Kalzip XT solution for Newport Station

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.

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