hot dip galvanizing magazine 1/2010
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Hot Dip Galvanizing Magazine 1/2010TRANSCRIPT
2010
1/4 Hot Dip GalvanizingInternational Magazine | ISSN 1363-0148 | www.galvanizing.org.uk
2010
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Two articles in this edition feature horses.
We start in Dubai with Ferrari World, a theme
park dedicated to the Prancing Horse on what
was previously an island of desert and scrub-
land. The whole project was completed in a
very short time span of 15 months, due, in
no small part to the use of the MERO three-
dimensional framework as the ‘chassis’ of the
building. (A building technique which is not
dissimilar to that used in some classic racing
cars of the ‘50’s and ‘60’s.)
Then we move on to one of my favourite
artists - Andy Scott. He made the beautiful
Clydesdale heavy horse which stands proudly
besides the M8 just south of Glasgow.
It has been said that horses are one of the
most difficult animals to draw, so to sculpt one
flawlessly in three dimensions is, to my mind,
real craftsmanship. However, as you will see on
page 10, horses are not the only animals that
Andy Scott has sculpted.
Finally, one of the benefits we claim for
galvanizing is its longevity, so it is appropriate
that we revisit some of the projects we featured
previously and see how they are faring.
The pavilion built for an expo besides a water-
way in Holland 10 years ago appeared, at first
sight, to be rusting. However, closer inspection
showed that it was not the galvanizing which
was the problem…
David Baron, Editor
Contents
2 Editorial
3 Ferrari World, Abu Dhabi GT chassis brought to life
6 Transport Exchange, Heerlen (Moon Quarter) Bus station
8 Office in Calbe Pragmatic structural solution
10 Andy Scott Public Art Connecting with the community
13 Expo pavilion 10 years on
Revisiting an old favourite
14 EN ISO 1461 updated
16 Galvanizing in Detail
Front cover:
Ferrari World Abu Dhabi
Photo: Aldar (www.aldar.com)
Editorial
2 | Hot Dip Galvanizing
Architecture
Ferrari World, Abu DhabiGT chassis brought to life
By Revels/Holger Glinde
In 2006, Yas Island was a flat landscape of desert and scrubland surrounded
by navigable water, east of Abu Dhabi City and close to the main highway past the
existing airport. To the north the views stretched out past low lying islands to the
open ocean of the Arabian Gulf. However, a spectacular new development is set
to change the landscape.
Aldar Properties PJSC is undertaking multi-
billion Dirham civic projects to help develop
Abu Dhabi, the capital Emirate of the United
Arab Emirates, into an international business
and tourist destination.
At the centre of the landmark Yas Island
mega-scheme in Abu Dhabi, sits the world’s
first Ferrari Theme Park. Aldar’s aspiration for
Yas Island was to create a uniquely powerful
and sophisticated blend of quality environ-
ments, attractions and lifestyle sports.
Benoy set about developing the ground brea-
king Yas Island master plan by establishing
the contextual relationship between the
key leisure components and the Retail Hub
that serves as a community destination for
the region. Benoy’s Ferrari World to the south,
aligns with the master planning of the Abu
Dhabi Formula 1 motor racing track.
Externally, Ferrari World expresses the langu-
age, values and passion of the Ferrari brand
itself.
Benoy’s vision to create a building that reflects
Ferrari’s sinuous form, is directly inspired by
the classic double curve side profile of the
Ferrari GT chassis.
The double curve was proportionately applied
in elevation to set the structure’s length and
height. This proportion gave rise to the dynamic
scale of the building at 700m from tip to tip of
the tri-forms.
Internally, a collection of over 20 high octane
attractions provide excitement for the whole
family. The focal attraction will be the 60metre
high ‘G-Force Tower’ – one of the most intense
‘freefall’ experiences in the world. Two roller
coasters continue the adrenalin-raising theme,
including the world’s fastest, reaching speeds
in excess of 200 km/h.
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Hot Dip Galvanizing | 3
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Architektur
Within the overall framework of a design and
built commission, MERO has been responsible,
not just for the design, the statistical calcu-
lations and the constructional development,
but also for the manufacture and installation
of all the steel structures.
Ferrari World is topped by a giant freeform roof,
with an area the size of 28 football pitches.
The complete roof structure, with an area of
almost 200,000m², consists of a MERO-KK
three-dimensional framework. With a total of
nearly 172,000 bars and 43,100 joints, it is
thought to be the largest three-dimensional
framework which has ever been constructed in
the world. All 172,000 bars have been given
long-term protection against corrosion through
galvanizing.
The entire awe-inspiring structure can be
divided into three areas: Funnel, Shield and
Triforms. Here, the so-called Shield is the
nucleus – 86,200m² in area and closed off by
façades, with a maximum diameter of 377m.
At its centre an imposing feature catches the
eye – the glassed-in Funnel. With an area of
9,440m², it has a diameter of 100m at its
highest point above the roof of the Shield, and
narrows to 18m at ground level. The three open
Triforms in the outer area are attached to the
Shield to form a 12 point Arabic star that will
cast a shadow over an area of approximately
100,000m². The geometry of the Triforms
initially describes a continuous extension of the
Shield, and each of them splits into two arms
about a third along its length, finally ending up
in a curving, three-dimensional shape, with a
maximum distance of 284m from the Shield to
the so-called Tips. The maximum span between
the Tips of two Triforms is 775m.
The three-dimensional framework described
here can be divided into a two-layer roof struc-
ture and a three-layer roof truss area. The prin-
cipal trusses take the form of a three-dimen-
sional framework, and are directly integrated
into the 2-layer roof structure. The size of the
three-dimensional framework grid was laid out
on the basis of the optimal dimensions for the
individual components from both an economic
and installation point of view.
The large-scale grid constructed in this manner,
in combination with the predominantly small
bar diameters, lends the structure an impres-
sive lightness.
The roof construction of the Shield is supported
on a minimum number of supports required
between 32m and 18m. At its centre, symme-
trically arranged around the funnel, are twelve
central supports of the three-dimensional
framework. Their square column cross-section
is divided, at the mid-point of its lower area,
into two opposed arcs, which merge seamlessly
into the triangular trusses of the roof structure
and thus recall the Gothic equilateral arches
from the cathedrals of past times.
The Funnel, the Shield and the three Triforms
act in a statically indeterminate manner.
So structurally, the steel construction of Ferrari
World can be split into five separate structures.
As against a level supporting framework, the
special calculations for the MERO three-dimen-
sional framework make possible a significant
reduction in the cross-sectional stresses, which
means that a particularly light – and thus
economical - system is created.
With the aim of having the building ready for
the start of the Abu Dhabi Formula 1 race on
Architecture
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01Architecture
Hot Dip Galvanizing | 5
1st November, 2009, some extraordinary additi-
onal requirements were imposed on the manu-
facture, logistics and installation processes.
The construction period began in April, 2008
and the completion date was July, 2009 – a
mere 15 months. The contribution made to this
achievement by the segmented steel construc-
tion was absolutely vital. It meant the extremely
tight construction period targets could be met
without any down time, but at the same time
keeping to the strictest building site safety
conditions.
Out of all the many construction projects that
have been constructed or are planned in
the UAE, Yas Island may prove to be not only
one of the most audacious but also the most
successful in achieving its ambitions.
Architects: Benoy
Photos: (1) Ferrari World Abu Dhabi,
(2,3,5) MERO-TSK International GmbH (www.mero.de),
(4) Interfalz (www.interfalz.de)
Funnel
Shield
Triform
Wall
Tip
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5
A competition was held for the design of an
interlinking area between the railway station
at Heerlen and the bus station.
The competition was won by Copier Steel
Constructions B.V. with Verhoeven Infra B.V.
and the design was carried out by architect/
artist Michel Huisman.
The project brief called for a structure that
would act as a link between the two different
modes of transport and protect passengers
from the elements. Huisman’s design however,
creates more than a link - it almost provides
a new public space for Heerlen which he has
named the ‘Moon Quarter’.
Steel constructionThe total project includes more than 240 tonnes
of steel. The specification prescribed that all
steel components had to be galvanized and
subsequently powder coated.
The overall design concept is that of a simple
arch structure that has a free span of
23m at a ridge height of approximately 14m
and is made up of four linked sections.
The largest sections are approx.
14 x 4 x 0.65m. The open structure fits easily
within its urban landscape providing
free-flowing traffic, advertising space, seating
areas and passenger information.
The large open steel structure is reminiscent of
a large rose arch. The design concept incorpo-
rates the arch to function as a support for the
adjacent Wisteria Floribunda Macrobotrys, also
known as Japanese Wisteria. It is hoped that
over time, the whole structure will become a
Wisteria covered arch.
Architect: M. Huisman, Heerlen
Execution: Verhoeven Infra B.V., Zaltbommel
Construction: Copier Steel Constructions B.V., Giessen
Client: Heerlen council
Photos: Gerard Reimerink, Amersfoort (5)
Copier Staalconstructies B.V., Giessen (p6 l.b.)
Traffic and transport
Transport exchange, Heerlen (Moon Quarter) bus station
By Gerard Reimerink
Well-designed and integrated transport hubs are not something that the UK is well
known for. Our continental cousins in the Netherlands however, seem to find it
quite easy to combine various modes of transport and make it easy to switch from
one to another.
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The site owner wanted to combine two buil-
dings it had purchased, which were located in
Calbe. Since the existing administration buil-
ding was too big, and also too far from the
production workshops, it was decided that
Portakabin-type offices should be positi-
oned directly in front of the south side of the
350-metre long workshop section.
In order to confer the necessary air of distinc-
tion for this simple solution, and to combine
the new administration block with the produc-
tion area in three-dimensional and functional
terms, the architects schneider + schumacher
were asked to propose a pragmatic structural
solution, which would suit the client’s budget
and also fit in with the stark industrial
environment.
To achieve this, Portakabin-type containers
were positioned at a distance in front of the
workshop wall.
The intervening six-metre space was roofed
over as protection from the rain, and single
glazing was applied to the front façades, which
provide transparency and openness for the new
entrance area.
This created a transition point between
the world of industrial production and the
administrative section of the plant, between
the interior and the exterior, between old and
new. Hot dip galvanized, large-format steel
deck plates, weighing up to 450kg, cover the
east and west façades of the office block,
together with the roof.
The south façade of the building is planned
as a ‘green’ wall, on which Virginia creeper
is growing. A galvanized steel structure made
up of rect-angular sections, gratings and
screen wire acts as an alignment balcony and,
together with the vegetation, provides shade.
Depending on the time of year, the creeper
changes its colour, so that it contrasts with
the galvanized deck façade. The mobile and
replaceable ‘Porta-kabins’ thus ‘grow into’
the location.
The interior façade of the administration
section has been clad with galvanized grating
mats, which give a hint of the ‘outer skin’ of
the container behind them.
It is a structure in its own right, but never-
theless it provides a connecting link between
the standardised container dimensions and
the grid-type façades of the existing industrial
workshops.
The architects schneider + schumacher won an
award for the new construction and alteration
work on the administration building in the
competition for the Hannes Meyer prize, awar-
ded by the Saxony-Anhalt branch of the
Federal Confederation of German Employers’
Association.
Architects:
schneider + schumacher Architekten, Frankfurt/M.
Photos: Kopf Holding GmbH (www.zinkpower.com)
Architecture
Office in Calbe Pragmatic structural solution
By Holger Glinde
This beautifully pragmatic design solution not only adds the required office space
for the existing building but is achieved in a very simple yet ingenious way.
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10 | Hot Dip Galvanizing
Andy Scott is one of the UK’s leading artists.
He graduated from Glasgow school of art with a
fine art sculpture degree and is an Associate of
the Royal British Society of Sculptures. To date
he has created over 60 sculptures in a variety
of media for a broad range of clients.
His output includes works as far a field as
Belfast, Brisbane, Scotland and Spain.
The design principles that create the core of
Andy Scott’s work can be defined quite simply
as the creation of recognisable objects, rooted
firmly in the realm of figurative art. The work
also aims to operate on varying levels of inter-
pretation, from the immediate acceptance and
appreciation to the considered appraisal and
ownership of local residents. Perhaps another
way of describing the work is that of the com-
bination of traditional sculptural dexterity with
contemporary fabrication techniques.
In many instances architects, developers and
landscape architects recognise the need for
aesthetic enhancement of environments,
but lack either the required space or budget
to incorporate free-standing sculptural works.
Andy Scott doesn't seek to compete with the
numerous steel fabrication companies.
His work relies on detailed hand-drawn
sketches and rigorous research into the
intended site, drawing upon aspects such as
the social history of the area that help to
provide a direct connection to the urban lands-
cape. Sometimes his work is to simply add
flourishes of beauty and elegance to otherwise
unremarkable landscapes. All of this is also
anchored to a realistic approach and attention
to detail such as maintenance, durability and
public expectation. Most of Andy’s sculptures
are galvanized to provide long term durability
but also to add a finish that helps the woks to
fit into their gritty urban environment.
Many of Andy Scott’s commissions arise
through close community consultation.
Groups such as Housing Associations and local
community councils commission Andy to create
artworks which create a sense of identity for
their areas.
This collaboration engenders a sense of aware-
ness, understanding and ownership in the
local residents, who in turn "adopt" the artwork
as their own. The success of this approach in
many instances can be exemplified through
Andy's zero vandalism record to date, and the
adoption of some works for a wide range of
peripheral uses.
Projects
The KelpiesThe Kelpies are based on mythical Scottish sea
horses and will be a staggering 30m in height
when completed at full scale.
The sculptures will form the landmark feature
of The Helix Environmental Regeneration
Scheme on the Forth and Clyde Canal near
Falkirk in Central Scotland. They will be part of
an innovative displacement of a lock boat lift
system which will bring vessels into the central
Scotland canal network.
The creation of the first set of scale maquettes
demonstrated the ideas behind the proposal to
Andy Scott has created steel sculptures all over the world from Ireland to Australia,
however he is probably best-known for his much-loved Clydesdale by the M8 on the
outskirts of Glasgow.
Sculpture
Andy Scott Public ArtConnecting with the community
By Iqbal Johal
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the public, to the associated project partners
and to the UK National Lottery assessors, who
have agreed to fund the project. A second set
of models was developed in closer detail to
form the basis of the complex engineering
calculations which will enable the construction
of the full scale work.
The two colossal horses’ heads will each dip
and rise through a five metre span, displacing
thousands of tons of water to enable the boat
lift mechanism to function. They will be a major
civil engineering project and will involve a part-
nership of engineers, transportation, logistics
and project managers.
The Heavy HorseUnveiled in 1997, this sculpture has become
one of the best known artworks in the Glas-
gow area. It is sited on Glasgow Business
Park beside the M8 motorway, and stands
four metres tall at the head. The huge
Clydesdale has become synonymous with the
city and has been taken to the hearts of the
local people in the Easterhouse area.
It is made of welded steel bard which vary from
6 to 20mm in diameter, and is galvanized.
In keeping with many of Andy’s commissions it
offers numerous levels of interpretation:
heavy goods transport, agriculture, the steel
industry once prevalent in the area, and even
the Clydesdale breed itself which was originally
bred in Lanarkshire.
However the true inspiration was a metaphor
for the city of Glasgow. Once a proud industrial
manufacturing city, the city has now refa-
shioned itself for the 21st century as a city
of culture… the horse was once a beast of
burden, but the sculpture stands free of the
bridles of work and has its name and tail in
pleats and ribbons for exhibition, yet is magnifi-
cently reminiscent of its hard working ancestry.
The Heavy Horse was followed a couple of
years later by another Clydesdale, which is now
sited in Boonah, Queensland. This sculpture is
now an official monument to the role the breed
played in the building of modern Australia.
The Easterhouse PhoenixOne of a series of artworks Andy has underta-
ken around the East end of his native Glasgow.
The Phoenix was commissioned by a consorti-
um of local residents who were aware of Andy’s
work through his commitment to community-
based projects. They gave him a brief based on
the concept of the phoenix as a mythological
bird which rises from the ashes, as an allegory
for the regeneration of the Easterhouse area
of Glasgow. After years of decline the area has
been transformed, and the community wanted
a sculpture to act as a prominent landmark on
the approach road to the estate.
The Phoenix is in fact sited only a couple of
kilometres form The Heavy Horse, on the north
side of the busy M8 motorway which links
Edinburgh & Glasgow. It stands approximately
four metres tall and has a wing span of four
metres, and is made of a lattice of welded and
galvanized steel bars. It stands on landscaped
rockery of “firebird gneiss” granite stones,
which are engraved with an inscription for a
poem written about the sculpture by a local
schoolboy. Such was the success of the sculp-
ture that it has since been adopted as the
emblem for a local school.
The continued attention to detail and the incor-
poration and linkage of his work to the commu-
nity will probably ensure continued success and
popularity of Andy Scott’s work.
(1) Arabesque, (2) Rise, (3) The Easterhouse Phoenix,
(4) The Kelpies, (5) Argestes Aqua, (6) The Heavy Horse,
(7) Arabesque, (8) The Lighthouse Gates
www.scottsculptures.co.uk
Photos: Andy Scott Public Art
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Case History
Expo Pavilion 10 years onRevisiting an old favourite
By Gerard Reimerink
The water way centre pavilion was constructed in 1995 and featured in our magazine
(June 1995 Issue No. 2 – Page 28/29). It was a temporary pavilion for providing
information on the developments of the traffic flow on the New Waterway, the
approach channel into Rotterdam for ships from the North Sea. The exhibition has
been dismantled but the restaurant with terrace is flourishing.
On a recent visit to Rotterdam we drove past
the Expo Pavilion Unicum near Hoek van
Holland purely by chance. Our attention was
drawn to the architecture of the centre.
The location with a beautiful terrace near the
water was very inviting so we took a short
break for a cup of coffee. However, visitors
would have been extremely shocked to observe
rusty brown staining in large areas of the steel.
What had happened?
MaterialThe whole of the pavilion structure had been
constructed using hot-dip galvanized sections.
The glass sits on the sections and is attached
to the steel via an adhesive process.
The viewing strips are double glazed in order
to prevent condensation as much as possible.
A number of fans have been installed in the
façade area in order to prevent the build-up
of condensation during wet weather and
when a large number of visitors are present.
As corrosion of the galvanized steel was un-
likely, even in this industrial maritime climate,
the Stichting Doelmatig Verzinken (SDV) deci-
ded to carry out a small investigation in June
2009. It appeared that stainless steel gauze
had been stretched over the grid facade.
After a few years, this had started to show a lot
of corrosion, presumably as a result of the salt
in the air and rain.
The rust was subsequently running onto the hot
dip galvanized components and staining these
brown (rust has an extremely strong colouring
pigment!)
Remaining lifeThe pavilion was designed and built with the
idea to dismantle it after a few years and
possibly rebuild it somewhere else.
It is therefore important to know how much
longer the steel is expected to last.
A magnetic layer thickness measurement was
therefore performed in various areas of the
steel. An average of 191, 225 and 289 µm of
zinc was measured in three different places.
The thinnest layer measured was 161 µm.
The various joints although brown and covered
in salt, still appear to be in good condition.
In a climate that is very harsh for many mate-
rials, the remaining thickness of zinc will still
provide protection for many years to come for
a temporary structure that has now become
permanent.
Photos: G. Schmittmann (SDV), Nieuwegein
Hot Dip Galvanizing | 13
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When EN ISO 1461 was published in 1999, it was a breakthrough for the european
and the international hot dip galvanizing industry. For the first time, all the national
general galvanizing standards were replaced by a single specification. Since then,
consumers have no longer needed to consider where their finished components were
galvanized - EN ISO 1461 was applicable internationally.
However, nothing is set in stone. In accordance
with international law, standards must be
checked at least once every five years, to
ensure that they are kept up to date.
Since EN ISO 1461 was issued, there has been
useful feedback from consumers, i.e. from
galvanizers, fabricators, specifiers and their
customers.
The revision process for the galvanizing stan-
dard, EN ISO 1461 ‘Hot dip galvanized coatings
on fabricated iron and steel articles – Speci-
fications and test methods’ is now complete.
The foreword to the 2009 edition sets out the
principal changes to the standard to assist
readers in identifying where differences in the
requirements of the standard might impact on
their understanding and use of the document.
Overall the revised version of EN ISO 1461 is
a good example for continuity and does not
include any major changes to the existing
standard. The 2009 edition of EN ISO 1461 is
now a well accepted and developed standard to
be used not only in the general steel construc-
tion industry but it also provides assistance for
the specification of all kind of products:
including lighting columns, lintels, guard rails,
balustrading, the list is endless.
Some highlights
Clause 5 'Acceptance inspection and sampling' The title of this clause in the newer version
reflects that this section deals not only with
sampling but also acceptance inspection.
Selection of a control sample (from an inspec-
tion lot) for coating thickness testing is now
dependent upon customer requirements.
The size of control sample required is still
related to lot size.
Technical
EN ISO 1461 updatedBy Iqbal Johal
1 Minimum coating thickness and mass on samples that are not centrifuged*
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Article and its thickness
Local coating thickness [micron]
Local coating mass [gm-2]
Mean coating thickness [micron]
Mean coating mass [gm-2]
Steel > 6mm 70 505 85 610
Steel > 3mm to ≤ 6mm 55 395 70 505
Steel ≥ 1.5mm to ≤ 3mm 45 325 55 395
Steel < 1.5mm 35 250 45 325
Castings ≥ 6mm 70 505 80 575
Castings < 6mm 60 430 70 505
Clause 6 'Coating properties' The 2009 version has added text to highlight
the need for agreement on the quality of
surface finish achievable on work that contains
different steels / sizes / etc. A note is also
included to indicate that agreements should be
made regarding whether to quench / passivate
or not.
Clause 6.2.1 'Thickness – General' Now links the reader to the guidance document
EN ISO 14713-1 for information on corrosion
performance of the coatings.
Clause 6.2.3 'Thickness - Reference areas' This has been tidied up to include a table
showing how many reference areas are
required in relation to the size of an article -
so a new table has been included in the
2009 version.
For work that is centrifuged, there are more
changes in the 2009 edition as compared
to the 1999 version.
Clause 6.3 'Renovation' In the 2009 version, allowance is made for the
use of thermal spray coatings and application
of zinc flake products - in addition to the usual
zinc rich paint and alloy stick materials.
There is now a requirement for a repair to be
a minimum of 100 microns (unless the article
is subject to additional coatings, e.g. wet
paints or powder coatings) - as opposed to
the requirement for repairs to be 30 microns
over the local coating thickness requirement
as set out in the 1999 version.
* Centrifuged refers to the action of spinning small
galvanized articles (such as nuts and bolts) in a basket
to remove excess coating.
Technical
2 Minimum coating thickness and mass on samples that are centrifuged*
HOT DIP GALVANIZING
An international journal published jointly by the galvanizing associations of Germany,
The Netherlands and Great Britain. It is licensed to associations in Spain.
Edited by: G. Deimel, H. Glinde (Editor in Chief), I. Johal, D. Baron,
Drs. G. H. J. Reimerink
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 permission of the editor © 2010.
Distributed in Australia by: Galvanizers Association of Australia, 124 Exhibition Street,
Melbourne, Victoria 3000, Australia, Tel: 0396541266, Fax: 0396541136,
E-mail: [email protected]
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Article and its thickness
Local coating thickness [micron]
Local coating mass [gm-2]
Mean coating thickness [micron]
Mean coating mass [gm-2]
Articles with threads:
> 6mm diameter 40 285 50 360
≤ 6mm diameter 20 145 25 180
Other articles (including castings):
≥ 3mm 45 325 55 395
< 3mm 35 250 45 325
Galvanizing in Detail
Galvanizing Delight
This waved tensile fabric effect together with
the changing white and blue glow illumination
provides a cutting edge structure for what
has been dubbed the “Coolest Car Park
in Cardiff”. There is a series of 6 scalloped
tensile fabric facades spanning the width
of the building 120m long with integral
DALI lighting systems.
These are programmed to change colour
and can create a rippling light show along
the fabric.
All the support steelwork for the façade
is galvanized to provide protection.
It also creates a stylish industrial finish
to the structure that is in keeping with
the building.
Architects and Photographs:
Tony Hogg Design
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