Professional Documents
Culture Documents
Issue 1/00
All Kalzip Fixing Manuals
issued prior to this date are invalid.
All rights reserved.
Without the written consent of
Corus Bausysteme GmbH
it is not permitted to copy this Fixing Manual,
or any part there of.
CONTENTS
Page
Introduction Regulations
The System
Site Preparation
Fixing KAL-ZIP
10
Roof Types
32
34
36
Site Work
39
41
10
Accessories
43
11
Special Tools
50
12
3
I N T R O D U C T I O N R E G U L AT I O N S
THE SYSTEM
KAL-ZIP 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.
Note:
Do not store open packages for long
periods of time!
S I T E P R E PA R AT I O N
4.1 Preliminary work
Before commencing work, compare the roof geometry and
dimensions of the previous works with
the approved plans.
S I T E P R E PA R AT I O N
Painted surfaces must be compatible with aluminium. Intermediate layers of non-corrosive
material must not accumulate dampness.
Suitable materials include plastic sheeting,
plastic board or bitumen felt strips. Wool
felt, for example, is unsuitable.
Type of atmosphere
Paired material
Rural
Urban/Industrial
Marine
Zinc
safe
safe
safe
Stainless steel
safe
safe
safe*
Lead
safe
safe
critical
Unprotected steel
critical
critical
critical
Copper
critical
critical
critical
*This applies only to stainless steel selftapping screws and blind rivets if electrolytic bonding is to be avoided.
F I X I N G K A L - Z I P
Principal rule:
Zip each sheet immerdiately
after laying! This is the only
way to ensure the load bearing
capacity of the system and to
provide the necessary protection
against wind forces.
Fig. 5.1
10
1.14
1.55
1.88
2.24
2.48
1.00
1.42
1.73
2.11
2.20
Fig. 5.2
1.20
1.60
1.95
2.30
2.60
Fig. 5.3
F I X I N G K A L - Z I P
Recommendation:
If the thermal insulation under the
KAL-ZIP sheets along the ridge
and eaves area is not weight resistant,
you should not walk on the sheets. Protect
routes that are used frequently for transporting material by using a provisional
footbridge (e.g. wooden planks) during
the fixing process.
Use seam clips to prevent planks from
sliding off.
2.30
2.85
3.30
3.80
4.30
2.18 (1.62)
2.76 (2.11)
3.19 (2.27)
3.70 (2.73)
4.13 (3.28)
1.90
2.53
2.94
3.48
3.72
11
F I X I N G K A L - Z I P
Fixing direction:
Sheet fixing is done in the direction of the small seam. The large
seam overlaps the small one. Fixing is
generally done from verge to verge.
In special cases it may be necessary or
sensible to change the sequence. Fixing
on dome-shaped roofs or roofs inclined
perpendicular to the KAL-ZIP may require a different fixing sequence. These procedures need to be planed in detail and
special profiles may be required.
Fig. 5.4
12
F I X I N G K A L - Z I P
5.4 Zipping KAL-ZIP sheets
The small seam upstand must be
clipped fully into position at the
clip head to prevent incorred zipping.
Sheet gauge
0.7 to 1.0 mm
1.2 mm
approx 20 mm
approx 22 mm
If 50 mm high KAL-ZIP is to be zipped, remove the skirts and fix the side
roller holders.
13
F I X I N G K A L - Z I P
5.6 Zipping transverse joints
The zipping machine must run
over the transverse joint in the
direction of the fall of the slope.
14
F I X I N G K A L - Z I P
Screw M 6
KAL-ZIP
Clip
15
F I X I N G K A L - Z I P
5.11 Contructing
transverse joints
The requirements placed on the
sealing properties of transverse joints on
shallow roofs are very high.
Therefore it is necessary to exercise
extreme care when jointing sheets.
Either welded or sealed joints can be
produce.
Rivets
Welded joint
The KAL-ZIP sheets to be jointed are
overlapped by approx 10-20 mm and
welded. Support the welded joints (e.g.
Z-profile).
Sealed joint
Figs. 5.7 to 5.9 show the fixing sequence
with KAL-ZIP 333. Apply the same
sequence to all other KAL-ZIP widths
accordingly.
Screws
Rivets
16
F I X I N G K A L - Z I P
Figs 5-10 and 5-11 show the
fixing sequence and the notches
for 1.2 mm gauge sheets. For
1 mm gauge sheets notches are required
on the small seam only. Notches are not
required for gauges of 0,9 mm and less.
Direc
tion
of lay
F I X I N G K A L - Z I P
a) Welded soaker
See Fig. 5.12, 5.13 and photo M
Place prefabricated soaker onto trimming but do not fasten to the supporting
structure in order to allow for sliding
movement over clips.
Only fasten to the supporting structure
if the plans specify the Fixed Points to be
positioned at the soakers.
F I X I N G K A L - Z I P
b) Sealed soaker
See Figs. 5.14 and 5.15
The prefabricated soaker is
provided with large seams on all sides so
that it can be fitted from the top.
F I X I N G K A L - Z I P
If soakers are to be installed into curved roofs, the basic materials for the soakers must also be made of curved KALZIP sheets.
5.13 Vents
After laying the KAL-ZIP-sheets, cut out
the bottom plate. Max. diameter (see below) if installed in the centre of a sheet.
Minimum 75 mm wide gutters are left on
each side.
KAL-ZIP
Max. diameter
305
333
400
160 mm
190 mm
250 mm
Fig. 5.16
20
Alternative:
Prefabricated aluminium vent welded to a
short KAL-ZIP sheet is sealed into the
roofing area by using silicone sealant
and blind rivets.
Fixing analogous to Fig. 5.10 and 5.11
F I X I N G K A L - Z I P
5.14 Eaves
Eaves filler
Install the eaves fillers as fixing work
progresses ensuring that they are fitted
as shown in Fig. 5.17
Fig. 5.17
Drip angle
Position at least 20 mm from end of
sheet so that the bottom sheet can be
folded down.
Distance A in Fig. 5.18 is related to the
anticipated thermal movement of the
KAL-ZIP sheet resulting from temperature fluctuation.
Allow 1 mm expansion for each metre
of sheet length from the Fixed Point to
the gutter.
Fig. 5.18
21
F I X I N G K A L - Z I P
5.15 Verge
Rivet the gable end channel with
the narrow side facing the verge
flashing to the KAL-ZIP seam at intervals
of 500 mm maximum. The joints may be
positioned at any point.
Verge flashing
Fabricate flashing as shown in Fig. 5.20
and hook into the gable end channel or
rivet onto the gable end support clip.
Fig. 5.19
22
Fig. 5.20
F I X I N G K A L - Z I P
5.16 Ridges
Fig. 5.21
Fig. 5.22
23
ROOF TYPES
6.1.2 Re-roofing
With small spacings between the purlins
of appr. 1.15 m is generally sufficient to
place clips only on every second purlin. In
order to evenly distribute the load to all
purlins, the clips are fixed to the purlins in
changing succession.
Stress calculation is required.
Purlin
Verge
Eaves
KAL-ZIP cover width
l = Truss distance
c = Clip distance
Fig. 6.3
Fig. 6.1
Verge
Purlin
Eaves
KAL-ZIP cover width
l = Truss distance
c = Clip distance
Fig. 6.2
24
Clip
Clip
Photo A
Using spreader beam to unload
Photo B
Re-roofing
25
Photo C
Fitting KAL-ZIP
Photo D
Zipping
Photo E
Rivetting Fixed Point
Photo F
Transverse joint
26
Photo G
Drip angle at eaves
Photo H
Verge
27
Photo I
Fixing clips to trapezoidal steel decking
Photo J
Drilling Fixed Point
Photo K
Ridge closure
Photo L
Closure filler
28
Photo M
Soaker welded into position
Phote N
Ridge, verge and gutter
29
Photo O
Catwalk
P
30
Photo P
Eaves
Photo Q
Ridge folding tool
R
Photo R
Hand closing tool
Photo S
Eaves folding tool
S
31
Photo T
Zipping machine
U
32
Photo U
Zipping machine
Photo V
Unzipping device
V
ROOF TYPES
6.2 Trussed roof
A load-bearing trapezoidal steel
inner skin is layed parallel to the
eaves. The clips are either fixed directly
to the high trough or indirectly to spacer
profiles.
The clips are positioned diagonally across
the inner skin. All inner skin high troughs
must be load bearing.
Verge
Clip
KAL-ZIP
Regular Layout
Steel TRP
Fig 6.4
Eaves
Eaves
Fig 6.6
Fig 6.5
The dimensions of the individual roofing
areas determined in accordance to DIN
1055 Part 4
6.2.2 Clip fixing
The clip fixing layout has to guarantee a
uniform transmission of both positive
and/or negative loads.
KAL-ZIP
Edge areas
Corner areas
Verge
Normal areas
Clip
Steel TRP
Eaves
KAL-ZIP cover width
l = Truss distance
c = Clip distance
Fig 6.7
33
S P E C I A L T Y P E S O F K A L - Z I P
7.1 Curved Roof
7.1.1 Transporting onto the roof
If pallets with curved KAL-ZIP
sheets cannot be lifted onto the roof in
their entirety, the sheets have to be lifted
onto the roof individually or in bundles by
using the crane (the pallet has to be left
on the ground).
Observe laying direction!
(Refer also to para 4.3)
34
S P E C I A L T Y P E S O F K A L - Z I P
7.2 Tapered roof
7.2.1 Installation widths
Between 230 mm and 680 mm
Minimum length: 1500 mm
Maximum length: Depending on transport
7.2.5 Ridges
Order special ridge closures to the required size.
Cut the closure fillers to size on site.
7.2.6 Verge
Always apply the gable end support clip
in order to more easily absorbe structural
tolerances.
Others as per Fig. 5.15
7.2.7 Sheet ends
Generally, the length of the sheets is
supplied with an extra 50 mm at both
ends. They have to be cut to size on site
if necessary; at both ends.
7.2.4 Eaves
It is very important to install a drip angle
as it gives the required rigidity to the
KAL-ZIP base.
Standard eaves fillers (cut to size) can be
applied from the upstand to the stabilising ribs. A self-adhesive sealing ribbon
can be used between the stabilising ribs.
35
Fig. 8.1
36
e) Put eaves closure g for the transluscent sheet on the transluscent sheeting
rail a and fix with rivets.
f) Fit the eaves end piece i so that it
holds KAL-ZIP c and eaves closure g.
g) Fix the transluscent sheets j and rivet
to both rails a.
(Head diameter = 14 mm)
Distance between rivets = 300 m
h) Cut out the ridge end piece k twice
to create space for the KAL-ZIP ridge
closure. Cut off the upstand on the upper
end. Adjust while fixing.
38
8.3 Rooflights
Do not walk on rooflights.
8.3.1 Installation
Rooflights are fixed to special soakers
(See Fig. 5.12)
Install rooflights in accordance with the
manufacturers instructions.
Take care that no additional, unintentional Fixed Point is created during fixing.
Often, rooflights are installed by companies unfamiliar with KAL-ZIP roofs. Their
operators may be less careful and cause
damage to the roof skin.
It is recommended to have the roof inspected by the construction supervisory
board before installing rooflights and to
instruct the rooflights companys employees about safety and care of the roof.
SITE WORK
9.1 Folding, Bending radii
Minimum radii must be observed
in accordance with material
quality and finish.
Fig. 9.1
1/4 H 1/2 H
2xt
3xt
generally
3/4 H
4xt
to 6 x t
5xt
9.4 Drilling
Use HSS drill bits, observe manufacturers instructions for screw and rivet
holes.
Hole diameters for self-tapping screws
are dependent on material type and gauge.
SITE WORK
Remove swarf before inserting the fastener.
Fit disc with seal onto the drill to
protect the drill chuck and material
surface, see Fig. 9.2
Fig 9.2
9.5 Self-tapping screws
Use screws made of stainless steel.
In general, use:
for steel supporting structures:
Gauges up to 3 mm:
Thread type A 6.5 mm
Gauges greater then 3 mm:
Thread type B 6.3 mm
for aluminium supporting structures:
Gauges up to 3 mm:
Thread type 6.5 mm
Gauges greater then 3 mm:
Thread type B 6.3 mm
for timber supporting structures:
Thread type A 6.5 mm
40
S U R FA C E F I N I S H E D A P P E A R A N C E
10.1 Storage:
Dust, condensation
Store pallets at an angle to allow
rain-water to drain off.
10
41
S U R FA C E F I N I S H E D A P P E A R A N C E
10.6 Removing dirt
Natural-finish surface:
Use an abrasive agent with a
pH-value of between 5 and 8 abrasive
cleaning e.g. fibre fleece. Abrasion traces
will be visible with abrasive cleaning. The
surface will be brighter as the oxide coat
darkens and the new coat will be bright
metallic at first.
10
42
11
Type/
Profile No.
Alu-clip Aluminium
Standard hole
arrangement
6.1
Fig. 11.1
10
25
50
60
80
90
100
110
120
130
140
150
KAL-ZIP
65/..
50/..
W1
W2
W1
66
81
106
116
136
146
156
166
176
186
196
206
*
20
45
55
75
85
95
105
115
125
135
145
*
25
50
60
80
90
100
110
120
130
140
150
20
35
60
70
90
100
110
120
130
140
150
160
W2 W3
Tk5 Tk10
25
30
40
45
65
70
75
80
95 100
105 110
115 120
125 130
135 140
145 150
155 160
165 170
Fig. 11.2
Double length clip
12
6.1
116
on request
Fig. 11.3
Fig. 11.4
10
Special clips
43
(Size in mm)
ACCESSORIES
ACCESSORIES
11
Gable end channel Aluminium
Type/
Profile No.
Sizes in mm
11 792
35 x 27 x 20 x 1.5
5000 long
Fig. 11.5
11 679
Gable end clip for KAL-ZIP 65/... Aluminium
Gable end clip 50 doe KAL-ZIP 50/... Aluminium 13 187
58 long
3 holes 7
Fig. 11.6
Gable end support clip Aluminium
12 753
60 wide
5000 long
12 643
60 wide
60 long
Fig. 11.7
Sliding ridge clip Aluminium
Fig. 11.8
KAL-ZIP flashing sheet Aluminium
with large sheet upstand
Fig. 11.9
44
Stucco: 586
with coloured sheet
depending on the
KAL-ZIP cover
width 6000 long
ACCESSORIES
11
Type/
Profile No.
Sizes in mm
Fig. 11.10
Seam clip Stainless steel
Fig. 11.11
Seam clip Aluminium
Fig. 11.11a
Ridge cap Aluminium
5019
235 x 125
5000 long
11 950
45 x 6 x 45 x 1.5
5000 long
0217
50 x 6
5000 long
0403
22 x 6
5000 long
Fig. 11.12
Spacer profile Aluminium
Fig. 11.13
Flat bar Aluminium
Fig. 11.14
45
ACCESSORIES
11
Type/
Profile No.
Sizes in mm
300/305
333/400
500
600
Cut to size of
KAL-ZIP profile
As required
As required
300
305
333
400
500
600
Cut to size of
KAL-ZIP profile
Fig. 11.16
Special size
1000 long
300
305
333
400
500
600
Cut to size of
KAL-ZIP profile
0074
40 x 20 x 2
5000 long
0202
Fig. 11.18
70 x 30 x 2
5000 long
1 x 400
6000 long
Fig. 11.15
Fig. 11.17
Drip angle
Fig. 11.19
46
ACCESSORIES
11
Type/
Profile No.
Sizes in mm
305
Cover width:
305 mm
Max. length:
20.000 mm
Fig. 11.20
Transluscent panel double skin Rhenoplast
305
Cover width:
305 mm
Max. length:
30.000 mm
Fig. 11.21
Cover Strip Aluminium
12 771
5000 long
UL
Fig. 11.22
Closure filler for double skin
transluscent panels Cellulose polyethylene
Fig. 11.23
Eaves end piece for double skin
transluscent panel PVC
Fig. 11.24
47
ACCESSORIES
11
Type/
Profile No.
Sizes in mm
Fig. 11.25
Ridge and Eaves end piece for transluscent sheet
Rhenoplast/PVC
Fig. 11.26
Eaves closure for transluscent sheet
Aluminium
- not available
- from stock -
Fig. 11.27
Transluscent sheet rail
Aluminium
12.300
5000 long
12.301
400 long
Fig. 11.28
Joint connection for transluscent
sheet rail
Aluminium
Fig. 11.29
48
ACCESSORIES
11
Type/
Profile No.
Sizes in mm
Special fabrication
in accordance
width sketch
Fig. 11.30
Welded mounting soaker
single skin or insulated Aluminium
Special fabrication
in accordance
with sketch
Fig. 11.31
Cover Strip for repairs
(not suitable for transluscent sheets) Aluminium
5000 long
Fig. 11.32
Comb-profiled jointing sheet
5084
3.5 x 80 x 5000
Fig. 11.33
Flat sheet cut from Coil
stucco-design, protective cladding on both sides
Aluminium (1/2 hard)
Fig. 11.34
0-
120
Special flashings:
60
00
0.8 x 1200 x
2000 to 6000
1.0 x 1200 x
2000 to 6000
0
20
SPECIAL TOOLS
12.1 Zipping machine
The statically important composite effect and rain-proof
seal of the KAL-ZIP sheets will only be
achieved if the zipping machine works
properly.
12
SPECIAL TOOLS
d) Curved KAL-ZIP
Modification of the zipping machine may be necessary for
working on curved KAL-ZIP.
Modification of the skirts is only required
for old type machines. The latest type of
machine does not have any skirts.
12
Crimp-curved sheets:
Skirts, contact rollers and guide rollers
must always be removed.
Roll-curved sheets:
Remove guide rollers with radii if less
than 2 m
e) Double skin transluscent panel
Skirts, contact rollers and guide rollers
must always be removed.
f) 50 mm high KAL-ZIP
Dismantle skirts (DDF 20-0) for zipping
50 mm high KAL-ZIP. In addition, apply
the short side roller holders (DDF 3.1).
No modification set is required up from
serial number 1170.
g) Unzipping device
see 5.8
51
SPECIAL TOOLS
12
Tools
Use
Zipping machine
220 Volt / 50 Hertz
Roofing pliers
cranked or straight
Unzipping device
52
DDF 3-0-3
DDF 3-0-2
DDF 3-0-1
12
DDF 5-2 Washer for front roller holder
SPECIAL TOOLS
53
54
Friction disc
DDF 6-0
DDF 7-1
DDF 7-2
DDF 6-1
DDF 6-2
12
SPECIAL TOOLS
SPECIAL TOOLS
12
Repair service
All tools can be professionally
serviced and repaired in our
workshop.
Shipping address:
Hoogovens Aluminium
Bausysteme GmbH
August-Horch-Strae 20-22
P.O. Box 10 03 31
D-56033 Koblenz
Germany
Phone: ++49(0)2 61 / 891-607
Fax:
++49(0)2 61 / 8 20 38
www.kalzip.com
Overseas:
The Netherlands
HAFKON BV
Postbus 46
NL-3140 AA Maasluis
The Netherlands
T +31 (0) 1059 15300
F +31 (0) 1059 15125
info@hafkon.nl
Spain
Corus Metal Ibrica S.A.
Divisin Sistema Kalzip
Avda. de la Plata, 67-31a
E-46006 Valencia Spain
T +34 (9) 6 374 56 85
F +34 (9) 6 374 04 33
kalzipcorus@hotmail.com
Belgium
Corus Building Systems NV
A. Stocletlaan 87
B-2570 Duffel Belgium
T +32 (0) 15 30 29 21
F +32 (0) 15 30 29 20
cbsbe@corusgroup.com
Denmark
A.E. Stlmontage a/s
P.O. Box 70 Hagensvej 54
DK-9530 Stvring Denmark
T +45-98 37 32 88
F +45-98 37 32 79
ae@kal-zip.dk
Austria
Robert Pfisterer
Bautechnische Beratung
Keplerstrae 16
A-4222 Luftenberg Austria
T +43 (0) 7237 5123
F +43 (0) 7237 2123
r.pfisterer@corusgroup.com
Switzerland
Bro Dach & Wand, Jrg Senteler
P.O. Box 247
CH-7302 Landquart Switzerland
T +41 (0) 8 13 22 38 38
F +41 (0) 8 13 22 38 39
kalzip@bluewin.ch
Cyprus
Phanos N. Epiphaniou Ltd.
21 Markou Drakou Avenue
Pallouriotissa P.O. Box 9078
CY-1621 Nicosia Cyprus
T +357 (0) 2 438 991
F +357 (0) 2 431 534
phanos@spidernet.com.cy
Greece
Phanos N. Epiphaniou Ltd.
82 Grammou Str.
GR-18345 Moschato Greece
T +301 9 405 941
F +301 9 412 465
fanos@otenet.gr
Middle East
Dubai
Corus Building Systems
P.O. Box 9217
UAE-Dubai United Arab Emirates
T +971 4 3388586
F +971 4 3389970
azad.nouri@corusgroup.com
Kuwait
Ali Alghanim & Sons
Trading & Contracting Group Co.
W.L.L. P.O. Box 21540
KT-Safat 13076 Kuwait
T +965 4 822190
F +965 4 821669
Far East
Singapore
Corus Building Systems Pte. Ltd.
41 Gul Circle Singapore 629576
T +65 768 9081
F +65 898 9374
admin_hbs@corus.com.sg
www.corus.com.sg
China
Corus Building Systems
Guangzhou Representative Office
Suite 1208 West Tower
Guangzhou International
Commercial Centre Tiyu East Road
Guangzhou P.R. CHINA 510620
T +8620 3887 0190 / 0191
F +8620 3887 0265
Hong Kong
Corus Asia Ltd.
6/F Jardine Engineering House
260 Kings Road
North Point Hong Kong
T +852 2887 5268
F +852 2887 9987
Europe: