Karlovy Vary Airport - Kalzip


Karlovy Vary Airport - Kalzip

Karlovy Vary Airport

Kalzip ® case study

Gateway to a new era

of air travel

New airport terminal building in Carlsbad

with a Kalzip aluminium envelope

An unusual airport terminal has been constructed in the spa town of Carlsbad

in the Czech Republic. This stunning building sets new standards in terms of

design and materials. In the construction of this ingenious piece of archi tec ture,

which is known as the “intermediate aircraft” and is open to many different

interpretations, Architect Petr Parolek, chose to use Kalzip aluminium profiled

sheets for the entire building envelope.

Carlsbad (Karlovy Vary) is the most

famous spa town in the West Bohemian

Spa Triangle and is situated above the

River Tepl at its junction with the River

Ohre. The hot springs were used as far

back in time as the Middle Ages. This

sophisticated town has been famous

since the 18th Century when it became

the meeting-place for emperors, kings

and tsars, politicians, statesmen, Russian

grand princes, Indian maharajahs and

2 Kalzip GmbH

the wealthy international aristocracy.

Carlsbad subsequently developed into

an architectural gem. The new airport

which serves this spa town also embraces

this architectural tradition. It features

an unusual terminal hall designed by

architect Petr Parolek. According to the

architect himself, this building resembles

a flying submarine and has been completely

clad in Kalzip aluminium profiled


"My idea for the new terminal building

was to create a design with different

symbolic meanings”, explains Petr

Parolek. “It could be a flying projectile,

a spaceship or a submarine – simply

a means of transport which hovers over

Carlsbad.” The unusual shape of the

building is formed by the geometry of

three regular tubbing segments which

were cut in a way which creates a uniform

construction principle.

Petr Parolek: “It is of course no coincidence,

but rather my intention, to utilise

the virtually unlimited potential of the

Kalzip system to its full advantage to

enable implementation of the precise

aerodynamic geometry of this building,

which has now been achieved.

At the beginning of the 1920’s a basic

airport was opened in the vicinity of

Carls bad. Due to the requirements of the

cosmopolitan visitors, the demands on

the airport grew rapidly. Following a

varied history, which includes the threatened

closure of the airport on politically

motivated grounds, the decision was

taken to reuse the complex following the

“Velvet Revolution” in 1989. The status

of “international” airport was granted

and Carlsbad soon reinstated its former

standards of quality. In 2004, ownership

of the airport was handed over to the

“Region Karlsbad”. It quickly introduced

an extensive modernisation programme

and an extension to capacity. Work

began with the modernisation of those

areas which were necessary for flight

operations such as runways, guidance

systems and air traffic control.

In order to meet the travel requirements

of the “Schengen Zone”, it was also

important to modernise the arrival and

departure hall which still dated back to

the 1930’s. The young, but nevertheless

experienced architect, Petr Pavolek, from

Brno, was appointed as the designer.

It very soon became clear to those in -

volved in the project that, alone in terms

of space, the existing buildings simply

could not cope with the demands placed

on them. For this reason, architect Petr

Parolek therefore proposed an extension

towards the South in the direction of

the pick up/drop off zone and car park.

This extension has now been opened.

Architect Petr Parolek

The primary objective of the extension

was to increase capacity, which since

its opening in May 2009 has reached

a level of 800 passengers per hour. This

is the approximate equivalent to checkingin

the passengers for four medium-sized

aircraft per hour and, with an annual

capacity of around half a million passengers,

opens up new reserves for future


Kalzip GmbH 3

Kalzip case study

Curved trussed girders in longitudinal direction

The existing buildings were renovated

and any subsequent extensions were

removed. The development axis re mained

unaltered. The new structure is position ed

at right angles to it and connects to its

former main entrance. Petr Parolek: “This

configuration resembles an H in plan view

and opens up two perspectives for ob serving

the airport: on arrival at Carlsbad,

4 Kalzip GmbH

passengers mainly observe the functional

and historical component of the building,

which also leads them into the corresponding

world of the spa town. On departure,

they observe the “intermediate aircraft”

an organic technoid shape which creates

an intermediate link to the world of flight.

This so-called “intermediate aircraft” is

a masterpiece in sophisticated, organic

architecture: its external shape has drawn

inspiration from the world of aircraft de sign.

The detailing used and the choice of

materials underline this impression as the

building envelope is constructed entirely

from aluminium. The slightly elliptical body

is structured in the longitudinal direction

through the arrangement and alignment

of profiled sheets in three segments, in

order to increase the arch of the 70-metre

long hall and to create a connecting

passageway to the main entrance which

has been cut away in a similarly elliptical

manner. These dynamics support the

symmetrically angled narrow sides and the

light slots to the uppermost segment. “Here

it was an important criterion for us to

define all geometric surfaces and radii in

a way which would allow the desired metal

skin to be optimised both in technical

and economical terms,” says Petr Parolek.

The inside of the hall is characterised by

the visible, supporting skeleton structure.

An unusual solution, in terms of both

structure and design, is the arrangement

of both curved trussed girders, contrary

Cross section

Kalzip case study

to conventional logic, in a longitudinal

direction in the hall. In this way, starting

from the same base point, they sweep

upwards and away from each other in

a V-shape. Via these trussed girders, a

logical system of compression and tension

bars and formers are tensioned. The

external metal skin takes on this form in

a recognizable manner.

Kalzip GmbH 5

Kalzip case study

The architects chose radii which would

allow the entrance area and the light

slots to develop organically out of the

shape of the building. The vertical

structuring of the individual sheet

panels gives the “intermediate aircraft”

its plasticity and creates a shortened

optical appearance in the longitudinal

direction. The two-storey hall is surprisingly

open and light, which is due to

the light slots already mentioned, which

have been cut horizontally into the roof

skin. In this way, they appear to be much

larger inside the building than one would

expect from the outside.

The “intermediate aircraft” has a foyer

which fulfils all functional requirements,

featuring a small catering unit, the

check-in desks, as well as two rentable

business and office units. On the

second floor there are sanitary facilities

and additional offices which open out

onto a gallery. The gallery can be

accessed via four staircases and lift.

New roll-forming technology enables complex

and organic shapes to be created

The unusual shape of the terminal

called for a special solution in terms of

the outer building envelope; one which

would fulfil both functional and optical

requirements in equal measure. The

architects chose to cover this organic

structure with aluminium in the form of

Kalzip profiled sheets from Kalzip GmbH.

Aluminium is a material which is not only

highly durable and visually appealing,

but also extremely flexible.

The sophisticated and complex geometry

of the building is not only curved in the

cross and longitudinal sections, but also

in terms of the ground plan. For this

reason, in order to create the construction

elements of the building envelope,

a new type of roll forming technology

provided the only solution to producing

freely-formed profiled sheets. This meant

that each profiled sheet was individually

adapted, practically tailor-made, to suit

6 Kalzip GmbH

the existing geometry. The overall area

to be covered consisted of a multitude

of individual components. This required

very close coordination with the installation

company and the preparation of

a precise installation plan. The actual

building envelope was divided into three

sections. This therefore creates a fluent

transition from roof to facade.

The roof consists of pre-curved profiled

sheets with a radius of 15.8 m and a construction

width of 300 mm up to 320 mm.

They are arranged in a manner which

accentuates the contours of the skylight.

The profiled sheets which blend into

the facade adjoin directly underneath.

They were manufactured in one piece

in the factory and with a radius of 5 m.

They run right down to the floor at both

ends of the building. To emphasise

the dynamics of the building structure,

the profiled sheets end in a visible

Cross section

Cross section

separation, which is continued in the

entrance area.

Here the adjoining profiled sheets which

go right down to the floor on the right and

left of the entrance, have a con stru c tion

width of 510 mm up to 520 mm. The

large, shaped components which frame

the entrance oval, conceal the drainage

system located beneath in a manner

which is aesthetically pleasing. The struc -

tural design of the building envelope

required a non-ventilated roof structure.

Steel trapezoidal profiles were mounted

on the supporting structure. The vapour

barrier was installed on top of these.

A specially designed multi-part and

height-adjustable substructure was then

fixed to the upper flanges of the steel

trapezoidal profiles. The Kalzip system

fasteners, the so-called clips, were then

installed on this.

Compressible thermal insulation was then

laid. The uppermost final outer layer is

formed by the Kalzip profiled sheets

which are installed in a non-penetrative


In the Kalzip system, the profiled sheets

with the small seam are clicked onto the

fixed system fasteners, covered with the

large seam of the next element and zipped

together to create a friction-locked


“We decided to use Kalzip because the

profiled sheets manufactured using the

new XT free-form technology were the

only ones able to fulfil the precise material

requirements, which were necessary

to create the organically technoid supporting

system of the new entrance hall

with its large span width,” explains Petr


Kalzip case study

Floor plan, ground floor

Kalzip GmbH 7


The product and technical information contained in

this document is accurate according to our knowledge

at the time of publication. Details do not refer to any

specific application and cannot give rise to any claim

for compensation. From time to time our product range

may alter as a result of our continued commitment to

product innovation and development. Kalzip cannot

guarantee that printed literature will contain the most

recent updates; the latest editions are available to

download at www.kalzip.com.

Copyright 2010

Kalzip GmbH

Part of Tata Steel Europe Ltd.

Kalzip GmbH

August-Horch-Str. 20-22 · D-56070 Koblenz

P.O. Box 10 03 16 · D-56033 Koblenz

T +49 (0) 2 61 - 98 34-0

F +49 (0) 2 61 - 98 34-100

E germany@kalzip.com




The address of your nearest local sales office

can be found on our website: www.kalzip.com adhoc

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