Kalzip’s Flying High in Dublin

Over 50,000m² of straight, curved and tapered convex curved Kalzip aluminium standing seam sheets have been installed on Dublin Airport’s impressive new Terminal 2 building, Pier E and associated buildings. Arup and lead architects Pascall+Watson specified a full acoustic Kalzip system for T2 which was installed by Portuguese building envelope project manager and contractor, Martifer.

Kalzip’s technical team worked very closely with Martifer and the project’s many demands have put the two company’s capabilities to the test. A combination of successful teamwork, thorough training, sheer hard work and determination proved vital in providing a number of creative solutions to various construction challenges and in meeting the client’s needs.

Martifer’s Hugo Camacho says, “Although we looked at a number of building system suppliers, Kalzip convinced us through a series of meetings and presentations that they would deliver the best solution for the building envelope. Kalzip simultaneously demonstrated that they possess the necessary technical design and commercial expertise to identify and overcome the many structural, acoustic and thermal requirements posed by this challenging building project.”

One particularly difficult task faced by the team was getting the decking to work successfully in conjunction with the high load span conditions. This was further complicated by the general span of the steelwork which in some places exceeds 9 metres. The intricate geometry of the steelwork and the extra loading of the rainscreen system also had to be accommodated by the Kalzip and the structural decking systems.

Most of the 1.2mm thick Kalzip sheets were roll formed onsite because it was more economic and environmentally friendly. T2’s acoustic requirements have been achieved using a shallow profiled fully perforated Kalzip liner panel system complete with 50mm thick 60kg density insulation to provide a ceiling that has been installed by Martifer from below.

The T2 building has two main sections which sit astride the existing access road to Terminal 1 - a Check-in area and a Departures / Arrivals area that are connected via a link bridge. A rainscreen system has been installed on the Kalzip sheets covering this Check-in area and the tightly curved parts of the Arrival / Departures area. Kalzip developed a special seam clip enabling Martifer to achieve a suitably robust connection between the Kalzip weather sheets and their rainscreen support system.

A central spine continues from the main 3-storey curvilinear T2 building through to the 400 metre long Pier E that will provide boarding gates and parking for up to 19 aircraft. PJ Hegarty & Sons are the main contractor and Lynch Roofing Systems Ltd the Teamkal contractor for Pier E.

Due to be operational towards the end of 2010, the new T2 development has been designed and managed by a senior project team comprising Arup, Pascall+Watson and Mace to meet the needs of both long-haul and short-haul passengers and airlines. When fully operational, T2 will be capable of comfortably handling up to 15 million passengers per year.

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