Kalwall®

high performance translucent building system

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What is Kalwall®?

Kalwall®, developed and manufactured in the USA for over fifty years, is a translucent, highly insulating, light diffusing building system for walls and roofing. A matrix of glass prisms inherent in Kalwall® absorbs external light levels and redistributes an interior ‘museum-quality’ light that virtually eliminates glare, hot-spots and shadows, and by encouraging natural daylight into the building is beneficial to health, productivity and general well being.

Kalwall®’s unique composite construction combines to reduce solar gain, while at the same time maximising thermal insulation, with the resultant cost and environmental benefits.

Kalwall® is rated a green and sustainable building component because of the way it is manufactured and its material composition. It reduces both the environ-mental impact of the building process and the building’s energy consumption. Importantly, it makes a substantial contribution to providing a safer and healthier indoor climate.

No other fenestration or system matches the performance of Kalwall®.

Powerful advantages

• Maximum Environmental Benefits

• Proven Structural Integrity

• Demanding Fire Code Compliance

• Design and Aesthetic Flexibility

• System Reliability and Integrity ... for over 50 years!

The most highly insulating daylight system in the world!

The primary element of the Kalwall® system is a flat or curved structural composite sandwich panel formed by permanently bonding specially formulated fibreglass-reinforced translucent faces to a grid core constructed of interlocked, structural aluminium/composite, thermally broken I-beams.

The natural thermal properties of the sandwich panel can deliver even greater energy performance by the inclusion of translucent fibreglass “Batts” during the manufacturing process and by specifying a fully thermally broken grid core. R Value options range from R O.8 to R 3.5 (NZ R Value m2.C°/w).

Kalwall® panels are installed with the efficient, proven Clamptite™ Aluminium system.

A External face sheet

B Glass fibre insulation

C Aluminium I-beams

D Internal, shatterproof face sheet

A

B

C

D

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Superior Load Capacity

When the wind starts to howl or rain and snow start to accumulate, or if someone walks across a skylight or skyroof, enormous loads push delicate poly-plastic panels far beyond their limit. Warping, buckling and collapsing result, followed by extensive interior damage and even bodily harm. Kalwall®’s composite panel delivers miraculous performance which can stand up to hurricane-force winds and other loads with ease.

This is NOT possible with competitive systems!

Kalwall® Structural Thermal Break Composite

• 68mm I-beam• 44mm Non-conductive break• Stronger than aluminium• Passes fi re testing to 650°C• Superior insulation in panels - R3 - 52 R value• Stops condensation - CRF 80+

Kalwall®’s Thermal Break Competing technology does NOT work!

CRF 80+

CRF 45-55

CRF < 30

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Wall Systems

• Rapidly and economically enclose space - totally pre-finished when in place.

• Controlled, natural daylight combined with finely tuned thermal and solar controls.

• May be either flat or curved sandwich panels.

• Structural Sandwich Panels up to 1500mm x 6000mm, 70mm or 100mm thick, are secured to building with simple, Clamp-tite™ aluminium extrusions. System seals panel/panel and building, allowing for expansion/contraction and proper weepage to channel any moisture to building exterior.

Curtainwall Systems

• Factory-assembled (70mm) sandwich panels, operating/fixed windows, louvres, even opaque panels.

• Provide rapid installation and permanent weather seal, unlike most stick-built, “frame and glaze” components which are all field-assembled.

• Kalwall® prefabricated Curtainwall Systems, like our Panel Wall Systems, are totally finished inside and out.

Replacement Window

• Kalwall® heavy-duty Window Replacement Systems, like our prefabricated Curtainwall Systems, are factory-assembled into easily managed building units.

• Kalwall® provides optimum performance-controlled daylighting and still allows for fulfillment of vision/ventilation requirements.

• Vandal, graffiti and impact resistance add up to minimal maintenance expenses with Kalwall®.

Available Kalwall Systems

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Skylights

• Centreline self-supporting ridges with 20°, 27°, 33°, 45°, slope to 24°.

• Kalcurve™ 180°; Low=Profile 90° in 300mm curb width increments.

• Lightweight - less than 145 Pa/m2 means substructure may be minimised. Only thrust-bearing curbs designed to accommmodate local live, snow and wind load designs are required.

Skyroofs

• Sandwich Panel Systems over substructure designed and installed by others.

• Flat, curved or combination for design versatility and consistent with all Kalwall® Systems.

• Easy, fast installation, coupled with large-sized panels to eliminate troublesome joints.

Structures and Systems

• Taking Kalwall® sandwich panel technology to another dimension - the marriage of aluminium box beams and Kalwall® panels into a monolithic, structural space enclosure.

• Variety of designs, unequalled by any other daylighting system.

• Design control, fabrication, delivery and complete installation for the ultimate in single-source responsibility!

• Installations completed in weeks - not months - due to component standardisations and CAD technology.

• Complete buildings featuring built-in non-corrosion and moisture resistance.

• Thermal break technology for the ultimate condensation control.

sandwich panel technology to another dimension - the marriage of aluminium box beams and Kalwall® panels into a monolithic,

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Safety and Security Features

• Healthy Daylighting

Science has proven the health benefits of sunlight. Studies show that employees are more productive, students learn better, absenteeism is reduced, and customers are more comfortable when shopping under daylight. Medical science also warns of the potential life-threatening health dangers when humans are overexposed to sunlight and certain spectra of the sun’s ultraviolet rays. Kalwall® filters out those damaging rays while providing occupants with the health and therapeutic values of managed, glare-free daylighting.

• Fire Safety

A thermoset FRP/aluminium composite that will not melt; the Kalwall® panel has many optional fire reaction capabilities.

• Earthquake Zones

The superior structural integrity and flexibility of the Kalwall®

system meets the most demanding seismic codes and is very well suited for earthquake zone applications. The system is uniquely engineered to withstand a building’s shaking, twisting and distortion during tremors and quakes, and the product is shatterproof.

• High Wind, Hail and Snow Load

Designed in accordance with ICC-ES, ASCE 7 methods and approved to FM 4881 and 4471 Wall and Roof System standards, Kalwall® stands tough in extreme conditions from high winds and desert sands to hail storms and intense snow loads.

• Hurricane-performance Standard

The superior structural integrity of Kalwall® meets the most demanding weather conditions on the planet. Kalwall® meets and exceeds hurricane standards ASTM E1886 and E1996, including the punishing flying debris cannon test promulgated originally in the Florida Building Code. Kalwall® has also successfully passed testing to ASTM E331 Water Penetration, ASTM E283-91 Air Leakage and ASTM E330-90 Structural Performance. Also tested and passed in NZ to NZS 4284 Standard.

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• Fall-through Integrity

The safety of building maintenance crews and the liability of individuals inappropriately interacting with a building’s exterior are often unspoken concerns for any building with skylights. Kalwall® skylights stand tough and can be walked upon. Approved to ASTM E661, every Kalwall® Skylight and Skyroof exceed the safety requirements of OSHA 1910.23 without the additional need for external screens or fixed standard railings.

• Vandal-resistant

The maintenance expense of vandalism is a concern regarding the ongoing expense of a buliding. Unlike glass, Kalwall® is highly vandal-resistant. Thrown rocks and even bricks, bounce off the surface of Kalwall®. Painted-on graffiti is easily removable. Optional extra-high impact faces withstand extraordinary impact forces in accordance with UL 972 standards. A building incorporating Kalwall® is more resistant to breaking and entering.

• Explosion Venting

Kalwall® Explosion Venting Wall Panel Systems can be incorporated into any building. Should an explosion occur, the dynamic pressures that can cause a structure’s collapse are automatically vented. Designed and manufactured to FM 4440 standards, Kalwall®’s Explosion Venting Wall Panels are released from their mounting system, yet remain attached to the structure to avoid exterior flying debris. In many cases, the panels can be reinstalled later.

• Anti-Terrorism Force Protection

Exterior line-of-sight vulnerability of building occupants is eliminated when incorporating translucent Kalwall® Wall, Curtainwall or Window Systems. While eliminating the concerns of clear fenestraton, translucent Kalwall® fills any space with balanced glare-free daylight. Kalwall® is compliant with ASTM E1642 and UFC 4-010-01 DoD Minimum Antiterrorism Standards for Buildings. In the case of explosions, Kalwall®’s inherent properties improved potential occupant safety by not contributing to dangerous flying debris.

• Testing, Certification and R & D

Kalwall®’s over 50 years of development and innovation offers designers, architects, contractors, building owners and operators a reliable, single source for daylighting. Kalwall®

meets or exceeds these most demanding code requirements and is on the forefront of code compliance. Testing by third-party, recognised laboratories and ongoing in-house testing has resulted in technologies and performance to help with the safety and security of building occupants.

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The Environment

Kalwall®

• eliminates direct-beam night-time illumination from leaving the building.

• helps achieve minimum energy performance and can contribute to optimised energy performance as a highly insulated light-transmitting system.

• contains ± 20% post-consumer recycled content. A Clearspan Skyroof™ from Structures Unlimited Inc can contain a ± 22% post-consumer recycled content.

• can contribute to the individual occupant control of ventilation by providing operable windows in panel unit walls and window replacement systems.

• provides daylighting without direct sunlight penetration, eliminat-ing the need for exterior shading devices and interior light shelves.

• can provide line-of-sight vision glazing by incorporating fixed or operable windows in wall systems and by incorporating glass gable areas and glass clerestories in roof applications.

• panels and systems can be recycled. Aluminium recycling is part of our every day life. FRP face sheets can also be recycled by grinding them up and using the resulting powder as filler in other FRP products such as cars, boats, building panels, tubs and showers, engineered lumber, pultruded structural shapes, wall panels and concrete.

• does not contain PVC.

• insulation does not contain urea formaldehyde.

• requires an absolute minimum of maintenance.

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United States Environmental Protection Agency - Energy Star - a government-backed programme helping businesses and individuals protect the environment through superior energy efficiency.

Greenspec (USA) - an independent publishing company committed to bringing members accurate, unbiased and timely green design information. GreenSpec carries no advertising and is not sponsored by any industry or manufacturer fees. There are 26 GreenSpec criteria organised into five categories:

• Made with salvaged, recycled or agricultural waste material• Conserve natural resources• Avoid toxic or other emissions• Save energy or water• Contribute to a safe, healthy built environment.

National Fenestration Rating Council, NRFC (USA) - a non-profit organisation that administers the only uniform, independent rating and labelling system for the energy performance of windows, doors, skylights and attachment products.

Underwriters Laboratories, UL (USA) has developed more than 1000 Standards for Safety. Standards for Safety are essential to helping ensure public safety and confidence, reduce costs, improve quality and, as a result, consumers live in a safer environment than they would have otherwise.

The US Green Builiding Council (USGBC) - a non-profit organisation committed to expanding sustainable building practices. USGBC is composed of more than 15,000 organisations from across the building industry that are working to advance structures that are environmentally responsible, profitable and healthy places to live and work.

FM Approvals (USA) - an international leader in third-party certification and approval of third-party certification and approval of commercial and industrial products. The FM Approved mark, which is backed by scientific research and testing, tells customers which products conform to the highest standards.

Kalwall® is accredited with the following environmental labels

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Heat and Energy Savings of Kalwall®

Kalwall® is the super-insulating, light-transmitting material that slashes energy loss by:

• Vastly improving insulation qualities of light transmitting areas - (R Values of 0.8, 1.0, 1.3, 1.6, 1.9, 2.2 and 3.5 are available).

• Eliminating air infiltration - due to Kalwall®’s unique Clamp-Tite™ installation system.

• Condensation control - due to fully thermally broken systems with CRF in excess of 80 for panels.

Similar energy savings apply to the cooling season.

Glazed areas in your walls and roof are the single largest source of wasted energy. We can help eliminate waste.

Heat and Energy Savings of Kalwall® vs Glass

SOME SAVINGS BY KALWALL SAVINGS BY KALWALL EXAMPLES VS SINGLE GLAZE VS DOUBLE GLAZE (R - 0.2) (R-0.6)

R 1.3 KALWALL 85% 54%

R 1.9 KALWALL 89% 68%

R 2.2 KALWALL 91% 73%

R 3.5 KALWALL 94% 83%

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Design and Installation

Components

Factory pre-assembled in any combination up to 1500m wide and 10700mm high. Panel units are ready for installation with no additional finishing. Panel units eliminate superfluous structure required with most other systems.

Panel Options

• Standard panel sizes Width 1200mm and 1500mm

Other widths up to 1524 are optional

Length 914mm to 6096mm standard

4880mm maximum for skyroofs

Thickness 40mm, 70mm, 100mm

• Standard grid designs Nominal grid size 300mm x 600mm

Standard 200mm x 500mm

Optional for flat and curved panels

• Optional grid designs Other designs and grid sizes available.

Please note that spans will vary with

different grid patterns. Consult factory.

• Translucent colours White and Crystal are standard, but other colours are available. The

Kal-tint series and pebble finish are options. Coloured translucent insulation inserts are available in an endless palette of colours.

• Metal finishes The installation system is available in mill finish or Kalwall® Corrosion

Resistant Finish, a high-performance coating that meets AAMA 2604, 2605 optional. The finish is highly resistant to acids, alkalis, salt, industrial and moisture-laden atmospheres.

Installation

• Quick, low cost Kalwall® interconnected structural components form rigid, modular

units which replace the heavy mullions and floating panels of other curtainwalls. The unique construction and extreme structural strength of the components permit the largest panel-unit wall sections to be installed quickly and efficiently.

STANDARD GRIDS

Shoji Reverse Shoji

OPTIONAL GRIDS

Verti-Kal Tuckerman

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Kalwall® 100 for even greater energy and structural performance

Technical SummaryKalwall® is a composite sandwich; various combinations are possible and test data should be interpreted from this point of view.

Heat and light transmissionListed below are the light transmissions, solar heat gain co-efficients and R Values for some Kalwall® panel face sheet combinations. Others are available upon request.

Distributed in New Zealand by

41 Morrin Road, Mt Wellington, Auckland 1006, New Zealand. www.jacobsens.co.nzwww.kalwall.com

Febr

uary

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Bond StrengthPanels and adhesives are tested according to the stringent requirements of “Criteria for Sandwich Panels” issued by ICC (International Code Council). Before specifying an alternate, insist on actual field proof of bond integrity over a 20-year period. Caution is urged in accepting look-alikes as equivalents.

WeightMost panels and systems weigh under 14.65 kg/m2.

Fire TestsAlthough some Kalwall® panels contain combustible binder resins (ignition temperature greater than 425°C), they will withstand a 650°C flame for one hour with no flame penetration: pass the Class A Burning Brand Test (ASTM E-108), or UL 790 listed Class A Roof system. All interior faces are CC-1 by ASTM D635. Optional flame-spread/smoke developed ratings by UL 723 tunnel tests, including Class A, are available. Kalwall® is listed by: ICC #PFC-1705; British Standard 476; Parts 3, 6, 7.NFPA 268 - Radiant Panel Test-Exterior Walls.

Kalwall® 70mm

Note: R 3.52 uses Lumira Aerogel insulation Example: Crystal Exterior/White Interior R 1.26 panel has 12% Light, Skyroof SHGC 0.11 and Wall SHGC 0.1

Non Thermally broken panels Thermally broken panels

FACE SHEET % LIGHT SKYROOF SOLAR HEAT GAIN COEFFICIENT WALL SOLAR HEAT GAIN COEFFICIENT COMBINATIONS TRANSMISSION AT 0° ANGLE AT 35° ANGLE

EXTERIOR INTERIOR R 0.33 R 0.69 R 0.88 R 0.98 R 0.33 R 0.69 R 0.88 R 0.98 R 0.33 R 0.69 R 0.88 R 0.98

COLOUR COLOUR R 0.75 R 1.26 R 1.76 R 3.52 R 0.75 R 1.26 R 1.76 R 3.52 R 0.75 R 1.26 R 3.52/R 1.76 Greenish Blue White 25 14 5 3 10 0.37 0.18 0.10 0.07 0.11 0.36 0.17 0.1 0.06 0.11

Aqua White 29 17 6 4 12 0.37 0.19 0.10 0.07 0.11 0.36 0.18 0.1 0.06 0.11

Rose White 30 18 6 4 12 0.38 0.19 0.10 0.07 0.11 0.37 0.18 0.1 0.06 0.11

Ice Blue White 35 20 8 6 15 0.44 0.22 0.11 0.07 0.12 0.44 0.21 0.1 0.06 0.12

Greenish Blue Crystal 37 20 7 4 15 0.47 0.21 0.13 0.08 0.13 0.45 0.21 0.12 0.08 0.13

White White 20 15 8 5 12 0.30 0.16 0.09 0.06 0.09 0.3 0.15 0.08 0.05 0.09

Crystal White 35 20 12 8 15 0.42 0.23 0.11 0.07 0.11 0.39 0.19 0.1 0.06 0.11

Crystal Crystal 50 30 15 10 20 0.55 0.27 0.14 0.09 0.12 0.51 0.23 0.13 0.08 0.12

Thermally broken panels

FACE SHEET % LIGHT WALL SOLAR HEAT GAIN ROOF SOLAR HEAT GAIN COMBINATIONS TRANSMISSION COEFFICIENT COEFFICIENT

EXTERIOR INTERIOR COLOUR COLOUR R 2.2 R 1.26 R 0.33 R 2.2 R 1.26 R 0.33 R 2.2 R 1.26 R 0.33 Crystal Crystal 8 17 50 0.08 0.18 0.5 0.09 0.21 0.56

Crystal White 7 14 35 0.08 0.15 0.39 0.08 0.18 0.43

White White 5 12 20 0.05 0.12 0.29 0.06 0.14 0.33