Download - Hot Dip Galvanizing Magazine 4/2011
Hot Dip GalvanizingInternational Magazine | ISSN 1363-0148 | www.galvanizing.org.uk
2011
4/4
1
Editorial
2 | Hot Dip Galvanizing2 | Hot Dip Galvanizing
Twenty years ago, when I was still quite new
to the world of galvanizing, the UK Galvanizers
Association was asked if it would like to join a
German-Dutch consortium producing a quarter-
ly magazine on hot dip galvanizing. Obviously,
we did. The rules were very simple; it was like
a game of cards. We each prepared articles
on various examples of galvanizing in our own
countries and then we would put them on the
table, one at a time, to decide which ones
would be included. Everyone then went home
and translated the articles into their own langu-
age before posting the copy to the printers for
them to set. Today, the technology has changed
considerably and so has the layout, but the
basic idea of sitting down with our European
partners and agreeing what should go into the
magazine hasn’t.
And hopefully it is the unusual mixture of
galvanizing applications that still make for
interesting reading. This edition features a
skywalk, a galvanized steel façade (is it my
imagination or are these becoming more
popular?) a design academy and, delight of
delights, a new home for Wallace and Gromit.
OK a new headquarters for Aardman Produc-
tions, Wallace and Gromit’s creators actually,
but I cannot help think that Wallace, the engi-
neer and inventor, would thoroughly approve
the use of such a traditional but highly
sustainable material in his own home.
Here’s to the next twenty years!
David Baron, Editor
2011
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Contents
2 Editorial
3 Stihl Arts and Educational Centre, Waiblingen Layered galvanized facade
6 Allgäu Skywalk Dramatic alpine vista
8 Pesie House, Leeuwarden, Netherlands Integrating with the landscape
10 KHLIM Media and Design Academy Perforated galvanized skin
12 HQ for Aardman Animations, Bristol Where ideas come to life
14 Zinc and its Uses Protective for Humans and Steel
16 Galvanizing in Detail
Front cover:
Layered galvanized facade
Photo: Hartwig Schneider Architekten, Stuttgart
Photo above right: IZA
Join our facebook pageFollow us on twitter - Galvanize_itView our flickr streamRead our blog - www.thezinctank.com
Hot Dip Galvanizing | 3
2011
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Located in the centre of the Stuttgart region in
the southwest of Germany, Waiblingen is known
for its half-timbered historic buildings and in
particular its town hall. Hartwig Schneider
Architekten were given the task of creating a
modern arts space without ruining the heritage
of the old town. The proposed site, comprising
dilapidated warehouses close to the river
Rems, did not at first glance offer much of an
opportunity for an inspired solution.
However, the finished project that includes an
arts educational centre and the Stihl Gallery,
provides a design solution that not only speaks
the architectural language of the 21st century
but also sits well with the character of the
medieval town.
The buildings have been described as “two
pebbles on the banks of the River Rems”.
Perhaps it is this slightly soft abstract air that
the buildings exude that links into the narrow
alleyways of the old town and the broad open
spaces beyond.
The new buildings have succeeded in reconnec-
ting the town to the river Rem which had been
lost due to previous developments.
At first glance the two buildings seem identical,
galvanized expanded metal surfaces alterna-
ting with cool cast glass elements. But the hori-
zontal division of the facade of the arts centre
gives a hint of the differences in the interior: it
marks the line of the mezzanine overlooking a
central hall extending over two floors.
Architecture
Stihl Arts and Educational Centre, Waiblingen Layered galvanized facade
By Holger Glinde
Art and museum projects are being used more and more to act as catalysts for local
and regional regeneration. In the rush to achieve a new grand project, the basic
concepts of design and compatibility are sometimes conveniently forgotten which can
result in very expensive, faceless buildings. On a positive note, cultural buildings can
breathe new life into forgotten landscapes.
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The art gallery opposite is designed as a single,
free-flow space.
The layered galvanized facade creates an
additional interplay with light that filters into
different parts of the building. Galvanized ver-
tical louvres act as close-knit metal fins which
can be manually controlled. The entrance to
the buildings is marked by a six foot high galva-
nized steel gate that resembles a modern inter-
pretation of a historic town gateway.
The architects have succeeded in not only blen-
ding old and new but have provided Waiblingen
with a landscape that renews a long lost con-
nection to the Rems. The use of galvanizing
could be seen as a very clever juxtaposition of
modern design with a coating that has conno-
tations to an industrial age. Galvanizing does
however provide an aesthetic that adds a cer-
tain solidity and its other more obvious benefits
of durability, sustainabilty and value for money.
Architecture
Architect/Photos:
Hartwig Schneider Architekten, Stuttgart
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Engineering
A visitor to the Allgäu Skywalk Project will have their outlook changed in a most
unexpected fashion. Amid the treetops runs a walkway which no visitor will forget in
a hurry. The crowning glory is a viewing platform up in the airy heights granting a
unique vista across Lake Constance and the Alps.
Allgäu Skywalk Dramatic alpine vista
By Iqbal Johal
Incomparable, unique, breathtaking – these are
just some of the most frequently heard com-
ments made by visitors who have completed
the Skywalk. It meanders through the forest
for approximately 540m, gradually changing in
height from 15 to 35m, just like the forest and
the weather around it. At times in misty gloom,
at times in dazzling light it is always an experi-
ence, even in the rain.
The Skywalk is designed as a free-hanging sus-
pension bridge structure. The cable and steel
masts act as suspension bridges spanning a
maximum length of 50 m with a total of up to
14 such bridges. Each consist of 2.5 m long by
1.8 m wide bridge segments with welded wire
mesh panel infills and a larch balustrade. The
steel towers that carry the suspension bridges
are up to 45 m high and are made from Man-
nesmann steel tubes with diameters from 500
to 600 mm. These conical sections are 2.7 m
long with assembly slots to aid quick erection
on site. Once the concept had been agreed the
client was vey keen to bring the project online
and this led to close collaboration between
designers, suppliers and steel contractors on
site. "One of our biggest problems was the
extremely short period we had to complete the
project,” says Norbert Vötterl of Biedenkapp
Steel Ltd. "We had to master the structural ana-
lysis, which included software analysis of the
structures, the fabrication and steel production
of all materials within a four month window”.
From the design point of view, the Skywalk con-
cept was seen not only as a tourist attraction
but a structure that needed to sit comfortably
within its environment. Great care was taken
on the choice of materials, corrosion protec-
tion and assembly on site so that the existing
landscape had a minimal amount of intrusion.
Galvanizing was seen to be the ideal choice
for the protection of all steel sections used
throughout the project.
Engineer/Photos:
Biedenkapp Stahlbau GmbH
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Architecture
Leeuwarden is a provincial town in the north of Holland. The landscape in this
region has been reclaimed from the sea and therefore it is mostly flat and consists of
green polders, dykes and many lakes. Pesie house was built in a new suburb of
Leeuwarden, an area literally on the edge of town situated next to a water reserve.
All the plots have a beautiful view of the water - the Himpenser Wielen - and the open
agricultural landscape.
Pesie House, Leeuwarden, Netherlands Integrating with the landscape
By Bruno Dursin
The unique layout contrasts greatly with the
closed nature of the surrounding neighbour-
hood. This open aspect played an important
role within the design and orientation of the
Steel House. Instead of a house in the middle
of the plot with a garden around it, the entire
surface of the plot has been used to create this
spatial structure with an empty inner core that
integrates and groups the residential and open
spaces. The volume is a simple orthogonal
structure based on a 6 x 6m grid that is linearly
defined into different zones, in an alternating
rhythm of outdoor and indoor spaces.
The spatial structures are closed when facing
the town but are then opened up to reveal the
shoreline to enable full interaction with the
lake. The central space is left empty to form
a patio.
Pesie house provides spacious living areas,
which consciously switch from being open
plan to small, enclosed spaces. As a result,
every area is part of a larger spatial unit.
Alternatively, the house can be secluded from
its environment via a system of electronically
controlled blinds that completely disconnect it
from the landscape.
The house is accessed via a mini footbridge
that gives the front elevation a definite feel of
security, and which completely hides the more
free flowing open aspect of the rest of the
house. The bridge theme is also reflected in the
large steel loggia with a gazebo over the water
and may also have been designed to reflect the
owner, Jan Pesie’s bridge building heritage.
The steel sections of the house facade are
galvanized and then coated with a white paint.
This is used throughout the structure of the
project to firstly provide protection but then to
give a pure and minimalist feel to the materials
Hot Dip Galvanizing | 9
that were used to create the spatial structure
of the house. An integral part of the design was
to ensure that large portions of the house were
constructed from prefabricated modules. These
were fabricated in a workshop and transported
to site by boat. The architects’ initial premise
was to construct a lightweight prefabricated
house with a very distinct and personal cha-
racter which coincided with the principles of
the client: a simple, square and sturdy steel
house. If the final design is paired back to its
basic skeleton, it would include a set of prefa-
bricated well-insulated steel modules, two steel
floors that are mounted on top of a concrete
box. This helps to form a basement under the
entire house including part of the patio. The
concrete box is also used to retain heat during
the winter and help keep the interior cool in the
summer. A heat pump is used for the power
supply for both heating and cooling.
Besides the white facade different components
are used to create "screens and blinds". Within
this simple and clear structure, each area has
been finished with its own interior design, the
highlight of this approach is the Kitchen box
with an ingenious sliding door design taken
from an old city bus.
Although the minimalist exterior provides an
audacious structure various other elements
within the house are galvanized including the
terrace staircase, the entrance footbridge and
the frame of the floating terrace.
Architect:
Eric Vreedenburgh—Archipelontwerpers
Photos:
Marcel van der Burg
The required spaces were highly divergent in
terms of surface area, volume and shape
(auditoriums, cafeteria, studios, documentation
centre, etc.). Both in terms of plan and eleva-
tion, such functions are difficult to integrate
within dimensions predetermined by an
underground car park.
The shape of the media and design academy
is the product of a new didactic concept; a
large proportion of the collective and circula-
tion spaces are deployed as space for study,
instruction and studios. This results in a study
landscape which, behind the steel cladding,
reveals itself as a single, glass-enclosed
volume. All of the other functions of the school
are hidden behind its perforated skin, where
they are all directly linked by means of extra
staircases and vistas.
The choice of materials for the facades, and
their detailing, combine harmonisation within
the context, on the one hand, while reinforcing
their identity, on the other.
The facades were clad with black foam
glass and perforated galvanized steel panels
that provide both shade from the sun and
insulation.
In the winter the facade, whose ‘scaled’ texture
results from the degree of overlap given to the
panels, both refers to the industrial character
of the other buildings on the site and suggests
coal’s crystalline structure. This creates a
subtle reference to the coal mining heritage of
the site.
Galvanized steel was employed for the entire
external and internal skin of the project. Its
facade is clad with perforated galvanized steel
panels - with a 50% perforation - placed in such
a way as to overlap randomly.
Architecture
The site of the former coal mine in Winterslag was selected as the location of the new
KHLIM Media and Design Academy. The project involved building above a pre-existing
underground car park. The design parameters for the academy included the adoption
of numerous complex interactions amongst the different functions it embodies.
KHLIM Media and Design AcademyPerforated galvanized skin
By Bruno Dursin
2011
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10 | Hot Dip Galvanizing
Feuerverzinken | 11
Differences in thickness and a slight ripple pro-
duce the effect of a ‘scaled’ steel skin. All air
and cable ducts for specialised technological
applications were executed in galvanized steel
and left visible, giving the building a clearly
industrial connotation and ensuring that all of
the applications will always be easily acces-
sible. All banisters and railings around voids
and differences in level were constructed from
galvanized steel.
The reasons for using steel were manifold. In
addition to its evident technical and construc-
tive advantages, the context also played an
important role: steel speaks an industrial archi-
tectural language, which harmonises exceptio-
nally well with the large steel hoist frames and
other relics from mining’s post-industrial past in
the surrounding area.
The Media and Design Academy has been
designed with the aim to stimulate creativity
and innovation. The new building offers an
interactive space for meeting, to experiment,
encouraging social contact and the exchange
of ideas between all students and teachers.
The design of the new building will play a major
role within this context with areas such as the
circulation zones having a crucial impact on the
success of this philosophy.
Architect:
Bogdan & Van Broeck Architects
Photos:
Thomas Mayer
Architecture
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Architecture
HQ for Aardman Animations, BristolWhere ideas come to life
By Iqbal Johal
This internationally acclaimed animations studio required a new headquarters on
their existing site in Bristol. The three storey building provides office and studio space
arranged around a tapered atrium providing breakout spaces, daylight and air
movement for natural ventilation. The building is designed to be highly sustainable
in both its materials and use of energy.
This Bristol based, Oscar-winning animation
house required a new Headquarters.
After a limited competition Alec French
Architects were invited to prepare an overall
masterplan to include new accommodation
for 200 employees.
The final building, built on land previously occu-
pied by portacabins and an existing car park,
is designed to give a positive presence to Gas
Ferry Road. An intensive dialogue with directors
and heads of the various departments deve-
loped the detailed brief. The free exchange of
“ideas” was clearly key to Aardman's success
and the new building needed to help facilitate
that process. Most of their activities – creative
and administrative – can take place in office
type space (large scale production takes place
in industrial sheds on the edge of the city or
in an adjoining warehouse). Looking at other
recent buildings with the client encouraged
the development of the concept of a series of
linked “rooms” retaining flexibility in use but
also a clear sense of identity for each working
group of 6-9 people. This approach also pro-
duced significant areas of wall space for their
required extensive displays of images and
materials.
A clear brief to reduce energy use, as part of an
overall sustainable approach, led to a central
three storey atrium providing significant extract
ventilation and controlled daylight. The main
circulation is by way of galleries overlooking
the atrium. Breakout spaces and an innovative,
laminated timber staircase, gently curved and
free spanning between floors, also occupy this
space.
There are many opportunities here for both
informal dialogue and the exchange of ideas,
and for Aardman's expression of their own very
special character. Galvanized steel has been
used for the walkway supports and link bridges
throughout the building. The feature of the
atrium is the free flowing three storey staircase.
This has an expressed crafted quality - reminis-
cent of certain Aardman features. The structure
of each stair comprises a curved, cranked
stringer from laminated birch veneer propped
at mid-span by a laser cut galvanized steel sup-
port frame, partly supported by four stainless
steel tension rods. The treads take the form
of laminated 'leaves' peeled up from the main
stringer. The tactile balustrades combine steel
bars with laser-cut, galvanized support posts
and a gently curving oak handrail.
The combination results in a stunning central
feature for the new building that should help
the studio to continue to produce Oscar
winning features hopefully with the help of
Wallace and Gromit.
Architect/Photos:
Alec French Architects
2011
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Zinc and its usesZinc is naturally present in rock, soil, water and
air and is essential to human, animal and crop
health and well-being. A very versatile material,
zinc also plays a key role in a variety of indus-
trial and product applications. A major use of
zinc is to protect steel from corrosion – making
steel more durable. Less corrosion also means
less cost and less environmental impact arising
from maintenance. At the end of their useful
lives, zinc products can be recycled, and zinc
content can be recovered without loss of
properties or quality.
Zinc: Major End UsesThe inherent characteristics of zinc – its dura-
bility and recyclability – make it a desirable
material for a range of applications in trans-
portation, infrastructure, consumer products
and food production.
Worldwide, over 11 million tons of zinc are
produced annually. Nearly 50% of this total is
used for galvanizing to protect steel from cor-
rosion. Approximately 17% is used to produce
brass and 17% goes into the production of zinc
based alloys, mainly for use by the die-casting
industry. Significant amounts are also used
for compounds such as zinc oxide and zinc
sulphate and zinc sheet applications including
roofing, guttering and downpipes.
The main application areas for zinc products
are: construction (45%), transport (25%), con-
sumer goods and electrical appliances (23%)
and general engineering (7%).
One of zinc’s most exceptional qualities is its
natural capacity to protect steel from corrosion.
When left unprotected, steel will corrode in
almost any environment. Zinc coatings protect
steel by providing a physical barrier as well as
cathodic protection for the underlying steel,
allowing its service life to be extended.
Damage caused by corrosion leads to costly
and time consuming repairs. By protecting
steel from corrosion, zinc performs an
invaluable service. It helps to save natural
resources by significantly prolonging the life of
steel goods and capital investments, such as
homes, cars, bridges, port facilities, power lines
and water distribution, telecommunications
and transport.
The long-term durability provided by galvanizing
is achieved at relatively low environmental
burden in terms of energy and other globally
relevant impacts, especially when compared to
the energy value of the steel it is protecting.
Global Zinc DeficiencyZinc is an essential micronutrient for human
health. It is vital for activating growth and phy-
sical and neurological development in infants,
children and teenagers. Zinc is found in all
parts of the body and is a component in more
than 300 enzymes. Zinc also accelerates cell
division and enhances the immune system.
Research has shown that zinc plays a vital role
The earliest records of the use of zinc as a separate metal can be traced to the
4th century BC, where it is described as "drops of false silver". The use of zinc
ores however predates this to the 10th century BC, where it was used to make
zinc–copper alloy brass. Today zinc is still a popular metal and used in a number
of important ways.
Miscellneous 4%Chemicals
6%Zinc Semi-
Manufacturers6%
Zinc Alloying17%
Brass and Bronze17%
Galvanizing 50%
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1 2
Technical
Zinc and its Uses Protective for Humans and Steel
By Holger Glinde/Iqbal Johal
in protecting the body from illnesses and
fighting infections.
Zinc deficiency in humans is a widespread and
global issue with about one-third of the world’s
population receiving insufficient zinc through
their diets.
Two billion people worldwide are not getting
enough zinc through their diets which is a
major health problem in developing countries,
especially among young children. Zinc deficien-
cy weakens their immune system and leaves
them vulnerable to conditions such as diarrho-
ea, pneumonia and malaria. Zinc deficiency
is also accountable for impairing physical and
intellectual development, preventing children
from reaching their full potential. UNICEF esti-
mates that diarrhoea accounts for nearly two
million deaths in children every year. Diarrhoea
is preventable and treatable, but in developing
countries, only 35% of children with diarrhoea
receive the recommended treatment of oral
rehydration salts and zinc supplements.
In 2008, the Copenhagen Consensus, a group
of internationally acclaimed economists, inclu-
ding five Nobel Laureates, concluded that com-
bating the world’s malnutrition problem through
the provision of vitamin A and zinc was ranked
the highest among the various cost-effective
solutions to the world’s pressing problems.
In 2010 the zinc industry, through IZA, laun-
ched the “Zinc Saves Kids” initiative in support
of UNICEF‘s global micronutrient supplemen-
tation program to address zinc deficiency for
at-risk children. The objective is to raise three
million dollars to help fund UNICEF-supported
zinc programs around the world.
Abstract from “Zinc and Sustainable
Development” - International Zinc Association
Further information “Zinc Saves Kids” -
www. Zincsaveskids.org
(1) Photo: David Iliff; (2) Zinc: Major End Uses
(3) UNICEF/Zinc Industry Initiative
(4) Global Zinc Deficiency in Humans
Legendlowmediumhigh
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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,
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]
3 4
Technical
This spring, Ooghduyne Beach Resort introdu-
ced 25 temporary beach houses in Julianadorp
aan Zee.
The houses, which were built in April and are
to be dismantled in October, consist of a sub-
structure of steel with a terrace and staircase,
upon which a superstructure of timber prefab
components were placed.
The steel structure was hot dip galvanized
as a way of protecting the houses from the
elements.
The houses stand at the foot of the dunes.
As they are located in an area of natural beau-
ty, muted colours were chosen, which blend
into the landscape.
The generously proportioned windows provide
guests with a magnificent view of the North
Sea coast.
The client wanted a solution that would entail
a series of temporary structures that could be
seasonally erected and demounted.
Photos: Frank Roor
2011
4/4 Galvanizing in Detail
Galvanizing Delight