Hot Dip Galvanizing Magazine 3/2011

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

2011

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Editorial

2 | Hot Dip Galvanizing

As usual, this third issue of the year is chiefly

a celebration of the 2011 GAGA’s. I salute

what Bell Phillips have done at Heron Court in

London – winner of the Galvanizing in Archi-

tecture Award, opposite, and the beautiful,

sustainable house and boathouse in Norfolk by

LSI Architects (winner of the Sustainable Gal-

vanizing Award, p 5) as well as the many other

worthy winners. However, my real admiration

is reserved for the Galvanizing in Engineering

winner – Exposure, or The Crouching Man as it

is affectionately known.

Some of you may remember the statue of

the Invisible Man by Antony Gormley, which

won a GAGA a few years ago. It consisted of

thousands of seemingly random pieces of gal-

vanized steel, which, when you looked through

them showed the outline of a man hidden

within. Close up it seems as if Antony Gormley

has done it again with a massive great pile

of bits of metal pointing in all directions. But

step back a bit and each of those bits of metal

comes into focus as separate elements in a

human shape. I am in awe of Antony Gormley

for coming up with the design and concept, of

the engineer who translated that design into

bits of metal, the fabricator who produced tho-

se 2,000 different shapes and, lastly, the galva-

nizer who found the way to galvanize them (not

straightforward, apparently).

David Baron, Editor

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Contents

2 Editorial

3 GAGA's 2011 The Winners

10 Luminous steel facade Schönhauser Straße pumping

station

14 Cradle of the industrial Ruhr Galvanized shell at St. Antony

16 Galvanizing in Detail

Front cover:

Luminous steel facade

Photo: Kaspar Kraemer Architekten BDA

Photo above right:

Kaspar Kraemer Architekten BDA

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2011

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Hot Dip Galvanizing | 3

Galvanizing Awards

The 2011 GAGA competition continued to attract a wide range of entries. Social

housing through to a railway station were represented this year. Maybe its not

surprising that in troubled times you turn to a process that is predictable, reliable

and according to one judge able to "raise its game to that of art".

GAGA's 2011 The Winners

By Iqbal Johal

1

Galvanizing in Architecture Winner

Heron Court, LondonBell Phillips Architects (1-3)Bell Phillips architects grabbed the chance to

make a difference to a run down block of 60’s

social housing and produced a design com-

prising two buildings arranged around a com-

munal south-facing courtyard.

The two buildings are splayed with a steel stair

core at the apex, opening the courtyard to the

south to maximise the available sunlight and to

provide views towards the mature trees along

the canal side.

The development has been designed to provide

a mix of tenures and dwelling types creating a

vibrant, sustainable community. All of the dwell-

ings have been designed to be double-aspect

to provide good quality natural light, views and

space.

The timber cladding used on the upper floors

incorporates vertical timber fins. The articula-

tion of the fins is carried through to the struc-

tural design of the balconies and walkways

which use a filigree of fine galvanized steelwork

dimensioned and arranged to align with the

timber. The design of the balconies comprising

a lattice of fine steelwork reaching out away

from the building towards the garden and canal

is inspired by the branches and canopy of the

surrounding trees.

Galvanized steel has been an essential con-

stituent in the construction. The lightweight

galvanized steel frame allowed fast construc-

tion methods to be deployed providing a long

lifespan at the same time. And in terms of

visible elements, the galvanized steel core,

bridge links, balconies and elements of clad-

ding all contribute to the overall success of

the scheme, which has significantly exceeded

the client’s expectations and demonstrates

that, while remaining within the boundaries

of a standard budget, social housing can be

innovative, elegant and a highly desirable place

to live.

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3

Galvanizing Awards


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5

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Sustainable Galvanizing Winner

The Haven, Norfolk BroadsLSI Architects (4-6)The project is located on a prominent site on

The Norfolk Broads, and it was the clients

intention to provide an exemplary replacement

house which was sustainable and graceful in

design, complementing the location.

One of the main challenges was to address

the high flood risk which required the entrance

floor to be set at 1.3 metres above ground

level. Given this risk and high moisture levels

on the site, the detailing of materials meant

that robust and elegant solutions had to be

sought. Galvanized steelwork was the material

of choice along with the modified softwood

Accoya.

The boat house adjacent to the main house

is designed to allow flood waters to flow

unhindered through its base section. Here a

galvanized grillage runs along the base of the

cladding giving the building a light touch to the

ground. The main structure of the boat house

and access gates are manufactured from galva-

nized steel, as is the slipway inside.

The house has high levels of insulation, gains

heat from a ground source heat pump and en-

ergy from photovoltaic panels mounted on the

boat house. The house is 60% more energy

efficient than a 2006 Building Regulation Com-

pliant house and achieves Code level 4 of the

Code For Sustainable Homes for energy.


2011

3/4 Galvanizing Awards

7

8

9

Galvanizing in Engineering Winner

Exposure, The NetherlandsHad-Fab Ltd (7-9)Exposure, also affectionately known as

‘The Crouching Man’ is permanently positioned

100m from the end of a polder just off the

coast of Lelystad in The Netherlands.

Had-Fab were first approached by Antony

Gormley in 2005. It was their traditional

business of manufacturing transmission towers

for the UK Electricity network that tied in with

Gormley’s latest idea to move away from his

earlier work of solid construction

to an open structure similar to Pylons.

Exposure invites you to investigate, to walk to

it. As you approach, the nature of the object

changes. You can see it as a human form in

the distance. Close up it becomes a chaotic

frame through which you can look at the sky.

At this point you realise its true complexity.

At 26 metres tall, Exposure weighs 60 tonnes,

contains 5,400 bolts and consists of 2,000

components all of which are galvanized. If the

crouching man was ever able to stand up, it

would be 100m tall and an adult standing next

to it would barely be able to peek over its feet.

The project was a challenge at every stage of

its development and this form of construction

would not have been possible just 10 years

ago before the development of the complex

design and detailing software that was used.

Due to the exposed position of the site of the

structure, galvanizing not only provides the

required protection but also adds to the overall

aesthetic.


Galvanizing Awards


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Galvanizing in Detail Winner

Shettleston Housing Association Office, GlasgowElder & Cannon (10-12)The restoration of the Co-operative Hall; a

historically, culturally and architecturally

significant building within Shettleston, will

afford the Association the opportunity to

further expand and to continue to effectively

serve the local community for the foreseeable

future.

The new build extension has been sited and

designed to acknowledge the mass of the

existing building and in terms of its elevational

treatment, provides a formal response which is

drawn directly from the vertical rhythm of the

stripped neoclassical sandstone facade.

The materials used are contemporary and

purposefully distinct from the existing building

to celebrate the reinvigoration of the offices,

taking a marked step away from architectural

moves which can appear as a pastiche of the

original. They are strong and robust in character

and an appropriate response for a building from

which the Association will operate for decades

to come.

In both the refurbished and new build elements

of the project the new internal environment is

one which has been arranged to afford all buil-

ding users the maximum opportunity to access

natural light and ventilation.

The project seeks to act as a beacon and

driver for investment in this historically deprived

area of Glasgow and to provide a base where

the Association can effectively work and serve

the local community. In this hard urban

environment the incorporation of the well

detailed street level gates corresponds to the

strong and robust character of the overall

design.

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Duplex Award Winner

Clongriffin Dart Station, DublinCeardean Ltd (13-15)The new station design provides a semi-open

space, with glazing offering full view of plat-

forms below and incoming trains, and is natu-

rally ventilated. The light curved roof provides

a rooflight letting in additional natural daylight,

and reducing the requirement of artificial

lighting for energy efficiency.

Residents of Clongriffin and the Coast Develop-

ments can now reach the city centre in as little

as 17 minutes. An important aspect of the sta-

tion design was that of providing easy and safe

access to platforms.

During the design development issues arose

relating to the fabrication, structural integrity,

ongoing maintenance and risk of vandalism.

It was decided late in the construction process

to redesign the stairs, to create a more durable

solution that would require less maintenance.

The design was manufactured in single stair

components that were galvanized in one piece.

These were then painted in a controlled envi-

ronment at the galvanizing plant.

The station is located beside the sea and by

minimising the components of the stairs, its

durability and resistance to the harsh sea

climate could be guaranteed.

As you move around the staircase the curved

nature sets a moiré pattern of solids and trans-

parencies playing against the striking staircase

geometries. The clean minimal surfaces focus

your attention to the yellow handrails which

guide you through the staircase.

Highly Commended

Artist’s Workshop, LondonCarmody Groarke (16)Carmody Groarke designed this new artist

workshop for artist Antony Gormley within the

yard of his existing studio in London. The work-

shop was consciously designed to be made

predominantly out of galvanized steel, in order

to withstand the industrial nature of the artist’s

creative process.

The building structure was made of a galva-

nized steel mono-pitched frame that was clad

in bespoke galvanized steel panels. Access

into each bay is through mechanically operated

galvanized steel roller shutter doors, which

were carefully integrated into the design of the

cladding and structure.

The cladding was designed to have no ‘visible

fixings’ to emphasise the solidity of the new

building and protect fixing points from weather-

ing. Cladding panels around the columns were

made from a single CR4 3mm mild steel sheet

as a ‘net’ shape, which was then break pressed

into its form and hot dip galvanized. All fixings

were pre-drilled prior to galvanizing to retain the

integrity of the process through assembly.

The use of galvanized steel as a cladding

material was considered for its robust nature,

its excellent durability as well as its aesthetic

appearance. Considerable research and pro-

totyping was undertaken to ensure that the

process of hot dip galvanizing was controlled

to achieve the desired accuracy of material

junction and visual appearance. This yielded a

design that maintains the protective qualities

of the galvanizing to prolong the lifespan of the

building and gives the building a reassuringly

solid appearance.

Photos:

(1) Kilian O'Sullivan (2) Benedict Luxmoore

(3) Bell Phillips (4,5) Richard Osbourne

(6) LSI Architects (7,9) Allard Bovenberg

(8) Had-Fab Ltd (10,11) Andrew Lee

(12) Keith Hunter (13,14,15) Daragh Muldowney

(16) Oak Taylor-Smith


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It will soon be time to launch the 2012 awards

competition. If you are currently working on

a project or have completed one within the last

couple of years that incorporates galvanized

steel, we’d love to hear from you.

The competition isn’t about size or scale but

each project is judged on its own individual

merit. To further distinguish the projects, there

are five categories:

• Galvanizing in Architecture

• Galvanizing in Engineering

• Sustainable Galvanizing

• Galvanizing in Detail

• Duplex Galvanizing

There is a prize fund of £3,000 and each

winner will also receive an engraved trophy and

a galvanized watering can. We also promote

the winners and short listed entrants on our

website and in the GAGA Book.

For more information contact

E: [email protected]

T: 0121 355 8838

W: www.galvanizing.org.uk

GAGA 2012 – Why not enter?


Architecture

How do you integrate a large hi-tech building needing to meet a whole bunch of func-

tional requirements without marring the landscape of the Cologne bank of the Rhine?

Luminous steel facade Schönhauser Straße pumping station

By Holger Glinde

The Cologne firm of Kaspar Kraemer Archi-

tekten were faced with this challenge when

they were awarded the construction job by the

Cologne Municipal Water Authority. The Schön-

hauser Straße high water pumping station had

become necessary as a result of the extended

flood defence plans for the city of Cologne, and

the intention was that even when the Rhine

was running extremely high the purified efflu-

ent and rainwater from the city could still be

piped into the Rhine without this leading to a

backflow into the sewer system.

In order to achieve this, efficient pumps were

required, including the necessary technical

infrastructure. For this reason, the pumping

station was divided, from a structural point of

view, into an engineering section and a struc-

tural section. The engineering section (part of

which is underground) houses six pumps, and

the structural section is responsible for the

electro-technical supply system.

Design and facade The conceptual idea of the design was to inte-

grate the building complex of the engineering

section into the “Rhine River Landscape Area”

by means of a planned flowing modulation of

the terrain and to emphasise the operational

building as a significant landmark. The faca-

de materials for the engineering section are

limited to basalt for the Eastern and Western

“escarpment wall“ and to growing grass for the

green roof which, for reasons of maintenance,

has to be able to bear heavy loads. These two

materials are those which predominate in the

Rhine bank area, and are characteristic of it.

In contrast to the facade of the engineering

section, the facade of the structural section

2011

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Section g-g

Section f-f Base detail

Facade detail

Roof detail


has a special role to play. From the design

point of view, it needed to create a contrasting

effect in terms of materials and form. The

cladding would also have to create a "screen"

which, in spite of numerous and irregularly

distributed interruptions in the concrete body,

such as access apertures and ventilation gra-

tings, lends the building a homogenous facade.

Moreover, a high degree of passive protection

against vandalism and “graffiti” was required.

To meet these criteria, a steel grid construction

was developed which took the form of a self-

supporting curtain facade. The horizontally

structured grids lap around the concrete body

of the structural section at a distance of 90

cm, within the wall and also in the roof area,

which represents the so-called fifth facade.

The entire facade structure is made from

hot dip galvanized and coated grids, some of

which were coated. This offers a high degree of

mechanical protection and, due to the structure

of the grids, there is little area for graffiti spray-

ers to attack. It simultaneously lends the buil-

ding a homogenous structure, and thus gives it

the desired symbolic quality.

All 6 two-vane doors, together with the service

feed apertures, are designed in detail in such a

way that they are subordinated to the homoge-

nous facade structure and do not introduce any

discordant elements.

Even at the design stage, the conceptual

approach adopted was to have the steel grid

facade illuminated at night for formal reasons,

and also to support the passive protection

against vandalism. With the help of the energy-

saving LED system which is mounted inside the

metal grid structure, various colour spectra are

formed on the concrete facade of the structural

section when the Rhine is at its highest. The

metal facade, which by day appears restrained

and homogenous, has a more independent

look when twilight falls.

Special lighting displays (for example for big

events such as the “Cologne Lights”, New

Year’s Eve or other festivities), are likewise

programmed into the public lighting system,

and can be centrally controlled from the control

room of the Cologne Municipal Water Authority.

In addition to the lighting of the operational

building, the basalt facades of the engineering

section will be spotlit by lights on the ground

for dramatic effect. The pumping station is

thus, in the truest sense of the word, a new

"highlight" along the Rhine Promenade in

Cologne.

Architect/ Photos:

Kaspar Kraemer Architekten BDA

Section through facade

Horizontal corner construction


Engineering

The architects, Ahlbrecht-Felix-Scheidt, and the

structural engineers Schülke und Wiesmann

were set the task of designing a structure to

comemorate the historical significance of the

location. Their solution comes in the form of a

minimalist steel roof structure that both pro-

tects yet adds an almost temporary feel to the

site. The roof shell lies exposed over the exca-

vation site, and covers the essential sections

of the archaeological digs. Visitors learn about

the St. Antony ironworks – the cradle of the

industrial Ruhr.

The 900 m2 roof is a landmark and a visible

sign that this is a special place. It takes the

form of a double-curved shell and rests on four

supports which form a rectangle measuring

40 x 18 metres. Along its longer sides, it cur-

ves approximately 2.5 metres. The shell roof

consists of 323 similar, but not identical, sheet

panels 5 millimetres thick, which overlap each

other like shingles. To give them some rigidity,

the lasered panels are each folded approxima-

tely 15 cm along one longitudinal side and one

transverse side.

The panels are screwed together along the

edges. Due to their double-curved shape and

the rigidity, the shell is self-supporting and

needs no welds. Hot dip galvanizing the steel

panels has provided long-term, sustainable

corrosion prevention, which also creates a lively

metallic surface which lends the structure the

desired technical charm.

Fig. 1: A self-supporting, hot dip galvanized roof

shell protects the remains of the Ruhr region’s

ironworks.

Fig. 2: The hot dip galvanized shell roof con-

sists of 323 similar, but not identical sheet

metal shingles.

Fig. 3: The hot dip galvanized panel shingles

are each canted approximately 15 cm on

one longitudinal and one transverse side

respectively.

When pig iron first flowed from the blast furnace of the St. Antony ironworks on

18th October, 1758, the steel heart of the Ruhr began to beat. Today what’s left of the

first ironworks in the region forms part of an industrial archaeological park.

Cradle of the industrial Ruhr Galvanized shell at St. Antony

By Holger Glinde

Architect/Photos: Ahlbrecht-Felix-Scheidt

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,

B. Dursin, 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 © 2011.

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

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

E-mail: [email protected]

2011

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Principle panel

This structure, Pavilion 360, has recently won

the famous Red Dot Design Award in Germany.

It has an area of 6m x 6m, of which the inner

room takes up approximately 12m2.

As a pavilion in the classical sense, its outlook

and profile are the same. It appears transpa-

rent and fragile, yet, at the same time it stands

without effort.

The four, load-bearing glass walls comprising

two elements each are made of toughened

glass and support the roof which is a reflection

of the ground plan.

Both the base and the roof structure are long

lasting and maintenance-free due to being

made from galvanized steel.

The pavilion was designed by architects Jürgen

Stoppel and Nuyken of Oefele, Germany.

This minimalist structure is available with

different variations such as with an integrated

designer fireplace or with a refrigerator set in

the floor.

Photo: Pavillon360

2011

3/4 Galvanizing in Detail

Galvanizing Delight

Documents

Hot Dip Galvanizing Magazine 3/2011