KAL-Zlp

Designs for a Lifetime

The KALZlp contemporary designs are extremely attractive,
but its beauty is more than skin deep. It is tough and durable,
and manufactured to the most exacting quality standards for
maximum strength and longevity, without the need for constant
maintenance.

After 25 years, sacrificial outer layer

of KAL-ALLO'f9 has protected the
inner core.

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

ravages of wind, rain,

worldwide is produced using safe,

and airborne pollution.

environmentally friendfy hydro

The KAL-ALLOY . from which

electric power. KAL-ALLOY,

KAL-Zlp and KAL-BAU sheeting

which has a proven long lifespan

and cladding sheets are

can be unzipped once the

produced has a unique

building has served its purpose

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

finish weathers to provide an
attractive even grey patina over
the whole roof area. Hoogovens
Aluminium uses high grade cfad
and unclad alloys, including a
high percentage of recycled
material, together with BS and
RAL colour coatings in a variety ot
paint systems, known as

construction by TEAMKAL,
Hoogovens approved, fully
trained installer network, ensures
that KAL-Zlp lasts a lifetime.

KALZlp AN IMPRESSIVE
ALLROUND PERFORMANCE

Our inhouse Quality Assurance

When it comes to life in service
KAL-Zlp is an equally convincing
proposition. Once installed, the
system requires virtually no
maintenance throughout the life of
the building. Unlike less durable

systems, it will not rust - even on

the cut edges - and there are no
fixing holes to corrode or leak.

KAL-KOLOR '" .

Programme ensures that the

highest standards are maintained
from ingot to finished product.
As a result, KALZlp is accredited .
with BBA Certification, French
D'Avis Technique and German
Zulassung with Hoogovens
Aluminium Building Systems,
Haydock, being accredited
ISO 9002.

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

MULTIPLE DESIGN OPTIONS

Straight Sheets
Cranked Sheets
Crimp Curved Sheets
Smooth Curved Sheets

KAL-Zlp, OFFERS ALL THE FOLLOWING FEATURES:

WEATHER TIGHT

LONGEVITY

No externally drilled holes

Proven exceptionally

tor tasteners to control thermal

long life highly

movement and

corrosion-resistant alloy

wind sucl/on around the

building perimeters.
Fully Zipped seams irrespective
ot the shape
ot the building.
Proven design tor integrated
roof openings and lightning
protection systems
Capable of withstanding
the highest wind suction

Surface plated for

protection against acid rain
and industrial emissions
Ideal for most environments

Tapered Sheets
Curved and Tapered Sheets

HEAT RESISTANT

KALALLOY minimises the

overheating effect that occurs
when the envelope material of
a building fails to reflect away
strong sunlight - contributing to
a pleasant working environment

LIGHT BUT STRONG

Light, cost-efficient

in hot weather.
FIRE PERFORMANCE

construction
Ideal for refurbishments

A double skin of KAL-L1NER'"

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.
This can, on occasion, save the

EFFICIENCY

integrity of the structure. leaving

Durable and versatile

only a local repair 10 the affected

area necessary.

No maintenance required

Exceptional spanning
characteristics

Recyclable
U/limate high recycle value
Exceptionally low cost in use

Natwesl Ufe Assurance. Btistol.

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

be installed.

recessed feature band details.

Our fast. accurate seNice is
designed to ensure the correct
co-ordination of our wide

accessories manufactured from

high-grade aluminium extrusions
- flat sheet in numerous gauges
- or from stainless steel
components.

component and accessory range.

Even the fixings can be specified
Defailing at ridge, eaves. verge,
dormers. soakers, access
hatches, internal valley gutters.
Guiness Building, DundalJ<.

changes in level, parapets,

lightning protection are all
achieved using proven

to Hoogovens standards.
KAL-FIX ,. is a range of screws
and tools specifically selected in
partnership with SFS Stadler for
KAL-SYSTEMS.

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

prevailing weather conditions.
While purposefully nol employing
any joint sealants or mastic strips,
the design of the KAL-ZIJ>8 seam
remains completely weather tight.
But it allows any entrapped

moisture from the construction

stage, or trom an existing failed
roof beneath, to vent through to

into account.
lannahill Centre, Paisley.

The liner, vapour control layer,

LONG SPANS

and thermally broken ST-Clip are

The high quality of aluminium

also specially designed, so that

used for KAL-ZIJ>8, combined

when installed they will keep warm

with the various sizes and gauges

air leakage into the roofing system

means that KAL-SYSTEMS can

to an absolute minimum, while

span considerable distances

good detailing ensures drainage

between structural supports -

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.

KAL-Zlp
Applications
KAL-Zlp offers an Ideal and highly cost-effective solution In all

NEW BUILD

roofing and walling situations. KALSYSTEMS can provide

exceptional strength while remaining lightweight. These systems
can be installed quickly and easily for new build construction,

Double skin insulated

constructions are normal

tor new build.

re-cladding and the over-roofing of failed roofs.

The roof construction comprises

REFURBISHMENT

OVER ROOFING

Single skin KAL-Zlp is primarily

Over-roofing is where KAL-Zlp

used in re-cladding or over-

is fixed over an existing flat roof

roofing.

(ie felt, ashphalt). A pitched

substructure is designed to shed

Re-cladding is where KAL-Zlp

is fixed over an existing asbestos

cement, or metal sheeted roof,
supported on a sub-purlin system
fixed to spacer brackets, which
are positioned into the troughs of
the existing sheeting. Insulation is
normally added to upgrade the
roofing thermal performance.

water away, preferably to an

external gutter. This comprises
a purlin system supported by a

the KAL-Zlp outer sheet,

mineral fibre insulation, a vapour

control layer, KAL-L1NER '" liner
sheet or KAL-DEK structural
decking. By selecting from a
range of clip heights, the insulation
depth is accommodaled between
the two skins.

lightweight frame or stub columns,

fixed back to the existing support
structure. It must be designed to
distribute all roof loads evenly. .
To upgrade the thermal
performance, additional insulation
is normally added.
In both refurbishment and overroofing, the new sheeting and
substructure is lightweight, adding
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

KAL-Zlp Technical Information

Profiles and Clips

PROFILES AND WEIGHTS (Kg/m')

GAUGE (mm)
Depth

Fig No

0.8

0.9

300

65/300

3.47

3.45

r
r
r

65/305
65/333
50/333
65/400

Cover Width

65
65

305

65

333

50

333

65

1
1

65
65
65

1
1

1.0

1.2

3.88

4.31

5.17

Self Supporting Sheet

3.86

4.28

5.14

Self Supporting Sheet

3.34

3.74

4.15

4.98

Self Supporting Sheet

3.16

3.54

3.92

3.57

3.96

4.76

Self Supporting Sheet

500

65/500

3.38

3.75

4.50

Fully Supported Sheet

600

65/600

3.22

3.58

4.30

FUlly Supported Sheet

600

65/600 5 rib

3.26

3.61

4.34

Fully Supported Sheet

400

3.19

Self Supporting 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 STCLIPS
KAL- ZIP sheet

TYPE

W1

W2

25

81

20

25

50

106

45

50

60

116

55

60

80

136

75

80

90

146

85

90

100

156

95

100

110

166

105

110

120

176

115

120

130

186

125

130

140

196

135

140

150

206

145

150

60

190

44 CAS

190

246

185

W2

Thermal --~!!o.:l#
barrier

pad

11

3eCRS

60

t1"

.~~:+

5.5diCl

Standard dip t.' Type

Base detail

'E' Type dip

Base detail
(Fa ftxrtg 10 ffWl. 75 mm WIde IIfT/bef putllns)

KAL-Zlp Technical Information

Structural and Movement

KAL-Zlp 305 LOAD SPAN GRAPHS ROOF APPLICATION

THERMAL MOVEMENT
AND FIXED POINTS

5.0

..*
iT

4.0

<i

9
~z

<n

used in long lengths, the

I:i+~;

understanding and control

.t:t

ErE !:to
.

30

"-

As KAL-ZIP- sheets are commonly

:t , +l

.1 .

"-

consideration. In general,

aluminium expands at

25

20

4-rrr h 9' ~\

:=.

@ Jf;\C

. tE! .-.+ 1\

.~'

+. :

of Ihermal movement is a prime

"
(j

:::>

approximately twice the rate ot

sleel and the same rate as GRP

<n
0

,~

o.

1.0

1.0

1.0

3.0

2.0

1.0

2.0

SPAN (m)

3.0

SPAN (m)

KALZlp 400 LOAD SPAN GRAPHS ROOF APPLICATION

2 or 3 times the rate of aluminium.

The colour and finish of a roof
will also play an important role in
determining the anticipated
thermal movement. Dark colours
will allain temperatures of
approximately 70C during hot
summer days, whereas lighl
colours and plain mill or stucco

ftFIFf-{"!f;-;-

5.0

PVC will expand at approximately

embossed finishes will only reach

40 to 50C.

4.0

~ ~.

"-

<i

9
~z

Z
"z

3.0

\_~-

O.

Fixed point

Movement

Cl'

:::>

<n
0
Z

STANDARD

~
>l'.
o.

(j

2.0

<n

0.9 "'

3.0

O.

2.5

1'.

2.0

RADIUSED EAVES

M<Nement

Fixed points

1.0

1.0

CRANKED EAVES

o1.0

2.0

3.0

Mtwement

1.0

2.0

SPAN (m)

SPAN (m)

GENERAL NOTES
I The above grnphs relote to the U56 of KAL-Zlpe In
muWpIe span condition only.
2. AI loads aro kN,rn' ond ore assumed to be applied
unirormly.
3. MallmLOm detlectiorl is takerl at fTlId-span
4. The self weight of the K,AlZjpe fool sheelWlQ has
been laken InlO account in \he aboYe Ioadings.
5. All spans are assumed 10 be equal or within 15'llo of
!he IarQeSl span.
6. The IoIIowwlg load ladOfS t\8vc been taken onto
8CCOU'lI in !he 00Sign capacity 01 the sheebng

7 For wmd SUCllOrl cond'lion, pull out values ot tix,ngs

to 9lfUCluro 10 be determined in accordance with
foong manufacturers lest data.
8. The above snow laadlngs are epphcable lor
KAL-2Ipe sheeting with ST-CIips type L60 or beloW.
For c~ps type L80 or above cheCk ST-C~p
lOAOlSPAN DATA SHEET Ior possible load reducll()l'l.
These can be Iound in !he KAL-21pe Io8dJspan

FtXED SOAKER
Fixed point
Movement
Movement

BOWED RIDGE
Fixed point
Movement

Movemenl

graPhS Md Iables brOChure.

9. For Ioad.'spen oond'bOolS 0\.II5Ide Iho6e shown
&bOYe range please contacl Hc:logoYeI'lS AJo..nwwm
~Systems.

Dead Load 1 4
Dead Load (re9I$IInQ \Wld uplift) - 1.0
Snow l.o9cl 1.6
WndLoad-14

Fixed painlS

3.0

Fixed point

FIXed poWll

12

Fixed painl

---J-I~

Fixed paint

KAL-Zlp
Technical Information
As KAL-ZIf>8 accommodates for

ANTICIPATED THERMAL MOVEMENT IN ALUMINIUM

thermal movement by moving

Finish

Approx Temp.

Movement

Attained

per metre Length (mm)

Stucco/Mill

40 - 50C

1.0

Light colour

40 - 50C

10

Dark colour

70 - aoc

1.5

over the head of the ST-Clips, this

will create a metal-to-metal friction
force that will try to overturn the
ST-Clip. This effect is greatly
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

KAL-ZIP" accommodates

occurring at the eaves position or

should be given to the positioning

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'

installed within stated tolerances.

is based on a number of given

the friction force and reduces the

effective length ot the KAL-ZIP"

criteria, such as intensity of snow

FIXED POINT

sheet.

~=:;:::::;=3;-'n-PIatle

loading, roof pitch and length,

To control thermal movement

ST-C~p

KAl-ZIP'

By using standard formulae with

and avoid creepage of the sheet

down-slope, a 'fixed point' is

the above criteria, the movement

forces can be determined and the

introduced into the system.

correct 'fixed point' can be

'Fixed poinls' are usually installed

at the ridge position, thus allowing
thermal movement to take place
at the eaves position. According

Fixings

Purlin

adopted. The following tables give

the recommended 'fixed point' for
various KAL-ZIP" widths under

Over-turning of ST-Clips due to

various intensities of snow loading.

RECOMMENDED FIXED POINTS

thermal movement of KAL-ZIP"

resisted by pull-out strength of

KALZlp 300 and 305

Snow load - 0.6 kN/m'

C
I
Ua.'=
~

30

25
20

15
10
5

Snow load

30

\
C

1\

~
1

.......

"-

......

20

0:

15

f2

0
0

'"

11
\

25

10

5 10 15 20 25 30 35 40

1"-

fixings from purlins.

0.75 kN/m'

1\

I.......

Key 10 recommended fixed points

.......

I1

25

5 10 15 20 25 30 35 40

20

~
8
~

'"

15
10
5
0

30
4

3\
\~
1

r-

r-....

5 10 15 20 25 30 35 40
Effective KAJ....ZI". sheet length (m)

~
0
0

10

'"

\\

15

bOIt~ ~

Aluminium Building Systems

.......

r:::::- ~

...... r-

i-

5
0

= nut and

~
1

fP

4 = Please consult Hoogovens

25
20

= 1 rivet

2 = 2 rivets

Effeclive KAL-Zlp sheellenglh (m)

Effective KALZlp sheet length (m)
KALZlp 333 and 400
Snow load = 0 6 kN/m"
Snow load'" 0 75 kN/m'

30

5 10 15 20 25 30 35 40
EffectIVe KAL-Zlp sheellenglh (m)

13

force

aclllQ on

width and weight of sheeting.

Effective length", length of sheet acting on

single roof pilch.

Snow load to be taken as average intensity

acting on silgIe roof pitch area.
Snow load intensity 10 be determined from

as 6399 Part 3.

head 01

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

based on effective KAL-ZIP" sheet

length and height of ST-Clip. The
tables are based on the use of the
KAl:ZIP" Sl'Clip fixed with SFS

The partnership of Hoogovens

(minimum yield strength

280N/mm'). The purlin top flange

width is assumed to be 60mm

minimum and the ST-Clips are to
be fixed centrally. The effective

Aluminium Building Systems and

SFS STADLER has produced
several innovations. The latest of
these is a stainless steel self
tapping screw with an aluminium
washer. The need for this product

MINIMUM PURLlN GAUGES

was highlighted in the Hoogovens

STUCCO EMBOSSED ALUMINIUM OR

Aluminium Building Systems

LIGHT COLOUR COATED SHEET

training school. Several trainees

pointed out the benefits that

(Approximate Thermal Movement 1mm per metre length)

STRAIGHT AND PRE-CURVEO SHEETS

NATURAl CURVEO SHEETS

could be gained from a suitable

stainless steel, self drill and tap

EFFECTIVE KAL-ZIP'S
SHEET LENGTH (m)
5 101520253035404550

, ,

----+---'.-1-
_ 1~
110
, ,

120
130
140
150
190

2.0
2.3
2.5
2.9
3.2
3.4
3.6
3.7
3.9
4.6

I,

80
90
~ 100
U)

25
25

- I

-~

-- --- c-

--

1.8
2.0
2.1
2.2
2.4
2.5
2.9
3.1
3.7

- -~-~r~ W~
-

25
25

60

EFFECTIVE KAhZIP"
SHEET LENGTH (m)
05101520253035404550

60

80
90
~ 100

U)

110

~f

_.

15

_~l
,

120
130
140
--I
150
- 1
190

11.5

1.6
1.7
2.0
2.2
2.3
2.5
2.9
3.2
3.3
3.5
4.1

r--: -;

---1-

I
2.0
2.2
2.5
3.1
3.3
3.5
3.7
3.9
4.1
4.2
4.9

fastener to improve the speed

of fixing the ST-Clips. The result is
a four-fold improvement in clip
fixing and a 28% overall time
improvement in installing the full
KAL-Zlp system. This helps
to keep the KAl:Zlp system
cost effective and competitive.
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
EFFECTIVE KAL_Zlpa
SHEET LENGTH (m)
5101520253035404550

25
--

25
60
80
90
~ 100

U)

110

120
130
140
150
190

..

--

.-

15

--

. -

NATURAl CURVED SHEETS

II

,
-

1.8
2.0
2.1
2.2
2.4
2.5
2.9
3.1
3.7

EFFECTIVE KAlZIPSHEET LENGTH (m)

05101520253035404550

, ,

1151

,,
1.8
2.0
2.3
2.5
2.9
3.2
3.4
3.6
3.7
3.9
4.6

"d
t-L

U)

25
25
60
80
90

--1='
-l

- !.E

100 110

120
130
140
150
190

- 1--

I-

I
1.6
1.7
2.0
2.2
2.3
2.5
2.9
3.2
3.3
3.5
4.1
14

, ,
I

1151

2.0
2.2
2.5
3.1
3.3
3.5
3.7
3.9
4.1
4.2
4.9

KAL-Zlp
Technical Information
RECOMMENDED FIXINGS FOR KALZIP ROOFING AND CLADDING
APPLICATION

DETAIL

FIXING TYPE

SFS FIXING

AND FREQUENCY

CODE NO

KAL-ZIf'3 ST-Clip with

6.3mm diameter stainless steel self

SX2/15

thermal barrier pad 10

drilling screw, complete with

T~~6~
"'d

mild steeValuminium

16mm diameter aluminium/EPDM

side rail

support of thickness l'

bonded washer.

barner

Fixings

PurliIV

tS2

A16
6.3 x 35

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.

ST-ClidB

Fixings

TImber
purlin

t >3.1S 11 63 x 38

6.3mm or 6.5mm diameler slainless

TDA-S-S16-*

minimum 75mm wide

steel self tapping screw compiete

6.5 x 64

timber purlin

with 16mm diameter SS/EPDM or

KAL-ZIP' ST-Clip to

bonded washer-NAB(C) type thread

sra~

Mild steel

decking ....

Fixngs

KAL-ZIf'3 ST-Clip with

4.8mm diameter aluminium

RV66

thermal barrier pad, to

buib type rivet with EPDM washer.

04-6-8W

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 KALZIP

-r-'U200

~--1".

-,- L

--1".

-,----

---

line 01 roof pitch

~

TOLERANCES
KAL-ZIf'3 is manufactured to high
engineering tolerances because
of the critical nature of the side
lap arrangement and engagement
over the head of the ST-Clip.
Greater considerations must be
given to manufacturing and
erection tolerances in steelwork
if it is designed to accommodate
KAL-ZIP.

I~
line of

rool pitch

lr"mm L

--T--

---

thermal movement over the

ST-Clips without locking and
introducing unwanted 'fixed
points'. It is assumed that the
KAL-ZIf'3 elements when fixed in
place will follow a straight line or
curve over their entire length.
Multiple curves resulting in dips or
sudden changes in slope may
cause a transfer of 'fixed point',
thus making redundant the normal
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

LATERAL RESTRAINT
As is common with other secret
fix systems, the KAL-ZIP" sheet
does not provide laferal restraint
to the top flange of purlins
although in a Double Skin Roof
Construction a O.7mm gauge
aluminium liner sheet will generally
provide sufficient restraint to light
gauge purlins.

KAL-Zlp
Technical Information - Thermal

BREATHABILlTY OF KAL-ZIP'
Due to low ventilation velocities
encountered when using long
length KAL-ZIP" sheets and/or low
pitched roofs, ventilation in the

A major benefit of the KAL-ZIP"

absorbent insulation will simply

roof system is that no sealants are

evaporate away through the

used, allowing fhe roof structure

KAL-ZIP" seams when

to breath. The construction is

atmospheric conditions allow.

weather-tight by virtue of the

anti-capillary groove within the

airspace above the insulation is

not recommended. A high quality

formed lap, but it is not air-tight.

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

ST-Clip

'U' Value

oversized to allow compression

(W/m'K)

during erection eliminating any air

Insulation
Thickness
Un-compressed
(mm)

space between the insulation and

KALZIP" 300 WITH KALLINER' 30/150 LINER

the outer KAL-ZIP" sheet.

KAL-ZIP"305 WITH KALLINER' 30/152 LINER

Insulation
Thickness
Compressed

(mm) - x

KAL-ZIP"333 WITH KALLINER' 30/167 LINER

KAl-ZIP'
sheet

0.432

110

100

80

0.387

120

100

90

0.351

130

120

100

0.320

140

120

110

0.295

150

150/140

120

0.223

190

180

160

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

Vapour
control

~""

0.409

120

100

85

0.368

130

120

95

0.335

140

120

105

0.307

150

150/140

115

0.230

190

180

155

KAL-ZIP' 400 WITH KALDEKo DECKING

Vapour

control
layer

Fixing
rivets

Thermal
bartier

KAL-DEKt.
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

0.254

140

160

140

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
OF STCLlP
The

'u' value lables do nollake

into account Ihe Thermal Bridging

effect ollhe 5T-Clips which should
be allowed for as stipulated in the
1995 Revision of Approved

through the stem 01 the 5T-Clip

TYPICAL 'U' VALUE

shoutd be taken into account.

OF STCLlPS

By utitising the proportional area

ST-Clip

method of calculation, the effect

of the cross sectional area 01
the 5T-Clip stem on the overall

'u'

value of the roof construction

should be determined.

Document Part L. of the Building

Regulations (England and Wales).

53mm

As Ihe KAL-Zlp sheeting is

supported on aluminium clips

'U' Value (W/m'K)

80

6.393

90

6.391

100

6389

110

6.386

120

6.384

130

6.382

140

6.380

150

6.377

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

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

KAL-Zlp 305

KALZlp 333

KALZlp 400

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 STCLlPS EXAMPLE

Utilising Ihe proportional area

Element

Area/m'

'U' Value

Adjusted 'U' Value

Insulated area

0.999441

0.432

0.4318

5T-Clips

0.000559

6.386

0.00357

method of calculation, a KAL-Zlp

305 insulated roof construction
with purlin centres of 1.8m and a

Final

finished insulation depth of 80mm

created by the use of 5T-L110
Clips would have a

'u' Value

0.43537

Under the above conditions the 'U' value of the roof construction has increased
by 0.00337 (0.8%) as a result of Thermal Bridging of the Sf-Clips.

'u' value as

table opposite shows.

17

KAL-Zlp
Technical Information - Thermal
from inside the building into

VAPOUR CONTROL LAYER

at all laps, perimeters and

the root construction, thereby

penetrations in order to ensure its

minimising the risk of condensation.

effectiveness.

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

should be continuous across its

building and therefore the

surface. It must be fully sealed

condensation risk.

It is good practice to enhance the

performance of a roofing system

A vapour control layer will restrict

the movement of water vapour

RECOMMENDED VAPOUR CONTROL LAYER FOR KAl-Zlp ROOFING SYSTEM

CATEGORY

EXAMPLE OF

(Risk of Condensation)

BUilDING

liNER/DECKING

GENERIC VAPOUR
CONTROL LAYER (VCl)

lOW

Occupancy or usage

Warehouse

of building does not

significantly add to the

Liner sheet.

No separate Vel

Factory

- fully sealed liner sheet.

Aircraft Hangar etc.

Structural deck

Reinforced virgin

perforated liner/deck.

polyethylene.

Liner sheet.

Reintorced virgin

moislure vapour present.

MEDIUM

High occupancy/air

Office, School,

conditioned buildings.

Sports Hall etc.

polyethylene.
Structural deck

Aluminium foil

perforated liner/deck.

encapsulated reinforced
virgin polyethylene.
Aluminium foil

HIGH

Buildings containing

Swimming Pool,

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

liner sheet.

process.

encapsulated reinforced

thick reinforced virgin

polyethylene.
Structural deck
perforated liner/deck.

Aluminium foil
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,

allowing the system to breathe,
removing any moisture from the
roof build-up as well as reducing
the risk of condensation. At all
times the design of the upstand
lap, incorporating an anti-capillary
groove, maintains the
weathertight integrity of the
KAL-Zlp sheets.
Where a double skin insulated
roof construction needs to be
airtight, this is normally achieved
at the vapour control layer/ lining
sheet pcsition. To help in
achieving an airtight construction
it would normally be necessary to

of achieving an etfective seal in

The areas that would require

the vapour control layer.

careful attention bofh from a

detailing and installation point of

Where exceptional 'air tightness'

view would be penetrations

requirements are specified, it may

through the construction junctions

also be necessary to completely

with the same form of

seal the liner sheefs as well as the

construction and abutments with

vapour control layer.

other forms of construction.

The installation and sealing of
In order to reduce the possibility

the vapour control layer should

of air seepage at these points

also be closely monitored on site

it is fundamental that the vapour

by the Clerk of Works staH,

control layer is continuous and/or

in particular at junctions and

fully sealed in the same manner

abutments involving ditferent

as that used for sealing the lap

forms of construction and/or

joints in the general construction,

sub-contractors.

eg the use of a butyl rubber

sealing tape.

St Mary's Car P8Ik, Sunderland.

19

KAL-Zlp
Technical Information - Acoustic
It is possible to modify fhe double

ACOUSTIC

SOUND ABSORPTION

skin KAL-ZIP' roof systems in a

Roofing and Cladding acoustic
performance divides into

number of ways to ensure

required levels of sound

two categories:- Sound Reduction

and Sound Absorption.

reduction. The introduction of high

density moisture resistant boards,

Both categories have different

high density insulation layers or

requirements and solutions.

multiple density layers of

insulation individually or in

SOUND REDUCTION

combination with each other,

Keeping sound out, e.g. near

can achieve high levels of noise

airports and city centres, and

reduction.

keeping noise in, e.g. at engine

test facilities, are common
objectives. In many instances
noise levels will need to be
reduced from one side of the
building envelope to the other.
The design and construction of
the root will play a large part in

Most materials will absorb some

sound. Hard surfaces like metal
and concrete reflect nearly all the
sound energy, absorbing very
little. Rockfibre's and glassfibre's
open surface texture make
efficient sound absorbers.
Their properties can be
incorporated into a KAL-Zlpo roof
by perforating the KAL-L1NER' or
KAL-DEK" liner sheet. Various

Hoogovens Aluminium Building

pallerns of perlorations, fUlly, web

Systems have been involved in

or trough perforated can be

numerous projects where a high

supplied, although the standard

sound reduction performance

pallern is 3mm diameter holes

was required and have extensive

on a 5mm isometric grid, for

test data on various KAL-ZIP"

KAL-L1NER'. This gives a standard

acoustic roof constructions.

perforated free area of 32.7%.

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
10 85 mm

a 15% free area.

TROUGH PERFORATED KAL-L1NER'

~
~

0.9 KALZI~ 400 shee1

FULLY PERFORATED KALL1NER'

WEB PERFORATED KAL-DEK"

L
STClip120 Wllh
thermal barrier

vapour control
layer

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

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
20

500 630 800 1000 1250 1600 2000 2500 3150

38.8

40.0 41.0 43.2

KAL-Zlp
Technical Information
Sound absorption properties of a

DESIGN IMPLICATIONS
WHEN USING KAL-L1NER'"
PERFORATED LINER SHEETS

Greater consideration must be

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.

surface can be determined by

testing to SS 3638 "Method of

2. VAPOUR CONTROL LAYER

given to the selection and

3. CONDENSATION

sound absorber.

1. STRUCTURAL

As acoustic insulation is below

The strength of a profile is

the vapour control layer, this layer

reduced by perforating,

is cooler than normal. Care must

A number of laboratory tests have

particularly if it is perforated all

be taken to ensure that the

been carried out to determine

over. 1.2mm gauge fUlly

'dew point' temperature does not

these coefficients for KALL1NER '.

perforated, 0.8mm gauge wide

occur below the vapour control

trough perforated and 0.7mm

layer allowing condensation to

sheet with varying perforations

gauge unperforated will all give

form. A ratio of 3:1 or 4:1 01

and lorms of insulation.

approximately the same spanning

insulation above the vapour

One example is detailed below.

capabilities in aluminium profiles.

(Coefficients above 1 can be

recorded due to the profile of
KALL1NER'" and

and

KALDEK~

KALDEK~.)

liner and decking

control layer to that below is

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

KALUNER'M TR301150---------.5..,l ...~

trough perforated
liner sheet

SOUND ABSORPTION RESULTS

Airo Limited Test Report U2101/1 . Double Skin Insulated

Frequency (Hz)

KALZIP~

Roof Construction with Perforated Liner

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