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Pedestrian Bridge in Pickering, Canada
Crossing the world record bridge by foot
The “Pickering GO Pedestrian Bridge” in the Canadian city of Pickering provides pedestrians with a safe route from the railway station in the south to the city centre in the north. With the Kalzip outer shell illuminated at night, it is a real eye-catcher.
The outer shell was installed in sections during the night so that the motorway did not have to be closed during the day. (Photos: Kalzip GmbH)
The pedestrian bridge in Pickering, Canada is already becoming a landmark in the city: with a length of 250 metres, it has made it into the 2021 Guinness Book of Records as the longest covered pedestrian bridge in the world. The span stretches over six railway tracks and Highway 401, one of the busiest motorways in the north of the USA and Canada with 14 lanes of traffic. The federal and provincial governments and the local transport company Metrolinx launched the pedestrian bridge project to provide visitors from Pickering GO station with a direct and safe connection to the district above the motorway with its shopping mall and local college. The visible Kalzip cladding gives the above-ground tunnel an organic shape. The standing seam profiles are illuminated in the dark evening hours, making the structure visible from the air.
Organic and yet inorganic: the metal pedestrian bridge winds its way across Highway 401 almost like a vein (Photos: Kalzip GmbH)
Perforation for light
The pedestrian bridge is a steel truss structure with a concrete floor and a steel deck roof. Normally used as a waterproof building envelope, the standing seam profiles 65/305 from Kalzip were used here for a purely visual effect.The convex curved standing seam profiled sheets are perforated with 6 mm diameter holes spaced 8 mm apart. Thanks to the slight transparency, pedestrians can enjoy natural daylight and protection from direct sunlight as well as a view of Highway 401. The perforated surface also allows the pedestrian bridge to be illuminated with LED light strips both inside and out.
Due to the complex shape of the bridge, the steel structure was first scanned using a terrestrial LiDAR sensor. Using the data obtained as a basis, Kalzip was able to create a plan to bend and cut the standing seam profiles accordingly depending on the section and curvature.
Exposed sections provide an unobstructed view of the motorway and the surrounding countryside. The profiled panels catch the colourful play of light. (Photo: Kalzip GmbH)
Construction with obstacles
In addition to calculations and construction plans, Kalzip also supplied the raw material in coils and a mobile roll-forming machine. A team of American and a German staff member operated the roll-forming machine and produced the standing seam profiles to the required length on site. The machine can be set to the requested profile shape and width and also offers the function of bending the finished profile sheets to the specified radius.
However, the installation of the standing seam profiles posed a somewhat greater challenge. The motorway lanes had to be partially closed to allow work on the outside of the bridge. A large part of the work was therefore carried out at night so as not to unnecessarily disrupt the important traffic route. The installation of the profiled sheets was also different to usual: instead of overlapping at the standing seams, the sheets were attached to the steel frame at slightly different angles. This creates a slight stepped structure depending on the section and viewing angle.
Silver by day, colourful by night
After a total of around ten years from the initial planning to the finished construction, the bridge was completed in 2018. The architecture becomes a highlight, especially in the evening and at night. Around 300 LED lights line the footpath and highlight the organic shapes. The colours of the lights alternate between pale lilac, violet, blue and petrol. Thanks to the AluPlusPatina coating and perforations, the play of light is transmitted both inwards and outwards. In 2019, the building received the “Urban Design Award” from the City of Pickering.
(Photos: Kalzip GmbH)
Thoughtfully considered. KALZIP.
Contact
Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz
Phone: +49 261 9834 0
Fax: +49 261 9834 100
E-Mail: yannick.de-beauregard@kalzip.com
House of Bavarian History in Regensburg
MODERN ROOF FOR THE HISTORY MUSEUM
The House of Bavarian History is a modern museum complex in Regensburg. The roofscape blends in with the panorama of the surrounding historic city. Profiled sheets from Kalzip were used to design the unusually composed roof area.
ADAPTED TO THE CITYSCAPE
On the former so-called Donaumarkt, the façade with its gray, geometric surfaces stands out clearly from the surrounding buildings. Viewed from the other side of the river, the profile of the building blends in with its surroundings: The roof mimics Regensburg’s skyline and thus fills the former gap in the Donaumarkt without trumping the existing building in terms of height.
SIXTEEN ROOF AREAS
Not visible to the passer-by: The entire roof is made up of 16 different geometric surfaces that slope in different directions. Adapted to the different angles and building heights, the triangular and trapezoidal surfaces are inclined in different directions and thus form a three-dimensional mosaic.
The Kalzip 65/400 aluminum profile sheets with their AluPlusPatina natural aluminum mill-finish surface contribute to the uniform appearance of the gray-metallic outer shell. On a functional level, the profiles are aligned according to their angle of inclination in order to enable perfect rainwater drainage.
ENERGY-EFFICIENT RIGHT UP TO THE ROOF
According to the client’s specifications, the House of Bavarian History was to consume as few energy resources as possible. To ensure that as little energy as possible is lost through the outer shell, the decision was made to use the DuoPlus energy-saving roof system from Kalzip when planning the roof. Thanks to its high insulation performance, the system structure minimizes heat loss in winter and protects against solar heat gain in summer.
Considered with care. KALZIP.
Contact
Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz
Phone: +49 261 9834 0
Fax: +49 261 9834 100
E-Mail: yannick.de-beauregard@kalzip.com
Brewery “De Halve Maan” in Bruges, Belgium
GOLDEN SHELL FOR THE BRUGES
The traditional brewery “De Halve Maan” in Bruges, known for its cult beer “Brugse Zot,” stands for innovation and tradition. As part of its expansion, a new bottling plant was built outside the city, impressing with a gold-coloured facade cladding from Kalzip. This not only reflects the colour of the popular blonde beer but also serves as a visible symbol of the brewery’s spirit of innovation.
SUSTAINABLE INNOVATIONS WITH A HISTORY
Located in the heart of Bruges for almost 170 years, the brewery combines historical brewing art with state-of-the-art technology. One example of this is the beer pipeline, over 3 kilometres long, which transports the beer to the new bottling plant in an environmentally friendly and efficient manner. The new site harmonises with these values by emphasising sustainability with a modern water recycling system and a solar system on the roof.
A FACADE THAT DOES MORE THAN JUST PROTECT
The golden aluminium profiled sheets from Kalzip, coated with AluPlusPatina in the colour Medium Gold G30, are not only visually striking but also represent robust quality and sustainability as they are made from a high percentage of recycled material. The facade also allows for a balance between privacy and natural light through clever perforations.
INVITING ARCHITECTURE MEETS FUNCTIONALITY
Large glass fronts and an open, inviting architecture allow visitors and business partners to gain a direct impression of the company. The combination of transparent elements and the distinctive golden facade emphasises the brewery’s commitment to innovation and aesthetics.
With this project, Kalzip has once again underlined its expertise in the realisation of sophisticated and sustainable architectural concepts that are both functional and aesthetically pleasing.
Considered with care. KALZIP.
Contact
Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz
Phone: +49 261 9834 0
Fax: +49 261 9834 100
E-Mail: yannick.de-beauregard@kalzip.com
Alexander Stadium in Birmingham
KALZIP HELPS TO REGENERATE STADIUM IN TIME FOR COMMONWEALTH GAMES
The enormous regeneration of Alexander Stadium in Birmingham was commissioned by Birmingham City Council, with a requirement for work to be complete in time for the Commonwealth Games in the summer of 2022. A range of products from Kalzip’s extensive range was specified for the project, which involved the construction of a new ‘West Stand’ along with construction of new North and South Bowl seating which increases the overall capacity from 12,700 to 18,000.
Planned down to the smallest detail
The Kalzip FC Cladding was specified for the fascia which extended to the full perimeter of the stadium roof. However, this posed a particular problem as the system isn’t designed to follow a fan shaped elevation when fitting the FC panels vertically. Therefore, a transition detail had to be developed in conjunction with Kalzip’s expert design department, in order to introduce bespoke transition panels at each grid line. This refined the orientation of the line to allow the next bank of panels to be installed correctly onto the subsequent bay.
An adjustable sub-structure was used to create the curve of the roof on to the flat decking. The Kalzip Deck Roof System was used to cover the roof. With this roofing system, a variation of geometries are possible, while also offering quick installation and durability against any weather conditions. Overall, 5,530 m² of Kalzip standing seam profiled sheets were installed on the roof and 830 m² of FC panels cover the facade.
A stadium not without its challenges
There were a number of challenges to overcome in order to complete Alexander Stadium, including working in line with strict COVID restrictions, so collaboration with all parties was key. Care was taken to ensure that everyone working on the project were able to adapt to the new working systems in order to prevent any drop in efficiency.
John McAllister from Kalzip said: “Due to the pandemic, the general availability of construction materials was more difficult than usual, with reduced availability and an increase in prices. As a result of Kalzip’s long-standing relationships with key primary international producers, we were able to navigate around the issue of material availability with a minimum of disruption, and also assist in keeping things on track and within budget for the client.
“Some of the standing seam panels used on Alexander Stadium measured over 40m in length, which certainly created some issues for us in terms of transportation and movement. The expertise of the team was essential for this, and careful planning was required to ensure that these panels were lifted onto the roof area safely and efficiently. A crane was used to transport the panels, and this ensured that no time was lost.
“Due to the dynamic shape of the stadium and the unique curvature of the roof, each halter clip needed to be set in its own specific position which required a high level of accuracy and attentional to detail. The setting out of halter clips was a meticulous, yet crucial job to the overall finish of the stadium’s roof.”
The Mayor of the West Midlands, Andy Street, who chairs the WMCA said: “It was fantastic to see the regeneration of the Alexander sporting arena, of which the whole region can be proud of, and one fit to host the world’s leading athletes for years to come. But far more importantly the construction works on the stadium played a major role for people’s livelihoods by supporting vital construction jobs and apprenticeships both on site and in the wider business supply chain.”
A project that supported local communities
The overall result was the successful completion of a prestigious project, ultimately the construction provided one of the very best sports stadiums in the country, which played host to the Commonwealth Games. This project also involved the You Matter Communities Scheme, providing local communities and people with an opportunity to access small grants, volunteer time and unused materials from the construction process.
Construction and installation of the World Athletics Class 1 facility, including a new 400m six lane warm up track, the relaying of a new 400m, nine lane competition standard track, formation of a practice throwing field, stadium lighting and various associated highway and infrastructure works were also completed as part of the wider project.
Considered with care. KALZIP.
Contace
Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz
Phone: +49 261 9834 0
Fax: +49 261 9834 100
E-Mail: yannick.de-beauregard@kalzip.com
Museum Lausanne
25,000 m² of Culture
In 2022, a futuristic building complex named Plateforme 10 was opened in the Swiss city of Lausanne, merging two museums under one roof. It houses the Elysée Photo Museum and the mudac, a Museum of Design and Contemporary Art. This newly created art district provides visitors of all generations with over 25,000 m² to explore the diversity and various types of art in the fields of visual arts, photography, and design. The structure, designed by Portuguese architect Aires Mateus, combines geometric shapes with carefully selected surface materials to provide a futuristic look. The building has a light corridor that serves as the entrance to both museums, as well as a reception area, a bookshop and a cafeteria
At first glance futuristic, sustainable at second
The building’s exterior facade might appear plain at first sight, but hidden behind the walls is a unique shed roof made of aluminium profile panels from Kalzip. The roof with its striking jagged profiles is only visible from an aerial view or from the surrounding residential buildings. Despite its unconventional appearance, it fulfils a functional purpose, as the south-facing sloping surfaces house photovoltaic modules on the standing seam profiles, which supply the museums with sustainable electricity and ensure an excellent energy balance. To bring daylight into the mudac on the first floor, windows were added to the north side of the aluminium shed roofs. Upon entering the exhibition space, visitors are greeted with an open room atmosphere, highlighting the geometric design language of the interior architecture.
Waterproof planning on the model.
The complex roof structure with its horizontal and inclined surfaces required detailed planning. Kalzip’s standard roof system was modified to accommodate the integration of windows. Instead of the typical crimping of the standing seam profiles at the seams, the profiled sheets with a width of 65/500 were welded at the bending point, ensuring a waterproof, tight transition between the horizontal and inclined roof surfaces. In Switzerland, aluminium is less frequently used for roofs due to its different welding properties compared to copper or zinc. However, the processing characteristics of Kalzip’s aluminium profiled sheets were ideal for the project requirements, which demanded a column-free roof structure with pre-stressed steel beams. To address the challenges of mitre cutting and welding the trapezoidal profile panels, a model was first created to fine-tune the details with the owners and architects.
A lightweight meeting all requirements.
To minimize welding work on the construction site, a specialized contractor with expertise in the now-rare welding of aluminium seams prefabricated most components in a nearby workshop. These pre-made elements were then delivered to the construction site and installed. This allowed the final roof system, consisting of Kalzip’s standard roof components, including trapezoidal steel profiles, composite clips to fix the profiled sheets and provide insulation space, and the prefabricated aluminium profiled panels, to be fitted efficiently and with ease of installation. The entire roof system, including the trapezoidal sheets, insulation, and aluminium panels, weighs only about 13 kilograms per square meter, and is significantly lighter than a traditional flat roof which would weigh around 70 kilograms per square meter. The aluminium roof panels were coated with AluPlusPatina Eloxal Natur to meet the city’s requirement not to dazzle residents with potential reflections from the aluminium roof.
As a result, the new cultural district in Lausanne not only impresses visitors with its futuristic design but also, like all Kalzip projects, stands out for its functionality, sustainability, and maintenance-free durability.
Considered with care. KALZIP.
Contact
Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz
Phone: +49 261 9834 0
Fax: +49 261 9834 100
E-Mail: yannick.de-beauregard@kalzip.com
New residential building “The Lighthouse” in Aarhus
“The Lighthouse” in Aarhus, Denmark’s tallest residential building with an unusual roof shape.
The artificially created district near the centre of the Danish port city Aarhus offers spacious new living space. The latest construction project, “The Lighthouse,” contributes significantly to this by adding 400 new apartments to the housing market. As the name promises, the building rises majestically like a lighthouse on the southeastern shore of the harbour area, and it is also Denmark’s tallest residential building.
Small roof, extensive planning effort, and an additional floor.
The building captivates with its unique architecture, especially the organic and geometric shapes of the roof, facades, and balconies. Particularly striking is the parallelogram footprint of the building, rounded on two opposite sides. The realization of this design was a challenge that Robert Thiebes of Kalzip mastered with confidence, using specialized software and on-site data collection. Particularly innovative are the diagonal standing seam profiles of the roof terrace, which allow for efficient rainwater drainage while also serving as a stylistic highlight. During the structural calculations, it was discovered that an additional floor was possible, perfectly suited for creating a sophisticated gastronomy and viewpoint for visitors at 142 meters above ground.
Installing accurate to the centimetre
During the processing on the construction site, the team of the executing company AE Stålmontage a/s started at the highest point of the roof and initially moved on one half of the roof towards the roof terrace. The assembly proceeded as usual: The profiled panels were placed on top of each other at the seam and flanged with a flanging machine.
The installation of the complex, three-dimensionally curved Kalzip XT sheets with a corresponding angle of inclination proved to be particularly tricky. Despite the flexible substructure, which offered a little room for manoeuvre during installation, as well as the clearly laid out construction plans, construction was briefly halted, as Robert Thiebes reports: “In this project, there was only a few centimetres of displacement space between the profiled sheets, which decided whether the next sheet would fit in or wedge in. In order to find the best possible solution to this problem, we travelled to the construction site, were able to quickly locate the error and instructed the employees accordingly.”
Roll-formed and twisted
Innovative techniques were necessary to implement the curved transition from the roof to the facade. Each individual standing seam profile of the building was numbered and prefabricated in advance, then specifically bent and twisted according to its designated location. As always, this required precise millimetre work, leaving no room for errors. The installation of the complex, 3D curved KALZIP XT panels with a certain angle of inclination posed the biggest challenge, as there was only a few centimetres of leeway for installation.
A wind-resistant challenge
The “Lighthouse” presented special challenges during planning and construction, especially due to limited storage space because of the surrounding buildings and proximity to the water. Consequently, all materials were stored in the neighbouring port docks. Transporting the standing seam profiles from Koblenz to Aarhus was a logistical masterpiece. To protect the different angles of inclination of the profile panels, they had to be stacked on pallets with special spacers. A crane transported these pallets to the roof. Due to the height and resulting wind suction, the unused standing seam profiles had to be secured with tension straps.
The finishing touch
With the completion of the roof, the exterior shell of the impressive “Lighthouse” building was finalized. The 480m² XT profiles from Kalzip, not visible to visitors, incorporate a sophisticated recess for a maintenance crane. “Despite the relatively small area, the ‘Lighthouse’ roof stands out for its unique and demanding shape, making it a complex and time-consuming challenge,” says Robert Thiebes.
Considered with care. KALZIP.
Contact
Kalzip GmbH
Yannick de Beauregard
Kalzip Marketing
August-Horch-Str. 20 – 22
56070 Koblenz
Phone: +49 261 9834 0
Fax: +49 261 9834 100
E-Mail: yannick.de-beauregard@kalzip.com