KALZIP – „Denmark Hill Station“

Europe’s first carbon-free train station

KALZIP® HELPS DELIVER FIRST CARBON POSITIVE STATION UPGRADE

The construction of a new entrance, cycle hub and platform canopies at a popular south London train station is being hailed as the network’s first ‘Carbon Positive’ project, with arrays of integrated AluPlusSolar PV panels being installed as part of a roofing package featuring products from the Kalzip® range. The new facilities at Denmark Hill Station are now operational and the project has since been recognised as Best Roof under 1500m2 at the annual Kalzip® Awards.

A crucial redevelopment

The £7.5 million Denmark Hill project has been led by BAM Nuttall Ltd with Invvu Construction Consulting being responsible for the design and project management on behalf of Network Rail. London based roofing contractor, Gribben Solar Roofing was the specialist installer of the AluPlusSolar roofs which total 260m2 across three platform canopies, the station building and an access ramp: generating an output of 35 kWp.

 

Work began on site in September 2020 with the construction of a retaining wall alongside Platform 4, ready for the installation of the new canopies on Platforms 2, 3 and 4 during a Christmas possession – requiring Gribben Solar Roofing and its suppliers to complete this phase of the work in a very tight time period. All of the materials were delivered to site a week in advance of the Christmas deadline. Crucially, the redevelopment of the station facilities, and its transformation in terms of energy performance has had to fully respect the heritage status of the original Victorian structures.

Versatility and speed

The design work was carried out in close consultation with the local planning authorities and the listed building authorities. The architects had specified Kalzip® on a number of projects before and noted that the Kalzip® AluPlusSolar system stands out as the most favoured system, because it’s so lightweight, versatile in terms of output and so quick to install.

 

Low maintenance and whole life cost

The Kalzip® AluPlusSolar profile can be produced in the full range of RAL colours as well as a variety of forms, including concave and convex to suit a wide variety of roof structures. Also being integrated and low in weight, they therefore offer architects and engineers greater flexibility compared to conventional PV arrays while delivering similar power output. With very low future maintenance implications, this all results in a far lower whole-life cost for a development.

 

About Kalzip

Kalzip sells and produces aluminium roof and 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.

You inspire we deliver. 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

ACOUSTIC PERFORMANCE IN SCHOOLS

In contrast to many other sectors, there is detailed acoustic performance guidance for educational buildings. Here Adrian Whitefoot, Technical Services Manager at Kalzip, looks at the requirements of Building Bulletin 93 and how the correct specification of building envelope solutions can help achieve these.

Ensuring good acoustics and minimising levels of noise in school environments is essential. A growing body of evidence has shown the impact of noise on academic performance and cognitive development. For example, a recent study from the Barcelona Institute for Global Health found that higher levels of traffic noise caused slower development in memory and attention among children aged 7 to 10.


A quiet place for children gives the best surrounding for an ideal learning environment. (© KGM Roofing)

The main source of legislation for acoustics is Approved Document E of the Building Regulations, and in particular section E4, which specifically relates to acoustics in schools. For guidance on achieving the required acoustic conditions, Approved Document E refers to Building Bulletin 93 (BB93), the guide for acoustic design published by the Department for Education. While section E4 of the Building Regulations does not apply to colleges and universities, the acoustic recommendations provided in BB93 may also be desirable in these environments and therefore can provide a design standard.

Building Bulletin 93 sets limits for the level of ambient noise in rooms and spaces within a school based on how it is used. For example, the limit in classrooms and general teaching areas in primary and secondary schools, including those used for music and drama, is 35dB LAeq,30mins for new buildings and 40dB LAeq,30mins for refurbished buildings. Higher limits are set for sports halls, dance studios and swimming pools, while lower limits are given for teaching spaces for students with special hearing and communication needs.

Noise pollution can come from a wide range of sources, especially in school environments. External sources include aircraft, traffic, rain impact, noise from playgrounds and outdoor sports, and sound transmitted from nearby school buildings. Internally, impact and airborne sound from students and teaching activities can be transferred between floors and through walls.

Noise reduction can be easily achieved with the use of the Kalzip Accoustic roof.

There are a number of measures that can be implemented in the specification of building envelope systems to improve the acoustic performance of both new build and refurbishment projects. Different insulation materials will have varying acoustic properties but one of the most effective methods for increasing sound insulation of roofing and facades is to increase the mass of the system. Its performance is governed by the ‘mass law’, which states that the sound insulation of a solid element will increase by approximately 5 dB per doubling of mass. With metal roofing systems this can be achieved by adding different densities and thicknesses of mineral wool or rigid slab insulation. Alternatively, for higher performance scenarios, various thicknesses of cementitious board can be introduced as part of the façade or roof build up. As a built-up solution, aluminium roofing and façade systems offer this flexibility to tailor the specification to meet the acoustic requirements.

In addition, acoustic and dampening membranes can also be used to increase sound insulation. For example, to reduce the sound of rain noise, an anti-drumming membrane can be bonded to the underside of an aluminium roofing system to achieve approximately a 6 dB reduction in sound intensity.

Controlling sound within teaching spaces must also be considered carefully when designing educational facilities. Excessive sound reverberation within a classroom can distort speech and make teaching and communication difficult. Building Bulletin 93 provides guidance on acceptable reverberation times (RT) depending on the intended use of the space. For example, for a new build nursery room or general purpose primary school classroom it is ≤ 0.6 seconds. In contrast, the same type of teaching space in a secondary school would only need to achieve a RT of ≤ 0.8 seconds. The correct specification of roofing and façade systems can help to minimise excessive reverberation as well. Perforated liners and structural decks can be introduced as part of the roof build-up to diffuse sound where improved sound absorption performance is required.

The Kalzip Accoustic roof is based on the proven Kalzip technology with the same flexibility.

Achieving the optimum specification to ensure acoustic targets are met alongside all other building performance and design requirements can be complex. That is why it is important to partner with a roofing and façade system manufacturer that can offer a wide array of solutions as well as technical support services. Leading manufacturers, such as Kalzip, will be able to use laboratory test reports and data from previous projects to provide specification guidance and assess the performance of a proposed system.

Ensuring the acoustic performance of school buildings is essential to provide an environment that supports learning and development. Building Bulletin 93 provides detailed guidelines, which the correct specification of building envelope materials and systems can help achieve.

KALZIP – „Subway in Grossreuth Nuremberg“

The sky beneath the earth.

Usually, you have to look at the sky to see Kalzip’s work, but it’s a different story with the new terminus of the U3 underground line in Nuremberg.

As part of urban development framework planning, the Nuremberg district of Großreuth near Schweinau is to be redensified in the long term – this process began with the construction of an underground station, which was put into operation at the end of 2020. Upon entering the station, the visitor immediately notices that this station is different compared to other underground stations. Daylight reaches the platform through skylights, and lighting draws attention to the station in the evening. No dirty tiles in various shapes and formats are to be found here, it is not dark here – a 750m2 blue sky covered with individual clouds greets the passengers here.

Divine installation technique and forward-thinking planning.

Due to the fact that the motif consists of real, high-resolution photographs, the special challenge in this project was to develop a detailed installation plan with position numbers that would enable the executing company to install the aluminium profile panels, which had been coated in advance, without any confusion. During the fabrication of the pattern for sampling, it was determined that the side edges of the aluminium profiles also needed to be coated with the motif so that the joints blended into the overall appearance as inconspicuously as possible. A mapping process was then used to create, record, and catalogue the exact coating plan with a slight overlap.

To compensate for inequalities and keep the overall construction low, grid click rails were installed, which also allow for easy replacement of damaged or soiled profiled panels. Given that local fire protection specifications also had to be complied with, all plastic parts and inlays were dispensed with during the installation of the profiled panels, and the suction effect of a train passing by at high speed was also taken into account.

Kalzip has thus once again completed a future-oriented and trend-setting construction project which, due to its sustainable design, will be enjoyed by passengers for a long time to come and which can serve as a successful example of future-oriented urban planning.

You inspire we deliver. 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 – „Predikherenkloster in Mechelen“

An abbey in a new guise

In 1652, the Dominican monks, the Predikheren, based in Mechelen, Belgium, were allowed to build a monastery and a small chapel. In the 18th century, the chapel was then expanded into a large church, which still adjoins the former monastery walls. In the meantime, the heritage-listed building belongs to the city. With a large-scale renovation, a new chapter is now beginning for the 370-year-old building by combining classic appearance, new use, and sustainable energy generation via a solar roof.

 

Monument protection requirements and photovoltaics…is that possible?

A major challenge in the renovation and modernisation of historic buildings is preserving the historic building structures and fulfilling monument protection requirements. The church was in a desolate condition. Damage to the façade and roofing allowed water to penetrate, making the building unstable. In order to meet the requirements for the preservation of historical monuments, a metal standing seam roofing was applied, which makes it possible to install a photovoltaic system in a modular way without detracting from the visual impact of the historical building. The roof-integrated AluPlusSolar system from KALZIP meets and exceeds exactly these requirements, as the very flat solar modules are already glued on at the factory and do not have to be subsequently clamped onto the roof.

The masonry and the façade were cleaned and restored, but for the roofing it was therefore decided to replace it all over. As the sensitive vaults of the church were located directly under the roof truss construction, the roof truss was first reinforced with new wooden beams and insulated so that the building was protected from rain during the construction work. After skilled craftsmen had removed the old roof except for the still intact, metal roof truss, the system-related composite clips were first installed on the roof and a mineral insulation layer was applied to insulate the building sustainably.

In the final step, the profiled panels were laid, which were mounted on the south-facing roof surface by the installers with the pre-installed standing seam profiles of the solar modules.

 

Unobtrusive, powerful and weatherproof.

The installed AluPlusSolar profiled panels are coated with AluPlusZinc Dark so that they blend inconspicuously into the overall appearance of the 500m2 roof area. A total of 180 highly efficient solar modules were installed on an area of 160m2, which provide an output of approximately 21.6kWp. As the Kalzip 50/444 profile used for the modules is connected on the back, a high level of weather protection is guaranteed throughout the year, an important point for historical renovation projects.

The aluminium profile is also significantly lighter than other roof coverings, which makes handling and processing much easier. The new robe is thus not only sustainable, almost maintenance-free and efficient – it also ensures that the old Predikherenklooster will remain a silent witness to time for us and future generations for a long time to come.

 

You inspire we deliver. 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 – „Pavilion Scheveningen“

Architecture on the Scheveningen waterfront

The Vision.

Scheveningen is an internationally known vacation destination and not only the largest but also the best frequented seaside resort of the Netherlands. Its endless beaches and the spectacular redesign of the beach boulevard in 2015 make this town worth a visit throughout the year. At this special place, the Dutch architect Wim de Bruijn has designed a unique pavilion, whose design and functionality has no equal. It opened to the public in 2021.

The impressive building at the end of Noordboulevard’s beachfront combines ‘the elegant shapes of the Morales-Boulevard with waves and shells at the beach, all together frozen still in a white composition of glass and steel’ describes de Bruijn of the new boulevard’s icon. At first, the roof shape of the wire frame model seemed to be impossible to construct but perfect teamwork by many different specialists made it possible.

Engineering:

The foundation of the exceptional 3D-shaped roof construction is Kalzip’s X-tail profile sheet. A vertically adjustable pipe construction made it possible to follow the designated contours of the standing seam roof cladding. This led to all the profiled sheets having different measurements, so the experts on site had to follow a strict installation plan which was provided by Kalzip. The steel substructure of the standing seam roof cladding prevents noise pollution from penetrating outwards and adapts to the wind movement on site

That was a very important subject to consider beforehand, since the pavilion is located precisely at the noise location of beachfront and boulevard (from stone to dune). The spectacular round shape and the aluminum roof cladding make this building an impressive eyecatcher from every direction.

Sustainability:

The three-storey building consists of a basement, a main floor with a terrace and a first floor with another huge terrace, that had to be ‘cut off’ the main roof to gain an exclusive elevated view onto the beach and the boulevard. But not only from the terrace you can enjoy the spectacular view, also through the insulated glass windows from the interior of the house, the beach feels as close as it gets. Daylight illuminates the main floor almost self-sustaining and contributes to the fulfilment of de Bruijn’s vision.

The pavilion has an excellent thermal insulation value (U-value=6), based on the combination of PIR and fiberglass systems that were used insulating the roof construction. The long-lasting aluminum consists almost fully of recycled materials and classifies as sustainable metal. The Noordboulevard covers most of its energy demand per solar panels which are also connected to the pavilion.

Teamwork:

To make de Bruijn’s vision a reality, the technical crew, Felspartner B.V. (Kalzip PremiumPartner) and Kalzip had to work as a synchronized team from the very beginning. It was crucial, that every specialist could bring in his experience as they began working with 3D models. A construction site at beachfront always brings its own challenges that could only be handled with a perfectly organized and well attuned team of experts. Teamwork, combined with skilled craftsmanship and communication at eye level led to an innovative and sustainable building, that blends in in its sensitive surroundings, connecting the elements of ocean, beach and water trough state of the art architecture and efficiency.

Kalzip – There’s no way to do it better.

 

 

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 – „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