Over 1,000 individual Kalzip aluminium standing seam sheets have
been installed on Network Rail’s stunningly designed new station at
Newport, South Wales. As well as straight, tapered and smooth curved
Kalzip sheets, many revolutionary Kalzip XT profile sheets of
various shapes and sizes were used for significant parts of the link
footbridge and concourse buildings where the aluminium cladding is
curved both on plan and in section.
Lead consultant Atkins with Grimshaw were responsible for the
futuristic design of Newport’s impressive and intriguing new station
which was built by Galliford Try Rail for client Network Rail and
use by the travel operator, Arriva Trains Wales. Experienced Teamkal
approved contractor, CDW Ltd installed all the Kalzip roofing and
cladding sheets together with a multiplicity of aluminium building
elements that were specially designed, manufactured and supplied for
the redevelopment project by Kalzip’s Fabrications Department.
The tremendous versatility of Kalzip XT profiled sheets combined
with the company’s sophisticated computer modelling software and
advanced computer controlled roll-forming technology makes it
possible to transform computer generated designs and structural
principles into reality. Kalzip XT is capable of achieving a wide
range of complex shapes from ellipses, cones, prisms, spherical caps
and other convex / concave classical geometries to more free-flowing
contemporary designs.
Chris Crombie, Grimshaw’s Associate in charge of the project says,
“Kalzip XT profiled aluminium sheets were ideal for Newport Station
because their flexibility and functionality enabled us to achieve
the 3-dimensional contouring and free-flowing building shape we
required using an extremely durable, lightweight standing seam
system.
“Perhaps the most crucial and important aspect of the project was to
build the station with minimal disruption to the operational railway
line. Working in conjunction with the engineers, contractors and key
suppliers, we determined that the solution lay in producing pre-clad
modules on-site so everything above and between the tracks could
then be lifted into place and made secure in the very short time
necessary to keep track closure to a minimum.
“This was achieved by dividing the very long footbridge into two
main spans with a separate module constructed for each span and a
third module for the staircase which runs down to the central
platform. The modules comprise a structural steel frame clad in
Kalzip aluminium standing seam with a continuous band of pneumatic
ETFE cushions at high level on the footbridge. The three fully clad
modules were then lifted onto specially pre-prepared bearing pads
and secured into position in little more than two days as planned.”
Encircled by triangular faceted planar glazing at ground level, the
Kalzip clad concourse buildings contain ticketing facilities, retail
outlets, lifts and expansive staircases under ETFE roofs to provide
optimum daylight - the ETFE cushions follow the spiral form of the
building and culminate with a circular oculus cushion at the highest
point. The adjacent Kalzip roofed ancillary buildings contain
waiting rooms and toilets together with a variety of offices for the
rail station and associated staff members.
The amazing array of bespoke fabrications designed, manufactured and
supplied by Kalzip included complex curved gutters, down-pipes,
fascia and soffit panels, tapered louvres, façades and numerous
curved aluminium elements in pre-coated PVF² coil and PPC sheets
coated to RAL 9006 and RAL 7015. Within this requirement for
literally thousands of mill finish, stucco embossed, stainless steel
and colour coated items, Kalzip was also able to satisfy the
architect’s request for bright yellow panels coated to RAL 1018 with
slotted perforations to encase the lift shaft located in the middle
of the link bridge.
Kalzip fabrications worked very closely with CDW, Grimshaw and
Atkins which resulted in a number of innovative, cost-saving
solutions to many challenging design issues that were faced in the
redevelopment of the new station that has understandably become an
iconic landmark building for the city of Newport.
For further information and a copy of the ‘Kalzip Systems’ brochure,
please email.
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