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

4/4

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

4/4

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.

2011

4/4

4 | Hot Dip Galvanizing

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

2011

4/4


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

2011

4/4


2011

02

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

4/4


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

2011

4/4

2011

4/4


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

4/4

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%

2011

4/4


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

2011

4/4

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