Corus Building Systems. Kalzip fixing manual

Transcription

1 Corus Building Systems Kalzip fixing manual

2 Kalzip fixing manual Contents Contents Page Section 1 Introduction 1:1 Section 2 The system 2:1 Section 3 Transport 3:1 Section 4 Site preparation 4:1 Section 5 Fixing 5:1 Section 6 Roof types 6:1 Section 7 Curved and tapered Kalzip 7:1 Section 8 Translucent sheets 8:1 Section 9 Site work 9:1 Section 10 Surface finished appearance 10:1 Section 11 Accessories 11:1 Section 12 Special tools 12:1 Section 13 Index 13:1 For ease of reference please refer to the index on page 13:1 Technical information sheets are available to support each section within the manual. Contact the Kalzip technical department for further information.

3 Section 1 Introduction Introduction 1.1 Regulations This fixing manual outlines the correct use of Kalzip, the fixing elements and its accessories. Kalzip sheets can only be fixed by companies approved and trained by us the manufacturer, and in accordance with current building regulations. The following instructions cover all stages from unloading the material to acceptance of the completed work. They are intended as a guide for standard applications and conditions but do not exempt the fixing contractor from critical examination. This applies in particular to low pitched roofs, roofs with openings and structures which are exposed to extreme physical conditions. It is assumed that the Teamkal contractor will provide full working drawings on which all dimensions, details and materials are specified. This fixing manual does not claim in any way to state the building regulations, recommendations of trade associations or codes of good practice. It is assumed that they are known and are complied with at all times. These instructions, recommendations and requirements are based on experience gathered by the manufacturer together with the practical experience of fixing contractors. Note: All dimensions are in mm unless otherwise stated. 1:1

4 Section 2 The system The system 2.1 Introducing Kalzip Kalzip is an aluminium standing seam system designed for both low pitched roofs (minimum 1.5 degrees) and steeper pitches. The aluminium sheets are fixed with clips which are locked into the roll and concealed by the adjacent sheet. This means that the fasteners are positioned beneath the roof covering. The roof skin is not pierced offering a penetration free system. The clips allow for sheet movement resulting from temperature changes. Movement takes place from the fixed point to the eaves and/or the ridge. When fixing the sheets, it is important to ensure that the pitch specified on the roof plan is observed, in particular near the ridges and eaves. Where possible, no opening should be made in the pan of the Kalzip sheet. Jointing with other building components must not impair the sliding movement of the Kalzip. Sheets of special widths, between 225 mm and 620 mm*, can be manufactured either with large and small rolls or with two large rolls. Kalzip dimensions Kalzip 50/333 Kalzip 50/429 Kalzip 65/305 Kalzip 65/333 Kalzip 65/400 Kalzip 65/ Thickness (mm) * Maximum width for AluPlusZinc, stainless steel and copper is 400 mm. Kalzip AF 65/ Kalzip AF 65/ Fig :1

5 Section 3 Transport Transport 3.1 Transporting to site or unloading at designated storage areas In general, Kalzip sheets are transported by road. It is normal practice to clean the external face of Kalzip sheets when used as wall cladding and the internal face when used as a single skin roof. Sources of supply for certified beams and sling belts can be supplied on request. Maximum load per suspension point must not exceed 0.8t. and projecting ends exceeding 4.0m must be avoided. 3.2 Unloading at site Access to the unloading point must be guaranteed, this applies for all deliveries. It is especially important to check the maximum access height as Kalzip can be delivered in high loads due to its low weight. MAX OVERHANG = 4m 0.8t 0.8t 0.8t 0.8t Fig. 3.1 MAX OVERHANG = 4m Before delivery the roofing contractor must check the site and it may also be necessary for the transport agent to check the route. Delivery dates must be agreed with us. Packages can weigh up to 2.0t (Check crane capacity). Owing to the different sheet seam upstands, pallets must be stored in accordance with the direction of laying to avoid having to turn the sheets on the roof. Installation has to be made in the direction of the sheets small seam upstand. Make prior arrangements for lifting gear such as cranes, forklift trucks, spreader beams, sling belts, etc. Protect edges of packages if sling belts are being used. 3:1

6 Section 3 Transport Unloading pre-curved Kalzip Take special care when unloading or lifting pre-curved Kalzip onto the roof. You must allow for the fact that extra sling belts will need to be used (see fig 3.2).Different length slings may also be necessary. Fig. 3.2 In many cases, the pallets cannot be placed directly onto the substructure. The profiled sheets have to be lifted onto the roof individually or in small bundles. Separate banding can be ordered. 3.3 Storage on the building site If possible store under cover to prevent the accumulation of dirt and condensation. Otherwise store at an angle on timber cross bearers and cover but allow for circulation of air and drainage. When storing on the roof, ensure that the load bearing capacity of the substructure is sufficient. Secure profiled sheets and packages against wind uplift and sliding. Exercise caution when opening packages stored at an angle: there is danger of sheets sliding sideways and/or in the direction of the roof slope. Note: Do not store open packages for long periods of time. Always cover translucent sheets to protect them from dirt and direct sunlight. Ideally cover with light coloured opaque tarpaulins to minimise magnifying glass effect which may cause distortion and discolouration. 3.4 Checking incoming materials Obtain confirmation of any material and packaging deficiencies from the forwarder and notify us immediately. Check that the number of packages and their contents agree with the delivery documents. Inform the supplier immediately of any dimensional or quantity deviations, etc. The period of time in which transport damages have to be claimed, is a maximum of 1 week after arrival on the building site although an earlier claim is advantageous to all parties. Permissible length tolerances for Kalzip sheet: for sheets up to 3 m in length: + 10 mm / - 5 mm for sheets over 3 m up to 30 m in length + 20 mm / - 5 mm for sheets over 30 m in length: + 1 mm / 1 m / - 5 mm Tolerances are based on a production temperature of 20 C. Additional allowances may be needed for on-site production. 3:2

7 Section 4 Site preparation Site preparation 4.1 Preliminary work Before commencing work, compare the roof geometry and dimensions of the supporting structure with the approved plans. It is particularly important to ensure that the minimum pitch around the eaves is not impaired by unevenness in the supporting structure. Use a shallower clip if necessary. Notify your client in writing of any discrepancies. 4.2 Kalzip licensing notice/certification A copy of the current relevant licensing notice/third party certification should be kept on every site. It contains important information concerning the qualification of the fixing personnel, accident prevention, load bearing capacity and the jointing of Kalzip sheets. It is imperative that this information is observed. 4.4 Special tools Before commencing fixing work, check the zipping machine, hand closing tool, ridge folding tool, eaves folding tool and unzipping device. The zipping machine must close fully and the roller sets must be correctly fitted. Always test the zipping machine before use and check for paint damage on colour coated sheets. Clean the hard chrome surface of the rollers if necessary and replace any damaged rollers (refer to sections 5 & 12). 4.3 Layout Follow the installation plans. Measure and string out roof and wall areas. Set out sheet widths so that they meet transitional points such as roof lights, smoke vents etc. in accordance with the plans. Depending on the sheet gauge and clip type, it is possible to increase the cover width (nominal width) by up to 3 mm. With curved roofs, the installation width can be 3 mm wider than the cover width. The sheets must not be spaced less than their cover width as this will restrict thermal movement. Observe the direction of fixing and store the pallets so that the small seam upstand always points in the direction of laying. 4:1

8 Section 4 Site preparation 4.5 Corrosion protection When fitting aluminium to certain materials direct contact must be avoided. No particular measures are necessary for aluminium support structures with a thickness of at least 1.6 mm. No particular measures are necessary for steel structures if the contact surfaces are galvanised or coated, e.g. trapezoidal steel sheets. Painted surfaces must be compatible with aluminium. Intermediate layers of noncorrosive material must not accumulate dampness. Suitable materials include plastic sheeting, plastic board or bitumen felt strips. (Wool felt, for example, is unsuitable). Precautions must be taken with structures if the timber preservatives include chloride naphthalene compounds or if they contain copper, mercury salts or fluoride compound. Aluminium and cement based products must always be separated by an intermediate layer. No measures are necessary when joining aluminium with titanium, zinc, aluminium zinc or stainless steel. Note: There is a danger of contact corrosion for uncoated aluminium if fitted to other metals. Falzinc and AluPlusZinc rainwater run-off from timber cladding Whenever using Falzinc and AluPlusZinc beneath timber cladding be aware that the timber might contain acids that could be dangerous to the zinc coating. Rainwater run-off from timber can be highly acidic and any leeching of the timber can cause corrosion to zinc materials. It also affects copper and lead materials in the same way. For further information on the above or any other Kalzip materials please refer to the Kalzip technical department. Aluminium compatibility with dissimilar material Material Atmosphere Rural Industrial Marine Zinc safe safe safe Stainless steel safe safe safe* Lead safe safe unsafe Uncoated steel unsafe unsafe unsafe Copper unsafe unsafe unsafe Timber treated with fire retardant or unsafe unsafe unsafe preserved with copper or floride compounds Concrete, mortar and alkali-bearing unsafe unsafe unsafe materials *This applies only for fixing screws and rivets made from stainless steel. Other stainless steel elements must be protected. 4:2

9 Section 5 Fixing Fixing 5.1 Principal rule Zip each sheet immediately 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. 5.2 Wind & weather Kalzip sheets are light and have a large wind uplift area. Therefore exercise caution when storing open packages and lifting Kalzip sheets onto the roof. Lash down open packages and stop fixing work in strong winds. Immediately fasten individual sheets and zip together paying particular attention to the last sheet (i.e. by provisionally fastening with the gable end clip). (see fig. 5.1) In windy conditions work should cease in accordance with current HSE and NFRC guidelines. 5.3 Load bearing capacity During installation, and after, for general maintenance and inspection purposes, it is possible to walk on Kalzip sheets that have been partially zipped together to the parameters shown in the tables overleaf. Slight deformation to sheet pans may occur if trafficking is heavy. This will not affect the technical performance of the Kalzip sheet, although aesthetically may be of some concern. Load spreading methods should be considered, as indicated, in areas which may be affected. Outside the parameters listed timber scaffolding (or other similar) boards should be used. (see fig. 5.2). The last sheet at the verge positions, individual unzipped sheets and translucent sheets must NOT be walked on. Fig. 5.1 During installation, load spreading methods should be used at eaves, verges, ridges, points of access, common walkways and around soakers to prevent deformation of Kalzip sheets. This may be accommodated or at the design stage by the incorporation of high density rockfibre insulation (140kg/m 3 ) to the underside of the Kalzip sheets in these areas. After installation consideration should be given to the introduction of permanent walkways on areas envisaged as being heavily trafficked/access points etc. Profiled sheets can be self curved over the ridge on low pitched flat roofs. Use high density rockfibre insulation (140kg/m 3 ) under the pan of the sheet at the ridge position to offer support. Depending on the position of the clips at the ridge, it may be necessary to change some clips for shallower types. 5:1

10 Section 5 Fixing Aluminium only other material data is available on request. Kalzip sheets partially zipped together (sheet with one seam zipped) Sheet Kalzip thickness 65/305 65/333 65/400 50/333 50/429 AF65/333 AF65/434 t Span Span Span Span Span Span Span (mm) (m) (m) (m) (m) (m) (m) (m) Kalzip sheets fully zipped together (sheets with both seams zipped) Sheet Kalzip thickness 65/305 65/333 65/400 50/333 50/429 AF65/333 AF65/434 t Span Span Span Span Span Span Span (mm) (m) (m) (m) (m) (m) (m) (m) Fixing clips Generally, clips are set out in a modular format and fixed symmetrically through the clip base. Observe manufacturer s instructions regarding fasteners such as screws or rivets, in particular drilled hole diameters and tightening torque s. Important note The use of set screws (bolts) is not recommended. Fig. 5.2 Kalzip E type clips The range of Kalzip E Clips are E10, E25, E140, E160 and E180. A 10 mm polyamide spacer is also available which fits on to the base of the three taller clips (E140, E160 and E180) to effectively increase the available range of E Clips. Refer to page 11:1 for details. All clips can be installed to structural decking and top-hat sub-purlins e.g. Kalzip deck roof 5:2

11 Section 5 Fixing system. Kalzip liner-deck roof system and Kalzip acoustic roof systems require top hats to pick up the hole centres. The E180 has a different hole arrangement making it also suitable for fixing direct to thin-gauge cold-rolled purlins (e.g. Kalzip liner roof system). The E10 is only suitable with the Kalzip 50 and AF profiles. The Kalzip E-Clip is the standard recommendation for use on roof areas with effective sheet lengths over 40 metres (length from the fixed point). Please see relevant Technical Information Sheet. Clip installation details Timber purlins As a general rule, the timber must be predrilled when using screws. This is not necessary when self-drilling screws are used. Self-drilling screw: e.g. SFS-SDK2 S x 45 without thermal barrier pad self-drilling screw: e.g. SFS-SXW-S x 50 or Kalzip fastener e.g. SFS-SDK2-S x 35 with 5 mm thermal barrier pad Kalzip fastener e.g. SFS-SDK2-S x 45 with 15 mm thermal barrier pad self-drilling screw: e.g. SFS-SXW-S x 50 or e.g. SFS-TD4-S-S x 64 5:3

12 Section 5 Fixing Through the lining into purlins or rafters without thermal barrier pad with 5 mm thermal barrier pad with 15 mm thermal barrier pad threaded screw: e.g. SFS-TDA-S-S x 76 pre-drilled with Ø 4.8mm Steel purlin without thermal barrier pad self-drilling screw: e.g. SFS-SX14/12-S x 38 with 5 mm thermal barrier pad self-drilling screw: e.g. SFS-SX14/12-S x 38 with 15 mm thermal barrier pad self-drilling screw: e.g. SFS-SX14/38-S x 61, SFS-SX14/4-38-S x 61 or self tapping screw: e.g. SFS-TDB-S-S x 38 pre-drilled in correspondence with flange thickness 5:4

13 Section 5 Fixing Kalzip structural deck steel trapezoidal profile (thickness max mm) without thermal barrier pad or with 5 mm thermal barrier pad Kalzip fastener: e.g. SFS-SDK2-S x 35 or bulbtite blind rivet: e.g. SFS-RV W with 15 mm thermal barrier pad Kalzip fastener: e.g. SFS-SDK2-S x 45 On a steel top hat profile (thickness 1.50 mm) without thermal barrier pad Kalzip fastener: e.g. SFS-SDK3-S x 30 or self-drilling screw: e.g. SFS-SX3/10-S x 28 or bulbtite rivet: e.g. SFS-RV W with 5 mm thermal barrier pad Kalzip fastener: e.g. SFS-SDK3-S x 30 or self-drilling screw: e.g. SFS-SX3/15-S x 38 or bulbtite rivet: e.g. SFS-RV W with 15 mm thermal barrier pad self-drilling screw: e.g. SFS-SX3/20-S x 52 Kalzip clips must not be attached using powder actuated fasteners! 5:5

14 Section 5 Fixing 5.5 Fixing Kalzip sheets Direction of lay Sheet fixing is done in the direction of the small seam with the large seam overlapping the small one. Fixing is generally done from verge to verge. In special cases it may be necessary or sensible to change the sequence. For example dome shaped roofs or roofs inclined perpendicular to the Kalzip may dictate a different fixing sequence. These procedures need to be planned in detail and special profiles may be required. The standard procedure for verge-to-verge installation is as follows: Fig. 5.5 Fig. 5.3 Fig mm M6 Stainless steel bolt Kalzip ST clip Fixing sequence a) Start at the verge detail, set out the row of clips to the datum line, ensuring that clips at the eaves and ridge of shallow roofs are positioned at the correct height so that an adequate slope is achieved b) Close the large seam of the first sheet with the zipping machine so that the gable end channel can be fixed and rivetted into position. The zipping machine must be supported by hand in order to prevent it tilting during running. c) Lock the sheet onto the pre-fixed clips or fix the second row of clips at measured intervals. d) Create a fixed point, using rivets or screws, as shown in figures 5.3 & 5.4 respectively, and as indicated on the working drawings. Note: Nut and bolt fixed points should be fitted after zipping sheets. e) Position the gable end channel and fix by rivetting to the large seam upstand at intervals of 400 mm max. Allow a space of 1 mm (1.5 mm for dark colours) per linear metre of sheet from the clips to ensure that the sheets can expand and contract. The larger leg is positioned within the Kalzip sheet. Leave a gap of 5 mm at the profile joint. 5:6

15 Section 5 Fixing f) Screw gable end clip to clip web (see fig. 5.5.) Pre-drill 4.5 mm diameter holes in clip web where working space is confined. Distance between top edge of clip head and centre of the hole: Kalzip 65 = 66 mm from top of clip to hole centre Kalzip 50 and AF = 52 mm from top of clip to hole centre Tighten the screws with a drive socket and ratchet if necessary. E type clips fixed point details The design of the fixed point for the E type clip is different. The fixed point cannot be created as normal by means of rivets to the clip head. Fig. 5.5a The fixed point is a nut and bolt design arrangement comprising 6 mm diameter stainless steel setscrew, stainless steel Nylok locking nut and 2 No. 19 mm diameter stainless steel/e.p.d.m bonded washers (M6-S-S19/3-6.0x35, S19/3-8, M6-SS Nylok. Kalzip Clip End clip verge rivet the gable hook to the web of the E clip. [Fig. 5.5a] Rivet reference: RV W Pilot hole at 5.3 mm diameter 5:7

16 Section 5 Fixing 5.6 Zipper maintenance checklist Ensure machine has a current PAT Certificate 1. Check that correct roll-sets are fitted and that they are clean, showing no signs of rust pitting or indentations. 2. Check tie bars for freedom of movement using a light oil for lubrication. 3. Check side, front and top guide rollers for excessive wear, or for signs of seizing. 4. Check locking handle cams and cam plates for excessive wear. 5. Visually check cable for any signs of damage. 6. Check for any excessive movement in roller shaft bearings, keyways and keys. 7. Ensure mating faces of machine base are free from indentations and close evenly. 8. Check unzipper type i.e. tee slot or bolt on. Used carefully, the zipping machine will last for many years with minimum maintenance. All rotating shafts are equipped with maintenance-free ball bearings. The bearings of the outer guide rollers must be lubricated with light-duty machine oil. Check the toothed drive wheels for dirt and foreign bodies and clean if necessary. Clean and slightly lubricate zipper rollers regularly in order to retain the chrome coating and to achieve the best zipping. Oil the tension bars in such a way that a thin oil film remains visible on the surface. Check setting. Clean contact surfaces. Set tension bars so that the zipping machine can be fully closed. Check all guide rollers for smooth operation and correct positioning. Perform zipping test and compare the roll dimensions in section :8

17 Section 5 Fixing 5.7 Zipping sheets The small seam upstand must be clipped fully into position at the clip head to prevent damage when zipping. For safety reasons, the sheets must be zipped together immediately after laying to achieve the composite effect necessary to ensure the load bearing capacity. Set up the zipping machine and use the set of rollers corresponding with the application below and refer to section 5.8. Always check the machine before zipping. Tension handle setting. It must be possible to fully close the zipping machine. The zipping rollers must be clean and free of burrs especially when being used on coated material. Refer to section 5.6 for further details on care, repair and handling of the zipping machine. Correct function of the zipping machine can be checked using the dimensions of the zipped seam ie. 0.7 to 1.0 mm approx 20 mm 1.2 mm approx 22 mm Zipping can be performed in any direction on sheets without transverse joints. The zipping machine can run on its own (automatic control). Zippers must be started and finished manually and operators must visually supervise the zipper when on automatic control. Zipping can be done from either eaves to ridge, or ridge to eaves. Curved Kalzip Modification of the zipping machine may be necessary for working on curved Kalzip. Removal of the skirts is only required for old type machines. The latest type machine does not have any skirts. Crimp-curved sheets Skirts and full front guide assembly must always be removed. Double skin translucent panel Skirts, contact rollers and guide roll assembly must always be removed. 50 mm high Kalzip Dismantle skirts (on older models) for zipping 50 mm high Kalzip and reset the side guide roll asembly. Transverse joints The zipping machine must run over the transverse joint from the overlaying sheet to the underlaying sheet. Refer to section 5.11 Constructing transverse joints for further information. Wall areas The zipping machine can zip upwards and downwards. It is mandatory to attach the zipping machine to a safety line. The space between the finished wall and scaffolding must be at least 350 mm. Errors Fit a cover strip over rolls to be repaired, then close with the zipping machine. On sheet thicknesses of 0.9 mm or less The zipper can be fed onto the end of the roll and then inched forward, checking for any deformation on the roll prior to commencing zipping. On sheet thicknesses above 0.9 mm The ends of the rolls should be pre-worked using the hand closure pliers and then the zipper can be fed onto the roll as before. Alternatively for any sheet thickness the roll can be back zipped. This is achieved by placing the machine onto the roll approximately 600 mm from the end of the sheet, apply pressure onto the locking handle, whilst inching the machine forward towards the end of the roll until it is fully closed. Feed the machine onto the pre-zipped roll as before. Guidance may be necessary on uneven or curved roofs (hand controlled), as the operator must then walk on the previously zipped seams. Guide roll assmbly and skirts need to be removed with crimp-curved sheets. When zipping 50 mm high Kalzip, check zipper type and reset the side roller holders assembly to the correct height (dependent on machine type). 5:9

18 Section 5 Fixing 5.8 Changing the roller sets or side rollers Required tools: Ring spanner 19 mm or hexagon socket spanner 19 mm Allen key 5 mm The following roller sets are at your disposal: 1) For material thickness mm, standard rollers. 2) For material thickness 1.2 mm, 1.2 rollers. 3) For translucent panels, daylight closure rollers Under normal circumstances it is not possible to incorrectly fix the various roller sets. 5.9 Unzipping Kalzip Fit the unzipping device and check that the height is correctly adjusted. Slightly open the large roll with the Kalzip peeler tool, alternatively use a screwdriver before threading in the tapered roller (see photo 5A) and inch the tapered roller into position (see photo 5B). The tapered roller will open the large seam and the sheet can be removed. If the sheets are to be re-used, adjust the height of the unzipping attachment to a low/medium setting to allow removal avoiding excessive deformation of the sheet roll Constructing fixed points All sheets must incorporate a fixed point to prevent slippage during expansion and contraction. There are a number of methods of forming a fixed point, each one dependant upon project specifics. The method adopted on the project should be shown on the design / working drawings. The most common fixed point methods are: a) Concealed rivet Drill a hole through the sheet at the small seam into the clip head to accommodate the blind rivet. Fit an mm long rivet. The large seam of the next sheet conceals the rivet head (see fig 5.3). b) Bolted After zipping, bolt the Kalzip upstand to the clip web using an M6 25 mm long stainless steel bolt with stainless steel nut and sealing washers (see fig 5.4). Note: If the fixed point is not positioned directly at the ridge, allow for longitudinal expansion of the sheets from the fixed point to the ridge when designing the ridge cap (see fig 5.6). Each sheet must have only one fixed point. Note: A curve in the sheet or a connection at a roof opening can also act as a fixed point. In such cases no additional fixed point should be used. Note: The fixed point should be as indicated on the design/working drawings. If in doubt please contact those responsible for preparing the design. Photo 5A roll opened to accept unzipper Photo 5B unzipper inched into position Fig 5.6 5:10

19 Section 5 Fixing Kalzip E clips fixed point details The design of the fixed point for the E type clips is different. The fixed point cannot be created as normal by means of rivets to the clip head. The fixed point is a nut and bolt design arrangement comprising 6 mm diameter stainless steel setscrew, stainless steel Nylok locking nut and 2 No. 19 mm diameter stainless steel/e.p.d.m bonded washers (M6-S-S19/3-6.0x35,S19/3-8, M6-SS Nylok. Sheet 1 is installed without notching and the large roll is zipped. Sheet 2 is notched for 200 mm on the small roll (as shown in fig 5.8) leaving the capillary tool intact. Sheet 3 is notched for 180 mm on the large roll (as shown in fig 5.8) to approximately the one o clock position. Sheet 4 is a repeat of sheet Constructing 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 used on roof pitches of 3 or over. On roof pitches below 3 the lap joints must be welded. It is important to follow the fixing sequence exactly in order to achieve permanent sealing properties. Figs 5.7 & 5.8 show the fixing sequence and the notching for 1.2 mm gauge sheets. For 1 mm sheets notches are required on the small seam only. Notches are not required on gauges of 0.8 mm and less. 0.9 mm being borderline, needs to be assessed and monitored during installation. 200 mm 180 mm Fig 5.8 Welded joint The sheets to be jointed are overlapped by approx mm and welded. (Support the welded joints, using a high density rock fibre insulation typically 180kg/m 3 density). Sealed joint Figs. 5.9 & 5.10 overleaf show the fastener positions with Kalzip 305. Apply the same sequence to all other Kalzip widths accordingly. Fig Note: The notch dimensions given above and in fig 5.8 relate to a 200 mm long overlap, for different length overlaps (e.g. when using welded joints) the notch dimensions should be adjusted accordingly. The notch on the small roll (sheets 2 and 4) should be the same length as the overlap with the large roll lap (sheet 3) being 20 mm less than the overlap length. 5:11

20 Section 5 Fixing stainless steel self-tapping screw 6.3mm diameter with sealing washer blind-sealed 4.8mm diameter rivets with st/st mandrels silicon sealing compound stainless steel self-tapping screw 50 silicon sealing compound Kalzip Fig Sealed joint acting as fixed point Note: The support type shown is for illustrative purposes only. 5:12

21 Section 5 Fixing blind-sealed rivet 4.8mm diameter with st/st mandrels silicon sealing compound Kalzip clip Fig Standard (floating) sealed joint Note: The support type shown is for illustrative purposes only Fixing soakers (see figs 5.11 to 5.18 overleaf) Kalzip soakers are designed and installed as a double skin construction in the pre-planned format (where the position of the opening is known during construction) or retro fit format (where the position of the opening is not known until after the installation of the roof). The build-up of the soaker is generally the same for both formats in that the inner skin is load bearing and fixed to the structure whereas the outer skin forms the weathering membrane and is fixed to the Kalzip allowing it to float. The position of the roof fixed point must be identified before commencing work on the soakers to ensure adequate movement of the outer skin. If the soaker is very large it may be designed as a fixed point meaning the whole lateral portion of the roof must be a fixed point and not just the soaker. 5:13

22 Section 5 Fixing Pre-planned soakers These are soakers whose position is known before or during installation of the roof. Before any work can commence the trimmer steelwork to the opening must be fully installed with the bearing surfaces on the same plane as the adjacent purlin top flanges. Fig 5.11 The inner skin of the soaker (usually galvanised mild steel) is fixed to the trimmer flanges. Fig 5.12 The liner sheets are installed around the inner skin and fixed securely to the trimmers trapping the bottom flange of the soaker in place. Filler blocks are inserted into the liner flutes to seal the profile. Fig 5.13 The vapour barrier is laid over the liner and carefully cut around the upstand of the soaker. Additional vapour control layer material is cut and attached to the laid sheet and dressed up the side of the inner skin to form an effective vapour seal around the opening. Fig :14

23 Section 5 Fixing Slabs of high density rockfibre insulation (140kg/m 3 ) are cut (usually 200 to 300 mm widths) and laid around the entire perimeter of the opening. The insulation not only eliminates cold bridging but also provides support during installation, welding and future servicing. Fig 5.15 Quilt insulation is then wrapped around the upstand of the soaker prior to the installation of the outer soaker skin. Note: If rigid insulation is used in the vertical area of the soaker then clearance gaps must be allowed between the insulation and the soaker outer skin to permit thermal movement. Fig 5.16 The outer skin of the soaker is then positioned on the high density slab giving an even gap all around the inner skin. Install the weathering skirt and fix to the liner skin only ensuring that the outer soaker is still free to move. The weathering skirt is to be of a material or design that eliminates cold bridging. Kalzip sheets are now installed and trimmed to suit the position of the soaker. Fig 5.17 Fig :15

24 Section 5 Fixing Notes: 1. There must only be one fixed point in the length of the roof. 2. The sheets must finish about 100 mm away from the upper and lower sides of the soaker. ST clips must not be closer than 100 mm to the ends of the sheets. 3. The seams must be splay cut back at 45 degrees to facilitate welding. 4. A 100 mm minimum gap must be maintained between the sides of the soaker and the nearest seams. 5. The corners must not be left with right angle cuts but bevelled to reduce the likelihood of stress cracking. 6. If the material is painted, the paint must be removed on all layers of metal 25 mm each side of the weld using a stainless steel wire cup brush mounted in a power tool. 7. All cutting must be undertaken with appropriate cutting tools. Grinders must not be used. The soaker can now be welded. Ensure that only trained and coded welders are used. The welding contractor must provide comprehensive risk assessments and a method statement for the job in hand. He must carry full insurance and be willing to guarantee his work. Only personnel with the necessary protective equipment must be allowed near the area being welded. If painted material has been used then the welded areas can be re-painted using the correct type of etch primer and air-drying topcoat. If PVdF(PVF2) is specified this paint can only be applied by authorised applicators. The opening component (rooflight, ventilator, access hatch etc.) can now be installed onto the soaker and fastened to the inner skin of the soaker through the weathering skirt using weather tight fasteners in accordance with the manufacturers instructions. The contractor must ensure that the fasteners do not interfere with the outer skin of the soaker thus allowing it to move freely with the Kalzip under temperature fluctuation. Retro fitted soakers (see figs to 5.21) These are soakers that are installed after the roof has been completed. A competent welding contractor can wholly complete the work or the roofing contractor can do the preparation work leaving only the welding for the welding contractor. All work must be done from load bearing planks laid across the seams. Before any work can commence, the trimmer steel work must be fully installed ensuring the top flanges are on the same plane as the top flanges of the adjacent purlins. The up and down slope trimmer sections must not be any closer than 200 mm to a purlin edge. Fig 5.19 The position of the soaker on the roof side is determined by drilling through the roof system from the under side using a long drill bit in each of the four corners of the opening. Using the prefabricated outer soaker, position it over the drilled holes and mark the Kalzip seams upslope and downslope. Remove the soaker then cut the seams down to pan level. Re-position the soaker on the stiffening ribs, mark the stiffening ribs downslope and upslope as well as the opening itself. Remove the soaker and cut the opening, trimming the stiffening ribs. 5:16

25 Section 5 Fixing The Kalzip vapour control layer is dressed back around the soaker inner and additional material added to ensure an effective seal. The previously removed insulation can now be packed around the soaker to eliminate any cold zones between the inner and outer skins. Fig 5.20 The roof insulation should now be removed and placed to one side for re-use. Continue to remove the insulation to about 100 mm beyond the edge of the opening. Insert pre-cut blocks of Kalzip high density rockfibre insulation (140kg/m 3 ) around the opening to support the cut edges of the sheets. Using a sharp craft knife cut the VCL diagonally across the opening to reveal the liner sheet. The liner sheet can now be cut open using an appropriate cutting tool to expose the edges of the trimmer steel. The outer soaker is now placed into position and the side flanges marked and trimmed to the nearest stiffening rib or seam. The corners of the soaker flanges are also cut at 45 degrees to reduce the chance of stress cracks from the corners. The soaker is placed into position again. The soaker can now be welded. A preformed soaker cravat is mechanically fixed to the inner soaker upstand and dressed over the outer soaker with a sufficient clearance gap to allow for thermal movement. The weathering skirt is to be of a material or design that eliminates cold bridging. If painted material has been used then the welded areas can be re-painted using the correct type of etch primer and airdrying topcoat. If PVdF(PVF2) is specified this paint can only be applied by authorised applicators. Fig 5.21 The soaker inner is supplied in its separate component parts for ease of installation. Manufactured from galvanised steel the components are twisted into place trapping the lower flange of the soaker between the liner sheet and trimmer steel. All components are then fastened to the trimmer sections and to each other to form a solid inner soaker capable of carrying the rooflight or ventilator etc. The soaker component can now be installed ensuring the weathering skirt is securely fastened to the flange of the inner soaker upstand. 5:17

26 Section 5 Fixing 5.13 Vent details After laying the Kalzip sheets, cut a hole of required diameter into the pan of the sheet, (maximum diameter of vent is as shown below if installed in the centre of a sheet). Approximately 75 mm clearance between vent upstand and Kalzip seam is required each side in order to maintain adequate drainage of sheet. Note: Extra care must be taken to ensure that the vapour control layer is fully sealed to avoid moisture escape resulting in condensation within the roof build-up 5.14 Eaves detail Fold down eaves end of the sheet (thus creating datum for front of filler) using the relevant eaves folding tool. Install eaves fillers as sheeting work progresses ensuring that they are fitted as shown in fig Kalzip Maximum external diameter mm mm mm mm A prefabricated aluminium vent soaker supplied welded to a short length of Kalzip sheet is installed into the roof area by welding or using silicone sealer and blind rivets. For roof pitches below 3 welding must be used. Fig.5.22 shows the vent soaker sealed into the Kalzip roof. The sealant and fastener layout is similar to Fig Fig 5.23 Drip angle Position the drip angle approximately 20 mm from the end of the sheet, (the distance A shown in fig is related to the anticipated thermal movement of the sheet resulting from temperature fluctuation). Please note orientation of the drip angle for ease of installation. The contractor must ensure that the installation of the vent soaker does not interfere with the thermal movement capability of the Kalzip sheet. Fig :18

27 Section 5 Fixing 1/3 2/3 Kalzip 20 Drip angle A Gutter Fig 5.24 For dimension A allow 1 mm (1.5 mm for dark colours) of thermal expansion for each metre of sheet length from the fixed point to the sheet end (a minimum of 20 mm must be allowed). Where Kalzip sheets differ in length, or where Kalzip translucent sheets are used, the drip angle must be stopped on both sides to allow for different rates of thermal movement. Leave a gap of 5 mm at drip angle joints. Folding down the eaves end of sheets on roof pitches below 5 is mandatory to assist with rainwater run-off and protect against wind driven rain. On roof pitches of 5 and above, folding down of the eaves end of the sheet is recommended. 5:19

28 Section 5 Fixing 5.15 Verge details Zip up the large roll at the verge position with the zipping machine; the small roll at the verge position does not need to be zipped. Position the gable end channel (note orientation of profile, see fig. 5.25) and fix the verge clips to correctly locate the channel section. Fix the channel by riveting to the seam at intervals of 400 mm max. Allow a clearance gap of 1 mm (1.5 mm for dark colours) per linear metre of Kalzip sheet from the verge clips to ensure that the sheets can expand and contract avoiding the creation of an unintentional fixed point (a minimum of 50 mm must be allowed). Leave a gap of 5 mm at the profile joints. E clips refer to fig 5.5a, page 5:7 Kalzip Clip End clip verge rivet the gable hook to the web of the E clip. Rivet reference: RV W Pilot hole at 5.3 mm diameter Fig 5.25 Verge clip Fix the verge clip with screws (see Fig.5.5) to the ST clip web from the exposed side. Where space is limited, pre-drill 4.5 mm diameter holes into the ST clips, then fix the screws with a ratchet, if necessary. Tolerance profile To assist in the installation of the verge flashings, the tolerance profile can be fitted by locking over the verge clips. (see Fig.5.25) The flashing can then be fixed to the top inside flange, which does not penetrate the roof build-up, allowing it to move independent of the sheets. Distance between top edge of clip head and centre of the hole: Kalzip 65 = 66 mm from top of clip to hole centre Kalzip 50 and AF = 52 mm from top of clip to hole centre Tighten the screws with a drive socket and ratchet if necessary. Fig :20

29 Section 5 Fixing Traditional verge flashings Fabricate flashing (as shown in fig 5.26) and hook onto the verge channel. Care must be taken to ensure that the dimensions shown are strictly adhered to in order to eliminate any rattling of the verge flashing. Tolerance verge flashings Fabricate flashing and fix to the top inside flange with suitable fasteners (fixing centres to be no greater than 300 mm). General note Fasteners must not be located in lap joints and only be located on one side of a butt joint. Verge/eaves end cap Fit a verge/eaves end cap to prevent both weather and vermin ingress Ridge details Fold the sheet ends up at the ridge with the appropriate ridge folding tool. Fit the ridge closures in the opposite direction of lay to the Kalzip (to the setting-out line) and fix the overlapping edges to the Kalzip seams with one rivet. Note: Do not fix the ridge closure over the head of a clip. Push in the closure fillers behind the ridge closures on the ridge side in order to protect them from UV-rays. Use the zed spacer to support the ridge flashing. The profile is to be fixed to every other seam using rivets. Spacer profiles are butt-jointed with a 5 mm gap. Fig Sliding ridge clip If the longitudinal thermal expansion of sheets has to be considered at the ridge area on mid slope, a sliding ridge clip must be used (see figs & 5.28). The sliding ridge clip is installed onto the seam of the Kalzip and becomes a support and fixing point for the ridge flashings. Consequently, the sheets have no fixed point at the ridge flashings but are allowed to expand underneath (observe the necessary distance between ridge closure and sliding ridge clip). Allow 1 mm (1.5 mm for dark colours) expansion for each metre length of sheet from fixed point to ridge (see fig. 5.27). Fix the ridge flashing with rivets to each side of the sliding ridge clip ensuring no fixed point is installed at the ridge position. The sliding ridge clip has to be able to slide over the Kalzip seam prior to the installation of the ridge closure. Fig :21

30 Section 6 Roof types Roof types The dimensions of the individual roofing areas are determined by the design specification and should be indicated on the design/working drawings. The following gives an overview of the two most common types of roof configuration. 6.1 Kalzip liner roof system The clips are fixed directly to the purlins through the inner skin (laid parallel to the Kalzip). A spacer profile (e.g. top hat) may be required for double skin roofs depending on the liner profile and the project specifications. Fixing of clips In general, the clips are mounted on each purlin or spacer at intervals corresponding to the Kalzip cover widths. Fig. 6.1 Standard Kalzip liner roof system 6.2 Kalzip liner-deck roof system A variation of the Kalzip liner roof system, the Kalzip liner-deck roof system utilises a low profile structural metal deck. This roof construction consists of a Kalzip standing seam outer sheet, Kalzip insulation, Kalzip vapour control layer and a Kalzip liner-deck sheet. The Kalzip standing seam outer sheet is supported off Kalzip aluminium or E clips in turn supported off a top-hat profile sub-purlin fixed direct to the Kalzip liner-deck sheet. Kalzip liner-deck when lightweight quilttype insulation is used. When high-density insulation is used within the roof system the external downward loads (e.g. snow) would be transferred as uniformly distributed loads. The top-hat sub-purlins maybe fixed direct over the purlins only (if the purlin centres are suitable for the Kalzip standing seam sheet) or for wide purlin spacings further top-hats can be installed mid-span. This arrangement transfers the external roof loads as line loads to the Fig. 6.2 Standard Kalzip liner-deck roof system 6:1

31 Section 6 Roof types 6.3 Kalzip structural deck roof system A load-bearing trapezoidal deck is normally laid parallel to the eaves. The clips are either fixed directly on to the high trough or indirectly on to top hat profiles. The clips are set out diagonally across the structural decking to simulate an even distribution of all external loads. Fixing of clips The clip fixing layout has to simulate an even transmission of both positive and/or negative loads. Set out one continuous clip line at the eaves and the ridge. Set out the remaining ST clips in a staggered format in accordance with the project s structural calculations. The centres are determined from the design loads (higher wind loads are experienced at both edge and corner areas); the Kalzip cover width and the corrugation spacing of the trapezoidal decking. A greater frequency of ST/E clips may be required at roof perimeters and corners (see fig 6.3). Fig. 6.3 Standard Kalzip structural deck roof system Note: Further information on liner/deck profiles is available in the Kalzip systems brochure. 6:2

32 Section 6 Roof types Typical layout ST Clips b Eaves/Ridge a Verge Kalzip Spacing of ST clips and E-clip to general roof areas * = cover width of Kalzip Eaves Structural decking Half clip spacing at edge and corner areas ST Clips Spacing of ST Clips and E Clips at areas of high local wind uplift Verge Kalzip Spacing of ST clips and E-clip to general roof areas * = cover width of Kalzip Eaves Structural decking High local wind uplift conditions will occur at eaves and verges with also a possibility at ridges on steeper pitched roofs Roof areas Normal areas Corner areas Edge areas Fig 6.4 6:3

33 Section 7 Curved and tapered Kalzip Curved and tapered Kalzip 7.1 Curved roof Lifting onto the roof If the pallets with curved Kalzip sheets cannot be lifted onto the roof in their entirety, they must be lifted individually or in bundles. Observe the direction of lay. Packs can be banded independently from the curved pallet but this must be specified at the ordering stage. (Refer also to sections 3.2 & 3.3). Preparing for fixing Set out the clips as described previously. Also check the drawings. Set the clips to within the specified tolerances, checking the alignment with a theodolite or laser if necessary. The use of a template is recommended in order to keep a regular distance between the clips. Smooth-curved sheets The Kalzip span should correspond with the design, however, as a guide it is recommended that the span be limited to between 1.5 and 1.8m. Installation width Kalzip cover width, 0 mm up to + 3 mm Modification of zipping machine. (Refer to sections 5.6, 5.7 & 5.8). Warning: The zipper must not be run on automatic over the curved section. Unlike straight Kalzip sheets, it is not possible to rotate curved Kalzip into position. Instead locate vertically from the top and push between the clip heads. Clip heights of less than L60 are rigid and more difficult to flex outwards. Because of this, we suggest that the cover width may be increased by up to 3 mm to ease the installation of the curved sheets. There are exceptions to this rule i.e. small radii curves, multiwave profile and thickness of material etc. If in doubt contact Kalzip technical department. 7:1

34 Section 7 Curved and tapered Kalzip 7.2 Tapered roof Installation widths Between 225 mm and 620 mm (flat tapers only) Between 225 mm and 620 mm (curved tapers) Minimum length: 1500 mm Maximum length: Dependent on transport There are many variations in shape for instance straight Setting out Tapered sheets must be laid onto the roof in accordance with the installation drawing. It is recommended to compare the actual dimensions of the support structure with the sizes indicated on the installation drawing before installation starts. Any discrepancies must be reported to the design office for further instructions. Load bearing capacity Refer to the table under section 5.3 for cover widths of up to 400 mm. Cover widths greater than 400 mm must be fully supported by Kalzip high density rockfibre insulatio (140kg/m 3 ). Eaves It is very important to install an extruded drip angle to provide the required rigidity to the Kalzip pan. Standard eaves fillers (cut to size) can be fitted into the Kalzip seam. A self-adhesive sealing strip can be used between the drip angle and pan. tapered convex curved tapered-convex curved Ridges Order special ridge closures to the required size. Cut the closure fillers to size on site. concave curved Verge Always install the extruded Kalzip verge components. 7:2

35 Section 8 Translucent sheets Translucent sheets 8.1 Translucent sheets Extra care is needed with all translucent sheets. They should be fitted immediately in order to avoid dangerous openings in the roof where people or objects could fall through. If it is not possible to fix the sheets immediately, the contractors must safeguard the openings. Where the rooflight installation is carried out by a different sub-contractor than the Kalzip approved roofing contractor, it is recommended to have the roof inspected by the main contractor and Clerk of Works prior to the installation of rooflights. Fully brief employees of the rooflight installation company about safety and care on the roof. Kalzip rooflights include four options: Kalzip Multivault SSR Kalzip Multivault GRP Kalzip GRP in-plane site assembled Kalzip GRP in-plane factory assembled Further information can be obtained by contacting the Kalzip technical department. 8:1

36 Section 9 Site work Site work 9.1 Correctly sizing and shaping flashings Length - Up to 6 metres. Girth - Always try to keep the smallest possible girth. - If excessive flat areas occur i.e.> 200 mm introduce additional bends, folds, swaging etc. and additional supports where necessary. Hardness - Flashing gauge 1 /4 or 1 /2 hard is best for flashings 3 /4 hard can be used but care must be taken with the radii of the bends. (see Fig.9.1 and table). - Min 0.9 mm Typically to match range of Kalzip sheeting t = gauge Fig. 9.1 Minimum Radii of bends (R) Material Hardness Stucco 1 /4 1 /2 3 /4 embossed Mill finish 2xt 3xt 4xt - 6xt Coil coated generally 5xt Flashing liner - Same gauge as the liner sheet. Longitudinal edges - Never leave a flat cut edge - Always form a welt or stiffening bend within 50 mm of edge. - Never flat lap flashings Gable/verge flashing - If horizontal leg exceeds 125 mm then support must be offered to external corner. 9:1

37 Section 9 Site work 9.2 TIG welding aluminium sheeting The recommended filler rods for welding Kalzip is 4043A (AlSi 5). It is easier to weld joints if they overlap a little (50 mm) unless otherwise specified. The colour finish on coated materials must be removed prior to welding and reinstated by an approved paint specialist. Recommended tool for this is a stainless steel cup wire brush. Under no circumstances must chemical paint strippers or grinders be used. 9.3 Cutting and sawing Kalzip A hand-held circular saw that has a hard metal blade with coarse pitch teeth (9-20 mm) or a nibbler is best suited. Guide the hand saw along a suitable straight edge for cutting straight roof edges. A large bow saw with a hard metal blade is suitable for cutting individual sheets. Other cutting tools are oscillating cutters, reciprocating saws, jigsaws and sheet-metal worker snips. 9.4 Drilling Use HSS drill bits and observe manufacturer s instructions for screw and rivet hole diameters. Hole diameters for self-tapping screws are dependent on material type and gauge. Remove swarf before inserting the fastener. Fit washer onto the drill to protect the drill chuck and material surface (see fig. 9.2). 9.5 Self-tapping and self-drilling/ self-tapping screws (eg SX2, SDK2, SDK3 etc) Use screws made from Austenitic 304 grade stainless steel. Refer to manufacturers data for pilot hole sizes, tooling and installation speeds etc. Design of fasteners must be in accordance with Kalzip recomendations. Note: Refer to section 5 fasteners and fixings. 9.6 Riveting Use rivets with stainless steel or aluminium bodies and stainless steel mandrels. Pre-drill and install rivets in accordance with the manufacturer s instructions. Do not use bulb-tite rivets where there is a risk of water ingress. The contractor must follow the rivet manufacturer s recommendations. The choice of fastener, application and material must be relevant to the design related conditions. Rivets must not be used for fixing ST clips without prior consultation with the Kalzip technical department. Ensure that the correct nosepiece is selected. This must be observed particularly if bulb-tite type rivets are used. Select rivet length in accordance with the grip length. Fig 9.2 9:2

38 Section 10 Surface finished appearance Surface finished appearance 10.1 Storage Store pallets ideally under cover and at an angle to allow water to drain off. If pallets are stored on the floor, there is an increased danger that they will be covered with dust from traffic and construction work. The cover must allow air circulation to permit condensation to drain away or evaporate. Material for single skin roofs should be well covered or the lower side cleaned before fixing Removing protective film The prime intention of the film is as a protection to the paint finish during the manufacture, handling and installation stages. It should not be used as protection to the sheeting or flashing after the installation - for example as protection against follow-on trades. It is also very important to remember that even when storing painted sheets with the protective film, they should not be exposed to the sun's rays. Materials should either be stored indoors or under non-translucent covers. Under normal weather conditions it is possible to leave the protective film on the painted sheets and flashings for a few days after erection. However due to extremely hot weather that may be present during the summer months, we would strongly recommend that the film be removed immediately after erection. The protective film is not ultra-violet resistant and thus exposure to the sun even for a day can cause a chemical change in the film adhesive to take place - resulting in extensive work being required in removing the film. It should be noted that painted aluminium sheets can attain surface temperatures much higher than the ambient external air temperature, in some cases up to + 80 C for dark colours. It is therefore imperative that the above information/instructions are carefully followed and the Teamkal Approved Roofing Contractor's personnel are notified - especially where painted material with protective film is being stored or installed Colour differences Due to production methods, colour differences may occur on both natural and coloured surfaces from different batches. On large buildings, it is recommended to plan the use of material from one batch. Material may also be divided up in accordance with individual building sections. It is therefore imperative to ensure that, where identical lengths are involved, material from the same batch is used for one building section only. The same material should be used for flashings where aesthetics may be of concern. Observe instructions on the design/working drawings. Coil coated and post coating Where the simultaneous use of both colour systems is unavoidable, differences can be minimised by co-ordinating colour and the degree of gloss. Note: In addition to aluminium other materials and finishes are available. Further details on request. 10:1

39 Section 10 Surface finished appearance 10.4 Removing dirt Natural-finish surface: Use a non-abrasive agent with a ph-value of between 5 and 8 and non-abrasive cleaning pads e.g. fibre fleece. Note: Abrasion traces will be visible with abrasive cleaning agents. The surface will be brighter as the oxide coat darkens and the new coat will be bright metallic at first. When using special cleaning agents, make sure that they are ecologically friendly to the environment and non detrimental to the aluminium surface. Always rinse off with water. Trial cleaning of small non visible areas is essential for assessing the impact of the cleaning method on the Kalzip material finish. It is often worthwhile delaying the cleaning process as weathering and dirt accumulation will reduce colour differences. A 5% chemically neutral soap solution applied to the sheets will normally be successful. Do not use solvents or abrasive agents. Coated surfaces: Use special non-abrasive, biodegradable cleaner that is compatible with the coating system and rinse thoroughly after cleaning. Always work with extreme care as major colour differences may occur. Splash water from scaffolding Wall cladding may become soiled by splash water from scaffolding. This can be avoided by keeping the scaffolding planks clean. Pressure and steam cleaning of Kalzip must be performed by a specialist. Care should be taken with pressure lances by not using too high a pressure; otherwise damage can occur. Heating of the water may be useful and even steam cleaning may be appropriate depending upon the surface finish and degree of dirt accumulation. 10:2

40 Section 11 Accessories Accessories 11.1 Clip types ST clips Kalzip self-supporting sheet ST clip Clip type height Kalzip 65/* Kalzip 50/* H W1 W2 (TK5) W2 (TK15) W1 W2 (TK5) W2 (TK15) L10 66 Not possible L L L L L L L L L L L L Note: TK = Thermal barrier pad TK5 = 5 mm thermal barrier pad thickness TK15 = 15 mm thermal barrier pad thickness H = height of clip without thermal barrier pad W1 = distance between underside of Kalzip sheet and underside of ST clip. W2 = distance between underside of Kalzip sheet and underside of ST clip with thermal barrier pad. Kalzip 65 Kalzip 50 Kalzip AF E clip Clip w2 w2 w2 type height H E10 66 N/A 20 5 E E140* E160* E180* * A 10 mm polyamide spacer is also available which fits on to the base of the three taller clips (E140, E160 and E180) to effectively increase the range of E clips. 11:1

41 Section 11 Accessories Standard L type ST clip base T type ST clip base (for fixing to min.75 mm wide timber) Double length (DL) type ST clip base Base dimensions for E140 and E160 Base dimensions for E180 clips Base dimensions for E10 and E25 Note: Special length clips are available on request 11.2 Thermal barrier pads TK5: 5 mm depth TK15: 15 mm depth Polyamide thermal barrier pads for standard length ST clips Polyamide thermal barrier pads for double length ST clips DTK5: 5 mm depth DTK15: 15 mm depth 11:2

42 Section 11 Accessories 11.3 Standing seam accessories Gable end channel (aluminium) Size in mm 35 x 27 x 20 x 1.5 x 6000 long Fig Gable end clip for Kalzip 65/... (aluminium) Gable end clip 50 for Kalzip 50/... and AF65/... (aluminium) Size in mm 58 long 3 holes ø7 Fig Tolerance gable profile (aluminium) Size in mm 60 wide x 6000 long Fig Sliding ridge clip (aluminium) Size in mm 60 wide x 60 long Fig :3

43 Section 11 Accessories Kalzip flashing sheet with large sheet upstand (aluminium) Size in mm Stucco: 586 with coloured sheet depending on the Kalzip cover width 6000 long Fig Cable clip (stainless steel) Size in mm Fig Seam clip (stainless steel) Size in mm Fig Seam clip (aluminium) Size in mm 60 x 80 mm Fig :4

44 Section 11 Accessories Spacer profile (aluminium) Size in mm 45 x 6 x 45 x 1.5 x 6000 long Fig Flat bar (aluminium) Size in mm 50 x 6 x 6000 long 22 x 6 x 6000 long Fig Ridge closure (aluminium) Fig Kalzip profile Special/hipped Painted 11:5

45 Section 11 Accessories Ridge filler (EPDM) Fig Kalzip profile Special/hipped Special size Eaves filler (EPDM) Fig Kalzip profile Special/hipped Special size Drip angle Size in mm 40 x 20 x 2 x 6000 long 70 x 30 x 2 x 6000 long Fig Dilaprene expansion joint (aluminium vulcanised) Size in mm 2 x 400 x 3000 long Fig :6