HDG Magazine 1_2014

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Wilhelm-Leuschner-Platz Station | 3 Blackpool Tramway | 6 The Alchemy of Galvanizing | 8 Godolphin House | 14

International Magazine

ISSN 1363-0148

www.hdgmagazine.co.uk

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1 | Although the station is 20 metres underground, the illu-sion of daylight is created by 130,000 back-lit glass blocks within 900 frames

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EditorialThere has been a lot of recent

noise about test scores and

knowledge, or lack of, attain-

ment levels within education.

Comparisons with certain

countries have resulted in the

obvious feeling of malaise and

a general mood of a second

class status within the ‘new’

thrusting world of education.

But, is this what the attain-

ment of knowledge should

be about - the position within a table of the league of nations. is

education more than a bunch of statistics? At a recent parents

evening, i was heartened to hear the overwhelming enthusiasm of

a teacher who wanted to teach not via a straight jacket but by an

exchange and exploration of ideas and concepts and a true under-

standing of the world around us.

Some of this is also true at a much broader level. We all encounter

or use many products and materials in our daily lives without giv-

ing as much as a second glance to their manufacture, production

or even their historical context. it was partly with this in mind that

we set off on our long journey that has recently come to fruition

in the form of the publication of The Alchemy of Galvanizing - Art,

architecture and engineering. (Page 8)

our book aims to explore, explain and celebrate the process that

helps protect steel that we find all around us today. We highlight

the use of galvanized steel within some of today’s most prominent

structures - Leipzig Glass Hall, Cork Civic offices and Snowdon

Visitors’ Centre. But size is not everything, the highly engineered

use of galvanizing on a smaller scale can be found within; Benyon

Wharf, Catmose Campus and Garsington opera Pavilion. Through-

out the book, art provides an important thread that links the world

of architecture and engineering and is highlighted by the extraor-

dinary work of Antony Gormley and Sophie Ryder’s more intricate

and abstract use of the process.

Have a browse, i am certain that you will find something of interest

to remember and impart.

iqbal Johal, Editor

Hot Dip Galvanizing – An international journal published jointly

by the galvanizing associations of Germany, Great Britain and Spain.

Edited by: i. Johal, G. Deimel, H. Glinde (Editor in Chief). 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

Distributed in Australia by: Galvanizers Association of Australia,

124 Exhibition Street, Melbourne, Victoria 3000, Australia, Tel: 039 6541266,

Fax: 039 6541136, E-mail: [email protected]

This magazine may not be copied without the written permisson of the editor

© 2014

Photo front cover | Deutsche Bahn AG/Martin Jehnichen

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Starkly geometrical, minimalistically reduced, the epitomy of

rationalism and right angles. anyone entering the Wilhelm-

leuschner-Platz Station of the new leipzig City Tunnel will

immediately recognise the typical style of Max Dudler, the

architect who designed the station.

The Wilhelm-Leuschner-Platz Station is one of four along the 1.4 km

length of the Leipzig City Tunnel. it extends north to south beneath the

Martin-Luther-Ring to the centre of Wilhelm-Leuschner-Platz. The

island platform at the station is 140 metres long and is located about

20 metres below the ground level. Access is provided by escalators,

fixed stairs and a lift. The interior of the station is characterized by

back-lit glass block elements, which help to create an impression of

natural daylight.

Glass block facade

The station’s walls and ceiling contain a total of 130,000 glass blocks in

900 frames. The glass tiles are inserted into a filigree lattice steel made

Wilhelm-Leuschner StationLight at the end of the tunnel

by Holger Glinde

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1 | The glass block frames are suspended from the ceiling by galvanized spacers

2 | Galvanized steel grids have been integrated between the tunnel wall and the mainte-nance structure to ensure easy access to the 700 light sources

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from exposed concrete. Due to the use of precast sections that had a maximum

cover of only 20mm, hot dip galvanized reinforcing steel was used in order to avoid

long-term corrosion damage, together with any possible unsightliness caused by

visible spots of rust. Approximately 75 tonnes of hot dip galvanized reinforced steel

was used in the facade facing. However, hot dip galvanized steel is not only suitable

for thin-walled structures or prestigious exposed concrete structures, but can also

be used for traffic structures subjected to road salt and buildings in a maritime

atmosphere.

Hot dip galvanized facade infrastructure

The 900 modules of the glass block facade, each of which weigh 1.5 tonnes, are

supported by a galvanized steel frame. Whilst the glass block modules were

suspended from the ceiling by means of hot dip galvanized ‘spacers’, the facade’s

wall elements are supported by a hot dip galvanized steel frame. in order to ensure

easy access for maintenance of the 700 light sources for the backlit facade, four

operating surfaces made from hot dip galvanized steel grids have been integrated

between the tunnel wall and the frame structure.

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Architect | Max Dudler, BerlinPhotos | Deutsche Bahn AG/Martin Jehnichen (1, 2);

Freistaat Sachsen/ DB AG (3)+ additional

pictures

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The Astronomers ParkSimplistic beauty

in the eastern suburbs of vitoria-Gasteiz, the political heartland

of the Basque Country in Spain, it is still possible to enjoy a

peaceful and relaxing walk in a park called ‘The astronomers’.

The name provides a clue to the history of the local area. Due

to its location and terrain, the park had had a long link with

astronomers using it to study the night sky. Current urban

development precludes any possibility to perform astronomical

observations, but the site still attracts local amateur astrono-

mers.

Since 2000, the park has been developed to provide sporting facilities. A

running track was laid along with a football pitch with a precast concrete

structure to act as a shelter for supporters.

With the increasing popularity of the local football teams, funding was

sought for the enhancement of facilities at the park. A brief was drawn

to include the construction of a new covered stand that would follow

sustainable principles, be durable, vandal-proof, require minimal mainte-

nance and be easy to extend.

LMM Architects were chosen for their unusual yet simple proposal that

met the brief. A 30-metre long trapezoidal, on side elevation, steel struc-

ture forms the main frame for the new stand. Galvanized steel inverted

‘L’ sections placed at five metre centres provide the skeleton of the

structure that is clad with galvanized sheet. The lower level of the new

stand uses precast concrete to provide changing rooms and a meeting

room. Seating has been placed on top of the precast sections with a

series of galvanized stairs that lead to the upper level of the stand.

The simple design linked with effective engineering provides a light,

durable, maintenance-free structure that can be used for many years to

come by the locals to enjoy their football.

1 | The trapezoidal stand has a double function; galvanized stairs lead to elevated seating above the ground level

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Architect/photos | Íñigo López, Jokin Iturregi and Edorta Mújica - LMM Architects

+ additional pictures

by Javier Sabadell

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Blackpool Tramway Starr Gate Depot

Blackpool rose to prominence as a major centre of tourism in England when a railway was built

in the 1840s connecting it to the industrialised regions of northern England. Within 40 years, an

11 mile electric tramway was opened, running alongside the coast from Blackpool to

Fleetwood. it was the last surviving first-generation tramway in the United Kingdom until 2012.

When the operators, Blackpool Transport Services decided to upgrade the tramway, a new depot was

required to house a fleet of up to 20 new Flexity 2 ‘Supertrams’. These state-of-the-art trams include many

improvements, such as 100% step-free access from platform to tram, dedicated wheelchair spaces, higher

seating and standing capacity, faster acceleration and quieter running. The traditional trams, however, still

provide a ‘heritage service‘ on weekends, bank holidays and during the summer.

Modernising a British institute

1 | The coastal location meant a galvanized frame was the obvious economic and sustai-nable option

2 | Raised shutters reveal the maintenance area

3 | The new state-of-the-art Supertrams are housed under the gently curving waveform roof

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by Iqbal Johal

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2014Starr Gate provides a new maintenance and

stabling depot for up to 20 of the new fleet

as well as a residual fleet of heritage trams.

The depot houses fixed tram lifting equip-

ment comprising monorail hoist, travelling

crane, wheel, lathe and access platforms

along with a tramwash and automated sand

system. Externally, the building features

striking waveform cladding illuminated by

LED lighting. Sustainable features include

surface water drainage attenuation and nat-

ural lighting.

The building, whose framework contains 400

tonnes of galvanized steel, spans 66 metres

by 12 metres. The ingenious roof design

reflects the proximity of the sea; alternating

rafters gently curve in opposite directions to

mimic the waves of the ocean.

Caunton Engineering wanted to ensure that

the best environmental practice was incor-

porated in planning, design, construction and

operation. They defined a robust, cost-

effective performance standard required by

regulations and raised awareness amongst

architects, designers and operators of how

the process of galvanizing provides the

benefits of durability and an appealing

aesthetic. The proximity to the irish Sea

makes intense demands on the

corrosion protection of the steelwork. By

utilising galvanizing however, all of the

onerous criteria for the project were met.

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Engineer | Caunton EngineeringPhotos | David Kidson

+ additional pictures

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The Alchemy of Galvanizing

Our readers may be well aware of the versatility and adaptability of the galvanizing

industry. We have featured over 200 projects in the recent past, just from the UK and

ireland, that detail both very large-scale infrastructure projects through to small,

intricately designed details that are still important within the context of our built

environment.

our brand new book, The Alchemy of Galvanizing: Art, architecture and engineering, with an intro-

duction by architect Will Alsop, celebrates the creative and technical contribution of galvanizing

to contemporary art, architecture and engineering. A series of essays from construction industry

professionals provides an insight to their experiences with the use of materials and their importance

within today’s buildings. The book also provides some interesting facts: Brunel used 36,650m² of

galvanized corrugated iron sheets that enclosed two thirds of the vaulted roof for Paddington Sta-

tion in 1854, and Antony Gormley used 2,000 galvanized components to form his latest creation;

Exposure

So please do take the opportunity to buy a copy of what will be an entertaining and informative

read. You can purchase copies at most online outlets. Further information is available

at www.artificebooksonline.com, www.galvanizing.org.uk or you can place orders at

[email protected].

Art, architecture and engineering

by Iqbal Johal

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+ additional pictures

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located between the cities of Santander and Bilbao in northern Spain, laredo is well-known for ‘la Salvé’, its picturesque, five

km-long beach and also for the historic part of the town, which dates back to Roman times. Economically, laredo is considered one

of the main resorts on the Cantabrian coast, with the local industry based on fishing, the service sector and tourism.

opened in 2011, the new port of Laredo has

been built next to the existing one and the

old city centre, sheltered to the north by a

curved groyne. At just over 700 metres long,

this provides a sea defence and withstands

waves of over eight metres for both the

marina and the fishing port basins.

The port has been designed with both leisure

boating and fishing needs in mind. it has a

fishing basin, a marina with jetties and the

old port‘s marina berths. it can moor 857

boats on 12 docks and accommodates crafts

up to 20 metres in length. it has the latest

Laredo‘s New Port Northern SpainCorrosion defence from the sea 1

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by Javier Sabadell

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system for 50-tonne craft, and a

car park for 420 vehicles.

The new port buildings include

a fish market containing an ice

factory. The building is divided

into three sectors: ice produc-

tion, fish processing and offices

plus cafeteria. Spread over two

floors, it has a total surface area

of 1,700 m². The facades were

erected with exposed concrete,

with hot dip galvanized steel

used in the structural frame and

within the stairs and flooring.

Given the aggressiveness of the

environment, in terms of both

rainfall and salinity, zinc was

chosen for the covers and to

protect the concrete walls.

The second building, with a floor

area of 2,700.00 m², accom-

modates differing sized-boats,

both for storage and repair and

maintenance. Constructed from

reinforced concrete, the marine

environment meant that due

consideration had to be given to

have some form of protection

for the reinforcing steel. on

balance, galvanizing the rebar

gave the best economic solution

for protection purposes.

1 | Laredo‘s new port buildings

2 | La Salvé beach extends five kilometres along the coastline

3 | Laredo‘s old port lies beyond the new fish market with the town in the distance

4 | All ancillary steel around the market including platforms, walkways and stairs were all galvanized

5 | Sloping facades omitted the need for guttering

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Architect/photos| Antonio Fernández (Axis Arquitectos)

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Most metal coated fasteners look bright and attrac-

tive when installed but often have thin coatings

and even in a mild environment will rust vigorously

after only a short period of time. it is important to

ensure that you have selected the right coating for

the required environment.

There are a variety of metal coatings that can be used to

protect small steel components. Taking the example of

using zinc, there are at least three different ways of using

it in such instances, all of which offer totally different

coating characteristics and performance.

These three systems are:

1. Centrifuge or spin hot dip galvanizing

2. Metallic Coating with zinc dust - sherardizing

3. Zinc electroplating

1. Centrifuge or spin galvanizing

The terms ‘spin galvanizing’ or ‘centrifuge galvanizing’

are used to describe the process for hot dip galvanizing

threaded components and other small parts. The process is very similar to galvanizing larger steel sections. Small

components however are placed in perforated containers, allowing items down to 8mm in diameter to be processed.

After immersion in the galvanizing bath the container is centrifuged at high speed so that the spinning action throws

off any surplus zinc and ensures a clean profile.

When the articles are immersed in the galvanizing bath, a series of zinc-iron alloy layers are formed with a metallur-

gical bond to the steel surface. These alloys are harder than mild steel and are normally covered by an outer layer of

comparatively soft zinc which remains after the spinning operation. This structure is unique and gives the galvanized

coating very good resistance to rough treatment - direct blows are cushioned by the outer layer of zinc and the hard

alloy layers resist abrasion.

As a general rule, nuts, bolts and washers down to M8 can readily be galvanized and threaded components up to

2m long can be processed. Special arrangements can often be made to centrifuge galvanized components outside

this range.

2. Metallic Coating with Zinc Dust - Sherardizing

Articles to be sherardized are first chemically cleaned or blasted and need to be thoroughly dried. Any remaining

water can cause problems when mixed with zinc powder. The clean, dry work is then placed in the sherardizing bar-

rel with the appropriate amount of zinc dust. in some cases fine sand has to be added to aid even distribution of the

Galvanized FastenersThe nuts and bolts of zinc coatings

by Iqbal Johal

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Photo below| Portland Bolt

dust and the temperature raised, prior to tumbling, until the desired coating

is achieved. The dust should be very fine as coarser powders take longer to

form the coating. The need to ensure even temperature within the barrels

imposes a size limitation on the process, which is generally used for small

and fairly intricate components.

3. Zinc Electroplating

A zinc salt solution is used to electrolytically deposit a layer of zinc on a

cleaned steel surface. Acid or alkaline electrolytes can be used. After cleaning

the work is transferred, as quickly as possible, to the plating solution. Good

adhesion of the plated layer to the substrate depends on a very close physical

conformity of the plating with the base metal. To achieve this, the base metal

must be scrupulously clean immediately before plating.

The table below summarises the coating characteristics and general coating

thicknesses that are available via each process. it is crucial from a corrosion

protection point of view that the correct system is specified for the relevant

environment to achieve the desired performance.

one difficulty that arises is that all of these process-

es use zinc and their different properties, coating

thicknesses and performance may be confused into

an overarching description of ‘galvanizing’. in fact

zinc electroplating is often known - misleadingly -

as electrogalvanizing. it is not therefore enough to

merely specify ‘galvanizing’ if long life is required.

if hot dip galvanizing is to be used, the specification

should clearly state that the fastener coating should

conform to BS 7371 : Part 6 + A1 and to be

galvanized by member of Galvanizers Association.

Process Coating Characteristics

Hot Dip Galvanizing • BS7371: Part 6 + A1.• Standard coating thickness 50 - 70µm. • Coat anything from 8mm diameter to 2m long.• Coating is integral with steel.• Alloy growth.

Sherardizing • BS7371-8.• Standard coating thickness 20 - 30µm. • Some alloy growth.• Limited to size of barrels, usually used for small components.

Zinc Electroplating • BS7371-3.• Standard coating thickness generally 2.5 - 15µm.• Depostion of zinc – no alloy.• Usually limited to small components.

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Godolphin House is one of Cornwall’s most outstanding and important historic houses.

it is a 15th century property that is the jewel in the crown of the national Trust in the

southwest of England. Until the middle of the 18th century it was the home of the

Godolphin family who made their fortune from the local tin-mining industry and they

became one of the wealthiest families in the Duchy. The structure we see today is

only part of what was once a very extensive, granite-built Tudor and Stuart house.

By the middle of the 16th century, Godolphin House was an impressive building consisting of three

main wings around a central courtyard. At this time, Sir William Godolphin - a soldier in the service

of Henry Viii - made some alterations to the house. During the 1630s, William Godolphin (grandson

of Sir William) added the north range, which is a long, symmetrical structure with a ground level

colonnade of Doric columns and mid-17th century mullioned and transcomed windows. Under the

colonnade there is a gateway, dated 1575, which leads through the original screen wall into the

courtyard.

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Godolphin House Restoration of the North Range

1 | Aerial view of Godolphin House

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by Iqbal Johal

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the pinnacle of its development, boasting

some 100 rooms. However, it fell into decline

in the early 1800s as the family preferred to

live in their London property. Large sections

of the house were demolished and Godolphin

was converted into a simple farmhouse.

Godolphin House was sold in 1929 to a local

Cornish miner and then sold again to the

Schofield family in 1937. it was eventually

bought by the National Trust in 2007.

Following the acquisition of the property, a

survey of the building showed that much of

the North Range was structurally unsound

and that a major programme of refurbishment

would be needed to preserve the building.

The roof was removed and the structural

wooden frame exposed for the first time in

almost four hundred years. it was revealed

that a combination of water ingress and

woodworm meant that many of the great

wooden beams that should have supported

the building had rotted away at one end.

The decision was made to repair the beams

in situ, as replacement would have entailed a

total demolition and rebuild of the structure.

However, being Grade i listed meant that

special consideration had to be given to the

choice of every material used in the repair

and conservation of the building. The existing

materials had lasted nearly 400 years and

the concept was that it should be another 400

years before any further work was necessary.

Steel rather than timber was chosen as

the material for the renovation due to the

complexity of the sections that would be

required. Galvanizing the steel was also seen

as a crucial element in order to preserve the

structure for another 400 years.

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Photos | David Baron

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2 | Picturesque cottage garden in the grounds of Godolphin House, the jewel in the crown of the National Trust

3+4 | The 400-year old wooden beams are repaired with galvanized members to last another 400 years

5 | The North Range where resto-ration works took place

Within a section of the Guadiana River that runs along the frontier

between Spain and Portugal, a new lookout point has risen from the

landscape. Slender reed-like galvanized steel sections provide support

to the platform as well as filtering light. The structure’s quite austere

design is meant to instill the occupant with a focus to the water’s

edge rather than the structure itself.

Photo | Luisa Alarcón y Mª Luz Galdames

Galvanizing Delight