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.
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.
Yannick de Beauregard
August-Horch-Str. 20 – 22
Phone: +49 261 9834 0
Fax: +49 261 9834 100