Kalwall

• The West Croydon Bus Station in London is a vital link for the millions of people every year commuting to work from the South and South East into London. The station forms a hub for over 150 buses per hour with the adjacent tram stop and West Croydon railway station providing routes to both East and West London as well as to the City and Docklands.• The redevelopment of the bus station forms part of a £50 million programme of the Main Street public pedestrianised space and transport infrastructure to transform the town centre by creating a more attractive environment in which to live, work, socialise and do business.• Designed by Transport for London’s in-house team of architects headed by Martin Eriksson, the project goal was to create a user-friendly waiting and assembly shelter to cope with a 20% increase in passenger numbers and provide a brighter more spacious environment to service the vast number of passengers using this interchange daily.The SolutionThe normal choice of construction for a translucent and weatherproof canopy would be to glaze the roof with glass. However the project team at TfL realised that Kalwall® offered a better solution in this location. It would not only solve the design requirements and contribute to a better design but would offer many other benefits over traditional glazing.For example, since Kalwall is much lighter than glass the supporting structure could be less strong and far less substantial. This meant the vertical supports were less obstructive and opened up a better view of the environment, including the very attractive St Michael’s Church located nearby which had previously been blocked from the view of waiting passengers. The corten steel (weathering steel) support could also be subtle and worked into arches and patterns meant to mirror and complement the church.Furthermore, Kalwall is visually far more attractive than glass while eliminating shadows, hotspots and glare and the stark contrasts of light and shade; all improving the experience for passengers underneath.As Kalwall diffuses natural daylight downwards and reduces vertical illumination and reflection upwards at night, it can control light pollution on the surrounding high-rise buildings while emitting a very attractive ethereal glow, making it a beacon for travellers.Maintenance-wise, Kalwall is also an effective choice. Soil and detritus are less obvious on Kalwall than on glass and cleaning is much simpler because access scaffolding is not required and maintenance staff can safely walk across its surface.The CommentsMartin Ericksson comments, “Transport for London has a long and rich design heritage. The approach to the redevelopment of West Croydon bus station has sought to build on this heritage and recognises that waiting for your bus should not just be a perfunctory experience, instead it should be a positive one enhanced by good architecture. Site constraints, high footfall and the poor design of the previous station, presented an excellent opportunity to demonstrate the difference good architecture can make through improved layout, better passenger movement and accessibility – whilst supporting the West CroydonMasterplan.Brick was chosen to connect the station to its urroundings, especially the adjacent listed church. Using Kalwall brought many advantages and benefits in relation to its lightweight yet strong structural qualities. It has helped enhance daylight transfer and protects from sunglare whilst reducing hotspots and solar gain. The material’s soft translucent qualities contrast beautifully with the building’s warmth and texture, providing a sheltered waiting environment with the added advantage of low maintenance and high performance.”

The Crouch End Picturehouse in North London is an interesting example of how Kalwall® can be used to convert an ugly 1950’s concrete building into a state-of-the-art space suitable for the 21st Century.  •   This project by Panter Hudspith Architects forms part of a wider initiative within the London suburb of Haringey aiming to re-establish the area as one of London’s cultural and arts centres. The result is a remarkable transformation of a building, originally a factory then an office, into a £4.5 million cinema complete with café, bar, restaurant and community rooms.  •   The unique style of this four-screen cinema has attracted much interest, not only because of the dramatic transformation but also because of its new external elevation. •   The use of Kalwall, coupled with other sustainable measures including solar panels and a green wall, means the picturehouse has achieved a BREEAM rating of Very Good. The Solution Panter Hudspith Architects replaced the original curtain wall and specified Kalwall® for the front elevation. Unusually, this unique translucent cladding is fitted with a tight 150mm wide grid, known as Verti-Kal™, which not only serves to emphasise height but is the first of its type in the UK. On this scheme the Kalwall panels also insulate to 0.78 w/m2 making the building eye-catching and sustainable. Unlike conventional glazing, Kalwall eliminates shadows and glare and the stark contrasts of light and shade. The system also enhances simplicity by eliminating the need for blinds, curtains or solar control. Even on cloudy days, the interior is bathed with natural daylight, which means less artificial lighting and, because Kalwall is highly insulating, energy costs are reduced. Kalwall is increasingly being used in the UK for new buildings and also for the refurbishment of cladding or rooflights on aged buildings. One of the main attractions of specifying Kalwall is its unique effect on both the interior and exterior. Although translucent, it offers the big advantage of privacy while the elevations appear crisp and simple. When illuminated at night they emit an inviting ethereal glow.  The CommentsArchitect James Jeremiah comments, “This is the first time we’ve specified Kalwall and it fulfils our vision of retaining the modernist characteristics of the building. One of our original concepts for the building was of a zoetrope (one of the earliest forms of moving image) and there’s a strong history of using transparency in films with people moving behind the shadows. We felt the Kalwall system was a very good fit for what we wanted to achieve”. Amanda Birch, Technical Editor Building Design writes, “To appreciate fully the building’s transformation, it is best viewed from the street. The concrete structure has been retained along with its striking line of concrete columns, which are now a strong feature of the front elevation. The original coloured insulated glass panelled system has been replaced at first and second floor levels with Kalwall’s 75mm thick insulated cladding system creating a dynamic façade that is particularly effective at night.

Copenhagen’s Amager Bakke is a visionary project in Denmark that doubles as a recreational playground and a waste-to-energy plant.The towering structure is over 280 feet high, has an estimated cost of $670 million and is a part Copenhagen’s commitment to become the world’s first carbon-neutral capital by 2025. Part of the facility is already on line.The waste-to-energy plant, a giant incinerator that burns household garbage to generate heat for approximately 160,000 households and electricity for 62,500 homes, began operating in March. The recreational component is still under construction.Kalwall® translucent sandwich panels provided a critical solution in this truly global project, with their aesthetic beauty, energy efficiency and, most importantly, their best-in-class explosion-venting properties.Kalwall panels are used in areas of the building where a potentially volatile event could occur. The panels work to vent pressure out of the building, allowing it to withstand an explosion without collapsing roofs or floors. The panels are designed to release from their mounting system, but remain attached to the side of the building to avoid becoming falling debris. The interior of the panels are shatterproof and include a Fiber-Reinforced Polymer(FRP) face sheet that can be customied to withstand 230 ft-lbs (312J) of impact.Staying close to the project’s mission of being environmentally conscious, Kalwall panels provide dramatic savings in energy consumption through exceptional thermal and daylighting performance that reduces heating costs and artificial light usage.Working through Sipral, a leading supplier of external building envelopes based out of Prague, the panels were delivered on schedule and required no on-site modifications. Amager Baake was designed by the highly-acclaimed architecture firm Bjarke Ingels Group (BIG) and has the world watching as it merges two completely different applications.BIG founder Bjarke Ingels hopes that Amager Bakke will “change public perceptions of what a public utility should be” by providing a social and physical infrastructure.Amager Bakke provides Copenhagen with a rooftop ski slope that is comprised of 1,600 feet of trails, as well as 10 running and walking trails. There is also a 260-foot climbing wall along the facade.Ingels said the concept of a structure that brings together two diverse interests can be lasting. “If you make a building that remains relevant to the people living around it, and using it and inhabiting it, it can last forever,” Ingels said in an interview with CNN Style.Photography: Christoffer Regild

Benenden Hospital is a state-of-the-art private hospital in Cranbrook, Kent specialising in a wide range of discretionary healthcare and well-being services to individual and business healthcare members.• The original hospital opened in 1907 by National Association for the Establishment and Maintenance of Sanatoria - to treat postal workers suffering from tuberculosis. By 1951 the Association had disbandedand the Benenden Healthcare Society took over the sanatorium, dramatically expanding the services available.• Architects C A Vaughan Blundell were appointed to design a new atrium and welcoming area to enhance the patient and visitor experience.• The £55m project attained a Breeam status of ‘Good’.The SchemeThe scheme, designed by architects C A Vaughan Blundell with assistance from SR Architects Ltd, has created a wonderfully light and airy entrance atrium designed to welcome and create an enhanced patient and visitor experience with maximised natural daylight. The extensive breakout and catering facilities support theatres, en-suite rooms, outpatient department and ophthalmic suite along with diagnostic imaging, rest and recovery areas. The main contractor was Willmott Dixon Construction.The AdvantagesThe skylights have a unique ability to bathe interior spaces with diffused and glare-free daylight, which creates a stimulating and healthy environment. In addition, their heavily insulated composition eliminates glare and hotspots, thereby reducing the load on temperature control systems and the need for artificial lighting.They provide additional light in the large atrium projecting it deep into the interior. They were specified complete with highly insulating Nanogel which achieves an impress U value of 0.28W/m2K, helping the project attain a Breeam status of ‘Good’. This is particularly impressive given the amount of curtain walling and clerestory glazing involved in the scheme.Kalwall skylights can be manufactured to large spans up to six metres. The aluminium or thermally-broken grid core with interlocking I-beams gives Kalwall incredible strength. The lightweight system reduces the need for supporting structures while offering the highest protection in terms of wind-borne debris and resistance to impact, abrasion and point loads. The exterior face is colour stable and includes a UV resistant, self-cleaning surface. This means that normal  rainfall helps to keep the surface free of dust and dirt while at the same time retaining its original colour during the weathering process. Furthermore, the inclusion of an erosion-prevention barrier protects the interior from weather exposure and the risk of fibre-bloom, cracking and crazing.The CommentsGeoff Holden, Senior Technician at C A Vaughan Blundell comments, “The use of Kalwall represented the best value balance of energy saving and cost and provided us with the ideal way to achieve spatial daylighting within the requirements of Part L”Jane Abbott, Hospital Director, “We want to ensure our patients have an excellent, efficient and streamlined experience from the moment they arrive until the time they leave.”

BH2 is a £30m development creating a newly-constructed leisure complex in Bournemouth  •  Originally a two acre NCP car park and bus station, main contractors Vinci has built a new 10 screen Odeon Multiplex cinema, café, casino, restaurant and retail complex.  •  Structura was appointed to design and supply Kalwall translucent facades to enclose the external fire escape routes around the perimeter of the building.  •  Structura installed multiple Kalwall translucent elevations, totalling over 1000m2, providing natural daylight to internal areas by day and a soft ethereal glow which brings the area to life at night.The SolutionPanter Hudspith Architects replaced the original curtain wall and specified Kalwall® for the front elevation. Unusually, this unique translucent cladding is fitted with a tight 150mm wide grid, known as Verti-Kal™, which not only serves to emphasise height but is the first of its type in the UK. On this scheme the Kalwall panels also insulate to 0.78 w/m2 making the building eye-catching and sustainable.Unlike conventional glazing, Kalwall eliminates shadows and glare and the stark contrasts of light and shade. The system also enhances simplicity by eliminating the need for blinds, curtains or solar control. Even on cloudy days, the interior is bathed with natural daylight, which means less artificial lighting and, because Kalwall is highly insulating, energy costs are reduced.Kalwall is increasingly being used in the UK for new buildings and also for the refurbishment of cladding or rooflights on aged buildings. One of the main attractions of specifying Kalwall is its unique effect on both the interior and exterior. Although translucent, it offers the big advantage of privacy while the elevations appear crisp and simple. When illuminated at night they emit an inviting ethereal glow.The CommentsArchitect James Jeremiah comments, “This is the first time we’ve specified Kalwall and it fulfils our vision of retaining the modernist characteristics of the building. One of our original concepts for the building was of a zoetrope (one of the earliest forms of moving image) and there’s a strong history of using transparency in films with people moving behind the shadows. We felt the Kalwall system was a very good fit for what we wanted to achieve”.Amanda Birch, Technical Editor Building Design writes, “To appreciate fully the building’s transformation, it is best viewed from the street. The concrete structure has been retained along with its striking line of concrete columns, which are now a strong feature of the front elevation. The original coloured insulated glass panelled system has been replaced at first and second floor levels with Kalwall’s 75mm thick insulated cladding system creating a dynamic façade that is particularly effective at night.

DAYLIGHTING TAKES OFF AT HEATHROWThe ageing glass skylights of Terminal 4 at London’s Heathrow Airport were in need of repair. The challenges for the project’s main contractor was finding a way to keep the project moving with little disruption to this busy terminal and also maintaining the airport’s security protocol.The answer was a single-source solution presented by Structura UK, the curtainwall engineers who are the exclusive distributor of Kalwall products in the United Kingdom and Ireland.18,836 square feet (1750 square meters) of Kalwall Skyroof® cladding were used above the terminal’s International Departure Lounge and check-in desks to replace the 30+ year old glass skylights. The Kalwall translucent sandwich panels are fully Aviation Security in Airport Development (ASAID) compliant with regards to blast performance and improve the solar control and insulation for the space below. In fact, Kalwall 100™ panels were specifically chosen to exceed code requirements, therefore future-proofing the project.The whole retrofit was completed externally using a custom moving scaffold and during evening hours, meaning there was no disruption to the inside of the building. And, as far as value, the lightweight translucent panels allowed for the existing substrate to be adapted and reused – a savings of nearly $9 million (£7m) in project costs and more than a year off the build timeline.“Structura UK was a new supplier to the major capital projects programme on the Airport (and) they delivered a flawless installation despite multiple challenging circumstances including adverse unseasonal weather, unexpected contaminated materials and multiple design changes,” says Ben Hooper, Senior Project Manager at Heathrow.Structura worked in conjunction with Structural Engineers Webb Yates for a scheme designed by Pascall+Watson architects. The project proved so successful that main contractor Balfour Beatty named Structura as their ‘Most Promising New Supplier 2018’. Kalwall offers complete line-of-sight protection, maintaining privacy for the security screening area and departure lounges while bathing the interior with diffused daylighting, regardless of the weather. Apart from providing the visual protection, its inherent strength and heavy-duty impact resistance make it ideal for secure locations such as this. It offers the highest protection in terms of windbornedebris and resistance to impact, abrasion and point loads. Not only is it man safe, but Kalwall achieves S:AA (BS 476 part 3) and Broof(t4) to EN 13501 part 5 for external fire performance.The exterior face is colour stable and includes a UV resistant, self-cleaning surface. This means that normal rainfall helps to keep the surface free of dust and dirt while at the same time retaining its original colour during the weathering process.

As part of the BBC DIY SOS build to support the Grenfell community, Structura UK is proud to announce it has helped to realise two ambitious projects to support the survivors of the Grenfell disaster. This includes a brand new Community Centre as well as a replacement for the Dale Youth Amateur Boxing Club which was previously located on the first floor of Grenfell Tower and destroyed in the blaze.Over 200 square metres of Kalwall® translucent cladding has been used along the whole elevation of the new Boxing Club using the newly adapted THERM+ curtain walling system from RAICO.This was the first project realised using the new system and has worked remarkably well. The ability to conceal the fixings and screws coupled with the mill-finished aluminium framing has created a wonderfully smooth and dramatic façade.RAICO President, Dr Stefan Lackner commented, “RAICO has a long standing reputation for innovation and partnerships with customers and associated product suppliers. Working with Structura and Kalwall to develop a solution to integrate windows and glazing into a Kalwall screen has created many potential opportunities. We are particularly pleased that the first live project for our new partnership was for this deserving cause.”

DAYLIGHT FOR SHOWCASING STUDENT SUCCESSWe have always recognised that daylighting is both an art and a science, which makes it an appropriate focal point for Mahwah High School’s new STEAM Lab. The STEAM (Science, Technology, Engineering, Arts and Mathematics) approach to education takes an important step in recognising the importance of and integrating the arts into a science-and-technology-geared curriculum. The arts foster creativity and ingenuity that allows for the successful application of other skills.The 9,000-square-foot facility—designed by Tokarski Millemann Architects and fondly nicknamed the “Thunderbird Think Tank” in honour of Mahwah High School’s logo—houses classrooms, indoor and outdoor labs and a gallery to showcase student projects.Tokarski Millemann was looking for the perfect material to use for the art gallery component of the facility. According to principal architect, Michael Millemann, “The vision was to create a ‘cube’ shaped space for the display of the students’ creative works which were previously tucked in a hallway. The material needed to create a beautiful glow from the exterior along with permitting only serene, diffused light to the interior.”Kalwall’s museum-quality daylighting™ delivers full-spectrum, diffuse natural light to allow for high visual acuity and accurate colour rendition within the gallery space. This creates a comfortable, welcoming environment for viewing artwork and other projects or hosting gatherings.A custom blue face sheet was developed to match the school’s logo. The blue is not a coating, but rather full-colour thickness through the entire exterior face, utilising Kalwall’s super-weathering technology. Due to the panel’s power of diffusion, the blue exterior does not affect the quality of light within the space, but it allows for a beautiful, soft glow at night that acts as a marquis for the school. During the day, Kalwall’s best-in-industry solar heat gain control prevents the cube from becoming a hot box and superior thermal performance ensures a comfortable environment all year long while lowering HVAC loads. Combined with daylighting’s ability to reduce reliance on electricity, Kalwall plays a major role in the project’s overall energy efficiency.Cost efficiency is another benefit Kalwall provided. Panels are low maintenance with a self-cleaning surface, meaning normal rainfall helps to keep the exterior free of sediment while at the same time retaining its original colour during the weathering process. The lightweight panel system minimised the need for additional internal structure for a very clean design, while rapid installation kept the project on schedule and on budget.“The Kalwall translucent panels exceeded our vision,” said Millemann. “We worked with Kalwall’s Steve Del Guercio and their team to develop a daylighting and structural strategy, and the custom panel colour. The Kalwall cube anchors the addition to the existing building and is a visual beacon located on axis with the entrance to the campus. Along with the client, we could not be happier with the final product.”The Mahwah High School STEAM lab will be an environment in which students can thrive for generations to come.Photos: Courtesy of Tokarski Millemann Architects

From the beginning, architects DLR Group designed Metea Valley High School in Aurora, Illinois, to light up education, both literally and figuratively. The sprawling campus with room for 3,000 students is broken down into a handful of more intimate, human-scale learning spaces, called “think tanks”, where interaction with faculty is encouraged. Two interior courtyards, open to the sky, offer fresh air during free periods. Shaped a bit like a bow tie, Metea combines three concepts – mind, in the midsection, and body and soul on either end – to offer students a truly 21st century school experience.Lighting up Metea in the literal sense comes largely from the extensive use of Kalwall translucent curtain wall throughout the school. Upon coming through the school’s main entrance, visitors are struck by the cheerful, airy, daylighted lobby. Controlled daylight also pours into the school’s innermost areas, traditionally a structure’s darkest, from the courtyards. Kalwall introduces daylight into the vast commons area that serves as the students’ lunchroom. In the gymnasium, Kalwall’s shadowless, glare-free light enhances ball handling in team events; sunlight does not glance off the shiny court surface. The diffuse-light-transmitting panels also prevent glare off computer screens, easing eyestrain. And in a dramatic demonstration of Kalwall’s superb flexibility, the design includes occasional, narrow, horizontal runs of clear glass – some serving as clerestories – adding visual interest as well as clear views to the outside.At 464,000 square feet, Metea could have been an energy-consumption nightmare, adding significantly to its $125 million total project cost. But innovations such as demand control ventilation, energy recovery wheels, and high efficiency boilers will save Indian Prairie School District 204, the state’s fifth largest, thousands of utility dollars every year and pay for themselves in just a few years. In fact, the building’s design is targeted to be 19 percent more efficient than ASHRAE 90.1 requires. Because translucent Kalwall admits so much controlled daylight, the school’s exterior light harvesting system, which monitors indoor light levels, can actually turn off electric lights in public spaces automatically when they are not needed. The harvesting system alone is expected to save the district over £16,000 a year in operational costs with a payback of under seven years.Illinois can get very cold in the winter and quite toasty in the summer. Highly insulating Kalwall helps there, too, keeping temperature extremes outside and lessening the need for and cost of heating and cooling. During the manufacturing process, standard 2-3/4” and optional 4” Kalwall sandwich panels can be infilled with various densities of specialized, translucent insulation. Architects and designers can achieve a thermal insulation value of up to R-20 (0.05 Btu/hr/ft²/F).At Metea Valley High School, DLR Group chose to include Verti-kal™, a unique design variation on the standard shoji or square grid layouts of Kalwall Translucent Systems. The panels incorporate internal, continuous supports to provide a vertical emphasis. As with all Kalwall translucent systems, Verti-kal distributes diffused daylight throughout the school, even on cloudy days, drastically reducing the amount of artificial lighting required and eliminating shadows and glare as well as stark contrasts of light and shade. Verti-Kal can be supplied in panels up to 5 ft. (1.5 m) wide and up to 12 ft. (3.6 m) high, minimizing the number of joints. The unique format creates an entirely different look while still utilizing the most highly insulating, diffuse-light-transmitting, structural composite technology.Any school system must concern itself with maintenance costs, and Kalwall excels there as well. The panels are vandal-resistant and self cleaning; dirt simply washes off with each rainfall. After dark, the diffuse, translucent properties of Kalwall contain interior lighting and prevent direct-beam light pollution. Instead, the exterior surface of the building simply glows beautifully, boosting Metea Valley High School’s aesthetics and welcoming both students and the surrounding community to a true masterpiece of daylighting.Photography: James Steinkamp