KALZIP – „Mariendorfer Damm, Berlin“

KALZIP – A ROOF WITH ROOTS

The planning and construction of rental housing comes with a lot of responsibilities and requirements. Not only does it need to be modern but also appealing and, of course, well-lit, contemporary architecture and matching infrastructure goes without saying.

But the most important obligation nowadays and for the days to come is sustainability

That led our focus on the roof construction, while building the new housing complex at the Mariendorfer Damm. The result is a roof with roots on nearly 1700sqm. Not only can this roof be planted, it is also helping to prevent urban soil sealing and provides food and shelter for many of our domestic insects.

The many possibilities of a standing seam roof

This was all made possible with the standing seam roof cladding system of Kalzip. Because of its simplicity, its compatibility with other construction systems and its excellent thermal and acoustic insulation features, the performing architects chose the Kalzip ‘NaturDach’ as solution of choice. Because it is being delivered separately as full package, the construction specialists on site could easily mount the ‘NaturDach’ on top of pre-installed profile board. The combination of those construction methods protects the roof against moisture and root penetration and speeds up the construction process which increases efficiency.

But not only the ground plan and the building’s cross-section made this project very special compared to other construction of this scale. The architectural style of this housing complex combined timber and steel construction. First, oriented strand boards were used in combination with a vapor barrier. After that, composite clips were added to ensure extensive mineral heat insolation and to prevent the formation of thermal bridges. The preinstalled aluminum sheets, which were placed under the hip and gambrel roof area, divert rain from a gradient of 2,5° until 60°.

 

Recyclable materials ensure sustainable implementations

This construction is a showcase project for illustrating the way Kalzip thinks, plans and builds sustainability throughout the world. The roof has no equal, the installed aluminum profile boards are made of 95% recycled material and because of their stability, they’re extremely durable and completely free of maintenance. If the operational phase of the building has ended, the installed profile boards can be completely dismantled and the single components can be led back into the recycling cycle.

There is no better way to do it. Kalzip.

 

Kontakt

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, Dach+Holzbau – „Vario LB auf Schule Achim, Bremen“

Variable roof for the comprehensive school

When constructing the roof for the new wing of the integrated comprehensive school in Achim, the architects attached particular importance to the fact that the ridge could be walked on and that a photovoltaic system could be clamped onto the surface afterwards. With a flexible roof truss system made of aluminium profiles, the desired roof geometry could be implemented quickly and easily.

A new building has been erected on the edge of a large school area accommodating various types of schools to re-found the Achim Integrated Comprehensive School near Bremen. The public school welcomes pupils regardless of the type of school they attend and thus offers them the opportunity to acquire a school-leaving qualification that matches their abilities. The newly constructed building complex provides sufficient space for current educational concepts in modern classrooms. The bright, inviting façade is complemented by a light aluminium roof.

Lightweight yet strong: The roof truss construction of extruded aluminium profiles provides the statics for a roof that can also accommodate a PV system at a later date. (Photo: © DAGEGO )

Requirements in planning

With a reinforced concrete ceiling as a basis, the roof could also have been designed as a simple flat roof. To match the appearance of the adjacent building on the site, a standing seam roof made of aluminium profiles was also chosen. According to the architects’ specifications, the pitched roof should be accessible via the ridge and have an appropriate guardrail. The task also included the uncomplicated installation of a photovoltaic system on the L-shaped roof construction in some areas. This is why the decision was made in favour of Vario LB from Kalzip. The roof truss system impressed with its uncomplicated modular principle, with which almost any roof geometry can be covered – regardless of the substrate. The roofing of the cold roof construction with standing seam profiled sheets also offers sufficient possibilities for subsequent adjustments.

 

Efficient use of materials

The Vario LB system consists of extruded aluminium profiles and is therefore very light and statically usable as a full roof truss system. The material is classified as non-combustible in building material category A1. Kalzip uses a particularly high proportion of recycled material in the manufacture of its products – between 75 and 95 percent depending on availability. Aluminium is also robust and durable. A high level of weather resistance and insensitivity to mechanical stress guarantees decades of value retention and low expenditure in terms of maintenance and care. “With the raw material situation becoming increasingly difficult at the time of planning, we were able to score points with the building owners with our system made of cost-effective and, above all, available raw material,” reports Friedemann Felix Dahling, who is responsible for the project as Area Sales Manager North at Kalzip.

In addition to the system components prefabricated in the Koblenz factory, Kalzip also supplied the installation plans including details and parts lists. “During the planning of the roof structure of the comprehensive school, we supported the architect and fabricator from the very beginning. This enabled us to record the wishes in an installation plan that also takes into account the verifiable statics and serves as a guide for the roofers,” says Friedemann Felix Dahling.

Base profiles were mounted directly on the reinforced concrete slab to serve as supports for the LB column profiles. (Photo: © Thorsten Scherz Photography)

 

Structure with lightweights

The roofing cooperative Bremen eG – DADEGO for short – was responsible for the construction of the roof. The reinforced concrete slab erected on the new building provided the workers with a level base. On this, they first fastened base profiles that serve as supports for the LB support profiles. These already determine the geometry of the roof through their heights, which are specified in the installation plan. The LB fork profile mounted on the supports is the pivot of the construction: here the LB tubular purlin was inserted, which was aligned according to the slope of the roof of 7°.

To ensure that the roof covering has sufficient load-bearing capacity for later access and a clamped photovoltaic system, the skilled craftsmen additionally attached bracing profiles to the purlins at 1.70 m intervals. “Since this is a plug-in system, you can’t do much wrong. In addition, we were able to fix the elements very easily with the corresponding screws, without much effort or the use of umpteen tools,” reports Michael Kording from DADEGO.

 

From skylight dome to rain gutter

With the completion of the roof truss, the skilled craftsmen were able to cover the system-compatible standing seam profiles. For secure installation, the LB turning clips are available here, which are inserted into the profiles of the tubular purlins and then fixed with a 90-degree turn. The DADEGO team laid the Kalzip 50/429 profiled sheets on the turning clips and then flanged them together.

The L-shaped roof surface is almost completely covered with aluminium profiled sheets, with one exception: a skylight dome was installed to allow later access to the roof via the ridge. In order to guarantee protection against the intrusion of rain, a circumferential collar plate and a system-compatible connection frame were already included in the planning. Rainwater is also safely drained off via rain gutters, which were attached to the lower side of the profiled panels by the roofers without much effort.

 

All requirements met

Within only seven working days, the four-man team was able to erect the roof truss and cover the roof area of about 1,700 square metres. Vario LB thus proves to be not only easy to work with, but also particularly economical. In addition to the system statics and the building authority approval of the system, the system-compatible fall protection from Kalzip offers additional safety on the roof. The clearly laid out application guide supports specialist tradesmen and planners in the correct implementation of the building authority approval. Subsequent construction projects on the roof can also be implemented. For example, the statics are designed accordingly for the additional weight of a photovoltaic system. There is also sufficient space within the cold roof construction for the installation of connections. This means that the pupils of the Achim Integrated Comprehensive School can follow their lessons under a doubly sustainable roof.

Simple assembly: The roofers fixed stiffening profiles to the purlins with a screw. (Photo: © Thorsten Scherz Photography)

 

Construction panel (selection)

Project: Roofing of a new building of the integrated comprehensive school in Achim (Bremen)

Construction time: 2021

Client: Community Achim

Roofing work: Dachdecker-Genossenschaft Bremen eG / DADEGO

 

 

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

The Hazards of specification switching

Written by Adrian Whitefoot

In recent years building safety has, quite rightly, been put under a spotlight, in particular as a result of the Hackitt Review following the Grenfell Tower tragedy. However, specification switching, often done on the basis of cost, can have serious implications for safety. Here, Adrian Whitefoot at Kalzip looks at the importance of ensuring building envelope systems perform as intended and that system integrity is maintained.

           (© Kalzip GmbH)

The commercial realities of construction projects mean that there is often a need to reduce costs where possible to meet financial constraints. This pressure has been intensified in the past year by the rising costs of materials. As a result, the specified roofing or façade system may be switched for a lower cost option. There is often an assumption made that because two systems look the same, and even use the same raw materials, that they are equivalent. However, the performance of the two can vary significantly and this can impact the building in a number of ways.

For example, an aluminium rainscreen cladding system specified for a building may have achieved a Euroclass A1 or A2 ‘non-combustible’ fire performance rating. While another aluminium cladding system may look similar, it will not necessarily have the same fire performance. This is because it may include a type of insulation that is rated as combustible or feature a different construction that does not limit fire spread. This means the building may be at greater risk in the event of a fire, especially if originally designed around a non-combustible cladding solution.

    (© Kalzip GmbH)

In roofing

With regard to roofing, an unsuitable system can impact the safety of those who have to access the roof during the life of the building, such as for maintenance and inspection of rooftop equipment. Any accessible roof areas must have the required strength, and this should have been considered during the design and specification phase. A similar but not technically equivalent system may not be designed for this purpose and could fail, potentially causing serious and even life-threatening injuries.

Wind loading

A further building safety issue when specifications are switched is wind loading. Both roofing and façade systems will be specified to withstand a calculated wind loading and predicted weather conditions. If the substituted system does not have the structural resistance, the consequences can be serious. During high winds, which many parts of the UK have already experienced this year, the structure can fail, and sections may detach from the building. This not only poses a risk to people in and around the building but can also have serious cost implications for both the repair of the roof and addressing any damage caused to the building’s structure and interior.

(© Kalzip GmbH)

Accuracy is key

The reality is that specifications may have to be reviewed during a project. But it is essential that the performance data of any potential new system is interrogated carefully to ensure that it is equivalent in all areas to the specified system. Manufacturers should be able to provide full and detailed information on the performance of its systems as well as relevant test data, including certifications from independent third parties, such as the British Board of Agrément (BBA). Leading manufacturers will have test data for their systems in a wide variety of situations and with various approved configurations.

It is also crucial to remember that certifications and performance data only apply to the whole system, with the exact components that were used during testing. Something as simple as an alternate type of fixing or different thickness of insulation can change the way it performs. Contractors should be extremely wary of any supplier who provides test data for a system where any components have been substituted. Swapping out a particular element invalidates the certification as well as any manufacturer’s warranty and can mean the contractor is held responsible for any failures or non-compliance.

Installation

Furthermore, it is also recommended that a system is only installed by a contractor team who is trained on that specific system. Although they may have experience with a generic type of system, there is no guarantee that the installation process is the same. Manufacturers will often offer training on their systems to help ensure installation is in line with the recommended procedure and help contractors to complete it as efficiently as possible. Leading manufacturers will also provide technical support throughout the installation and carry out inspections to ensure that it is being installed as designed.

Building safety can easily be compromised when specifications are switched without due care. When considering an alternative roofing or façade system, it is important to look carefully at the details to ensure all performance criteria are met and, importantly, that the data applies to the whole system in question.

Download here:
Kalzip PR Hazards of Specification Switching

 

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

New daycare centre in Murg

A sustainable lighthouse project for Murg:
The new daycare centre “In der Mühle”

 

Visually structured

The municipality of Murg in the Waldshut district is located directly on the Rhine on the German-Swiss border and offers a picturesque idyll. The Murg flows ripplingly alongside the long plot of land on which a new jewel for the community was built: the daycare centre “In der Mühle”. Even though the planned daycare centre had to offer space for 6 classes, a visually bulky building was out of consideration given these conditions.

The new building with Kalzip roof construction seen from above (© Ernesto Preiser Architektur)

Community with an ecological mission statement

Local architect Ernesto Preiser therefore opted for a finely structured combination of wood and aluminium. In doing so, he also picks up on the history of the property, as a wood sawmill stood on this site for many decades. Almost 200 tonnes of wood were used in the prefabricated components and ensure an outstandingly natural indoor climate with the best energy standards. The right roof solution for such a modern, sustainable building? Of course, made by Kalzip. In TitanSilver, it forms a visual counterweight to the vertical wooden panels and ensures high functionality with low maintenance for years to come. With a surface area of over 600 m², this is a point that should not be neglected – after all, dilapidated buildings cost local authorities billions of euros every year.

Ideally integrated into the surroundings thanks to subtle architecture (© Ernesto Preiser Architektur)

Design with rough edges

The building in Murg impressively proves that this does not necessarily create a cool, businesslike atmosphere inside. Without a false ceiling, the roof construction offers airy room height and a cosy effect thanks to the cladding with wooden panels.

From the outside, the daycare centre complex is visually divided into 5 structures, which are organically lined up with irregular angles. This creates not only a structure but also functional space for all the necessary details in the interior and exterior areas. The roof construction also follows this approach and has an irregularity that creates tension – a real challenge for the roof system and the craftsmen.

A place to grow without constraints and break out of rigid structures (© Ernesto Preiser Architektur)

Local partners on site – knowledgeable approach

Thanks to the Kalzip roof system and the expertise of local partner Schneider + Sohn Sanitärtechnik und Blechnerei, the special geometry of the roofs could be implemented quickly and efficiently.

More than a few local residents were amazed at how quickly the construction of the new daycare centre went ahead: just a space, a fully roofed building was already standing after just a few weeks. Kalzip’s roof and façade solutions score particularly well in this core area of expertise. Thanks to the prefabricated parts and an enormously large network of partner companies, organisation and installation is not a piece of magic.

 

With a modular solar system? No problem with Kalzip roofs

The Hochrhein region is known for its many hours of sunshine, so the new building was partly equipped with solar panels in the spirit of ecological foresight. While such an undertaking can be quite complex with some roof constructions, Kalzip roof constructions are ideally prepared for this and allow quick, uncomplicated installation. Even a subsequent extension would be unproblematic, should the municipality decide to do so in the coming years.

The daycare centre can cover a part of its electricity requirements on its own with the installed solar panels. (© Ernesto Preiser Architektur)

 

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

Roof refurbishment market halls Sendling

The market hall 3 on the Munich wholesale market:
Refurbishment during ongoing business

 

Three times market hall

The roof of Market Hall 3 at the Munich wholesale market was refurbished using a Kalzip system.  The innovative solution persuaded the operators to refurbish the other halls as well.

These halls are busy long before sunset

Market flair since 1912

Munich’s Sendling district has been bustling with activity for over 100 years on the site of the wholesale market. The area, now 310,000 m2 in size, still houses the four historic wholesale market halls, from administrative buildings and warehouses to the gardeners’ hall, with which one of the largest transhipment points for fruit and vegetables in the whole of Europe was opened in 1912.

Hall after hall is lined up in Munich Sendling on the wholesale market

Redevelopment with obstacles

After the Second World War, the destroyed roofs were repaired with pumice boards as supporting structure. With galvanised steel sheets, a flat sloping roof could be functionally erected. But in the meantime, the roof cladding had rusted and the pumice concrete planks were dilapidated.

The Munich architectural office BH Architekten was commissioned to draw up the conversion plans. Problem: The lack of load-bearing capacity of the roof framework would not have withstood the load of conversion work or new roofing. A specialist consultant from Kalzip provided the planners with the solution by using the Vario LB system.

The condition of the roofs slowly became a security risk

Metal instead of pumice concrete

To protect the tradesmen working in the building from any falling pumice debris, the skilled craftsmen first pulled in a layer of trapezoidal sheeting underneath the pumice concrete floorboards. On the outside, the old metal roof covering was removed and the pumice concrete planks were demolished on both hip roof surfaces.
In order to completely relieve the unstable pumice boards, the building was now raised by a wooden support structure and a metal roof truss was erected as a new supporting structure. This was professionally implemented by the metal roofing specialists Binder und Sohn from Ingolstadt.

The conversion work during ongoing operations

 

A new lightweight roof construction was used

With a system made of aluminium from Kalzip, the overall structure could be realised with significantly less weight. The innovative Vario LB system simplified the assembly work: Instead of the usual steel angles, a “purlin shoe” was fitted to the wooden counter-battens. The system’s aluminium round purlins were used as load-bearing battens, and the usual fastening points for the profiled panels were installed on the upper side of the purlins on a rotable clip.

“The round purlins easily bridged the spans between the counter battens. In addition, the individual components of the system are very flexible in their alignment and combination, which meant we could simply work according to the modular principle in the way we needed,” says Thomas Binder, managing director of the metal roofing company Binder und Sohn.

The first market hall with a new roof, the adjacent halls are already in preparation

 

Three is followed by two

After only twelve weeks, the refurbishment of the approximately 1,700 m2 roof area of the market hall was completed. At the beginning of the work in May 2021, only Hall 3 was initially planned. During this time, it became apparent that the roofs of the other two halls were also in need of renovation. So the operators decided to have Hall 2 re-roofed in the same year and that of Market Hall 4 from April 2022 – convinced by the work of the team from Binder und Sohn as well as the modular system from Kalzip.

 

 

About Kalzip
Kalzip sells and produces aluminium roof facade profiles for the areas of industrial construction, leisure facilities/sports facilities, transport and housing. The Kalzip Group employs 160 people worldwide and is represented in almost all regions of the world. Since October 2018, Kalzip has been a company of the Donges Group. Donges Group is a leading supplier of bridge and steel construction as well as roof and facade systems in Europe. The group consists of the brands Donges SteelTec GmbH, Flachdach- Technologie GmbH & Co. KG, Kalzip GmbH, Nordec OY and Norsilk SAS and employs around 1400 people in 14 countries.

 

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

Refurbishment of Inverurie Community Campus

The Inverurie Community Campus in Aberdeenshire:
A modern meeting point for pupils and citizens

 

Kalzip roofing and cladding package protects £56M Inverurie Community Campus

The team responsible for the £56 million redevelopment of an Aberdeenshire community campus has employed a comprehensive selection of Kalzip® profiles in different colours and widths to complete the roof and cladding of the major structures: including the main teaching block, swimming pool and sports hall; subsequently winning the Development of the Year (Public Buildings) category at the Scottish Property Awards.

The showpiece of Aberdeenshire – the freshly refurbished Community Campus for the entire community 

An inpirational place to learn

Designed by Halliday Fraser Munro and built by main contractor, Robertson Construction, the Inverurie Community Campus project also included a £3 million sub-contract for the roofing and cladding work, which was delivered by specialist installer Curtis Moore.

Replacing existing premises, the new school features 73 classrooms and labs, along with sports facilities, a large dining hall and kitchen, and a conference room. It can accommodate 1,600 pupils – making it one of the largest schools in the North-East of Scotland – and provides a range of amenities for the wider community, including a six lane pool and training pool, outdoor football pitches and a fitness suite.

The largest school in the north-east of Scotland and meeting point for sports enthusiasts 

An array of products that perform

Amongst the Kalzip® profiles supplied to Curtis Moore for the contract were 65/400 and 65/500 flat panels in the 0.9mm gauge in two tones of bronze for the facades; as well as 65/500 1.0 mm gauge material featuring a PVF2 finish to the roof. There were also 35/200 perforated as well as plain liners. Materials for the vapour control layer installed under special acoustic insulation included clear membranes, foil and tapes.

The irregular facade design fits perfectly in the surrounding and has an almost organic wooden look 

Expertise to ensure the current fit

One of the key design challenges which Kalzip’s technical department helped the project team address was the setting out of the windows; the solution to which involved employing three different sheet widths to achieve the most economic use of material, as well as creating aesthetically attractive elevations.

Standing strong against the elements

The Kalzip® standing seam roof and cladding panels with their PVF2, stucco embossed and other finishes offer outstanding weather performance and durability, well able to withstand the Scottish climate throughout a long, low maintenance life. Kalzip® duly provided a 25-year guarantee for the completed installation, though the system will deliver a minimum 40-year service life.

Appearances are deceptive: the facade has to stand more than sunshine in the scottish climate 

 

About Kalzip
Kalzip sells and produces aluminium roof facade profiles for the areas of industrial construction, leisure facilities/sports facilities, transport and housing. The Kalzip Group employs 160 people worldwide and is represented in almost all regions of the world. Since October 2018, Kalzip has been a company of the Donges Group. Donges Group is a leading supplier of bridge and steel construction as well as roof and facade systems in Europe. The group consists of the brands Donges SteelTec GmbH, Flachdach- Technologie GmbH & Co. KG, Kalzip GmbH, Nordec OY and Norsilk SAS and employs around 1400 people in 14 countries.

 

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

Sustainable production halls at TRUMPF

New buildings on the company premises of TRUMPF near Stuttgart:
Industrial buildings as electricity supplier

Large module for small technology. This was the theme of Kalzip’s involvement in the completion of the Trumpf manufacturing halls in Ditzingen. Three halls were fitted with Kalzip roofs, which combine a modern design with an integrated solar roof solution.

The company premises of TRUMPF in Ditzingen near Stuttgart

Playing with angles and heights

TRUMPF has been providing ready-made solutions in the fields of machine tools, laser technology, electronics, and power tools for almost 100 years. The architectural firm Barkow Leibinger from Berlin provided the design for the newly constructed buildings. Instead of the usual simple flat roofs, the architects opted for dynamic-looking roof construction. Slightly pitched gable roofs and butterfly roofs with slopes of 5° each alternate three to four times per hall and form a straight line at the ridge and eaves when viewed from above.

The design from the Architekturgesellschaft Barkow Leibinger is playing with contrary angles

Active use of roof space

In addition, Kalzip contributed to a special feature with its roofing components. In contrast to other manufacturing halls, the new buildings in Ditzingen were largely covered with solar panels, which contribute to sustainable energy generation. The architects’ desire to achieve the highest possible utilisation of solar modules with a homogeneous surface area presented both the manufacturer Kalzip and the fabricators with challenges.

Appearance and function are going hand in hand

 

Practical challenges in transport and assembly

A further challenge was the special production in excess length. For the building project in Ditzingen, profiled sheets with a length of up to 28 metres and with up to 12 solar modules on one profile were created – making them the largest AluPlusSolar profiled sheets ever produced and delivered by Kalzip. The transport was correspondingly difficult: loaded onto an overlength lorry, the profiled sheets were permanently kept under surveillance by an escort vehicle belonging to the haulage company. In addition, a police escort accompanied the lorry on the route from the Kalzip plant in Koblenz via the motorway to the construction site in Ditzingen. Kalzip profiled sheets were installed as the final layer. Due to roof permeations and transitions, the sheets were produced in different lengths accordingly.

To be able to connect the solar modules and with the inverter, the fitters had to install each panel individually, which required a special effort from the team: “We have installed Kalzip systems before, but never on this scale. Placed on the standing seam of the previous profiled panel, around 11 installers had to hold the panel at an angle so that the electrician could connect the wires underneath,” explains Tobias Brohmann.

The dimension of the solar modules as a challenge on the construction side

Enough electricity for a whole village

But all the hard work paid off. The highest possible utilisation of solar panels was achieved. Except for a few centimetres of edge strips and at roof intersections, solar panels have been installed on the roof surfaces of a total of about 15,200 m2 over the entire area. A total of around 10,000 panels achieve an output of 1,138.5 kWp – an amount of energy to supply 100 one-family houses with electricity – and thus ensure sustainable and ecological energy generation.

 

About Kalzip
Kalzip sells and produces aluminium roof facade profiles for the areas of industrial construction, leisure facilities/sports facilities, transport and housing. The Kalzip Group employs 160 people worldwide and is represented in almost all regions of the world. Since October 2018, Kalzip has been a company of the Donges Group. Donges Group is a leading supplier of bridge and steel construction as well as roof and facade systems in Europe. The group consists of the brands Donges SteelTec GmbH, Flachdach- Technologie GmbH & Co. KG, Kalzip GmbH, Nordec OY and Norsilk SAS and employs around 1400 people in 14 countries.

 

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

Development of the German Air Traffic Control Campus

The German Air Traffic Control training centre in Kaufbeuren:
tradition and modernity brought into harmony

Since 2017, German Air Navigation Services (DFS) has not only provided training in the civil sector but has also taken over military air navigation services training in cooperation with the German Bundeswehr. The Kaufbeuren campus was expanded and converted to offer 60 to 80 trainees per year the best possible conditions for their courses.

The German Air Traffic Control campus in Kaufbeuren

State-of-the-art technology

The heart of the campus is the newly built training centre, where the basic and specialised training of trainees to become air traffic controllers and flight advisers takes place. In order to be perfectly prepared for the highly technical professional environment in which they will later be working, DFS offers state-of-the-art technology: Paperless and exclusively digital training materials are already standard, and the simulator rooms are impressively close to reality. The other training rooms also offer everything a technician’s heart could wish for in a modern training centre.

Here, the future air traffic controllers and flight advisors will find ideal training conditions

 

The challenge of transferring this contemporary and technically advanced working and learning from the inside to the building envelope was the task of the office Henn Architekten-Ingenieure from Munich. Their design of the training centre goes to extremes: the basic form of the building corpus with a gable roof, as can be found thousands of times in the surrounding Swabian towns and communities, forms the core of the design language. In contrast, there is a radical reduction, the design is limited purely to surface and structure and thus sets an exclamation mark.

Oriented towards the region and yet completely independent in its aesthetics

Reduction down to the last detail

What appears so simple at first glance only succeeds on closer examination thanks to many well thought-out details. The lowest floor with its continuous glass façades forms the base of the building, the concise gable roof corpus seems to float on it. Even on closer examination, there are no supporting columns to be found – the technical properties of the material make this possible. The rainwater drainage system is also perfectly integrated into the design and, as a functional element, does not destroy the basic concept. Hidden under the building envelope, they can ideally fulfil their task thanks to the visible surface of the profiles. The company Pröckl GmbH was responsible for the execution of the project.

Clear edges as far as the eye can see. They characterise the design by Henn Architekten-Ingenieure.

Seeing, but not being seen

The perforated profile of the Kalzip profiled sheets 65/400, which are used for both the façade and the roof, also provides another functional feature. They allow a view of the outside from the inside, whereas the view of the inside of the building from the outside is not possible due to the aluminium cladding and the façade behind it.

This is how light metal can seem. The perforated Kalzip profiles create a play of transparency.

 

About Kalzip
Kalzip sells and produces aluminium roof facade profiles for the areas of industrial construction, leisure facilities/sports facilities, transport and housing. The Kalzip Group employs 160 people worldwide and is represented in almost all regions of the world. Since October 2018, Kalzip has been a company of the Donges Group. Donges Group is a leading supplier of bridge and steel construction as well as roof and facade systems in Europe. The group consists of the brands Donges SteelTec GmbH, Flachdach- Technologie GmbH & Co. KG, Kalzip GmbH, Nordec OY and Norsilk SAS and employs around 1400 people in 14 countries.
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

Building of the Ajman-Kadyrow-Mosque

The Ajman-Kadyrow-Mosque in Chenya:
Russias most modern Mosque

 

Kalzip solves structural challenges

In May 2014, the Ajman Kadyrov Mosque in the city of Argun in Chechnya was ceremoniously opened. Kalzip also contributed to this celebration with its roof structures in high dimensions. The Ajman Kadyrov Mosque, also known as “Mother Heart”, is considered Russia’s first ultra-modern mosque.

The building site in Argun had enormous challenges for the construction to overcome

Traditional components, new interpretations

The architecture of the building is particularly striking: Instead of the classic square ground plan with dome and imperial spires, the mosque designed by the Turkish architect Deniz Jeyhun Baikan uses a modern formal language. The roof forms a hemisphere that appears to rise from the ground when viewed from the main entrance. Three other sides let daylight into the interior through large glass fronts and at the same time connect the main building with the three minarets.

In order to realise the architect’s visions, a well thought-out plan was needed. The special geometry of the building had to be taken into account, which led to an unsatisfactory result in the first attempt at a solution. The ornaments were to be projected onto the dome. Due to the geometry of the building, the model would have run in different places and been unrecognisable as such from the viewer’s perspective. But equipped with the appropriate software, Kalzip was first able to calculate a surface from the measurement of the roof from around 2,000 points, reflecting the points on the convex dome. The ornamental model was then transferred from the existing image file onto the surface created in this graphic and aligned in such a way that no distortions were created. In addition, the model enabled the necessary material to be prefabricated and delivered at the Kalzip factory in Koblenz for an exact fit.

The complex 3D-visualization of the dome surface with ornaments

From Rendering to implementation

To ensure a satisfactory result, some construction challenges had to be managed. For example, the unevenness of the concrete dome was levelled out to allow the use of Kalzip’s Flexikon substructure. The visible layer under the ornaments was laid with flat sheets from Kalzip, which were already coated in the factory with a “copper antique” colour.

Assembling of the gold-colored ornaments with substructure on the laid flat sheets 

Golden by day – colourful by night

Thanks to the complex construction, the oriental ornamentation is particularly effective regardless of the time of day. The gold-anodised aluminium panels with a matt surface gently reflect the daylight and invite visitors to linger. With the concealed LED lighting, the roof is illuminated at night underneath the ornaments in different colours, enhancing the three-dimensional effect. The heating system, which is also invisible, ensures unrestricted operation even in the cold winter months and avoids damage from sliding snow.

The LED-illuminated Ajman Kadyrov Mosque in the evening mood

 

About Kalzip
Kalzip sells and produces aluminium roof facade profiles for the areas of industrial construction, leisure facilities/sports facilities, transport and housing. The Kalzip Group employs 160 people worldwide and is represented in almost all regions of the world. Since October 2018, Kalzip has been a company of the Donges Group. Donges Group is a leading supplier of bridge and steel construction as well as roof and facade systems in Europe. The group consists of the brands Donges SteelTec GmbH, Flachdach- Technologie GmbH & Co. KG, Kalzip GmbH, Nordec OY and Norsilk SAS and employs around 1400 people in 14 countries.
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

The new building of Tenerife Airport has a Kalzip Standing seam roof

The Tenerife South Airport’s connection building is expected to increase the airport’s size by 50 per cent

In 2018 the Government of Tenerife decide to extend the Island’s Airport. For the amount of 53,9 million euros the new connection building was planned with Casadevall & Sayeras arquitectes commissioned to design the building. The new building will house, as a priority, security control filters and provide continuity from the gates to boarding lounges and the departure and arrival halls.

Kalzip is the specialist for airport roofs

In the past, architects have repeatedly relied on Kalzip for the planning of airport roofs. As a result, a certain know-how has developed at Kalzip over the years. This know-how was the key to success when it came to the tender for Tenerife Airport.

The curved roof, which shelters the entire interior space, is the main element of the project. It is composed of curved lattice beams and a light deck-type slab, complemented by the metallic finish of the roof based on aluminium standing seam Kalzip system, with a low reflective patina finish surface. The build-up utilises a double layer of rock wool insulation and Kalzip polyamide E clips to provide thermal and acoustic properties according to the project specification.

In the end over 11,750 sqm of Kalzip 65/333 in Kalzip AluPlusPatina Nature mill finish surface were installed on the new junction building.

Special design for a Junction Building

“We do not know of another passenger terminal in which a new ad hoc building has been designed basically to contain the security controls. We are talking about approximate dimensions of 150 meters long by 95 deep. Our proposal aims, by means of a soft design “gesture”, to encompass, cover, the entirety of the new space. We achieve this with an arc segment with a circumference of radius 150 meters. With this formal strategy, the façade surface is minimized, which we envisage entirely glazed. Thus, from the new departure lounges and the adjacent circulation space, it is possible to continue enjoying the marvellous maritime profile.” Said Dolors Sayeras, one of the projects leading architects.

Linear transverse skylights emphasize the curved character of the roof and direct passengers in their transit from the ground side to the air side, achieving a diaphanous and light interior space, diffusing the light evenly thanks to a semi-white and white false ceiling permeable to vision.

3D visual of the planned junction building. © Casadevall & Sayeras arquitectes.

Photo of the construction phase – The Kalzip sheets have already been installed.

About Kalzip

Kalzip is an international manufacturer of aluminium roof and facade systems. Producing in Germany, the company has a distribution network in Great Britain, France, Spain, Dubai, and India. Kalzip produces on modern, partly mobile roll-forming lines and can therefore offer high-quality, customer-specific roof systems for stadiums, sports halls, traffic structures, industrial buildings, commercial buildings, and residential areas. Kalzip provides a comprehensive range of products for both new buildings and renovation projects.

Kalzip has been a company of the Donges Group, the leading supplier of bridges, steel constructions, roof and façade systems in Europe, since 2018. The Group, employing 1300 people worldwide, has the companies Donges SteelTec GmbH, FDT Flachdach Technologie GmbH, Kalzip GmbH, NORDEC OY, and Norsilk SAS under its roof.

Contact

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

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

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