Kalwall - Jacobsen

Kalwall
®
high performance translucent building system
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 environmental 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
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Maximum Environmental Benefits
Proven Structural Integrity
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Demanding Fire Code Compliance
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Design and Aesthetic Flexibility
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System Reliability and Integrity ... for over 50 years!
The most highly insulating
daylight system in the world!
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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.
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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.
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External face sheet
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Glass fibre insulation
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Aluminium I-beams
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Internal, shatterproof face sheet
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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
Kalwall®’s Thermal Break
Competing technology does NOT work!
CRF 45-55
CRF 80+
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CRF < 30
68mm I-beam
44mm Non-conductive break
Stronger than aluminium
Passes fire testing to 650°C
Superior insulation in panels - R3 - 52 R value
Stops condensation - CRF 80+
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Available Kalwall Systems
Wall Systems
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Rapidly and economically enclose space - totally
pre-finished when in place.
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Controlled, natural daylight combined with finely
tuned thermal and solar controls.
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May be either flat or curved sandwich panels.
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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
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Factory-assembled (70mm) sandwich panels,
operating/fixed windows, louvres, even opaque
panels.
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Provide rapid installation and permanent weather
seal, unlike most stick-built, “frame and glaze”
components which are all field-assembled.
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Kalwall® prefabricated Curtainwall Systems,
like our Panel Wall Systems, are totally finished
inside and out.
Replacement Window
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Kalwall® heavy-duty Window Replacement
Systems, like our prefabricated Curtainwall
Systems, are factory-assembled into easily
managed building units.
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Kalwall® provides optimum performancecontrolled daylighting and still allows for
fulfillment of vision/ventilation requirements.
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Vandal, graffiti and impact resistance add up to
minimal maintenance expenses with Kalwall®.
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Skylights
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Centreline self-supporting ridges with 20°, 27°,
33°, 45°, slope to 24°.
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Kalcurve™ 180°; Low=Profile 90° in 300mm
curb width increments.
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Lightweight - less than 145 Pa/m2 means
substructure may be minimised. Only thrustbearing curbs designed to accommmodate local
live, snow and wind load designs are required.
Skyroofs
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Sandwich Panel Systems over substructure
designed and installed by others.
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Flat, curved or combination for design versatility
and consistent with all Kalwall® Systems.
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Easy, fast installation, coupled with large-sized
panels to eliminate troublesome joints.
Structures and Systems
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Taking Kalwall® sandwich panel technology to another dimension - the marriage of aluminium box beams and Kalwall® panels into a monolithic,
structural space enclosure.
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Variety of designs, unequalled by any other
daylighting system.
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Design control, fabrication, delivery and complete
installation for the ultimate in single-source
responsibility!
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Installations completed in weeks - not months due to component standardisations and CAD
technology.
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Complete buildings featuring built-in
non-corrosion and moisture resistance.
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Thermal break technology for the ultimate
condensation control.
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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®
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eliminates direct-beam night-time illumination from leaving the
building.
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helps achieve minimum energy performance and can contribute
to optimised energy performance as a highly insulated lighttransmitting system.
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contains ± 20% post-consumer recycled content. A Clearspan
Skyroof™ from Structures Unlimited Inc can contain a ± 22%
post-consumer recycled content.
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can contribute to the individual occupant control of ventilation
by providing operable windows in panel unit walls and window
replacement systems.
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provides daylighting without direct sunlight penetration, eliminating the need for exterior shading devices and interior light shelves.
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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.
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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.
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does not contain PVC.
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insulation does not contain urea formaldehyde.
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requires an absolute minimum of maintenance.
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Kalwall® is accredited with the following environmental labels
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:
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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.
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Heat and Energy Savings of Kalwall®
Kalwall® is the
super-insulating, light-transmitting material that slashes energy loss by:
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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).
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Eliminating air infiltration - due to Kalwall®’s unique Clamp-Tite™ installation system.
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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
EXAMPLES
SAVINGS BY KALWALL
VS SINGLE GLAZE
(R - 0.2)
SAVINGS BY KALWALL
VS DOUBLE GLAZE
(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.
STANDARD GRIDS
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
40mm, 70mm, 100mm
Thickness
Shoji
OPTIONAL GRIDS
• Standard grid designs
Reverse Shoji
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.
Verti-Kal
Tuckerman
• 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.
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Technical Summary
Kalwall® is a composite sandwich; various combinations are possible and test data should be interpreted from this point of view.
Heat and light transmission
Listed 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.
®
Kalwall 70mm
Non Thermally broken panels
FACE SHEET
COMBINATIONS
% LIGHT
TRANSMISSION
SKYROOF SOLAR HEAT GAIN COEFFICIENT
AT 0° 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
Thermally broken panels
WALL SOLAR HEAT GAIN COEFFICIENT
AT 35° ANGLE
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 0.370.180.100.070.110.360.170.10.06 0.11
Aqua
White
29 17 6
4 12 0.370.190.100.070.110.360.180.10.06 0.11
Rose
White
30 18 6
4 12 0.380.190.100.070.110.370.180.10.06 0.11
Ice Blue
White
35 20 8
6 15 0.440.220.110.070.120.440.210.10.06 0.12
Greenish Blue
Crystal 37 20 7
4 15 0.470.210.130.080.130.450.210.120.08 0.13
5 12 0.300.160.090.060.09 0.3 0.150.080.05 0.09
White
White
20 15 8
Crystal
White
35 20 12 8 15 0.420.230.110.070.110.390.190.10.06 0.11
Crystal
Crystal 50 30 15 10 20 0.550.270.140.090.120.510.230.130.08 0.12
Note: R 3.52 uses Lumira Aerogel insulation ®
Kalwall 100
Example: Crystal Exterior/White Interior R 1.26 panel has 12% Light, Skyroof SHGC 0.11 and Wall SHGC 0.1
Thermally broken panels
for even greater energy and structural performance
FACE SHEET
COMBINATIONS
EXTERIOR
INTERIOR
COLOUR
COLOUR
Crystal
Crystal
% LIGHT
TRANSMISSION
WALL SOLAR HEAT GAIN
COEFFICIENT
ROOF SOLAR HEAT GAIN
COEFFICIENT
R 2.2
R 1.26
R 0.33
R 2.2
R 1.26
R 0.33
R 2.2
R 1.26
8
17
50
0.08
0.18
0.5
0.09
0.21
R 0.33
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
Bond Strength
Panels 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.
Weight
Most panels and systems weigh under 14.65 kg/m2.
Fire Tests
Although 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.
February 2011
Distributed in New Zealand by
41 Morrin Road, Mt Wellington, Auckland 1006, New Zealand. www.jacobsens.co.nz
www.kalwall.com
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