HDG Magazine Issue 1 2018

galvanizing

01 | 2018 International Magazine

ISSN 1363-0148

www.hdgmagazine.co.uk

HOT DIP GALVANIZING

HOT DIP GALVANIZING

01 | 2018

Zugspitzbahn Ski Lift | 2

CB1, Cambridge | 8

The Wheelhouse, Erfurt |12

Bus Shelter, East Anglia |14

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HOT DIP GALVANIZING

Editorial

Improvement of our infrastructure

has been an ongoing

government commitment

for many years. Recent

dedicated infrastructure

plans including the creation

of the Infrastructure and

Projects Authority have

given an increased impetus

and to some extent, greater

accountability to promised

programmes and funding.

1

An area that has attracted the largest amount of government

spend is that of transport. Over £100 billion is in the pipeline for

transport with the objective of expanding capacity and relieving

congestion. It is hoped that improved transport infrastructure will

unlock opportunities for regeneration and help development of

new housing.

The provision of transport that is efficient, reliable, user friendly

and ticks all our sustainability goals is and has been a hard target

to achieve. Although cars remain the most prevalent form of

transport, with positive strides being made to their efficiency, a

quiet revolution has been taking place on our roads.

1 | Construction was a constant

struggle with wind, altitude,

temperatures and logistics

2 | 1100 individual hot dip galvanized

steel components were

used to construct the tower

3 | The base station offers spectacular

views across the valley

Design consortium | Baucon –

Hasenauer.Architekten – AIS

Cable car manufacturer |

Doppelmayr / Garaventa

Photos | Bayerische

Zugspitzbahn Bergbahn AG

One of our simplest forms of transport, cycling, is helping to knit

our disparate forms of travel together. In this issue we feature

public transport in all its guises; train, bus, cycling and a ski lift

for good measure.

Iqbal Johal, Editor

Hot Dip Galvanizing – An international journal published jointly

by the galvanizing associations of Germany, United Kingdom & Ireland

and Spain.

Edited by: I. Johal, 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: ga@hdg.org.uk, Internet: www.galvanizing.org.uk

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

© 2018

Photo front cover | Bayerische Zugspitzbahn Bergbahn AG

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HOT DIP GALVANIZING

01 | 2018

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by Holger Glinde

Tallest

highest, fastest

Zugspitzbahn Ski Lift

Germany’s highest mountain has a new cable car. After three years of planning and construction, the Zugspitzbahn transported its

first visitors on 21 December 2017. The project was not only unique in terms of construction and ropeway technology, but also in

project size and complexity. Constructing at almost 3,000 m posed quite formidable challenges in battling against weather and logistics.

The new cable car route creates significant improvements for visitors. Waiting times on peak days will be a thing of the past, as up to 580 people per hour

can be transported. The new cable car can boast three superlatives: with a height of 127 m, it has the world’s highest steel support for aerial tramways, at

1945 m it serves the world’s largest valley height difference in a section and at 3,213 m the world’s longest free span.

While the design of the new base station was comparatively unspectacular, the construction of the steel structure and the base station was a struggle with

wind, weather, altitude and logistics. For the tower support, 1100 individual hot dip galvanized steel components with a total weight of 420 tonnes were

bolted together by experienced mountain climbers. In order to give the Zugspitze visitors the best possible view of the alpine mountains, the base station

projects 35 m from the mountainside and was designed as a transparent steel-glass structure with the inclusion of more than 1000 tonnes of galvanized

steel.

Permanently hot dip galvanized

Hot dip galvanizing is the standard corrosion protection for cable car construction. The use of hot dip galvanizing achieves a lasting and sustainable

corrosion protection coating. Unlike coatings that are extremely sensitive to UV exposure of alpine environments, hot dip galvanizing is completely

UV-resistant and able to deal with severe drops in temperature. The long term protection afforded by hot dip galvanizing offers maximum safety and

ensures that during the entire service life of the cable car no corrosion-related repair work is required, which would be extremely difficult and costintensive.

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01 | 2018

HOT DIP GALVANIZING

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Engineer | Mott MacDonald

Photos | David Hopkinson,

AHR (1), Mott MacDonald (2)

by Iqbal Johal

Grand

entrance

Leeds Station Southern Entrance

Leeds Station is the second busiest railway station outside London and sits at the

heart of the region’s economy. More than 100,000 passengers use it each day.

Increasing passenger demand, congestion to the existing northern entrance and an

aspiration to reduce journey times to the expanding south of the city resulted in

the need for the new Leeds Station Southern Entrance (LSSE). The new entrance is

expected to serve up to 20,000 passengers daily.

1 | New southern entrance to Leeds

railway station

2 | Complex network of galvanized

steel forms the ground floor concourse

over the River Aire

Innovative thinking

The southern entrance is located over the River Aire, where residential towers, an electrified railway

and a pedestrian bridge all constrained the site. This however was the ideal location to meet

the project objectives of accessibility from the south and to create a landmark building.

An innovative approach was adopted to deliver the required solutions, this included:

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HOT DIP GALVANIZING

01 | 2018

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use of prefabrication and barged delivery to site

strengthening of the existing Victorian masonry viaduct and station

roof

use of overwater ground investigation to inform the pier design

tailored working methods in and around the three operational railway

lines

FE analysis of the soil structure interaction for the pile design

use of bespoke lifting equipment.

Technical excellence

Many of the innovative solutions for the project lie unseen below the

new building. This includes the foundations and galvanized steel that

form the ground floor concourse.

The foundations comprise two concrete piers supported on 24,900 mm

diameter piles socketed into bedrock below the river bed. Over water

ground investigation proved essential to confirm the depth to rock; its

highly fractured nature led to a change in piling methodology prior to

construction. Advanced soil structure interaction, verified by finite element

analysis, was undertaken together with consideration of flexural

rigidity of the composite pile sections.

The piers support a concourse deck formed from a grillage of 600 mm

deep steel beams, which support the superstructure, transferring column

loads to the new piers. Fifty percent of the concourse is constructed

below the existing viaduct and above the river. Up-stand trusses

supporting the new floor and escalator pit span through one of the

barrel vaults, transferring load to new foundations outboard.

The new super-structure, comprising a curved steel diagrid frame,

exposed internally, is partially supported by a Victorian masonry

viaduct and the existing station roof.

A complex assessment of these structures was undertaken to determine

capacity, including measurement of strain under existing rail load

using innovative video gauging. Strengthening of the existing quadripartite

ribs involved the erection of 7.5 tonne steel arches within the

confined space of the viaduct, anchored to the existing piers with 1 m

long embedded bolts.

Hot dip galvanizing

Hot dip galvanizing was chosen as the method of corrosion protection

to all steelwork located above the River Aire forming the ground floor

concourse, as well as the bridges linking the concourse to the river

banks. In order to achieve the required performance the specification

included grit blasting the steel prior to galvanizing in order to achieve

a thicker coating and hence additional protection. It was felt that galvanizing

offered benefits over a painted finish in terms of life to first

maintenance and the overall durability afforded to steelwork located in

such a harsh environment.

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HOT DIP GALVANIZING

by Iqbal Johal

Parking

delight

Bike hub parking facilities, UK

1

Supported by backing from government, a quiet revolution has seen an increase in cycling

across the UK and Ireland. Although the uptake is higher in certain concentrated areas of the

South East, almost all major railway stations have reasonable bike parking facilities.

The UK government wants cycling and walking to become the norm by 2040 and will target funding at

innovative ways to encourage people onto a bike or to use their own two feet for shorter journeys.

Plans include specific objectives to double cycling, reduce cycling accidents and increase the proportion

of 5 to 10 year-olds walking to school to 55% by 2025.

£101 million has been promised to improve cycling infrastructure and expand cycle routes between city

centres, local communities, and key employment and retail sites. In addition to this, it is already apparent

that things are changing on the ground. Cycling rates are rising across the UK with a 23% rise in

miles cycled today in comparison to 10 years ago. There is however a lot more that needs to be done,

UK still lags far behind our European counterparts. One of the noticeable changes is the integration of

cycle parks next to public transport, particularly railway stations.

1 + 4 | Cycle hub for London

Borough of Waltham Forest at

London Bridge Road station

2 | Security is an important aspect

of the new cycle hubs - biometric

security at Chelmsford

station

3 | Efficient use of existing space

at Chelmsford station

5 | A 600 space cycle hub at

Reading station

These cycle hubs are ideal for travellers who need to combine different modes of transport, train, bus

and bike. Many of the rail operators are creating a network of bespoke cycle hubs alongside stations

that are part of their network, mimicking their practices from countries such as the Netherlands.

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HOT DIP GALVANIZING

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The hubs offer secure sheltered parking for

bikes and include a whole host of facilities:

CCTV

key fob entry

help points

enhanced lighting

two tiered user friendly assisted cycle

parking racks

biometric security.

One interesting theme throughout many of

the new hubs is the use of galvanized steel.

Its historical use within the support equipment

is now being reflected within the structures

built around the parking equipment. Its

inherent benefits make it an easy choice as a

means of protection for steelwork:

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durability – long term corrosion protection

with a 50 year plus of maintenance free life

toughness – ability to withstand the daily

wear and tear and constant loading and

unloading of bikes

sacrificial protection – self healing abilities

of the coating in areas of damage.

Photos | Falco UK Ltd

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HOT DIP GALVANIZING

by Iqbal Johal

Bikes

galore

CB1, Cambridge

A building which houses a 231 room Ibis hotel and retail space,

is nothing new unless it also serves as a multi-storey cycle

park which is ten times larger than any other cycle park facility

in the UK. As an exemplar building CB1 sets a precedent for

other towns and cities aiming to encourage cycle use as part

of their strategic plans to improve the urban environment and

transport facilities in general.

The building forms the northern enclosure of the new Station Square

in Cambridge and is part of the gradual realisation of the CB1 Rogers

Stirk Harbour designed masterplan for Brookgate which will transform

the station area of Cambridge.

CB1 is located in a prime position for the city’s transport links - directly

in front of Cambridge Station and the new transport hub. The railway

station, bus interchange (including the Cambridgeshire Guided

Busway), taxi rank and cycleways provide commuters with plenty of

options for reaching their destinations quickly and comfortably.

Formation Architects’ challenge was to integrate the cycle park, hotel

and retail space into a coherent, singular building, which addressed

the new Station Square and responded sensitively to the neighbouring

listed station building.

The height and footprint of the new building were determined by the

parameter plans of the consented CB1 masterplan. Cyclists enter

the building from the quieter Northern Access Road to park their

bicycles on one of three floors accessed by a large ramp. Secure, lit,

covered storage is provided for 2,850 bicycles on conventional and

double-stacker stands. A cycle hire and repair shop is located on the

ground floor, providing maintenance, cycle hire, cycle accessories and

cycle sales, making the facility a true cycle hub and strengthening fur-

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Architect | Formation Architects

Photos | Louis Sinclair

HOT DIP GALVANIZING

01 | 2018

1 | As an exemplar building CB1

sets a precedent for other towns

and cities aiming to encourage

cycle use

2

2 | Secure, lit, covered storage is

provided for 2,850 bicycles on

conventional and double-stacker

stands

1

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01 | 2018

HOT DIP GALVANIZING

ther the sustainable transport options in a city where there is already a high propensity to cycle.

Above the cycle park are the hotel bedrooms in a U-shaped plan forming an internal courtyard

on the second to fifth floor. Cyclists can exit and enter the building via a wide staircase onto Station

Square.

Galvanized steel is incorporated throughout the cycle park providing an important ancillary role.

Long term, resilient protection is afforded to the network of bike support steelwork and perforated

panels and handrails running along the ramps and around the three storey structure.

The main façade addresses the station square. The corners are recessed to create a well-proportioned

central section and a subtle transition of scale to the northern wing of the existing listed

3 | The building forms the northern

enclosure of the new Station

Square in Cambridge

4 | Galvanized steel is incorporated

throughout the cycle park providing

an important ancillary

role

3

station. Stone at ground and first floor gives the building a solid base

and defines the vertical hierarchy. Green coloured panels by the side of

the windows emphasise the vertical proportions and complement the

gault brick of the listed station building.

The cycle park is outwardly expressed on the building façade by double

storey perforated metal panels on the first and second floors, set

between brick pillars which also serve to define the regular spacing of

the hotel rooms above. These panels provide wind and rain protection

for the cycle park and reflect the use of the space through an abstracted

cycle related motif applied onto them.

Open seven days a week, the CyclePoint is brightly-lit and, in another

helpful touch, has parking areas identified with a different colour

scheme on each floor and individually numbered stands to enable

customers to easily identify cycles on their return.

The new complex offers safe and secure spaces, in a dedicated facility,

covered by CCTV, open 24 hours a day, free of charge. It has more

than tripled the cycle parking capacity at the station and provides an

optimistic outlook of things to come.

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HOT DIP GALVANIZING

01 | 2018

by Holger Glinde

Industrial

prefab

Bike Pavilion, Mainz

1

The city of Mainz has in recent years developed a trend towards

being a more bike friendly city. In terms of private bike parking

however there continues to be a shortage of suitable parking spaces.

Against this backdrop, SYRA_SCHOYERER ARCHITEKTEN developed a

prototype for a bicycle pavilion for the City. True to the office philosophy of

rewriting the everyday, the design for the bicycle pavilion was based exclusively

on industrially prefabricated mass-produced products. Only one small

allowance to special construction was made; the flat steel facade bars have a

90 degree twist, creating a slightly more open façade than a series of flat bars

would offer.

1 + 2 | The entire galvanized steel

pavilion was completely assembled

in the factory and transported

as a finished structure to

site

With the help of a simple design and standardized elements, a sturdy pavilion

has been conceived with concise yet restrained architecture that protects a

carousel for up to twelve bicycles from inclement weather, vandalism and

theft.

The entire galvanized steel pavilion was completely assembled in the factory

and transported as a finished structure to site. The new prototype has provided

a new vision for the city that will act as a spur for its use as well as inspiration

for similar structures.

2

Architect | SYRA_SCHOYERER

ARCHITEKTEN, Mainz

Photos | SYRA_SCHOYERER

ARCHITEKTEN

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HOT DIP GALVANIZING

by Holger Glinde

Piece

of cake

The Wheelhouse, Erfurt Station

1

Urban mobility will look very different in ten years from today. For some time, there has been a shift from cars to public transport

in combination with the use of bicycles. Many cities are promoting this through the development of additional bicycle lanes and

creating parking facilities for bicycles in the form of ‘bike and ride’ stations in the vicinity of public transport interchanges. A good

example of this is ‘The Wheelhouse’ in the immediate vicinity of the Erfurt ICE train station. It is the second such facility at the

Erfurt ICE train station and is intended to meet the increasing demand for safe, weather-protected bicycle storage facilities.

The Wheelhouse designed by Osterwold ° Schmidt Exp. Architects

BDA, is a galvanized steel frame wedge, with its two sides hollowed

out at both sides to create double tired parking for 200 bikes. An

internal secure space also offers an extra-secure storage room with

charging stations for electric bikes. The location and access of the new

facility was of paramount importance, this meant the use of a very

small footprint of vacant land running alongside the station with quick

access via a footbridge.

The incorporation of a wedge-shaped structure takes full advantage of

available space and by cleverly cutting into both sides of the structure

a semi enclosed area is created that also helps to provide quick, easy

access. Hot dip galvanized steel combines the advantages of longevity

and robustness, that will withstand the continual loading, unloading of

bikes and the daily knocks and bangs associated with these processes

without unduly affecting the coating. The use of an expanded metal

skin promotes a high incidence of light during the day and luminosity

during the night. Depending on the light conditions, the expanded metal

creates an alternating effect between securing ‘shell’ and translucent

skin.

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Architects | Osterwold ° Schmidt Exp. Architects BDA

Photos | Michael Miltzow

HOT DIP GALVANIZING

01 | 2018

2 3

4

1 | The Wheelhouse is sited on a

very small footprint of vacant

land running alongside the

station with quick access via a

footbridge

2 + 3 | Hot dip galvanized steel

combines the advantages of

longevity and robustness, that

will withstand the continual

loading, unloading of bikes

and the daily knocks and bangs

associated with these processes

4 | The structure is formed from a

galvanized steel frame wedge,

with its two sides gorged out at

both sides to create double tired

parking for 200 bikes

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HOT DIP GALVANIZING

by Iqbal Johal

Resilient

reuse, recycle

Bus Shelter, East Anglia

1

1 | The design of the shelter is

based on a simple ‘kit of parts’

cantilevered galvanized steel

structure arranged around a

central spine

2 | The shelter has been constructed

using low carbon, recycled

materials where suitable to

reflect the UEA’s sustainability

aspirations

3 | The choice of sustainable

materials was approached in a

number of ways, including use

of recycled materials, design for

reuse and deconstruction, choosing

highly durable materials

- galvanized steel - with low

maintenance requirements

Architect | LSI-Architects

Photos | LSI-Architects

The University of East Anglia has unveiled its new bus shelter as part of a joint

initiative by Norfolk County Council and UEA to improve the image and efficiency

of public transport on campus. The striking design aims to create a more

positive and informative experience of public transport.

The design of the shelter is based on a simple ‘kit of parts’ cantilevered galvanized steel

structure arranged around a central spine. The angles of the roof structure change along

the length of the shelter, creating a striking, folded effect.

The modular nature of the design provides scope for use of the design elements within

other structures on the campus. Architect Kirstin Aitken commented “Our design for the

shelter makes use of the idea of modularity and repeatability. We developed this idea in

the concept stage by creating a simple, interactive, peg based model which allowed us to

try out the effect of different combinations of roof angles along the structural spine. The

ultimate aim is that this new exciting design for a bus shelter challenges people’s expectations

in much the same way that we hope to encourage staff and students at UEA to look

again and consider taking public transport.”

The shelter has been constructed using low carbon, recycled materials where suitable to

reflect the UEA’s sustainability aspirations, while some of the seats take the form of swing

seats, providing an element of fun to the waiting time. The choice of sustainable materials

was approached in a number of ways, including use of recycled materials, design for reuse

and deconstruction, choosing highly durable materials - galvanized steel - with low maintenance

requirements, and, in less vulnerable locations, use of timber.

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3

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Galvanizing

Delight

Manuel Martí constructs the ethereal, fluctuating and incomplete sculptures, one of his latest being ’Silencio’. A combination of welded bolts are

used to create the sculpture which once finished, is hot dip galvanized. With some variations on the design, a paint coating is applied to reflect the

passing of time.


Artist & photos | Manuel Martí

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