PRESS RELEASE: Anniversary with review of milestones

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55 Years of Kalzip

Koblenz-based supplier of roofs, facades and building envelopes made of aluminum and metal celebrates anniversary with review of milestones.

May 2023

Koblenz-based provider of aluminum and metal roofs, facades, and building envelopes celebrates its anniversary by looking back at milestones. Since 1968, Kalzip has been producing roof and facade systems on modern roll-forming equipment. Originally introduced as a product name based on the first owner, the US company Kaiser-Aluminium, Kalzip has since established itself as the synonym for individually manufactured standing seam roofs internationally. With various innovative products and services, the company has been able to realize many prestigious projects in its 55-year history and thus record some milestones in its history. To appropriately honor the company’s anniversary, various actions are planned, including a temporarily modified logo, a history page, and the Premium Partner Award, which is the focus of the anniversary.

 

Anniversary Logo – Let’s Go Retro!

At the beginning of the year, a small change on Kalzip’s website and social media channels drew attention to the anniversary: the current logo will be temporarily replaced. The combination of two old logos shows the cross-section of the original standard profile, with the KAL-ZIP lettering above it. The historically correct split spelling refers to the company’s original name – Kaiser Aluminium. The syllable “Zip” as an abbreviation for “Zipper” describes the zipper principle with which the standard profiles are firmly connected. Thus, the “new old” logo reflects the introduction of the standard profile “KAL-ZIP” in 1968.

History Differently

Instead of a boring historical overview, kalzip.com/history regularly provides new information on the company’s history – short and sweet. For example, the first major construction project in Germany cannot be missing: the aluminum roof on the Nuremberg Congress Hall was installed in 1968 and can still be found on the building today. Another milestone: the move to the Koblenz location, which is still the company’s headquarters today. In chronological order, interested parties can look forward to further exciting sections, such as the construction of the protective cover around the Chernobyl disaster reactor.

Celebrating milestones as they come

Regular updates are posted on the various social media channels to draw attention to Kalzip’s milestones. In a planned video series, long-time Kalzip employees will talk about their most exciting construction projects. In addition to various online actions to draw attention to the company’s anniversary, celebrations will also take place offline. All employees are invited to celebrate 55 years of Kalzip at a big summer party at the headquarters in Koblenz. And the Premium Partner Meeting, including the award ceremony, is also dedicated to the anniversary.

 

Bildmaterial:

Remained at its core: Since 1968, the headquarters and main production site of Kalzip have been located at the Koblenz site. (Photos: Kalzip GmbH)

 


The aluminium roof on the Nuremberg Congress Hall was installed in 1968 and is, therefore, the first major construction project of Kalzip in Germany. (Photo: Kalzip GmbH)

 

Herausgeber:
Kalzip GmbH
Pressekontakt: Yannick de Beauregard
August-Horch-Str. 20 – 22
56070 Koblenz
Tel:  +49 261 9834 217
Mail: Yannick.Gouder-de-Beauregard@kalzip.com

Redaktion:
Brandrevier GmbH
Beate Kranen
Kettwiger Straße 2-10
45127 Essen
Tel.: +49 201 874 293 14
Mail: kranen@brandrevier.com

 

 

Estadio de Futbol Monterrey, Mexiko

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KALZIP – „Primary school in Wriedel, second representation“

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A new cafeteria for the Swallow Elementary School in Wriedel

In order to meet the requirements for mandatory all-day care, the Swallow Elementary School in Wriedel, near Hamburg, has received a new cafeteria for lunchtime meals. The modern, one-story building is covered with an aluminum gable roof and has an integrated solar system that provides the school with sustainably generated electricity. Interested visitors, teachers, and students can use a monitor to learn about the system’s performance.

The cafeteria plays a central role in the open all-day school operation, not only because students need to be fed, but also because it is intended as a space for community building, says school principal Sabine Liebmann. “The cafeteria is not only used for eating, but also as a meeting room. It replaces the auditorium that we didn’t have,” says Liebmann.

Bright and educational

Skylights were installed on the roof as a natural source of light so that daylight can enter the room at any time. The over 300 square meter roof area is covered with photovoltaic modules, which fill most of the aluminum profile panels to maximize the potential of the overall area.

The aluminum standing seam roof with photovoltaic system was constructed using the tried and tested AluPlusSolar system from Kalzip and consists of individually prefabricated aluminum profile panels. The very flat solar panels are already glued to the profiles in the factory to avoid any impact on the connection due to dust, dirt or moisture and to facilitate installation for skilled tradesmen. The Kalzip 50/444 profile used for the interconnection is known for its weather resistance and durability.

 

Efficient, robust and sustainable despite minimal weight

The skilled tradesmen first installed the system-specific composite clips on the slightly sloping roof area, which was provided with a vapor barrier. This was followed by a mineral thermal insulation layer to efficiently and sustainably insulate the building. Since the module connections are located behind the panels, each panel had to be placed individually on the standing seam of the previous panel.

The aluminum standing seam roof with photovoltaic utilization impresses with its lightweight design and high energy efficiency, as it weighs significantly less than other roofing systems and has therefore already proven to be the system of choice in many previous construction projects. Overall, around 100 students now attend the new cafeteria and enjoy events in their new auditorium.

 

Considered with care. KALZIP.

Contact

Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz

Phone: +49 261 9834 0
Fax: +49 261 9834 100

E-Mail: yannick.de-beauregard@kalzip.com

Secure fit with visual verification

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SDK fasteners are now available exclusively at Kalzip /Perfectly coordinated system from a single source /The entire system is easily visually verifiable

For decades, the iconic SDK fastener, with its distinctive square head, has held millions of metres of standing seam roofs in place – an indispensable part of the Kalzip product range. Now available exclusively at Kalzip, the company has secured the international distribution rights for the SDK screws. This means when you order a Kalzip system, you will receive the complete fastening system for the standing seam roof installation.

Fastener head shears off

The SDK fastening system offers several benefits for the installer. The fastener cannot be overtightened, as the square fastener head shears off at a precisely predetermined torque, ensuring optimal fastening. At the same time, the shearing off prevents damage to the construction and guarantees the perfect, force-fit connection of both components. This is especially important for thin components, such as trapezoidal profiles, as a fastening base. Once the fastener is seated in the system exactly, it can only be removed with a hexagonal wrench. The perfect fit of the fastener can be visually verified, saving time for site management and providing additional security, especially when work is carried out by subcontractors or teams unfamiliar with the product.

With the correct fit, the fastener head of the SKD fasteners shears off allowing for a simple visual control of the proper processing. (Photo: Kalzip)

 

System perfectly coordinated

“The system comprising of a standing seam metal, clip and fastening material is designed for optimal performance. We truly believe that SDK fasteners are the best fastening solution for Kalzip standing seam sheets. The fasteners can now be conveniently ordered as a package from the system manufacturer, along with clips and standing seam sheets, reducing the effort for installers. It is for this reason why we took this opportunity to improve our service offerings by permanently securing the distribution rights for the SDK system fastener.” explains Christoph Schmidt, Sales Director of Kalzip GmbH. To simplify material procurement, the fasteners are integrated into the tender texts as usual, eliminating the need to search for individual components and requiring only one order to be placed.”

SDK fasteners are now exclusively available at Kalzip as a perfectly coordinated standing seam roof system from a single source. (Photo: Kalzip)

Considered with care. KALZIP.

Contact

Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August Horch St. 20 – 22
56070 Koblenz

Phone: +49 261 9834 0
Fax: +49 261 9834 100

E-mail: yannick.de-beauregard@kalzip.com

KALZIP – “Kwelderland in Delfzijl/Netherlands

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The Kwelderland Residential Area in Delfzijl, Netherlands

A house by the sea – with sustainable added value.

It is well known that Kalzip is often involved in spectacular buildings in extraordinary environments. Most of the time, these are projects that are made accessible to the public after the completion of the construction work. In the Dutch port city of Delfzijl, a private construction project has now been realized that has many special features that bear Kalzip’s signature.

The Kwelderland residential area (Dutch: marshland) is located on three adjacent peninsulas surrounded by waterways, a typical landscape feature of the Netherlands. A special feature of the apartment complex is the brick walls, which were supplemented by additional wooden construction on the upper floor and an anthracite-grey metal roof. To meet current sustainability requirements, the south-facing houses were arranged in parallel so that the PV system integrated into the roof can make optimal use of the available hours of sunshine.

Beautiful old walls – modern new roof.

One of the architectural features of the modern residential complex is that the roof was not completely covered with aluminium profile panels, but the top-floor apartments have a pergola that is only covered by the roof rafters. This small but fine and widely visible detail highlights the special construction of the apartments. The skilled craftsmen provided a vapour barrier to protect the load-bearing panels on the rafters from moisture.

The composite clips installed subsequently are designed to provide sufficient space for the installation of mineral wool insulation while minimizing thermal bridges due to their material and narrow bridge. To ensure a uniform look, the foldable aluminium sheets of the clad rafters were coated with Kalzip’s RAL8019 (anthracite grey) colour over the roof loggias, the detail connections and the chimneys. This coating is scratch-resistant and extremely UV-resistant and has an extremely high surface hardness. Furthermore, the dark surface supports the effectiveness of the photovoltaic system, whose similar colour scheme optimally completes the stylish and modern design of the residential complex.

Carefully considered, efficiently executed.

Instead of an already integrated photovoltaic system in the roof, the planners wanted a PV variant that could be mounted onto the standing seam roof after the completion of the roof covering work. The supplied WS mounting system from Kalzip makes this possible and guarantees an easy, fast, and therefore economically efficient installation.

The used standing seam profiles in the size 50/429 could also be installed quickly and easily, as a mobile construction crane could lift the aluminium profiles directly onto the roof for “seamless” processing. The width of the profiles used also fits perfectly with the roof geometry and allows the recess of the pergolas to be connected to the roof on both sides without having to cut the profiles.
This meticulous technical (pre-)planning, combined with Kalzip’s many years of experience, made it possible to complete all three roofs with a total area of approximately 1150m2 in just six weeks, and the first apartments could be quickly occupied.

The residents can expect a future-oriented and sustainable living space that convinces with generous balconies, modern architecture, and excellent connections to schools, train stations, shopping, and of course, the sea on all fronts.

A typical Kalzip project.

 

Mit Bedacht bedacht. KALZIP.

Contact

Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz

Phone: +49 261 9834 0
Fax: +49 261 9834 100

E-Mail: yannick.de-beauregard@kalzip.com

KALZIP – „Wintringham Primary Academy, Saint Neots“

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A COMBINATION OF HIGH PERFORMANCE AND DISTINCTIVE ARCHITECTURE – THE AVOCADO SCHOOL BUILDING EXCELS

The township of Wintringham received a new flagship building in the form of Wintringham Primary Academy in St Neots, Cambridgeshire, completed in 2021. Cambridgeshire County Council commissioned the building affectionately known as the ‘Avocado’ due to its unique roof shape. The project is a clear demonstration of the excellence of workmanship that Kalzip provide to clients through the installation of the Kalzip standing seam roof system and the quality of the bespoke curved aluminium soffit and aluminium fabrications.


Philip Marsh, Founding Director at dRMM (de Rijke Marsh Morgan Architects), who was responsible for the school’s design, said: “Wintringham Primary Academy’s distinctive shape was formed by Passivhaus principles. By arranging teaching spaces around a central grove, the aim was to increase daylighting and cross ventilation from multiple aspects. The shape allows a spatial arrangement which supports the idea of a school ‘in the round’.

“The client required a roof system that was robust and low maintenance, and one that would stand the test of time. A Kalzip standing seam profile roof was selected after considering a few options, ultimately the Kalzip system provided the best option in terms of durability. Additionally, the Kalzip roof also offered compatible bolt-on solutions for roof maintenance systems that were easy to integrate. The project required a fall restraint mansafe system and roof access stair which could be simply incorporated as part of the roof system. From the moment we started liaising with Kalzip for their technical input they were most helpful and were able to answer all our technical queries in great detail.

“Kalzip 50/429, stucco embossed aluminium was specified for the project, which was site rolled at the eaves with the longest sheet measuring 72 metres. Additionally, intricate detail work was required on the curved aluminium fabrications, along with the drainage requirements on the complex roof shape. Having received high-level technical information at the early stages of enquiry, we were confident Kalzip’s experience would be beneficial. We also specified 280mm Kalzip insulation plus 40, compressed to 255mm within a cavity created by E180 clips, S5 & S10 spacer pads, galvanized steel top hat supports fastened down to a Glulam Beam timber structure to achieve the thermal requirements.”

There were some logistical challenges for this bespoke project, mostly surrounding the tight budget and construction programme. Just 12 months were allowed for the construction with completion to coincide with the start of the new school year. Kalzip’s systems are predominantly manufactured offsite, which led to a quick and simple installation onsite, despite the complex nature of the roof.

Wintringham Primary Academy is a prototype typology for an all-timber school that delivers an inspirational learning environment, which surrounds itself with greenery inside and out. To enhance wellbeing, dRMM prioritised a timber aesthetic, natural light, ventilation and direct access to the surrounding landscape in response to the school’s affinity with forest school principles.

As part of a team headed by contractor Morgan Sindall, dRMM worked with Cambridgeshire County Council (CCC) and the Diamond Learning Partnership Trust (DLPT) to develop the vision. This called for a three-form entry primary school for up to 708 children, including a nursery that could be run independently if required. The 3615m2 school was completed in 2021 after a construction programme of just 14 months despite the restrictions of the pandemic.

There were a number of challenges to overcome, and Kalzip’s vast experience was certainly required at numerous points. As a result, Kalzip was awarded Morgan Sindall’s ‘Perfect Delivery” award for the Wintringham Primary Academy project. Wintringham also achieved the RIBA East Regional Award and the RIBA East Sustainability Award in 2022 and was highly commended in the Structural Timber Awards.


For more information please visit: www.kalzip.com/en/

Considered with care. KALZIP.

Contact

Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August Horch St. 20 – 22
56070 Koblenz

Phone: +49 261 9834 0
Fax: +49 261 9834 100

E-mail: yannick.de-beauregard@kalzip.com

KALZIP – „Hangar for airship Theo in Mülheim an der Ruhr“

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A Hangar for Theo

Retirement is the gold standard for “Theo” the airship.

The airship “Theo” is considered the unofficial mascot of the Ruhr area, as this airship circled above the Ruhr metropolises for almost 50 years. In 2024, the moving landmark will retire. To ensure that “Theo” feels comfortable on the ground in the future, its old hangar has been enlarged, renovated, modernized, and raised to the latest ecological standard. The new, climate-neutral multifunctional hangar can now be used as a venue for 1500 people, surpasses all structural and static requirements with minimal maintenance effort, and is incomparably durable.

Indeed, it sounds like a Kalzip project. The fact that Kalzip was able to meet this unusual challenge was made possible by an expert committee of the International Association for Metal Construction, which recommended that only a building envelope made of 95% recycled aluminium standing seam profiles could meet the extensive climate neutrality requirements of the building concept. This called for a climate-neutral building that meets the Gold Standard requirements of the Society for Sustainable Building. But those who know Kalzip know that it is precisely this type of challenge that drives the company.

 

A 6,500 m2 custom-made structure made of 557,000 kilos of wood and 1,500 wood components.

Since the supporting structure of the new hangar consisted exclusively of wood, no cornerstone was laid in 2022, but a “foundation wood-laying.” The term fits well because a total of 557t of wood from domestic forests was used as a sustainable and renewable building material for the supporting structure. The special feature of this spectacular supporting structure is that a total of 592 nodes were joined together in the main load-bearing areas without a single piece of steel in a truss span of 42m. This required not only tremendous physical effort and extensive construction practical experience from a well-rehearsed team of specialists but also countless work steps at 6500 m2.

A total of around 1500 wood components were manufactured and assembled with millimetre precision. A prerequisite for the professional and efficient installation of the profile sheets at lofty heights was not only the demanding three-dimensional planning and produced the tapered profiled and curved aluminium profiles in advance, but also the precise installation of all fastening elements, both in the elongated, simply curved area and at the quarter-sphere, three-dimensionally shaped hall endings. Due to the dome-shaped form of the new hangar, it was not possible to erect scaffolding, so the aluminium sheets had to be mounted at lofty heights using mobile work platforms. This required individual protective clothing, a safety harness, and a safety net for fall protection.

One system, many solutions.

The complex ecological requirements and the special building geometry require a flexible system that can cope with all challenges and adapt to them. The substructure system FlexiCon RR80 from Kalzip exceeds these requirements. In combination with the installed aluminium standing seam profile, it compensates for existing height differences in the load-bearing surface and also guarantees efficient installation because the installation of the aluminium profile sheets and their insulation is carried out in one work step. To ensure a distortion-free, temperature-related expansion movement of the profile sheets, the clip of the standing seam profile was aligned three-dimensionally during installation on the saddle.

The system developed by Kalzip is also used in dome roofs, flue towers, or other three-dimensional buildings. The FlexiCon system allows the aluminium sheets to be mounted horizontally and vertically with uniform rounding. An important visual feature of the airship hangar. Another advantage of the composite clip system used is that no thermal bridges occur, which would impair the energy efficiency of the building.

 

From beginning to end, a green thread

Theo is proud of the eco-friendliness of his new multifunctional hangar. At the beginning of the construction work, 8000m3 of excavation material was crushed on site and reused as the foundation for the project. The targeted use of resource-saving materials and the reuse of building materials saved a total of over 156t of CO2. The two 400m2 large and 72t (without aluminium cover) heavy door wings are powered by four 80PS electric motors. The aluminium cover can easily be dismantled and added to the recycling cycle after the end of its useful life or it can be reused and repurposed in suitable areas of the building.

Through this future-oriented construction method, it is sustainably ensured that Theo and his visitors of all generations will enjoy his new hangar for many years to come.

Considered with care. KALZIP.

 

Contact

Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August Horch St. 20 – 22
56070 Koblenz

Phone: +49 261 9834 0
Fax: +49 261 9834 100

E-mail: yannick.de-beauregard@kalzip.com

Futurebuild 2023 at ExCel in London

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In partnership with BIPVco, Kalzip will exhibit at this year’s Futurebuild event from 07-09 March 2023 in London. As both companies focus on sustainability, Futurebuild is a perfect match. For nearly 60 years, Kalzip has worked on its sustainability processes.

Talking about the future building construction

Over 20,000 decision-makers and disruptors are expected to attend, all eager to discover new products and solutions for their businesses. Futurebuild 2023 will showcase the latest products and services within the built environment from manufacturers and suppliers. Influential thought leaders and pioneering thinkers will moderate the high-profile panels.

For Kalzip and BIPVco, it’s the perfect opportunity to share their processes, innovations, and solutions with thousands of industry influencers and shapers. Futurebuild 2023 is divided into six sections, providing you with innovative solutions that address the biggest challenges facing the built environment.
These sections are: Buildings, Energy, Critical Infrastructure, Interiors, Offsite and Resourceful Materials.

Solutions for a sustainable building including the power of solar roofs

Kalzip’s and BIPVco’s stand N36 will be located in the energy section, which fits perfectly because both companies have been working on sustainability topics like net-zero carbon processes and photovoltaic roofing solutions for many years. Bringing the products of both together, with Kalzip AluPlusSolar a wide range of roof shapes can be achieved. Barrel duo or mono-pitch roofs can be designed as energy roofs just as easily as individually curved shapes. Kalzip AluPlusSolar can also be used for the entire building envelope and facade surfaces. Kalzip offers architects planning possibilities for designing solar living spaces in an environmentally conscious manner – economically, sustainably and aesthetically.

   

Highly complex bent surfaces or public building projects with high standards of longevity: Kalzip & BIPVco can handle every challenge. Read more about the product

 

Visit us at Futurebuild and register now!

 

Contact

Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz

Phone: +49 261 9834 0
Fax: +49 261 9834 100

E-Mail: yannick.de-beauregard@kalzip.com