In order to reduce the excessive frictional force commonly associated with the thermal cycling of long sheet lengths, the new polyamide Kalzip E-clip was thoroughly tested in order to satisfy the demands of the project. The test results confirmed a substantial reduction in the force created between the head of the clip and the Kalzip seam when compared with the alternative aluminium extruded ST clips. In addition, the E-Clip improves the sound reduction performance of the system and also offered no significant thermal impairment when ‘hot-box’ tested.

The first satellite building to be completed under phase one will also be roofed with 14,000 square metres of Kalzip to provide a consistent appearance with the main terminal building. A special Kalzip 406mm profile was developed to meet the specific design requirements of this project.

Pictures courtesy of BAA Heathrow, Terminal 5

Some 30 ancillary buildings, which will accommodate supporting facilities, will also be clad with a Kalzip fabrications system. The architect chose Kalzip fabrications because they are able to manufacture the louvre blades to the same pitch and depth as the sinusoidal profile and prove their performance. A uniquely designed and specially fabricated louvre was manufactured to perfectly match the cladding profile making it indistinguishable from the rest of the elevation.

To complete the package, a range of Kalzip fabrications and accessories were specially developed including clip-fix copings and fascias, claddings, joints and feature flashings, all of which were adapted to suit the varying building sizes.

The development of such a huge scale project is an awe-inspiring feat of engineering made possible by painstaking attention to detail, first class materials and the use of innovative solutions to speed up construction.And when it is complete, the breathtaking expanse of Terminal 5 will surely become a blueprint for the future of construction in the UK.