
- 2.2 3.2 t-L 110 2.5 3.5
U) - U) - 1--
120 2.4 3.4 120 2.9 3.7
- - I-
130 2.5 3.6 130 3.2 3.9
-- -
140 . - 2.9 3.7 140 3.3 4.1
150 II 3.1 3.9 150 3.5 4.2
190
-
3.7 4.6 190 I 4.1 4.9

14
 KAL-Zlp®
Technical Information

RECOMMENDED FIXINGS FOR KAL·ZIP· ROOFING AND CLADDING

DETAIL APPLICATION FIXING TYPE SFS FIXING

AND FREQUENCY CODE NO
KAL-ZIf'3 ST-Clip with 6.3mm diameter stainless steel self SX2/15

T~~6~
barner
"'d
Fixings
thermal barrier pad 10
mild steeValuminium
drilling screw, complete with
16mm diameter aluminium/EPDM
tS2 A16
6.3 x 35
PurliIV t
side rail support of thickness l' bonded washer.
6.3mm diameter stainless steel self TDC-S-S16
lapping screw complete with 16mm tS3 6.3 x 32
diameter SS/EPDM bonded washer.
S 3mm - AB(e) type thread. TDB-S-S16
3.1mm - 11.0mm - B type thread. t >3.1S 11 63 x 38

ST-ClidB
TImber
purlin ~
Fixings
KAL-ZIP' ST-Clip to
minimum 75mm wide
timber purlin
6.3mm or 6.5mm diameler slainless
steel self tapping screw compiete
with 16mm diameter SS/EPDM or
TDA-S-S16-*
6.5 x 64

bonded washer-NAB(C) type thread

sra~
KAL-ZIf'3 ST-Clip with 4.8mm diameter aluminium RV66
Mild steel thermal barrier pad, to buib type rivet with EPDM washer. 04-6-8W
decking .... Fixngs
mild steel decking ~ O.63mm

. Rxing length (and fIXing code) may need to be increased dependent upon pull-out strength required and grade of timber.

CLIP FIXING TOLERANCES FOR KAL·ZIP·

-r-'U200

~--1".
-,- L --1".
-,---- - --- I~line of
rool pitch -
lr"mm L
--T-- ---
line 01 roof pitch
~ L ~ L

TOLERANCES thermal movement over the LATERAL RESTRAINT

ST-Clips without locking and
KAL-ZIf'3 is manufactured to high As is common with other secret
introducing unwanted 'fixed
engineering tolerances because fix systems, the KAL-ZIP" sheet
points'. It is assumed that the
of the critical nature of the side does not provide laferal restraint
KAL-ZIf'3 elements when fixed in
lap arrangement and engagement to the top flange of purlins
place will follow a straight line or
over the head of the ST-Clip. although in a Double Skin Roof
curve over their entire length.
Greater considerations must be Construction a O.7mm gauge
Multiple curves resulting in dips or
given to manufacturing and aluminium liner sheet will generally
sudden changes in slope may
erection tolerances in steelwork provide sufficient restraint to light
cause a transfer of 'fixed point',
if it is designed to accommodate gauge purlins.
thus making redundant the normal
KAL-ZIP·.
designed fixed point. It should
The tolerances outlined are be noted that KAL-ZIf'3 is not self
recommended to enable KAL-ZIf'3 levelling and will follow undulations
elements to accommodate full within the supporting structure.

15
 KAL-Zlp®
Technical Information - Thermal

BREATHABILlTY OF KAL-ZIP' A major benefit of the KAL-ZIP" absorbent insulation will simply
roof system is that no sealants are evaporate away through the
Due to low ventilation velocities
used, allowing fhe roof structure KAL-ZIP" seams when
encountered when using long
to breath. The construction is atmospheric conditions allow.
length KAL-ZIP" sheets and/or low
weather-tight by virtue of the
pitched roofs, ventilation in the
anti-capillary groove within the
airspace above the insulation is
formed lap, but it is not air-tight.
not recommended. A high quality
Any moisture on top of the non
vapour control layer should be
used with an insulation quilt of
TYPICAL 'U' VALUES OF ROOF CONSTRUCTIONS
non hygroscopic material such as
rock fibre. This should be 'U' Value ST-Clip Insulation Insulation
oversized to allow compression
(W/m'K) Thickness Thickness
Un-compressed Compressed
during erection eliminating any air (mm) (mm) - x
space between the insulation and KAL·ZIP" 300 WITH KAL·LINER'· 30/150 LINER
the outer KAL-ZIP" sheet. KAL-ZIP"305 WITH KAL·LINER'· 30/152 LINER
KAL-ZIP"333 WITH KAL·LINER'· 30/167 LINER

0.432 110 100 80

0.387 120 100 90
0.351 130 120 100
KAl-ZIP'
·0.320 140 120 110
sheet
0.295 150 150/140 120
0.223 190 180 160

KAL-ZIP' 400 WITH KAL·LINER'· TR 35/200 LINER

0.409 120 100 85
0.368 130 120 95
Vapour 0.335 140 120 105
control
0.307 150 150/140 115
~""
0.230 190 180 155

KAL-ZIP' 400 WITH KAL·DEKo DECKING

0.432 80 100 80
0.387 90 100 90
0.351 100 120 100
0.320 110 120 110
0.295 120 150/140 120
0.273 130 150 130
Vapour Fixing Thermal KAL-DEKt.
control rivets bartier decking
0.254 140 160 140
layer
0.238 150 170/180 150
0.189 190 210/220 190
Based on Rock Fibre Insulation Quill (Density 23kglm3 approx.) Tllefmal conductivity
(le vaJue) is O.037WlmK. For 'U' values lower than those shown above, a sub-purlin
may have to be introduced. Pfease consult Hoogovens AJcJmit'Iium Building Systems.

16
KAL-Zlp®
Technical Information

THERMAL BRIDGING through the stem 01 the 5T-Clip TYPICAL 'U' VALUE
OF ST·CLlP shoutd be taken into account. OF ST·CLlPS
By utitising the proportional area
The 'u' value lables do nollake ST-Clip 'U' Value (W/m'K)
method of calculation, the effect
into account Ihe Thermal Bridging 80 6.393
of the cross sectional area 01
effect ollhe 5T-Clips which should 90 6.391
the 5T-Clip stem on the overall 'u'
be allowed for as stipulated in the 100 6389
value of the roof construction
1995 Revision of Approved 110 6.386
should be determined.
Document Part L. of the Building 120 6.384
Regulations (England and Wales). 53mm 130 6.382
140 6.380
As Ihe KAL-Zlp· sheeting is
150 6.377
supported on aluminium clips
190 6.368
(5T-Clips) which penetrate the
insulation layer, the 'u' value
Area ot each SI-Clip
58)( 5.3 '" 307.4 mm2 ~ lnsulalion

TOTAL CLIP AREA (mm'/m') OF ROOF AREA

This table shows the total cross sectional area (mm') of 5T-Clips per m' of roofing for given purlin c/c.

Purlin e/e (m) KAL-Zlp· 300 KAL-Zlp· 305 KAL·Zlp· 333 KAL·Zlp· 400
1.0 1023.64 1008.27 92220 768.50
1.2 854.57 839.20 768.50 639.39
1.4 731.61 719.32 660.91 550.25
1.6 639.39 630.17 577.91 479.54
1.8 568.69 559.47 513.36 427.29
2.0 513.36 504.14 461.10 384.25
2.2 467.25 458.03 421.14 350.44
2.4 427.29 421.14 384.25 319.70
2.6 393.47 387.32 356.58 295.10
2.8 365.81 359.66 328.92 273.59
3.0 341.21 335.07 307.40 255.14
3.2 319.70 313.55 288.96 239.77
3.4 301.25 295.10 27051 227.48

THERMAL BRIDGING EFFECT OF ST·CLlPS • EXAMPLE

Utilising Ihe proportional area Element Area/m' 'U' Value Adjusted 'U' Value
method of calculation, a KAL-Zlp·
Insulated area 0.999441 0.432 0.4318
305 insulated roof construction
5T-Clips 0.000559 6.386 0.00357
with purlin centres of 1.8m and a
finished insulation depth of 80mm
Final 'u' Value 0.43537
Under the above conditions the 'U' value of the roof construction has increased
created by the use of 5T-L110 by 0.00337 (0.8%) as a result of Thermal Bridging of the Sf-Clips.
Clips would have a 'u' value as
table opposite shows.
17
KAL-Zlp®
Technical Information - Thermal

VAPOUR CONTROL LAYER from inside the building into at all laps, perimeters and
the root construction, thereby penetrations in order to ensure its
It is good practice to enhance the
minimising the risk of condensation. effectiveness.
performance of a roofing system
by incorporating a high The vapour control layer should The type of vapour control layer
performance vapour control layer. always be installed on the warm to be specified would be
side of the construction and dependent upon the use of the
A vapour control layer will restrict
should be continuous across its building and therefore the
the movement of water vapour
surface. It must be fully sealed condensation risk.

RECOMMENDED VAPOUR CONTROL LAYER FOR KAl-Zlp· ROOFING SYSTEM

CATEGORY EXAMPLE OF liNER/DECKING GENERIC VAPOUR

(Risk of Condensation) BUilDING CONTROL LAYER (VCl)
lOW
Occupancy or usage Warehouse Liner sheet. No separate Vel
of building does not Factory - fully sealed liner sheet.
significantly add to the Aircraft Hangar etc. Structural deck Reinforced virgin
moislure vapour present. perforated liner/deck. polyethylene.
MEDIUM
High occupancy/air Office, School, Liner sheet. Reintorced virgin
conditioned buildings. Sports Hall etc. polyethylene.
Structural deck Aluminium foil
perforated liner/deck. encapsulated reinforced
virgin polyethylene.
HIGH Aluminium foil
Buildings containing Swimming Pool, liner sheet. encapsulated reinforced
large open areas ot water Textile Factory, virgin polyethylene with
or where water is used as Kitchen Area, 2 rows of sealing tape.
part of the manufacturing Shower Area etc. Site welded O.5mm
process. thick reinforced virgin
polyethylene.
Structural deck Aluminium foil
perforated liner/deck. encapsulated reinforced
virgin polyethylene with
2 rows of sealing tape.
Site welded O.5mm
thick reinforced virgin
polyethylene.

18
KAL-Zlp®
Technical Information

AIR PERMEABfLITY OF seal the roof at all interfaces with At penetrations the incorporation
DOUBLE SKIN KAL-Zlp· other elements of the of a fUlly sealed preformed vapour
ROOF CONSTRUCTION construction, components and conlrol layer 'soaker' may be
penetrations. considered to assist in the ease
KAL-ZIP" is very permeable, of achieving an etfective seal in
The areas that would require
allowing the system to breathe, the vapour control layer.
careful attention bofh from a
removing any moisture from the
detailing and installation point of Where exceptional 'air tightness'
roof build-up as well as reducing
view would be penetrations requirements are specified, it may
the risk of condensation. At all
through the construction junctions also be necessary to completely
times the design of the upstand
with the same form of seal the liner sheefs as well as the
lap, incorporating an anti-capillary
construction and abutments with vapour control layer.
groove, maintains the
other forms of construction.
weathertight integrity of the The installation and sealing of
KAL-Zlp· sheets. In order to reduce the possibility the vapour control layer should
of air seepage at these points also be closely monitored on site
Where a double skin insulated
it is fundamental that the vapour by the Clerk of Works staH,
roof construction needs to be
control layer is continuous and/or in particular at junctions and
airtight, this is normally achieved
fully sealed in the same manner abutments involving ditferent
at the vapour control layer/ lining
as that used for sealing the lap forms of construction and/or
sheet pcsition. To help in
joints in the general construction, sub-contractors.
achieving an airtight construction
eg the use of a butyl rubber
it would normally be necessary to
sealing tape.

St Mary's Car P8Ik, Sunderland.

19
 KAL-Zlp®
Technical Information - Acoustic

ACOUSTIC It is possible to modify fhe double SOUND ABSORPTION

skin KAL-ZIP' roof systems in a
Roofing and Cladding acoustic Most materials will absorb some
number of ways to ensure
performance divides into sound. Hard surfaces like metal
required levels of sound
two categories:- Sound Reduction and concrete reflect nearly all the
reduction. The introduction of high
and Sound Absorption. sound energy, absorbing very
density moisture resistant boards,
Both categories have different little. Rockfibre's and glassfibre's
high density insulation layers or
requirements and solutions. open surface texture make
multiple density layers of
efficient sound absorbers.
insulation individually or in
SOUND REDUCTION Their properties can be
combination with each other,
incorporated into a KAL-Zlpo roof
Keeping sound out, e.g. near can achieve high levels of noise
by perforating the KAL-L1NER'· or
airports and city centres, and reduction.
KAL-DEK" liner sheet. Various
keeping noise in, e.g. at engine
Hoogovens Aluminium Building pallerns of perlorations, fUlly, web
test facilities, are common
Systems have been involved in or trough perforated can be
objectives. In many instances
numerous projects where a high supplied, although the standard
noise levels will need to be
sound reduction performance pallern is 3mm diameter holes
reduced from one side of the
was required and have extensive on a 5mm isometric grid, for
building envelope to the other.
test data on various KAL-ZIP" KAL-L1NER'·. This gives a standard
The design and construction of
acoustic roof constructions. perforated free area of 32.7%.
the root will play a large part in
Please ask for further details. KAL-DEKo has 3mm diameter holes
achieving these objectives.
on a 7.37mm isometric grid giving
100 Rockwool
insulatiOn compressed a 15% free area.
10 85 mm

TROUGH PERFORATED KAL-L1NER'·

0.9 KAL·ZI~ 400 shee1

~
FULLY PERFORATED KAL·L1NER'·

~
WEB PERFORATED KAL-DEK"

~
L vapour control
ST·Clip120 Wllh _ layer
thermal barrier
KAL:lINER- 0.7 TR351200
liner sheel
PLAN VIEW OF STANDARD
KAL-L1NER'· PERFORATION PATTERN

SOUND REDUCTION INDEX (SRt) TEST RESULTS

Salford University Test Report No TU95/10/3 - Double Skin Insulated KAL-ZIP' Roof Construction
Frequency (Hz) 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150
Test Result (dB) 16.2 15.3 14.6 17.0 20.8 26.1 30.7 34.7 36.4 36.2 35.4 36.4 38.8 40.0 41.0 43.2

20
KAL-Zlp®
Technical Information

Sound absorption properties of a DESIGN IMPLICATIONS 2. VAPOUR CONTROL LAYER

surface can be determined by WHEN USING KAL-L1NER'" Greater consideration must be
PERFORATED LINER SHEETS
testing to SS 3638 • "Method of given to the selection and
measurement of sound in a Where KAl:L1NER ,. perforated installation of the vapour control
reverberating room". Absorption liner sheets are used to provide layer as this will be the only
coefficients have a value between a sound absorption solution, element resisting moisture vapour
o and 1 with 0 being a total sound other design implications must entering the construction.
reflector and 1 being a total be taken into account.
3. CONDENSATION
sound absorber.
1. STRUCTURAL As acoustic insulation is below
(Coefficients above 1 can be
The strength of a profile is the vapour control layer, this layer
recorded due to the profile of
reduced by perforating, is cooler than normal. Care must
KAL·L1NER'" and KAL·DEK~.)
particularly if it is perforated all be taken to ensure that the
A number of laboratory tests have
over. 1.2mm gauge fUlly 'dew point' temperature does not
been carried out to determine
perforated, 0.8mm gauge wide occur below the vapour control
these coefficients for KAL·L1NER '.
trough perforated and 0.7mm layer allowing condensation to
and KAL·DEK~ liner and decking
gauge unperforated will all give form. A ratio of 3:1 or 4:1 01
sheet with varying perforations
approximately the same spanning insulation above the vapour
and lorms of insulation.
capabilities in aluminium profiles. control layer to that below is
One example is detailed below.
not uncommon, especially in
Please ask for further details.
swimming pool rool constructions.

TYPICAL ACOUSTIC ROOF CONSTRUCTION

WITH PERFORATED LINER AND SLAB
INSULATION AS PER TEST REPORT l/201/1

Insulation

KAL-ZI~ sheet - - - - ;

30 mm Rockwool
AWS slab

Vapour control
laye,

ST-Clip with
thermal barrier

~~atI~~--- Top hat sub-purlins

cm lop hat support
brackets
KAL·UNER'M TR301150---------.5..,l ...~
trough perforated
liner sheet

SOUND ABSORPTION RESULTS

Airo Limited Test Report U2101/1 . Double Skin Insulated KAL·ZIP~ Roof Construction with Perforated Liner
Frequency (Hz) 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Sound Absorption 0.11 0.09 0.24 0.35 0.50 0.77 0.87 1.02 1.08 1.05 1.08 0.90 0.60 0.53 0.56 0.60 0.57 0.60
Coefficient

21