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Our quarterly magazine features an eclectic mix of projects from the UK, Ireland, Germany and Spain in order to inspire, educate and inform our reader.
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83|Small-ScaleStadia
8|TransparentTechnology
10|ContainerDesign
12|Buildingwithlivingtrees
Hot Dip GalvanizingInternationalMagazine|ISSN1363-0148|www.galvanizing.org.uk2008
1/4
Manyyearsagotherewasafashionfor
elephantjokes.Oneofthemwentsomething
likethis:Question:“Howdoesanelephant
climbanoaktree?”Answer:“Itsitsonan
acornandwaitsforspring.”Iwasremindedof
thisjokebythewonderfularticleonpageeight
aboutorganicstructureswheregalvanized
walkwaysaresupportedbyliving,growing
trees.Icanimaginethesalesmansaying
somethingalongthelines:“Youcanhaveitat
anyheightyoulike-deliveryjusttakesabit
longer”.Seriously,agreatidea–itsolvesall
sortsofproblemstodowithenvironmental
impactandfoundations,butitisnotinthe
categoryof‘instantsolutions’.
Forthatyouhavetogooverthepageto
theContainerDesignonpage10–
anotherbrilliantidea,butinadifferent
directionentirely.
Heretheyhaverecycledcontainersthat
havepassedtheirsell-bydateintosimple,
accommodationunits.Iwasalsoimpressed
bythedesigner’ssuggestionthatfully
kitted-out,recycledcontainerscouldbeship-
pedtodisasterzonesastemporaryhousing.
Ifyourhomehasbeenflattenedbyanearth-
quakeortsunami,thestrengthofasteel
containermustseemquiteappealing.
Andfinally,backtotheelephants.Question:
“Howdoesanelephantgetdownfroman
oaktree?”Answer:“Itsitsonaleafandwaits
forautumn”.Evenifyoudidn’tenjoyit,your
nearestsixyear-oldchildmight.
DavidBaron,Editor
Contents
2 Editorial
3 Small-Scale Stadia Cost-effective solutions
6 Sustainable Living in Freiburg
Solar-powered Estate
8 Transparent Technology
Computer Centre, Munster
10 Container Design
Innovative, recyclable and
versatile
12 Building with living trees Organic structures
14 Galvanizing: The low-energy
solution
Reducing the carbon footprint
of steel structures
16 Galvanizing Delight
Front cover:
The Joint Computer Centre, North Speicherstadt
in Munster by Schoeps und Schluter Architects,
Munster (page 8)
Editorial
2 | HotDipGalvanizing
2008
1/4
Architecture
Small-Scale StadiaCost-effective solutions
By Iqbal Johal/Holger Glinde
Big bold stadia designs that make dramatic statements are the vogue today
especially for the major football teams across Europe. There is however, demand
for small-scale well-designed spectator stands that fulfil the requirements of
both clients and spectators. This article deals with three different projects that have
involved imaginative solutions to very specific local issues.
Brentford FCEalingRoadTerraceRedevelopment
ANDArchitectsLtdwereaskedbyBrentford
FootballClubtodevelopaschemetoprovide
coveredseatingtotheEalingRoadstandas
partoftheongoingFootballFoundationfunded
redevelopmentatGriffinPark.
BrentfordFCwasfoundedin1889andbecame
knownasthe“Bees”byitssupporters.In1904
theclubmovedto“GriffinPark”whichisstillits
hometoday.TheEalingRoadTerracewasa
singleground-bearingsteppedconcretetier
thatprovidedstandingspaceonlyandwas
opentotheelements.ANDArchitectspropo-
sedaslopedcantileveredroof,approximately
62minlengthand11mdeepovertheentire
lengthoftheterracebetweenexistingfloodlight
towers.Thecompletedstructurewasmade
fromaseriesofframes,eachshapedlikean
inverted‘L’andfixedtothetopoftheconcrete
terraceatitsbase,withcold-formedpurlins
spanningbetweentheframes.Thisstructure
wasthencladwithlightgreymetalprofiled
claddingwithasectionoftranslucentpanels
totherearelevationtoallowdaylightthrough
totheterracing.Thedecisiontousegalvanised
steelwastakenbothonaestheticandpractical
grounds:togiveauniformappearancewiththe
claddingwhilstbeingdurableandrelativelylow
maintenance.Thesimplicityofthedesignand
constructionmethodhelpeddeliveraproject
thatwasbothontimeandonbudget.
Princes Park Stadium, Dartford, KentPrincesParkStadiumrepresentswhataLocal
BoroughCouncilcanachieveintermsofa
well-built,sustainableprojectthatcanprovide
asenseofpositivecommunityspiritthatwill
HotDipGalvanizing| 3
2008
1/4
1
3
8 | ThermischVerzinken
Architecture
continuelongintothefuture.Fromthevery
startthiswasalocalcommunityprojectwith
DartfordBoroughCouncilacutelyawareofthe
senseofcivicprideinvolvedwithbringingthe
localfootballteambackintotheheartofthe
community.ThesuccessfulopeningofPrinces
ParkStadiuminNovember2006hasseenthe
localcommunitythrowtheirsupportbehind
theirfootballteam.Now,withproperfacilities,
allwithinwalkingdistanceofthetowncentre,
supporternumbershaveincreasedhealthily.
Locatedonaprominent,butunderutilised
playingfieldssiteclosetoDartfordtowncentre,
the11,405m²stadiumwasconceivedasa
continuationoftherollingKentcountryside.
Thesingle-storeyterracesandtwo-storeyclub-
housearepartiallyburiedintothegroundand
coveredbycurvingglulambeamstructures
supportinglivingsedumroofs.Thiseffectively
loweredthewholebuildingsothatitwasnotas
intrusiveuponthelocallandscape.
Theterracesareconstructedfromprecastcon-
creteunitsandacontinuous,levelperimeter
walkwayprovideseasyaccessforallsupporters
ofvaryingmobility.Removableconcreteblocks
onthesteppedterracesallowforthefuture
conversionfromstandingtoseatedaccommo-
dation.Galvanizedsteelplaysanimportant
roleinhelpingtolinkallthebasicmaterials
togetherinprovidingsupportstotheterracing
andhelpingtoprovidesafeaccessalongallthe
perimeterwalkways.
Flutmulde Sports Ground, Gifhorn ThenameSchulitz+Partnerstandsforinnova-
tiveandambitiousarchitecture,whichisdeve-
lopedonafunctionalbasis.
Itisclearfrommanyoftheirconstruction
projectsthattheBrunswickarchitectshavea
specialaffinitywithgalvanizedsteeland
glass.Forexample,thefiligreeSkywalkat
theExpoinHanoverortheconversionworkon
theLowerSaxonyStadium(tomakeitintoa
4
2
2008
1/4
Architecture
Feuerverzinken| �
WorldChampionshipvenue)arejusttwoofthe
manyprojectswhichhavewonarchitectural
prizesforthisfirm.
Thefactthattheteamofarchitectssurroun-
dingProfessorHelmutC.Schulitzcanalso
executeverysmall-scaleconstructionpro-
jectswithstyleandélanisdemonstratedby
thegrandstandroofoftheFlutmuldesports
groundinGifhorn.Aspartofare-designofthe
sportsground,theMTVGifhornSportsClub
purchasedthreemobilegrandstands.They
neededaroof,whichhadtobedesignedon
ashoestring.Schulitz+Partneradoptedthe
sameapproachasforabigproject.Theyhad
nointentionofsacrificinghigharchitectural
qualityorneglectingtopayattentiontodetail,
andcameupwithadesignwhichwasbased
onasimpleadditiveprinciple:20suspended
andrear-clampedframesarchoverthelittle
grandstand.Convextrapezoidalpanelsare
clampedbetweentheframesinsuchaway
thatdrainagecantakeplacethroughthe
gutter-shapedframecarriersandtheprops.
Galvanizingwasusedtoprovidelong-term
durabilityandrobustnesstothestructure.
Photographs:
Brentford FC Princes Park
Flutmulde Sports Ground
Client:BrentfordFootballClub
Project cost:approx.£500,000
Architects: ANDArchitectsLtd
Photos:(1, 3)BrentfordFC,(2)ANDArchitectsLtd.
Client:DartfordFootballClub
Architects: AlexanderSedgleyArchitects
Photo:(4)PaulHarmer
Client: MTVGifhorn
Architects: HelmutC.SchulitzandMatthiasThoma,
Schulitz+Partner,Brunswick
Project cost: € 100,000
Photos: (5, 6, 7) HelmutC.Schulitz,Brunswick
2008
1/4
5
6
7
5 6 7
1 2 3 4
Inaddition,soundstructuralmaterialsare
intendedtoprovidehigh-qualitylivingforthe
occupants.Theplanwastousesolarenergy
asapowersource.TheFreiburgarchitect
HorstDisch,whohasalreadyattractedagreat
dealofattentioninthepastforhisinnovative
solarstructures,cameupwithaconceptwhich
fulfilledtheserequirements.
Inadditiontothewell-insulated,impervious
buildingenvelopeandaventilationsystem
incorporatingheatrecovery,itismainlythe
solarroofpanelswhichareresponsibleforthe
positiveenergybalanceofthetimber-frame
houses.Inthiscontext,thefiligreegalvanized
steelsections,whichnestleuptotheSouth-
facingroofpaneandfaçade,areessential.
Itfunctionsasasupportstructureforthe
balconiesandsolarroofs,andmakesit
possibletomountlargephoto-voltaicunitson
thepassivehouses.Thisenablesthehouses
tobecomelittlepowergenerationunits,gene-
ratinguptofourtimesasmuchenergyasis
consumedwithin.Atthesametime,thedeep
balconiesactasashadingsystemtothefloors
below.Inorderforittobepossibletomake
thetimber-framehousesenergy-efficientatall,
thegalvanizedsteelroofdeckwasintroduced
asanessentialelement,sinceonlythiscan
providetherequiredstabilityandflexibility.
Theenergy-efficienthousesareacombinati-
onofsolartechnologyandarchitecture.The
structuresofferaconvincingalternativeto
conventionalapproaches.Sixtyhousesofthis
typehavealreadybeenerectedintheFreiburg
solar-poweredestateontheSchlierberg.In
additiontothesocialuse(protectionofthe
environment),therearealsoadvantageswith
regardtooperatingeconomy.
Thehousesnotonlyincurlowancillarycosts,
butevengeneratehighadditionalincomefrom
remunerationforsolarpower.
Detailed functioningThegalvanizedsteelstructureactsasamoun-
tingforthephoto-voltaicmodule.
Architecture
Sustainable living in FreiburgSolar-powered estate
By Holger Glinde
The idea for the energy-efficient houses of the Freiburg solar-powered estate
sounds simple. They are intended to be structures which produce more energy than
their occupants can consume, therefore creating a positive carbon footprint.
6 | HotDipGalvanizing
2008
1/4
Feuerverzinken| �
Thelargesolarroofgeneratesenvironmentally
friendlypower,andhelpstoprotectagainst
theweatherandsunlight.Ifsnowfalls,the
airrisinginfrontoftheSouthfaçadeintothe
interveningcavityhelpsintherapidmeltingof
thesnowontotheframelessmodules,sothat
thesolarequipmentgeneratesmorepowerin
Winter.Thelightbalconystructure,withgreat
transparencyanda“floatingsolarroof”carries
overthethickexternalenvelopeofthehouses
withitssolidinsulation.Theeffectoftheentire
constructionandthesolartechnologycanbe
measured.Thisisalsosupportedbythesemi-
transparencyoftheglassmodule,whichmakes
thecellsvisibleandthrowslightandshadow
ontothefaçade.Atthesametime,costscan
bereducedbecausethesolarroofisused
asprotectionagainstboththeweatherand
sunshine,sothattheeconomicefficiencyof
thehouseisincreased.
Building materials and other materialsTheroofareacoveredwithphoto-voltaic
modulesconsistsofpre-fabricatedgalvanized
“steelladders”,whicharemountedontheroof
areausingamodularsystem.Theverticalloads
areintroducedatspecificpointsintothetimber
roofconstructionbymeansofsealedsteel
platesthatarefastenedtoitinacompression-
proofandtensile-resistantmanner.
Heatexpansioneffectsareexcludedthrough
slots.ThelargeSouthroofprojectionis
supportedbytheelongatedbalconystructure.
Thebalconiesconsistofafiligreegalvanized
steelstructuremadefromhollowsectionsand
sectionsofgalvanizedgratings,whicharelined
withDouglasfirtimber.Thankstotheuseof
galvanizingforallthesteelcomponents,
long-term,maintenance-freeandecological
corrosionprotectionisguaranteed.
Architect/Photos: HorstDisch,Freiburg
Architecture
2008
1/4
For many years, North Speicherstadt in Münster, an area which is under a preservation
order, acted as a barracks and a military storage depot, and more recently it has
been rented out for civilian use by the Westfälisch-Lippische property management
company. Small consulting firms, agencies and publishing companies, data and
telecommunications service providers, as well as public institutions, are among the
heterogeneous group of tenants that make Speicherstadt a diverse but unified area.
Architecture
Transparent TechnologyComputer centre, Münster
By Holger Glinde
TheJointComputerCentreforMünster,which
operatesonbehalfoftheentireprovince,
occupiestheblockknownas“Anden
Speichern9„.Therequirementsimposedon
theblockintermsofsecurityandtechnical
capabilitieshavemadeitnecessarytoerect
anancillarytechnicalblockcloseby.
TheMünsterarchitectsSchoepsundSchlüter
wereselectedtodesignit.Thenewbuilding
makesnoattempttoassertitself,butfitsinto
theexistinggroupoflistedbuildings.
Atthesametime,itdoesn’ttryfora“period
look”,butrepresentsacontemporaryinterpre-
tationoftheexistinggroupofbuildingswhich
isappropriatetoitsuse.
Thefootprintofthebuildingcanbeaccounted
forbyitsstratifiedfunction.
Thegroundfloorcontainstheclosedrooms
withthecontrolsystemtechnology,thestandby
dieselgeneratingequipmentforthecomputer
centreandtherefrigerationcontrolcentre.
Internally,thegalvanizedsteeldesignconsists
ofheat-insulatingsandwichsectionswithan
externalfaçadeofgalvanizedsteel.
Theroofstorey,whichisalsomadefromgalva-
nizedgratingmaterial,providestheprotection
requiredagainstcorrosionfortheexternal
coolingunitsofthecentre,togetherwith
maximumventilation.
Theprotectivefaçadepullsthebuilding
togethertoformacompact‘box’formodern
technology.Thebuildingenvelopeplayswith
theobserver,dependingontheanglefrom
whichitisviewed.Sometimes,thebuilding
seemstobeamonolithicblock,aheavy,
absolutelyclassicalhouse,thenitdissolves
completelyanddisplaysatransparentpart
ofthestructure.
Theconstructionfollowsthefunction,which
hasbroughtaboutastrikinglysimpledesign
solution.Thegalvanizedsteelload-bearing
systemisformedfromstructuralsteelcolumns
incombinationwithsteeltrussesandrafters.
Itstandsonastablereinforcedconcretefloor,
withstripfootings.
Theenvelopeconsistsofhotdipgalvanized
gratings.Theentireconstructionwaspre-
fabricatedandneededonlytobebolted
togetheronsite.Theuseofgalvanizing
providedtheclientwiththedesired50year
maintenance-freelife.
Architects/photos:
SchoepsundSchlüterArchitekten,Münster
2008
1/4
8 | HotDipGalvanizing
2007
03
ThermischVerzinken| �
2008
1/4
Thepossibilitiesofprefabricatedconstruction
havepreoccupiedarchitectsformorethana
century.
Anumberofprominentnameswithintheworld
ofarchitecturehavetriedtodevelopavisionfor
theultimateconceptforprefabricateddesign.
ThelikesofWalterGropius,KonradWachs-
mannandLeCorbusierhavealldabbled
withinthefield.
EricReynoldsofUrbanSpaceManagement
seestheContainerCityconceptas“atactic
forrecycling”.Thesystemcanbeseenasan
innovativeandversatilesystemthatprovides
affordableaccommodationforawiderange
ofuses.USM’sprototypeContainerCity,uses
redundantfreightcontainersasthebasicunit
formixed-usedevelopment.
ItislocatedatTrinityBuoyWharf,London,
wheretheRiverLeaflowsintotheThames
andisacrosstheriverfromtheMillennium
Dome.TrinityBuoyWharfwastheprincipal
workshopofTrinityHouse,thebodyresponsible
formaintainingBritain’slighthousesandlight-
ships,from1803untilitsclosurein1988.
USMhasrefurbishedthelistedbuildings
there,andconstructedthreephasesof
containerbaseddesignedprojects,thefirst
twodesignedbyNicholasLaceyandPartners
in1999-2000.
Thethird,theRiversideBuilding,wascom-
pletedlastyearbyAhrendsBurtonKoralek.
Aquarteroftherentsforthestudiosand
live/workunitsgotoacharitabletrustwhich
managesthesite.
Theshippingcontainerwasinventedby
MalcolmMcLean,anAmericanhaulage
operatorandthefirstcontainershipsailed
fromNewark,NewJerseyin1956totheUK.
Withinarelativelyshortperiodoftimethe
containerhadrevolutionisedthefreight
industryworldwide.
Thetypicalcontaineris6mlongand2.5m
wideand2.5mhigh.Thedimensionsarecare-
fullychosentoenableeasytransportation.
Thereisnoabsoluterecordofthenumberof
containersinusebutitisestimatedtoruninto
manymillions.
TherawmaterialisCortensteelthatisableto
resisttheeffectsofseawater.
EricReynoldsholdstheviewthatthereisno
needtomanufacturenewmodulesforprefab
constructionprojectswhenthereisaready
supplyofcontainersthatcanberecycledto
formidealstartingpointsforprojectssuchhas
theContainerCity.
“Thecontainersarecheap,adaptableand
transportable”,Reynoldssays.
An innovative, versatile system that links used shipping containers to provide
high-strength, prefabricated steel modules that can be combined to create a variety
of end-user needs may not be architectural nirvana. It does however provide one
avenue for the prefabrication concept that combines low cost with reliability.
10 | HotDipGalvanizing
Architecture
Container DesignInnovative, recyclable and versatile
By Iqbal Johal
2008
1/4
1 2
HotDipGalvanizing| 11
Architecture
“Wecameupwiththeideaofinstanthomes
forNewOrleansafterthehurricane–wecould
havedeliveredthemreadyforoccupationfor
£27,000each,buttheideawasn’ttakenup.”
IthascommissionedABKforaforthcoming
schemeinLafayetteStreetinNewYorkCity’s
“cast-irondistrict”.
ReynoldsdescribestheapproachatTrinity
BuoyWharfasamatterof“pilingupthe
containersandminingourwaythrough”.
AnimportantelementfortheContainerCity
conceptistheuseofancillarymaterials
“theglue”thatbondseverythingtogether.
Inthetraditionoftheoverallindustrialconcept,
galvanisedsteelplaysanimportantroleandis
interestinglyusedbothinternallyandexternally
throughouttheproject.
Connectingsectionsbetweenthecontainers
andsupportsteelworkforaccess,and
walkwaysareallexposedgalvanizedsteel.
Infactithelpstopullalltheindividualparts
togetherintoacohesivewholewhileeasily
blendingintotheaestheticoftheproject.
UrbanSpaceManagementwiththedriveand
enthusiasmofEricReynoldshassuccessfully
usedtheContainerCitysystemtocreateoffice
space,retailspace,artiststudios,aschool,
anurserycentreandlive/workspace.
ThemodulartechniqueadaptedbyUSMhelps
tocutconstructiontimesandcostbyuptohalf
thatoftraditionalbuildingtechniqueswhile
stillbeingabletobemoresustainableatthe
sametime.
Photos: (1, 2, 3, 6) RiversidebyUSMLtd.
Architect:ABK,London
Photoby:www.containercity.com,SarahHewson
(4) CoveParkbyUSMLtd.
Photoby:www.containercity.com
(5) MorpethSchoolbyUSMLtd.
Photoby:www.containercity.com
4
5
3
6
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Architecture
Building with living treesOrganic structures
By Holger Glinde
Timber is a traditional material in architecture for the construction of load-bearing
structures, and has been in use for millennia. What is only just evolving is organic
design – namely, using trees as load-bearing structures in architecture.
Thisrecentdevelopmenttriestoharnessthe
naturalgrowthprocessoftreesforusein
structuralfunctions,andtocarryoverourfas-
cinationforthenaturalworldintoarchitecture.
TherecentlyestablishedStuttgartfirmof
architects,LudwigStorzSchwertfeger,has
carriedoutitsfirstfewconstructionprojects
usingthistheme.Aprototypebridgeconstruc-
tedin2005wasbasedontwoprinciples-
professionalengineeringconstructionand
naturalgrowth.Theprojectdemonstratesthe
specialcharacteristicsofthisnaturalformof
architectureinanexemplaryway.
Thedesigndeliberatelycombinesinanimate
componentsfromtheworldoftechnologywith
thenaturalstructuralstrengthandrigidityof
trees.Aclear,geometricallanguageofshapes
wasselectedasacontrasttotheorganic
structuresoftheplants.Acolumnarstructure
wasformedfromrapidlygrowingwillows.
Itcarriesasurface,madefromhotdipgal-
vanizedlatticework,whichpeoplecanwalk
across.Allstructuralloadscanbeabsorbed
bythetypeofwillowused.“Weusedhotdip
galvanizedsteelbecauseofitsdurability,and
ongroundsofcost.
Sofar,wehavefoundthatwithourtypeof
construction,zincisextremelycompatiblewith
thenaturalworld”commentsFerdinand
Ludwig,oneofthedesignpioneers,with
referencetothedecisiontousehotdipgalva-
nizing.Zincisanaturalelementandpeople,
animalsandplantscan’tlivewithoutit.
Buildingwithlivingmaterialsmeansplanting
structuresinsteadofcastingconcretefoun-
dations.‘Rootfoundations’areanespecially
protectivetypeofanchorageforstructures,and
donotrequireanyartificialsubstancestobe
introducedintothesoil.
12 | HotDipGalvanizing
2008
1/4
Butintermsofconstructionpractice,thelack
offoundationsalsomeansthatconstruction
mustproceedwithoutaflat,levelsurface
formingafirmbase.
Itwasveryobviousafterashortperiodoftime
thatthistypeofdesigndoesnotcomeinto
beingthroughthecreativepowersofhumanity
alone,butarecontinuouslybeingalteredbythe
processesofgrowth.
Thisaffectstheformofthestructure,butalso
thedetailsofconstruction.Wheretechnical
elementsarecombinedwithlivingtimber,
callousesarecreated–i.e.thereislocalised
diametergrowth,andplantswhicharelinked
tooneanothergrowtogetheratthesenodal
points.Onesignificantaspectoftheapproach
isthatdiametergrowthsofthistypeare
deliberatelyencouragedandputtoconstructive
use.Theso-called‘constantstressaxiom’is
thebasisofconstructioninthiscase:treestry
toachieveuniformdistributionofstressesover
theirsurfaces,andattempttoreducestress
peaksbyaddingmorewoodattheplaces
wherethestressesarestrongest.
Forthisreason,theplantsareveryfirmly
compressedagainsteachotheroragainst
addedcomponentssothatinthecourseof
time,constructiondetailsofthistype,and
thustheentirestructure,becomemoreand
morestable.
Thenaturalbuildingapproachrepresents
anattempttocombinetheknownecological
advantagesoftimberasastructuralmaterial
withtheself-regulatingintelligenceofthetree.
Theintentionistoderiveatechnicalbenefit
fromtheself-forming,self-repairingandself-
optimisingprocessesintrees.Innormalload-
bearingstructuresthecontinuouslyadjusting
‘livingtimber’reactsinadynamicandadaptive
manner,withoutanyadditionalmonitoringand
regulatingmechanismstothestresseswhich
arise.Livingtimberhasnaturalhigh-tech
attributeswhenitisusedasalivingconstruc-
tionmaterial.
Basedontheknowledgeobtainedtodate,
staticcalculationscanbemadewithregard
tonaturalbuildingatthesiteswherethere
aresuchstructures.However,onlyrelatively
simpleload-bearingstructures,limitedtosize
andcomplexity,arebeingformed,whichalso
meansthattheapplicationrangeislimited.
Naturalbuildingisnotclaimingtoreplaceany
conventionalformsofconstruction.
Itsprospectslieinspecialconstructiontasks,
wheretheecologicalandsensuousqualities
ofthestructuraltechniquecanbeshownto
theirbestadvantageandhaveasignificant
influenceonthedesign.
Asarule,thisformofdesignusesman-made
materialsaswell,hotdipgalvanizedsteel,
duetoitslong-lifeanditsmultipleecological
advantages,addstheidealfinishingtouch.
Architects/photos:
LudwigStorzSchwertfegerGbR,Stuttgart
Architecture
HotDipGalvanizing| 13
14 | HotDipGalvanizing
2008
1/4 Sustainability
Hot dip galvanizing is the simplest and most efficient method of protecting steel
from corrosion. Its dip process is inherently efficient but the greatest benefit comes
from the durability of galvanized steel structures and components.
Galvanizing: The low-energy solution Reducing the carbon footprint of Steel Structures
By Murray Cook, EGGA Director
Thelong-termdurabilityprovidedbygalvanizing
isachievedatrelativelylowenvironmental
burdenintermsofenergyandotherglobally
relevantenvironmentalimpacts,especially
whencomparedtotheenergyvalueofthesteel
itisprotecting.Infact,theenergyrequiredto
galvanizeonekilogrammeofsteelrepresents
just0.4%oftheembodiedenergyofthesteel
itself.Asaresult,theembodiedenergyofsteel
canbepreservedforalongtimeandeventually
recycledforuseinaninfinitenumberofcycles
ofre-use.
Ithasbecomeincreasinglyimportanttounder-
standtheenergyprofileofconstructionpro-
ductsandservices.Inrecentyears,anumber
ofstudieshavedocumentedtheenergyprofile
ofthehotdipgalvanizingprocessandthe
galvanizedsteelthatisproduced.
Arecentreviewoftheselife-cyclestudies,by
LifeCycleEngineering(Torino,Italy),hasshown
reasonablyconsistentvaluesforthegross
energyrequirementandglobalwarming
potentialassociatedwithhotdipgalvanizing.
ThisreviewissummarisedinTable1.
Whilsttherearesomesmalldifferencesin
resultsduetovariationsinprocessesstudied,
typeofworkprocessedandthemodelsused,
theresultsindicatethatglobalwarmingpoten-
tialliesintherange0.1-0.33kgCO2eqv./kg.
ofsteelcoatedandgrossenergyrequirementin
therange3.4-5.3MJ/kgofsteelcoated.
Thiswouldappeartobeasmallpricetopay
forthelong-termdurabilityofsteelstructures
thatisachievedandtheenergy-intensivemain-
tenanceoperationsthatareeliminated.When
galvanizingisnotused,theenergycostsof
maintenancearesignificantandcaninclude:
•Repeatedapplicationofpaint
•Accesssystemstoallowmaintenance
painting
•Roadclosuresandtrafficdelays
Severalstudieshaveinvestigatedthelifecycle
energysavingsassociatedwithuseofgalvani-
zingforlong-termprotection,comparedtothe
principalalternative,i.e.,paint.Twoofthese
studieswerereportedinpreviousissuesof
thismagazine(4/2004 pp14-15 and 4/2006
pp14-15).
Acomparisonofpaintandgalvanizingforcoa-
tingofasteelbalconysystemwascarriedout
byVTTBuilding&Transportin2004.
Thestudyconcludedthat,overa60-year
servicelife,themaintenance-freegalvanized
coatingresultedinlessthanhalfthelifecycle
energyofthecompletebalconysystemcompa-
redtotheuseofapaintsystemwithassocia-
tedmaintenancepainting.
In2006,theTechnicalUniversityofBerlin
comparedpaintandgalvanizingforcoatingofa
steel-framedcarpark.Thestudyconcludedthat
theuseofgalvanizingforjustonesuch500
tonnesteelstructure,overa60-yearservice
1 Energy-relatedimpactsassociatedwithhotdipgalvanizing–asummaryofavailabledata(source:LCE,Torino)
Study
TU Berlin (Germany)
MRPI (Netherlands)
VTT Building and Transport (Finland)
EGGA Pan European Life Cycle Inventory
Gross Energy Requirement(MJ/kilogrammeofsteelprotectedbygalvanizingtoENISO1461)
notapplicable
3.4
4.3
5.3
Global Warming Potential(kgCO2equivalent/kgofsteelprotectedbygalvani-zingtoENISO1461)
0.09
0.2
0.2
0.33
Reference and Notes
VTT/IZA2004
EGGA2006.Dataexcluderecyclingcreditforzincrecycledatend-of-life
2 Photo:mattessekiguchipartnerarchitects,Heilbronn
2008
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HOT DIP GALVANIZING
AninternationaljournalpublishedjointlybythegalvanizingassociationsofGermany,
TheNetherlandsandGreatBritain.ItislicensedtoassociationsinSpain.
Edited by: G.Deimel, H.Glinde(EditorinChief),I.Johal,D.Baron,
Drs.G.H.J.Reimerink
Published by:GalvanizersAssociation,Wren’sCourt,
56VictoriaRoad,SuttonColdfield,WestMidlandsB721SY,UK
Tel:+44(0)1213558838 Fax: +44(0)1213558727
E-Mail:[email protected]:www.galvanizing.org.uk
Thismagazinemaynotbecopiedwithoutthewrittenpermissionoftheeditor©2008.
Distributed in Australia by: GalvanizersAssociationofAustralia,124ExhibitionStreet,
Melbourne,Victoria3000,Australia,Tel:0396541266,Fax:0396541136,
E-mail:[email protected]
Sustainability
life,wouldresultinasavingofover50tonnes
ofCO2.Forcomparison,burning1000litres
ofpetrolinacargeneratesapproximately2.5
tonnesofCO2.
Comparisonsforspecificstructuresmayvary,
butitisclearthatavoidingmaintenancewill
resultinsignificantlylowerenergydesign
solutions.
Evenbeforeservicelifeburdensaretakeninto
account,theinitialgrossenergyconsumption
ofhotdipgalvanizingcomparesveryfavourably
toothermethodsofprotectingsteel.Thisis
partlyduetothehighlevelsofenergyefficiency
thatareachievedbymoderngalvanizingfacili-
tiesandalsotherelativelylowenergycostsof
zincproduction.
Ofcourse,energyisrequiredtoheatthehot
dipgalvanizingbathandthisisusuallysupplied
bynaturalgas.Thegalvanizingindustryhas
madegreateffortstomanageitsenergyuse
efficiently.
Forexample,theindustryintheNetherlands
andUKhassetformaltargetsforenergy
efficiencyandthishasencouragednew
technologyandmanagementproceduresto
reachthesegoals.Importantaspectsof
energyefficiencyinclude:
•Operatingtheprocessonamulti-shiftbasis
•Useofmoreefficientinsulatedbathlids
(usedduringmaintenanceordowntime).
•Greateruseofwasteheatforheatingof
pre-treatmenttanks.
Galvanizing’smainrawmaterialiszinc.Zinc
hasalowso-called“freeenergyofformation”
comparedtomostothermetals.
Thisisanimportantchemicalcharacteristic
whichmeansthatitisrelativelyeasytosepa-
ratezincmetalfromitsores.Figure3shows
theenergyuseforprimaryproductionof
variousbasemetalsusedinconstruction,
includingzinc,inrelationtobothweightand
volume.
Amoredetailedknowledgeoftheenergy-
relatedaspectsofhotdipgalvanizinghas
highlightedthebenefitsofitsuseinreducing
thelifecycleenergydemandofsteelstruc-
tures.Whenmeasuredonalife-cyclebasis,the
avoidanceofmaintenanceduringservicelife
canleadtosignificantreductionsinthelegacy
ofenergydemandofasteelstructure.
Thisshouldleadtoafreshinterestinuseof
thissimpleandeffectivemethodofcorrosion
protectioninprojectswheresustainability
criteriamustbemet.
3 Energyuseforprimaryproductionofvariousbasemetalsinrelationtobothweightandvolume(valuesforiron/steelsetat1ineachcase)(source:Naturvårdsverket(1996).Metaller:MaterialflödenIsamhället.NaturvårdsverketRapport4506) 4 EnergyandGlobalWarming:Someusefuldefinitions
Carbon Footprint
Acarbonfootprintisameasureoftheimpacthumanactivitieshaveontheenvironmentintermsoftheamountofgreenhousegasesproduced,measuredinunitsofcarbondioxide.
Embodied energy
Embodiedenergyisthesumofthetotalprimaryenergyconsumedinthemanu-factureandsupplyofproducts.Thiswouldnormallyincludetheenergyusedinextraction,processingandrefining,transport,production,packaginganddeliverytothesiteinaconditionreadytousewithoutfurtherprocessing.Therearetwotypesofembodiedenergy:cradle-to-gateandcradle-to-site.Thedifferenceinthetwodefinitionsistheenergyassociatedwithtrans-portingtheproductfromfactorytositeofuse.
Global Warming Potential
GlobalwarmingismeasuredaskilogramCO2-equivalents.Globalwarmingisthegradualincrease,overtime,oftheaveragetemperatureofearth‘satmosphereandoceanssufficienttoinducechangesontheearth‘sclimate.Thisincreaseonearth‘stemperatureisrelatedtotheincreaseoftheemissionofgases,suchas,CO2,methane,watervapour,nitrousoxideandCFC’s,amongothers,fromman-madesources,mainlyfromthecombustionoffossilfuels.
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4
3
6
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Rel
ativ
e en
ergy
con
sum
ptio
n
Energy/weight
Energy/volume
Fe Zn Cr Cu Ni Al
Fe=Iron,Zn=Zinc,Cr=Chromium,Cu=Copper,Ni=Nickel,Al=Aluminium
Panopticons*,fundedbytheNorthwestRegi-
onalDevelopmentAgencyandtheLancashire
EconomicPartnership,isavisionaryscheme
tocreateauniqueseriesof21stcenturyland-
marksacrossEastLancashireassymbolsof
therenaissanceofthearea.
“SingingRingingTree”isthethirdPanoptionto
becompletedandistheculminationofwork
donebyarchitectsTonkinLiu.
Althoughonfirstglancetheconceptseems
verysimplealotofdesignskillwasinvolvedin
makingitintoavisuallybeautifullandmarkwith
anexceptionalfinishingtwist.Theplacement
ofthehollowgalvanizedtubeshasbeenset
withsuchprecisionthathasthewindpasses
throughthemthetreesingsinharmony.(Listen
totheSingingRingingTreewww.youtube.com).
Architects: ArchitectsTonkinLiu
Photo: IanLawson
Galvanizing in Detail
Galvanizing DelightBy Iqbal Johal
2008
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*structure,spaceordeviceprovidingacomprehensiveorpanoramicview