Corus Building Systems

Kalzip installation manual

Contents
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
Section 12

Page
3
3
4
5
6
13
14
15
15
16
17
21
22
23

Introduction
The system
Transport
Site preparation
Installation
Roof types
Curved and tapered Kalzip
Translucent panels
Site work
Surface-finished appearance
Accessories
Special tools
Contacts
Index

Introduction

The system

1.1 Regulations
This installation manual outlines
the correct use of Kalzip, the
installing elements and its
accessories. Kalzip panels can
only be installed by companies
approved and trained by us the
manufacturer, and in accordance
with current building regulations.

2.1 Introducing Kalzip

Kalzip is an aluminum standing
seam system designed for both
low pitched roofs (minimum 1.5
degrees) and steeper pitches.
The aluminum panels are
installed with clips which are
locked into the roll and
concealed by the adjacent panel.

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 installing
contractor from critical
examination. This applies in
particular to low pitched roofs,
roofs with openings and
structures which are exposed to
extreme physical conditions.

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
panel movement resulting from
temperature changes.
Movement takes place from the
fixed point to the eaves and/or
the ridge. When installing the
panels, 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 panel. Jointing
with other building components
must not impair the sliding
movement of the Kalzip.

It is assumed that the installing

contractor will provide full
working drawings on which all
dimensions, details and
materials are specified.
This installation 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
installation contractors.

Panels of special widths,

between 10 and 23, can be
manufactured either with large
and small rolls or with two large
rolls.

Note: All dimensions are in

inches unless otherwise stated.

Kalzip 50/429

Kalzip 65/305

Kalzip 65/333

Kalzip 65/400

Kalzip 65/500

Kalzip AF 65/434

fig 2.1

Transport
3.1 Transporting to site or
unloading at designated
storage areas
In general, Kalzip panels are
transported by road.
It is normal practice to clean the
external face of Kalzip panels
when used as wall cladding and
the internal face when used as a
single skin roof.
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.
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. Bundles can
weigh up to 4500 lbs (Check
crane capacity).
Make prior arrangements for
lifting gear such as cranes,
forklift trucks, spreader beams,
sling belts, etc. Protect edges of
bundles if sling belts are being
used. Sources of supply for
certified beams and sling belts
can be supplied on request.
Maximum load per suspension
point must not exceed 1800 lbs.
and projecting ends exceeding
13 ft must be avoided (see fig 3.1)
Owing to the different panel
seam vertical legs, pallets must
be stored in accordance with the
direction of laying to avoid
having to turn the panels on the
roof. Installation has to be made
in the direction of the panels
small seam vertical leg.

1800
lbs

fig 3.1

1800
lbs

1800
lbs

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.
In many cases, the pallets
cannot be placed directly onto
the substructure. The profiled
panels 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 to 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 panels and
packages against wind uplift and
sliding.
Exercise caution when opening
packages stored at an angle:
there is danger of panels 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 panels
to protect them from dirt and
direct sunlight. Ideally cover with
light colored opaque tarpaulins
to minimize magnifying glass
effect which may cause
distortion and discoloration.

1800
lbs

fig 3.2

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 one
week after arrival on the building
site although an earlier claim is
advantageous to all parties.
Permissible length
tolerances for Kalzip panel:
- for panels up to 10 ft in length:
3
3
+ /18 - /16
- for panels over 10 ft up to 100
ft in length:
3
3
+ /4 - /16
- for panels over 100 ft in length:
1
3
+ /16 / 10ft / - /16
Tolerances are based on a
production temperature of 70F.
Additional allowances may be
needed for on-site production.

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 installing
personnel, accident prevention,
load bearing capacity and the
jointing of Kalzip panels. It is
imperative that this information
is observed.
4.3 Layout
Follow the installation plans.
Measure and string out roof and
wall areas. Set out panel widths so
that they meet transitional points
such as roof lights, smoke vents
etc. in accordance with the plans.

Depending on the panel gauge and

clip type, it is possible to increase
1
the cover width by up to /8.
With curved roofs, the installation
1
width can be /8 wider than the
cover width.
The panels must not be spaced less
than their cover width as this will
restrict thermal movement.
Observe the direction of installation
and store the pallets so that the
small seam vertical leg always
points in the direction of laying.
4.4 Special tools
Before commencing installation
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 color coated panels.
Clean the hard chrome surface of
the rollers if necessary and replace
any damaged rollers (refer to
sections 5 and 12).
4.5 Corrosion protection
When fitting aluminum to certain
materials direct contact must be
avoided.

Atmosphere
Rural
safe
safe
safe
unsafe
unsafe

Industrial
safe
safe
safe
unsafe
unsafe

Marine
safe
safe*
unsafe
unsafe
unsafe

Timber treated with fire retardant

or preserved with unsafe copper
or fluoride compounds

unsafe

unsafe

unsafe

Concrete, mortar and alkalibearing materials

unsafe

unsafe

unsafe

Zinc
Stainless steel
Lead
Uncoated steel
Copper

Painted surfaces must be

compatible with aluminum.
Intermediate layers of noncorrosive material must not
accumulate dampness. Suitable
materials include plastic
paneling, 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.
Aluminum and cement based
products must always be
separated by an intermediate
layer.
No measures are necessary
when joining aluminum with
titanium, zinc, aluminum zinc or
stainless steel.
Note: There is a danger of
contact corrosion for uncoated
aluminum if fitted to other
metals.

Aluminum compatibility with dissimilar material

Material

No particular measures are

necessary for aluminum support
structures with minimum 16
gauge thickness.
No particular measures are
necessary for steel structures if
the contact surfaces are
galvanized or coated, e.g.
trapezoidal steel panels.

*This applies only for fasteners and rivets made from stainless steel.
Other stainless steel elements must be protected.

In windy conditions work should

cease in accordance with local
regulations.

Installation
5.1 Principal rule
Zip each panel 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 and weather
Kalzip panels are light and have
a large wind uplift area.
Therefore exercise caution when
storing open packages and lifting
Kalzip panels onto the roof.
Lash down open packages and
stop installation work in strong
winds. Immediately fasten
individual panels and zip
together paying particular
attention to the last panel (i.e. by
provisionally fastening with the
gable end clip). (see fig. 5.1)

fig 5.1

5.3 Load bearing capacity

During installation, and after, for
general maintenance and
inspection purposes, it is
possible to walk on Kalzip
panels that have been partially
zipped together to the parameters
shown in the tables below. Slight
deformation to panel pans may
occur if traffic is heavy. This will
not affect the technical
performance of the Kalzip panel,
although aesthetically this 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 panel at the rake

positions, individual unzipped
panels and translucent panels
must not be walked on.
During installation, load
spreading methods should be
used at eaves, rakes, ridges,
points of access, common
walkways and around curbs to
prevent deformation of Kalzip
panels. This may be
accommodated or at the design
stage by the incorporation of
high density insulation
3
(8.75lbs/ft ) to the underside of
the Kalzip panels 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 panels can be self
curved over the ridge on low
pitched flat roofs. Use high
3
density insulation (8.75lbs/ft )
under the pan of the panel 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.

fig 5.2

Walkability of Kalzip panels when partially zipped together (panel with one seam zipped)
Panel
thickness
(in)

Kalzip
65/305
Span (ft)

65/333
Span (ft)

65/400
Span (ft)

50/333
Span (ft)

50/429
Span (ft)

AF 65/434
Span (ft)

.027
.031
.035
.039
.047

5.41
7.05
7.38
7.87
9.18

5.41
7.05
7.38
7.87
9.18

6.07
7.87
8.58
8.58
8.58

5.25
6.89
7.05
7.21
7.54

5.25
6.56
6.72
6.89
7.21

6.56
8.53
8.58
9.18
10.17

Walkability of Kalzip panels when fully zipped together (panel with both seams zipped)
Panel
thickness
(in)

Kalzip
65/305
Span (ft)

65/333
Span (ft)

65/400
Span (ft)

50/333
Span (ft)

50/429
Span (ft)

AF 65/434
Span (ft)

.027
.031
.035
.039
.047

7.21
9.51
11.0
12.4
12.4

7.21
9.51
11.0
12.4
12.4

7.54
9.84
11.1
12.4
12.4

6.23
8.20
8.69
9.18
9.84

6.23
8.20
8.53
8.85
9.51

8.39
11.4
11.6
11.8
11.8

5.4 Installing clips

Generally, clips are set out in a
modular format and fastened
symmetrically through the clip
base.
Observe manufacturers
instructions regarding fasteners
such as screws or rivets, in
particular drilled hole diameters
and tightening torques.
Important note
The use of set screws (bolts) is
not recommended.
5.5 Installing Kalzip panels
Direction of lay
Panel installation is done in the
direction of the small seam with
the large seam overlapping the
small one. Installation is
generally done from rake to
rake. 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
installation sequence. These
procedures need to be planned
in detail and special profiles may
be required. The standard
procedure for rake-to-rake
installation is as follows:

b) Close the large seam of the

first panel with the zipping
machine so that the gable end
channel can be fixed and riveted
into position. The zipping
machine must be supported by
hand in order to prevent it tilting
during running.
c) Lock the panel onto the prefixed clips or install the second
row of clips at measured
intervals.
d) Create a fixed point, using
rivets or screws, as shown in
figures 5.3 and 5.4 respectively,
and as indicated on the
design/working drawings.
Note: Bolted fixed points should
be fitted after zipping panels.
e) Position the gable end
channel and install by riveting to
the large seam vertical leg at
intervals of 15 max. Allow a
1
3
space of /4 ( /8 for dark colors)
per 10 linear foot of panel from
the clips to ensure that the
panels can expand and contract.
The larger leg is positioned
within the Kalzip panel. Leave a
3
gap of /16 at the profile joint.

Installation sequence
a) Start at the rake 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.

f) Screw gable end clip to clip

web (see fig. 5.5.).
3
Pre-drill /16 diameter holes in
clip web where working space is
confined.

fig 5.3

fig 5.4

fig 5.5

Distance between top edge of

clip head and center of the hole:

Kalzip 65 = 2.6 from top of

clip to hole center
Kalzip 50 and AF = 2 from
top of clip to hole center

Tighten the screws with a drive

socket and ratchet if necessary.

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 5.7.

fig 5.5

5.7 Zipping panels

The small seam vertical leg must
be clipped fully into position at
the clip head to prevent damage
when zipping.
For safety reasons, the panels
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 i.e.
0.027 to 0.039 approx 0.78
0.047
approx 0.86
Zipping can be performed in any
direction on panels 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 panels
Skirts and full front guide
assembly must always be
removed.
Roll-curved panels
Remove guide rollers if radii is
less than 6.5 ft.
Double skin translucent panel

Skirts, contact rollers and guide

roll assembly must always be
removed.
2 high Kalzip
Dismantle skirts (on older
models) for zipping 2 high
Kalzip and reset the side guide
roll assembly.
Transverse joints
The zipping machine must run
over the transverse joint from the
overlaying panel to the
underlaying panel. Refer to
section 5.11 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
13.75.
Errors
Fit a cover strip over rolls to be
repaired, then close with the
zipping machine.
On panel thicknesses of
0.035 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 panel thicknesses above
0.035
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 panel

thickness the roll can be back
zipped. This is achieved by
placing the machine onto the roll
approximately 24 from the end
of the panel, apply pressure onto
the locking handle, while 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
assembly and skirts need to be
removed with crimp-curved
panels.
When zipping 2 high Kalzip,
check zipper type and reset the
side roller holders assembly to
the correct height (dependent on
machine type).
5.8 Changing the roller sets or
side rollers
Required tools:
Ring spanner,
Hexagon socket spanner, 0.196
The following roller sets are at
your disposal:
1. For material thickness 0.027 0.039, standard rollers.
2. For material thickness 0.047,
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 panel can be
removed. If the panels 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 panel roll.
5.10 Constructing fixed points
All panels 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 panel at the small
seam into the clip head to
accommodate the blind rivet. Fit
an 0.43 - 0.47 long rivet.
The large seam of the next panel
conceals the rivet head (see fig
5.3).
b) bolted - after zipping, bolt the
Kalzip vertical leg to the clip web
using an x 1 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 panels from the fixed point
to the ridge when designing the
ridge cap (see fig 5.6). Each
panel must have only one fixed
point.

Photo 5A roll opened to accept

unzipper

Photo 5B unzipper inched into

position

A = Allowance for thermal expansion

4
7

fig 5.6

Note: A curve in the panel 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.
5.11 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 panels.
It is important to follow the fixing
sequence exactly in order to
achieve permanent sealing
properties.
Figs 5.7 and 5.8 show the
installation sequence and the
notching for 0.047 gauge
panels. For 0.039 panels
notches are required on the
small seam only. Notches are
not required on gauges of 0.031
and less 0.035 being borderline,
needs to be assessed and
monitored during installation.

3
fig 5.8

fig 5.7

Note: The notch dimensions

given above and in fig 5.8 relate
to a 8 long overlap, for different
length overlaps the notch
dimensions should be adjusted
accordingly. The notch on the
small roll (panels 2 and 4)
should be the same length as
the overlap with the large roll lap
(panel 3) being 1 less than the
overlap length.

Sealed joints
Figs 5.9 and 5.10 show the
fastener positions with Kalzip
305. Apply the same sequence
to all other Kalzip widths
accordingly.
Note: The support type shown is
for illustrative purposes only.

Stainless steel self-tapping srew

0.25 diameter with sealing washer
blind-sealed 0.19 diameter
rivets with st/st mandrels

silicon sealing compound

0.79

3.94
1.18

1.97
7.87
Kalzip

Panel 1 is installed without

notching and the large roll is
zipped.
Panel 2 is notched for 8 on the
small roll (as shown in fig 5.8)
leaving the capillary tool intact.
Panel 3 is notched for 7 on the
large roll (as shown in fig 5.8) to
approximately the one oclock
position.
Panel 4 is a repeat of panel 2.

Stainless steel
self-tapping screw

silicon sealing
compound

fig 5.9 Sealed joint acting as fixed

point

10

blind-sealed rivet 0.19 diameter with st/st mandrels

Note: The support type shown is

for illustrative purposes only

silicon sealing compound

1.97

fig 5.10 - Standard (floating) sealed

joint

1.97
2.95

1.97

.
2.95

1.97
1.97

1.97

0.79
1.18

7.87

3.94

1.97

Kalzip

7.78

5.12 Eave detail

Fold down eaves end of the
panel (thus creating datum for
front of foam filler) using the
relevant eaves folding tool.
Install eave foam fillers as
paneling work progresses
ensuring that they are fitted as
shown in below (fig 5.23).

Clip

1/3

2/3

Kalzip

Drip angle
A

Gutter

fig 5.24
1

fig 5.23

Drip angle
Position the drip angle
approximately from the end
of the panel, (the distance A
shown in fig. 5.24 is related to
the anticipated thermal
movement of the panel resulting
from temperature fluctuation).
Please note orientation of the
drip angle for ease of
installation.

For dimension A allow /4 (3/8

for dark colors) of thermal
expansion for every 10 ft of
panel length from the fixed point
to the panel end (a minimum of
3
/4 must be allowed).
Where Kalzip panels differ in
length, or where Kalzip
translucent panels are used, the
drip angle must be stopped on
both sides to allow for different
rates of thermal movement.
3
Leave a gap of /16 at drip
angle joints.
Folding down the eaves end of
panels on roof pitches below five
degrees is mandatory to assist
with rainwater run-off and protect

11

against wind driven rain. On roof

pitches of five degrees and
above, folding down of the eave
end of the panel is
recommended.
5.13 Rake details
Zip up the large roll at the rake
position with the zipping
machine; the small roll at the
rake position does not need to
be zipped. Position the gable
end channel (note orientation of
profile, see fig. 5.25) and fix the
gable end clips to correctly
locate the channel section.
Attach the channel by riveting to
the seam at intervals of 15 max.
1
3
Allow a clearance gap of /4 ( /8
for dark colors) per every 10
linear feet of Kalzip panel from
the verge clips to ensure that the
panels can expand and contract
avoiding the creation of an
unintentional fixed point (a
minimum of 2 must be allowed).
3
Leave a gap of /16 at the profile
joints.

 Gable end clip

Attach the gable end clip with
screws (see Fig.5.26) to the
aluminum (ST) clip web from the
exposed side. Where space is
3
limited, pre-drill /16 diameter
holes into the (ST) clips, then fix
the screws with a ratchet, if
necessary.

General note
Fasteners must not be located in
lap joints and only be located on
one side of a butt joint.

Distance between top edge of

clip head and center of the hole:
Kalzip 65 = 2.6 from top of
clip to hole center
Kalzip 50 and AF = 2 from
top of clip to hole center
Tighten the screws with a drive
socket and ratchet if necessary.

5.14 Ridge details

Fold the panel 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 attach the
overlapping edges to the Kalzip
seams with one rivet.
Note: Do not attach the ridge
closure over the head of an ST
clip.
Push in the foam closure fillers
behind the ridge closures on the
ridge side in order to protect
them from UV-rays. Use the zee
spacer or flat bar profiles to
support the ridge flashing.
The profile is to be attached to
every other seam using rivets.
Spacer profiles are butt-jointed
3
with a /16 gap.

Tolerance profile
To assist in the installation of the
rake flashings, the tolerance
profile can be fitted by locking
over the gable end 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 panels.
Traditional rake flashings
Fabricate flashing (as shown in
fig 5.26) and hook onto the gable
end channel. Care must be
taken to ensure that the
dimensions shown are strictly
adhered to in order to eliminate
any rattling of the rake flashing.

Rake/eave end cap

Fit a rake/eave end cap to
prevent both weather and vermin
ingress.

Tolerance rake flashings

Fabricate flashing and attach to
the top inside flange with
suitable fasteners (fixing centers
to be no greater than 12).

5.15 Sliding ridge clip

If the longitudinal thermal
expansion of panels has to be
considered at the ridge area on
mid slope, a sliding ridge clip
must be used (see figs. 5.27 and
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.

fig 5.25

fig 5.26

A = Allowance for thermal expansion

fig 5.27

Consequently, the panels 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).
3
Allow ( /8 for dark colors)
expansion for every 10 linear
feet of panel 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 5.28

12

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.

Typical layout
Rake

Clip
Trough
distance
TRP

6.1 Purlin roof

The clips are attached directly to
the purlins.
Attachment of clips
In general, the clips are mounted
on each purlin at intervals
corresponding to the Kalzip
cover widths.
6.2 Decking roof
A load-bearing metal deck is
normally laid with rigid insulation
over the deck. A bearing plate is
placed atop the insulation and
clips are installed over the
bearing plate with fasteners that
extend to the bottom flute of the
metal deck. The clips are set out
diagonally across the structural
decking to simulate an even
distribution of all external loads
Attachment of clips
The clip attachment 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 clips in a
staggered format in accordance
with the projects structural
calculations. The centers are
determined from the design
loads (higher wind loads are
experienced at both edge and
corner areas) and the Kalzip
cover width.
A greater frequency of ST clips
is required at roof perimeters
and corners (see fig 6.3).

Steel TRP

Kalzip
C

Kalzip

Cover width

Eaves

C = Clip distance
l = Truss distance

Half clip spacing at edge and corner areas

Rake

Trough
distance
TRP

Kalzip
C

Steel TRP

Eaves
Kalzip

Cover width

C = Clip distance
l = Truss distance

Roof areas

b
Eaves/Ridge

Normal areas
a
Edge areas
Corner areas

fig 6.3

13

Curved and tapered

Kalzip
7.1 Curved roof
Lifting onto the roof
If the pallets with curved Kalzip
panels 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 and 3.3).
Preparing for installation
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.
Unlike straight Kalzip panels, 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 type
L60 are rigid and more difficult to
flex outwards. Because of this,
we suggest that the cover width
1
may be increased by up to /8 to
ease the installation of the
curved panels. 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.
Smooth-curved panels
The Kalzip span should
correspond with the design,
however, as a guide it is
recommended that the span be
limited to 5 ft.
Installation width - Kalzip cover
1
width, 0mm up to + /8
Modification of zipping machine.
(Refer to sections 5.6, 5.7 and
5.8).

Crimp-curved panels
Crimp-curved panels are only
used for very tight radii. The
distance between the clips is
correspondingly small.
Installation width - Kalzip cover
1
width: 0mm up to + /8
Modification of zipping machine
(Refer to sections 5.6, 5.7 and
5.8).
Warning: The zipper must not
be run on automatic over the
curved section.
7.2 Tapered roof
Installation widths - Between 9
and 29 (flat tapers only)
Between 9.5 and 19 (curved
tapers)
Minimum length: 5 ft
Maximum length: Dependent on
transport
Setting out
Tapered panels 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
15.75. Cover widths greater
than 15.75 must be fully
supported by high density
3
insulation (8.75 lbs/ft ).
Eaves
It is very important to install an
extruded drip angle to provide
the required rigidity to the Kalzip
pan. Standard eave foam 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.
Ridges
Order special ridge closures to
the required size. Cut the
closure fillers to size on site.

14

Rakes
Always install the extruded
Kalzip rake components.
Panel ends
Generally, the lengths of the
panels are supplied with at least
an extra 2 at both ends and
should be cut to size depending
on clip positions and geometry of
roof etc.
Kalzip panel shape variations

Translucent Panels

Site work

8.1 Translucent panels

Extra care is needed with all
translucent panels. They should
be installed immediately in order
to avoid dangerous openings in
the roof where people or objects
could fall through. If it is not
possible to install the panels
immediately, the contractors
must safeguard the openings.

9.1 Correctly sizing and

shaping flashings

Where the rooflight installation is

carried out by a different subcontractor than the Kalzip
approved roofing contractor, it is
recommended to have the roof
inspected by the main contractor
prior to the installation of
rooflights. Fully brief employees
of the rooflight installation
company about safety and care
on the roof.
There is a wide range of Kalzip
rooflight options and further
information can be obtained by
contacting the Kalzip technical
department.

Gable/rake flashing - If
horizontal leg exceeds 5 then
support must be offered to
external corner.

Length - Up to 20 ft.
Girth - Always try to keep the
smallest possible girth.
- If excessive flat areas occur
i.e.> 8 introduce additional
bends, folds, swaging etc. and
additional supports where
necessary.
1
1
Hardness - /4 or /2 hard is
3
best for flashings /4 hard can
be used but care must be taken
with the radii of the bends.
(see fig.9.1 and table below).
Flashing gauge
Min 0.035 } Typically to
Max 0.047 match range of
Kalzip paneling
Longitudinal edges - Never
leave a flat cut edge
- Always form a welt or stiffening
bend within 2 of edge.
- Never flat lap flashings
t = gauge

9.2 Cutting and sawing Kalzip

A hand-held circular saw that
has a hard metal blade with
coarse pitch teeth (0.37-0.78) 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 panels.
Other cutting tools are
oscillating cutters, reciprocating
saws, jigsaws and panel-metal
worker snips.
9.3 Drilling
Use HSS drill bits and observe
manufacturers 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).
9.4 Self-tapping and selfdrilling/self-tapping screws
(e.g. 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
recommendations.

fig 9.1

Minim um Radii of bends (R)

Material

H ardness

Stucco embossed

Mill finish

2xt

3xt

4xt-6xt

generally

5xt

Coil coated

15

9.5 Riveting
Use rivets with stainless steel or
aluminum bodies and stainless
steel mandrels.
Pre-drill and install rivets in
accordance with the
manufacturers instructions.
Do not use bulb-tite rivets
where there is a risk of water
ingress.
The contractor must follow the
rivet manufacturers
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 bulbtite type rivets are used. Select
rivet length in accordance with
the grip length.

fig 9.2

Surface - finished
Appearance

coordinating color and the

degree of gloss.

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 installing.

10.4 Removing dirt

Natural-finish surface: Use a
non-abrasive agent with a pHvalue of between 5 and 8 and
non-abrasive cleaning pads e.g.
fiber 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 aluminum
surface. Always rinse off with
water.
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 color 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 nozzle 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.
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 color
differences. A 5% chemically
neutral soap solution applied to
the panels will normally be
successful. Do not use solvents
or abrasive agents.

10.2 Removing protective film

Before zipping, only peel off
sufficient protective film from the
small seam so that the
overlaying roll will trap no film.
The effect of UV rays can
cause a chemical reaction in the
adhesive and extensive work may
be needed to remove the film.
It is recommended that the film
be removed within two weeks.
Opaque or transparent UVresistant film can be left on the
surface for up to two months. If
in doubt please consult the
Kalzip technical department.
10.3 Color differences
Due to production methods,
color differences may occur on
both natural and colored
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 color systems is unavoidable,
differences can be minimized by

16

Accessories
11.1 Aluminum (ST) clips
ST clips - Kalzip self-supporting panel
Kalzip 65/*

Kalzip 50/*

ST clip
type

Clip height
H

W1

W2 (TK5)

GK5

2.44

L10

2.60

Not possible
Not possible

L25

3.18

0.78

0.98

L50

4.17

1.77

L60

4.56

L80

W2 (TK15)

W1

W2 (TK5)

W2 (TK15)

0.59

0.78

1.18

0.78

0.98

1.37

1.37

1.18

1.57

1.96

1.96

2.36

2.36

2.56

2.95

2.16

2.36

2.75

2.75

2.95

3.34

5.35

2.95

3.14

3.54

3.54

3.74

4.13

L90

4.96

3.34

3.54

3.93

3.93

4.13

4.52

L100

5.74

3.74

3.93

4.33

4.33

4.52

4.92

L110

6.14

4.13

4.33

4.72

4.72

4.92

5.31

L120

5.53

4.52

4.72

5.11

5.11

5.31

5.70

L130

6.93

4.92

5.11

5.51

5.51

5.70

6.10

L140

7.32

5.31

5.51

5.90

5.90

6.10

6.49

L150

7.17

5.70

5.90

6.30

6.30

6.49

6.88

L160

8.11

6.10

6.30

6.69

6.69

6.88

7.28

L190

9.29

7.28

7.48

7.87

7.87

8.07

8.46

ST clips - Kalzip fully supported panel

Kalzip AF 65/*, AS 65/*
ST clip
type

Clip
height H

W1

W2 (TK5)

W2 (TK15)

GK5

2.44

0.19

Not possible

L10

2.59

0.19

Not possible

Note:
TK = Thermal barrier pad
TK5 = 0.19 thermal barrier pad thickness
TK15 = 0.59 thermal barrier pad thickness
H= height of clip without thermal barrier pad
W1= distance between underside of Kalzip panel and underside of ST clip
W2 = distance between underside of Kalzip panel and underside of ST
clip with thermal barrier pad.
Note: Dimensions in the tables above are in inches.

17

Standard L type ST clip base

T type ST clip base (for fixing

to min. 3 wide timber)

Double length DL type ST clip

base

Note: Special length clips are

available on request
11.2 Thermal barrier pads
Polyamide thermal barrier
pads for standard length ST
clips

Polyamide thermal barrier

pads for double length ST
clips

2.49

4.76

2.49
2.49

TK5: 0.19 depth

TK15: 0.59 depth

DTK5: 0.19 depth

DTK15: 0.59depth

11.3 Standing seam

accessories

Gable end clip for Kalzip 65/...

(aluminum)
Gable end clip 50 for Kalzip
50/... and AF65/... (aluminum)

Tolerance gable profile

(aluminum)

Material no
Size in inches
Material no
Size in inches

Material no
Size in inches
(or 16.4) long

Gable end channel (aluminum)

Material no
319
Size in inches 1.37 x 1.06 x
0.78 x .059 19.6(or 16.4) long

584
2.28 long
1261
3 holes 0.27

18

328
2.36 wide 19.6

Sliding ridge clip (aluminum)

Kalzip flashing panel with

large panel upstand (aluminum)

Cable clip (stainless steel)

Material no
Size in inches
long

Size in inches 23 with colored

panel depending on the Kalzip
cover width 19.6(or 16.4) long

Material no

Seam clip (stainless steel)

Seam clip (aluminum)

Ridge cap (aluminum)

Material no

Material no

Size in inches 9.25 x 4.92

19.6(or double length DL* type
ST clip base 16.4) long

326
2.36 wide 2.36

607

209

608

Spacer profile (aluminum)

Flat bar (aluminum)

Ridge closure (aluminum)

Material no
325
Size in inches 1.77 x 0.23 x
1.77 x .059 19.6(or 16.4) long

Material no
323
Size in inches 1.96 x 0.23
19.6(or 16.4) long
Material no
324
Size in inches 0.86 x 0.23
19.6(or 16.4) long

Material no
Kalzip profile
228
305 (2.5x12)
224
333 (2.5x13.1)
225
400 (2.5x15.75)
388
Special/hipped
376
Painted
Size in inches Cut to size of
Kalzip profile

19

Ridge filler (EPDM)

Eaves filler (EPDM)

Drip angle

Material no
349
350
352
333
Size in inches

Material no
301
304
305
Size in inches

Material no
320
Size in inches 1.57 x 0.78 x
0.078 19.6(or 16.4) long
Material no
322
Size in inches 2.75 x 1.18 x
0.078 19.6(or 16.4) long

Size in inches

Kalzip profile
305 (2.5x12)
333 (2.5x13.1)
400 (2.5x15.75)
Special/hipped
Cut to size of
Kalzip profile
39.37 long
Special size

Kalzip profile
305 (2.5x12)
333 (2.5x13.1)
400 (2.5x15.75)
Cut to size of
Kalzip profile

Dilaprene expansion joint

(aluminum vulcanized)

Omega profile (aluminum) - for

installation of Kalzip profile
translucent panels.

Cover strip for repairs

(aluminum) not suitable for
installation of translucent
panels

Material no
619
Size in inches 0.039 x 15.75x
19.6(or 16.4) long

Material no
Size in inches
long

Material no
Size in inches
long

Comb-profiled jointing panel

Flat panel cut from coil

stucco-design, protective clad
alloy (aluminum 1/2 hard)

329
19.6(or 16.4)

78- 19.6

0.13 x 3.15 x

Various lengths and gauges are

in mill finish, stucco and color.
Contact our fabrications
department for further
information.
Special flashings: Fabrications
only in accordance with
sketches, lengths up to 19.6
max.

48- 60

Size in inches
19.6(or 16.4)

615
19.6(or 16.4)

Size in inches 0.027 x 48 x 78

to 19.6(or 16.4)
Size in inches 0.05 x 60 x 78 to
19.6(or 16.4)

20

Special tools
12.1 Zipping machine front view
100 167 roller holder, front drive side
100 186 casing upper part, opposite side
100 166 roller holder, front
100 179 screw for roller holder, front
100 187 casing lower part opposite side

100 177 clamp handle

100 183 stretch pin
100 194 complete for Kalzip 65/50

100 134 contact roller

100 133 front guide roller
100 132 wide slide roller

12.2 Zipping machine side view

100 149 cord with plug

100 155 top handle

100 150 cord protection

100 148 switch handle
100 156 switch

100 191 friction plate

100 175 nut for clamping bar
100 176 washer for clamping bar
100 140 roller std 0.7 - 1.0
100 141 roller 1.2
100 142 roller omega profile

12.3 Unzipping device

jacking screw
cast body

tapered roller

right hand thread

left hand thread

21

12.4 Fixing accessories

Additional roller sets
Type CL for OMEGA profile
Type 1.2 for material thickness 0.047

Hand closure pliers

Closing panel seams by hand

Ridge folding tool for Kalzip

305 (12.0) - 333 (13.1) - 400 (15.75) 500 (19.68) - 600 (23.6)

Folding Kalzip panels at the ridge

Eaves folding tool for Kalzip

305 (12.0) - 333 (13.1) - 400 (15.75)

Folding down Kalzip panels at the

eaves

Wide nosed pliers cranked or straight

Folding down small bends or hipped

details

Unzipping tool

Unzipping Kalzip panels (can only be

used together with zipping machine)

Spreader beam (on rental basis)

Unloading long panels of up to 164

Spreader beam length up to 78
Spreader beam length up to 118

Peeler tool

To ease Kalzip panel removal

12.5 Repair service

All tools can be professionally serviced
and repaired in our zipper maintenance
workshop.
Contact information
For further information contact us on
219-879-2793 and ask for the
relevant department
Customer services
Site services
Technical
Transport
Zipper maintenance

22

Index
Accessories
Clips

Contacts
Corrosion
Curves

Fasteners
Finishes
Fixed points
Installing

Flashings

Joints
Kalzip
Ridges

Roof types

Section
11.2
11.3
11.1
5.4
5.15
5.13

barrier pads
Kalzip accessories
clip types
attachment
sliding ridge clip
gable end clip
contacts
protection
crimp curved panels
curved roof
lifting onto roof
preparing for installing
smooth curved panels
unloading pre-curved Kalzip
zipping crimp curved panels
zipping curved Kalzip
zipping roll curved panels
eaves detail
eaves for tapers
rake/eaves end cap
riveting
self tapping and drilling screws
color differences
constructing
clips
cutting and sawing Kalzip
drilling
drip angle
fixing tool accessories
Kalzip panels
load bearing capacity
preparing curved panels
principal rule
ridge details
riveting
sequence
sliding ridge clip
tolerance rake flashings
traditional rake flashings
gable end clip
rake details
gable tolerance profile
rake/eaves end cap
wind and weather
sizing and shaping flashings
tolerance rake flashings
traditional rake flashings
constructing sealed joints
constructing transverse joints
zipping transverse joints
introducing Kalzip
profiles fig
ridge details
ridges for tapers
sliding ridge clip
decking roof
purlin roof

4.5
7.1
7.1
7.1
7.1
7.1
3.2
5.7
5.7
5.7
5.12
7.2
5.13
9.5
9.4
10.3
5.10
5.4
9.2
9.3
5.12
12.1
5.5
5.3
7.1
5.1
5.14
9.5
5.5
5.15
5.13
5.13
5.13
5.13
5.13
5.13
5.2
9.1
5.13
5.13
5.11
5.11
5.7
2.1
2.1
5.14
7.2
5.15
6.2
6.1

23

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18
18-20
17
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11
22
5
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14
14
14
14
4
9
8
9
11
14
11
16
15
19
9
7
15
15
11
21
7
6
14
6
12
16
7
12
12
12
12
11
12
12
6
13
12
12
10
10
9
3
3
12
14
12
13
13

Site practice and

maintenance

Site preparation

Site work
Storage Kalzip
Tapers

Tools

Translucent panels
Transport

Unloading
Unzipping
Rakes

Zipper machine

Zipping

Section
3.4
10.4
10.2
3.3
10.1
3.2
3.1
3.2
4.2
4.3
4.1
9.2
9.3
10.1
3.3
7.2
7.2
7.2
7.2
7.2
7.2
7.2
12.1
4.4
5.6 - 5.8
8.1
3.4
3.4
3.1
3.2
3.1
3.2
5.9
12.3
5.13
5.13
5.13
5.12
7.2
5.13
5.13
5.8
12.1
12.2
5.6
5.7
5.7
5.7
5.7
5.7
5.7
5.7
5.7
5.7
5.7
5.7

checking incoming materials

removing dirt
removing protective film
storage on building site
storing Kalzip
unloading at site
unloading at storage area
unloading precurved Kalzip
Kalzip licensing notice
Kalzip preparation layout
preliminary work
cutting and sawing Kalzip
drilling
panels
on building site
eaves
load bearing capacity
ridges
setting out panels
panel ends
tapered roof
rake
fixing tool accessories
special tools
zipper (see zipper machine)
translucent panels
checking incoming materials
length tolerances for Kalzip
transporting to site
at site
at storage area
precurved Kalzip
Kalzip panels
unzipping device fig
tolerance rake flashings
traditional rake flashings
gable end clip
rake details
rake for tapers
gable tolerance profile
rake/eaves end cap
changing rollers
front view fig
side view fig
zipper maintenance checklist
0.035 or less
2 high Kalzip
above 0.035
crimp curved panels
curved Kalzip
double skin translucent panel
errors
roll curved panels
panels
transverse joints
wall areas

24

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