Hot Dip Galvanizing Magazine 3/2010

2010

3/4 Hot Dip GalvanizingInternational Magazine | ISSN 1363-0148 | www.galvanizing.org.uk

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Editorial

2 | Hot Dip Galvanizing

I suppose that a magazine dedicated to some-

thing as inert as galvanizing doesn’t often

cause you to go ‘aaaawwww’ when you open

it. However, the baby elephant, opposite, could

well have that effect. But, having caught your

attention and then read the article, you will no

longer be able to visit a zoo or animal enclo-

sure without looking for the galvanized steel.

Welcome to the Order of the Galv Anoraks!

To quote Michael Caine, not a lot of people

know that… Bradford has an area called Little

Germany and one of the buildings there won

the Galvanizing in Architecture award at this

year’s GAGA’s (Galvanizers Association Galva-

nizing Awards) held in London recently. (This is

as it should be, as one of our partners in this

magazine is the German Galvanizers Associa-

tion.) As ever with the GAGA’s, I defy you not

to find something that you like. My favourite?

Phil Johnson’s ‘Arts and Crafts’ inspired steel-

work does it every time for me. Serious whisky

drinkers might prefer the distillery, though.

And finally – my thanks to Marta who put in a

kind word for this magazine on BBC Radio 2’s

Radcliffe & Maconie Show recently. Marta –

that wasn’t a dose of Post-Modern irony was it?

David Baron, Editor

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Contents

2 Editorial

3 Friendly Zoo Environment Protection and Comfort

6 Hot Dip Galvanizing Awards 2010 The Winners

13 Coloured and Durable EN 15773 - Promoting good

communication

14 Modern-day Warehouse Galvanizing and modular

construction

16 Galvanizing in Detail

Front cover:

Roseisle Distillery

Photo: Keith Hunter Photography

Photo above right: Ulla Trampert/pixelio.de

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In conjunction with this are issues of providing

a habitat for animals that is humane, practical

and conducive to as natural way of life as pos-

sible. We feature some examples that provide

the best of present design.

Dublin Zoo (1,5)The investment by Dublin Zoo of over €4.5

million in a new 8,000 m² elephant enclosure

demonstrates the importance attached to this

world-leading breeding programme of Asian

elephants. The enclosure houses Bernhardine,

Yasmin, Anak and new arrival Asha, the first

elephant born in Ireland.

The elephant house is a straightforward galva-

nized steel frame structure with a metal clad

roof. Internal gantries support the pen divisions

and gates and all the internal steelwork and

fittings are galvanized. Galvanizing makes sen-

se in the corrosive environment of an animal

enclosure. It provides a lifetime guarantee and

the sort of maintenance-free solution appropri-

ate for these magnificent animals who them-

selves have a life span of over 75 years.

Key to the Dublin Zoo breeding programme

is a need to examine the elephants regularly

through their pregnancy to maintain them in

perfect breeding condition.

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There has been a long, historical link to the use of galvanized steel within the agricu-

ltural/horticultural sector, establishing its use in the environment of animals. On first

thoughts it may come as a surprise to some that galvanized steel plays an important

role in other animal environments as well, namely zoos. On reflection, it becomes an

obvious choice considering the coating’s innate properties:- durability, toughness and

sustainability.

Architecture

Friendly Zoo EnvironmentProtection and Comfort

By Gerard Reimerink/M. Franke

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Elephants in captivity have particularly sensi-

tive feet and regular pedicures are essential,

as well as other veterinary treatments and

pregnancy checks. Examining a 4.5 tonne ele-

phant in a safe manner is a tricky business.

A lot of exposure was used to implement the

final design of the enclosure.

The design is simple yet functional. The crush

chute has an array of safety features so that

both the elephant and the veterinary care staff

are safe when the elephant is undergoing an

examination. Panels in the crush open in infi-

nitely variable sections to allow veterinary staff

safe access to all parts of the elephant's body.

Crush width can be adjusted to suit all sizes

and ages of elephant so that complex proce-

dures can now be carried out without stress or

sedation. International elephant expert, Alan

Roocroft has described the crush as an essen-

tial tool in the integral management of the

veterinary and breeding process of an elephant

in conservation.

Giraffe Enclosure, Rotterdam Zoo (2,3)The enclosure, modelled on an African coral,

has been designed to take advantage of pas-

sive solar heating and natural ventilation and

lighting. Specially designed ‘cuddle walls’ (steel

elements heated by the burning of wood chips)

provide warmth for the giraffes without the

need to heat the whole enclosure.

SustainableThe Savannah House is unique: it is the first

building designed for animals according to

the principles of the sustainability philosophy

called Cradle to Cradle. It is an assignment

that fits the ambitions of the Rotterdam Zoo,

where sustainability is one of the key issues.

“It forced us to unite the tensions between

the neutral climate requirements ambitions

and that of a healthy climate for the African

animals.

The end result gives a special satisfaction”

says Menno Lam of LAM architects

(Wageningen).

Healthy indoor climateThe accommodation for the giraffe is designed

as a “shelter”, of which the archetype of the

African coral has served as the model. The

design provides a comfortable place for the

animals. It also gives them more living space,

the giraffes are free to go in and out as they

please. To create a sustainable building with

a good indoor climate, the design takes into

account the natural elements of sun, wind and

rain.

For natural light and heat, so-called passive

solar energy is used. The galvanized roof is

transparent and the height of the walls is

determined for the best solar potential both

inside and outside, because even on a beau-

tiful sunny winter day, the animals are able to

stand at the north side outside the building. On

cold and cloudy days it is usually sufficient only

to provide heat for the animals instead of the

whole 4500m³ building. This is possible due to

the “cuddle-walls” which use heat from burning

woodchips instead of fossil fuels.

Natural ventilation also contributes to the

pleasant atmosphere. This is achieved by the

orientation of the building towards the most

common wind direction. The principle of nega-

tive air pressure pulls the wind through the

building. The annual rainfall of approximately

330,000 litres off the roof of the Savannah

House will be collected and used for the thirsty

plants in the adjacent building.

Many materials within the “licking-range” of

the giraffes are applied untreated. This is to

prevent the use of toxic substances, which

obviously would be picked up by the giraffe’s

tongue when licking exposed elements..

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Savannah House is not only comfortable for

the animals, but is sustainable too. This is not

only reflected in the design concept but also

in its use of materials including untreated FSC

timber, galvanized steel that forms the roof

structure, grasses and pressed bamboo.

Amersfoort Zoo (4,6,7)

In Amersfoort Zoo, hot-dip galvanized steel

has also been used for rhino gates, a ‘walk-

through area’ for macaws, the night enclosure

for baboons and a tiger compound. This com-

pound is home to two white tigers which are

extremely rare in the animal world.

By using galvanizing as a surface treatment,

the steel structure of the enclosures which

are set up outside, is given the best possible

protection against corrosion as a result of the

climate. Furthermore, the hot-dip galvanized

structure requires little or no maintenance.

The mechanical properties of the applied

coating are also important; of all galvanizing

offers the best protection against impact and

abrasion. The tiger area has an extremely

varying shape in width and depth as well as

height. It has been built around a large number

of trees and has been fully integrated into

the environment. The structure is built using

galvanized steel carriers which are connected

to each other at the top by cross beams. The

multi-faceted supporting structure is connected

to various other sections. The varying shape of

the area is further emphasised by the upper

side which varies in height and has also been

constructed using galvanized steel beams. A

particular detail is the connection of the enclo-

sure to a building which represents an ancient

palace. Visitors can therefore see the white

tigers not only from the outside but also from

the palace.

There are many more traditional uses of galva-

nized steel structures within a zoo environment

including gates, walkways and canopies.

The inherent characteristics of galvanizing’s

durability and inbuilt toughness makes it an

obvious coating to use.

We should never lose sight of the fact that alt-

hough zoos offer a great experience for oursel-

ves, our children and opportunities in the field

of research, the wealth and well-being of wild

animals should never be taken for granted.

Photos:

(1,5) Dublin Zoo, Andrew Longwill

(2,3,4,6,7) G. Reimerink

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Architecture

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Die Tragkonstruktion des Gebäudes besteht

aus regen schirm artigen Stützen mit Kragträ-

gern in den Abmes sungen 12 x 12 m bei 2

bzw. 3 m Abstand. Die Stahlkonstruktion mit

einem hohen Anteil an Hohlprofilen wurde

sichtbar belassen. Bei den querverstrebten

Haupt armen der „Regen schirme“ handelt es

sich um vorgefertigte Elemente, welche die

Aufnahme der Dachlasten bei minimiertem

Werkstoff einsatz er mög lichen. Die diagonale

Anordnung der Haupt rahmen und die formbe-

dingte Gewölbewirkung führt zu einer beson-

ders steifen Konstruk tion, die Kreuzverbände

im in den Wänden überflüssig macht.

Der ursprüngliche Konstruk tions entwurf wurde

mit Hilfe eines 3D-Softwarepakets verfeinert

und optimiert, um dann die wirtschaftlichste

der alternativen Lösungsansätze zu realisieren.

Den Verbindungen wurde dabei besondere Auf-

merksamkeit ge widmet, da die Konstruktion

in der Werkstatt vorgefertigt und anschließend

nach dem Feuerverzinken vor Ort vollständig

verschraubt wurde. Baustellenschweißungen

waren nicht er forderlich; – ein wesentlicher

Bei trag für den ästhetischen Eindruck, für die

Wirksamkeit des durchgängigen Korrosions-

schutzes und nicht zuletzt auch für die Kosten-

kontrolle.

Der Pavillon steht auf der Küsten-

mauer und ist deshalb hohen Windlasten

ausgesetzt. Die Bemessung erfolgte deshalb

in Anlehnung an den australischen Wind-Code.

Als Ergebnis wurden die durch Horizontalträ-

ger versteiften Fensterrahmen in die Trag-

konstruktion integriert; die Horizontalträger

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Der Pavillon steht auf der Küstenmauer und

ist deshalb hohen Windlasten ausgesetzt. Die

Bemessung erfolgte deshalb in Anlehnung an

den australischen Wind-Code. Als Ergebnis

wurden die durch Horizontalträger versteiften

Fensterrahmen in die Trag konstruktion inte-

griert; die Horizontalträger bilden dabei die

Dachkante des Pavillons.

Ein restauriertes und nunmehr wieder funktionsfähiges Dampf karussell aus dem 19.

Jahr hundert wurde vor kurzem im Hafen der australischen Stadt Geelong der Öffent-

lichkeit vorgestellt. Dieses Karussell mitsamt zu gehöriger Dampf maschine, Orgel und

Musik ka pel le wurde durch einen unverwechselbaren Stahl- und Glas-Pavillon vor den

Witterungs einflüssen des aggressiven Küs tenklimas geschützt.

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Sport- und Freizeitbad „ISHARA“ Attraktive Bäderlandschaft am Bielefelder Hauptbahnhof

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1 Fußgängerbrücke | Ernst Steiner 2 Fußgängerbrücke | Ernst Steiner


“As has happened last year, the judges have

exercised their right to cut their coat according

to their cloth, so this year sees us with four

recipients of the hallowed watering can. The

Architecture Award goes to a small Anlgo/Ger-

man firm, ironically doing some deft and con-

sidered galvanized interventions in Bradford’s

Conservation area of Little Germany. The win-

ner of the Engineering prize is awarded to the

bravura of an industrial hanger for whisky dis-

tillation in Scotland. The Duplex prize goes to a

small addition to a faceless football changing

block that completely changes the relationship

of the building to the pitch outside it, and the

Detail winner is a gate that impinges on its

church to which it is attached with the lightest

of touches. All of them raised the mechanical

and ostensibly prosaic nature of galvanizing to

a form of artistry to make them well-deserved

winners. The high level of submissions left us

pondering our choices well into the afternoon.

It also gave us the opportunity to award ‘Highly

Commended’ accolades to three projects that

incorporated galvanizing into their fabric, and

which, as building, social agenda, or incorpora-

tion into the landscape, were justified in their

own rights and deserved individual recognition.

Both these and the award winners serve as

exemplars of galvanizing, and show how its

industrial nature and simplicity can be raised

to something that is both functional and endu-

ring. The simplest solutions are at the root of

all good architecture, and this year’s winners

prove that point beautifully.”

Jan-Carlos Kucharek, RIBA Journal

The GAGA competition for 2010, sponsored by Zinco UK, continued to elicit strong

views and opinions from the judging panel. One of its endearing qualities is that it

attracts a variety of entries ranging from delicate, highly crafted to the urban

community changing projects and everything in between.

Galvanizing Awards

Hot Dip Galvanizing Awards 2010The Winners

By Iqbal Johal

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Galvanizing in Architecture Winner

Tayson House, Bradford — Kraus Schönberg Architects (1-3)Development of the grade II listed Tayson

House involved the refurbishment and new

extension of a Victorian warehouse building.

In the 19th Century, central Bradford attracted

a merchant German community that gave rise

to the formation of Bradford’s ‘Little Germany’.

The formation of Bradford’s Little Germany

took place in various stages which can be seen

in the different sizes of the warehouses.

Starting with two to three storey buildings in

the early 1830s, the trend changed towards

grander structures in the late 1850s. Tayson

House was built around 1870 and its four

floors have a two storey neighbour. The new

infill structure tries to mediate between the two

historical buildings, making a clear statement

in its own time – the present.

The new extension is hung from a steel frame

creating a minimal interface with the existing

buildings.

By creating its own architectural language, the

glass, galvanized steel and timber structure

can be seen as a separate entity. This allows a

continuation of the industrial character of Little

Germany and helps to regenerate the area. The

industrial legacy of little Germany in Bradford,

with ornate sandstone façades and cast iron

metalwork, led to the choice of a cladding

material in galvanized steel.

The façade consists of 3mm galvanized steel

plates which are folded around the corners of

the new extension.

The aim was to give the structure a similar

solid appearance as the surrounding buildings,

avoiding cladding joints as much as possible.

The new structure retains a certain autonomy

by cantilevering over the front and rear

façade and thus being easily visible from

the street.

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Galvanizing in Engineering Winner

Roseisle Distillery, Scotland — RIM Fabrications (4-7) Roseisle Distillery in Elgin is Scotland’s first

major distillery in 30 years and, with a gross

internal area of 3,000m², also its largest, with

a potential output of 10 million litres of malt

whiskey per year. The building is a modern

interpretation of the traditional still house and

maximizes natural ventilation and daylight.

The layout and massing of the building express

whisky-making’s three main processes:

mashing, fermentation and distilling.

The mashing stage takes place in the western

and central volumes of the distillery. Malted

barley passes through a de-stoner and a grin-

ding mill and then enters two mash tuns, which

mix it with water to produce wort. The liquid is

fermented in 14, 10 metre high cylinders to

produce wash, a fluid similar to weak beer. The

wash then flows into the still house at the east

end of the building which contains seven pairs

of copper stills. The wash rises as it is heated

by the stills and passes through downward-slo-

ping tubes into condensers where it is distilled

again. This completes the distillation process.

For architectural reasons, the mash house

is higher than necessary: a lower roof in this

central area, which projects in plan, would have

looked proportionally awkward.

A wonderful feature of the distillery is the abili-

ty for visitors to view the 8m high stills through

a liquid - crystal window in the conference room

that can be clear or opaque.

There are a number of features that make

Roseisle stand out as a distillery like no other.

The almost sculptural design of the copper

stills help to almost create a ‘cathedral ‘ like

space combining the galvanized steel frame,

copper stills and the stainless steel tanks. The

interplay of materials with their precise detai-

ling help to transform what would normally be

a typical process plant into a grand space that

has been achieved with flair and simplicity.

Duplex Award Winner

Tolka Rovers AFC, Dublin —Denis Byrne Architects (8-10)Tolka Rovers AFC was founded in 1922. After

moving between different locations, they

settled in 1979 at Griffith Avenue with the

opening of a new sports complex. Increased

demand for higher standards in changing faci-

lities and additional space for functions and

corporate entertaining required an extension

of the existing building. The addition of a two-

storey viewing gallery and changing rooms has

provided the required facilities.

The restricted space between the pitch and

existing buildings with a public access road to

a car park was addressed with a shallow and

stretched volume resulting in the upper floor

cantilevering over the footpath below. An expo-

sed steel structure expresses the cantilevered

design and frames the different uses on both

levels. The ground floor contains two new chan-

ging rooms with showers and washrooms for

the home and the away sides with a separate

changing room for the referees.

A new disabled lift connects the existing bar to

the ground level via the new viewing gallery. A

balcony and a fully glazed function room on the

upper level opens the existing bar area to the

pitch, allowing members to follow the match in

the dry. Sliding partitions facilitate the separati-

on of different spaces for various often simulta-

neous functions.

Galvanizing in Detail Winner

South Porch Gates, West Lothian - P. Johnson & Company (11-13)St Michael’s Church has stood on this site in

the Royal Burgh of Linlithgow since 1242, it

is one of the largest burgh churches in the

Church of Scotland.

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Through the ages, many of the Scottish kings

and Queens have been patrons of St Michael’s

and Mary Queen of Scots was baptised here

in 1542.

The South Porch Gates were commissioned by

The Society of Friends of St Michael’s Church.

The Gateway was designed, forged and instal-

led by P. Johnson & Company, artist blacks-

miths at Ratho Byres Forge, and dedicated by

the former minister in April 2009.

The Gateway, which consisting of two gate leafs

and an overthrow, has been hand crafted using

traditional blacksmithing skills and techniques.

The hot forging of mild steel, punched holes,

forged tenons, rivets, fire welding, forged leaves

and tapers are all evident of the highly skilled

craftsmanship utilised to create the gates.

The design, which consists of intertwining

tendrils, leaves & hanging grapes, is repre-

sentative of the true vine. The Gateway took

three blacksmiths, working at the fire and anvil

and then riveting the elements of the gates

together, three months to complete. Due to

Grade A listed building status, permission had

to be obtained for the addition of a gate to the

building. The gate design was approved but

no fixings were allowed into the fabric of the

building to hang the gate. The overthrow is

ingeniously clamped around the curved pillars,

holding it firmly in place. The gates are hinged

from the overthrow above and the ground

below.

The gates and overthrow were etched using

T-Wash, spray painted with two coats of under-

coat and then two top coats of Ratho Grey

MIO, (micaceous iron oxide paint), a very hard

wearing paint which adheres well to the acid

etched galvanized finish. Graphite powder was

mixed into the paint, which then burnished

the surface to give a lustrous finish. The South

Porch Gates look very much a part of this anci-

ent historic building. The durability of the gates,

both in the timeless design and workmanship

to create the gates and the use of galvanizing

and painting as an appropriate finish ensures

that the South Porch Gates will endure as part

of the fabric of this historic church for many

generations to come.

Highly Commended

The Small Animal Hospital, Glasgow - Archial Architects (14-16)Located at the entrance to the grounds of

the Garscube Estate, Glasgow, the new Small

Animal Hospital, part of the University of

Glasgow’s Faculty of Veterinary Medicine, provi-

des state of the art services for animal owners

and referring practitioners throughout Scotland

and Northern England, including the most

advanced diagnostic, therapeutic and surgical

techniques.

The primary driver in the design for this facility

was how to create a large hospital building

without ruining the beautiful green space for

which the Garscube Estate is justly renowned.

Essentially, the solution was to use the topogra-

phy of the site, lift up the ground, peeling off

the grass, and place the new building under-

neath. The sloping roof form, by its nature,

allowed an uneven split of accommodation with

two-thirds at ground level and one-third on the

upper floor – this matching the client’s brief.

As various aspects of the new facility did not

require natural light – much of its 4500 sq m

involves internal spaces such as the treatment

area, oncology, and diagnostics – this deep

plan design solution was able to meet the com-

plex needs of the hospital whilst maintaining

the integrity of the location. However, to provide

natural light to internal circulation areas and

to give the building an open and welcoming

feel, the design team introduced a number of

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key penetrations through the building’s sloping

grass roof plane, i.e. the funnel which introdu-

ces light into the heart of the central treatment

area, and an innovative ‘crystal’ glass cupola or

lantern, which spills light on to the public con-

course. This creates a presence to the street

and an iconic public image to the local and

wider community.

Internally the building is simply organised both

horizontally and vertically with a clear divisi-

on of public and private hospital space. The

working hospital held within the gabion wall

pinwheels around a central treatment hub that

acts as the heart of the building offering clear

and unrestricted views towards, daycare, inten-

sive care, operating suites, diagnostics, and

oncology. The upper level of the public access

side of the building has a café /rest area

separating the visitors from the pets below

and offering unrestricted views back to the

surrounding landscape, the campus entrance

and beyond.

The remainder of the upper floor is given over

to staff social space, meeting rooms, library,

student study, and staff office spaces, with

views over the estate and access onto the

grass roof.

The project was traditionally procured at an

overall build cost of £10.5m, with a square

metre rate of approximately £2300 per square

metre. The finished building has superseded

the users’ expectations and is now widely

regarded as Europe’s most advanced animal

hospital, setting a new benchmark for veteri-

nary hospitals in the future. At close quarters,

the eye is immediately drawn to the galvanized

weldmesh gabion basket cladding, filled with

brown quartzite stone, using a rectangular

section wire rather than the more typical

round wire gauge. The external principal roof

supports (e.g. the ‘Y’ columns) have also been

coated with an intumescent layer for fire pro-

tection and spray painted with a smooth gloss

decorative colour finish. The other galvanized

metalwork has all been left uncoated, and with

the heavy galvanized lintels complementing the

robust finish of the gabions.

Highly Commended

Twin Peaks, Whitstable - Thinking Space (17,18)This simple boathouse was designed to be

tough but welcoming. The site is just to the

east of Whitstable and very close to the sho-

reline. The building was designed to act as a

boat store in the winter and a space to enjoy

the ever changing sea and skyscape in the

summer.

The design includes an open plan living area

and two cleverly designed sleeping platforms in

the roof pitches with views of the sea. In win-

ter, storm swells can bring the water right up

into the garden and the location of the building

needs to stand up to the harsh environment.

To appreciate the wonderful estuary views,

virtually the entire sea facing façade is formed

of sliding glass panels.

Additional protection is provided to all the ope-

nings by the addition of articulated protective

panels that winch down to form ramped decks,

and up to protect the windows.

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The building itself is conceived as an almost

primitive hut (after Laugier) with the structure

clearly expressed internally and externally. Gal-

vanizing was the natural choice for protecting

all the steelwork. The clarity and materiality of

the construction gives grain and interest to the

spaces.

Highly Commended

Memorial Recreation Ground, London — Saville Jones Architects (19,20)In 2005, Saville Jones Architects were appoin-

ted to undertake a Feasibility Study on Memo-

rial Recreation Ground in West Ham – an

important location in football history being the

site where the Thames Ironwork Football Club

was founded in 1897, later to become West

Ham United.

On completion of the feasibility study, Saville

Jones was appointed by the West Ham and

Plaistow NDC to develop and implement the

design within Memorial Recreation Ground.

The remodelled and re-landscaped park entran-

ce, including a tall, painted galvanized ‘kissing

gate’ and fence, leads to two, new sustainably

designed changing pavilions – one pavilion

serving the grass pitches and the other the arti-

ficial grass pitch.

The gate structure was carefully designed to

prevent access to the park by motorcycles.

Both pavilions include a Sedum green roof to

maintain the biodiversity of the park, whilst

allowing the buildings to blend into the green

landscape which surrounds them. Security

and robustness were important factors for the

buildings, as they are not in continuous use

throughout the year and are located in a well

used public park, therefore the outer skin of the

pavilion was designed to require little mainte-

nance and discourage graffiti artists from using

them as canvases.

Stone filled galvanized gabion baskets wrap

around large sections of the pavilions, posi-

tioned within galvanized steel T-section bays

and topped with a galvanized steel weldmesh,

which protects the high level glazing of the buil-

ding. This low maintenance galvanized ‘skin’

armours the building from the elements and to

date has successfully discouraged vandalism.

Large, protective doors printed with football

images secure the main entrances to the pavili-

ons, providing both visual interest and security

during periods of closure. Elsewhere in Memo-

rial Park, the configuration of the pitches was

amended to include a floodlit 3rd Generation

Artificial Grass Pitch, along with new drainage

to the first rugby pitch and one senior football

pitch.

Photos:

(1,2,3) Kraus Schönberg Architects

(4,5,6,7) Keith Hunter Photography

(8,9,10) Eugene Langan

(11,12,13) Shona Johnson

(14,15,16) Andrew Lee

(17,18) Thinking Space

(19,20) Haydn Jones

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Architektur



For many years galvanizing has been used to provide a long maintenance-free life

for steel. The industry has always advocated good communication between specifier,

contractor, fabricator and the galvanizer. This ensures that the end user receives the

product that they desired on specification.

One slight downfall of galvanizing for some, is

that it only comes in one colour: ‘silver grey’

and if you require anything different, then life

becomes a bit difficult. However, help is at

hand with many systems that can be applied

on top of galvanizing to achieve the desired

colour – a system known within the industry as

‘duplex’ (application of a wet paint or powder

coating). In the same way that good communi-

cation is important with galvanizing, the same

is even more important when specifying a

duplex system.

EN 15773* published in 2009 provides useful

guidance on the communications and agree-

ments necessary to achieve a good quality

duplex system for the client. The standard uses

EN 13438:2005* as the default standard for

powder coating and hot dip galvanized articles

but also acknowledges that alternative product

specific standards may also be referenced.

Some of the areas that are covered by the new

guidance standard include:

• Fabrication and composition of the material

• The zinc coating

• Storage, transport and application

• Pre-treatment

• Packaging, storage and movement of

finished products

• Installation

• Inspection

Definitions

These include the specifier, steel constructor/

manufacturer, powder manufacturer, carrier

and supplier of chemicals. These are the com-

ponents which, together with the designer, gal-

vanizer and applicator of the organic coatings,

determine the quality of the duplex system.

Specification details

Once the design has been completed, the key

for a good end result lies with specification

details to the applicators. However, others

also play a role. The new EN 15773 standard

includes information which indicates who is

involved in each stage and which documents

are relevant for good quality. Ordering must be

accurate and the client must ensure that the

required information is available at every stage.

Similarly product suppliers should inform the

client correctly and on time.

Preparation of coating surface

Special attention to the preparation of the coa-

ting surface is required for a good end result.

Galvanizers often use a finishing system for the

galvanized product in order to comply with the

various expectations for its end use. In some

cases an almost smooth surface is required

while in others the removal of large irregulari-

ties in the zinc surface is sufficient. This can be

indicated at the time of specification.

Testing

The preferred standard EN 13438 sets out

adequate benchmark for the preference of the

selected system. This together with the requi-

rements in EN ISO 1461 therefore offer the

correct balance for both product supplier and

client(s).

The further defining of roles within this new

guidance document will, it is hoped, help spe-

cifiers and clients with galvanizers and appli-

cators to achieve the desired result that we all

aim for.

*EN 15773 Industrial application of powder organic

coatings to hot dip galvanized or sheradized steel

articles.

*EN 13438:2005 Paints and varnishes. Powder organic

coatings for galvanized or sherardized steel products for

construction purposes.

Technical

Coloured and DurableEN 15773 - Promoting good communication

By Gerard Reimerink

2010

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HOT DIP GALVANIZING

An international journal published jointly by the galvanizing associations of Germany,

The Netherlands and Great Britain. It is licensed to associations in Spain.

Edited by: G. Deimel, H. Glinde (Editor in Chief), I. Johal, D. Baron,

Drs. G. H. J. Reimerink

Published by: Galvanizers Association, Wren’s Court,

56 Victoria Road, Sutton Coldfield, West Midlands B72 1SY, UK

Tel: +44 (0) 121 355 8838 Fax: +44 (0) 121 355 8727

E-Mail: [email protected] Internet: www.galvanizing.org.uk

This magazine may not be copied without the written permission of the editor © 2010.

Distributed in Australia by: Galvanizers Association of Australia, 124 Exhibition Street,

Melbourne, Victoria 3000, Australia, Tel: 0396541266, Fax: 0396541136,

E-mail: [email protected]

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However, with the gradual implementation of

different ways of sourcing and storing goods

this has led to a totally new form of warehou-

sing. Modular, light shells have become a domi-

nant feature of our landscape and are taken

for granted by some or are seen as an eyesore

within our urban realm by others.

Recent retailing trends have even led to the

development of warehouse-style retail stores.

The new breed of modern day warehousing at

the top end of the market are not just modular

buildings but highly designed and efficient

structures fine-tuned to offer the exact require-

ments of their owners.

Here we highlight some simpler designs from

Germany that are available across the world.

They offer a simple, permanent or temporary,

solution for storage and distribution. The new

design techniques offer limitless options on

the exact design and functionality for the final

structure and offer major advantages over the

traditional warehouses of the past.

The new modular designs offer:

• a more cost effective solution than their

site-built counterparts

• speed of construction/faster return on

investment - modular construction allows for

the building and the site work to be com

pleted simultaneously, reducing the overall

completion schedule by as much as 50%

• off-site construction is non weather depen

dent which increases work efficiency and

avoids on-site damage and therefore saves

costs on repair

Architecture

Modern-day Warehouse Galvanizing and modular construction

By Holger Glinde

Traditional warehousing has declined since the latter part of the 20th century, with

the gradual introduction of just-in-time techniques. The promotion of product delive-

ry directly from supplier to consumer has meant the decline of the traditional grand

warehouses of the 18th and 19th centuries.


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• low waste - with similar design concepts

being used and an inventory of exactly what

quantity of materials are needed for a given

job. This will also ensure that much less

waste will be produced

• more environmentally friendly construction

process - modular construction generates

less materials waste and less site distur

bance than comparable site built structures

Protecting the steel that is often used for these

structures is normally not considered an impor-

tant aspect of the design solution.

Here is what Jens Geißner, the managing direc-

tor of Haltec Hallensysteme GmbH, a leading

manufacturer of modular systems says on the

subject: “In principle, steel structures from

Haltec are hot dip galvanized, and this gives

them considerable added value. The steel is

given long-term protection against corrosion, it

is extremely robust against mechanical dama-

ge, it needs no additional coating, and thus an

important contribution is made to sustainable

construction.”

Galvanizing goes hand in hand with the pro-

cess of modular construction:

• the coating is carried out in a factory

controlled environment off-site so the

vagaries of the weather do not play any role

in its application

• it aids in the quick erection of the structure.

It's toughness characteristics mean that on-

site damage is limited

• it does not hamper a major benefit of

modular construction in that the structure

can be demounted and re-erected without

damaging the coating so the protection to

the steel remains for many years to come.

With cost, waste and the importance of mate-

rial use becoming ever more important issues,

the protection systems used within modular

design should be at the forefront of the design

brief.

Photos: www.haltec.net

Architecture

2010

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There are two provincial roads which run

through Doorn (U). At the crossroads is the

town centre which includes the town hall, the

church, a restaurant and shops. The most

important attraction here is “Huis Doorn”, the

last residence of former Emperor Wilhem II of

Germany.

A 48 metre long bench made from galvanized

steel and FSC wood has been positioned with

its back to one of the main roads. IPV have

used the same basic features which are used

for their bridge designs - the design is simple,

effective and inspired.

Design: IPV Delft, Delft

Manufacturer: Falco, Vriezenveen

Galvanizing in Detail

Galvanizing Delight

2010

3/4

Documents

Hot Dip Galvanizing Magazine 3/2010