Uniclass L5221:P4:D71/2 CI/SfB 71/72 (4-) Xh

Creating the learning environments of the future

Creating the learning environments of the future Credits clockwise from top: University of Central Lancashire, Preston Howells Junior School, Cardiff University of Central Lancashire, Preston Kidderminster College, Worcestershire What is Kalzip? Kalzip is the world’s leading “Each time we specify a Kalzip standing aluminium standing seam roof seam roof we get the perfect job first time. system. During the past 40 years more than 70 million square metres With alternative standing seams we of Kalzip have been installed have to revisit sites time and time again. around the world, providing The difference in quality is not just external envelope solutions the material but in the installation for every type of building. and Kalzip’s engineered details.” Alastair Mallett, Hunter and Partners, Architects Kalzip is a precision engineered, multi-component system with proven durability, high performance and low maintenance. All systems are precisely tailored to the individual project, delivering outstanding corrosion resistance, noise absorption, thermal performance, condensation control, wind loading and spanability. All systems are installed by approved, highly trained Teamkal contractors.

In addition to aluminium, materials available include zinc, stainless steel and copper. Other alternatives include photovoltaics, Nature Roof and offsite systems. Clockwise from top: Kalzip is a part of Woodstone Primary School, Leicester (x3) Limited Carr Manor High School, Leeds “ The choice of Kalzip was ideal due to the shape of the roof, in particular the curved, tapered sheets. Working closely with Kalzip’s designers we produced an excellent roof envelope.” Mick Papworth, Managing Director KGM Roofing Ltd on Woodstone Primary School, Leicester Challenging times More, different, better Meeting the challenge

The school of the future is going The Kalzip range of standing seam to be radically different from the and other Government initiatives roofing and cladding systems is traditional model. are creating unprecedented ideally equipped to help you meet are history, fast being replaced by opportunities for educational this complex set of challenges. a new vision: beautiful, sustainable, construction throughout the UK. durable, transformational spaces, Yet in CABE’s 2006 Schools Audit, Our technical, design and shared with the surrounding 50% of buildings completed in installation expertise leads the community, ICT-friendly, suffused the previous 5 years were judged world. Our bespoke systems with natural light; an ideal home either or , with only offer maximum design freedom. for personalised learning. This is 4% rated . We are ideally placed to help you a challenging brief, and many win tenders and create landmark schools, colleges and academies. more challenges surround it. As a result, commissioning bodies such as Local Education The maintenance requirements Partnerships are under intense for Kalzip roof systems are Government pressure to be much practically nil, they are BBA more demanding. Regulations certified and have a minimum have also never been stricter. life expectancy of forty years. BREEAM, SEAM and CABE are just three of the bodies demanding A long, life enhancing, exceptional standards. And PFI problem-free future is assured, Clockwise from top: arrangements have changed the exceeding the DfES expectation Ogmore Vale Primary School, Bridgend of a thirty year lifespan Charleston Primary School, Dundee financial rules too – whole life for “flat” roofs. Northampton Centre for Learning costs and best value now matter Howells Junior School, Cardiff more than capital expenditure. Flat being defined as “anything under 10 degrees” and Kalzip roofs can be installed to a minimum pitch of 1.5 degrees.

Optimum thermal and A mass improved Kalzip standing Councillor Sheila Newman, educational performance seam roof, designed to maximise City Council’s thermal and acoustic performance Executive Member for Children’s Gorton Education Village, and minimise energy consumption, Services, adds: “The new campus Manchester is an integral part of this eight will offer fantastic facilities for acre, £25.4 million community pupils and the local community Architects campus in East Manchester. and will do much to help us further Ellis Williams Architects Ltd raise standards of attainment and Contractor A joint venture between improve life chances for young Laing O’ Rourke Construction North Manchester City Council, people in the Gorton area.” Teamkal contractor FK Roofing Services Ltd New East Manchester Ltd and Partnership for Schools, this Revision is the first Building Schools for the Future project in the � Demanding thermal performance North of England. standards for schools and colleges are set by ADL2A Bringing together Cedar Mount and Melland Special Education � BREEAM and SEAM set Needs High Schools, the building even higher standards features a two storey 100 metre long internal “street.” Facilities � Kalzip is inherently shared by both schools and ADL2A compliant the local community include a sports hall, library, ICT facilities � Early involvement of our and a medical suite offering technical team makes the highest physiotherapy and hydrotherapy. BREEAM and other bodies’ Tom Russell, Chief Executive of standards achievable New East Manchester Ltd described the Education Village as a “state of the art building” offering a “21st century learning environment.”

Exemplary behaviour Revision

In 2005 CABE published � Building Schools for the Future to promote design is up and running quality. It is no coincidence that two out of the seven case studies � This and other initiatives mean featured as exemplars are that lots of educational building schools with Kalzip roofs. is going to be happening throughout the UK More than 1.9 million square metres of Kalzip have been � Local authorities typically team-up installed on 1,000 school projects, with a PFI consortium or form a proof that Kalzip and education Local Education Partnership are perfect partners. Involving our design and � They are under intense technical expertise at the earliest Government pressure to create a possible stage can enable very different kind of school architects and contractors to meet the sustainability and other � Imaginative, sustainable, standards nowadays required educationally aware design by commissioning bodies. is the key to winning bids

Clockwise from top: � The extended school is now the Kalzip AluPlusSolar norm. Kalzip is the roofing and Graeme High School, Falkirk cladding system that can provide the quality, flexibility, longevity and sustainability you need to bid for projects and deliver them successfully

� Early Kalzip involvement pays dividends – and not only in terms of time and money saved

Kalzip is Glasgow’s Having set out to provide its The bids were successful and primary resource citizens with “the best schools in Grainger Building Services Ltd the world” in 2000, Glasgow City were soon hard at work on Haghill Haghill Park Primary School, Council launched a programme to and St Benedict’s Primary Schools, St. Benedict’s Primary School, completely overhaul its provision while McKay Roofing Ltd were Glasgow of pre-12 education in 2002. responsible for four more primary schools incorporating Kalzip roofing Architects City Building (Glasgow) LLP For Phase 1 of this ambitious systems in Phases 2 and 3. Contractor scheme the council invited “best City Building (Glasgow) LLP value” bids for two schools from the So successful were these projects Teamkal Contractor council’s in-house Building Services that when the £70 million Phase 4 Grainger Building Services Ltd department. The chosen design was awarded to City Building included an aluminium standing (Glasgow) LLP, the arm’s length seam roof, and Building Services company set up to succeed the immediately contacted Kalzip. Building Services department, all 11 new schools were designed to This was no surprise, as the have Kalzip roofs installed by Kalzip team had already been Miller Roofing Ltd. successfully involved in more than 20 PPP/PFI school Even more recently, Kalzip building projects throughout received the global order for Central Scotland. Clarkston Primary School, which No other supplier could offer means that all 17 North Lanarkshire the unbeatable combination PPP schools will have Kalzip of durable clad alloy material, roofs. The total quantity of Kalzip outstanding long-term, low will be around 72,000 square maintenance performance, metres. Grainger Building Services and the presence of at least Ltd and McKay Roofing Ltd have six highly trained Teamkal completed these projects with contractors in the region. Grainger Building Services Ltd being responsible for the majority. “ With the Local Education Partnership and ICT, people are thinking about learning outcomes rather than just buildings. This is a huge change.” Quote from Partnership for Schools research project into Local Authority and Private Bidder attitudes, March 2006 The school in the community Whatever the size and geometry of the building it will be designed, “ Schools are dissolving manufactured and installed into communities, with precision. communities are flocking into schools.” Better design brings better results Professor Stephen Heppell Foreword to the Building Schools Exhibition & Conference Guide, Local authorities are being February 2006 strongly urged to commission schools that use design to Kalzip is the ideal system for the enhance education, prompted rapidly growing concept of the by the wake-up call of the recent - a building that Audit Commission Report which combines community facilities concluded that with its educational role.

Today’s school is as likely to “There is a probable link between incorporate a community theatre the quality of school buildings or a public library as classrooms. and educational attainment that is To do so it must inevitably be a not being adequately reflected in one-off design. Equally important school procurement strategies.” is its need to be reliable, long lasting and low maintenance, because it is going to be used The case histories featured around the clock, 7 days a week. throughout this book show how Kalzip’s flexibility enables each With Kalzip systems each unique unique design to create optimum set of problems can be met with learning conditions. a unique solution. Outstanding corrosion resistance, noise

absorption, thermal efficiency Clockwise from top: and condensation control Backwell High School, (Designed by GSS Architecture) (x2) come as standard. Kidderminster College, Worcestershire

Top marks for speed The architects’ choice of a Kalzip roof system helped to ensure timely Middleton St George completion and Part L compliance, Community School, as well as making possible the Darlington, County Durham sweeping curves that make the building so impressive. Architects Silvester Ashton Partnership Kalzip also offered the flexibility Contractor to bring distinctive detailing to Dorin Construction Ltd the fascia, soffit and verge areas, Teamkal Contractor and problem-free interfacing Chemplas Ltd with the building’s traditional masonry construction. As the name suggests, this village primary school on the outskirts of Darlington was designed to share its sports facilities, large hall and multi-use games area with the surrounding community.

The 315-place school’s Victorian predecessor had been burnt down by vandals, so a speedy replacement was essential to minimise the time pupils and teachers would have to spend in temporary accommodation. Accessible, The solution, the centre’s Revision sustainable, visible sophisticated Kalzip structural deck roofing system, provides a � Tomorrow’s school will typically Levenshulme High School striking visual contrast to the include facilities shared with the Health and Fitness traditional red brick of the existing surrounding community Centre, Manchester school buildings. The renewable energy produced from sunlight by � Design and construction quality Architects the integrated 6.7kW AluPlusSolar have proven ability to enhance Walker Simpson Architects Ltd photovoltaic system amounts to educational standards Contractor around 4,500 kWh of clean electricity AMEC Capital Projects per year, and is estimated to save � Commissioning bodies know this Teamkal contractor 2.5 tonnes of CO per annum. Richmond Cladding Services Ltd 2 and judge proposals accordingly

The power is used to run lighting � For the new Health and Fitness Every Kalzip system is bespoke, and electrical equipment within Centre at this south Manchester easily accommodating any type of the centre. Any surplus electricity girls’ comprehensive school, the community facility and permitting is fed back into the National Grid, brief to architects Walker Simpson education enhancing design with the school’s power bill was clear but daunting. reduced accordingly.

Design a facility that could be fully shared with the surrounding community. Include a main hall constructed to Sport England standards. Add fitness and sports therapy suites, changing rooms, classrooms and office accommodation. Put it all under a single roof. And make it truly and visibly sustainable. “ The building has been very well received. The Kalzip system allows a flat and curved roof element and enabled the building to be built efficiently according to the design.They interface very well with the other materials.” John Holroyd, Walker Simpson Architects Ltd Educated installation Teamkal training is Building schools lifelong learning is a team game Installation by an approved Teamkal contractor is as integral Teamkal education is a continual Kalzip technical team work closely to every Kalzip system as the process, CITB-approved and with architects, main contractors materials that go into it. Since conducted at the largest in-house and Teamkal installers, tailoring the partnership was established training facility in the industry. specifications precisely to the in 1995 it has grown into the Kalzip’s installers are constantly design including calculations, most highly regarded network in assessed on business and financial assembly instructions and technical the industry, responsible for as well as technical standards. advice. A comprehensive technical world-famous and award-winning support service is available to the projects such as Daniel Libeskind’s Exam time entire project team at every stage. Imperial War Museum North in With extensive roofing and cladding Manchester, the GCHQ “doughnut” Rigorous inspection completes expertise and advanced CAD in , and Richard Rogers the picture. Our BBA certification equipment, the most economical Partnership’s Welsh National covers the entire Kalzip roof and sustainable solution to even Assembly in Cardiff; hundreds system and we have a team of the most complex design can of successful schools and other dedicated site inspectors who be swiftly achieved. academic buildings too. take sole responsibility for ensuring superlative workmanship Architects, contractors and clients and compliant installation. are under unprecedented pressure to set exacting standards. Kalzip and Teamkal together help to provide the cohesive supply chain and culture that delivers those Opposite: standards without compromise. The Priory, Great Yarmouth

Kalzip helps Leeds roofs, providing both outstanding lead the PFI league technical performance and the clean modern lines required to Carr Manor High School, Leeds complement designs using through colour render, architectural masonry Architects and rainscreen cladding. Seymour Harris Architects, A key objective of consortium Watson Batty Architects partners, Investors in the Main contractors Community, was “to allow staff Carillion, Wates to focus on pupil needs and Teamkal contractors Cover Structure Ltd raising standards, rather than on buildings and operational issues.” Kalzip is proving integral to the The case for choosing long-life, success of two separate PFI low maintenance Kalzip schemes, together bringing no less systems could hardly be than new or refurbished more succinctly made. schools to the city of Leeds, which now has more PFI credits The £36 million Education than any other local authority. Leeds PFI, involving Watson Batty Architects and Wates, is responsible for a mix of “Longevity and freedom ten new build or refurbished from maintenance compared primary schools. to normal metal roofs.” To maintain consistently high Steven Horsman, Watson Batty Architects standards a modular approach was adopted using a standard The £90 million Leeds Combined palette of materials. In the words Schools PFI includes four of architect Steven Horsman from secondary schools plus one joint Watson Batty, Kalzip was chosen campus housing a secondary and for all ten roofs because of its a primary school – all designed “longevity and freedom from by Seymour Harris Architects maintenance compared to with Carillion as main contractor. normal metal roofs.” All five projects feature Kalzip

A lesson in completing on Yet despite the project’s time and within budget complexity, Teamkal contractors Lakesmere Ltd handed the Walsall City Academy completed project over on time and within budget. Architects Barnsley, Hewett and Mallinson Revision Contractor Bowmer and Kirkland Ltd � Every Kalzip system is installed Teamkal Contractor Lakesmere Ltd by an approved, highly trained Teamkal contractor One of the first of the new generation of City Academies to � Our technical team and Teamkal open, Walsall City Academy’s contractors integrate seamlessly 7,000 square metre Kalzip roof into the project team features a combination of 3,000 square metres of clad alloy stucco � Expert advice and design input embossed Kalzip straight sheets are freely available at every stage and 4,000 square metres of roll formed tapered sheets – � Rigorous inspection is integral creating an elaborate roof design, to every Kalzip system dominated by an imposing rotunda, and delivering Kalzip’s customary long, maintenance free lifespan.

The Kalzip team liaised closely with the Walsall City Academy project team to create an integrated Kalzip system that met the required thermal and acoustic performance standards cost-effectively without compromising the aesthetics.

Sound thinking In locations with a great deal enhances learning of external noise, schools near railway lines or airports for Acoustic performance is widely instance, systems incorporating recognised as the single most high density Kalzip board have led influential factor in creating to recorded sound reduction rates optimum learning conditions. of between 33dB and 52dB. All newly built or refurbished LEA maintained and independent Nature study schools are required to comply with BB93 Section 1. There is the further option of a In over 120 independent tests Kalzip Nature Roof. The sedum conducted worldwide, and on and vegetation don’t only look numerous buildings across all beautiful and enhance the applications, Kalzip systems environment, they also add have proved their ability to mass to the Kalzip system, meet and go far beyond creating dB reductions. the BB93 criteria. Clockwise from top: Absorbing Ingleby Mill Primary School, Stockton-on-Tees

Kalzip roof can meet a variety of acoustic performance requirements by incorporating high-density insulation, acoustic boards and/or flexible membranes. Perforating the metal liner sheet and adding a “soft” material can also enhance sound absorption.

A standard insulated Kalzip roof system with a steel trapezoidal liner will have an approximate weighted sound reduction (Rw) of 36dB.

BB93 and budget All three schools were completed William Penn is a 2,600 square compliant during 2007. Wates were then metres replacement new build contracted to maintain and operate primary school constructed on the Beechwood, Arbour Vale the facilities for a period of 28 years. existing site to accommodate 420 and William Penn Schools, The need for roofs that will provide pupils with 52 nursery places. reliable, low maintenance service for such a long period was the Crucially, both Beechwood Architects determining factor in the final and William Penn remained fully Architects Co-partnership PFI consortium led by Wates Construction decision to go with Kalzip. operational throughout the Teamkal contractor construction work. Prater Limited Beechwood and Arbour Vale schools occupy the same site, Revision Kalzip was the architects’ first with separate entrances and choice for the roofing system on identities but some shared � Acoustic performance is the this ambitious £44 million scheme facilities. Beechwood is a new single most crucial difference to build three brand new schools build replacement on the existing a building can make to and associated community facilities site for an 11,700 square metres educational achievement for the Borough of Slough. secondary school with 750 pupils aged 11–16 and 150 post-16 � BB93 Part 1 compliance ACP’s early involvement of the places. Arbour Vale is a school is obligatory Kalzip technical team proved for children with special needs crucial. Their expertise and advice incorporating a residential unit � Kalzip offers outstanding acoustic helped the consortium to comply for young people with autism. standards – proven in over with the exacting BB93 standard 120 tests conducted worldwide for acoustic performance. The shared site will also include Ingenuity and flexibility also sport and leisure facilities including � Kalzip provide comprehensive helped to meet the challenging a 25 metre swimming pool, with U-value calculations budgetary requirements, revising community access outside school the original specifications without hours, plus adult learning facilities � Kalzip Nature Roofs have acoustic compromising either the aesthetics and a Professional Development as well as environmental benefits – tapered roofs with curved Centre for Slough teachers and fascias – or BB93 compliance. other school staff. QS pressure to switch to a less reliable roofing system was successfully resisted as a result.

The heat is on Inherently compliant

Approved Document L2A of the In this increasingly demanding Building Regulations was updated regulatory climate, it’s good to in 2006 to demand a reduction in know that the Kalzip system is

the annual CO2 emissions rate inherently ADL2A compliant. of at least 23%. Designed, manufactured, installed and inspected to minimise According to the DfES document U-values, ensure insulation continuity, prevent thermal bridging and control condensation. , the design U-values for roofs contribute Kalzip roofing and cladding towards this improvement and systems have also been shown will typically range between repeatedly to achieve excellent 0.20 and 0.18 W/m2K. air tightness figures, with attention to detail at the To gain the coveted highest interfaces especially critical. BREEAM Schools 2006 rating a Once you have commissioned building needs to demonstrate a a Kalzip system the specified 70% improvement in the predicted thermal performance of the Building CO2 Emissions Rate (BER) roof is assured, because we over the Target CO2 Emissions supply every component, Rate (TER) detailed in ADL2A. including the insulation and vapour control layers, and arrange installation by an approved Teamkal contractor.

Clockwise from top: Horsenden Primary School, Ealing (x2) Lower Wortley Primary School, Leeds

“ The product has proven itself in defeating malicious attacks from intruders and vandals on a number of buildings. We are pleased the product can also accomodate some of the more adventurous styles our design partners are incorporating.” Alistair Burns, Team Leader, Corporate Technical Services Group, Manchester City Council Target zero Infinitely recyclable Aluminium’s lightness also means that fewer building materials are In April 2007 the then Education Kalzip’s main material, aluminium, required for the supporting Secretary Alan Johnson announced is perhaps the world’s most structure. And the entire Kalzip the Government’s commitment sustainable building fabric. Earth’s system can be recycled at the to create 2,000 carbon neutral third most abundant element, it is end of the building’s life. schools in England by 2017. so recyclable that almost three quarters of all the aluminium that Clockwise from top: That’s a demanding target, given has ever been produced is still Goldsmiths College, London (x3) Cambridge University Plant that schools currently emit an in use today. Growth Facility estimated 10 million tonnes of University of East London CO2 per year, amounting to 15% And when, after a long and of all public sector emissions. problem-free life, Kalzip aluminium sheets are dismantled, they can Sustainability is already a key be recycled again with no loss factor in the assessment of bids of quality or volume. The process for new school buildings. The uses 95% less energy than primary evaluation production, preventing an estimated criteria make sustainability 80 million tonnes of greenhouse an important part of any gas emissions per year globally. bid proposal. And of course because aluminium is so easy to recycle, it has Sustainable Kalzip significant scrap value.

Such pressures mean that sustainability’s importance to bid success will continue to increase “Bidders are requested to provide detailed from now on. From AluPlusSolar statements clarifying their approach to and SolarClad to Nature Roof, environmental management, environmental Kalzip offers a range of solutions services strategy, energy strategy and that are ideal for meeting the demanding sustainability BREEAM. Sustainability features can requirements of local authorities and should be used as learning tools.” and their partners. The Partnership for Schools evaluation criteria

Sustainability, All this and security too, because sensitivity, security this is not only a college, but also a military establishment that provides Defence 6th Form residence for 6th form students College, Loughborough who have been selected for officer training in the armed forces. Architects H L M Architects The architects’ solution involved Contractor a combination of Kalzip aluminium Project Services Ltd standing seam roofing and Teamkal contractor Nature Roof. Hi-Spec Cladding and Roofing Ltd

The new college is located next The brief for this relocated to the Grade 2 listed Beamanor boarding college required an Hall just outside Loughborough. excellent SEAM (Schools Simple, crisp eaves offset textured Environmental Assessment blockwork and cedar cladding Method) rating, which called for in the resulting design, which optimum natural ventilation and combines environmental sensitivity daylighting, high thermal mass, with a modern campus feel. green roofs and energy conscious fittings. The sedum roofs play an “The brief required an excellent SEAM rating integral part in the building’s which was met through the various aspects of environmental performance as well as its aesthetics. Gratifyingly, the design, including natural ventilation, high the design was warmly supported thermal mass, green roofs, energy conscious within the village and by the fittings and high daylighting factors.” . Lucy Plumridge, Regional Director, H L M Architects Sheffield on Defence 6th Form College, Loughborough

The generation game As demanded by the PfS criteria, the Kalzip PV system also doubles Sandbrook Community as a learning resource. A display Primary School, Rochdale panel in the foyer contributes to the children’s science curriculum by Architects indicating the amount of electricity The Impact Partnership being generated at that moment, Contractor the total wattage generated to Birse Build Ltd date and the amount of CO2 this Teamkal contractor has prevented being emitted. Richmond Cladding Services Ltd

This new £6 million Community Revision Primary School is a fine example � The Government is now both of sustainability in education committed to building not and of the , just sustainable but carbon providing out of hours activities neutral schools for children and adult learning facilities for the local community. � Sustainability is one of the key factors upon which bids To reduce its carbon footprint the for new educational building design incorporates naturally day projects are assessed lit spaces, a solar hot water system and a Kalzip AluPlusSolar integrated � Kalzip is made from highly photovoltaic roof system. sustainable aluminium

The factory laminated PV panels � It offers a variety of solutions are fixed onto an impressive such as photovoltaic panels barrel-vaulted 215 square metre which can bring carbon section of the roof covering the neutrality within reach assembly hall, just part of a 3,100 square metre Kalzip standing seam system – all, of course, constructed in sustainable aluminium. “ We specified Kalzip for Sandbrook because it is a good quality system that is suitable for low pitches, satisfies all performance requirements and enables fast, early completion.” John Case, The Impact Partnership Environmental beacons Nature Roof grows on you

The Government has called for Kalzip’s advanced green roof schools to be system provides measurable implying that the buildings environmental benefits and is should not just sustainable, a perfect way to maximise the but to be sustainable. already considerable green Add the target of 2,000 carbon credentials of the standard neutral schools (in England Kalzip system. alone) by 2017 and the case for considering photovoltaic In Nature Roof Kalzip is systems and green roof solutions covered with low growing, self becomes even stronger. regenerating, drought resistant plant cover. As well as creating Kalzip are innovative pioneers a blaze of colour on the rooftop, in both fields. it generates a healthy, child-friendly The generation game micro-climate around the building, locking up airborne pollutants, and dramatically improving Two PV systems have been air quality. introduced to the Kalzip range, adding the ability to generate Nature Roof also soaks up electricity from sunlight to all rainwater, releasing it gradually the standard Kalzip benefits. to reduce the strain on ground drainage and help to prevent AluPlusSolar is a fully integrated possible flooding. system suitable for use on warm or cold roof structures. Clockwise from top: Kalzip AluPlusSolar SolarClad is a non-integrated Waterside School, system which can be retro-fitted Defence 6th Form College, Loughborough to existing roof systems (ideal for refurbishment projects) or used in new build.

Theme and variations Copper As you would expect with copper, No two Kalzip systems are the initial bright appearance ever visibly identical. Because gradually changes to a mellow every one is bespoke and the bronze, then develops the familiar system is so flexible, it can make green patina as it weathers. Fully elaborate computer-modelled or partially weathered options are roof shapes involving curves also available if you can’t wait and wave forms reality. The for nature to take its course. array of finishes and other variations available add even Colour coated greater design freedom. If the aluminium requires an additional protective coating Kalzip’s choice of finishes because of an aggressive environment, or if the design Standard simply calls for a colour finish, The standard stucco embossed Kalzip profiled sheets are available Kalzip finish provides a reflective in a choice of colour coatings. surface which gradually dulls down to a uniform patina. Foldables Falzinc and TitanSilver AluPlusPatina Falzinc is a lightweight foldable An alternative with a high quality aluminium sheet with a durable pre-weathered matt finish that zinc top layer. Suitable for a wide reduces reflection by up to 20%. range of applications, Falzinc is especially appropriate for high AluPlusZinc quality skilled metal working. All the performance benefits It can be easily folded, edged, Clockwise from top: of aluminium plus the unique flanged and precisely welded Stucco embossed aluminium aesthetics of zinc. in even the most inhospitable Copper conditions. TitanSilver finish AluPlusZinc is also available. Coloured Kalzip Stainless steel Stainless Steel A range of austenitic stainless AluPlusPatina steel finishes is available.

Low cost, high satisfaction Zinc was chosen partly because of the need to minimise glare for The Bradbury Learning visually impaired people, although Centre, Queen Alexandra soft aesthetics sympathetic to the College, Birmingham surrounding residential area were also important. Architects Associated Architects LLP The new building, so admired Contractor architecturally that it has been Greswolde Construction Ltd used for RIBA events, houses Teamkal contractor a range of specialist facilities EHS Holdings Ltd including a performance suite, Product AluPlusZinc recording studio, tactile learning environment and library – with A new building bringing more light, airy classrooms described space and enhanced facilities to by the college as “encouraging this even more dynamic teaching and learning.” brought initial budget problems for the design team. “Encouraging even more dynamic It quickly became apparent teaching and learning.” that the original choice of a zinc College spokesperson standing seam roof would drive costs above the £2 million budget. Fortunately the team had worked with Kalzip before, and found that a Kalzip AluPlusZinc roof system could provide the desired look at an affordable cost.

Quality and deliverability The roof system was designed and installed by Teamkal King’s Oak Primary contractor Varla (UK) Ltd with School, Barnsley special flashings, fascias and “secret gutters” to protect Architects the zinc from the cedar. H L M Architects Contractor The design creates excellent Carillion levels of natural daylight and Teamkal contractor ventilation, with classroom spaces Varla (UK) Ltd facing south to overlook the play Product Falzinc areas. This also provides good separation between pupils and King’s Oak in Wombwell, a new vehicles for safety and security. build replacement for two former Rooms for community use are primary schools, is part of a £50 grouped around the main entrance million, 13-primary school building for easy out of hours access. programme under the Barnsley Grouped Schools PFI project. Revision All the schools are designed to combine primary and nursery � Bid winning designs for new teaching spaces with educational buildings need to community facilities. as well as sustainable

At King’s Oak the consortium � Kalzip solar and Nature Roof chose to meet the brief – robust, systems provide excellent and low maintenance, sustainable – by highly visible sustainable solutions combining a Kalzip Falzinc raised seam system with the distinctive � Kalzip offers maximum design use of cedar boarding. freedom, enhanced by a wide range of styles and finishes “ The use of materials stretched the norm for what we had seen in PFI schemes, but most of all the designs combined quality with deliverability.” David Russell, Principal Architect at the time of the bid for Barnsley Metropolitan Borough Council New roof: new school As with every project, the first step is to talk to the Kalzip technical It’s essential to remember that team about the most appropriate design solution for the building in proposes the rebuilding or question. And of course you and refurbishment of every secondary your clients can rest assured that school in England by 2015. the installation will be completed by approved, highly trained When it comes to roof Teamkal contractors. refurbishment, Kalzip offers the ideal combination of light weight, Revision weather resistance, outstanding thermal and acoustic standards, � Kalzip’s lightness, durability minimal maintenance and speed and versatility makes it ideal of installation. The perfect for refurbishment projects alternative to expensively demolishing and rebuilding. � There are likely to be a lot of these as the Transforming initiative gets into its stride Kalzip can provide specially

fabricated steel substructures, � Early involvement of the either as ‘dead load systems’ Kalzip technical team and (usable down to a minimum pitch Teamkal installer will provide of 2 degrees) or a self-supporting the optimum solution system suitable for pitches of 22 degrees and more. Clockwise from top: Hobbayne Primary School, London With these resources it’s Howells Junior School, Cardiff possible to create a conventional St. Jude’s School, double-pitch roof, a barrel vault roof or even a wave-form roof, transforming the aesthetics of the building and giving it a second life of forty years or more.

University of Central Lancashire, Preston

Institute of Technology, Blanchardstown “We specified Kalzip for Sandbrook because it is a good quality system that is suitable for low pitches, satisfies all performance requirements and enables fast and early completion. Its consistent appearance also played a part as the roofs are visible from higher surrounding areas and it enabled the curved section to the hall and adjacent straight pitched section to be achieved without lateral joints. It also enabled a smooth conical roof section to be constructed over the curved plan area of the school.” John Case, Senior Architect, The Impact Partnership, on Sandbrook High School, Rochdale

“The building has been very well received. The Kalzip systems allow for flat and curved roof elements which lend themselves to the original design “The quality of finish in the schools is superb concept.The reflective and all the building materials were carefully roof panels then stand chosen to achieve this end result. With its in contrast to the matt excellent reputation for standing seam roofing render surface and the in Scotland, Kalzip was the natural choice for metallic surface of the these schools because we wanted to roof profiled wall panels.” them with a system that looked outstanding, John Holroyd, Architect, Walker Simpson, whilst being very versatile, maintenance on Levenshulme High School, Manchester free and durable. We were also extremely impressed with the wealth of support from Kalzip and the comprehensive training they offered to our in-house construction staff.” Peter Jenkins, GCC’s Construction Manager, Haghill and St Benedict’s Schools, Glasgow Roofing specifiers checklist

Use this at a glance guide to make sure all the important design and structural issues have been addressed and all the pitfalls avoided for your next projects.

Table 1: Structural specification

Specification Kalzip Over purlin construction Have maximum purlin centres been advised and load span tables issued ■ for profile, clip type and material thickness?

Structural deck construction Have structural deck calculations been provided and loadings checked ■ by the project structural engineer?

Long sheet lengths >40 m If the sheet length is greater than 40 metres from the fixed point have the thermal expansion and in-plane forces been taken into account? ■

Fasteners Have the correct type and number of fasteners been allowed for? Does the manufacturer offer a project specific fixing schedule and specification? ■ (A common cause for roof failures has been attributed to incorrect and insufficient fasteners being used)

Lining sheet profile Is the lining sheet profile suitable and robust enough to accommodate foot traffic without damaging the material? A minimum 30 mm depth is recommended. ■ Additional risk if the profile is perforated.

Fixed point Has the fixed point calculation and method been issued? The management of ■ thermal expansion relies on a project specific fixed detail.

Tapered roof sheets Have mechanically tapered roof sheets been allowed for? ■

Swimming pool project Recommendation for aluminium lining sheet in PVdf or aluminium structural deck. Have aluminium tophats/saddles been allowed for? Steel bracket and rail or ■ tophats should not be used in this type of construction due to the risk of corrosion and structural failure. Table 2: Thermal performance/air tightness

Specification and performance Kalzip U-Value performance Have you received comprehensive U-Value calculation data to ADL2A and

MCRMA Technical Paper 14 Guidelines? Does the build-up meet the required ■ U-Value performance?

Insulation performance What is the insulation K value and is it clearly identified in the calculations? ■

Thermal bridging Has the thermal impairment of the clips, sub purlin and/or bracket and rail been accounted for and calculated? ■

Purlin spacing Has purlin spacing been allowed for in the U-Value calculations? ■

Vapour control Has the correct vapour control been included for the building use? The vapour control layer also assists air tightness in particular around perimeter ■ and interface details.

Hipped ridge or valley Has an aluminium welded detail been included to these areas? ■

Penetrations through roof Have welded upstands/soakers been incorporated into all roof penetrations? ■

Condensation risk Has a condensation risk analysis been provided? Taking into account the internal ■ relative humidity and maximum internal temperature.

Table 3: Acoustics

Specification and performance Kalzip Sound reduction performance Does the system meet the required sound reduction requirements and has tested data been provided to confirm the performance of the system with ■ regard to sound reduction requirements?

Has tested data been provided to confirm the performance of ■ Sound absorption performance the system with regard to sound absorption requirements?

Has tested data been provided to confirm roof system performance in ■ Rain noise relation to rain noise? Table 4: Fabrications and gutters

Specification and performance Kalzip Fabrication material Do the fabrications meet MCRMA Technical paper 11 guidelines? ■ and finish Have aluminium PPC perimeter fabrications been allowed for?

Curved roof fabrications Has allowance been made for curved flashings along the verge? ■

Gutter performance Have gutter calculations been provided as part of the design? ■

Table 5: Finish and durability

Specification and performance Kalzip Clad alloy stucco embossed Is the material clad alloy which includes a 5% thick layer of A1Zn1? ■ Clad alloy is recommended for marine environments.

Stucco embossed Has the minimum thickness tolerance of the aluminium been confirmed and can the manufacturer provide confirmation of this? ■

PVdF painted material Has a PVdF finish been allowed for? ■

AluPlusPatina finish Has 1.0 mm AluPlusPatina finish been allowed for? ■

AluPlusZinc finish Has 1.0 mm AluPlusZinc material been allowed for? ■ Table 6: Installation and quality

Installation requirements Kalzip Installer experience/training Has the installer received comprehensive training on fixing the standing seam roof system? Does the installer have a minimum of 1in 3 operators trained to the ■ required standard?

Site service support Will you be offered dedicated site service support during and after installation ■ of the standing seam roof system?

On site roll forming capacity Does the manufacturer have sufficient on site roll forming capacity for this project and additional capacity for busy periods/possible maintenance downtime? ■

Table 7: Guarantees and certification

Responsibility Kalzip Full roof system responsibility Does the manufacturer supply the whole roof system and will they be responsible for the performance of the system including everything above the purlin/structural ■ deck and not just the standing seam top sheet?

BBA agrément certification Does the manufacturer have a BBA agrément certificate for the whole roof system ■ including insulation, vapour control layer and lining sheet/structural deck?

Acknowledgements with thanks to all those who have contributed to this book. Copyright all material appearing in this book is subject to copyright and reproduction in whole, or in part, without written permission is prohibited. www.kalzip.com

While care has been taken to ensure that the information contained in this brochure is accurate, neither Tata Steel Europe Limited nor its subsidiaries accept responsibility or liability for errors or information which is found to be misleading.

Copyright 2012 Kalzip Ltd

Kalzip Ltd Haydock Lane Haydock St Helens Merseyside WA11 9TY T: +44 (0) 1942 295500 F: +44 (0) 1942 295508 E: [email protected]

English