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Sports Centre in Northern Spain | 3 Laboratories, University of Alcalá | 5 Galvanizing Explained | 10 Sea Gem, East Sussex | 12
International Magazine
ISSN 1363-0148
www.galvanizing.org.uk
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1 | The rythmic external volume of the new sports centre is the direct expression of its needs
2 | The artificial grass creates a surreal undulating landscape
3 | The ceiling of the swimming pool area consists of perforated galvanized strips which form an almost absorbant veil
Editorial
the first issue of 2013 sees the introduction of two major changes
for Hot Dip Galvanizing magazine: our editorial team now includes
the Spanish Association and the launch of our magazine microsite.
A warm welcome to our Spanish colleagues at AtEG who will bring
an even broader range of European articles to our readers. We
kick off our new collaboration with two innovative examples from
Spain: the amazing feat of creating a surreal landscape within the
midst of a road interchange, housing and an industrial backdrop. in
sharp contrast, the brutal yet mysterious laboratory block at one of
Spain‘s most illustrious universities shows the full versatility of the
use of galvanized steel. A design that has no breaks or windows
yet creates an awe of intrigue is quite an achievement.
Let‘s hope we have many
more such examples from our
iberian neighbours that will
fascinate you.
2013 also sees the launch of
our new microsite
www.hdgmagazine.co.uk
which provides you with
another convenient way of
accessing the magazine. the
microsite hosts an archive,
additional content and access
to our ipad app.
So, enjoy reading the magazine in whichever format you prefer!
iqbal Johal, Editor
Expanding frontiers
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
© 2013
Photo front cover | Carlos Casariego and Kike Aflame
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Langreo, located in northern Spain, is a place where you would be forgiven
for gaining the impression that free space was at a premium. A combination of
topography, industry and a dense housing footprint give credance to first impressions.
ACXT architects were set the unenviable task of converting an old coalfield into
something very different.
the Sports and Leisure Centre in Langreo (Asturias, Northern Spain) attempts to create a
new open landscape rather than just a new building. it minimizes the impact of its volume. it
plays with imaginary tectonic forces acting on the valley by folding the ground. the building is
a composition of folds, of green waves correlated with the different interiors. the aim of the
design was to provide a model for the redevelopment of the immediate area. the surface area
of the green roofs could be extended to form plazas and gardens in adjacent areas currently
occupied by ruined buildings. the initial idea of designing the roofs for people to walk on was
abandoned from health and safety issues and probable high maintenance costs. these were
finally covered with artificial grass. the L-shaped area where the building is erected, is a highly
constrained space. its boundaries include a train commuter platform, police headquarters, the
Nalón River and the local football field. the rhythmic external volume is the direct expression of
the interior needs: larger height clearance in the sports courtyard and the rhythmic gymnastic
area, lower levels in the swimming pool, and so on. in this way, three “hills“ can be distinguished
Undulating, surreal landscapeSports Centre in Northern Spain
by Javier Sabadell
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in correspondence with the functional divisions: the multi-purpose sports courtyard, the closure
of the swimming pools and the general service area. Within the “hill“ structure, there is a
predominance of black and green colours. Large concrete block walls, painted in black, seem the
shrine to the culture of the ancient mining areas. the black of the coal makes a perfect contrast
to the green of meadows of this beautiful Spanish region, always illuminated by ochre, yellows
and oranges. the symbolic folding of the topsoil reveals the strata and massive coal subsurfaces,
as it happens in the surrounding of the swimming pool, painted in black. this simple but effective
solution reminds the spectator that Langreo is the Spanish capital of coal mining.
the materials used for finishing the interior have been carefully choosen, durability and
functinality being of utmost importance. Apart from the artificial grass, the roof has 10 cm of rock
wool insulation, which provides excellent thermal and acoustic insulation.
the ceiling of the swimming pool area consists of perforated galvanized strips which form an
almost absorbent veil, providing protection as well as helping to acentuate the undulating profile
of the external profile. this is the only area in the whole building designed with a transparent
skin, which also does a great deal to accentuate the unpleasant echo typical of these structures.
Architect | Javier Perez UribarriPhotos | Carlos Casariego and Kike Aflame
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Brutal yet beautifulLaboratories, University of Alcalá
The almost brutal design for the new laboratory building on the University campus of
Alcalá serves a dual purpose: that of hiding and creating a mystical space.
the Architects were given a difficult design conundrum: to group a series of laboratories that
would include the storage and use of hazardous chemical products and still keep a link with other
faculties of the Campus and teaching areas. For this reason, due to the needs, the use and the
context of the project, the building was designed to fight against the character of its facades.
the building is a hermetic volume without fissures or windows that, at the same time, remains
open to the sky through the deep courtyards from where light penetrates. this light is collected,
filtered and evenly distributed internally. this manipulated light separates the labs and the control
rooms while ventilating the available areas.
the new laboratory building marks itself out as being unique both in its design and use of
materials. the focal point of the building are its huge doors that not only represent the way in
and out, they also open and close the entire space. When closed, the whole building is orientated
within itself facing the open courtyards. When opened, the horizon enters breaking the solid
verticality and opening up the building to its landscape.
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1 | The new laboratory building is almost a sealed hermetic volume with no windows or obvious openings
by Javier Sabadell
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Architect | Héctor Fernández ElorzaPhotos | Héctor Fernández Elorza
2 | Shimmering interplay of light and colour is captured by the large galvanized panels
3 | Seen at a distance, the structure displays a no-nonsense enclosed brutality
4 | Galvanized panels are fixed to the building frame by a series of screw fittings
5 | Full-scale doors create the dramatic effect of letting light flood into the building and break the almost sealed interior
the surrounding buildings are finished with uniform concrete and brick
however, the new laboratory building responds through the latent
character of its facades: large 5mm thick galvanized sheets. these
create an almost shimmering effect in the summer sun that help to
form different patterns of light and colour.
the purpose of the laboratory is to take in waste residues that
are ordered and classified. the designers have responded to this
opportunity by playing on the building‘s context to hide the handling
of undesired waste but at the same time creating a structure that
demands enquiry and inspection.
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Bauhaus pavilionTemporary Building in Tempelhof, Berlin
Reduce, reuse and recycle are the dominant keywords in the international discussion
on sustainability with regard to construction. The triad which combines the reduction
of waste volumes by avoiding waste, reusing materials as directly as possible and
material conversion through recycling – according to the experts, represents the
ideal route to take. The Bauhaus Reuse Pavilion is a pilot project of how structural
elements can be reused.
the mobile, temporary building is located on the site of the former tempelhof Airport in Berlin. the
pavilion consists of reused floor to ceiling window sections from the Bauhaus in Dessau, together
with two recycled shipping containers, and will be modularly extended in a second construction
phase. A hot dip galvanized steel structure connects the Bauhaus window and the containers to
form a prototype building. it is intended to serve as a temporary meeting place for the pioneering
“Nature Learning Centre” project and the “M.i.N.t. Green Classroom”. the pioneering projects form
part of a pilot urban development scheme for the site. A transparent classroom is being developed
for children and young people, where they can experiment with and learn from nature, and the
pioneering projects are transforming into an everyday resource for schools, kindergartens and
childrens’ daycare centres. in addition to being used as a teaching centre and a natural laboratory,
the pavilion itself also offers an object lesson in relation to the contentious issues of recycling in
construction, building culture and simple sustainable building. the pavilion is a reusable kit, and
will be extended by additional sections. to conserve energy, the pavilion is being equipped with
photo-voltaic equipment and solar heating, and will become part of the “smart grid” which is
being developed on the site of the former airport. All its elements, even the foundations, can be
completely dismantled and are intended to be fully recyclable. the robust and durable hot dip
galvanizing process is once again displaying its outstanding sustainability characteristics in this
project. the zukunftsgeraeusche GbR was responsible for the design and implementation of the
Bauhaus Reuse project, in co-operation with the technical University of Berlin.
1 | The pavilion uses floor to ceiling window sections together with two recycled shipping containers
Concept | www.zukunftsgeraeusche.dePhoto | www.zukunftsgeraeusche.de
by Holger Glinde
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The first of a group of five experimental houses has been erected on the campus of the Technical University of Kaiserslautern.
various high-performance building materials are being subjected to a practical test as part of the so-called Small House village
Project.
Small House i is intended to test out the practical possibilities for the
use of infra-lightweight concrete, and is a co-operative inter-disciplinary
project, directed by the Kaiserslautern professors Wolfgang Breit, Jürgen
Schnell and Joachim Schulze. infra-lightweight concrete is understood as
being concrete with a specific weight below that of lightweight concrete.
the concrete used in Small House 1 has a dry bulk density of less than
700 kg per cubic metre and uses hot dip galvanized reinforcing steel.
the aim of the project is to find a new type of concrete mix and put it
to practical use in making high-insulation concrete usable as exposed
concrete in external areas subjected to weathering.
in contrast to the conventional multi-layer construction consisting of
a load-bearing structure, a fill layer such as rendering or other wall
finishes, Small House 1 was constructed as a single shell. the monolithic
walls of the experimental building, with integrated core insulation, offer
advantages in relation to a reduction in the construction period, the
possibility of thermal storage capacity, and an uncomplicated structure
open to vapour diffusion. As well as outstanding heat insulation properties
at low external temperatures, high-insulation lightweight concrete can
also provide very good protection from summer heat. Moreover, if they
take the form of exposed concrete, solid walls made from lightweight
concrete can provide new design options. their surfaces differ from
typical rendered facades, which are usually made up of composite
thermal insulation systems.
the technical specifications for the infra-lightweight concrete used were
demanding. the bulk density must be as low as possible, but nevertheless
there are demanding requirements to be fulfilled with regard to the
strength, the water penetration behaviour and the corrosion prevention.
So when it came to the reinforcing steel, it was decided to utilise hot dip
galvanized reinforcing steel. Even at low pH values, up to pH 5, hot dip
galvanizing ensures adequate corrosion protection for the reinforcement.
the onset of reinforcement corrosion can thus be excluded for long
periods of time.
Galvanizing aids lightweight concreteExperimental House, University of Kaiserslautern
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1 | Single shell, ultra lightweight concrete house erected on the campus of University of Kaiserslautern
2 | Galvanized reinforcement placed during construction. The reinforcement forms an important aspect of the ultralight concept
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by Holger Glinde
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Galvanizing Explained
There is an ever increasing use of the term “galvanizing”
to describe the coating of steel with zinc. The term is
derived from the name of italian scientist Luigi Galvani.
Due to no legally binding definition the term is now
used to describe a whole host of systems. We try to
clarify some important misconceptions. Steel can be
coated with zinc using various processes, however, not
all are the same even though they may attach the term
“Galvanizing” within their description. The processes will
vary with respect to how they are applied, the thickness
of the zinc coating and its characteristics. All of these
have an important influence on vital issues such as
performance and physical properties.
the immersion of steel in a bath of molten zinc is referred to as hot dip galvanizing. this term
however can be used to cover two slightly different processes:
Hot dip galvanizing - post fabrication; individual components that make up a staircase,
for example, are chemically cleaned and immersed in a bath of molten zinc. this creates a
metallurgically bonded coating that provides complete coverage of the steel component with a
coating thickness of 50 to 200 micrometers, both internally and externally for hollow sections,
including edge protection.
Continuously galvanized steel strip - pre fabrication; large coils of steel strip are automatically
fed via a system of rollers through a cleaning phase and quick immersion (2/3 seconds) into a
zinc bath. this provides a hot dip galvanized coating that is however much thinner (5 and 40
micrometers) than that achieved via post hot dip galvanizng. Also the galvanized strip steel is a
preliminary product which is further processed following galvanizing, i.e shaped, punched and cut
to size. this destroys the protective zinc layer at the cut and punched edges. Due to the difference
in coating thickness and hence performance hot dip galvanizng and continuously galvanized
sheet are used in different ways. pre galvanized sheet is mainly used in internal environments
such as air conditioning systems whereas post hot dip galvanized steel is mainly used for outdoor
applications, as a rule, due to the requirement for longer periods of protection.
Metallic Coatings normal coating thickness [µm]
Alloy formation with the substrate
Typical applications
Hot dip galvanizing (Batch/Post galvanizing) EN iSo 1461
45 - 85 Yes Structural steel sections ranging from beams and columns to small components including nuts and bolts
Hot dip galvanizing (continuous strip) - BS EN 10346 or
EN 10147
7 - 42 Yes Metal sheets for mostly internal applications, eg air-conditioning ducts
Thermal spraying with zinc - EN 2063
80 - 150 No Structures in the steel construction sector
zinc-Electro plating - EN iSo 2081 or
EN 10152
5 - 25 No Small components and coiled sheet
The misunderstood process
by Holger Glinde
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Grit blasted steel surfaces are coated with
droplets of semi-molten zinc sprayed from a
special gun. the coatings are always slightly
porous, sensitive to shortcomings in the
preparation of the steel, and need skill in
application. they cannot be applied to the
inside of tubes and hollow sections
Zinc platingZinc is deposited electrolytically from a
solution of zinc salts. only very thin
coatings are economically feasible and
coatings are not uniform except on the
simplest shapes. A zinc plated coating may
also be formed -with variable thickness - by
mechanical deposition. this is sometimes
referred to as mechanical galvanizing but
unlike galvanizing there is no metallurgical
bond with the basis steel.
SherardizingSteel parts are tumbled in zinc dust at
temperatures just below the melting
point of zinc. Coatings are thin but closely
follow the contour of the steel parts.
Zinc dust paintsthese are formulated with a high proportion
of metallic zinc dust pigment togive
electrical conductivity, and are applied
to clean- generally blast-cleaned - steel.
the formulation and application of the
paint needs careful control for satisfactory
performance.
Good long term performance depends on
adequate thickness of zinc and satisfactory
coating formation. Do not be fooled by
today’s generic use of galvanizing to
describe different processes of applying zinc
onto steel.
Hot Dip Galvanizing – post fabrication: A batch process in which the parts to be galvanized are dipped in molten zinc (galva-nizing of fabricated articles in accordance with EN ISO 1461)
Continuously galvanized steel strip – prefabrication: The continuous galvanizing of steel strip coils which are immersed in molten zinc via an automated process
Zinc Plating: A zinc salt solution is used to electrolytically deposit a layer of zinc on a cleaned steel surface
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if you take a walk along the East Sussex coast you may be surprised at the beauty of the local
landscape. A sandy almost golden beach will be beneath your feet, a ruggedness is added by
rare sand dunes, and looking out to sea, the ever-changing weather adds a mystical feeling to the
light. in the distance you will see the cliffs of Fairlight Cove and the Rother estuary.
turning your head however in the opposite direction and you will also be hit by a rather remarkable sight.
A recent addition to the local landscape has added another twist. What used to be the site of a ramshackle
bungalow has been transformed into a breathtaking modern interpretation of a luxurious beach house.
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Sheltering from the seaSea Gem, East Sussex
by Iqbal Johal
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1 | V-shaped design maximises panoramic views while sheltering from the wind
2 | Spiral duplex staircase provides direct access to the living areas 2
Actually “beach house” seems to be an unfair description, Sea Gem, the name given to the house
by its owners after asking for suggestions from all those that worked on the project seems far
more apt. the owners having sought an ideal location for a holiday home were happy to make a
few quick repairs to the existing building. they quickly realised this was not a good way forward
and appointed Hazel McCormack Young to design a new house with ideas of a New England/
Hamptons style building in mind. However, HMY pointed out that to maximise the views of the
beach, the house would need lots of glass and a more traditional weatherboard house couldn‘t
deliver. the new design initially took the owners by surprise by making too much of a statement
but also realised that it could be something really special.
the building is based around a V-shape which makes the most of the panoramic view but also
provides natural shelter from the wind. the bold use of floor-to-ceiling glazing floods the house
with light and, when the tide is in, the view from the first floor living/dining area turns the ocean
into a wonderful infinity pool. When the tide is out, there are panoramic views of miles of golden
sandy beach. the horizon is always apparent, holding a movement of sky, sea and sand - a truly
amazing experience.
Building homes on a beach isn’t straightforward, with issues such as flood risk and the constant
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handles have been removed, as they instantly corrode. Sea Gem’s
upside-down design, with three bedrooms on the ground floor and the
open-plan kitchen and living space upstairs, troubled the Environment
Agency, “who seem to think that if you have the bedroom downstairs,
you will drown in the night”, the owner says. “i pointed out that
the previous building was a bungalow, so it was all downstairs. We
eventually found a solution by raising the house a couple of feet off
the ground on stilts, so we are sufficiently above the sea level, and
we have some pretty serious foundations.” the design is intended to
not only make the most of the unique beach front but also to link the
house into landscape. A series of terraced areas seamlessly connects
the central living space onto the beach front. At the same time this
space is given privacy by the two wings of the building. A special
request from the owners, a roof-top study, has resulted in a triple
aspect, third storey lookout study which has been set back to the north
of the building so that it has a minimal impact onto the neighbouring
properties. the flat roof is to be used for installing solar panels and
also provides a small roof terrace. the views this space provides are
so stunning that it is probably highly unlikely that any work will ever be
done.
A variety of materials have been used to construct the building.
Concrete and masonry have been used for the lower part of the
building and composite galvanized steel and masonry forms the
balcony structure at first floor level. At third floor level the study
is formed from a galvanized steel frame that is clad in full-height
glass panels. A simple robust finish of off-white render is used for
the external walls with panels of timber matching the timber used
on the terraced areas. Due to the exposed location, no screw went
unchecked. Every single fixture and fitting had to be correctly specified
with combinations of marine grade stainless, galvanizing and powder
coating and some aluminium. the focus for galvanizing and powder
coating included; balconies and handrailing, fixings for the brise soleil,
fixtures for the landscaped areas and the feature spiral staircase.
Anecdotal evidence shows the galvanizing plus powder coating
performing better than the stainless steel.
the project team created a real sense of ownership that was reflected
in the quality of the finished building. Hazle McCormack Young have
built the first truly contemporary home on Camber Sands. Maximising
the relationship with the landscape was vital, the design has certainly
exceeded expectations.
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Architects | Hazle McCormack YoungPhotos | James Galpin
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3 | View out to sea from the patio terrace
4 | Main entrance to the house
5 | Tide‘s out! View from the shoreline of Sea Gem
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Berlin Villa
Two identical villas in Berlin have been created by Schneider and Schumacher Architekten, Frankfurt. The cantilevered roof design helps to create a versatile outdoor area at the back of the villa. A series of galvanized profiles creates an extension of the interior into the garden. In this way, the interior is extended outward and the boundary between the home and garden blurred. The galvanized surfaces also reflect the incident light and give the otherwise plain façade a visual depth. Photo | Dr. Stüber, Berlin
Galvanizing Delight