Hot Dip Galvanizing Magazine 1/2010

2010

1/4 Hot Dip GalvanizingInternational Magazine | ISSN 1363-0148 | www.galvanizing.org.uk

2010

1/4

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.

2010

1/4

Hot Dip Galvanizing | 3

1

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

2010

1/4


2

2010

01Architecture


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

3

4

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.


2010

1/4

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.

2010

1/4


2010

1/4


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

1

2010

1/4

2 3

4

2010

1/4

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


5

7

6

8

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


2010

1/4

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*


2010

1/4

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]

2010

1/4

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

2010

1/4

Documents

Hot Dip Galvanizing Magazine 1/2010