Case Studies Newport Station South Wales

Newport Station South Wales

Client: Network Rail
Lead Consultant / Architect: Atkins / Grimshaw
Main contractor: Galliford Try Rail
Teamkal Contractor: CDW Ltd.
Tata Steel products: Kalzip® aluminium standing seam, Kalzip® XT, Kalzip® Fabrications
Year: 2011

The challenge

One of the most crucial and important aspect of this stunningly designed project was to build the station with minimal disruption to the operational railway line.

Working in conjunction with the engineers, contractors and key suppliers, it was 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.

By dividing the very long footbridge into two main spans, separate modules needed to be constructed for each span and a third module for the staircase. The modules specified a structural steel frame clad in aluminium standing seam with a continuous band of pneumatic ETFE cushions at high level on the footbridge. The three fully clad modules then had to be lifted onto specially pre-prepared bearing pads before securing into position over a period of just two days. 

The solution

Over 1,000 individual Kalzip® aluminium standing seam sheets were installed on the project. 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.

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.

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.

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