Inspiration

Digestion towers & silos

DIGESTION TOWERS

Flexibility and precision for digestion towers


Digestion towers are essential components of modern wastewater and biogas plants. They pose particular challenges for architects and engineers, as they must not only be technically sophisticated, but also durable and flexible in design. New buildings require precise planning and implementation, while refurbishments demand a high degree of adaptability to existing structures. With its free-form roof and façade systems, Kalzip offers the ideal solution to meet these requirements – with flexible structures that adapt perfectly to the complex geometries of digestion towers.




DIGESTION TOWERS

Functional and architectural system solutions for silos and digestion towers

Silos and digestion towers are highly specialised structures in industrial and utility infrastructure. They must absorb enormous static loads, withstand weather conditions for decades and, at the same time, meet increasing demands for sustainability and cost-effectiveness. In addition to pure functionality, a precise and durable building envelope also plays a decisive role.

Kalzip roof and façade systems offer tailor-made solutions for this purpose. With conical standing seam profiles, special installation concepts and robust aluminium surfaces, even large round structures can be permanently protected. The systems combine technical precision with flexibility in design and create durable solutions for infrastructure buildings subject to high stress.

Kalzip systems are the ideal choice for digestion towers because they:

  • Combining flexibility and precision: our free-form systems enable complex geometries and individual designs to be implemented for roofs and façades.
  • Guaranteed durability and robustness: Kalzip products are resistant to aggressive environmental conditions and offer a long service life – ideal for digestion towers.
  • Offering adaptability for refurbishments: Thanks to flexible roof structures, existing structures can be efficiently modernised and adapted to current requirements.
  • Combining aesthetics and functionality: our systems combine technical precision with a modern look that blends harmoniously into industrial environments.

With Kalzip, architects and engineers design digestion towers that are both technically and visually impressive and meet the requirements of modern wastewater and biogas plants.

FREE-FORM SYSTEMS


WHY THE KALZIP FLEXICON FREE-FORM ROOF SYSTEM OFFERS MAXIMUM FLEXIBILITY IN PLANNING AND ARCHITECTURAL ELEGANCE

Kalzip FlexiCon offers the following for silos and digestion towers Free-form roof system: a technically sophisticated, precisely fitting and weatherproof solution. The modular aluminium substructure enables precise adaptation to curved tower shapes and ensures reliable installation.

  • Large height differences can be compensated – ideal for curved and cylindrical silo tops
  • Three measuring points enable precise adjustment – ensuring permanent tightness under façade loads
  • XT free-form profiles adapt to organic contours – perfect for round and sloping towers.
  • Economical substructure – reduces costs even with complex roof geometries
  • Durable, corrosion-resistant aluminium alloy – low maintenance in aggressive emissions
  • Complete engineering and project-related manufacturing – planning reliability and on-time implementation

The FlexiCon system offers maximum shape adaptation, a flat surface and the highest technical precision for silos/digestion towers – ideal for efficient and safe container roofing.



DIGESTION TOWERS

Architectural design options for silos and digestion towers with the Kalzip freeform system


Colours, materials and surfaces:
Silos and digestion towers are striking structures in industrial and utility infrastructure. Kalzip offers a wide variety of surfaces and coatings – from natural aluminium to AluPlusPatina and metallic finishes. This gives even highly functional structures an architectural quality with a clear visual impact from a distance.

Product highlight for silos and digestion towers:

  • Free-form systems – enable precise and secure roofing of round and conical structures, even at great heights and with unusual geometries.

Combinability:
The free-form system can be combined with functional components such as maintenance openings or light wells. This results in durable building envelopes that combine robustness and flexibility.

Sustainability as a design feature:
Through the use of recyclable aluminium and energy-efficient structures, silos and digestion towers make a visible contribution to sustainable infrastructure.

Architectural trends:
In addition to pure functionality, visual impact is also becoming increasingly important. Metallic surfaces and precise shaping give silos and digestion towers an architectural presence that highlights their technical capabilities.

This diversity gives rise to infrastructure buildings that combine maximum functionality with a durable and architecturally striking building envelope.






FAQ

Digestion towers require precise planning in order to meet complex geometrical and technical requirements such as stability, durability and protection against aggressive environmental conditions.

When carrying out refurbishment, it is important to use flexible solutions that can be adapted to existing structures while improving the functionality and service life of the digestion tower.

Materials for digestion towers should be corrosion-resistant, durable and low-maintenance in order to withstand the particular stresses caused by moisture and chemical influences.

DIGESTION TOWERS

References on this topic

Mercedes-Benz Arena, Berlin

BMW Plant Leipzig Central Building

Eurowheel, Vorchdorf

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Carnival Arts Centre, Luton

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City Centre Crystals, Las Vegas

House of the Family, Vaterstetten

Fire brigade equipment house, Frickingen

Sports hall – Université du Québec à Chicoutimi (UQAC)

Car park Bowie High School, Austin TX

IKEA Dubai

Olympic Aquatics Centre London

Algonquin College Student Commons in Ottawa

German Football Museum, Dortmund

Karlovy Vary Airport

Logistics hall Leschaco, Bremen

Sustainable factory halls – TRUMPF GmbH & Co. KG

New construction of Port 8 Cruise Terminal Warnemünde

Petrus Jakobus Church in Karlsruhe

WIBU office building and warehouse, Ahrensburg

Tournesol All-Weather Bath, Idstein

FFE Training centre Courtepin

Epsom Downs Racecourse

Josef Seliger housing estate, Ottobrunn

ADMI AHOI office building in Hamburg

Football stadium Etihad Stadium in Manchester

King Abdulaziz International Airport in Jeddah

University of Siegen, Siegen

Photo Elysée Lausanne

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Caudwell International Children’s Centre, Newcastle-under-Lyme

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Canteen at Ludwig-Meyn-Gymnasium, Uetersen

Wintringham Primary Academy, Saint Neots

State Office for Social Affairs, Saarbrücken

Refurbishment of artificial ice rink (KEBA) in Aarau, Switzerland

Clausthal-Zellerfeld University of Technology

Scania Gerd Breuer GmbH, Duisburg

Ghelamco Arena football stadium in Ghent, Belgium

Ice Dome Bolshoy, Sochi

Denmark Hill Train Station – London

Ferry Terminal Norderney, Norddeich

New AGRU plastics technology building in Bad Hall

Fire Station, Sickte

Ship lift Oder-Havel Canal, Niederfinow

24´7 Twentyfourseven in Bremen

Allerhuset, Copenhagen

Warwick Lodge Dental Centre, Southend on Sea

Gymnasium noyer Perrot, Moissy Cramayel

Sports hall, Sainte Luce sur Loire

New construction of logistics centre SBF Poing, Munich

Sports hall in Siegen, Germany

Martinusgemeinde town hall, Frankfurt am Main

New Safe Confinement, Chernobyl

New residential quarter Mariendorfer Damm, Berlin

Seneca College – Magna Hall, Toronto

New Concession Automobiles building in Montpellier

Police Department Burgau

Residential complex The Iceberg, Aarhus

EON Training Centre, Lüneburg

DFS – German Air Traffic Control, Kaufbeuren

car park in Milton Keynes, England

The Olympic House (IOC Headquarter), Lausanne

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Arcam architecture centre in Amsterdam

Pickering GO pedestrian bridge in Pickering, Canada

Raoul Fonquerne swimming pool in Sète

Kameha Grand Hotel in Bonn

Kelvin Hall in Glasgow

Restaurant Filhet Allard, Bordeaux

New building Vigo University – Department of Maritime Sciences

Cal Poly Pomona Student Services Building

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Sports facility “Am Biel”, Zwickau

New construction Imperial War Museum North, Manchester

New Dublin Airport T2

Refurbishment of workshops for disabled people, Erding

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King Abdulaziz Center for World Culture – Ithra

Vigo University – Department of Maritime Sciences

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Day Care Centre “In der Mühle”, Murg

Grand Canal Theater, Dublin

New residential building Thomas B. Thriges Gade (TBT) in Odense

Residential quarter City Centre St Pölten

Inverurie Community Campus, Inverurie

Résidence Hotel du Rail, Rennes

Office building Messchenveld, Assen

Fire station, Bieberach an der Riß

Islington Waste & Recycling Centre, London

IVY Station in Culver City, CA – Residential & Office Building

Chrom-Schmitt GmbH & Co. KG, Baden Baden

Play Museum, Soltau

F. Mittérand Hospital in Pau

Residential house, Freudenberg

Beach Pavilion Scheveningen, The Hague

Evangelical Community House in Heddesheim

Residential building Karréen in Esbjerg, Denmark

New primary school canteen in Wriedel

Artificial ice rink Kleinholz – Olten

New BVB Fanshop in Dortmund

Vesebe e.V., Hennef

Barajas Airport, Madrid

Architectural office Hellwig, Lorsch

Blechbüxx, Hilgert

Venue Burns Monument Centre, Kilmarnock

Underground Station Grossreuth near Schweinau, Nuremberg

NYE Nord hospital in Horsens, Denmark

Rydens Enterprise School, Walton On Thames

Kindergarten Mühlenwinkel, Höxter Ottbergen

Scottish Exhibition and Conference Centre, Glasgow

El Prat Airport in Barcelona, Spain

OVO Hydro event arena in Glasgow

Gateway to a new era of air travel

23. February 2023/by Yannick Gouder de Beauregard

Ikastola Altzaga, Erandio

Sports club Boulevard Club Toronto, Ontario

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Middle station Scharmoin, Lenzerheide

Museum of Cultures, Basel

TECA event complex in Aberdeen

Secure fit with visual verification

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Evangelical Lutheran Parish, Regensburg

Market hall, Garges-lès-Gonesse

Rondo Generała Jerzego Ziętka railway station, Katowice

Façade renovation Eichendorff Gymnasium, Koblenz

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