Hinzert documentation pavilion

Hinzert in Hunsrück is surrounded by a picturesque landscape. There are virtually no signs of the horrors
that took place here between 1939 and 1945 when this was the site of a concentration camp in which
more than 13,000 people were maltreated. To ensure that the lesser-known Hinzert concentration camp
and its captives might never be forgotten, a competition for a documentation pavilion was initiated.

Landscape surrounding site SS of cials at the camp site

The project selected for construction was designed by Wandel Hoefer Lorch + Hirsch along with
Schweitzer Ingenieure a structural consultant. The design's main attraction was its self-supporting
envelope of welded Cor-Ten steel plates that had a glass facade at the end facing the former camp.
Printed on the glass seemingly superimposed on the landscape is an archive photograph of the
prisoners’ barracks that acts as a portal into the horrific past.

The Corten steel envelope End facing glass facade

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 The interior is dominated by timber-lined walls and soffits that follow the triangular panelled exterior.
Texts and images describing the history of the camp have been directly applied using an inkjet process
on the birch plywood surfaces of the exhibition hall while a few original documents still in existence are
displayed in glass showcases embedded within the walls. The exhibition is a much-needed visual
continuation of the memories that up until now had been handed down by word of mouth only.

Unfolded view of the timber panelled interior Interior of the building

The building envelope is a load-bearing structure and facade all in one; it needs no further structural
elements or cladding. More than 3,000 14 mm triangular Cor-Ten steel plates, every one of them
different were prepared on a CNC (computer numerical control) milling machine and assembled in the
factory to form 12 large-format elements which were then welded together on site. The angles between
the individual plates were chosen so that the elements have an adequate structural depth and the whole
construction forms a folded plate structure with sufficient stability. After welding, the surface of the steel
was sand-blasted and evenly pre-oxidised. Subsequent treatment with hot paraffin made way for
additional relief and a semi-gloss finish.

12
7

11 8 6

1
10

5
3
2 4

The 12 large format elements Folded plate surface

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One of the main factors that contributed to the selection of weathering steel is the fact that the site is
located in a rural area thus for a planned life of 100 years, the corrosion of weathering steel per surface
exposed to the weather is at 0.11 mm which is the most ideal circumstance for this material.
Additionally, the climatic conditions are also suitable and ensure the longevity of corten steel.
Furthermore, since the structural cladding was prefabricated it took a shorter period to assemble and
erect thus minimising labor costs while also reducing the impact and maintaining the pristine conditions
of the site. Aesthetically the corten steel showcases an organic outlook and merges seamlessly with the
natural landscape.

Welded corten steel plates The colour palette of the landscape

The foremost reason weathering steel was utilised is due to its inherent corrosion resistance, unlike other
steels. Natural iron ore contains iron as a stable oxide. The melting process raises iron and steel to a
higher energy level therefore they become thermodynamically unstable and are always trying to return
to the lower energy state. Corrosion is the process of returning the iron atoms to iron oxide in the
presence of oxygen and water. The rust layers formed on most conventional structural steels detach
from the metal surface after a critical time, and the corrosion cycle commences again. Hence, the rusting
rate progresses as a series of incremental curves approximating to a straight line, the slope of which
depends on the aggressiveness of the environment.

However Weathering steel, with its copper-bearing

Schematic comparison between the corrosion loss
properties, under normal weather conditions
(alternating wet and dry periods) forms a distinctive
orange to rich purple-brown protective patina over
the underlying surface. This barrier grows outward
and inward from the surface. Unlike common rust,
the oxide formed on weathering steel is a thick,
stable, impervious Ferro-oxyhydroxide that will
afford the base metal extensive resistance to
corrosion by impeding access to oxygen and
moisture. Once the oxide develops correctly,
further changes are very slow in most
environmental exposures but the rusting process
does not stop entirely. If a more even surface finish
is desired, the mill scale caused by the rolling
process should be removed by shot-blasting.

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Weathering steels are classed as stainless steels. Nevertheless, they contain fewer alloying constituents
(< 1%) and are therefore cheaper. The weather resistance is due to these alloying components, primarily
chromium and copper while the addition of phosphorus (0.06–0.15%) enhances the effect. The material
marketed under the name COR-TEN (characterised by its CORrosion resistance and high TENsile
strength) was patented in 1932 in the USA with the alloying constituents copper, phosphorus, silicon,
nickel and chromium. They were initially intended for ore-carrying hopper carts that were used to
transfer iron ore and coal to the furnace. A stronger, more durable steel alloy that had exceptional
hardness and one that did not require painting was ideal for the transferring of iron ore. It wasn’t until
the 1950’s that the steel was introduced to the field of architecture.

Deere and company Deere and company The Picasso

In certain instances as seen for the Hinzert documentation center, the steel can be pre-weathered to
accelerate the process of oxidation which without intervention takes weeks or months for a large
expanse of the metal to corrode and achieve the aesthetic effect envisioned by the designer. Pre-
weathering or artificial weathering involves exposing the surface of these high strength, low alloy steels
to an oxidising agent (many of these involve the use of chloride-based compounds) that creates a
condition where the surface is active and the oxidation of the iron on the surface is accelerated. The key
for any weathering steel process is to start by roughening the surface by sanding or blasting to increase
the “tooth” which holds moisture to the surface. The surfaces are treated immediately afterward with
acidic treatment which starts the oxidation process on by creating numerous localised corrosion cells on
the surface. Once the surface reacts, the strong electrolyte is thoroughly rinsed off preferably with
deionised water. The surface is dried and wetted in continuous cycles until a thick, dark, rich
oxyhydroxide, with stable qualities similar to those that develop naturally over time is obtained.

Examples for weathering chemical compounds are Ammonium chloride (NH4Cl), Hydrochloric acid (HCl)
and Hydrogen peroxide (H2O2). The chloride ion in solutions of ammonium chloride and hydrochloric
acid is a strong oxidiser as it pulls electrons from the iron atom. Hydrogen peroxide is also a strong
oxidiser. It provides oxygen to the iron. Combinations of hydrogen peroxide and the chloride ion work
quickly on developing iron oxide on the surface by stripping the iron of electrons and providing oxygen
to combine with the steel. It is important, however, to understand that some of these act rapidly and
form the oxide and hydroxide without binding well to the underlying steel. The surface may appear to
have the colour and tone required, but it will slide off in powdery layers as it dries. Success comes when
the process is allowed to slowly grow and there is diffusion into and out of the base metal. For the sake
of consistent and predictable results, there are proprietary methods used to achieve the thick
Ferric-oxyhydroxide surface. These methods are produced in a controlled environment where the
humidity and temperature are regulated. As the steel is allowed to weather in the environmentally
controlled chamber, the ferric hydroxide thickens, and the crystalline surface becomes less sporadic and
more continuous. The layers are strongly bonded together and the oxide cannot be rubbed off.

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 Weathering steel costs approximately between 10% to 15% more than standard steel. This extra cost
can be offset against the cost of providing corrosion protection (initial painting, scaffolding, making
good and renewing the paint finish). The environmental problems associated with paint VOC emissions,
and the disposal of blast cleaning debris from future maintenance work are avoided. Furthermore health
and safety issues relating to initial painting are evaded, and the risks associated with future maintenance
are minimised. Periodic inspection and cleaning should be the only maintenance required to ensure the
building continues to perform satisfactorily. Hence, weathering steel structures are ideal where access is
difficult or dangerous, and where future disruption needs to be minimised. Additionally The minimal
future maintenance requirements of weathering steel greatly reduces both the direct costs of the
maintenance operations, leading to major savings far in excess of capital costs. Overall construction
durations are reduced as both shop, and site painting operations are eliminated. Therefore the total life
cycle cost of a weathering steel structure could be up to 30% lower than a conventional coated steel
alternatives. However weathering steel is unsuitable for costal areas, continuously damp conditions and
in localities with high air pollution.

1 2

The other main architectural feature is the birch panelled interior (2) is embedded within the the corten
steel envelope (1) as depicted above.

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 Other details pertaining to the project are given in the diagram

above.

References;
Reichel, A 2007, Building with steel, 1st edn, Birkhäuser, Munich
Weathering Steel Bridges, Dolling, C.N. and Hudson, R.M., Bridge
Engineering, Issue 156
Zahner, L , steel surfaces, 1st edn, Wiley
Weathering Steel - Design Guide for Bridges in Australia

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