15384_HDG_Magazine_0118_GB_K4 FINAL

01 | 2018 International Magazine 

ISSN 1363-0148 

www.hdgmagazine.co.uk 

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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01 | 2018 


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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01 | 2018 

3 

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 


1 

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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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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01 | 2018 



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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01 | 2018 

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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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01 | 2018 



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 


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 


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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01 | 2018 


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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01 | 2018 



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 


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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01 | 2018 



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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01 | 2018 

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3 

15

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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