Kalzip helps appleton with its appetite

Staff in the new offices of a unique UK laboratory have had their appetite for a more aesthetic view sated by Kalzip’s standing seam roofing.

They found their outlook onto the felted flat roof of the restaurant at Rutherford Appleton Laboratory at the Harwell Science and Innovation Campus in Oxfordshire was uninspiring to say the least and brought in Architects Design Partnership LLP (ADP) to cook up a new design.

The architects specified Kalzip 400 straight and tapered stucco embossed standing seam roofing for the £500,000 refurbishment and extension of the restaurant which caters for the 1,200 staff who support the work of more than 10,000 scientists and engineers in the university research community.

Having used Kalzip numerous times before, ADP were able to avoid a lengthy research period in finding the best solution for the brief. The system proved ideal on a “very complicated roof for a fairly small building” they said.

In addition to the existing roof, which is a complicated clam shape, they constructed a lower level circular steel framed extension which formed a series of high level clerestory glazed openings. This in turn involved a number of complicated flashings and roof drainage but these were “easily resolved with on site fabrication”.

The existing roof was overclad with Kalzip to match both the roof of the new extension and the materials used on other nearby buildings including the distinctive Diamond light source synchrotron facility that also boasts a Kalzip roof.

“The client wanted to carry the architectural language of the neighbouring buildings into the appearance of the restaurant,” said ADP’s Craig Cullimore. “One client request was to improve the appearance of the roof of the restaurant when seen from the new offices above in the adjacent building and they are very pleased with the finished project, both in terms of function and appearance. The roof unified the new extension with the existing restaurant.”

Lee Shepherd, estimating manager for Gable (UK), the Kalzip approved Teamkal installers, commented that it was a relatively complicated design using a mixture of straight and tapered sheets.

“This project outlines the versatility of the Kalzip system. Working from an original design concept, it provides a weathertight solution to a refurbishment project,” he said. “It entailed installing the products onto existing felted roofs and providing junctions with new build steelwork. These were completed with facet curved inbound gutters and a pre curved fascia detailed with facetted soffit planks.

“The building has a central cupola roof with facetted sheets providing a high level turret. The roof slopes falling away from this all have straight Kalzip sheets providing valley gutters, fully welded to ensure a Robust Detail.

The expansion was taken up with a sliding ridge detail. Due to the nature of the design, the verges were formed from raked sheets and then welded again, providing a detail that provides peace of mind for the client.

“The outer section of the building was completed with tapered sheets and again terminated with a facet curved inbound gutter and pre curved fascia/soffit detail. Pre curved interface details were overcome with Kalzip abutting louvres and clerestory windows. To provide a slimline detail, the mono ridges to the lower level were welded with the sheets falling into the inbound gutter.”

John Dymock, contracts manager with main contractor Knowles & Sons, added: “It was a very complex roof but Kalzip is a very good product.”

Rutherford Appleton Laboratory is run by the Science and Technology Facilities Council and is named after the physicists Lord Ernest Rutherford and Sir Edward Appleton. As well as the Diamond, it also hosts ISIS, the world’s leading pulsed neutron source.

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