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Our quarterly magazine features an eclectic mix of projects from the UK and Ireland and Germany in order to inspire, educate and inform our reader.
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2012International Magazine
ISSN 1363-0148
www.galvanizing.org.uk
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olympic Village: Shared communal landscape | 4 london velodrome: Undulating and curvaceous | 8 olympic park: Rejuvenation – large and small interventions | 12 lea valley Cable Tunnels: Going underground | 15
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Editorial
Welcome to the second issue of our redesigned magazine. i
have taken over the hot seat from David Baron, our previous
editor, having sub edited the magazine for longer than i would
like to admit. i would like to thank David for his hard work and
commitment to the magazine over the the last 20 years.
i will endeavour to keep you updated with an eclectic mix of
interesting, informative and delightful projects from the world of
galvanizing.
our special 2012 olympic Games issue features projects both large
and small that will play an important role within the Games.
the curvaceous Velodrome
takes design of its type to
new heights, emphasising
the pursuit of efficiency,
lightweight construction and
high performance standards.
the olympic park has not
only transformed an area
that used to be an industrial
wasteland into one that will
host many of the sporting
venues but will in Legacy,
contribute to connecting and
creating communities across
the area.
Smaller scale projects that may not immediately grab the headlines
have had an important role to play. the rerouting of overhead
power lines to underground tunnels was critical to the functioning
of the olympic site.
For digital readers, don‘t forget our magazine is available on the
Apple app store.
New Broom.
Hot Dip Galvanizing – An international journal published jointly
by the galvanizing associations of Germany and Great Britain. it is licensed
to associations in 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
this magazine may not be copied without the written permisson of the editor
© 20121
Hockeywarm-up
area
The Orbit
Entrance
Entrance
A12
Stratford High Street
Temporary Southern Spectator
Transport Mall
Entrance
Loop road
Loop Road
North-W
est Concourse
The Greenway
River Lea
Temporary Northern SpectatorTransport Mall
North-East Concourse
Stratford International station
HS1
Stratfordstation
West Ham station
Tower HamletsTT
Hackney
Newham
AquaticsCentre
OlympicStadium
Warm-up area
Water Polo Arena
Sponsors’Hospitality
Zone
HockeyCentre
International Broadcast Centre/
Main Press Centre
Velodrome
BMX Circuit
Eton Manor
BasketballArena
Handball
Arena
EnergyCentre
Stratford City
Athletes’Village
Central Concourse
C
a
B
iqbal Johal, Editor
Photo front cover | Justin Setterfield for LOCOG (London 2012)
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1 | Plan of the Olympic site a The Velodrome B The Olympic Park C The Athletes' Village
2 | Aerial view of the Olympic site
WastelandtransformedLondon Olympics 2012
When, in July 2005, the iOC president Jacques Rogge made the dramatic announcement that
london had won the campaign to host the 2012 Olympics, it set off a dramatic programme of
planning, building and organising that may well go on until 2013.
the task that lay ahead was in itself one of olympic proportions, the most dramatic of which was turning an
area that had been an industrial wasteland into an olympic park. the project was complicated further by the
banking crisis, funding issues and controversy over designs. to their credit, the organising committee have
taken all of this in their stride and the project has been delivered on time and on budget. the organisation
for the games is a complex web of not just building venues to host 26 sports but housing 14,700 athletes,
accommodating 21,000 media wallahs and creating an enjoyable experience for 10.8 million spectators from
across the world. to achieve all of this, a workforce of around 200,000 will be required by the time the Games
begin.
in our special issue celebrating the olympics, we look at the way galvanized steel has in its own inimitable
way contributed towards the challenge of making the 2012 games the best there has been.Photo | London 2012 (2)
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1 | The balcony railings acquire a lighter appearance with height
Shared communal landscapeOlympic Village
With the world’s attention normally drawn to the high profile
stadia that will host the various events for the Olympic Games,
an important aspect that can sometimes get overlooked is that
of accommodating, in london’s case, over 17,000 athletes and
officials.
London’s olympic Village however was of crucial importance from an
early stage of the planning process. the Village will be used to transform a
formerly deprived part of London and build the foundations on which inward
investment can flow and form an important legacy project of the Games.
the Athletes’ Village will be converted into 2,818 homes, half of which will
form social housing. it is these social ambitions that make the olympic
Village the critical component on which London 2012‘s regeneration legacy
depends. the £1bn development is the biggest housing construction project
a British government has underwritten for decades.
the design team took their cue from the grain and character of London.
three thousand trees have been planted. As well as the residential
accommodation, a whole array of urban amenities have been interwoven
into the masterplan, including public spaces, communal gardens, shops, a
medical centre and a 1,800-student academy.
the Village is split into 11 plots that comprise a total of 67 buildings.
Seven plots have been designed by a single architect while the remaining
four are the product of a combination of architects. the blocks are
interspersed by a series of wide boulevards and public spaces among
which there are two principal squares. A surprising yet refreshing feature
of the designs is the use of generously sized balconies throughout the
development. Attempts have been made to soften the grid and bring the
façades to life by using an interesting palette of colours and materials in
order to reflect the visual diversity of London.
by Iqbal Johal
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panter Hudspith Architects‘ element of this unique project is in a prime
location, fronting onto the main square in the middle of the Village. their
role comprised 123 apartments, 500m2 retail space, a concierge facility for
half of the Athletes’ Village and the podium landscaped courtyard within the
plot.
Design Principles
the design for these three cores introduced a number of key features to
the Athletes’ Village:
double storey panels to reduce the apparent
repetition of units over height
utilising a ‘kit-of-parts’ within the precast mould
to efficiently create variety in the façades
strong primary and gable façade treatments
to articulate the mass of the buildings
recessed corner balconies to create truly habitable
and semi-private external amenity spaces
a strongly varied skyline to integrate the buildings
into the wider long-term masterplan
in conjunction with this sustainability was a very important aspect of the
design criteria. Extensive consultation at early stages with the client to
rethink the original brief resulted in a reconfiguration of the massing to
introduce an extra core, which enabled more than 85% of apartments to be
dual or triple aspect, greatly enhancing their outlook and daylight quality.
Careful analysis of glass proportions, reveal sizes and orientation meant
that the combined passive measures alleviated the potential for overheating
in summer, even using projected 2050 weather data. the roofing details
were studied and have resulted in the extensive use of green/brown roofs
throughout all cores, reinstating the original biodiversity of the site.
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offsite manufacturing was utilised wherever possible to minimise site
wastage and improve standards, notably for the precast façade panels,
balconies, bathroom pods, utility cupboards and metalwork. Any waste
construction material on site was managed and segregated to aid
recycling and reuse. Code for Sustainable Homes level 4 was achieved
and the retail units achieved BREEAM Excellent.
Metalwork
the metal railings to the corner recessed balconies were given a subtle
enrichment through the use of both metal flats and bars. Rather than
the flats being evenly spaced, as would normally result from structural
analysis, they were randomly interspersed. in addition, the quantity
of flats is considerably greater closer to the ground where increased
privacy is necessary, when the balconies are viewed obliquely. this also
results in the railings acquiring a ‘lighter’ appearance with height. the
balconies were seen to add an important contribution to the design of the
development by providing an important link to the external environment
and private ‘space’ for the permanent residents.
Galvanizing with painting was deemed to offer the best quality finish and
long term durability reinforcing the sustainable credentials that had been
followed throughout the project. the visual nature of the top rail of the
handrails was deemed critical by both the design team and client, refining
the overall perception of the quality of these corner balconies. the top
rails were therefore given a further coating onsite producing a remarkably
consistent and attractive surface.
At level 1, around the shared communal landscape courtyard within
the plot, 250m of vent grills supply air to the parking below. the use
of a galvanized finish produced a very uniform and discrete mid-toned
grey band either side of the pathway that surrounds the courtyard. the
metal railings on the podium deck which line the edges of the townhouse
gardens was procured under the landscaping package. the steel was
galvanizied and powder coated to achieve the required aesthetic and at
podium level, the railings were in-filled with timber to provide privacy. As
such, the nature of the podium railing is very different to the apartment
balconies and the end result produces a very refined, elegant aesthetic
that convincingly conveys the quality message that is synonymous with
the Athletes’ Village.
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2 | Galvanized and powder coated finish produced an uniform, discrete finish for the courtyard metalwork
3 | Open courtyards is a feature of the Olympic Village
4 | Private gardens around the perimeter of the courtyard
5 | Colonnade feature of the upper floors creates an animated sky-line and help to provide large balconies
Architect | Panter Hudspith ArchitectsClient | Olympic Delivery AuthorityPhotos | Panter Hudspith Architects (1,2,4,5),
London 2012 (3)
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Undulating and curvaceous
Bikes ridden at speed around a banked arena seem to draw
upon some primeval instinct that engenders a competitive
edge for the riders and an almost uncontrollable zeal amongst
the watching crowd. Maybe there is an intrinsic link within
the human psyche to competition, speed and danger at close
quarters that can be traced from the Circus Maximus in Rome
through to the atmosphere created by the competitions that
take place within velodromes of the modern era.
Fast forward to London 2012 and the competition for the velodrome
design. this represented one of the unique opportunities within the venue
designs. How to cater for a complex geometry that would offer unfettered
sight lines for a seated crowd of 6,000 spectators within a sport that
Great Britain was expected to win a number of gold medals.
by Iqbal Johal
London Velodrome
1 | Dramatic view of the Velodrome in its park setting
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the winning team of Hopkins Architects and Expedition Engineering followed a very simple
design philosophy: that of the spirit of bicycle design - the pursuit of efficiency, lightweight
construction, high performance standards and above all, synergy. “We took an integrated
architectural and engineering approach“, says Mike taylor (Hopkins). “How to do more with
less.“
the end result is a beautifully striking structure that is simple yet complex and sits quite lightly
within its landscape. A doubly curved roof rests on top of an undulating, curvaceous base that
houses the track and the seating areas. the shape of the roof has already earned it the nickname
“the floating pringle”. A “shrink wrap” effect of the roof design helps to wrap the building around
the track minimising the interior volume and in turn reducing heating and cooling requirements.
Early within the design conception a cable net roof support system was seen as the perfect fit
for its form and span. there were however issues that needed to be resolved. typical cable nets
support lightweight fabric structures that work like a tennis racquet - a grid of cables in tension
with a large compression ring at the perimeter to isolate the net‘s tension forces - the Velodrome
cable net is not typical and presented two major challenges:
- a weathertight, insulated roof was needed, to retain the graceful lines of the building
- to dispense with the use of a large perimeter ring beam
this twofold conundrum presented the biggest structural engineering hurdle on the project. the
first challenge was how to connect the rigid roof deck to a flexible cable net structure and allow
for the necessary movement joints. it was decided early in the design process that the cables
would be clamped together by galvanized steel nodes at each intersection and that these nodes
would be used to provide support for the prefabricated timber panels that formed the roof deck.
However, these nodes would move relative to one another by up to 5mm under various load
conditions, so it was not possible to connect the panels rigidly to each node. A clever solution
was eventually adopted that enabled the timber panels to be fixed rigidly to only one node and
allow them to slide via a slotted system on the other support points.
Undulating and curvaceous
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the second challenge involved designing a structure to transfer out
the high cable tension forces from the roof. this would normally be
achieved by having a large ring beam in compression around the
structure. However this would interfere with the “light” touch design
approach. the solution was found by designing the building‘s steel
upper seating bowl and entire structure below to be mobilised in
transferring out the cable forces. this had the positive result of only
a small ring beam structure being needed that allowed a sharp eaves
edge detail.
the net is formed of pairs of 36mm diameter spiral galvanized strand
cables, on a 3.6m grid, and locked together with galvanized forged
steel nodes at each cable intersection. the cables are pre-stressed so
that the roof structure remains stable and in tension under all loading
conditions. the 16km of cables were transported to site and the 1,000
or so nodes clamped to form the net before the whole structure was
lifted to roof level. the entire on-site cable net construction process
took only eight weeks. With the net lifted in place, the prefabricated
timber roof panels were craned into position and the remainder of
the roof added. “the roof has about 100 tonnes of steel in it and the
structure is as light as the team dare go and still get the details to
work“, says Mike taylor.
the Velodrome’s double-cable net roof is the building’s most innovative
feature and forms a key part of its light carbon footprint. initial studies
had shown that a conventional steel roof would be cheaper but the
project contractor commissioned a detailed study to look at cost,
programme and environmental aspects. this explored four options for
the roof: gluam, gluam and cable, all cable and conventional steel.
the study concluded that although the initial costs for the cable
net option were greater there was a 3 month saving off the build
programme - saving £2 million and a saving on the reduced amount of
steel used. Compared with steel arches, the cable net used 27% less
steel. there were also health and safety benefits from reducing the
amount of work at height that would be needed. the final roof weight,
including cables, nodes and ring beam, is a mere 30kg/m2, half that of
the Beijing stadium.
2 | Double-cable net roof - the building's most innovative feature.
3 | Vital galvanized connection node for the cable net roof
4 | Internal panoramic view of the race track and cable net roof
5 | External view of the ’sharp eaves edge detail‘
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Architect | Hopkins ArchitectsClient | Olympic Delivery AuthorityPhotos | London 2012 (1, 4, 5),
Hopkins Architects (2, 3)
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1 | Parklands area in the north of the Olympic Park
2 | Park parapet in the landscape
Rejuvenation – large and small interventionsOlympic Park
Situated to the east of london, encompassing four of the most deprived boroughs
of london, the site that has become the Olympic Park started from very humble
beginnings.
the full legacy of centuries of industrial activity on the site became apparent when work started
in 2005. More than five years of work has resulted in its total transformation. it has literally been
scraped clean, power lines that crossed the site have been buried and the completion of the largest
soil-cleansing operation ever undertaken in the UK. the dereliction has gone, and in its place is
a 246ha parkland crossed by new roads and bridges and threaded through with waterways. it is
buzzing with new life including wildlife habitats, trees and plants.
the olympic Delivery Authority appointed a multi-disciplinary team to deliver materplans for the
olympic games that included the creation of the new park. Allies and Morrison Architects formed a
key part of this team. the park works have been split into three tranches - remediation, bridges and
highways, and landscaping - as well as procuring a green ”energy centre”.
Most of the media attention has, quite naturally, concentrated on the major venues, but the
completion of the contaminated land treatment, infrastructure and utilities has provided the
backbone for not only the olympic and paralympic Games but also for the future legacy
development. Some of the figures involved are mind boggling: 30,000 people will have worked on
the park and 6,449 will be working at the park on the busiest day of the games.
by Iqbal Johal
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collaboration between Allies and Morrison, Arup and Atkins. Before work started, the olympic park
site was made up of isolated fragments of land with poor connections between local communities.
the programme to build new structures, bridges and highways will not only provide access during
the Games but will leave an open and accessible area in Legacy.
When the Games are over, 101ha of the site will become the Queen Elizabeth olympic park - the
largest new urban park in the UK for over a century. the southern section will become a “festival“
park, with riverside gardens, wildflower display meadows and walking and cycle paths along
restored and previously inaccessible waterways. the northern section uses green techniques to
manage flood and rainwater, and will provide quieter public space and habitats for existing and rare
species, from kingfishers to otters.
Within this area, a former landfill site has been remediated to create a wetland bowl with 15,000m2
of riverside spectator lawns, timber seating, frog ponds, loggeries, wetlands, woodlands, tree-lined
footpaths and the largest man-made wet woodland in the UK. the park will boast 4,000 new
semi-mature trees, over 2,000 of which have been grown in Hampshire and already planted.
Park parapet
Amongst all of the major works small interventions have in their own way made an important
contribution to the overall project. Allies and Morrison have alongside their overarching masterplan
contributed to the design and implementation of some of these smaller works.
the design principle for the typical footbridge parapet was developed and ultimately used
extensively across the park. the intent was to create a visually lightweight but robust parapet that
could effortlessly approach and cross bridges, traverse the landscape, define and protect edges
and transform as particular conditions or design standards demand. the process for the design and
implementation of the parapets underwent a rigorous design scrutiny from first principles to fulfil the
criteria for the numerous approving authorities.
in order to maximise off-site fabrication a component approach was adopted. Geometries and
spacing were standardised where possible and a materials hierarchy established to complement the
park landscape. this included galvanized steel to provide the required durability alongside stainless
steel sections to fulfil requirements of design adaptability. the elements of the parapet (post, leaner,
cycle rail, infill mesh) are provided (or removed) as the site conditions dictate. provision has been
made for integrating LED lighting. Around 8 linear kilometres of this bespoke parapet will have been
installed across the olympic park.
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Construction Bridges
A key theme of the 2012 olympics is that of sustainability. Every aspect
has been studied to maximise use or reuse of structures and materials
both for the Games and in Legacy. A prime example of this is the reuse
of at least two galvanized steel construction bridges. these were initially
built for access for plant and equipment but will now be used for the road
race cycle circuit as part of the Legacy Velopark.
one of these bridges will actually be used three times: it has already
been used as a construction bridge, it has been adapted and widened
as a temporary crossing over Stratford High Street for pedestrians
travelling to the Games from the Greenway, and once the Games have
finished, it will be moved up the river Lea and adapted again and form
part of the Legacy road race bridges.
3 | Construction bridge to be retained and adopted for the Legacy cycle road racing circuit
4 | Image of construction bridge in Legacy mode
5 | Construction bridge used as a temporary bridge over Stratford High Street
6 | Park parapet on bridge
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Architect | Allies and Morrison ArchitectsClient | Olympic Delivery AuthorityPhotos | London 2012 (1), Atkins (3),
Allies and Morrison Architects (2,4-6)
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1 | Plan showing cable tunnel route
2 | Cable tunnel steel supports that run throughout the tunnel network
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Client | Olympic Delivery AuthorityPhotos | London 2012
Going undergroundLea Valley Cable Tunnels
at first sight, a project that involves rerouting power lines may seem
insignificant or even described as a bit boring. However, the complex and
challenging project to move two sets of existing power lines from pylons into
tunnels was fundamental to the Olympic Park site. (Without the removal of
these power lines that went through the centre of the planned Olympic park the
development of the rest of the venues could literally not get off the ground.)
the bare bones of the project included the creation of 10 shafts, 13 km of tunnels, over
200km of cabling and the removal of 52 existing overhead pylons adding up to a project
cost of £250 million. Significant hurdles had to be overcome from the outset: difficult ground
conditions, approval from a plethora of landowners, river crossings and utility approvals, and
a very challenging deadline of three and a half years (half the industry norm). Extensive off-
site trials were conducted in tunnel mock-up environments to develop both cable installation
and jointing techniques.
the tunnelling and shaft work were completed by August 2007 - 13km in 13 months. Laying
of the cables proved to be just as challenging. the innovative design of cable rollers and use
of bespoke tunnel vehicles for plant and materials transportation allowed up to three cable
lengths totalling 2400m to be pulled through the tunnel at any one time. Cable lengths for
the 400 kV cables were such that the joint bays were spaced at 800m centres. Hundreds
of metres of galvanized cable support systems have been used throughout the tunnels to
ensure that no costly maintenance is needed for these systems.
the power was switched underground during August 2008, allowing work to remove the
overhead pylons and overhead lines to begin in September 2008.
the careful planning, collaboration and innovation used by the project team set a benchmark
for world-class delivery of high-voltage cable tunnels.
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Studio East Dining
Studio East Dining was a temporary pavilion, designed by Carmody
Groarke, built on top of an eight-storey car park adjacent to the
olympic site. the structure was made entirely out of standard
galvanized scaffolding poles taken from the site and wrapped in
an industrial-grade polythene membrane. the pavilion design took
into account the very short life span of the restaurant and the need
for it to return to a construction site. the individual and intimate
dining spaces within the structure and angular form of the pavilion's
roof is generated by the various directions that each of the dining
rooms point, framing breathtaking panoramic views and creating
a spectacular silhouette against the backdrop of the London 2012
olympic site. Photos | Luke Hayes
Galvanizing Delight
+ additional pictures