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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: ga@hdg.org.uk, 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: gaa@gaa.com.au

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

+ additional

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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