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STEEL
AWARDS
2020WELL DONE TO ALL
PROJECT TEAM MEMBERS!CLICK TO VIEW WINNERS AND COMMENDATIONS
The SAISC provides technical support to its members
With access to experienced and qualified individuals, and over 60 years worth of local Southern African project case studies, the SAISC is well placed to assist with technical queries relating to Steel Construction and Structural Engineering. Assistance with technical queries is a service offered to our professional individual members and company members. Email your queries to technical@saisc.co.za or contact (011) 726 6111.
The SAISC provides marketing and publicity support services to its members
Since the association’s inception in 1959 as the “Structural Steel Publicity and Advancement Association”, our primary objective has been to sing the praises of all players in the industry, while extolling the virtues of structural steel.
Our members are the kind of people who put their heads down and get on with the job. Their focus is completing a project with excellence, not necessarily on promoting their achievements. Using our Steel Construction Journal, our website, our social media platforms and press releases to other respected industry publications, we tell those success stories. Foundational marketing and publicity services are available to members as part of their annual membership fee. More comprehensive marketing services including video, photographic and audio recording services are available to members at a special discounted rate.
The SAISC runs training and events for members and non-members
The SAISC has a wide range of CPD credit-bearing training courses aimed at young engineers. These courses incorporate face to face workshop sessions, video modules, and practical assignments. Public training dates are arranged based on the number of delegates interested in a particular course. If you have 8 or more delegates interested in a particular training course, an onsite course can be held at your premises on a date suitable to you. Download our course catalog here.
In addition to our training courses, we host business breakfasts, networking cocktail events, golf days and of course our annual Steel Awards gala events.
While all events are open to the public, special discounted rates are enjoyed by our members.
The SAISC voices the concerns of all of its members when lobbying government, policymakers and industry stakeholders
As a neutral party with members in all functions and levels within the Southern African steel construction industry, the SAISC strives to achieve its goal of a sustainable, healthy and wealthy industry for all players. This is sometimes a challenge as well as a delicate balancing act, as members are likely to have opposing views and objectives. We endeavor to facilitate opportunities for members to engage in an open, respectful and robust discussion where the end goal is for the industry as a whole to survive and thrive.
We invest great time and effort in engaging all levels of government on behalf of the steel construction industry to ensure that our members’ concerns are escalated and that policymakers are made aware of practical implications.
Steel Awards 2020
Steel Awards is without a doubt the event of the year for the Southern African steel industry.
The SAISC would like to extend a hearty thank you to our industry stars and 2020 Steel Awards sponsors:
- Unica Iron and Steel – Main Sponsor National
- Macsteel – Digital Trailblazer
- Cadex Systems SA – Photo Competition
- Safal Steel (Pty) Ltd – Innovation and Sustainability
- Metal Cladding Category – Safintra South Africa
- Tubular Category – ASTPM
- NJR Steel – Partner
- Stewarts & Lloyds Holdings (Pty) Ltd – Partner
- BSi Steel – Partner
- Pro-Roof Steel and Tube – Partner
- Aveng Trident Steel – Partner
Your commitment to the industry is commendable. Thank you for your continued support as we celebrate the achievements and tenacity of the Southern African steel construction industry!
Steel Awards 2020 takes place on 15 October 2020 as a fully live-streamed event. Follow #SAISCSteel20 to keep up to date with all the event buzz!
The SA Steel Industry produces great work:
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Tyris Evergreen ApartmentsThe Tyris Evergreen apartments comprises two 3-storey apartment blocks, including basements. This 108-unit complex is situated in the heart of the bustling Fourways area.By utilizing a light steel frame building approach, the team was able achieve rapid construction, as well as superior thermal and acoustic performance. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. Nominator Mitek Industries Main Contractor Mitek Industries Steelwork Contractor EcoStrut If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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The Precinct Lifestyle HubWith the housing market in decline Century Property Developments diverted their business model into the rental game. To attract tenants a lifestyle hub was commissioned into construction. The building features a movie theatre, spa, games room, restaurant, and gym. All with the intent to ensure Century Property Developments rental portfolio is the most attractive to clients in the Midrand Area. Structural frame and challengesThe structure consists of a portal frame structure fabricated using universal beams with two floor levels which use universal beams to support various types of concrete floors. To reduce cost and maintain feasibility of the entire project various slab interactions were utilized. Hollow core technology combined with a composite slab was utilized. The front portal extended down to the lower ground floor; thus, the steel work was required to be constructed in various phases. Allowing for access to pack the hollow core slabs meant structural steel columns had to be erected without the portals, following the packing of the slabs the portals could be completed. The bridge connecting Building 2 to Building 3 was design using 3D scan technology from Paramatic South Africa. This was to maintain the natural koppie and ensure the design best aligned with the rock feature available to us. This bridge was constructed from the top down. The walkway propped and installed, the columns installed and then the foundations cast. This was to ensure the bridge aligned perfectly with the footings and touched the earth lightly limiting the environmental impact of the construction. Impressive technical aspectsThe extensive spans obtained by the hollow core slabs for the Ground floor above the cinema. This was at the edge of Elematics South Africas capabilities.How this project demonstrates the benefit of steelAbility to save time with manufacture off-site, the industrial look obtained from exposed portal frames. The exposed steel lends itself to challenging aesthetic decisions. All connections, joints and interactions required careful consideration to ensure the final product was in line with the architectural requirements. The building is honest in its structure and architectural intent. How the project team worked togetherThe original steel contractor went under, and Tass Engineering got involved in the project very late and had to expedite the detailing, supply, manufacture, delivery and erection in order to ensure that a quality product was handed over on time to ensure the success of the housing estate completion. Tass Engineering with the late starting point excelled to achieve tight deadlines. The coordination amongst the slab installers, Tass Engineering and century property development excelled to ensure a successful project.Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. STRUCTURAL STEELWORK Completion date of steelwork 1st August 2019 Completion date of full project 15th February 2020 Tonnage and steel profiles used 82.795 I-Beams, Lipped channel, and Angle CLADDING (If applicable) Completion date of cladding 1st November 2019 Cladding profile/ type used Roof Sheeting Cladding area coverage Project Team Role Company Nominator Tass Engineering Client/ Developer Century Property Developments Architect Century Property Developments Architect Century Property Developments Structural Engineer ADA Consulting Engineers Engineer Century Property Developments Quantity Surveyor Century Property Developments Project Manager Century Property Developments Main Contractor Century Property Construction Steelwork Contractor Tass Engineering Steel Erector Cladding Manufacturer Cladding Supplier Cladding Contractor NG Roofing Galvanising Corrosion Protection - Primer Tass Engineering Paintwork Contractor - Site / Final coat Cutting Edge Photographer, Photo competition Century Property Developments If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Ngezi Portal 3 – 13000t Stockpile CoverThe structural design of the Ngezi Portal 3 was completed by FL Smidth. Appointed by the Client, Zimbabwe Platinum Mines (Pvt) Ltd. ZIMPLATS is one of the three Platinum mines in Zimbabwe with a total of five mines in production, and the sixth mine in the construction phase. The structure consisted of twelve main boxed gantries, 2.5m deep x 2m wide x 54m long. The twelve boxed gantries are welded to base plates on the concrete plinths at the base and bolted to a 7m dia center ring at the top. This structure covered the Mine’s main ROM stockpile with a capacity of 13 000t. All work was carried out around the already-installed Stockpile Feed Conveyor. The Mine and Stockpile Feed Conveyor continued to operate during night shift operation throughout the installation period. Safety measures were of paramount importance as the Mine enjoys an excellent safety record. Shop Detailing Shop detailing was completed in Tekla. Detailing and model reviews were done at regular intervals to ensure the design intent was understood and carried into the shop detail drawings. Constructability Reviews During the shop detailing phase, numerous meetings were held to optimize the constructability of the structure. Safety of the site installation crew was of prime importance, with access walkways being added to ensure their safe transit up and down the structure during installation. Trial Assembly During the constructability reviews, a few concerns regarding the installation sequence were highlighted by the team. A decision was taken to trial assemble two main gantries with the lattice and infill steelwork between the two. The trial assembly was completed without a single modification having to be made. Trial assembly was assembled and disassembled in two weeks. Once the trial assembly was completed, the green light was given for full production to proceed. Manufacture Manufacturing was done at Viva Engineering’s workshop in Spartan, Kempton Park. The CNC and preparation department cut their teeth on the structure and were excited to make use of the newly acquired FICEP SP16T6 CNC Anglematic which had been commissioned two weeks prior. This machine worked its way through the structure and resulted in the CNC department completing material preparation three weeks ahead of internal planning. Repetitive gantry sides were assembled in jigs which were inspected and signed off by Viva’s Quality Department before assembly work started. Welding Process utilized was GMAW and was done with the AMIGG 500PM pulse arch welding machines, resulting in superior weld quality with 90% less spatter and minimal cleaning. Cross-Border Exports and Logistics The structures were expertly packed by the Viva dispatch and logistics team, ensuring that the structures were safely secured and vehicles across the border were optimized. In total there were 31 vehicles dispatched to site. Vehicles were cleared through Beitbridge Border post and on average were on site within nine days from dispatch. The center ring, whilst split, fell outside normal transport gauge and needed abnormal transport to site. Installation Installation on site at Bimha Mine, Ngezi, Zimbabwe, was carried out by Hogarths Engineering; a Bulawayo based Structural/Mechanical Engineering Company. Erection Sequence Overall, three cranes were used during installation – 250t, 90t and 55t units. Initially, large base plates were bolted onto the cast-in plates, on top of the concrete plinths. The erected gantries would be welded to these base plates once levels were checked and confirmed. The 12 main gantries were pre-assembled on the ground in positions convenient for lifting. The 90t lattice boom crane was positioned on top of the stockpile, where it lifted in and held the center ring in position ready to receive the main gantries. The twelve gantries were lifted into position by the 250t crane and bolted to the center ring being held by the 90t crane. This crane continued to hold the center ring whilst intermediate cross gantries, bracing and purlins were lifted in and fitted. Both the 150t and 55t cranes were in service feeding these members. Overall installation of steelwork took 3.5 months, with completion in early December 2019. No major site alterations or repairs were necessary. Thankfully there were no safety incidents during the installation period. Sheeting Roof Sheeting is 0.8 IBR Chromadek, Traffic Green colour. Total is 5500 square meters, with 8000 fixings. Sheeting installation started shortly after the first three bays of steelwork were completed. Completion of the sheeting was a week after completion of the steelwork. ISO 9001-2015 (Certification body – TUV) Viva Engineering obtained their ISO Certification in August 2019 and Hogarths in February 2020. Certification was at the same time as this work was being completed in our workshop and site, showing that simultaneous production and continuous improvement initiatives are possible. Key Points Structural mass - 380T Radius – 50.2m Diameter / Distance between supports – 100.4m Coverage – 7 914m2 Top of structure height – 36.520m Comparison Northgate Dome – 11 000m2 Viva Engineering and Hogarths Partnership The Viva-Hogarths partnership was formed in 2010. Since then, this partnership has developed into a dynamic and energetic partnership which has successfully completed a number of complex projects in Zimbabwe over the last 10 years. This partnership is of great value to clients looking to execute turnkey supply and installation work in Zimbabwe. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. STRUCTURAL STEELWORK Completion date of steelwork Last load to site 01/07/2019 Completion date of full project December 2019 Tonnage and steel profiles used 380t Project Team Role Company Nominator Viva Steelfab Engineering Client/ Developer Zimbabwe Platinum Mines Architect Structural Engineer FLSmidth Engineer Quantity Surveyor Project Manager Main Contractor Hogarths Engineering Steelwork Contractor Viva Steelfab Engineering Steel Erector Hogarths Engineering Cladding Manufacturer ClassEcon Roofing & Tiles Cladding Supplier ClassEcon Roofing & Tiles Cladding Contractor PWR Roofing Services Galvanising Monoweld Galvanizers Paintwork Contractor Photographer, Photo competition Photographer, Other submitted images If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Menlyn Main West Atrium StaircaseThe 15500m² building is the latest addition to the mixed use precinct of Menlyn Maine. Its primary purpose is for offices, with a small retail space at ground floor level. It is envisioned that the retail space be operated as a restaurant / deli for the office users as well as providing another alternative to the Menlyn Maine Central Square retail development. The buildings within Menlyn Maine are built onto the boundary line, thereby responding directly to the urban streetscape as well as defining it. Associated retail space with external spill out balconies activates the streetscape and provide an additional layer of security by means of ‘eyes-on-the-street’.The Architectural Brief The brief was to design a unifying element which ties all of the levels together seamlessly, whilst complementing the volume and geometry of the atrium which hosts it. The client wanted the stair to not seem alien in the space, but rather to blend seamlessly with the surrounds. It was envisioned that the staircase would form a talking point to onlookers, and a unifying interior feature to all floors. At the heart of the building, the multiple-volume atrium functions as a gathering space in the semi-public ground floor. Flanking the northern side of the atrium, the design of the atrium stair is based on the notion of a stair as a social interaction space – an area where people have a chance meeting or interact socially. The stair becomes the platform of showcasing and animating vertical movement in the atrium space, thereby optimistically engendering the use of the stair in lieu of the lifts. The seamless wrapping of the atrium-passage balustrade with the atrium staircase, visually connects the various levels and aids in contextualising human-scale and experience. Why Steel was used In conception stage, the materiality came secondary to the design. The staircase was designed to be intricate and organic, with the curves and proportions carefully manipulated to suit the space and adjacent features. Once the team were happy with the design, it became very clear that the only way in which the staircase would be structurally and visually achievable would be if it was constructed from steel. Due to the spans, WSP had recommended that the staircase be built from steel to reduce the self-weight of the structure. It was integral to the design that the staircase cantilevers from a slab edge with no intermediate supports. Initially the architect proposed this staircase to be constructed out of concrete however inevitably steel was the only material which made this possible.Structural Framing A combination of straight and curved I beam stringers were used on either side of the stair, with large base plates on either end welded to cast-in supports on the slab edges. All slab edges had to be significantly strengthened to host the stringers. Angle irons were welded to the stringers at very specific intervals to host a Vastrap plate, which in turn hosted a solid timber tread. The careful coordination, sizing and positioning of the steel elements ensured that the finishes junction perfectly with one another. The most impressive technical aspect of this staircase is that the staircase could be 100% manufactured off site, and installed as a retro-fit item. The precision of the staircase, and the complexity of the installation makes this quite an accomplishment. This is not a traditional half pace stair since one side of the risers are angled away. This created an eccentric support. Additionally the deflection of the structure had to be limited as glass balustrades were to be used. Individual cast in frames had to be placed and cast with great accuracy to ensure accurate post fitment of the face plates onto the protruding bars. The site welding quality and monitoring was of great importance since these large staircases are supported at the stinger ends, welded to the face plates and horizontal anchor plates with 10mm prepared welds. With 21 meters of vertical up, 8 meters of overhead and 10 meters of down hand welds, daily tracking, inspecting and doing non-destructive weld testing was done to ensure each staircase meets with the design requirement before lifting the next staircase into position. With the cast in frame in place and additional re-bar at these positions to strengthen the slab edge, fitting the 120 number of M24 RE 500 chemical anchors into position was always going to be difficult. The rebar and cast in frame positions were scanned and marked out on the slab surface in order to drill and fit these anchors into position. Once the anchor positions were determined and drilled, the anchor plates were match drilled to suit each anchor position. Challenges The biggest challenge was the enormous weight of the staircase in terms of dead and imposed live loads, along with the millimetre precision which was required to make all interfaces perfect. With each stair weighing close to 4 tonnes in steel alone, a maximum of 2 stairs could be placed on the ground floor slab before the slab would collapse. Each staircase had to be split into two pieces at landing level in order to be able to transport the pieces to site and lift them over the building, into the atrium in order to fit the pieces into place with the tower crane. In order to achieve the level of accuracy, each staircase built complete in a jig during fabrication. Welding distortion was of great concern and had to be closely monitored in the workshop to ensure the large pieces remained within tolerance. Once on-site, each piece was lowered into place, supported on scaffolding props, bolted at landing level and welded to the vertical faceplates at the slab edges whilst suspended. Because each staircase had to be constructed in two pieces and welded to faceplates, considerable site welding had to be done.How this project demonstrates the benefit of steel as a material This staircase would not have been possible should any other material be used. The cantilever from a concrete slab edge, along with the weight which the stair is able to support (an African elephant on the landing) could not be done with anything other than steel. WSP was able to reduce the self-weight of the structure and adapt the curves required by the architect. The precision is by far the most special part of this project. Steel sections are notorious for having quite large tolerances in sizes. In this application, there was simply no room for tolerance or errors. Between the Architects’ detailing, the engineer’s sizing, and the supplier’s detail drawings and manufacturing, each element married perfectly. How the project team worked together More meetings were had about this staircase than any other element in the building. It was important that each party involved was 100% up to speed with what was required, and how we planned on achieving it. Given the complexity of the curves, fixings and junctions, it was sometimes impossible to communicate on drawings or over emails. For this reason, Boogertman and Partners made use of 3D printing technology, 3D visualizing technology and very strong software to communicate the intent to all consultants. Once on-site, the main contractor made use of all of these tools to clarify the intricacies with all installers involved. WSP was in constant communication with the site team, especially with respect to the level of accuracy required to ensure that the connection points lined out. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 197 Amarand Ave Menlyn Maine Pretoria Google Maps link https://www.google.co.za/maps/dir//-25.7862173,28.2821603/@-25.7865583,28.2822444,18z STRUCTURAL STEELWORK Completion date of steelwork 04 February 2020 Completion date of full project Approx. 20 March’20 Tonnage and steel profiles used 29ton UB457*191*67 – VT4.5 landings & treads Project Team Role Company Nominator Tass Engineering Client/ Developer Barrow Properties (Pty) Ltd Menlyn Maine Investment Holdings (Pty) Ltd Architect Boogertman Partners Structural Engineer WSP, Structures, Africa Quantity Surveyor RLB Pentad Quantity Surveyors Main Contractor Barrow Construction (PTY) Ltd Steelwork Contractor Tass Engineering Steel Erector Tass Engineering Photographer, Photo competition Tass Engineering Photographer, Other submitted images Tass Engineering If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Tshwane Regional MallTshwane Reginal Mall is a new mall in Mamelodi Pretoria. Steel was integral to architectural look and design of the mall, especially with the bold steel entrances and pop out roof along the mall. Structural framing The main mall roof structure mainly consisted of I-beam rafters with Metsec purlins, allowing for long spans and a reduced overall tonnage to the structure. The Large entrances were constructed of large curved box sections. Fabricated out of plate. Top and bottom flanges laser cut to shape, and side web plates rolled to suit. Split tee sections with rolled CHS sections creating the fanning sun screens along the outside. Inside the mall supporting these entrance roofs are huge CHS struts impressively supporting the roofs. This theme is continues throughout the mall with large concrete columns and CHS “tree structures” supporting pop out roofs along the main mall areas. The food court have stainless steel pipes like “sticks” decorating the area. Outside all along the front of the mall, there are heavy I beam canopy structures adding to the bold look of steel as you approach the entrances. The entire parking lot roof was erected on top of the fourth floor slab. So this required spider cranes to be able to work on top of these slabs. Then on the other hand the heavy entrance box sections required large 50ton cranes to be able to lift the large sections into place. The benefits of using steel In a mall like this most of the structure is build out of concrete and bricks. But the appeal to the mall is the Bold steel sections used in the entrance, External walkways, and large steel pipes supporting the roofs inside the mall walkway areas. This can only be achieved by the architectural use of steel. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. Physical address of the project Street Address Town Province Tsamaya Avenue Mamelodi Gauteng Google Maps link https://goo.gl/maps/dsdMcjCMxm6m5dENA STRUCTURAL STEELWORK Completion date of steelwork June 2020 Completion date of full project 2021 Tonnage and steel profiles used 500t - Hot Rolled, Tubular and Metsec Profiles Project Team RoleCompany NominatorFerro Eleganza (Pty) LtdClient/ DeveloperIsibonelo Property Services (Pty) LtdArchitectSVA International (Pty) LtdStructural Engineer Pure Consulting (Pty) LtdEngineer Quantity Surveyor (PQS)Nonku Ntshona & AssociatesProject ManagerLMKV Management ConsultantsMain ContractorGD Irons Construction (Pty) LtdSteelwork ContractorFerro Eleganza (Pty) LtdSteel ErectorFerro Eleganza (Pty) LtdCladding Manufacturer Cladding Supplier Cladding ContractorChartwell Roofing (Pty) LtdCorrosion Protection GalvanisingArmco Superlite (Pty) LtdCorrosion Protection Paintwork ContractorJokes Building Construction CCPhotographer, Photo competitionFerro Eleganza (Pty) Ltd If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Nike Store Spiral Staircase, RosebankWith Nike Rosebank we had to overcome some interesting challenges to connect the two store levels, which sit almost perpendicular to each other, with a single vertical integration system. Due to the positioning of the two levels, this meant that the staircase would be at the forefront of our trading space on the ground floor and a conventional staircase design would consume a very large portion of our trading floor area, these are both limiting factors when you consider that retail rental space in Rosebank comes at a high cost and every effort is made to maximize ROI. Finding the right solution for this store put us on a very lengthy design process (almost 4 months), where we tested multiple staircase designs and configurations between the Nike Designers in Europe, our local Architectural Partners (TCRPv) and CADCON in South Africa. The Nike Designers drew inspiration from European multi-level residential structures that have limited floor area to accommodate conventional staircase designs and as such make use of spiral staircases to connect the levels. These staircases are often quite minimalistic in design and don’t have to carry multiple occupants simultaneously unlike retail environments, so in order to beef up our design to carry the weight of simultaneous users, we had to develop a unit that was structurally sound without becoming overly weighted (from a visual sense) with heavy and multiple support posts, we wanted the consumer to be able to experience both levels of the store as they used the staircase and not feel as if they are navigating through a silo. We transitioned the timber floor finishes from the First Floor environment onto the staircase treads to give the unit a softness and to help us link the two gender split retail spaces. These factors brought us to the design that you get to experience in the store, a structure that consists of mild steel plates running on two separate stringers, with its full weight (about 4 tons) being carried on only two foot plates. Over and above the staircase design, there was also major structural work done to the existing Basement and First Floor level slabs to give us the opening to see the ground floor as you descended the staircase and to give us the support to carry this staircase mass.This spiral staircase is certainly a first for Nike across our global footprint of retail stores and I think can safely say that there is no other retail space in South Africa that uses this unconventional vertical integration method.It was both challenging and eye-opening to see this structure being designed, manufactured, delivered and installed, while still constructing a retail space around it, definitely something I will always remember. - Europe What is the purpose of the structure/ project? The staircase was a critical architectural element in the Nike Store as this needed to be an element which would both physically and visually connect the two floors and in order for the store to maintain a sense of “connection” and “cohesiveness” despite the store being split over 2 levels. In terms of the stores overall design, the staircase had to make a statement; one which would create a sense of interest (spatially) but also be inviting to shoppers to explore whilst also strengthened the flow and movement through the store and irrespective of the change in floors. Careful thought and consideration was given to the ergonomics of the staircase to ensure that more than one person could travel between the levels simultaneously. • What was the brief to the architect? One of the biggest challenges with the Nike Rosebank store was to successfully connect the two store levels as there was limited opportunity, and area, where the floors could overlap. The existing slab construction and extent of existing services further limited the staircases positioning. Ultimately through careful co-ordination and team work, a possible position was identified at the front of the store, ideal for maximum visibility to shoppers, but now further restricted by the glazing line of the actual store, but which was ultimately overcome by the compact stair design which you see today. • Was the project envisaged in steel from the start? If not – why was it built in steel in the end? Yes, steel was always envisaged as the preferred material for the stairs. We believe that the flexibility and durability of steel adds a dynamic element to a building project, allowing designers to think outside the box. • Give a brief description of the structural framing. What type of sections were used and why? It was important to Nike that the structural design of the stair would not detract from the greater “sculptural element” that we needed to achieve. To achieve this, the following needed to happen;• The balustrade and stringers needed to be made seamless. • Due to the distance in height between the two floors, a landing was required to ensure a comfortable journey between floors. This concept although simple, complicated the structural design of the staircase. • The risers needed to be designed as open to keep the structure visually as “light” as possible. • Each tread needed to be bent from a single metal sheet so as to avoid unnecessary joints and junctions. • The treads needed to be filled with concrete to stabilize and mitigate the vibrations whilst walking between floors walking. It is noticeable how solid the staircase feels when a person is walking on it. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Oxford Street The Zone Rosebank GPS Co-ordinates STRUCTURAL STEELWORK Completion date of steelwork 20/11/2019 Completion date of full project 30/11/2019 Tons of structural steel used 3 Tons Structural profiles used Combination of Platework and Tubular If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Refinery Business ParkProject motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 48 North Reef Rd, Wilbart, Germiston Google Maps link Project Team RoleCompany Nominator Client/ Developer ArchitectCimato Moroldo ArchitectsStructural Engineer Engineer Quantity Surveyor Project Manager Main Contractor Steelwork Contractor Steel Erector Cladding Manufacturer Cladding SupplierSAFINTRA South Africa (Pty) LtdCladding ContractorA&I Sheeters CLADDING (If applicable) Completion date of cladding 31/09/2019 Cladding profile/ type used Widedek – Thunderstorm and Saflok – Zincal Cladding area coverage 2000M² Cladding tonnage 50 tons If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Mabopane SquareMabopane square is a commercial development in Pretoria. Safintra South Africa provided 57.2 tonnes of Saflok covering 10 400 square meters, and 18.8 tonnes of Newlok, covering 3300 square meters for this project. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Mabopane Pretoria Google Maps link CLADDING (If applicable) Completion date of cladding November 2019 Cladding profile/ type used Safintra Saflok 700 ZincAl | Safintra Newlok ColorPlus Cladding area coverage Saflok – 10 400m² | Newlok – 3 300m² Cladding tonnage 57.2 tons | 18.8 tons Project Team Role Company Nominator Client/ Developer McCormick Property Architect MDS Architecture Structural Engineer Hannes Hattingh Consulting Engineer Quantity Surveyor Project Manager Main Contractor Mike Buyskes Construction Steelwork Contractor Steel Detailer KRU Detailing Cladding Manufacturer Cladding Supplier SAFINTRA South Africa (Pty) Ltd Cladding Contractor Steel Roofing If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Ascendis MedicalText by AOJ and Gregg Cocking / PRchitectureThis landmark project is located on a prime corner of the Boundary Park Industrial Park development currently underway in Northriding, Johannesburg. The site location and tenant’s large office staff complement led to a less conventional office and warehouse ratio of 60:40. “This model is seemingly becoming more common nowadays with a shrinking global economy and the improvements in technology. Many large companies with distribution facilities are downsizing and consolidating their operations,” says Alessio Lacovig of Architects Of Justice (AOJ). The tenant, Ascendis Medical, is one such company. With a progressive directorship at its helm, it needed to consolidate three facilities into one to optimise operations and improve business efficiencies. This large and rather complex program was cleverly distributed by AOJ over three floors of P-Grade equivalent offices totalling 6 500 m². Apart from a strong focus around sustainability, the office was designed around two key principals from the onset, one being user experience and the other the creation of a statement building. In the design, the office footprint was shaped around an irregular open courtyard to increase the perimeter façade. This maximises the building’s presence from the adjacent street intersection, increases the amount of natural daylight entering the building and enhances the external views from within the building. Both the shape of the courtyard and the longer perimeter façade result in a building that appears even larger from the major intersection on which the building is located, emphasising it’s importance as Ascendis’ new head office. The highly intricate and impressive glass corner entrance is the most striking architectural element of the building; shaped to improve passive solar control of the triple volume entrance foyer. AOJ’s directive to make the building as prominent as possible, and the site conditions, whereby the building sits elevated from the road intersection, made it possible to include a 2 000 m² basement parking level, which at the same time improved earthwork cut-to-fill ratios and stormwater management. This elevation of the building also gives the main foyer and its linked walkways on all floors fantastic views as the surrounding contours fall to the north. “Maybe this was lucky in a way, but it ultimately came about from considering the design early on in the process and thinking of how we could make the most out of the communal spaces,” says Lacovig. The Ascendis building was the first of four to be designed by AOJ at the Boundary Park precinct. “In order to secure Ascendis as a tenant, Orpen Group, the developer, first needed to illustrate the potential of the development and the site to them, which lead to an initial design pitch, by AOJ, to Ascendis for the building. “This pitch clearly went really well,” notes Lacovig. “With the site being at a major intersection on Malibongwe Drive, a very busy thoroughfare, the opportunity was there to make the landmark building.” The initial mindset focussed on creating a shimmering glass building to relate to Ascendis as a company which competes globally. Façade “Our design was a response to the client’s desire for a fully glazed façade that would suit an international style of architecture, to fit with what is more commonly seen in areas like Sandton but that would costs less to build,” explains Lacovig. “The conventional way to achieve this is to use curtain walling because you're trying to get glass to span floor-to-ceiling over several floors, and you subsequently need double or triple performance glazing, which further pushes the price up.” AOJ’s approach was different; they identified the two aspects of most value when making a ‘glass building’, being the user experience from the inside and what the building looks like from the outside. By running the glazing continuously across the length of the office, and from the ceiling height down to 800mm above the floor (effective desk height) and not from slab to slab in a relatively dense office space, you can achieve the desired perception of transparency from the inside. “For a building of this scale, it also reduces the construction cost because there is less glass and it also increases the speed at which the contractor can build on site, because they are now applying a more conventional building method of brick work and openings for windows, rather than having a concrete structure and relying on a single supplier to finish off the façade,” explains Lacovig. “From the exterior, what this does is reduce the amount of glass on the façade which is exposed to the sun, which automatically reduces unwanted solar heat gain.” A second full glazing element was introduced as an additional skin to the façade. “This second skin is not only the major aesthetic element of the building, but it is also a noise buffer (as it deflects road noise from Malibongwe Road). In addition, a fixed solar control element was added; this also serves as an access walkway for easy cleaning of the windows from the outside,” he says. Ultimately, it was about creating a façade which was functional, and not just an aesthetic showpiece. “Good design is multifunctional. We needed the large glass façade, and the economic constraints very quickly pushed our creativity to make this element more valuable,” says Lacovig. The coloured blue glass came into play as an idea to tie the building back to the Ascendis brand, and it was designed in such a way that the client can cover it with vinyl in the future if they want. The only break to the glass façade comes in the form of a solid box, in which the building auditorium is housed. This also serves as a signage wall for Ascendis branding. “The predominant material on the façades of the building is facebrick,” says Mike Rassmann from AOJ. “This choice was largely to reduce maintenance on the building and one cannot get away from the fact that cementitious products are a big polluter of the environment, and if you have to plaster a façade of this size you will be using a large amount of cement, not to mention paint. Using a facebrick façade is in many ways a responsible thing to do, although it does require more attention during construction to get the bricks laid properly.” Part of the challenge AOJ had was trying to find the right colour brick; “We wanted a modern looking building, and for the brick not to show behind the blue glass. This is quite difficult to do it with facebrick’s earthy, natural tones, so we picked the most muted dark brick available which has the added benefit of not showing dirt as much as a lighter brick would,” explains Lacovig. The brick used in the courtyard, on the other hand, was a lighter colour brick which was specified for improved reflection of daylight within this space. Courtyard The courtyard was an integral part of the architect’s design from the outset. “A courtyard in an office building gives you the ability to have a wider office floorplate, because you can have natural light entering the workspace from two sides,” Lacovig points out. “We ended up having a 17-metre-deep floorplate, which, if you illuminate from only one side of the façade, becomes very dark.” This 17m depth is also the consequence of the basement parking grid layout and is well suited for the buildings structural design. “While the courtyard does create a social space, it was more about making the building energy efficient and more comfortable for users. It enables more natural ventilation and more natural lighting, thus reducing energy consumption as you don't have to have lights on throughout the day nor do you have to fully rely on mechanical ventilation to moderate the internal temperature, which, in a building of this size can add up quite quickly to hundreds of thousands of rands,” he says. The courtyard is directly linked with the main foyer reception of the building on one side and the staff canteen on the other. This proximity allows this social space to be used for informal meetings between staff and visitors alike. A covered glass structure creates a walkway that ensures moving to the canteen from the reception is comfortable even in bad weather and also provides sheltered seating space. Large north facing stacking doors can be used to open the canteen space onto the courtyard on more temperate days, and makes this space appropriate for larger gatherings The building, with a 60:40 split between office block and warehouse is seen more as a head office with a distribution facility attached, rather than a warehouse with an office facility attached. “During the design, there was a toss-up between Orpen building exactly what Ascendis needed at that point, and being mindful of Ascendis’ imminent growth by adding a third floor. This made things a little more complicated for AOJ,” says Lacovig, “but that is part of the process, and despite the back and forward, much of the original design intention remained in the completed building.” The third floor consists of additional office space for growth and a 100-seater auditorium with meeting rooms as part of a training centre, allowing the company to expand without relocating in the future. On the west corner of the same floor, a bar and outdoor terrace offers a place for staff and visitors to socialise while taking in the surrounding views and setting sun. The warehouse component incorporates a double storey pilot office at the centre of the interface between the warehouse and the yard, giving the operational staff full control over the dispatch and receiving processes. A two-storey staff block with change rooms and worker’s canteen space is linked to the yard of the office, keeping the utility aspects of the building on the same side. A backup water supply is housed on the internal portion of the pilot office roof to keep the facility operational for up to seven days should municipal supply be interrupted, while the warehouse roof was designed to accommodate solar PV panels in the future, which, given the current challenges South Africa is facing, would completely address the need for the building’s water and power security. A higher floor specification was used in a dedicated section of the warehouse, so VNA (Very Narrow Aisle) racking could be used to take advantage of the 14m warehouse height and improve use of the floor area. “Additional foundation footings were also incorporated into the warehouse floor, adjacent to the courtyard wall to allow for even further growth of the office space by 10m into the warehouse. This would effectively complete the fourth side of the courtyard space. That has not happened – and it might never happen – but it is another way that our design futureproofs the building for Ascendis and Orpen,” notes Lacovig. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 460 Malibongwe Rd Kya Sands, Randburg GPS Co-ordinates 27956 78, -26.044 789 CLADDING (If applicable) Completion date of cladding Cladding profile/ type used Safintra Saflock 700/WideSpan Cladding area coverage 9000m² + 2300m² Cladding tonnage 45 tonnes + 11.5 ton Project Team Role Company Nominator Safintra South Africa Client/ Developer Orpen Group Architect Architects of Justice Structural Engineer Engineer Quantity Surveyor Ferrer Hagim QS Project Manager Main Contractor Steelwork Contractor Steel Erector Cladding Manufacturer Cladding Supplier SAFINTRA South Africa (Pty) Ltd Cladding Contractor Hollyberry Roofing If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Menlyn Maine West Atrium SkylightPark Lane West is a new premium grade commercial development in Menlyn. At the center of the 7 storey building there is 26m long by 17m wide atrium skylight which brings natural light into the building Architectural BriefThe architectural brief was to create a modern skylight, with lightweight steel members and a very clean geometry, that would bring the right balance of heat and light into the atrium below. Due to the need for a lightweight structure which could support large glass lites, steel was the obviously material of choice. Structural Framing Rectangular hollow sections were selected for the main beam so concealed connections. In addition, since the structure was designed as a braced three-pin pitched roof, the hollow sections efficiently carried the bending and compression forces. Small diameter round tubes were used for longitudinal apex bracing.Due to the accuracy of the steelwork and efficiency of the glazing installation team, up to 16 glass panels could be installed in one day. Ie, this equates to the weight of the full steel structure in glass panels per day. The low pitch ridged roof consisting of neatly fabricated hollow steel sections and large glass panels created a simple but bespoke looking skylight.Cladding To reduce the number of steel beams, large point supported glass panels were used. Each panel was 2.2m wide x 3.3m long and weighed approximately 350kg.Challenges Since all the glass lites were fully tempered and prefabricated the steelwork needed to be installed to a very high degree of tolerance to ensure each glass lite would fit. Extensive QAQC checks were carried out both in Tass’s factory and onsite before the cladding was installed. How does this project demonstrate the benefits of steel as a material?High yield strength of the S355 tubes enabled small beams to be used while the hollow sections enabled neat hidden connection details. In addition, due to the stringent deflection requirements of the glass, both during installation and long term, the high stiffness of structure enable the joints between each glass panel to be sealed with a neat strip of silicone only. No mullions were required. How did the project team work together? LEAF Structures worked very closely with the professional team, as well as the general contractor, to come up with a solution that met the architectural intent, budget, and site constraints. During the design phase, several structural and cladding solutions were developed and priced so the client could pick their preferred option. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 97 Amarand Ave, Waterkloof Glen, Pretoria, 0010 Google Maps link STRUCTURAL STEELWORK Completion date of steelwork October 2019 Completion date of full project March 2020 Tonnage and steel profiles used 5.2 tons. CHS 200x100mm CLADDING (If applicable) Completion date of cladding December 2019 Cladding profile/ type used Point support fully tempered laminated glass Cladding area coverage 460sqm Cladding tonnage 24 tonnes Project Team Role Company Nominator LEAF Structures Client/ Developer Menlyn Main Architect Boogertman and Partners Structural Engineer LEAF Structures Engineer Quantity Surveyor Project Manager Main Contractor Barrow Construction Steelwork Contractor Tass Engineering (Pty) Ltd Steel Erector Cladding Manufacturer LEAF Structures Cladding Supplier LEAF Structures Cladding Contractor LEAF Structures If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Action Chapel International Tema ChurchAction Chapel International Tema Church was always intended as a large church and conference venue. Unfortunately, the project stood idle, half-completed for a few years due to the congregation having to find more funds.The architect designed this structure as an imposing very large church with a distinctive roof shape in order to create an unusual aesthetic look.The ability to re-create the Architect’s vision for an unusually aesthetic roof structure that had challenged the local skills and was only able to come to reality by using the Ultra-Span LGS roof system. Why Steel?his project was envisaged from the start to be done in heavy hot-rolled steel sections. Large steel sections are however expensive and not easily obtained in Ghana and as such slowed down the completion of this project until the team from Africa Building Partners got involved and with their substantial experience of Ultra-Span roof structures in Ghana –they were able to get this structure designed in Ultra-Span with a spinal support structure in hot-rolled steel sections with assistance from MiTek Industries South Africa.The structural frame This project was envisaged from the start to be done in heavy hot-rolled steel sections. Large steel sections are however expensive and not easily obtained in Ghana and as such slowed down the completion of this project until the team from Africa Building Partners got involved and with their substantial experience of Ultra-Span roof structures in Ghana –they were able to get this structure designed in Ultra-Span with a spinal support structure in hot-rolled steel sections with assistance from MiTek Industries South Africa. Cladding The Africa Building Partner team also took charge of the roof + side cladding by utilizing an innovative lightweight approach in the form of 2.0mm THICK UPVC SHEETING, IBR profile. This equated to: 7644kg (3.9kg/ m²) Light Steel Frame Building This relatively large, aesthetically challenging roof structure only became possible through the use of LGS –Ultra-Span roof trusses which were supported on the spinal hot-rolled steel support girder and on the perimeter concrete ring beams. Had this structure been done as originally intended in full hot-rolled steel, it would have required an additional 96Tons of steel as well as a delay in completion of up to 3 months. The use of Ultra-Span roof structure thereby contributed immensely in overall cost savings on this project. The final client –the church association, has provided a letter of recommendation expressing their fullest satisfaction with ABP (Africa Building Partners) and their professional and innovative approach to this project. ChallengesThe biggest challenge was the local design and construction of the hot-rolled spinal steel girder structure due to a lack of local skills and material supply issues --- this process took almost 2 months to complete. The assembly and installation of the complete Ultra-Span roof structure only took approx. 1 month, again immense time savings were achieved by the Ultra-Span roof structure through pre-assembly of complete roof portions and lifting these into position by crane.The benefits of using steelOnly through the appropriate use of Ultra-Span LGS trusses in conjunction with the necessary spinal steel girder truss in hot-rolled steel –did this project come to reality –whilst also providing the final end client substantial cost and time savings.How the project team worked together As explained earlier, unfortunately the project stood idle, half-completed for a few years due to the congregation having to find more funds as well as difficulties in completing the whole roof structure using traditional hot rolled steel structures due to suspect quality of the concrete work and the enormous mass of the steel roof structure. Only through the involvement of the MiTek licensed Ultra-Span manufacturer – Africa Building Partners could this project be completed expertly and with cost savings to the 100% satisfaction of the end client.Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province TEMA ACTION CHURCH TEMA – AFLAO ROAD TEMA ROUNDABOUT, TEMA - GHANA Google Maps link N/A STRUCTURAL STEELWORK i.e. cold rolled steel beam girders Completion date of steelwork 07/10/2019 Completion date of full project 17/01/2020 Tonnage and steel profiles used 200x200x8/12 SHS, 200x200x4SHS, 100x100x3SHS Project Team Role Company Nominator Mitek Industries Client/ Developer Tema Action Chapel International Architect Custom Built - Boxos1318 Osu Accra Structural Engineer Aya-Top Tech & Fabrication Ltd. Engineer Abp Quantity Surveyor Project Manager Abp Main Contractor Abp Steelwork Contractor Aya-Top Tech & Fabrication Ltd. Steel Erector Aya-Top Tech & Fabrication Ltd. Cladding Manufacturer Ultralam Mexico Cladding Supplier Abp Cladding Contractor Abp Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor Aya-Top Tech & Fabrication Ltd. Photographer, Photo competition Abp Photos Submitted Photographer, Other submitted images Abp Photos Submitted LIGHT STEEL FRAME BUILDING WORK (If applicable) i.e. Ultra-Span Completion date of LSFB work 08/11/2019 Completion date of full project 17/01/2020 Tons of LSF used 7000Kg Span of trusses and Kg/m2 (if applicable) MAXIMUM SPAN = 24.8m Type of cladding used 2.00mm THICK UPVC SHEETING CLADDING (If applicable) i.e. roof sheeting Completion date of cladding 17/01/2020 Cladding profile/ type used 2.0mm THICK UPVC SHEETING, IBR Cladding area coverage 1750m² ROOF. 210 m² SIDE CLADDING PROFILE Cladding tonnage 7644kg (3.9kg/ m²) If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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LG WarehouseProject motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEWPhysical address of the project Street Address Town Province 2 Sundew Road, Ottowa,Cornubia Industrial Park, Durban KwaZulu Natal Google Maps link Project Team RoleCompanyNominatorSAFINTRA South Africa (Pty) LtdClient/ DeveloperZenprop PropertiesArchitectHilton Lawrence ArchitectsStructural Engineer DG Consulting EngineersEngineer Quantity Surveyor Project Manager Main ContractorAbbeydale ConstructionSteelwork ContractorCousins SteelSteel ErectorCousins SteelCladding ManufacturerSAFINTRA South Africa (Pty) LtdCladding SupplierSAFINTRA South Africa (Pty) LtdCladding ContractorCladcoCorrosion Protection Galvanising Corrosion Protection Paintwork Contractor Photographer, Photo competitionKierran Allen Photography CLADDING (If applicable)Completion date of cladding15 October 2019Cladding profile/ type usedRoof: Saflok 700 AZ150 0.53 Zincal Cladding: Widedek AZ150 0.47 Seaspray & Thunderstorm Cladding area coverage 23 500 m2Cladding tonnage121 Tons If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Mount Edgecombe Business ParkGrowthpoint Properties brief for the Mount Edgecombe Business Park Phase 1 called for an upmarket industrial facility that offered a well-designed, aesthetically pleasing, yet practical series of units with maximum flexibility. The economics dictated a cost-effective solution to achieve Growthpoint’s required return on investment to ensure value to the shareholders. The basic layout comprised of 15 units of 650 to 1800 square meters. The units had to be able to be easily linked together to allow for potential demand of a growing tenant. The Structural system had to thus be clear and flexible.The site The site is well situated in the Mount Edgecombe industrial zone near Umhlanga Ridge north of Durban Central. The site provides for easy access to the national roads as well as close proximity to Durban’s northern economic powerhouse. Phase one had to be planned in conjunction with a second phase across the main access road to achieving one large Industrial Complex that will develop and promote the Growthpoint Industrial Park Brand. Design solution In Phase One, the access and on-site vehicular manipulation for the multiple units was the Architect’s priority. The car parking was separated and defined, as far as possible, from truck loading. The result was two steel-framed and cladded “sheds” that best makes use of the rectangular shape of the site. A clever collaboration between the architect and structural engineer in the early design phases culminated in an economic building grid that also accommodates the various sizes of units required. The sharp lines of the steel cladding wrap the shed in a crisp manner that celebrates the “steel box”. Roof and side cladding read as one, thus accentuating the mechanistic aesthetic of steel. Continuous clean eaves lines were achieved by the architect by excluding projecting canopies and recessing the roller shutter loading doors. The clean lines of these steel sheds were subtly interrupted and articulated at the Office/ Mezzanine components, using a simple concrete frame cut into the steel cladding. The earthly muted grey tones and subtle planes of the concrete frames do not detract from the sleek steel shed while allowing for controlled signage and sheltered entrances. These elements add an understated definition and complementarity to the straight lines of the structural steel box. The steel framed, louvered sun control on the Office façades which fold over the larger windows returns this concrete and brickwork component back to the steel aesthetic and results in a harmonious composition of scale. This Office element allows for expression of the individual tenants and adds an appropriate Urban Scale on the street front which again demonstrates the flexibility of the Steel Building type. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 54 600094 Street Mount Edgecombe KwaZulu Natal GPS Co-ordinates -29.703360 , 31.038727 Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 21 July 2019 Completion date of full project WBHO to confirm Tonnage and steel profiles used 286 tons – angles, channels, beams and metsec profiles Project Team Role Company Nominator SAFINTRA South Africa (Pty) Ltd Client/ Developer Growthpoint Properties Architect Ries Shaw Architects Structural Engineer WSP Consulting Structural Engineers Engineer Quantity Surveyor Project Manager Main Contractor Steelwork Contractor Churchyard & Umpleby Construction (Pty) Ltd Steel Erector Churchyard & Umpleby Construction (Pty) Ltd Cladding Manufacturer SAFINTRA South Africa (Pty) Ltd Cladding Supplier SAFINTRA South Africa (Pty) Ltd Cladding Contractor MJC Industrial Roofing Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor Photographer, Photo competition Kierran Allen Photography If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding 6th September 2019 Cladding profile/ type used Roof: Saflok 700 AZ200 0.53 Seaspray Cladding: IBR AZ200 0.53 Seaspray Cladding area coverage 17 500m2 Cladding tonnage 93 Tons
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PX Shed 123PX Shed Warehouses were built as a storage and distribution hub. The warehouses are currently being used by C. Steinweg Bridge. They are a company that stores and distributes a diverse range of products throughout KwaZulu Natal. This facility has three warehouses in total on the site. Warehouse 1 and 3 are used to store and distribute edible goods and products. Warehouse 2 is being used to store fertilizer; therefore, the initial brief was to design warehouses which could store these various types of products, and also manage to be a distribution facility from a central location. There are also various office components around the site of varying scales allowing for the management and control of this massive facility. Warehouse 1 & 3These two warehouses were designed by the architects and engineers with steel cladding being the main aesthetic. The use of steel structure allows for wide spans to achieve the required uncluttered interiors essential for large scale economical storage. The steel structures both have monitors running along the top of the warehouse, this is to allow light to enter and to have airflow. Together the warehouses are approximately 91 435m2 in total, was envisaged to be done in steel with sheeting. The most optimum type design or structure was for this to be a sheeted and structural steel warehouse. Hot rolled I beam sections, lattis girder trusses, cold formed purlins, and girts were used in the construction of these warehouses. The crisp, clear nature of this simple steel building on the horizon can be appreciated from far off. The sheeting for these structures were Safintra’s Saflok 700 0.53mm AZ200 Sea Spray on the roof, and Widedek 0.53mm AZ200 Seaspray for the cladding. The total amount of steel required in order to complete these warehouses was 475 tons of material. Warehouse 2This warehouse was designed by the architects and engineers in mind that it would be storing fertilizer. All the steel work needed to be specially coated, and the cladding material had to be Aluminium PVDF as fertilizer emits fumes that erode standard materials. So there the design had to cater for this problem. The use of steel structure allows for wide spans to achieve the required uncluttered interiors essential for large scale economical storage. The steel structure has ridge vents running along the top of the warehouse, this is to allow for airflow. The warehouse is approximately 76 291m2 in total. The most optimum type design or structure was for this to be a sheeted and structural steel warehouse. The sheeting for warehouse 2 was Safintra’s Saflok 700 0.80mm Aluminium PVDF Heron White on the roof. Safintra only supplied the roofing material for this warehouse. The total amount of material required in order to complete the roof portion of the warehouse was 445 tons of material. Due to the excessive lengths that were required to sheet all three warehouse, on site rolling had to be done with Safintra’s Saflok 700 Mobile Mill. This required both space, planning and lifting onto the roof from ground level. Different sections were milled at different areas of the site so as to help with eased of erection, traffic requirements on a congested site and to minimise double handling of the sheets on site. The sheeting was hoisted to the roof from various sides of the buildings. Overall the teams of professionals working on the PX Shed project worked well together, and had a great understanding with each other. With this it helped achieve what was set out to be done, and provide a suitable working environment for the client. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 151 South Coast Road Bayhead Durban KwaZulu Natal GPS Co-ordinates -29.902624 , 30.986170 Google Maps link CLADDING (If applicable) Completion date of cladding Warehouse 1 & 3 Completion Date: 1 August 2019 Warehouse 2 Completion Date: 1 October 2019 Cladding profile/ type used Warehouse 1 & 3 Roof: Saflok 700 AZ200 0.53 Seaspray Cladding: Widedek AZ200 0.53 Seaspray Warehouse 2 Roof: Saflok 700 Aluminium PVDF 0.80 Heron White Cladding area coverage Warehouse 1 & 3 91 435 m2 Warehouse 2 76 291 m2 Cladding tonnage Warehouse 1 & 3 475 Tons Warehouse 2 445 Tons Project Team Role Company Nominator Safintra SA (Pty) Ltd Client/ Developer Newlyn Developers Architect Siza Architects Structural Engineer Kantey & Templer Engineer Quantity Surveyor Project Manager Main Contractor Patcon Engineering Steelwork Contractor Cadcon (Pty) Ltd Steelwork Contractor Avellini Brothers Steel Erector Cadcon (Pty) Ltd Steel Erector Avellini Brothers Cladding Manufacturer Safintra South Africa Cladding Supplier Safintra South Africa Cladding Contractor Browndeck Roofing Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor Photographer, Photo competition Kierran Allen Photography If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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SAB Office, Halfway Gardens MidrandThe SAB Billboard office is an innovative use of space directly next to a busy national road.The office structure is a modular steel frame building, accommodating for future expansion plans.By incorporating the billboard as a shading device the project team was able to achieve a constant temperature in the building. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Erf 1421, Halfway Gardens, EXT 17 Gauteng Google Maps link Project Team role Company Nominator Safintra South Africa Client/ Developer Architect Anstey Architects Structural Engineer Engineer Quantity Surveyor Project Manager Main Contractor C&S Projects Steelwork Contractor Ferro Eleganza Steel Erector Cladding Manufacturer Cladding Supplier SAFINTRA South Africa (Pty) Ltd Cladding Contractor Monro Sheeters If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding 30 / 09/ 2019 Cladding profile/ type used Saflok 700 Sea Spray Cladding area coverage 400M² Cladding tonnage 2 tons
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K+N Warehouse & OfficesThe 250 ton K&N warehouse structure is 124 meters long and 84 meters wide. The height of the high roof portion is 18 meters. The variation in roof height allows for well placed use of translucent sheeting, allowing natural light into the space. The variation also accommodates the client’s racking structure. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province ERF 1832; Green Close 3, JT Ross Plumbago Park, Witfontein Ext 54, Kempton Park, 1619, Gauteng. GPS Co-ordinates 26°04'16.0"S 28°16'32.8"E Google Maps link https://goo.gl/maps/CwKr6YbpxErGxp699 STRUCTURAL STEELWORK Completion date of steelwork June 2019 Completion date of full project August 2019 Tonnage and steel profiles used 250 tons UB and UC columns, Angle lattice trusses, IPE, UC and angle lattice girders, PFC gable rafters, Pre-galvanised CFLC purlins and girts, Angle and CHS bracing. If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Hella’s Automotive South AfricaThe new warehouse and offices for Hella Automotive serve as the gateway to Africa and helps to strengthen HELLA’s administration and logistics operations. The Architectural BriefThe curved design of the building and roof structure was derived and influenced by the Hella Automotive logo which consists of an oval shape and the word Hella written in the centre. The design, therefore, captures the shape through a seamless oval extrusion through the entire length of the building and the glass façade reveals centrally the activities within the building. The curved design of the building and roof structure required steel girder trusses that give the building its unique shape.The unconventional curved design proved to be both economical and supports Hella’s ethos of transcending the conventional. Because of the building’s location adjacent to the freeway and it being experienced by motorists at high speeds, it was an important design consideration to come up with a design that will be both eye-catching to the passer-by and simultaneously provide a pleasant working environment for the employees and promote the Hella Brand. Architecturally the building moves away from the post and lintel construction where the elements have connection points into a free-flowing structure that blurs the lines between wall and roof.Cladding Global Roofing Solutions rolled and cranking sheeting on site. Handling the entire length curved sheeting was challenging to hoist the curved full-length sheets onto the roof. The pictures truly emphasise the complexity which was successfully achieved. Global Roofing Solutions rolled and cranked the Klip-Lok 406 sheeting on site. Scaffolding had to be built approx. 6-meters into the air to accommodate the sheet length and curve herewith to roof and clad the building. Having GRS’s quality and technical teams on site to support the accuracy for this detail made it a success. Sheeting was hoisted up using cables and straps onto the roof for installation.ChallengesCurved, steel girder trusses that give the building its unique shape, but also carries all the load, demanded of the structural engineers to think out of the box. They produced a design and drawings for the manufacturing of these members – without which the building would not have been a success. These trusses were manufactured in a local factory in Uitenhage.How this project demonstrates the benefits of steel as a materialThe GRS Klip-Lok 406 concealed fix steel roof sheeting was rolled out in one length on site to accommodate the design of the building. Special care had to be taken from a Health and Safety point of view since both the plant and the handling of these great lengths can present challenges – especially during periods of high winds. How the project team worked togetherBNM has been involved with a number of industrial projects for the Coega Development Corporation before but this was BNM Architects - Andrew’s first building of this nature. The team consisted of BVI consulting engineers (for structural, civil, mechanical and electrical) and FWJK Quantity Surveyors. The success of the project can only be attributed to a closed working relationship amongst all the members of the team. Jacques van Zyl (BVI) was the Principal Agent. The design was well executed by a very capable contractor – WBHO Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 81 Nürburgring Street, SEZ, Port Elizabeth, 6100 Google Maps link https://goo.gl/maps/e5tUy6QdhwMmXhez5 Project Team Role Company Nominator Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Client/ Developer CDC Architect BNM Structural Engineer Bvi Engineer Bvi Quantity Surveyor FWJK Project Manager Bvi Main Contractor WBHO Steelwork Contractor Steel Erector Cladding Manufacturer Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Cladding Supplier Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Cladding Contractor Scheltema & co Corrosion Protection Bluescope Steel If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding 04/25/2019 Cladding profile/ type used Klip-Lok 406 with Curving Cladding area coverage 5000m2 (4000m2 roof + 1000m2 cladding) Cladding tonnage 31 tons
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SKFThe new SKF warehouse is a steel structure composed of girder, truss and tubular bracing systems. Metsec sections were used for the side cladding rails. The warehouse structure contains a 35 tonne overhead crane as well as a 10 tonne gable gantry crane. A key feature of the project is the tubular posts supporting the office slab, as well as the tubular louvre support system which wraps around the building. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Erf 487 6 Marlin Road, Jet Park, Boksburg, Gauteng Google Maps link https://goo.gl/maps/YRL9FLd8j5xzfKY28 STRUCTURAL STEELWORK Completion date of steelwork December 2019 Completion date of full project March 2020 Tonnage and steel profiles used 240 tons UB and UC columns, UB and angle lattice girders, Angle lattice trusses, SHS eave beams, Metsec purlins and girts, Angle and CHS bracing, Bent plate box gutters, IPE and UB gable rafters, UB and angle lattice crane beam columns, UB and PFC compound crane beams, CHS slab support columns, Tubular louvre supports. If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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EMS Head Quarters - Dora NginzaThis building, commissioned for use by the National Department of Health as their Emergency Medical Services Headquarters, houses a call centre and manages the dispatch of emergency paramedic response units within the Port Elizabeth area. The architect’s brief was to design a building that would aid in consolidating the EMS Headquarters into one centralised location and distribution point, as well as to bring an identity and civic presence to the EMS, reflecting the role that they play in society. The design, both structurally and aesthetically, makes use of a selected pallet of materials which contribute towards a clean, yet interesting architectural experience. In addition to the main building, the site incorporates covered parking areas for ambulances, parking for staff, a carwash, a helipad, and a helicopter hangar – constructed almost entirely out of steel. The main building is predominantly a concrete frame structure which makes use of some steel elements, bringing a lightness to the interior spaces. The main structural steel element is the roof structure, constructed from circular hollow steel sections and on display in the main entrance foyer, while steel columns are used to support the peripheral internal walkways. These are complemented internally by steel finishes, such as balustrading and cladding to the reception area.The structural framingSteel elements were used extensively for the façade features such as the shading louvre elements, decorative pergola elements, balustrades, and walkways – which are used both for maintenance and shading to floors below. In strategic places the roof eave rafters were also detailed as steel elements which are left exposed to tie in with the external aesthetic of the building, creating large, thin floating planes. The carport structures and helicopter hangar are constructed almost entirely of steel and clad to match the roofing of the main building. The hangar is a standard steel portal frame structure with purlins and cladding rails. CladdingThe sheeting selected for the project was the Zip-Tek 420 profile. This was not the original selection as it was initially intended to be a conventional Klip-Lok concealed fix system. This, however, would have resulted in jagged edges and valleys which would likely have caused problems in the future with water ingress and would have detracted from the elegant appeal of the curved building. The Zip-Tek 420 sheet can be tapered, which allowed for a seamless, elegant roof over the curved building, eliminating the risk of water leaks. With this specific profile being very wide and deep, with excellent water carrying capacity, the decision was made to use it for the entire project. The tapering of the roof sheeting is a detailed process, which consists of each sheet being drawn and cut individually. Each side of the sheet - both male and female ribs - had to also be rolled individually and not in one single process, as would have been the case with conventional sheeting. In order to make sure that this was a success, and to avoid complications on site, a point cloud survey was done after the roof trusses were installed, providing the sheeting supplier with the exact site geometry to work off. This aided in minimizing risk typically associated with both the manufacturing process of the purpose made sheets, and with the on-site installation.The tapering of the roof sheeting is a detailed process, which consists of each sheet being drawn and cut individually. Each side of the sheet - both male and female ribs - had to also be rolled individually and not in one single process, as would have been the case with conventional sheeting. In order to make sure that this was a success, and to avoid complications on site, a point cloud survey was done after the roof trusses were installed, providing the sheeting supplier with the exact site geometry to work off. This aided in minimizing risk typically associated with both the manufacturing process of the purpose made sheets, and with the on-site installation. What is special/ unusual/ innovative about the steelwork in this project?Curved roof – This unconventional design adds a monumentality to the building and without the innovative use of steel would not have been successfully achieved. Constant co-ordination within the project team and a forthcoming attitude from the contractor certainly aided in the successful implementation of this design element. How does this project demonstrate the benefit of steel as a materialDecorative steel – Steel is conventionally thought of as a structural material. In this case, its structural benefits were taken advantage of in order to design lightweight walkways and shading devices that added value to the aesthetic design of the building. Had these elements been designed using an alternative material, such as timber, the lightweight nature and economic efficiency would have been impossible to match. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Spondo Street New Brighton Port Elizabeth Eastern Cape Google Maps link https://maps.app.goo.gl/zHs49Zu4iwM8ZESX6 Project Team RoleCompanyNominatorGlobal Roofing Solutions - A division of Consolidated Steel Industries (Pty) LtdClient/ DeveloperDepartment of Roads and Public WorksArchitectImbono FJA ArchitectsStructural Engineer MottMacdonaldEngineer Quantity SurveyorSVP Quantity Surveyors and Project ManagersProject ManagerSVP Quantity Surveyors and Project ManagersMain ContractorTranstructSteelwork Contractor (Facades and Balustrades)Rizel Engineering ServicesSteelwork Contractor (Shading Louvres)Wild Dog EngineeringSteel Erector Cladding ManufacturerGlobal Roofing Solutions - A division of Consolidated Steel Industries (Pty) LtdCladding SupplierGlobal Roofing Solutions - A division of Consolidated Steel Industries (Pty) LtdCladding ContractorRV Smith PE If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding Cladding profile/ type used GRS Zip-Tek 420 Cladding Cladding area coverage 360m2 Cladding tonnage
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Corruseal New Offices and Warehouse , BoksburgCorruseal planned to build the new corrugated cardboard facility along similar lines to the facility it has in Cape Town. This Boksburg facility was planned to be a Phase 1 development with a view to adding to it at a later date. This initial phase of the factory was built on a greenfield site and would cover an area of over 41 000m2 excluding the gatehouse. The factory required large minimally obstructed spaces to accommodate the production lines and to move materials. It was decided to have columns on a grid spacing of 25 x 13.5 metres throughout. The minimum clear height on the eaves of the production area was set at 9.0 metres. The clients brief included for 1.5 metre high roof monitors to incorporate translucent sheeting and smoke ventilation. Roof loading was required to support a future PV installation.Why steel?The project had a fast track construction program of some 6 months so the choice of a structural steel warehouse frame was the obvious choice. The detail of the roof configuration and type of columns was dictated by construction time pressures and practical constructability considerations. A brief description of the structural framingThe main elements included 25 metre span trusses (or rafters) at 6.75 metre centres which were supported on girders spanning 13.5 metres. The internal footprint of the factory extended some 121 x 175 metres with no obstructing bracing in the production floor areas. All bracing was thus to be located in the perimeter walls. The lower portion of the perimeter walls were to have precast RC panels (varying between 1.5m and 2.1m high) with cladding above the precast walls to the eaves. Alternating translucent cladding strips were included in the vertical walls to suit the architects’ requirements. The design of the 25 meter spanning elements compared lattice trusses versus cellular beam rafters. These elements also had to be fabricated with a 500 metre “top chord” radius to suit the roof profile. The trusses designed with a 1.5m depth (with continuity over the girder supports) proved to be a significantly more economical design. The trusses were designed with parallel chords and lacing. Sections selected were all various sizes of hot-rolled angles with gusset plates at node connections. The 500m radiused chord was easily achieved in this form. Cold formed lipped channel purlins at 1.562m centres were required to support the sprung effect of the curved roof cladding. The truss bottom chord was braced with hot rolled angle knee braces bolted to the purlins. The roof monitors stand 1.5 meters high x 6.75 metres wide (truss to truss). This sub-frame was constructed out of cold formed lipped channel sections (175 x 75 x 20 x 2.5) with knee bracing off the truss to control wind loading on the monitor. The 13.5 metre spanning x 1.5 metre deep girders supporting every alternate truss were designed with hot-rolled channel sections on the top and bottom chords and hot rolled angles for the lacing. The selection of channel sections (with flat face horizontal) provided an efficient compression strut without requiring addition lateral bracing. The lacing was connected to the channels with welded gusset plates located on the channel centre line. The girders were designed to be continuous over the supports thus providing further economy of section weight. Fabrication and erection The main challenge on this project was the program. In order to meet the required delivery dates the footprint of the roof structure was divided into a number of zones that matched the sequence that the structure was to be erected in and allowed for the envelope of the building to be closed in a phased manner. This ensured that all the steelwork in each zone was fabricated ready for delivery when required which allowed the installation to be completed and handed over for sheeting early in the program. The erection process was also carefully looked at so as to pre-assemble as much of the steelwork onto the roof trusses at ground level before hoisting so as to minimise the installation of the smalls in the air which is always time consuming. This method of construction thus allowed the follow-on contractors access to the enclosed structure at an early stage in the construction and enabled the savings on the program to be maximised. Cladding The roof sheets were rolled directly onto the roof using a scaffold tower ramp and due to their length required the attendance of a large number of workmen to handle the sheets. To control the effect of thermal expansion / contraction, the 175m roof cladding length was divided into thirds with the upstream sheet riding over the downstream sheet with a double purlin detail as advised by the cladding specialist sub-contractor. The skylight roofs however have full length sheets 150m. long which was also decided by the cladding specialist sub-contractor.How the project team worked togetherThis project was built with such speed and efficiency that it required a team of professionals, contractors and specialist subcontractors who had experience with similar projects. This experience is critical in order to plan and execute all the activities to merge towards the phased completion dates of the different component parts of the project. The 3D structural shop drawings were very professionally undertaken by an experienced and dedicated operator. This set the critical structural steel component of the project onto a winning footing. How this project demonstrates the benefits of steelThe building of a roof structure of this size in the time that was allowed could have only been done in steel and shows that steel is the material of choice when it comes to factory and warehouse roofs. A curved roof of this size is really impressive when viewed from the outside and is a testament to what can be achieved with steelwork when suitable planning is employed. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Cnr. Atlas & Commissioner Roads , Boksburg. Google Maps link STRUCTURAL STEELWORK Completion date of steelwork September 2019 Completion date of full project December 2019 Tonnage and steel profiles used 820 ton : Hot rolled columns , beams , angles , tubes , Cold rolled purlins & girts. Project Team Role Company Nominator TASS Engineering P/L Client/ Developer Corruseal Group Architect ZAARC Structural Engineer Kantey & Templer Engineer Kantey & Templer Quantity Surveyor Corruseal Group Project Manager Corruseal Group Main Contractor Abbeydale Construction Steelwork Contractor TASS Engineering P/L Steel Erector THLN Construction Cladding Manufacturer SAFAL Steel Cladding Supplier SAFINTRA South Africa (Pty) Ltd Cladding Contractor Tate & Nicholson Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor DRAM Industrial Painters Photographer, Photo competition Peter Hassall Photography If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding October 2019 Cladding profile/ type used Roof : Saflok Zincal AZ150 / Sides : Widedek Colorplus AZ150 Cladding area coverage Roof : 42,000m2 , Sides : 10,000m2
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PX5 Warehouse Conveyors StructuresThe PX5 Warehouse and conveyor structures project entailed the construction of fertilizer storage and distribution building. The building consists of concrete bases and retaining walls with a structural frame comprised of castellated sections. Due to the very onerous nature of fertilizer on the corrosion protection, as well as the adverse effect of fertilizer to galvanizing, the team was forced to use a very onerous paint specification. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province South Coast Road, Rossburgh, Durban Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 30/8/2019 Completion date of full project 10/10/2019 Tons of structural steel used 2,500 Tons Structural profiles used Combination of Rolled Profiles and Tubular If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Johannesburg Development Agency - Bus Rapid Transport Stations (JDA - BRT)The Bus Rapid Transport Stations for the Rea Via is an architecturally pleasing steel structure, designed as a steel structure with glass facades. Structural Framing The project makes use of a wide variety of steel sections. The Columns are shaped plate girder sections, sloping or leaning over. The rafters are Tee-Section rafters cut from I beam sections. Also shaped from wider to thinner at the furthest point. These are hanging from CHS hangers. With CFLC sections as purlins to receive the sheeting. The Façade steelwork is a complex design, with a curved CHS pipe rolled on the two ends creating and oval façade to receive the glass. Welded to this top cord of the pipe are plate support brackets which support a large CFLC which acts a support to all the information boards that are required inside the station. This entire façade sits on shaped plate brackets which are fixed to the concrete floor. Challenges There were definitely many challenges in both fabrication and erection of these structures. The final product looks lovely but there many technical issues that needed to be overcome to be able to achieve this finished product. Fabrication As all the steel is exposed all welding on the shaped plate girder columns had to be done to the greatest of care. To achieve an aesthetically pleasing finish. The splitting of the Tee-Section rafters causes distortion to the sections. Which needed to be straightened before fabrication could proceed. The façade steelwork pipe and support brackets had to be fabricated to the greatest of accuracy. If the brackets were out by just a few millimetres the effect on the straightness of the CFLC would become very noticeable. Erection The design of this structure required very precise and accurate erection procedures. Which needed to be adhered to from the very first part. And that would be placing the columns on the HD bolts. The sloping columns receive all the steelwork, and the interface between the final façade steelwork and the concrete interface is of the utmost importance. So these columns needed to be erected at exactly the correct level, and at exactly the correct slope. This was done and confirmed by using an electronic slope spirit level. The roof rafters, purlins and hangers were fairly straight forward to erect. Much time went into installing the façade steelwork. This curved pipe structure then bolted between the sloping columns. Which spacing had to be exact otherwise these pipes would not fit. The levels of this façade pipe could only be adjusted by the levels of the columns. Once the top pipe was perfectly aligned the bottom pipe could be installed onto the concrete floor. The shaped brackets below the bottom façade pipe had ten to be measured on-site and be fabricated to ensure the perfect interface between the concrete floor and the bottom pipe. No large grouting was accepted by the architect. Apart from the technical aspects mentioned above. These stations needed to be erected in the middle of the most busy JHB streets. Only the island which became the “site” was cordoned off. So space was very limited. This was accomplished by using small spider cranes, and bringing the steel to site in the correct sequence as required by the erectors. How this project demonstrates the benefits of steelAccomplishing what was required by the architect, the look, constructability and finish would only have been done by using steel. How did the project team work together? As this design was so complex, there was good communication required between Concrete and steel contractors. Surveys of concrete was done before workshop drawings were completed. Between steel and glass contractors, many hours of our teams working together to make sure all the details work. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 249-253 M11, Orange Grove Johannesburg Gauteng Google Maps link https://goo.gl/maps/wgJKWXPCDL14HBrQ9 STRUCTURAL STEELWORK Completion date of steelwork Currently Still Busy Completion date of full project 2021 Tonnage and steel profiles used 360t – Cold Formed and Tubular Project Team RoleCompanyNominatorFerro Eleganza (Pty) LtdClient/ DeveloperJDAArchitectDeltaStructural Engineer WSP Group Africa (Pty) LtdEngineer Quantity Surveyor (PQS)AecomProject Manager/Principal AgentAOSMain ContractorStefanutti Stocks A Re Shomeng JVSteelwork ContractorFerro Eleganza (Pty) LtdSteel ErectorFerro Eleganza (Pty) LtdCladding Manufacturer Cladding Supplier Cladding ContractorDoublejack Construction (Pty) LtdCorrosion Protection Galvanising Corrosion Protection Paintwork ContractorDram Industrial PaintingPhotographer, Photo competitionFerro Eleganza (Pty) Ltd If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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The Engineering 4.0 building houses the University of PretoriaThe new Engineering 4.0 facility was established and beacons the collaborative effort between SANRAL, University of Pretoria and CSIR. The facility is prominently positioned on University of Pretoria grounds next to the N2 and N4 intersection. The brief was to accommodate the SANRAL National Road materials Reference Laboratory, SANRAL Training laboratory, and Accelerated Pavement Testing facility, an Active traffic track and an upgraded Concrete research laboratory. Together with the laboratories, the brief required a foyer reception with social and collaborative teaching spaces. The facility was designed with future phases and a masterplan in mind, securing an expandable and adaptable facility to accommodate future Civil Engineering disciplines and related partnerships. Structural FramingThe new Engineering 4.0 facility required a simplified structure to house a complex programme. The concrete and steel shell of the structure was used to create large expanses of open workspace. These spans allow the options for adaptable internal spaces to safeguard the ever-changing nature of technology and methods in the transportation engineering industry. Steel columns were used on the ends of the elongated structure with appropriate cladding selections. The east of the facility is made up of steel columns and metal sheeting, which allows easy removal in the event of future expansion. This option was an essential to unlocking the expansion of the laboratory facility and together with the extension of the overhead crane. The 20m spanning overhead crane will continue along the entire length of the laboratories. The dividing fire wall between the Concrete research facility and the SANRAL National Road materials Reference Laboratory is constructed from steel columns supporting 4x 7850x4800mm size concrete Tilt-up panels. The foyer area of the facility is made up of a linear grid that intersects a radial grid, determined through a dense existing forest area. The H sections emphasise the rotation of each column along the radial walkway. I-beams were used as the horizontal elements create a continuity in the vertical and horizontal elements and the connections between the two. The H and I elements create a frame for a glass foyer which creates a tectonic environment with a relationship between the interior spaces and the surrounding environment. Impressive technical aspects The project overall had several technical innovative elements. The soil conditions of the site had its own challenges. Every column footing had to be over excavated by +-2,5m and filled with soil Crete to stabilise the soil. The laboratory and storage walls and roofs are constructed with concrete Tilt-up system. This is a system where concrete panels are cast flat onsite and lift into positions with a crane. Position of stack casting and crane positions are all planned. The biggest wall panel onsite is an 11 350(h) x 7 490(w) x 150mm thick panel. Specialised laser floor for the laboratory that was designed by a specialist sub-contractor with high tolerances and hardness. A 900mm thick “strong floor” with M30 x 100 long rebar couplers on a 500x500 grid is installed, with a detail to demonstrate the construction build-up as a teaching tool. Water harvesting methods have been implemented. Rainwater catchment through roof areas and stormwater design assist in filling the retention pond. Irrigation water is stored in 3x 10 000l JoJo tanks, filled from the retention pond with a borehole top-up. Solar PV panels have been earmarked to be installed soon, and at the start of the project, the areas had to be identified that the structural loads could we designed accordingly. How does this project demonstrate the benefits of steel as a material? Steel is often used as a tectonic element due to its slender appearance compared other structural materials. The project uses exposed structural steel elements in expressing architectural design lines and enhances the visual effect through using colour harmoniously with its adjacent materials and surroundings. What is special/ unusual/ innovative/ aesthetic about the steelwork in this project? The building as an educational facility was considered as a training and teaching product. The workmanship of this project was essential due to its visibility to public visitors, students and professionals in the field that would visit the facility and experience the building daily. The aim was to deliver a “product”/project of good quality, that it can be used as a training and teaching tool. There are many instances where exposed structural elements and fixings were considered and made visible How did the project team work together? The architect and the consulting engineer worked on a regular basis in the design process of the project. The sub-contractor was responsible for connection detailing and the ideal would have been to have them onboard at an earlier stage to iron out minor detailing of connections. None the less, the team managed to work together in short period of time. Splicing details, cross bracing, column, and beam connections were all specially looked at. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province University of Pretoria Private Bag x 20 Hatfield 0028 https://www.up.ac.za/eng4 Google Maps link https://goo.gl/maps/n2HRwYU3sQHU1DXQ8 STRUCTURAL STEELWORK Completion date of steelwork January 2020 Completion date of full project March 2020 Tonnage and steel profiles used 230 Tonnes - standard HR sections Project Team Role Company Nominator Central Welding Works Client/ Developer University of Pretoria Architect ARC Architects Structural Engineer Aurecon Engineer Aurecon Quantity Surveyor Gro2 Consulting Project Manager University of Pretoria Main Contractor WBHO Steelwork Contractor Central Welding Works Steel Erector Central Welding Works Cladding Manufacturer Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Cladding Supplier Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Cladding Contractor Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Paintwork Contractor Dram Industrial Painters Structural Steel Detailer KRU Detailing Nomination Document Submission KRU Detailing If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Constantia EmporiumConstantia Emporium is a contemporary convenience and lifestyle centre located in the leafy suburb of Constantia, Cape Town. Located on a land restitution site, it is envisaged that the new retail centre will act as a catalyst for further development on the remaining restitution sites. The centre is anchored by a flagship Checkers, Woolworths, Clicks, two eateries and offices. The ground floor accommodates the upmarket line shops, anchor tenants and eateries, whilst the offices are located on the upper level. The architectural design was in response to the rural wine making surrounds and rich history of the site, the practical and honest nature of farm shed design was deemed a fitting inspiration for the contemporary architectural language of the project. This dressed-down and hard-wearing architectural style celebrates familiar rural homestead forms and incorporates a layering of materials including off-shutter concrete, steel, glass, slatted timber and profiled steel sheet cladding. The use of exposed steel features plays a pivotal role in achieving the design aesthetic and forms the basis of nearly all the design elements used to complete the project.A brief description of the structural framing The Anchor tenant roof consists of a complex combination system of trusses and girders, which covers more than 3300 square metres. The steel trusses and girders are made up of angle iron members. The truss and girder system was the best design option for this steel structure, due to the large spans and restrictions on the number of supporting H-columns in the trading floor below. The main roof comprises of 3 raised sections with ‘valleys’ separating them. This proved to be a challenge as a conventional truss and girder system could not be used. Instead of connecting in the same plane, the girders were lowered with trusses connecting above it, which makes the structure quite unique. Portions of the roof intersect with and wrap down the large wall, breaking up the elevation along the M3 highway. The line shop roofs comprise of steel portal frames or rafters. The feature trusses of the main barn roof over the central eatery brings interest and character to the dramatic double volume space. Six pairs of custom-designed crisscross rectangular hollow section (RHS) trusses converge at the roof apex in an elegant bolted plate connection. This is complimented with solid timber cladding, elegant tension cable detailing and delicate dropped ceilings which follow the form of the trusses. There were numerous special steel elements in the project ranging from exposed steel canopies to timber clad portal structures as well as a suspended steel bridge and the steel/ glass lift structure. The suspended steel bridge inside the mall is a powerful example of the ability of steel to produce a captivating floating effect. The bridge structure connects the lift shaft structure to the first-floor level. The design intent was to achieve a floating walkway structure with minimal support. The bridge structure consists of a beam and joist system cantilevered from the support columns and suspended from the roof slab above with steel hangers. The challenge here was the extreme detail and accuracy required during construction and assembly. Intensive detailing was required to incorporate the steel handrails along the edge of the walkway The glass lift shaft is the central feature of the mall. The glazed exterior exposes a carefully detailed internal framework of structural steel H-sections which bring interest to the internal mall space. There was some difficulty in its assembly and erection as the columns in some instances were double volume with lengths of more than 8.0m. Much of the character of the building is derived from carefully proportioned exposed H-section portals married with finely detailed timber beams and slats. The steelwork was carefully coordinated with the timber with predrilled sections and pre-welded plates. Cladding rails and cladding structures needed to be provided too extreme accuracy and steel angle rails were the most suitable material in terms of durability and strength. The result is understated elegance and sophistication. The elegant double-height structural steel canopy is the main feature of the entrance façade. Topped with aluminium slats for solar control, the minimalist steel C-section framework cantilevers generously over slender circular steel columns with expressed bolted connections. Stainless steel planter cables reach high up to the frame from the sumptuous planters below and were carefully coordinated to avoid on-site drilling or welding. This feature sets the sophisticated, understated tone of the building. The lower main entrance canopy continues the theme by combining exposed suspended H-section framework with finely detailed timber slats and timber sub-structure.A brief description of the cladding process Safintra Saflok 700 was used to clad the roofs and large portions of the facades. The architects colour palette included black, concrete greys and timber. They, therefore, wanted a roof sheeting that was black with no undertone of blue-grey and selected unique finish Colourplus Textured in the colour: Smokey Grey. The textured finish did make handling of the product more complex to avoid scratches and damage during installation. The architects required special flashing details to provide a crisp edge to the roof. The architects also specified that all ribs to the roof sheet were to line up with the ribs to the vertical cladding to create the appearance that the roof wrapped down onto the facades.Engineering, fabrication and erectionThe erection of almost all of the steel elements was challenging due to the high level of precision required. All steel was fabricated in Durban and then delivered to Cape Town for erection. The project had an extremely tight project deadline and there was no time for errors and rework. In some cases, a surveyor had to be called out to assist with the setting out of the high-level steelwork. The holding down bolts, bridge hanger connections were cast into columns, beams or slabs leaving no room for error. The feature steel trusses over the central eatery were erected with a spider crane that had to be brought up from Durban. The crane had to stand on the suspended ground floor slab and the coordination of the loading with the structural engineer was complex. This suspension bridge connected the lift shaft with the ablutions and 3 separate office spaces all located on separate portions of slabs cast at different stages of the project, extreme accuracy was required to ensure all the floor levels tied up within the required tolerances. The project required an exceptionally high-quality finish. The majority of the steelwork was used to create the buildings design features. The steelwork, therefore, needed to be precise not only in its fabrication but also erection.Impressive technical aspectsThe project successfully demonstrates how steel can be used in conjunction with other materials such as timber and glass to create slick, contemporary design features. The most challenging or appealing use of structural steelwork was the “spider truss-rafters” in the Line Shops Roof 1. These connections at the eaves and apex were more architectural, with more aesthetically pleasing end connections. Furthermore, the marriage between steel and timber is well displayed in this roof by the timber cladding of the rafters. Forming the “spider truss-rafters”, with the use of RHS 250 x 100, shaped fin plates, uc-sections, stainless steel cables and CHS buckle, was quite innovative. It was further complimentary/unique in that the trusses did not span the structure conventionally, but rather straddled across the ring beams like a “steel spider” armoured in timberHow the project team worked togetherThe sub-contractor produced very detailed IFC models of the steel elements before they proceeded with the detailed shop drawings. This allowed the engineers to visually inspect the models to ensure compliance with the design intent and issue relevant comments early on to avoid any abortive work in the production of the shop drawings. The architects were also able to load these models into the Revit model to check the steel design as well as incorporate accurate steelwork in their drawings and details. How this project demonstrates the benefit of steel as a material The project uses a variety of steel members and sizes in different configurations to achieve the architectural design features. The clean lines and bold visual impact of steelwork make it compelling to expose and showcase. Superb compatibility with the use of timber. Further project/construction benefits ticking all the boxes in terms of speed of installation on site (after components are fabricated off-site), speedy adjustments on-site and the inherent strength of steel allowing it to be far more slender than alternative materials. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 55 Ladies Mile Road Constantia Cape Town Western Cape Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 29 September 2019 Completion date of full project 26 November 2019 Tonnage and steel profiles used Steel Columns & Beams – 44,640 t · 150 x 150 x 4.5mm x 20.64kg/m Square hollow section columns · 152.4 x 4.0mm x 14.64kg/m Circular hollow section columns · 152 x 152mm x 23kg/m H-section columns · 03 x 203mm x 46.10kg/m H-section columns · 305 x 305mm x 97kg/m H-section columns · 160 x 80 x 4.5mm x 16.4kg/m Rectangular hollow section beams · 203 x 133mm x 25.1kg/m I-section beams · 250 x 100 x 4.5mm x 23.8kg/m Rectangular hollow section beams · 300 x 140 x 6.0mm x 39.5kg/m Rectangular hollow section beams · PFC 200 x 75mm x 24.3kg/m beams · PFC 230 x 90mm x 32.2kg/m beams · 150 x 150 x 8.0mm x 36kg/m Square hollow section columns · 200 x 200 x 6.0mm x 35.82kg/m Square hollow section columns · 254 x 254mm x 73.10kg/m H-section columns · 127 x 6.0mm x 17.90kg/m Circular hollow section columns · 203 x 203mm x 52kg/m H-section beams · PFC 200 x 75mm x 24.3kg/m beam · IPE 160 x 82mm x 15.8kg/m I-section columns · IPE 160 x 82mm x 15.8kg/m I-section beams · PFC 180 x 70mm x 21.1kg/m beams · 50 x 50 x 4.5mm x 6.548kg/m Square hollow section columns · 203 x 133mm x 25.1kg/m I-section beams Steel purlins, girts, bracing – 63,490 t · Round hollow section bracing · 150 x 50 x 20 x 2,5mm Thick cold-formed lipped channel purlins · 150 x 75 x 25 x 2,5mm Thick cold-formed lipped channel purlins · 200 x 75 x 20 x 2.5mm Thick cold-formed lipped channel purlins · Welded bracing, anti-sag rails, etc with flat connection plates, bolted to steel · 100 x 50 x 20 x 2,5mm Thick cold-formed lipped channel bulkhead supports Steel Trusses – 69,090 t · Lattice steel roof trusses of angle rafters, tie beams, rails, struts, braces, cleats, etc and flat bearer, gusset and connection plates, bolted to steel · Lattice steel roof girders of steel angle rafters, tie beams, rails, struts, braces, cleats, etc and flat bearer, gusset and connection plates, bolted to steel Steel Rafters – 2,830 t · 24mm x 3.55kg/m Solid round truss ties · 203 x 133mm x 25kg/m I-section rafters · 250 x 100 x 6.0mm x 31.53kg/m Rectangular hollow section rafters · 254 x 146mm x 31kg/m I-section rafters · 305 x 165mm x 40kg/m I-section rafters · IPE 100 x 55mm x 8.1kg/m I-section rafters · PFC 180 x 70mm x 21.1kg/m Parallel flanged channel rafters · 254 x 146mm x 31kg/m I-section rafters · 254 x 254mm x 73kg/m I-section rafters Steel Gutters & RWDP – 11,090 t · Box gutters 400 / 450 / 500 / 600 / 800mm girth, four times bent along length including necessary collared and sealed expansion joints · 75mm Internal diameter pipes · 10mm Internal diameter pipes · 150mm Internal diameter pipes · 200mm Internal diameter pipes TOTAL TONNAGE = 192,280 t CLADDING (If applicable) Completion date of cladding 17 November 2019 Cladding profile/ type used Roof & Side Cladding: Safintra Saflok 700 – 0.53mm thick Colorplus Textured colour: Smokey Grey Cladding area coverage Roof Cladding: 5842 sqm Side Cladding: 1703 sqmTotal: 7545 sqm Cladding tonnage Roof Cladding: 32,13 sqm Side Cladding: 9,37sqmTotal: 41,50 sqm Project Team Role Company Nominator SAFINTRA South Africa (Pty) Ltd Client/ Developer Shoprite Checkers (Pty)Ltd Architect SVA International (Pty)Ltd Structural Engineer DVP INC Consulting Engineers Engineer DVP INC Consulting Engineers Quantity Surveyor AECOM (Pty)Ltd Project Manager Main Contractor WBHO Construction (Pty) Ltd Steelwork Contractor Churchyard & Umpleby Construction (Pty) Ltd Steel Erector Churchyard & Umpleby Construction (Pty) Ltd Corrosion Protection Churchyard & Umpleby Construction (Pty) Ltd Galvanising Churchyard & Umpleby Construction (Pty) Ltd Paintwork Contractor MRH Blasting & Coatings (PTY) LTD Cladding Manufacturer SAFINTRA South Africa (Pty) Ltd Cladding Supplier SAFINTRA South Africa (Pty) Ltd Cladding Contractor Scheltema & Co (Pty) Ltd Corrosion Protection Scheltema & Co (Pty) Ltd If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Deli SpicesThe purpose of the Deli Spices project was to create a first of its kind food lab/ innovation centre and office suite.The brief called for an extensive revamp to an existing Industrial space and to transform it into a completely functional Innovation Centre. Steel played a pivotal role in achieving the outcomes that the professional team envisioned from the onset. Columns - Girders - trusses and purlins rails form part of the subframe. ChallengesTying the new steel framing into the existing steel structure. The outer framing required a sequence for installation which meant every panel had to be numbered before the installation commenced. Impressive technical aspectsThe existing material framing was steel and the use of added steel framing allowed the project to connect old and new structural elements in a quick and seamless mannerHow the project demonstrates the benefits of steelThe existing material framing was steel and the use of added steel framing allowed the project to connect old and new structural elements in a quick and seamless manner. The steelwork is an integral part of the aesthetic especially the visible draped screen which playfully accentuates a wave pattern throughout. It is visibly impressive and functional in that it allows for filtered light to permeate into office spaces. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected PROJECT OVERVIEW Physical address of the project Street Address Town Province 10 Bertie Avenue, Epping Industria Google Maps link STRUCTURAL STEELWORK Completion date of steelwork December 2019 Completion date of full project March 2020 Tonnage and steel profiles used Project Team Role Company Nominator SAFINTRA South Africa (Pty) Ltd Client/ Developer Deli Spices Architect Paul Matthews Architects Structural Engineer Moroff & Khuhne Engineers Engineer Quantity Surveyor PBNS QS Project Manager Main Contractor Isipani Construction Steelwork Contractor Anchor Projects Steel Erector Cladding Manufacturer SAFINTRA South Africa (Pty) Ltd Cladding Supplier Cladding Contractor Cladco Roofing CLADDING (If applicable) Completion date of cladding January 2020 Cladding profile/ type used Safintra Saflok 700 Cladding area coverage 2100 m2 Cladding tonnage 11.151 tons If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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House O’ ConnorThe design of House OConnor had to make the best of the incredible views of the Southern face of Table Mountain. Further to this, the brief was to create a striking, avante-garde yet homely space with a large open-plan living / dining / kitchen. The architects also wanted to create a seamless link between the indoors and the outdoors. The use of steel was important from the word “go” as it is the only way the architects and engineers could achieve the large openings and uninterrupted spans necessary to achieve the vision. The project team worked very well together to solve some complex structural challenges, most of which were made possible with the use of structural steel. This is most evident in the large open plan space, the glass and steel “forest link” structure, the floating concrete roof over the entrance hall as well as in the mono-pitch roof structures which interrupt the main “flat” roofs of the house. The living space is striking in the sense that there are no columns or supports interrupting the space even though one of the mono-pitch roof structures is placed at an angle over the space. These mono-pitch structures comprise steel portal frames with bamboo cladding on the inside and SAFLOK 700 cladding on the outside. The north-facing sections are glazed to frame views of the mountain from deep within the house and also to let winter sun into spaces which would otherwise be cold and dark. One of the corners of the main mono-pitch roof over the living room is supported on a large steel I-beam. This was the only viable solution to this problem as concrete beam would have had a depth of almost 1m to do the same job and this would have interrupted the view! This same steel beam was essential in order to create an open corner between two large sliding doors from the lounge and dining room. Where one would normally have a column on this corner, the architect and engineer were able to omit this due to the use of steel; when the doors are open there is a complete free-flow of space and uninterrupted views. The use of steel enabled the architect to create a walkway (the “forest link”) from the living wing to the bedroom wing of the house. There are no structural supports along this walkway, which creates the feeling of walking outside through the garden, though one is still in the house. Another notable feature of the house is the floating concrete roof over the entrance hall. The use of slim steel posts made it possible to support the roof in such a way that it appears to float above the walls. The gap between the walls and the slab is glazed which means that the underside of the slab is washed with light reflected off the surrounding roofs during the day and with light from strip lighting at night. Other than these striking architectural features, the use of steel hollow sections for columns and beams made it possible to have large windows and an uninterrupted pergola structure at the outdoor entertainment area. A steel walkway structure with a bamboo ceiling greets one as you arrive at the house and leads you to the front door, making steel the main element of the first impression of house Oconnor. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 20 GEMINI WAY, CONSTANTIA, CAPE TOWN Google Maps link STRUCTURAL STEELWORK Completion date of steelwork JUNE 2019 Completion date of full project OCTOBER 2019 Tonnage and steel profiles used ……….TON. 100X100X4 SHS 120X120X4 SHS 120X120X5 SHS 203X133X25 RHS 76X76X4 SHS 160X80X5 RHS 200X100X8 RHS IPE 180’s 457X191X98 I-BEAMS 175X74X2 LIPPED CHANNEL 125X50X20X2.5 LIPPED CHANNEL Project Team Role Company Nominator Safintra Client/ Developer PRIVATE Architect JOE DE VILLIERS architects Structural Engineer GENI consulting engineers Engineer Quantity Surveyor Project Manager JOE DE VILLIERS architects Main Contractor ACCURA construction solutions Steelwork Contractor ACCURA construction solutions Steel Erector ACCURA construction solutions Cladding Manufacturer Cladding Supplier YOUNGMAN ROOFING Cladding Contractor ACCURA construction solutions Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor ACCURA construction solutions Photographer, Photo competition CLADDING (If applicable) Completion date of cladding OCTOBER 2019 Cladding profile/ type used SAFLOK 700 Cladding area coverage 360m2 including roof If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Pods at Dwarsberg Trout HideawayDwarsberg Trout hideaway brief the architect to design pod units for a vacant portion of the farm to be used as guest accommodation. The client initially requested to make use of shipping containers to form the structure. The architect underwent a process of investigating repurposing shipping containers but due to the limitation in design, challenges with transport and the complexity of building with containers, it was suggested working with light steel. The client’s inspiration from shipping containers was used to inform the cladding of the structure and the dark grey charcoal colour was chosen to allow the units to fade in the landscape. The light steel frame allowed for more freedom in design, construction was simplified since only a few skilled labourers are necessary and the time on site was reduced. The lightweight steel frame was used to form the structure as this was easy to design off site and assemble on site. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province FARM 1/794, DWARSBERG, WORCESTER GPS Co-ordinates Dwarsberg Farm 33°47'16.6"S 19°19'47.5"E, Rawsonville, 6845 Project Team Role Company Nominator Safintra Client/ Developer Dwarsberg Trout Hideaway Architect ModH Design Structural Engineer Frame group Engineer Quantity Surveyor Project Manager Spaas Main Contractor Steelwork Contractor Steel Erector Cladding Manufacturer Cladding Supplier Cladding Contractor Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor Photographer, Photo competition Peartree CLADDING (If applicable) Completion date of cladding July 2019 Cladding profile/ type used Corrugated sheeting Cladding area coverage External walls & roof. If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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New Barloworld and Caterpillar Head Office and ShowroomThe new Barloworld and Caterpillar head office and showroom in Isando. is dedicated to heavy earthmoving equipment. The development consists of a head office, world-class showroom and new training campus.The showroom alone is a first-of-a-kind in the country and is split into two zones, namely “tyre” and “track” product categories, with both open and enclosed areas. Emmy Leeka, CEO of Barloworld Equipment, said the project was conceptualised as a series of iconic buildings nestled in an indigenous landscape, with the showroom facing the R24 highway for maximum exposure. Features of the new buildingThe head office, comprising two elongated buildings, are linked by an enclosed glazed bridge.Its design encompasses flush-glazed strip windows. The prevalence of glass in both buildings ensures maximum sunlight because of their north-facing orientation. This minimises the need for artificial heating and lighting.Both the head office and showroom roof structures were designed to cater for photovoltaic panels.The most immediately noticeable feature of the new showroom structure is its elongated front-facing bubble profile, inspired by the curved shape of the Caterpillar excavator tread. Not only is this an iconic visual tribute to the legendary earthmoving equipment showcased within, but it also allows this huge machinery to be comfortably exhibited in the voluminous interior space this design creates. Couple this with a vast glass façade, which makes the interior exhibit perfect visibility of the busy R24 highway, and this becomes far more than a cutting-edge combination of corporate head office and flagship showroom. How can such huge apparatus easily enter or be extracted from this space? The building claims a never-been-done-before international breakthrough with a staggering 8.8m x 5.5m piece of the prominent glass frontage being fully retractable via intricate motor-driven automation. The architectural briefFittingly, Barloworld Equipment’s impressive new head office and Caterpillar equipment showroom in Isando breaks new ground. It was a monumental brief – Barloworld Equipment, dealer for iconic Caterpillar earthmoving equipment, was leaving Sandton and wanted a state-of-the art head office on the R24 at Isando that reflected their corporate identity and accommodated staff in comfort. But beyond that, they wanted the development to include a flagship Caterpillar showroom for their equipment – excavators loaders, dozers and graders that build the nation’s roads, dams, harbours and airports, and are usually too big to accommodate indoors except in barnlike servicing warehouses out of the spotlight. ‘This is the first showroom in the country dedicated to heavy earthmoving equipment,’ says Aashen Lalloo, development manager at Eris Property Group. ‘The brief to Paragon Architects was to balance iconic design with functional aesthetics while maintaining a cost-effective solution.’ Paragon, of course, were up for the challenge – the design power behind some of the most advanced buildings in the country, they relish pushing the envelope architecturally and technically, reaping awards with the likes of Sasol Place, Alice Lane and 140 West. Their approach to Barloworld Equipment was both simple and singular. ‘Who hasn’t played with toy earthmovers as a kid?’ says David Cloete, the architectural technician Project Leader for the project. ‘We wanted to hero the equipment, and it may sound corny, but some of the best ideas came when we bought a set and played with them while brainstorming.’ They began with what has become a Paragon signature: the two-tower building linked by an atrium and brought it down to earth to conform to the height restrictions of a site close to OR Tambo International. The result was two long, low structures – one three storeys, for the showroom, the other two storeys, for offices. Then taking inspiration from the circular tracks of a classic Caterpillar earthmover, they turned them into what Cloete calls ‘two bubble shapes’ – striking, glass-walled edifices, floating on a low podium above a semi-basement parking level, and linked by an enclosed glazed glass bridge, covering 4500m² all told. The 3200m² showroom bubble was built to face directly on the busy R24 – creating the ultimate traffic stopper, commanding immediate attention with its striking shape and the machinery that inspired it displayed inside in two sections, one for track Caterpillars, the other for those with tyres. Beyond this, just that glass corridor away, lie the company headquarters: two floors of flexible open-plan office space with sophisticated floor-to- ceiling flush-glazed windows. It was an ingenious solution, but hard won. The challenges began with the very earth the structures stand on, which is the clay variety and notoriously unsteady, especially after torrential Gauteng rains. ‘Not ideal for building foundations,’ as Cloete says. ‘For a high-rise like most of our projects, you need to dig deep, but because we were only going up three story’s, we dug just three meters below the surface and laid man-made sub-surface to compact the soil beneath a raft foundation. It needed to support all that Caterpillar equipment, and the biggest pieces weigh up to 60 tons.’ Next challenge was the dimensions of the showroom, and how to move the equipment in and out. ‘It requires massive clearance in height as well as width to turn one of these mammoths.’ Paragon took for its starting point the roller shutters used to access the Caterpillar servicing warehouses. ‘But we wanted to use glass, not metal.’ So in what they believe is a world first, they elected to vertically slide a 8.4m by 5.5m section of the high-performance glass frontage upwards, using a complex motor system installed upstairs and hung from a structural beam. The challenges did not end there. Architecturally, the only straight feature in the bubble structures is their glass frontage, and Paragon needed to achieve curved roofs and sides that sealed with the straight lines to make the structures weatherproof and insulate them thermally. Here again, the solution was deceptively simple: ‘Good old corrugated iron,’ says Cloete with satisfaction. ‘I love its connotations of industry and farms, where Caterpillar has its roots with its creation of factories and dams. It worked spectacularly and helped bring in the project on budget.’ A steel girder framework was created to provide for the track-shaped design of each of the two bubbles, with large spanning trusses that carry the roofs, all sitting on a specially devised grid (‘increased to 12m or 15m,’ says Cloete) to accommodate the different-sized equipment required. Then the corrugated iron was applied like an external skin. Throughout it all, Paragon worked closely with Trencon Construction, the main contractor. ‘We operated as a team, which was of paramount importance given with the intricacies of design combining the use of glass and steel,’ says Trencon contracts manager Ernst Bezuidenhout. The steel structure was difficult both to manufacture and erect, and they used tension cables in the roof structure to help with installation of the glass and adjust the fit of the façade panels. Although the developers were not targeting a green-star rating, Paragon practices ensure all their projects would qualify for at least three green stars, Cloete says. ‘So, we oriented the two buildings to face north to ensure maximum sunlight and minimize the need for artificial lighting and heating. And we designed the roof structures to cater for photovoltaic panels for solar power, to feed the electrical requirements for the offices.’ The flush-glazed unitized glass façades feature performance glass, and the canopy formed over these by the roofing have a sizeable 3.5m cantilever (another Paragon signature), that provides shading in summer while being exposed in winter, heating the interiors naturally. Sustainable Building FeaturesThe Barloworld Equipment head office building and showroom incorporate green elements in line with Paragon’s practices: They were positioned to face north to reduce energy requirements.The roof structures for both bubbles were designed to cater for photovoltaic panels.The canopy of the top edge of the bubble design facade has a 3.5m cantilever to give substantial shading in summer, but the façade is exposed in winter to heat the internal space naturally.Low-rated sanitary fittings were specified throughout for minimal water consumption.Was the project envisaged in steel from the start?Yes, in short this would have not been possible to achieve the desired design without the use of steel as explained below. The project was envisaged to be steelwork from the start, but not all elements: The steel fascia trim along the length of the building was investigated to make use of a different material, however structural steelwork proved to be the only material that proved flexible enough to form the required shape.The roof structures to cater for photovoltaic panels for solar power, to feed the electrical requirements for the offices.’ The flush-glazed unitized glass façades feature performance glass, and the canopy formed over these by the roofing have a sizeable 3.5m cantilever .The two ends of the building consist of curved structural steel horizontal sheeting that both cantilevers out about 15m from the base and is about 15m tall. This presented an engineering challenge to keep the deflections within allowable limits whilst also keeping the structural elements economical and within the allowed sizing envelope, especially since the large cantilever bow also carried a flush glazed façade which has very stringent allowable deflections. We made use of stressed cables to hang the bowing cantilever arches from the remainder of the roof. To control and monitor deflections and to ensure the safe erection of the structure we issued the contractor with specific installation methodologies and sequences to follow. The cables needed to be stressed in two sequences at certain times during the erection process to ensure that they did not over-stress the structure which did not yet carry all the building’s self-weight. We also requested that the cables were kept open for final adjustment if required up to the very end of the project before having them trimmed and instructed the contractor to take accurate surveys of the structural steel positions as it was being erected and finalized. These two end barrels of the building imposed significant horizontal forces onto the roof that needed to be catered for. We made use of brace bays to take these loads back to the foundations however there was no opportunity for any bracing to the front of the building since it was to be a fully retractable glass façade. Instead we pulled the one vertical brace to the floor back to the nearest acceptable position which was beyond the centroid of the barrel load which whilst still feasible increased the loads onto the bracing system significantly. Curved plate girder channels and compound curve RHS sections made from plate were difficult to fabricate and install while maintaining the fixed glass support line on site. Impressive Technical Aspects of this projectThe building curves in 2 planes - These two end barrels of the building imposed significant horizontal forces onto the roof that needed to be catered for. The head office, comprising two elongated buildings, are linked by an enclosed glazed bridge.Its design encompasses flush-glazed strip windows. The prevalence of glass in both buildings ensures maximum sunlight because of their north-facing orientation. This minimises the need for artificial heating and lighting.Both the head office and showroom roof structures were designed to cater for photovoltaic panels.The most immediate noticeable feature of the new showroom structure is its elongated front-facing bubble profile, inspired by the curved shape of the Caterpillar excavator tread. Not only is this an iconic visual tribute to the legendary earthmoving equipment showcased within, but it also allows this huge machinery to be comfortably exhibited in the voluminous interior space this design creates.What is special/ unusual/ innovative/ aesthetic about the steelwork in this project? The two ends of the building consist of curved structural steel horizontal sheeting hat both cantilevers out about 15m from the base and is about 15m tall. This presented an engineering challenge to keep the deflections within allowable limits whilst also keeping the structural elements economical and within the allowed sizing envelope, especially since the large cantilever bow also carried a flush glazed façade which has very stringent allowable deflections. We made use of stressed cables to hang the bowing cantilever arches from the remainder of the roof.To control and monitor deflections and to ensure the safe erection of the structure we issued the contractor with specific installation methodologies and sequences to follow. The cables needed to be stressed in two sequences at certain times during the erection process to ensure that they did not over-stress the structure which did not yet carry all the building’s self-weight. We also requested that the cables were kept open for final adjustment if required up to the very end of the project before having them trimmed and instructed the contractor to take accurate surveys of the structural steel positions as it was being erected and finalized. These two end barrels of the building imposed significant horizontal forces onto the roof that needed to be catered for. We made use of brace bays to take these loads back to the foundations however there was no opportunity for any bracing to the front of the building since it was to be a fully retractable glass façade. Instead we pulled the one vertical brace to the floor back to the nearest acceptable position which was beyond the centroid of the barrel load which whilst still feasible increased the loads onto the bracing system significantly. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Electron Avenue Ext, Isando, 1600 Google Maps link https://goo.gl/maps/DYb8LbbVDTNTUA8t8 STRUCTURAL STEELWORK Completion date of steelwork August 2019 Completion date of full project December 2019 Tonnage and steel profiles used Plate girder channels and curved beams + normal HR sections 220 tonnes CLADDING (If applicable) Completion date of cladding September 2019 Cladding profile/ type used Corrugated 10½ & Klip-Tite Cladding area coverage ± 11 165m² Both cantilevers out about 15m from the base and is about 15m tall Cladding tonnage Klip-Tite = 34 537 Ton & Corrugated = 48 279 Ton Nominator Central Welding Works Nominator Global Roofing Solutions Client/ Developer Eris Property Group Architect Paragon Architects Structural Engineer DG Consulting Engineers Engineer DG Consulting Engineers Quantity Surveyor Matla Quantity Surveyors Project Manager SIP Project Managers Main Contractor Trencon Construction (Pty) Ltd Steelwork Contractor Central Welding Works Steel Erector Central Welding Works Cladding Manufacturer Global Roofing Solutions Cladding Supplier Global Roofing Solutions Cladding Contractor Chartwell Roofing (Pty) Ltd. Paintwork Contractor Dram Industrial Painters Paintwork Contractor First Class Projects CC Structural Steel Detailer KRU Detailing Nomination Document Submission KRU Detailing If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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ABinBEV in SagamuSAB Miller, prior to its takeover by ABInBev, identified the need for a new brewery in Nigeria and selected a site in Sagamu located approximately 60 km north-east of Lagos. The initial brewery size was for 1.8 mega hectolitres, however, shortly after commencing with the design work, the decision was made by ABInBev to proceed with design work for a revised capacity of 3.2 mega hectolitres. Structural steel as choice of building material The 3.2 mega hectolitre brewery is approximately 41 000 m² in building area consisting of a number of different buildings, e.g. packhall, brewhouse, engine room, CHP & boiler house, full-bottle store, administration buildings. With the inherent flexibility that structural steel offers, combined with the main buildings all having requirements for large clear spans, some in excess of 32m, in order to accommodate the respective equipment, steel was the clear choice of construction material. Structural steel provided the various buildings on the project with an ability to absorb inevitable late design changes associated with a project of this type. In particular, the structural steel facades of four of the buildings, earmarked for future expansion at the outset of the project, provided the perfect flexibility required in the structure at the time of various expansions. The steel grade that was available locally was 275 MPa and prior to commencement of the revised design, a list of section sizes available from the Nigeria market was obtained and utilised in the design. During the review of shop drawings, some of the section sizes were no longer available requiring a design check of the structural elements to find suitable alternatives. In most instances, the result was a heavier section having to be used. Value engineering was a key consideration in the design and fine-tuning was required wherever savings could be realised. For example, a decision was taken to provide additional columns in one section of the packhall building, which meant that instead of a girder with trusses connecting to the girder as per the main design rationale, the girder could be removed and the trusses then connected directly to the columns. This resulted in a significant saving in the overall steel weight of the structure. Other steel buildings and components include: 240 m2 four-storey malt intake tower consisting of steel composite floors 875 m2 five-storey sorghum intake tower consisting of steel composite floors 2016 m2 seven-storey mill tower consisting of steel composite floors Covered gatehouse entrance in steel approximately 890 m² 600 m of steel pipe bridges 400 m of covered pedestrian walkways 56 m2 tyre store 787.5 m2 keg Store 387.5 m2 hops store 2326 m2 generation and boiler warehouse 4950 m2 brew house and cold block 1575 m2 engine room 480 m2 forklift workshop 1335 m2 amenities building 155 m2 induction building 477 m2 empty bottle store canopy 351 m2 water treatment plant Steel supporting members for safety lines, which became a requirement from ABInBev during the construction stage of the project. Conclusion In spite of its limited local availability, structural steel was the ideal choice for the Sagamu Brewery project, providing the flexibility to deal with various design expansions and the solutions for large clear span elements. The use of steel, combined with good collaboration between the architect, the structural engineer, the rest of the professional team and the contractor, has created a structure that will be economically efficient and meet the requirements of the client for resilient, sustainable design. Aurecon is proud to be associated with a project of this calibre. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Abeokuta-Sagamu Expressway Sagamu Ogun State Google Maps link https://goo.gl/maps/efxexzkL6eEKEpG27 STRUCTURAL STEELWORK Completion date of steelwork Feb 2019 Completion date of full project May 2019 Tonnage and steel profiles used 2900 tons Cost of steelwork NGN 1,795,735,245.00 = 4.9 Million USD Project Team Role Company Nominator Aurecon Consulting Engineers Client/ Developer ABInBev Architect PPS Architects (Pty) Ltd Structural Engineer Aurecon Consulting Engineers Quantity Surveyor De Leeuw Group Main Contractor Vita Construction Steelwork Contractor Vita Construction Steel Erector Vita Construction Cladding Manufacturer Vita Construction Cladding Contractor Vita Construction Galvanising Vita Construction Paintwork Contractor Vita Construction If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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BAKERS TRANSPORT Cato RidgeRies Shaw Architects were commissioned to provide a Distribution Warehouse of 25 000 sqm and an Office Building of 3 000 sqm on a sloping site alongside the N3 Freeway. The site is triangular. The siting for the Warehouse was chosen for ease of access but is also along the longest boundary. This is the most elevated area of the site. The Architects capitalized on this acropolis setting with a sleek but detailed response which celebrates the effortless linear quality of Steel Buildings. THE DESIGN BRIEF A distribution Warehouse for storage and subsequent distribution of a range of products. An Office Headquarters and Admin support building THE RESPONSE WAREHOUSE A single, large, steel sheeted Warehouse was designed by the Architects with steel cladding being the main aesthetic. The site is relatively remote, so the use of lightweight elements of great strength was the obvious choice. This is exactly what steel provides. Carefully edged and defined office and ablution elements are strategically cut into the large steel box to contrast and enhance the steel box while defining clarity of purpose. White edging contrasts with the dark colour of the sheeted box which is further enhanced with lighting. A steel structure was designed by Kantey and Templer structural engineers measuring 14m at the eaves and consisting of reinforced concrete perimeter columns on a 24 x 24 m grid supporting steel lattice trusses. 3x Spine lattice girders rationalized the spans and member sizes. The resultant configuration was easy to fabricate and erect. A brief description of the structural framingThe main warehouse structural frame comprises interconnected trusses and lattice girders supported on a column grid of 24m by 24m. For economic and practical reasons the lattice girder trusses comprise I sections and angle sections and the trusses comprise angle sections. The canopies comprise triangular tubular trusses for aesthetics where required and I sections and angles sections elsewhere for economical and practical reasons. In order to develop an efficient structural configuration for the tilt-up concrete walls, an 8m bay spacing was selected. Under normal circumstance this would render the purlins as single span and thus less efficient, arrangements were however made for the supply of 16m long purlins which allowed for much more efficient double-span purlin design. The use of steel structure allows for wide spans to achieve the required uncluttered interiors essential for large scale economical storage. The steel structure is split along the center with a sloped polycarbonate ridge line step to allow light to enter. The structural engineers were able to maintain continuity of the main perpendicular trusses through the ridge step in order to allow for improved design efficiency of the structural steel. Dark grey coloured steel compliments the red fire water supply pipes and the white underside of the insulation blanket, so the structure is celebrated as the main event. Loading on the long side of the Warehouse was required. The triangular site shape came into play and resulted in a saw tooth loading dock configuration. The Architect and Engineer combined their efforts to provide a practical solution, marrying structure with the quite intricate loading configuration with carefully placed support steel and a 3 dimensional circular hollow section steel edge beam (or triangular lattice). The downpipes from the canopy gutter were concealed within circular hollow section canopy columns. The canopy columns were integrated into the concrete dock structures which eliminated the need for separate concrete stub columns and foundations. The mono pitched roof supplies a linearity which moderates the bulk of the warehouse with a quintessential steel aesthetic response. The Architects further modulated the warehouse form with subtle stepped roof and angled gable planes. Extended eaves added practicality and are joined in an angular configuration at the gables. Hot rolled structural steel girts were selected in lieu of the conventional cold rolled girts connected with additional cleats to the concrete corner columns in order to establish stable raking gable wings. The steel aesthetic is thus further celebrated by these contrasting sheeting planes that make great use of sunlight impacting at various times of the day giving the building a liveliness. Exterior up-lighting accentuates the looming eaves, highlighting the steel support structure. The crisp, clear nature of this simple steel building on the horizon can be appreciated from far off, which was important to the Architects due to the project’s freeway setting. The subtly angled edges change the overall image as one’s angle of vision changes when passing by. The result demonstrates the rewarding potential of the Essential Steel Box.The warehouse structure is clad with dark grey concealed fix steel sheeting and opaque white translucent sheeting. The translucent white sheets were positioned to coincide the sloped apex ridge step and sloped gable step with a horizontal eaves strip thereby forming a narrow starkly contrasting white frame against the dark grey background. This simple trio of concrete boxes in the office block contain large vertical steel louvres that dominate the aesthetic of the freeway elevation. The Architects naturally opted for steel as the appropriate material. These over-scaled steel elements are framed in coloured steel and filled with punched aluminium panels. They perform their sun control function and consciously celebrate the steel material connection with the warehouse. Steel allows for the subtle connection to the concrete frames being only at the top and bottom. The scale and design of these elements again celebrate the close relationship with the freeway and the changing perspective while passing by. Impressive technical aspects of the projectThe architect used striking angular features within gable end steps, sides and the roof apex step. This means that the gables have cantilever triangular wing walls that project beyond the perpendicular longitudinal side elevation walls which required special consideration from a structural engineering perspective. In order to keep a consistent theme, the architect wanted to create a low profile edge to define the large 24m deep truck loading canopy. An innovative solution was required since the spacing between the main external support columns is 32m. The structural engineers, Kantey & Templer, proposed a triangular tubular truss as the main external edge support element. This proved to be an effective solution since it provided several desirable outcomes. Firstly, the exposed edge angle was 60 degrees which matched that of the gable step. Secondly, the tubular truss created an aesthetically pleasing exposed structural element. Thirdly, the canopy box gutter downpipes could be concealed within the tubular columns; and finally tubular sections provide the most efficient structural sections for the compressive axial forces created in large-span trusses. Hot-rolled structural steel girts were selected in lieu of the conventional cold-rolled girts which were connected with additional cleats to the concrete corner columns in order to establish slender but stable and striking inverted raking gable wings. As is often the case in warehouse projects; construction speed is of the essence. In order to facilitate rapid construction, a decision was made to use 8m wide tilt-up precast concrete walls. This resulted in the adoption of an 8m wide truss bay spacing which also worked well with the concrete surface bed joint spacing. Cold-formed lipped channel purlins make up a large proportion of the total structural steel mass of the building and must, therefore, be designed efficiently. In line with this objective, the preference is to have multiple span purlins. Under normal circumstances, it would not be feasible to utilise 16m purlins due to fabrication and transportation constraints. This specific requirement was stipulated within the tender documentation and the contractors were able to arrange accordingly in advance allowing for an efficient purlin design. How does this project demonstrate the benefits of steel as a material? The use of structural steel offers several general benefits for warehouse construction including: extensive off-site fabrication resulting in fast on site erection and installation; large roof spans resulting in high volume spaces with a low density of internal columns; structurally efficient lightweight construction resulting in cost effective structures. In this particular case the versatility and relatively slender structural strength of steel has facilitated the design of an aesthetically pleasing warehouse building. What is special/ unusual/ innovative/ aesthetic about the steelwork in this project? In order to render warehouses financially feasible, the structural steel design needs to be as light as possible. Under normal circumstances, the result is a simplified box with uninspiring aesthetics. Where elaborate architecturally pleasing warehouses have been developed, this has often resulted in a heavier and therefore more expensive design. In this instance, the professional team was able to design a warehouse structure that is both contemporary and aesthetically impressive but also as financially economical as a typical box-type warehouse. A relatively low additional cost has been applied to the external structural features of the warehouse to produce the most impactful visual impression but at a negligible cost considering the scale of the structure. The result is an impressive warehouse structure immediately adjacent to the National N3 carriageway that provides passers-by with unexpected and visually appealing building outline with striking angular features that are accentuated by the elevated and diagonal orientation of the structure relative to the roadway. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Harrison Cato Ridge KwaZulu Natal Google Maps link STRUCTURAL STEELWORK Completion date of steelwork June 2019 Completion date of full project October 2019 Tonnage and steel profiles used 605.24 Ton (including Canopies) CLADDING Completion date of cladding July 2019 Cladding profile/ type used Roof: Saflok 700 AZ200 0.55 Rain Cloud Cladding: Widedek AZ200 0.55 Thunderstorm Cladding area coverage 39 200 m2 Cladding tonnage -204 Tons Project Team Role Company Nominator RIES SHAW ARCHITECTS Client/ Developer GROWTHPOINT PROPERTIES Architect RIES SHAW ARCHITECTS Structural Engineer KANTEY & TEMPLER Civil Engineer KANTEY & TEMPLER Electrical Engineer EG AFRICA Mechanical Engineer I-MEP Fire Engineer NATIONAL FIRE & SAFETY Quantity Surveyor KANTEY & TEMPLER Project Manager GROWTHPOINT PROPERTIES Main Contractor WBHO Steelwork Contractor PARAGON STEEL STRUCTURES Steel Erector PARAGON STEEL STRUCTURES Cladding Manufacturer Safintra South Africa Cladding Supplier Safintra South Africa Cladding Contractor MJC Industrial Roofing Corrosion Protection SIGMA COATINGS Paintwork Contractor INSIMBI COATINGS Photographer, Photo competition ANDREW GRIFFIN PHOTO Photographer, Other submitted images ANDREW GRIFFIN PHOTO If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Douala Grand MallDouala Grand Mall is a new mixed used development situated in close vicinity of Doula International Airport. The mall is the first phase of a multi phased development in the area and was commissioned to provide a luxury shopping experience to the public. When completed Douala Grand Mall will be the first of its kind in Cameroon. The development comprises a 2 level shopping mall with basement parking and is approximately 112.0m x 120.0m on plan. Towards the east of the mall is a single level hypermarket approximately 56.0m x 40.0m on plan. The development was conceptualized by the project architect (Benoy) to be a 2 level steel structure, constructed on a reinforced concrete basement substructure. Raubex Renovo was appointed as the main contractor, with WSP Group Africa appointed as the Civil and Structural Engineers. The steelwork superstructure comprises duo and mono-pitch portalised frames with a first floor at approximately 5.85m above ground level. Localized raised steelwork platforms, with suitable grating to support various plant, are situated above the roof line. The roof consists of a composite roof panel system (Kingspan), spanning between cold rolled steel purlins (Metsec). The elevations are predominantly cladded with a composite wall panel system (Brucha), with a glass façade facing the food court to the south. The first floor is a 190mm deep composite slab with a metal deck (Bacacier). The slab/deck is connected to secondary steel beams with shear studs to create a composite construction. In order to reduce the weight of the secondary steel beams WSP introduced cell beams (Macsteel). Due to floor-to-ceiling height restrictions WSP had to revise the conceptual first floor Pratt girders. The girders were replaced by 1.0m deep plate girders as primary beams, spanning between various universal columns (UC) sections on grid. With a restricted ground floor ceiling void WSP had to co-ordinate various services through the plate girders. This resulted in finite element analysis to be carried out, in order to manage local stresses, round the 1.2mx0.5m service openings in some of the plate girders. The perimeter ground floor steel columns are supported on a reinforced concrete retaining wall, enclosing the basement parking. The internal ground floor steel columns are in turn supported on RC columns on grid or suitable transfer beams. On ground floor level stability is achieved through transverse and longitudinal vertical ‘X’ bracing and portal braced frames. On the 1st floor level vertical ‘X’ bracing is only provided in the longitudinal direction for stability. Although the steelwork superstructure is in essence a portalised Pratt truss and column system, WSP found the following technically challenging: Custom made plate girder beams with sizable service openings, requiring finite element design. Large skylight openings in the roof structure. Box girder design with a 16.0m span to support a roof truss coming in at 90 degrees. Connections of the perimeter columns to the retaining wall. Complete perimeter steelwork sub-structure to provide support to the vertical cladding, including parapets. Douala Grand Mall was conceptualized in the UK and based on an European type of construction, therefore, promoting speed of erection with minimum labor. The project lends it well to this type of construction, with fabrication carried out in South Africa with quick and easy erection on site. Another driving force behind the steelwork superstructure is the poor ground conditions, resulting in low bearing capacities. The steelwork superstructure approach did, however, come with the following challenges: Long lead times due to the importing of all the steelwork. Containers not being released in time by the port authorities. Any steelwork changes on site had to be carried out with local lower grade steel. Local steel comes at a premium price although it is of a lower grade. Given the above technical and logistical challenges the project team collaborated very well on the project. The steelwork contractor (Cadcon) was involved early on in the project to provide guidance on the procurement of the steel and lead times to get material on site. Macsteel also contributed with the fabrication and design of the cell beams. Issues were also identified early on and everyone on the project team were proactive in order to resolve any issues. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Douala Grand Mall Autoroute de L’aviation Au Lieu dit Bonadiwoto Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 31/04/2020 Completion date of the full project 15/06/2020 Tonnage and steel profiles used Approx. 1 688 CLADDING Completion date of cladding 15/05/2020 Cladding profile/ type used Brucha (various) Cladding area coverage Approx. 7 600m2 Cladding tonnage Approx. 133 Project team role Company Nominator WSP Group Africa Client/ Developer Actis Architect Benoy Architect of Record PKA Architects Structural Engineer WSP Group Africa Civil Engineer WSP Group Africa Quantity Surveyor Project Manager Main Contractor Raubex Steelwork Contractor Cadcon (Pty) Ltd Steel Erector Cadcon (Pty) Ltd Cladding Manufacturer Brucha Cladding Supplier Brucha Cladding Contractor Raubex Corrosion Protection Galvanising Corrosion Protection Paintwork Contractor Photographer, Photo competition WSP Group Africa Photographer, Other submitted images WSP Group Africa If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Country Club of JohannesburgThe Country Club of Johannesburg is an old and proud pillar of Johannesburg community life. The club has a rich heritage and history of change and renewal and in this spirit, the current leadership saw fit to improve the entertainment offering. Expanding the lovely terrace area functionality by covering, creates a year round open outside sheltered mecca for functions and relaxing meals. The clients briefed Rebel Base collective, dynamic architects with a flair for design, safe in the knowledge that they would imagine a space that tips a hat to the past while peering into the future. Rebel Base, known for challenging the status quo in design, approached the project with the expectation of satisfying all practical needs whilst relishing the challenges of structural and social heritage. Their undulating roof responds to the desire to create a light, voluminous yet intimate space. It hovers above the existing art-deco handrail, a treasure to be retained. The rounded perforated-ceiling surface provides optimal acoustic performance, reflecting sound in different directions thus minimising direct reverberation. The clear story windows allow light into the open space whilst creating framed views to the sky and into the canopy of the grand old oak tree, which is further celebrated through a semi-circular cut out in the eastern-most vault. The soft tapered profile of the vaults allows the building roofline to merge into the sky and carries the eye out to the northern forest. The roof effortlessly contributes to the architectural form finding and is tied to the existing club with a material palette of steel, concrete (in various forms and finishes), recycled clay paving and glass that have been intricately detailed to craft something elegant, simple and timeless whilst still being honest and raw. All the components result in a bold yet soft structure which nods to the old Art-deco extension of the restaurant’s interior, unfolds itself into the hero oak tree and the rolling lawns whilst the weighty utilitarian base of the reflecting and trickling water feature allows the roof to fly. The pavilion acknowledges the club’s legacy whilst unreservedly launching it with a rebellious hovering time machine into the future. Early meetings between architect and engineer, Hull Consulting, morphed into brainstorming sessions on achieving the desired clean curved lines within the practical considerations of available materials and skills. No doubt NASA engineers would have looked to exotic composite materials for the elliptical sectioned main beams, but this was to be built on a far tighter budget. Concrete, while being capable of providing the necessary shape was excluded due to cost and weight, half the structure being required to be supported on existing building foundations. In any case, why build a shutter to mould a pourable material, when the negative of the shutter constitutes your finished structure anyway. Plywood, not practical, fibre glass, not economical, time and time again, steel showed itself to be the only viable alternative. The final structural system evolved into unique custom formed stiffened curved box section main elements, supporting curved I beam and lipped channel purlin vaulted arched roof segments. The arches kick into concrete outside edge columns cantilevering out of concrete foundations. As an added bonus, thin walled steel box sections allowed for removing an internal line of columns, freeing up the interior to more table layout options. The design, being atypical and complex in that the main structural elements are thin walled nonstandard curved box sections, required some initial effort, but with the basic structural principals established, the true challenge lay in the intricate structural detailing. Immediately after the tender was awarded to the main contractor, Bartlett Construction, they appointed Quicksilva Structures Africa to fabricate and erect the steelwork. Subsequent design meetings were expanded to include input from Quicksilva’s structural detaining and erecting teams. By burning the midnight oil, the detailers married all considerations, resulting in a structure that was able to be fabricated, transported and erected within tight timelines and to budget. Quicksilva’s brief included all curved roof sheets, perforated ceiling panels and custom window frames: if its steel you see, they did it. In the end, only steel could have met all the design, manufacture and erectability requirements, “finished and klaar”, as some would say. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected PROJECT OVERVIEW Physical address of the project Street Address Town Province 1 Napier Rd, Auckland Park, Johannesburg Google Maps link https://www.google.co.za/maps/place/26%C2%B010'59.0%22S+28%C2%B000'46.3%22E/@-26.1830518,28.0123018,19z/data=!3m1!4b1!4m6!3m5!1s0x0:0x0!7e2!8m2!3d-26.1830531!4d28.0128492?hl=en STRUCTURAL STEELWORK Completion date of steelwork End Nov 2019 Completion date of full project Jan 2020 Tonnage and steel profiles used Aprox 30 ton, IPE100, 219CHS, plate hollow custom beams CLADDING (If applicable) Completion date of cladding Jan 2020 Cladding profile/ type used Cranked corrugated chromadek sheets, perforated plate ceiling Cladding area coverage 550 sqr meters Cladding tonnage About 6 tons If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Boxer Distribution Centre IbhubesiDuring early 2018 Boxer Superstores recognised that the operational requirements at their Regional Distribution Centre at Cato Ridge were rapidly outgrowing the current facility. The Developer was able to offer a new site at Ibhubesi Industrial Park, Lynnfield, relatively close by and adjacent to the N3 Durban-Johannesburg highway. The Developer was the Main Contractor, and a full project team was assembled from personnel and firms with whom previous similar projects had been successfully completed. Structural Engineering The design brief centred around the storage capacity required (which was in terms of number of “pallet slots”) and the floor area required for the receiving and dispatch staging logistics (loading/off-loading space). The Industrial Park provided the required access roads. A four-hectare platform was constructed to provide for adequate traffic circulation, with the bulk earthworks commencing in October 2018. This civil work, plus the foundation works were carried out in parallel with the main structural design. The main superstructure was configured around the racking layout and the receiving/dispatch staging areas which were determined in conjunction with Boxer Superstores Operations Management. The central section houses the racked storage section – the height determined by category of reach-truck to be used along with operational constraints & costs, plus floor slab design/construction costs. The two staging areas were then run along each side with a lower roof height, the length of the building. An off-loading tunnel covered area was created on the receiving side and covered loading bays (at-grade and container platform) on the dispatch side. Structural steel was identified by the Design Team as the optimum material for the superstructure - this provides a degree of flexibility (it is common to have design adjustments during a project of this nature), and fabrication is carried out off-site whilst foundation works are underway. Steel also provides for speed of erection and closure of the building envelope for floor construction and installation of the various services. The Structural Engineer and Steel Fabricator deemed that the basic cross-section of the building should follow a portal frame configuration. It was initially considered to use cellular beams for the main portal frames but, at the time, long lead times for supply pushed to the use of castellated beams to suit the construction programme.The two principal challenges in the design process were(i) generating lateral stiffness across the building cross-section for wind loading without cross-bracing (which could not be fitted within the racking and staging areas), and(ii) to ensure the stability of a partially erected superstructure to provide “lock-up” to allow roof sheeting and vertical cladding to proceed without full completion of the superstructure frame. The main challenge to the steel fabricator was to fabricate portions of the building to facilitate the sequential erection working from one end of the building, ie. it was necessary to complete fabrication of all elements for specific sections of the building to tie-in with the construction sequence/programme, rather than just manufacturing the total number of each component for the entire building, with erection only commencing after all steelwork was fabricated. This project demonstrates the large clear spans that can be achieved using structural steel for industrial buildings where clear floor space is a major priority, along with a degree of flexibility for design changes, and speed of erection. The Project Team worked together from the outset with input on all the necessary aspects for the facility, including design time, supply time of materials, construction times and sequence, steel fabrication time, critical stage completion for further construction stages, and overall project completion. Architectural and Cladding: A single, large, steel sheeted Warehouse was designed by the Architects with steel cladding being the main aesthetic. The use of steel structure allows for wide spans to achieve the required uncluttered interiors essential for large scale economical storage. The steel structure is split along the centre to allow light to enter. The warehouses being approximately 6 700m2 in total, was envisaged to be done in steel with sheeting as it was designed around the possibility of future racking and stacking heights. The most optimum type design or structure was for this to be a sheeted and structural steel warehouse. Hot-rolled I beam sections, lattice girder trusses, cold-formed purlins, and girts were used in the construction of this warehouse. The crisp, clear nature of this simple steel building on the horizon can be appreciated from far off. The sheeting for the structures was Safintra’s Saflok 700 0.53mm AZ150 Zincal on the roof and Widedek 0.47mm AZ150 Seaspray for the cladding. The total amount of steel required in order to complete this project was 32 tons of material. Due to the excessive lengths that were required to sheet the roof portion of the buildings, on-site rolling had to be done with Safintra’s Saflok 700 Mobile Mill. This required both space, planning and lifting onto the roof from ground level. Different sections were milled at different areas of the site so as to help with ease of erection, traffic requirements on a congested site and to minimise double handling of the sheets on site. The sheeting was hoisted to the roof from the side of the building. ConclusionOverall the team of professionals working on the Boxer Warehouse project worked well together and had a great understanding with each other. With this, it helped achieve what was set out to be done, and provide a suitable working environment for the client. In conclusion, this project is a fine example of what may be achieved by co-ordinated design and construction team work. The design team worked in liaison with the construction team to provide design information in accordance with the construction programme. The use of steel in the building contributed significantly to the fit of the superstructure around the racking, it provides the clear span space required by Boxer for their operations and allowed for speed of erection of the building envelope – approx. 22 000 square metres roofed area, 548 tonnes of structural steel. Steel erection commenced in April 2019 and was completed in July 2019. Overall project completion was achieved in October 2019, twelve months after commencement of the bulk earthworks. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEWPhysical address of the project Street Address Town ProvinceIbhubesi Industrial Park R103 Lynnfield Park Near Pietermaritzburg KwaZulu NatalGPS Co-ordinates 29.693S / 30.475EGoogle Maps link STRUCTURAL STEELWORKCompletion date of steelworkJuly 2019Completion date of full projectOctober 2019Tonnage and steel profiles used548 tonnes CLADDING (If applicable)Completion date of cladding25 June 2019Cladding profile/ type usedRoof: Saflok 700 AZ150 0.53 Zincal Cladding: Widedek AZ150 0.47 SeasprayCladding area coverage 6 700 m2Cladding tonnage32 Tons Nominator Safintra SA (Pty) Ltd Nominator Martin & Associates Consulting Engineers Client/ Developer Afroprop Natal (Pty) Ltd Architect Structural Engineer Martin & Associates Consulting Engineers Project Professional Engineer Martin & Associates Consulting Engineers Project Manager Afroprop Natal (Pty) Ltd Main Contractor Afroprop Natal (Pty) Ltd Steelwork Contractor Cousins Steel Steel Erector Pro-Erect Steel Riggers Cladding Manufacturer Safintra SA (Pty) Ltd Cladding Supplier Safintra SA (Pty) Ltd Cladding Contractor Cladco Photographer, Photo competition Kierran Allen Photography Photographer, Photo competition Afroprop Natal (Pty) Ltd Photographer, Other submitted images Martin & Associates Consulting Engineers If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Mercedes-Benz W206 Body Shop, East LondonIn November 2017, WSP joined forces with Stefanutti Stocks to respond to a bid for the construction of a new body shop for Mercedes-Benz South Africa as part of a major expansion to produce a new generation vehicle to be launched in 2021. This 45,000m2 building forms part of a R10 billion investment at the East London manufacturing plant where four new facilities, totalling 100,000m2, were constructed. The body shop is typically the second stage of an automotive production line. After being formed in the press shop, the various body panels are assembled in the body shop before being treated against corrosion and then proceeding to the paint shop, powertrain assembly, and then general assembly.The Architectural Brief Daimler, the parent company of MBSA, appointed another consulting team to develop the technical specifications and high-level scheme for the overall facility, focusing on the various operational requirements from the client and equipment manufacturers. These operational requirements for the body shop necessitated a double-storey building with a wide column spacing of 14.4m by 18m. The 22,000m2 suspended the first-floor is situated at 10.5m above the ground floor, offering 8.5m clear operational space underneath, and can withstand large storage loads of up to 4000kg per square meter. The first floor is covered by the lightweight steel roof, which also houses a 1800m2 plant area, above another 8.5m high operational zone. In addition to this, the façade consists primarily of a sheeted steel structure, with a steel-framed brick wall providing the necessary firebreak to the adjoining building. The primary focus of WSP’s structural bid development was the buildability of the extremely heavy first-floor structure. In order to meet the programme requirements, construction had to take place concurrently on the ground-floor, first floor, and roof level. The erection of the steel structure had to slot in between the construction of the 2m deep inverted T-shaped primary concrete beams and the installation of the 30ton precast secondary beam system. The advancement of the steel erection was an integral part of the dovetailed construction programme in order to clear the space for the heavy lifting equipment for the precast concrete beams. The necessary speed and agility could only be achieved with material as light and nimble as structural steel. The Structural Framing The lightweight steel frame for the roof came with the following challenges: The roof build-up mimics a European-style tanked flat roof, as opposed to the gravity-drained sheet metal roof types common in South Africa. The roof type consists of various layers of insulation and waterproofing, weighing five times more than the cladding for a conventional South African warehouse roof. A portion of the roof houses the plant room for the building and is subjected to extremely high loads compared to typical warehouse roofs.Due to the complexities of the hybrid first-floor structure, the roof structure had to be erected after placement of the primary first-floor beams, but before placement of the secondary beams and precast floor panels. This had to be a fast, reliable, and redundant process due to its critical role in the construction programme. To support the unusually high roof loads, the 18m trusses make use of horizontally orientated channel chords in lieu of angles, which would typically be used for trusses of this length. The lattice structure consists of two sets of optimised angles welded to each side of the channel chords, reducing the requirement for heavier gussets while also lending a higher degree of lateral and torsional stiffness to the truss, ensuring easier handling on site. The girders follow the same rationale, but exchange the channel chords for universal beams, providing more compression capacity for their higher loads over the 14.4m spans. The connection design and detailing, especially for the girder-to-column and truss-to-girder nodes, focused on a reduction of risk during the erection process. All major connections are first seated and secured, after which the main structural bolts or plates are fastened. This greatly reduced handling of heavy bolts and plates while girders or trusses were suspended from cranes. Internally, the roof structure is supported by slender UB columns which were later partially encased by concrete to reduce the effective length of the steel section and protect it against accidental damage at floor level. The façades consist of intermediate UB columns spanning vertically to sets of CHS bracing, which directs the lateral forces to the primary reinforced concrete columns at roof level. For the exposed, tunnel-like canopy on the eastern facade, simply supported castellated beams were utilised to limit the weight of the long-span beams while also providing a reticulation route for electrical and sprinkler services above the clear height required for delivery vehicles.Cladding While Daimler’s technical specifications called for the internal and external layers of the building’s side cladding to be made from aluminium sheeting, there was a unique application of steel SAFLOK 700 sheeting as a load-bearing underlayer of the roof build-up. The SAFLOK sheeting was rolled from 0.8mm thick steel and installed inverted to offer a flat working surface. Load-bearing capacity and safety factors were determined via testing prior to installation. The bitumen-faced mineral wool panels were secured into the steel sheeting with self-tapping screws on large plastic washers. Challenges The competitiveness of the project demanded that the steelwork be designed very economically, which always results in fabrication and transport being more challenging. The lattice elements for the trusses and girders were optimised to the smallest possible sizes without risking susceptibility to detrimental distortions during galvanizing. Furthermore, a detailed stacking method statement avoided damage during transport and lay-down on site. While the steel erection onto half-completed concrete beams 10.5m above ground posed a significant OHS challenge, WSP’s safety-focused connection design and a laterally stiff concrete column perimeter added valuable stability and reliability to the erection process. What is most impressive about this project from a technical perspective? If it was not for the inherent benefits of steel as a construction material, the impressive programming feat of this project would not have been possible. The safety and speed of the lightweight steel solution enabled the roof construction to slot in between two significant concrete construction phases of the first-floor structure.How the project team worked together Due to the complex nature of this factory, all the BIM models (engineering, architecture, fit-out) needed to have a very high level of detail to ensure that in-depth coordination and clash detection could be completed virtually before causing delays on site. WSP developed an LOD350 structural model with all steel elements modelled to a high degree of accuracy in 3D, instead of falling back to 2D drawing details for secondary steel items. In addition to conventional drawings, WSP was able to issue 3D models of multiple assemblies to aid the workshop modelling process as well as the review thereof. Another major benefit of the collaboration between WSP and the workshop detailer was the agreement to model a typical roof bay and facade portion at a very early stage for in-depth review before proceeding with the bulk of the typical structure. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the projectStreet Address Town Province Cotton Road East London Eastern Cape Google Maps link https://www.google.com/maps/place/33°01'37.6"S+27°53'46.9"E STRUCTURAL STEELWORK Completion date of steelwork June 2019 Completion date of full project December 2019 Tonnage and steel profiles used 1,112 ton UB, UC, C, L, CHS, CFLC CLADDING (If applicable) Completion date of cladding July 2019 Cladding profile/ type used Safintra Saflok 700, Safintra Industrial 7 Cladding area coverage 42 742 m2 Cladding tonnage 218 ton Project Team Role Company Nominator WSP Project Lead Factory Planning, Client Mercedes-Benz South Africa Owner's Engineer Aecom Architect Osmond Lange Architects + Planners Structural Engineer WSP Engineer WSP Quantity Surveyor MLC Project Manager Arbuthnot Projects Main Contractor Stefanutti Stocks Steelwork Contractor Impact Engineering CC Steel Erector Impact Engineering CC Cladding Manufacturer SAFINTRA South Africa (Pty) Ltd Cladding Supplier Safal Steel Cladding Contractor Impact Engineering CC Corrosion Protection Phoenix Galvanizing Galvanising Phoenix Galvanizing Paintwork Contractor - Photographer, Photo competition WSP Photographer, Other submitted images WSP, Stefanutti Stocks If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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San Sereno Senior LivingThe San Sereno Senior Living estate was a refurbishment project that was undertaken by Kunz Raubenheimer Architects for Auria Senior Living. The brief was to upgrade the existing communal facility by altering the layout and adding a new extension to the communal facility of this retirement estate located in Bryanston. The existing communal facility was built in 1992 and was in dire need of an upgrade. The aged building had to be transformed into a world-class contemporary facility which would provide a comfortable living environment to residents, accommodate impaired movement and mobility, ensure that all areas are compliant to the elderly act and provide all the necessary amenities within the rapidly changing senior living environment. The Architectural briefThe brief that Kunz Raubenheimer received from the client was to alter the existing communal facility on a functional and operational level, while at the same time improving the quality of living of the residents through the architecture. The existing layout lacked a sense of hierarchy of space, due to the confusing location of front and back of house functions. The staff/administrative component had a prime view and was the focus of the existing building, thus only benefiting the staff rather than the residents. The building was hermetic and completely closed off towards the incredible view over the bowling green. The focus had to be shifted from the staff to the residents as the communal spaces should become an extension of their living rooms. The existing layout was not conducive to creating a comfortable environment where residents could meet and interact. Wayfinding was non-existent and the spaces were not organized in a logical/practical manner. Physically impaired residents struggled to access the different spaces, due to the absence of inclusive design principles. There was a significant shortage of natural light and ventilation within all the spaces and the spatial experience was morbid with an institutional character which discouraged most residents from utilizing the existing facilities. Due to the fact that the project was a live site, the conceptual approach to the construction methodology employed by Kunz Raubenheimer Architects was to design steel building components that could be manufactured off-site and assembled on-site like a “Mechano” set. This ensured that construction noise was reduced on-site and that the construction program could be accelerated. The residents appreciated this architectural approach, as it made the construction process more bearable for them and it was due to this unique approach that they gave their full support and approval for the upgrades. The existing architecture’s massing and roof design was very heavy and looked institutional due to it being red concrete roofing tiles. In response to this Kunz Raubenheimer architects designed a series of lightweight steel screens and pergolas that could be fixed to the existing facades to hide these roofs. New steel and timber pergolas were also designed within the courtyards to create shaded spaces for residents to relax. The new Exercise room and Gym were designed with a unique slanting roof structure that functioned as a solar scoop to draw in filtered sunlight and a steel and timber solar screen for solar control. The different communal areas were connected via a series of means of steel and timber pergolas that created pleasant outdoor spaces and formed the golden thread that tied the different areas together as a whole. The structural framing 120 x 60 x 3,5 mm M/S Rectangular hollow sections were used for the beams of all the pergolas, this profile was the optimal size and depth to achieve the desired spans. A set of four, 70 x 70 x 6mm |M/S Equal leg angle irons, in a crucifix layout, were used for the construction of each pergola column as well as the columns for the solar screen of the new Exercise room and Gym. These columns allowed beams to be slotted in and bolted to the columns from four different directions for the structure of the pergolas. An IPE 200 section, that was cut to profile, was used for the structural support of the benches that was cladded with thermally treated timber and cantilevered out from the columns. This lightweight, cost-effective profile was perfect to realize the design of the cantilevered benches. 60 x 60 x 6mm M/S Equal leg angle Irons were used for the steel louvres that was constructed to screen off the existing roofs. 60 x 60 x 5mm M/S Back to back angle irons were used for the balustrade stanchions, which allowed for a combination of glass infill and thermal treated timber slats at the Coffee shop deck balustrade. Back-to-back angle irons were also used for the construction of a lightweight M/S Girder truss, which gave the ceiling its distinctive form to open-up towards to North and brings in natural light. The mainframe or superstructure of the pergolas was done in steel which was cladded with thermally treated timber louvres to combine a material with a warmer finish/appearance with the steelwork. Impressive technical aspectsWhat made this project most impressive from a technical perspective is that most of the built areas consisted of a kit of parts, that was pre-manufactured off-site and then assembled on-site to latch on to the existing structure. In order to minimize noise and disruption on-site during construction, all the different steel components were designed to be pre-manufactured in a factory, which would allow for a high degree of accuracy. These building components, consisting of columns, beams and louvres that were then brought to the site to be bolted together and assembled on-site like a “Mechano” set. All the pergolas and solar screens thus utilized a bolted assembly which saved a lot of time during construction and ensured a high degree of accuracy. This construction method however required Kunz Raubenheimer architects to work very closely with the Main contractor and all the different sub-contractors to ensure seamless coordination and assembly on site. The architects and engineers also worked together to design the most slender and cost-effective components from various different steel sections. Benefits of using steelBy using various steel sections for the superstructure of the pergolas and timber solar screens, a high degree of accuracy was achieved which could then be cladded with Rhinowood, that was a natural material with higher deflection. Due to the high accuracy and low deflection of steel as well and it’s tensile strength which allows it to span great distances, it was the perfect material to use for the manufacturing of the building components. Holes were pre-drilled during manufacturing off-site and all the various components were bolted together which would not be possible with other materials that have a greater deflection. The steelwork combined with Rhinowood and glass gave the dated existing building a much more contemporary appearance. The columns were also designed to consist of smaller steel components that were bolted together to give them a sense of lightness and to break up the large solar screens into smaller more aesthetically pleasing proportions. Through careful co-ordination and teamwork, this complex refurbishment project was realized on a live site, in order to transform the existing building into a luxurious, contemporary Senior living communal facility that became the flagship project of the client and establishes a new gold standard for Senior living in South Africa. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 30 Fleming Street, Mill Hill, Bryanston, Johannesburg Google Maps link https://goo.gl/maps/UK7rKLBZ9usSY1u76 STRUCTURAL STEELWORK Completion date of steelwork April 2019 Completion date of full project June 2019 Tonnage and steel profiles used 24 Ton Project Team Role Company Nominator Kunz Raubenheimer Architects Client/ Developer Auria Senior Living Architect Kunz Raubenheimer Architects Kunz Raubenheimer Architects Structural Engineer Struxit Projects Engineer Quantity Surveyor Matla QS Project Manager Main Contractor Tyris Construction Steelwork Contractor Bronkmann Pipe & Steel Steel Erector Bronkmann Pipe & Steel Cladding Manufacturer MKL CARPENTRY Cladding Supplier MKL CARPENTRY Cladding Contractor MKL CARPENTRY Corrosion Protection Galvanising Corrosion Protection Bronkmann Pipe & Steel Paintwork Contractor Tyris Construction Photographer, Photo competition Ingbue Photographer, Other submitted images Ingbue If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Forever ViewThe 27 ha property overlooks the Knysna Lagoon towards the North, with the Outeniqua and the Swart BergMountain ranges in the distance. It is set within a pristine natural dune fynbos conservancy on the Western Heads.The views are spectacular where each day there is a magnificent display of ever-changing sunrises and sunsetsand everything between. The Knysna Lagoon is also constantly displaying her beauty as the mist rolls, and tidesrise and fall. On 07 June 2017 the Wild Fires in the Knysna area took the original house on the property away, but it couldnever take the view away. It was a long and hard walk to process the loss and to get to a stage where the ownerscould get together their resources, plan and re-build a new home to replace the devastating loss.The Architectural BriefThe owners commissioned Andre Vercueil a local Knysna architect (who is also one of the share holders) todesign a new house on the 27ha property. The opportunity now arose to plan the home in a slightly differentlocation to optimize the views a little better. The brief was to be bold with a contemporary steel framed structure,lots of glass towards the views, a floating structure above the ground level, to set the home on deep pillars andfoundations to prevent structural damage by the endangered dune moles, to do something unconventional, exploitthe views and the northern aspect, to live out towards the north and the view, to blend in with the pristineendangered dune fynbos and to plan for a future ‘off the grid’ installation. A further requirement was to plan andexecute the works within a budget of 2,1mil, which is what the insurance paid out for the loss on the originalhouse. The structural framingThe project has always been envisaged in steel for a number of reasons – to be light, daring and unconventional,faster in construction time, simplistic and minimalistic.The main structure (floor beams and supporting columns) are made up of 203mm x 133mm I-beams, with 5.8mmwebs and 7.8mm flanges – these sections were selected to match the structural capabilities as well as thethickness of walls to comply with the required thermal properties together with the drywall construction. Thecorners were made up in 120mm x 120mm equal angles with base plates to bolt on to the I-Beams. The steel suppler managed to find some 130mm x 130mm x 3mm square tubing (which the which were left over from another project as these are not standard), which were used for additional supporting columns. The staircases were made up of 200mm x 75mm flanges. The window and door surrounds, as well as the sloped angles were made up in 125mm x 75mm x 3mm lipped channels.CladdingThe wall cladding was made up of 12mm Nutec high density cladding board against treated S.A.Pine wall framing with soft joints, with Knauff insulation wool. The roof cladding was made up of Colorplus 0.47 AZ200 Ultima corrugated roof sheeting, apex flashings, side wall flashings and headwall flashings on Climasential foil, on treated 76 x 50 S.A.Pine purlins, with Knauff insulation wool.ChallengesThe complexity of the design necessitated the utilization of a 3D design software package to assure that the components are manufactured to exact tolerances and that all holes for screws, bolts, conduiting, etc. are drilled before the beams are galvanized. The manufacturer advised the architects that they have never before had such a unique and complex design to contend with. Several hundred shop-drawings were prepared for the manufacturing process. Needless to say there were some small errors in the design and manufacturing process, but fortunately some amendments could easily be done on site. There were at least two beams which had to be sent back to the factory for more serious amendments. During the construction phase, it was established that there was too much flex/bounce in the upper balcony, which necessitated the additional installation of a small steel column and cross bracing in the external wall.How does this project demonstrate the benefits of steel as a material?Steel construction had obvious benefits in construction – longer spans, slim designs, speed of erection, pre-fabrication precision, sustainability, flexibility, strength, resilience, durability, reduced cost and a worthy investment. This project demonstrates all the benefits of steel construction. The most obvious in this project is the unique character, the slim lines of a simplistic and minimalistic layout, the airy and light floating appearance of the structure disappearing in the landscape. Everyone exposed to the project acclaimed the uniqueness of the design and the simplicity in its expression despite the complexity of the design and manufacturing process.How did the project team work together?It was such a pleasure to see how the engineer, the steel manufacturer, the electrician, the plumber, the main contractor and all the artisans and all the labourers worked with pride on this project because it was so unique and ‘out of the box’. The contractor eagerly wanted to take on this challenge, but unfortunately bit off more than he could chew towards the end, which resulted in some challenges which the client had to take on in finding the right people to do the finishing touches. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Forever View Pres C.R Swart Drive Portion 47/216, Uitzicht, Brenton, Knysna Western Cape Google Maps link STRUCTURAL STEELWORK Completion date of steelwork July 2018 Completion date of full project May 2019 Tonnage and steel profiles used 12.62 tonnes 130x130x3-SHS Columns 203x133x25 UB Rafters 200x75-PFC Rafters 125x65 CFLC Purlins Project Team Role Company Nominator Andre Vercueil Consulting Architects cc Client/ Developer The De Graaf Testamentary Trust Architect Andre Vercueil Consulting Architects cc Structural Engineer DHA Project Managers Structural & Civil Engineers Engineer DHA Project Managers Structural & Civil Engineers Quantity Surveyor Project Manager Main Contractor Elcoserv Projects cc Steelwork Contractor JLMA Engineering Steel Erector JLMA Engineering Cladding Manufacturer Global Roofing Solutions - A division of Consolidated Steel Industries (Pty) Ltd Cladding Supplier Mossel Bay Roofing Cladding Contractor Bitou Roofing & Renovations Corrosion Protection SAFAL Steel Galvanising South Cape Galvanizing (PTY) LTD Corrosion Protection JLMA Engineering Paintwork Contractor Davco Painting Photographer, Photo competition A&M Photography & Video Prod. Photographer, Other submitted images A&M Photography & Video Prod. If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding May 2019 Cladding profile/ type used Colorplus Colorplus 0.47 AZ200 Ultima corrugated roof sheeting Cladding area coverage 400m2 Cladding tonnage Not available
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Rise Student Living - Units on ParkLocated in Park Street, Hatfield, Pretoria this project offers affordable student accommodation, aimed for the NSFAS students, within close proximity to the University of Pretoria and the Hatfield Gautrain Station. The architects’ approach and design philosophy with student accommodation consist of a framework with a definite balance between social and academic spaces that focusses on the well-being of students through striking architecture. Being situated in a context with an influx of buildings associated with student accommodation the building had to be unique and therefore focus was placed upon bringing colour to an urban environment. Architectural brief The brief of the architect was to design the footprint of this building as a reaction to the somewhat complicated site. Due to the Gautrain being adjacent to the building, the footprint was designed and precisely located in such a manner to react to the vast expropriated area of the Gautrain. The concept of the floorplan is to find the perfect balance of importance between the accommodation and the social spaces. The two ‘wings’ are connected in such a way to define and articulate courtyard spaces and encourage students to experience and utilise these social spaces. Furthermore, the originality of the building can be seen from any of the surrounding streets. The colourful sea of balconies, on both facades, brightens the harsh urban fabric of the surrounding context. These balconies not only serve as the face of the building but also offer a washing line space for students who could not necessarily afford laundry services. The important ‘element of youthfulness’ was one of the main drives when looking at the overall design of the building. Not only can this be experienced from the outside of the building but also within each social space and courtyard. Why steel was used The balconies were the most important design principle from the initial concept development of this building. The balconies were expected to consist of a material allowing a shiny, bright and colourful appearance. A wide range of design options were used in order to explore different materials and different construction details. This resulted in meaningless efforts due to a higher cost than budget allowance. The quantity surveyor suggested the balconies to be constructed of brick and plaster which would result in a more affordable option. It was at that point that the architects investigated laser cut mild steel that enabled the balconies to not only have the desired appearance but also fit within the presented budget. These boxes were designed and drawn as a flat surface laser cut panel cut from 2mm mild steel, bent and welded to the final design. The balconies as steel component were carefully considered with regards to the design specifics, strength and as aesthetic component. Therefore, the final decision was that the balconies were designed as a laser cut ‘folded’ box latching on to the concrete slabs provided, keeping exposed fixings to a minimum. A sandbag test was carried out in order to ensure the strength of these balconies. These steel boxes were fabricated off site and erected on site from the top level down. A base colour was applied as these boxes arrived on site and the final coat was only applied when the boxes were in place on the façade. This was done in order to ensure that 33 colours were applied correctly to 546 balconies. How this project demonstrates the benefits of steel as a material Steel can easily be classified as an extremely bold structural material and finish used to envelope vast floor areas. This project is a complete virtual presentation that steel can be used as an excellent aesthetic material especially applied in separate quantities. The only way the architects were able to accomplish the desired design was through the use of steel. Not only was steel an important element on the exterior of the building it was also used as important design principle in the interior of the building. All sanitary fittings were custom designed in mild steel and supplied by KINK Design and all furniture were designed by KDS Architects and supplied by Dokter and Misses in mild steel and Birch Ply Wood. This provided steel ‘accessories’ for 552 units. How the project team worked together Due to the size of the project it was imperative that the entire project team was involved from the inception of the building. Communication between the entire professional team was important in order to ensure that the final design reflects what was intended at the concept phase of the building. Conclusion This project is a representation that steel is an extremely flexible material that enables all designers to express themselves freely, in this case from façade design elements to finer interior design. Although the primary mass of this building is constructed of a concrete framework the aesthetic key component was only possible through the use of steel. The steel boxes provided the identity of the building through enabling colour, shadows and overall articulation. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 1118 Park Street, Hatfield, Pretoria, Gauteng Google Maps link https://goo.gl/maps/4ybvayzVjE9eLZPX6 STRUCTURAL STEELWORK Completion date of steelwork Safe to say with PC date as below Completion date of full project Practical Completion date: 31 October 2019 Tonnage and steel profiles used 32.76 tonne; Laser cut flat sheet Project Team Role Company Nominator Krige Design Studio Architecs Client/ Developer Eris Property Group & WBHO Architect Krige Design Studio Architects Structural Engineer Aurecon Engineer Quantity Surveyor IBP Central Quantity Surveyors Project Manager IBP Central Construction Project Managers Main Contractor Rhodes Steelwork Contractor LaserFab Steel Erector Bailton Steel Paintwork Contractor Pivot Group Photographer, Photo competition Papercut Photography Photographer, Drone footage 255 Architects If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected. CLADDING (If applicable) Completion date of cladding November 2019 Cladding profile/ type used Prospan 762 and IBR Pro 686 Cladding area coverage 18 672 m² Cladding tonnage 93.5 Tons
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Capitec – Project IkhayaCapitec Project Ikhaya is a modern, open office building intended to provide a free-flowing collaborative work environment. The structure is predominantly concrete framed, but structural steel and composite steel and concrete construction was used in a complimentary way. The bridge links and the floor over the main entrance require light, long-span structures with limited headroom implications. The parking structure required the use of a solution that would be removable in the long term to allow conversion of the building for a different use. A brief description of the structural framing HQ Walkway Bridges - Macsteel / Westok Cellular Beams with Bond-Dek composite flooring HQ Main Entrance Floors- Macsteel / Westok Cellular Beams with Bond-Dek composite flooring- Macsteel / Westok Ultra-Shallow Floor Beams with Voidcon permanent formwork floors spanning between floor beams HQ Roof- I-Section portal frames with transfer systems supporting rectangular hollow section roof light pods HQ Entrance Canopy- I-Section roof framing; supported on slanted circular hollow section columns Parking Structure Infill Floors- H-Section columns supporting I-Section composite floor beams with Bond-Dek composite flooring Were there any challenges in the fabrication of the project from the engineer’s design ? From a fabrication and erection point of view the most critical parts were related to the composite floors and walkways. Cellular and USFB members are manufactured in Gauteng, resulting in lead times to be factored in carefully on an accelerated construction program. The manufacturing process of the USFB required delicate craftsmanship from the coded welders, as the different web thicknesses required sufficient weld prep to ensure perfect assembling and efficient weld penetration, in order to pass NDT testing. Cast-in items providing supports required careful planning and coordination due to the faster than originally planned concrete frame construction. In some instances, it was necessary to resort to infill casts and coming back later to install cast-in components. Level and setting out control were tight and required careful coordination Temporary supports for the long-span multi-level systems were intricate and obstructive to other construction activities Due to the use of hangers to support the composite floors in the entrance area and the requirement for propped construction; construction of the composite infill had to be from the top down What is most impressive about this project from a technical perspective? Geometrically the building is quite complex due to the curve-linear shape of the superstructure. The shape combined with the height restrictions on the site and the mismatch between the column grid in the lower parking levels resulted in a complicated structural frame. Furthermore, there was a requirement to have long-span pedestrian bridges crossing the central building atrium and the need for a very open reception area. Combining this with a shallow ceiling system and exposed concrete soffits forming a specific design language throughout the building posed challenges. The pedestrian bridges crossing the atrium had more ceiling space available and also served as links for services crossings. The use of composite cellular beams provided a cost-effective long span system that could cater to the dynamic performance requirements and allow services to cross without paying the penalty in terms of weight. The ceiling configurations above the main entrance resulted in a very shallow available floor depth and a long span. The total span in this area between columns is 18m. Bridging this span was done by using a thickened reinforced concrete floor cantilevering over the support columns, supporting a simply supported Ultra-Shallow Floor Beam (USFB) system spanning almost 13m. The USFB system comprises of asymmetric steel sections with circular voids in the webs. The top flanges are narrower to allow permanent formwork to be dropped in, to span from beam to beam, resting on the bottom flanges. Composite action is achieved by using conventional reinforcing bars placed in the web openings (bars perpendicular to the beam span; plug composite action) Due to the long spans a propped construction methodology was adopted to limit the final deflection. To complicate matters further, the tips of the concrete edges supporting the USFB floor system on the building edge, had to be column-free at ground level to create a weather canopy. This was accommodated by suspending the perimeter of the 1st and 2nd floors using high capacity rods from a cantilever transfer beam at roof level How does this project demonstrate the benefits of steel as a material? Steel can be used successfully in combination with more conventional concrete construction in a complimentary way. Some structural systems and configurations necessitate the use of steel with its long-span and overall weight reduction capabilities. What is special/ unusual/ innovative/ aesthetic about the steelwork in this project? This is not really applicable, since the structural framing is largely concealed by cladding and ceiling systems. How did the project team work together? The use of Building Information Models (BIM), representative of the actual construction, assisted greatly in ensuring that all parties involved clearly understood the configuration of the planned structure and how the various components interacted. In addition to this, an open mind from the Contractor’s team to implement something out of the ordinary assisted in getting the job done. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Neutron Road Techno Park Stellenbosch Western Cape GPS Co-ordinates Latitude: 33°57'54.82"S Longitude: 18°49'51.49"E Google Maps link Closest location on Google Maps http://tiny.cc/u3d0jz STRUCTURAL STEELWORK Completion date of steelwork HQ Building – August 2019 Parkade Building – March 2020 Completion date of full project HQ Building – February 2020 Parkade Building – June 2020 Tonnage and steel profiles used 475t Project Team Role Company Nominator Macsteel Trading Client/ Developer Capitec Properties (Pty) Ltd Architect DHK Structural Engineer AECOM Engineer AECOM Quantity Surveyor De Leeuw Stellenbosch Project Manager SIP PM Main Contractor WBHO Steelwork Contractor LJ le Roux Industries (PTY) LTD Steel Erector LJ le Roux Industries (PTY) LTD Photographer, Photo competition Terry February Photography If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Leopard Hills Private Game Reserve by Bundu DakkeThe Leopard Hills private game reserve is located in the western sector of the renowned Sabi Sand Game Reserve, bordering the world famous Kruger National Park. In a recent upgrade to the luxury units, steel provided the client with a durable, low maintainence solution. By installing light weight steel Harvey thatch tiles over the original natural thatch roof, the project team was able to improve insulation, and increase the roof’s longevity. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Sabi Sand Game Reserve Hazyview 1243 Google Maps link Kruger Park https CLADDING Completion date of cladding January 2020 Cladding profile/ type used HARVEY THATCH TILE Cladding area coverage 2432M2 Cladding tonnage 19 tons If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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where MAN and MOUNTAIN meetWelgevonden Game Reserve forms part of the Waterberg Biosphere in the Limpopo Province of South Africa and is one of the most accessible premier malaria-free wilderness reserves in the country. The reserve is home to the ‘big five’ and over 130 different mammal species, 350 bird species, more than 2000 different plant species and is best known for its fascinating and rare ancient rock formations and layers of sandstone mountain ridges and ravines. 57 Waterberg is an existing private game lodge originally constructed in the early 2000’s in the familiar wooden pole and thatch vernacular. In respectful contrast, the contemporary 2019 extension and renovation project which includes five new luxury guest suites, an upgraded main lounge and entrance foyer, new and expanded chefs kitchen, laundry and various other ancillary functions envisioned a ‘new dawn’ where the buildings become secondary to the guest experience – a place where the landscape and natural surroundings come first. The conceptual 'IDEA' for this project was based on creating a space that 'celebrates' the context, one that appears as if it is the refinement and revelation of the land. The aim is to capture the unique qualities of the 'place' – essentially creating a new nature where the buildings ‘merely facilitates’ visitors to experience the untamed African bush. “Architecture is not based on concrete and steel, and the elements of the soil. It's based on wonder.” – Daniel Libeskind These new structures, and particularly the new guest suites, aren't meant to be looked at, but to be looked out from. More than anything, these spaces are sheltered viewing platforms. The focus is on the overwhelming presence of the layers of mountains, the natural bushveld, the countless animals, and the endless open space Due to very strict time constraints in combination with the remote location the complete construction process was based on separating all the various trades and planning for offsite manufacturing and on-site assembly – connecting and completing like an intricate three-dimensional puzzle. All building elements and components were further designed and planned as ‘single trade and unfinished’ – an approach that ensured the most direct and honest construction assembly. What is the purpose of the structure/ project? Welgevonden Game Reserve is a 36,000 Hectare Big Five private game reserve, with abundant wildlife, in the Waterberg District, of the Limpopo Province of South Africa. A 2.5-hour drive, or an easy 45-minute flight from Johannesburg into one of the airstrips, makes Welgevonden one of the most accessible premier malaria-free wilderness reserves in South Africa. “It was wildest, untouched Africa, and it was magic” – Jane Goodall The target market and purpose for the project is absolutely focussed on local and international tourism. The primary design focus was on creating ‘a place’ that would allow ‘MAN’ to meet the ‘MOUNTAIN’ Beyond the rational and functional design this project aims to trigger and facilitate an emotional or spiritual awakening to the African landscape What was the brief to the architect? New accommodation requirements as per client brief: Five new freestanding luxury guest suites New guest ‘arrival space’ - entrance foyer and reception desk Renovation of existing main lodge structure including new chef’s kitchen, laundry, bar and terrace with recessed fire pit Master planning of where all functions needed to be positioned and particularly the guest suites, all circulation walkways, privacy of guests and overall focus on and connection to the landscape Construction period time constraint of only 14 weeks for the complete project from the day the last guests departed, and the day first new guests arrived – ALL construction needed to be completed within this limited available time. ** This submission is focussed on the new guest suites** Was the project envisaged in steel from the start? If not – why was it built in steel in the end? On the practical side the project design and execution was driven by an extremely short construction period of only 14 weeks – this coupled with the remote location lead to the unique approach of isolating each building element to allow not only off-site manufacturing but more importantly simultaneous processes – with each trade ( puzzle piece ) or building element being manufactured to extremely accurate specifications in isolation and then fitting into the full assembly on site. The primary steel frame serves as the skeleton or backbone onto which all other components or building elements connect. This project and construction approach would not be possible without the structural stability and accuracy that steel provides. Give a brief description of the structural framing. What type of sections were used and why? Primary column profile - 225 x 225 x 6 SHS The oversized 225 SHS profiles allowed easy integration with modules and scale required by either 220mm clay brick infill walls or 3 track Palace aluminium sliding door systems. Primary floor beam profile - 254 x 146 x 31 I Beam The maximum spans and cantilevers, which reinforced the idea of a floating structure, determined these profile sizes. Roof / RC Slab edge profile - 305 x 102 x 25 I Beam The cast in-situ ( mixed on site ) reinforced concrete slab with all required falls and edge detailing determined the structural depth of the 305 I beam. This profile effectively serves as permanent formwork for the floating roof canopy. Tell more about fabrication and erection process if it was complex, difficult, innovative etc. What is most impressive about this project from a technical perspective? Besides the time constraints and the huge importance of accuracy for the structure additional challenges for the project was around how all elements/components would be transported to site and how it would be placed in position and assembled. All building components and material needed to fit onto smaller vehicles due to the narrow and rough access roads to the site. Assembly was mostly done with manual/physical labour and all connection points and scale of components had to work around these limitations. The most impressive aspect about these structures is how ‘simple’, precise and easy it all appears as it ‘floats’ above the landscape as a fully completed project. How does this project demonstrate the benefits of steel as a material?The success of this project hinged on two crucial attributes or benefits of using steel – Structural stability and quick, accurate off-site manufacturing. The ‘lightweight’ construction made it possible to complete the project, with substantial integrity, around a primary frame or ‘skeleton’ What is special/ unusual/ innovative/ aesthetic about the steelwork in this project? The primary construction material for the project is mild steel profiles, which ‘touch the earth lightly’ and shape the skeleton or mainframe onto which all the other building components attach Secondary materials include cast in situ reinforced concrete for the ‘floating’ roofs, Wooden decking for the floors, ceilings and terraces, Aluminium and glass for the shopfronts. The furniture, which was designed on the matching principle as the main room structure, is based on the same use of trades, materials and assembly process A very unique design aesthetic of the project is therefore the approach that ALL built forms, from primary structure to the smallest furniture piece, is designed and manufactured with the principal of having a ( visible ) STRUCTURAL STEEL FRAME or skeleton onto which and around which all secondary trades and finishes attach. How did the project team work together (e.g. contractor involved early, challenges/ ease of communication etc.) Given the extremely limited construction period and the absolute accuracy that was required to successfully complete the project there was a huge amount of co-ordination and positive project team management required. All designs had to be 100% confirmed and completed, with all trades and role players to full completion taken into consideration, before any manufacturing on the primary structure could commence. The typical construction process often allows various ‘inaccuracies’ that would in theory be ‘fixed’ by the next trade….. This project however required that all trades commenced with manufacturing of ALL building elements at basically the same time – This meant that while the concrete footings were cast on site the main steel frame, the aluminium doors, toughened glass panels, wooden floor beams, crystalite shower floors, bathroom vanity concrete tops and various other was being manufactured. Complete ‘faith’ in the design accuracy was required and this can only be achieved if all role players work together with a common goal. All professional consultants, the main contractor ( who’s ‘can do attitude’ made a HUGE impact ) and various sub-contractors came together around this ‘common goal’ and the success is a credit to fantastic team work. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 57 WATERBERG SITE 57 WELGEVONDEN GAME RESERVE VAALWATER LIMPOPO Google Maps link https://g.page/FiftySevenWaterberg?share STRUCTURAL STEELWORK Completion date of steelwork 19 July 2019 Completion date of full project 31 August 2019 Tonnage and steel profiles used 73 Tonnes Columns 224SHS Roof I beams 102 x 305 Floor I beams 146 x 254 / 200 IPE Project Team Role Company Nominator W design architecture studio cc Client/ Developer Welgevonden Lodge (Pty) Ltd t/a 57 WATERBERG Architect W design architecture studio cc Structural Engineer Struxit Projects Pty Ltd Engineer Struxit Projects Pty Ltd Quantity Surveyor Welgevonden Lodge (Pty) Ltd t/a 57 WATERBERG Project Manager W design architecture studio cc Main Contractor Frans Smith Building Services Steelwork Contractor Snyman Staalwerke cc Steel Erector Snyman Staalwerke cc Corrosion Protection Frans Smith Building Services Paintwork Contractor Frans Smith Building Services If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Baakens Valley Pedestrian BridgeThe Baakens Valley Pedestrian bridge is an iconic structure in Port Elizabeth. As part of the Mandela Bay Development Agency’s plan for the precinct, the bridge is a key part of rejuvenating the area.By extending and connecting the inner city to the Baakens Valley, the bridge plays a crucial part in creating a world class precinct for the community.The iconic structure is a composite design that makes extensive use of circular hollow sections. PROJECT OVERVIEW Physical address of the project Street Address Town Province 16 Lower Valley Rd Port ElizabethEastern Cape Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 05/06 July 2019(On site); 20 July2019 Crane Lifted Completion date of full project 12 December 2019 Tonnage and steel profiles used 14.8 tonnes – CHS Profiles & 2-profiles If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Fairways Resorts – Drakensberg Gardens by Holley HarveytileThe Fairways is a Gold Crown resort, situated in the Drakensberg Gardens Golf & Spa resort, bordering on 860 acres of World Heritage site.In a recent upgrade to the luxury units, steel provided the client with a durable, low maintainence solution. By installing light weight steel Harvey thatch tiles over the original natural thatch roof, the project team was able to improve insulation, and increase the roof’s longevity. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Fairways Drakensberg Resort Google Maps link https://goo.gl/maps/DD9mkJagcqvLHbH58 CLADDING Completion date of cladding MARCH 2020 Cladding profile/ type used HARVEY THATCH TILE Cladding area coverage 2800M2 Cladding tonnage 11 tons If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Botha’s Halte Primary SchoolA new primary school building was designed by Meyer & Associates Architects Urban Designers to replace the dilapidated Botha’s Halte farm school, in the Breede River Valley, outside Cape Town. Although the project was privately sponsored, it is a public school operated by the Western Cape Education Department. The new buildings provide a high-quality facility for 250 rural learners from a predominantly disadvantaged and poor farmworker community. The buildings have been designed around sustainability principles while respecting the cultural heritage of the area. A didactic design approach was followed, whereby these aspects are demonstrated throughout the complex as part of the teaching and educational processes. The “Anna Zaal” (circa 1927), the small first school building on the property, was restored to act as the entrance to the new school. It is accessed from a forecourt, acting as a threshold between the public and private aspects of the complex. The buildings are tucked into the landscape, with an accessible planted roof and the remainder of the curved roof-scape imitating the rolling foothills of the surrounding Witzenberg Mountains. The external colours are recessively dark with bright accents around openings and entrances, to fit into the scenic landscape. In contrast, the historical “Anna Zaal” and the new conical water and wind tower are both white, to reflect the link with the white-washed Cape Dutch building traditions of the past, and to emphasise a green and ecologically sustainable future. The tower also references other regionalist heritage typologies, such as frontier corbelled huts from the area and natural structures such as ant heaps, with its own ecological design lessons. The interiors, in contrast, are light with bright colours employed throughout, to stimulate creativity and inspire intellectual and emotional development. Furniture and equipment have been purposely selected by the architects to this end. The buildings operate largely independent from the unreliable public electricity grid, with solar and wind generating capacity – the benefit of this is demonstrated to learners via interactive displays. Stormwater is harvested and stored in a reservoir under the buildings, from where the grounds are irrigated. This is topped up by a borehole as well as treated effluent from a sewerage package plant. Accommodation includes a fan-shaped multipurpose hall, three specialist classrooms as well as a state-of-the-art science laboratory. A centrally located discovery centre, with its distinct steel tree columns, acts as additional break-out and audio-visual teaching space. All classrooms lead seamlessly out on to play areas, dedicated to specific learner age groups. Externally, two Astroturf play areas are provided - one for older learners for formal and competitive play with spectator seating, and the other, a secure and intimate exploratory play area for younger learners. Two productive play areas are also included - a lemon tree orchard and a productive vegetable garden, serving the school feeding scheme and also the Bosjes restaurant up the road. The school buildings demonstrate how contemporary technologies and inventive architectural design can be employed to benefit a rural disadvantaged community in South Africa. What makes this project special? The Botha’s Halte Primary School building is a sensitively designed educational building which both inspires and brings hope to a disadvantaged rural community. The project demonstrates that even rural schools in South Africa can get access to the best educational tools available and that a regionalist approach to architecture can deliver a building which both speaks to its context and its place in time. It is an original piece of architecture, which demonstrates through its unique layout, form and use of steel, how sustainability principles and cultural heritage can be incorporated into the pedagogy of educational buildings. The interiors are light and bright and designed with the learner as the client in mind. A general openness and fluidity of interior spaces have been incorporated into the layout, compared to the insular and inward-looking layouts associated with the older schools in South Africa. The design team, together with the client have proactively aimed at implementing innovative solutions to pro-actively change the perspective and the future of these learners. This school serves as an educational outreach hub, from where the nearby University of Stellenbosch conduct teacher training and distance learning specialist classes to other outlying communities. This building serves as a model and case study for the development of future public rural schools in South Africa. The project demonstrates the innovative use of steel throughout. Roof trusses were manufactured from steel throughout the project, except in the restored Anna Zaal portion, where purpose made timber roof trusses were employed for heritage value. The steel trusses over the auditorium act as anchors to counterbalance the leaning curved wall which forms the backdrop to the auditorium. The expressive roofs are all covered in steel roof sheeting with immaculately detailed roof edges and eaves in folded metal. The most spectacular aspect of the building complex is the tubular steel “tree columns”, found in the central Discovery Centre, which act as the central audio-visual and digital learning hub for the school. Not only does the tree columns reference the “tree of knowledge” idea but also has broader significance for rural learners where education may at times occur in the shade of trees in an informal manner. The four “tree columns”, each different in its configuration, are individually sculpted and constructed from tubular steel sections, fitted and welded together, to carry structurally, a large central concrete roof and planted roof above. Four light scoops pierce through the roof garden above, and light up the “tree columns” itself, similar to the light filtering through the tree canopy in a forest, to provide a soft even natural light quality to the Discovery Centre. The application and use of Steel as material, has therefore played a major role in establishing this building as a future benchmark for rural educational projects in South Africa. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Botha’s Halte Primary School, Off R43 Botha Kelder, Worcester, Western Cape, 6849 Google Maps link https://goo.gl/maps/ZN2E8NLTV7Pc5ET77 STRUCTURAL STEELWORK Completion date of steelwork 1 February 2019 Completion date of the full project 1 September 2019 Tonnage and steel profiles used 45 Tonnes. Various profiles on circular steel tree columns, pergola, and structure. Project Team Nominator Meyer and Associates Architects, Urban Designers Client/ Developer Bosjes Trust Architect Meyer and Associates Architects, Urban Designers Structural Engineer Grobler and Associates Electrical Engineer Bührmann Consulting Engineers Civil Engineer AVDM Quantity Surveyor 2ii Consulting Project Manager - Main Contractor J J Dempers Group Steelwork Contractor Triomf Staal Steelwork Contractor (Steel tree columns) Link Engineering Steel Erector Triomf Staal Cladding Manufacturer - Cladding Supplier - Cladding Contractor - Galvanising Paintwork Contractor Photographer, Photo competition Adam Letch Photography Photographer, Other submitted images Meyer and Associates Architects, Urban Designers If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Featherbed Restaurant FacilityThe purpose of the Featherbed Restaurant Facility project was to rebuild the restaurant that had burnt down in the Knysna fires of 2017. The structure had to be such that it streamlined the construction process to ensure the earliest possible reopening of the restaurant for business.The brief to Tracey Mills of TMBA (Pty) Ltd was to design a newrestaurant within the parameters of the coverage of the old restaurant withan additional 44.99m2 additional coverage being allowed. Since the fires had eradicated most of the vegetation stabilising the banksclose to the water’s edge, the environmental departments restricted anydigging within a certain distance from the high-water mark.The strip foundations of the structure, therefore, had to be pushed backwhich limited the area that could be utilised for the main building.A solution was found to stabilise the existing ground level by installingpiles along the front edge of the main restaurant. These piles were closetogether so that any storm surges would not erode the ground from underthe restaurant. The foundations and surface beds were then constructed on top of these piles.Cantilevered concrete beams were constructed to extend the externalfloor area and to provide deck area in front of the restaurant which isutilised by the day-trippers as well as the restaurant patrons.Since the restaurant needed to be re-opened for business as soon aspossible, the structure had to be such that it streamlined the constructionprocess and reduced the construction period. Therefore, steelwork and fast curing concrete were used for the main structure.The project was envisioned in steel from the start as this would allowthe infill panels to be built while the rest of the steel structure was beingerected, thereby fast-tracking the construction process.Structural FramingThe steel column size of 200x200x4.5 (E on the drawings) was used tosupport the beams for the main building:This was to provide a surface that was easy to connect to the aluminium windows and doors as well as the brickwork and concrete walls.The steel column size of 100x100x3.0 (F on the drawings) was used tosupport the beam under the rafters.These columns were used and placed under each rafter in order toprovide a surface to fix the roof windows that were installed inbetween each rafter.The steel beam size of 533x210x92 (A1 on the drawings) was used wheremost of the loading occurred.The steel beam size of 533x210x82 (A2 on the drawings) was used forthe larger spans between columns.The steel beam size of 305x165x40 (B on the drawings) was used for thesmaller spans between columns with less loading.The steel beam size of 203x133x25 (C on the drawings) was used tosupport the rafters and the landing of the external staircase.The steel beam size of 203x203x46 (D on the drawings) was used tosupport the rafters in the middle of the span.The challenge for the engineer, Serett Maree of Tuiniqua, was to designthe steel structure in a way that made the erection thereof as easy aspossible. Due to the nature of the narrow site and that a crane had to be used toerect the steel, the steel structure had to be erected in phases withoutplacing undue loads on the concrete surface beds and foundations.This provided a challenge for the contractor, Cameron Wardable of CapeIsland Construction, the steel manufacturer and erector, Jan Du Rand ofJLMA, and the engineer on site.How does this project demonstrate the benefits of steelThis project would have taken a lot longer to complete had the design notincorporated steel structural framing from the beginning.If steelwork had not been used then this would have seriously affected thecompany’s, John Benn (Pty) Ltd, from trading as early as they did.The steel was also a major aesthetic element for the finished product.What is special/ unusual/ innovative/ aesthetic about the steelworkin this project?The steel in this project provides the major aesthetic in this project.A variety of different materials were used for the infill panels, either ascladding or as the main building material, which further added to theoverall textural and aesthetic appeal of the project.The steelwork allowed the concrete slabs to be poured using an offshutteraesthetic during the erection of the steelwork.The use of off shutter concrete was to fast track the finishing stages as noskimming or painting was necessary.This would not have happened had they not used steelwork. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Portion 59 of 216, Uitzicht, Brenton Knysna Western Cape Google Maps link STRUCTURAL STEELWORK Completion date of steelwork April 2018 Completion date of full project March 2019 Tonnage and steel profiles used I-beams and square profiles Project Team Nominator TMBA (Pty) Ltd Client/ Developer John Benn (Pty) Ltd Architect TMBA (Pty) Ltd Structural Engineer Tuiniqua Consultants Environmental Control Eco-Route Environmental Consultancy Quantity Surveyor McIntosh Consultants Project Manager Main Contractor Cape Island Construction Steelwork Contractor JLMA Engineering Steel Erector JLMA Engineering Cladding Manufacturer Cape Island Construction Cladding Supplier Cape Island Construction Cladding Contractor Cape Island Construction Corrosion Protection Galvanising JLMA Engineering Corrosion Protection Cape Island Construction Paintwork Contractor Cape Island Construction Photographer, Photo competition Hylton Herd Photography Photographer, Other submitted images Hylton Herd Photography If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Whale Trail StaircaseParaMatic was commissioned by a contractor on behalf of CapeNature to measure the site then conceptualise and detail the new steel stairway to Stilgat at the De Hoop Nature Reserve in the Western Cape. ParaMatic used a 3D scanner to capture the site and modelled and detailed the new stairway in Tekla Structures. The De Hoop Whale Trail is a world-famous long-distance hiking trail in the De Hoop Nature Reserve administered by CapeNature. The 54 km trail has overnight stops along the trail and runs through mountain and coastal regions. Part of the trail runs along a coastal ridge with a detour down a steep valley to a renowned swimming cove and picnic spot at Stilgat. The hiking path runs approximately 100 m from the sea and is subject to daily exposure to sea air, mist and wind borne salt spray. The original timber and wire rope ladders on the mountainside have long since decayed from rot and corrosion and the climb from the mountain path to the sea is perilous. With an increasing trend in the average age of hikers, the client realized that the route either had to be closed or made safe. Cable or chain ladders were considered too risky for the profile of the hikers and a stairway was approved for the path to Stilgat. The brief The owner proposed and approved a stairway but stipulated that the stairway had to be aesthetically unobtrusive, sympathetic with the area, modular and lightweight and make a minimal use of cement works. Maximum off site manufacture was required. No survey data on the site was available. The remoteness of the site makes regular maintenance impractical. The site is far from the Reserve main offices on a rough road and is in a pristine, undamaged coastal zone. On-site contractors are hard to manage on such a large site as De Hoop and the owner wanted site activities to be as short as possible and with the smallest possible labour force. The project was also on a tight deadline so as not to affect the 2020 Summer hiking calendar. Morning mist, wind spray and heavy early morning condensation are regular environmental considerations. Softwood rots quickly and is wholly unsuited to the climate. Uncoated steel corrodes within days. Wherever possible, the staircase had to follow the mountainside to allow it to blend in with the undergrowth and avoid breaking the silhouette of the cliff. The stairway had to allow for perennial river flow in the stream bed and not block the stream in full flow. Access to a lookout point was discussed. Road access close to the site is only possible using a small four-wheel drive vehicle, with a rough climb from the unloading point to the installation site. All components therefore had to be suited to portage over rough terrain without endangering the installation contractor’s staff. Site welding had to be eliminated or minimized. Drilling using battery packs would be acceptable, so anchor foundations into existing rock was considered the preferred route for fixing wherever possible. Heavily burdened hikers must be able to descend the stairs without slipping on wet surfaces. The area does experience intermittent fires, but is remote and considered inaccessible to fire fighters with other priorities during a fire. It was not practical to route the stairway away from flammable vegetation. The structure must be essentially fire proof and if a component is fire damaged, the design should allow for replacement without welding. Fire damage should not compromise the immediate stability of the structure. The cost of a stainless steel structure was beyond the budget of the project. A structural, duplex hot dip galvanized solution was considered the most likely functional and economic solution.Why steel? The owner proposed and approved a stairway but stipulated that the stairway had to be aesthetically unobtrusive, sympathetic with the area, modular and lightweight and make a minimal use of cement works. Maximum off site manufacture was required. No survey data on the site was available. The remoteness of the site makes regular maintenance impractical. The site is far from the Reserve main offices on a rough road and is in a pristine, undamaged coastal zone. On-site contractors are hard to manage on such a large site as De Hoop and the owner wanted site activities to be as short as possible and with the smallest possible labour force. The project was also on a tight deadline so as not to affect the 2020 Summer hiking calendar. Morning mist, wind spray and heavy early morning condensation are regular environmental considerations. Softwood rots quickly and is wholly unsuited to the climate. Uncoated steel corrodes within days. Wherever possible, the staircase had to follow the mountainside to allow it to blend in with the undergrowth and avoid breaking the silhouette of the cliff. The stairway had to allow for perennial river flow in the stream bed and not block the stream in full flow. Access to a lookout point was discussed. Road access close to the site is only possible using a small four-wheel drive vehicle, with a rough climb from the unloading point to the installation site. All components therefore had to be suited to portage over rough terrain without endangering the installation contractor’s staff. Site welding had to be eliminated or minimized. Drilling using battery packs would be acceptable, so anchor foundations into existing rock was considered the preferred route for fixing wherever possible. Heavily burdened hikers must be able to descend the stairs without slipping on wet surfaces. The area does experience intermittent fires, but is remote and considered inaccessible to fire fighters with other priorities during a fire. It was not practical to route the stairway away from flammable vegetation. The structure must be essentially fire proof and if a component is fire damaged, the design should allow for replacement without welding. Fire damage should not compromise the immediate stability of the structure. The cost of a stainless steel structure was beyond the budget of the project. A structural, duplex hot dip galvanized solution was considered the most likely functional and economic solution.Structural framing Steel is the material most suited to manufacture of varying lengths and geometries. Standard hot rolled sections were used for the stair stringers and platforms. All elements were limited in mass to ensure they could be hand carried onto site for bolted assembly. The client provided a typical section for the handrail detail which had to be modified to suit hot dip galvanising after welding. The client agreed that standard stair treads had an industrial appearance and that non slip grating types treads could be painful in a fall. The final stair tread concept was a carcass of a thin plate with bolted-on machined timber stair inserts, selected for their anti-slip properties. Treads are replaceable, using counter sunk bolts. A damaged insert would not affect the short term usability of the stairway. Hardwood or recycled plastic treads were specified as these do not require treatment or maintenance. Site Survey: No information on the site was available. ParaMatic used a Leica BLK360 to scan the site and obtain a point cloud. Before the scan, we identified and marked the most probably route using barrier tape and pegs and scanned this path. The Leica is small and portable and is easy to place in awkward positions. A typical scan takes 2-3 minutes and approximately 40 scans were made. The pointcloud and panoramic photographic detail allowed us to identify practically every surface and feature of the rock faces and digitise the routing for the stairway. No physical measurements were taken. Individual scans are composited to make up a single point cloud model of the site. All the decisions regarding final stair dimensions were made in the drawing office Before installation, we returned to site with foundation drilling templates and marked the positions of each of the stair components for drilling of the holding down bolts. Using exposed rock surfaces wherever possible. Cost and Speed: The owner’s budget for detailing was even lower than that of a standard structural steel frame supplied at standard fabrication rates. Detailing in Tekla allowed the model to be developed over the point cloud, eliminating the iterative testing which slows projects and delays detailing. Tekla Stuctures is especially powerful for detailing of special details and configurations and facilitated rerouting after the model was reviewed. Tekla produces consolidated bills of material which allowed us to quickly check that we were within our mass budget and provided detailed cutting lists and component drawing to ensure that the manufacturer was able to purchase accurate materials and bolts requirements and deliver precisely the detailers intent. After two days of scanning, we were able to produce the model and detail drawings within 10 days of drawing time Installation: What is most impressive about this project from a technical perspective? The owner had originally anticipated that the finished material would be delivered by helicopter, owing to the remoteness of the site. By detailing accurate, finished sub-assemblies in small, portable, site bolted frames, the owner was able to eliminate helicopter transport and more importantly inspect prior to delivery and confirm that components met the required dimensions, reducing site corrections to a minimum. ParaMatic were able to deliver on the promise of a purpose designed stairway with a limited budget quickly and effectively by importing a point cloud into the model. Traditionally, a point cloud is data heavy and is used to generate a model which is then used for further detailing. Tekla Structures systems architecture allows for modelling and viewing in realtime without delays and machine crashes. How does this project demonstrate the benefits of steel as a material? Steel is a perfect building element for elaborate builds – the ready availability of structural sections and the ability to bend and weld stock plate from the same material for a cost effective yet unique and hardy product. Joining and coating processes are simple and well understood and relatively simple. Further, steel allows for relatively simple site alterations and welding without significant quality compromise. What is special/ unusual/ innovative/ aesthetic about the steelwork in this project? Absolutely no measurements were taken on site and the modeller was totally reliant on the output of the scanner. Usual practice is to visit site with a clipboard, camera and a tape measure. The nature of the site makes this impossible. Steep, loose slopes break up lines of sight and the only practical site solution without a scanner would have been to build modular frames and cut and weld them on site to suit the topography. While surveying has a role, the data returned by the surveyor has no “look and feel” and does not provide for determining better alternatives in the second round of design. Using prefabricated frames changes the nature of the project, eliminating the need for boilermakers and welders to be given safe working plaftorms and converts the project into a simple erection sequence carried out by competent steel erectors. It is unusual for handrails to be fully detailed and manufactured prior to delivery to site. Scannign made this possible. How did the project team work together (e.g. contractor involved early, challenges/ ease of communication etc.) The ParaMatic team visited the site with the Project Originator and Champion, employed by the Owner, and the project Engineer. On a cold, windy and wet day we marked out the best route with barrier tape and discussed alternatives. After the routing was finalised and agreed and paced out we scanned the route from cliff top to beach level. On returning to the offices, we prepared a first model which was forwarded to the client for comment and approval. Overlaying the model on the point cloud allowed all parties to visualise the routing and issue approval to continue. Without the scan of the site, we would have to rely on tape measure and photographs, normally problematic on a complex site. The scanner allowed us to plan around vegetation and decide when vegetation could be easily removed for later regrowth, again taking decisions up front which would have been referred to the field engineer during the construction. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province De Hoop Nature Reserve, Bredasdorp, Western Cape Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 31/03/2020 Completion date of full project 15/04/2020 Tonnage and steel profiles used 5.8 tons of Channels, Tubes and Platework If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Sappi Saiccor Woodyard Upgrade – Conveyor SystemA complete woodchip conveying package supplied by TAKRAF Africa to Sappi’s Saiccor mill in Umkomaas, KwaZulu-Natal, South Africa, featured a unique four-conveyor, double-decker, walk-in type gallery, with the gantry bridge spanning 45 m, at a height of 24 m, over the existing Sulphur plant. The double-decker gantry houses the four conveyors in a 2 (top deck) + 2 (bottom deck) arrangement.This double-decker design, together with other innovative design and technical features, enabled TAKRAF Africa to produce a successful solution within the severely confined space of the brownfields site and integrate it into the existing mill infrastructure.The woodchip conveying package, the Sappi Saiccor Woodyard Upgrade (SSWU), handles increased production made possible by expansion to the Saiccor mill from 780 000 tpa to 890 000 tpa.The package conveys woodchips from existing and new chipping lines to feed two new stockpiles at up to 680 tph. Using four screw reclaimers (from another OEM) and associated conveyors, woodchips are reclaimed from the stockpiles at a maximum 403 tph and conveyed to existing infeed digestor conveyors to feed existing silos.The package covered design, engineering, installation and commissioning of 24 trough conveyors, 10 m to approximately 200 m long and some with incline angles of 19°; three Redler en-masse chain conveyors; transfer towers; and related systems. Conveying capacities range from 5 tph to 806 tph and belt speeds from 1.5 m/s to 2.8 m/s. Technical and aesthetic highlightsThe project incorporated ground-breaking steel structures, the most impressive being the double-decker gallery and large spanning stockpile gantries. Gantry G1 (weighing 72 tonnes), for example, spans 45 m over the plant. This is rarely done in conveying applications.Consideration of structural framing and stability of gantries during engineering enabled lifting the double-decker gantries into position without interference with the existing plant. The head-end gantry G3, spanning over a Blower Building, was the largest lift, weighing over 85 tonnes.The stockyard consists of A-frame support trestles, which transfer large forces from stockpile gantries to piled foundations. The trestle baseplates are considered as pinned connections to ensure that the A-frames only transfer axial forces to the foundations.With reference to the cladding, while most of the 13 600 m2 used was fabricated from aluminium and painted blue to aesthetically match the existing plant, the double-decker conveyors were clad with stainless steel sheeting as protection from the corrosive environment. The structures were assembled, lifted and fixed into position without cladding to prevent damage to the latter. Most of the cladding was therefore installed at height, with structures reaching 35 m high.Other innovative features include three reversible conveyors feeding two reversible shuttle conveyors to convey material to either of two stockpiles from the different chipping lines. Chutes were designed using DEM technology, as woodchips tend to exhibit airborne behaviour at certain velocities. Stockpile stacking is done by automated zone control with equal spreading of different wood species.The bypass system from the stacking route to the reclaim conveyors, used if a reclaim machine is undergoing maintenance or in case of unplanned downtime, has a self-supported pipe design requiring no intermediate trestle support. A bypass plough mechanism diverts material temporarily from the existing chipping line to a newly supplied conveyor.Redler conveyors convey fines generated by the screening system. Besides their ability to fit in with restricted layouts and space, their multiple discharges facilitate building of a “conshelled type” stockpile and assist in loading a truck evenly.FabricationStructural steel fabrication is the norm in the bulk materials handling industry, providing conveying systems with the durability and strength to withstand harsh weather and heavy industrial use.Structural steel also offers flexibility to the structural design engineer. This is evident in the various different framing systems that were utilized on the project to deliver intricate solutions in the restrictive constraints of the layouts and existing infrastructure.Additionally, the strength per mass ratio of steel allows design of structures that can be lifted into position after pre-fabrication and assembly, as with the double-decker gallery and woodpile galleries.In total, structural steel of approximately 1 700 tons was designed, fabricated and installed within a 12-month project duration. All hot-rolled structural steel profiles were rolled and fabricated in South Africa.Due to the short timeline, fabrication was split between local South African fabricators. Structural detailing and fabrication companies were selected early in the project to assess their capabilities in manufacturing timelines and prevent ‘overloading’. Availability of certain section sizes was a key element, with four structural detailing, five structural fabrication and one dedicated flooring and hand railing company(ies) used.Structural framingConveyor gantries and galleries have trussed sides and tops and bottoms. Each conveyor gantry is portalized at the trestles to transfer lateral forces in the top chords to the trestles. Two types of trestles support the 45 m spanning woodpile galleries in the stockyard: Type A trestles resist vertical, horizontal and longitudinal forces on the galleries, while Type B trestles resist vertical and horizontal forces to reduce the effect of thermal movement. Due to constrained interfaces and limited space, a conventional transfer tower at the head-end was not possible. A transfer gantry concept was therefore developed to ensure conveyor system stability by transferring all longitudinal belt and wind forces on the conveyor back to an anchor trestle. This is typical on the reclaim, double-decker and incline conveyors. The incline conveyors have sliding joints at the top trestle joining to the gallery to ensure longitudinal forces are transferred to the anchor trestle and not the gallery. The transfer towers are traditional braced and portalized structures. ErectionAs this was an operational plant, certain tie-ins had to be completed during limited shutdown windows, while also interfacing with new and existing Civils and LPS power supply services. Client involvement in construction meetings ensured access for pre-assembly and lifting with minimal disruption to other construction activities. More than 50 % of construction was completed next to existing plant operations. Some big lifts were completed early morning or late afternoon to reduce impact on other construction activities. Team-workAs the fast-track contract called for precise planning, the project team was aligned at the project start. Dedicated teams were set up for the basic design and the project was internally planned in three areas to allocate engineering responsibilities to mechanical and structural teams and drawing office section leaders. ‘Design base / criteria’ ensured that the structural team worked on the same baseline for the relevant loading criteria.The quality assurance and control team provided effective communication with workshops to ensure no repeat inspections, while inclusion of the project manager in the engineering team’s daily meetings facilitated project scheduling.Safety was a critical consideration from the start, and particularly so during execution, with challenges such as working at height and working in a very confined, brownfields site. Due to the project team’s safety focus, the project was closed out successfully with only one lost time injury (LTI). Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEWPhysical address of the project Street Address Town ProvinceUmkomanzi Drift R197 Umkomaas 4170Google Maps linkhttps://www.google.co.za/maps/place/Sappi+Saiccor+(Pty)+Ltd/@-30.180527,30.7709497,15z/data=!4m5!3m4!1s0x0:0xf89ed4af015a3a0f!8m2!3d-30.180527!4d30.7709497 STRUCTURAL STEELWORKCompletion date of steelworkMARCH 2019Completion date of full projectMAY 2019Tonnage and steel profiles used1600 Project Team NominatorTAKRAFClient/ DeveloperSappi Pty Ltd - Saiccor OperationsArchitect / Clients Engineer / Owners EngineerSIVESTStructural EngineerTAKRAFMechanical EngineerTAKRAFDrawing OfficeTAKRAFExternal Drawing officeAtomic ProjectsExternal Drawing officeCad HouseQuantity Surveyorn/aSteelwork ContractorLouwillSteelwork ContractorQR SteelSteelwork ContractorImpact EngineeringSteelwork ContractorAvellini BrothersSteelwork ContractorFP EngineeringSteelwork ContractorCoertzen Engineering ConsultantsSteel ErectorTlotloCladding ManufacturerGlobal Roofing Solutions - A division of Consolidated Steel Industries (Pty) LtdCladding SupplierGlobal Roofing Solutions - A division of Consolidated Steel Industries (Pty) LtdCladding ContractorTlotloCorrosion ProtectionRand Sandblasting ProjectsGalvanisingn/aPaintwork ContractorRand Sandblasting ProjectsPaintwork ContractorLouwill Engineering (Pty) LtdPaintwork ContractorQR SteelPaintwork ContractorImpact Engineering CCPaintwork ContractorCoertzen Engineering ConsultantsPhotographer, Photo competitionUNPRECEDENTED PicturesPhotographer, Other submitted imagesUNPRECEDENTED Pictures CLADDING (If applicable)Completion date of claddingMARCH 2019Cladding profile/ type usedIBR686Cladding area coverage 13600m²Cladding tonnage84,76 tonne If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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The new replacement swing bridge, V&A WaterfrontThe V&A Waterfront (V&A), situated in South Africa’s oldest working harbour, is a mixed-use development for both residential and commercial, offering visitors from near and far a world-class experience when it comes to entertainment, shopping, dining and accommodation. The V&A already had a swing bridge that was well-used and well-loved. It was an efficient structure that opened and closed up to 60 times a day, carrying up to 2.4 million people per year. It was, however, 22 years old: a lifetime in the context of the V&A and the 2 m wide walkway, which once seemed appropriate, could no longer cope with the rising numbers of pedestrians. The team was therefore commissioned to design a new wider bridge The engineering brief The challenge set by the client was: The new bridge had to be equally quick and efficient, effective and reliable as the existing; The construction cost had to stay within a tight budget; and The works had to limit the disruption to the public, the V&A and the environment. Both steel and FRP were considered at the early stages of the project as the only materials that were light enough to limit the loads on the moving mechanical parts and to limit the foundation size. However, as the design progressed the use steel was the obvious choice. Its advantages were: Its strength enabled the creation of a stiff yet slender pylon as well as a relatively shallow central spine beam. The material is robust and can withstand some impact. It created a relatively light weight structure that limited the power needed to move the bridge. The local expertise to fabricate the bridge was readily available in Cape Town. It enabled the bridge to befabricated offsite and easily assembled on site and lifted into place. It gave great opportunity to sculpt a beautiful structure. Structural framing The new swing bridge has a span of 40 m. The deck is cable-stayed with a single plane of 4 locked coil cables connecting to a central, upstand spine beam. The spine beam is a 500 mm wide fabricated box with a total depth of 800 mm, but only 470 mm protrudes above the top of the deck. The reclining pylon is in the continuity of the main central beam and its stiffness transfers the cable loads into the piled substructure. The steel with timber deck is rotated on a slewing bearing, which is stressed down onto a doughnut-shaped pile cap by 34 vertical Freyssibars. The steel deck comprises cantilevering cross beams that are fabricated I-sections; a longitudinal edge beam that is a triangular closed section; and bracing members that are standard angle and T-sections. The end beam houses the bridge wheel assembly and is a box section to resist the loads at the deck tip. The pylon is a fabricated box that has been sculpted to provide strength and stiffness where required. The stay cable anchorages are discretely housed within the top of the pylon with an access panel at the back to allow for stressing and inspection. ChallengesThis was a very challenging build. The bridge is over 40m long and 3m wide with the mast section extending over 10m into the air. Once completed it weighed more than 40T. In the workshop the eccentric shapes of the individual sections (some as big as 16T) created big challenges with regards to the moving and rotating for the welding and fabrication. One of the project objectives was to limit disruption to the V&A. Hence, the bridge was assembled on a nearby jetty. Once completed the bridge was carefully craned onto a barge and towed to its final position. The bridge was then lifted off the barge and mounted onto the slewing bearing. It was an amazing process that took 2 days and careful co-ordination and it was a first for many to see a completed bridge sail away. The interface between the bridge and the circular slew bearing was a critical joint that required very tight flatness and dimensional tolerances. If not achieved the bearing’s working life might be reduced or worse the fit-up with the bearing might have been compromised. The bridge 3.5 m diameter ring beam that connects it to the bearing was fabricated from heavy plate sections to resist the forces needed to prestress it down onto the bearing. The dimensional control required in fabricating this element was a significant challenge and required all the skills of the welding team. The architectural intent was for the pylon to be a continuation of the central upstand beam. As such, it is a very slender element. The fit up of the stiffeners and diaphragms as well as the various fabricated pieces of the pylon, ring beam, spine beam and deck elements had to be carefully considered to ensure that the required welding operations were practical. The sequence of closing the hollow box sections and of jointing them on-site also presented several conceptual problems. The 3-dimensional Revit model developed by the design team was essential for testing this aspect of the design. The modelling work done undoubtedly saved time in the fabrication yard and on-site. Impressive technical aspects of this project A moving bridge project is unique in itself and for the design team the greatest technical achievement was the combination and integration of mechanical, structural, marine, geotechnical, construction and architectural expertise to create a simple but beautiful structure that moves. The use of a slew bearing was a technical innovation not seen before in Africa and the design team had to undertake detailed research and modelling to validate it could be used for a bridge of this type.Having to manufacture the bridge on one side of the harbour, ship to across the harbour and offload it onto the bearing on the other side of the harbour introduced elements that we never normally deal with. Ensuring the bridge didn’t fall off the barge and into the sea was always in the back of our minds.How this project demonstrates the benefit of steel as a material As mentioned above steel offered the opportunity to create a relatively lightweight and slender structure that could be sculpted into a single attractive form. It’s proven robustness and strength is unrivalled. The bridge was fabricated into a single sculpted form. It is not a collection of parts; deck, mast, beam. It is rather a bridge with its own identity that can be recognized as a landmark. The use of steelwork has enabled architecture and structure are integrated together. The curves and sculpting of the various box elements create a beautiful bridge that seemingly rotates and supports itself by unseen parts. How the project team worked together The core design team: SMEC South Africa, Stefanutti Stocks, Eadon Consulting and the V&A Waterfront came together 4 and a half years before the bridge was finally open to the public. The early contractor involvement, the dedication from the client and the passion from all the designers involved throughout the design and construction processes ensured the success of the project. The vision to create something beautiful for Cape Town to be proud of was shared by all those involved and fuelled good working relationships. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEWPhysical address of the project Street Address Town ProvinceV&A Waterfront, New Swing Bridge (connecting the Pierhead Precinct with the Clock Tower Precinct)Google Maps link STRUCTURAL STEELWORKCompletion date of steelworkAugust 2019Completion date of full projectAugust 2019Tonnage and steel profiles used46.3 tonnes, Ex Plate 25 – 100mm Project Team Company Nominator Anchor Steel Projects Client/ Developer Waterfront Properties Architect Coasite Craft of Architecture Structural Engineer SMEC Engineers Engineer SMEC Engineers Quantity Surveyor SMEC Engineers Project Manager Steffanutti Stocks Coastal Main Contractor Steffanutti Stocks Coastal Steelwork Contractor Anchor Steel Projects Steel Erector / Project Coordinator Anchor Steel Projects Cladding Manufacturer Cladding Supplier Cladding Contractor Corrosion Protection Galvanising Advanced Galvanising Corrosion Protection MRH Shot Blasting and Corrosion Control Paintwork Contractor MRH Shot Blasting and Corrosion Control Photographer, Photo competition Anchor Steel Projects Photographer, Other submitted images Anchor Steel Projects If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Vamosem Semi Mobile Crushing PlantThe project entailed the fabrication of complete mobile crushing plant for a mine in Mozambique Reason why steel (hot rolled/ lightweight/ tubular/ cellular/ Platework) was chosen: Steel/Platework was chosen as the material of construction due to the industrial nature of the project. What is special/ unusual/ innovative/ aesthetic about the steelwork/plate work/cladding in this project? This SMC plant was detailed, fabricated by local South African companies which really showcases the level of experience and expertise that South Africa has. Green building rating/environmental or sustainability considerations At Betterect’s fabrication facility in Chamdor Krugersdorp, environmental concerns are kept in the forefront of our minds. All offcuts of steel are collected and recycled. Special considerations such as the design process, fabrication, transport, and erection The design of the SMC Plant was undertaken by ThyssenKrupp Germany, however, the detailing of the steelwork/plate work was undertaken by Betterect. The project included the fabrication of over 1 000 parts totaling to close to 950 tons of steelwork, plate work, grating, and hand railing and the pre-assembly thereof. The fabrication of this steelwork/plate work was extremely labour intensive and required the strictest quality requirements as all welds required 100% non-destructive testing and needed to pass either radiographic or ultrasonic testing. The reason for such high-quality standards was due to the enormous loads/tonnages placed on the steelwork/plate work during operation at the mine in Mozambique. There were many technical fabrication requirements which included preheating, welding of exotic materials, laser alignment, heavy lifts and more. The steelwork was painted with an industrial three-coat paint specification to withstand the grueling exposure to elements and operational requirements. The hopper base frame weighed close to 45 tons and required abnormal transport loads to the site, which included police escorts in some area on route to the site due to the size of the equipment. Challenges and solutions The large number of loose parts and the uncompromising level of quality were challenges faced on the project. Satisfaction/ testimony of the client This was a technically challenging project due to the stringent NDT requirements and the quality level of the fabrication by Betterect was extremely high. Overall, it was a successful project with the equipment currently in operation. What makes your entry special and different from other entries that may be in your category? This project was truly a South African Engineering accomplishment and showed the world the capabilities of our fabricators and design houses. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province Moatize Coal Mine, Tete, Mozambique Google Maps link STRUCTURAL STEELWORK Completion date of steelwork 12th December 2019 Completion date of full project 12th December 2019 Tonnage and steel profiles used 920 tons Project Team Role Company Nominator Betterect Client/ Developer ThyssenKrupp Industrial Solutions Structural Engineer ThyssenKrupp Industrial Solutions Steelwork Contractor Betterect Cladding Manufacturer Global Roofing Cladding Supplier Global Roofing Cladding Contractor Global Roofing Paintwork Contractor Betterect If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.
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Gateway Shopping CentreGateway Theatre of Shopping has had a fundamental influence on the boom in the development of Umhlanga Ridge. The primary motivation to undertake this project was to match increasing consumer demands, to respond to a request from global brands for representation in the mall, to act on interest from local brands for additional space and the directive from the Client to revitalize the social and entertainment nodes of the mall. The expansion introduced leading global brands such as H&M, Starbucks and Hamley’s. A new mall extension was developed to expand existing key brands and an interactive Food Court was designed as the nexus of the entertainment node of Gateway. Architectural Brief The brief was to relocate the current existing food and entertainment offerings and to create a spacious and comfortable FEC component, taking advantage of natural light and breath-taking views over the Durban landscape. The design was to respond positively to the need for a central gathering area providing food and entertainment thereby acting as a positive catalyst for new and innovative aesthetics. From inception, the main architectural elements were envisioned to celebrate steel as the primary aesthetic, to create a cohesive design in perfect synergy with the existing architecture while adding to the character of Gateway with new materials, shapes, colours and forms, merging into a harmonious and elegant new style. While collaborating with the Structural Engineer, it was identified early in the design phase that the development would need to be a lightweight solution due to load limitations in the existing structure and foundations. The use of steel was expanded to be employed as the primary structure, to ensure the global weight remained within the restrictive parameters. Structural Framing The structural framing strategy was twofold. First, the Public spaces were designed around bespoke Architectural steel sections meticulously crafted to be unclad and expressed as the finished aesthetic. Second, retail spaces were constructed around standard steel profiles, externally finished in aluminium sheeting and cladding, aligning to the loading strategy. The use of leading 3D modelling software, cutting edge structural analysis and fabrication techniques facilitated the intensive collaboration with the Architect, Engineers and Fabricators to create each bespoke element, resolve any clashes and produce a fully coordinated, finalised design before any steel was procured for construction. Using Autodesk and Tekla 3D modelling and design software, compiled with CNC steel fabrication, the team was able to effectively resolve and fabricate all the bespoke and standard steel elements with a high level of precision and accuracy. The use of these methods was carried through to informing the construction strategies employed, which achieved significant time and cost savings and further empowered the Architects to explore and achieve a complex and high level of architecture. Due to the complex geometries in the design and critical tolerances required, large portions of the steel structure had to be fabricated and assembled off-site in controlled facilities. The erection process was extremely challenging and complex for these elements. As the finished aesthetic, a high level of accuracy had to be maintained throughout, which necessitated exceptional coordination and innovative techniques to achieve. In some instances, the erection process was further complicated by having to hoist the elements up to heights exceeding 30 meters with the use of lightweight cranes, specified due to load restrictions of the structure. Cladding The cladding materials selected for this project were Kliptite in mill finish aluminium, which was selected due to its corrosion resistance, wind upliftment negating design and alignment with the Architectural aesthetic. Hulabond aluminium cladding in metallic finishes was selected to compliment the Kliptite sheeting. The aluminium sheeting was concealed-fixed to the sweeping rooftops which were designed as three intersecting curved planes, set along three axis. Each was connected by inversely raking facades of aluminium sheeting and Hulabond cladding. Several areas of the curved cladding were fixed at a height exceeding 30 meters off the ground level. How does this project demonstrate the benefits of steel? This project demonstrates the ability to utilise steel as not just a structural material to be clad or hidden away, but also as the primary aesthetic feature in any form of Architecture. Through innovative design and collaboration with the Engineers, a striking piece of Architecture can be achieved that is both aesthetic and structural in nature, existing in perfect symbiosis with each other. This allows a high level of design to be explored, whether intricate or elegant, but always one that pushes the boundaries of Architecture, structural and steel design. To quote Arthur C Clarke, “The only way to discover the limits of the possible is to go beyond them into the impossible”. The inclusion of Starbucks into Gateway necessitated a unique aesthetic solution and was designed by the Architects to become a new feature of Gateways iconic main entrance. The external façade of Starbucks was envisioned as a 41-meter-long “floating” glass curve, arching behind the main entrance columns and converging with the existing curtain wall with no visible supporting structure. This was achieved using two bespoke curved steel polygonal sections, designed as the finished aesthetic to create an elegantly slender support for the 250m2 sheer glass curtain wall, the steel Bondek floor slab and the steel roof structure. The Palm Court was created with tensile structures running parallel along the restaurant line and connecting to the Starbucks structure. The tensile membranes were connected to a bespoke steel tube support structure comprising of feature posts and “hidden” back bracing. The posts were formed of 200mm diameter steel sections measuring at 8.6 meters high with closed curve bevel tipped ends. The Architectural steel of the Food Court was designed as a curved and raking ribbed structure, fashioned to form a slender refined profile. Unclad and expressed as the finished aesthetic, the steelwork arrangement created a seamless connection with the external environment, allowing an abundant influx of natural light into the space. The main vaulted roof was constructed from bespoke steel curved rafters, braced with raking “tree” members, all fashioned from trapezoid profiles. These supported the primary longitudinal sections which connected to a double curvature, curtain wall head beam, supporting a 78 meter wide, 630m2 curved glass curtain wall. The roof structure included an expansive skylight measuring 192m2, formed from the longitudinal sections and curved trapezoid rafters. The Food Court featured the largest suspended glass floor ever constructed in a shopping centre in South Africa, measuring 56m2. The “floating” glass floor was constructed from steel box sections fixed to an 820x500mm steel curved edge beam with an unsupported span of 20 meters. The Food Pods were debuted in this development. These were new concept interactive eateries unique to Gateway Theatre of Shopping. The Food Pods featured “floating” helical aluminium spiral elements, draped over stainless-steel extractor ducts, designed to cascade from the steel roof structure. The Food Court featured a 240m2, kaleidoscopic façade cladding, designed from geometrically placed triangular teak panels, supported by an intricate steel subframe, all set at individual unique angles. Due to the highly complex geometries involved, this could only be realized through the use of 3D modelling software. The external area featured a bespoke, steel supported tensile structure and a 2-meter wide point-fixed cantilever walkway. Leading to a bridge spanning 20 meters, it surrounded and crossed a feature sunken garden. These elements were all designed from bespoke steel sections clad in composite timber decking. How the project team worked together The project team worked extremely well and successfully together. This was primarily due to the extensive use of cutting edge software solutions and significant, coordinated collaboration with the fabricators and Contractors, from project initiation and throughout the design and construction process. Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected. PROJECT OVERVIEW Physical address of the project Street Address Town Province 1 Palm Boulevard Umhlanga Rocks Durban Kzn Google Maps link https://goo.gl/maps/NSUd77c4pp58uZnW8 STRUCTURAL STEELWORK Completion date of steelwork 01.02.2019 Completion date of full project 01.03.2019 Tonnage and steel profiles used Tonnage not available, bespoke profiles used as well as standard profiles PROJECT TEAM: Nominator Impendulo Design Architects (Pty) Ltd Client/ Developer Old Mutual Properties Architect Impendulo Design Architects (Pty) Ltd Structural Engineer Tobell Stretch and Associates Engineer Tobell Stretch and Associates Quantity Surveyor AECOM Project Manager Profica Main Contractor WBHO Steelwork Contractor Primary Avellini Bros Steel Erector Primary Avellini Bros Steelwork Contractor Tensile Mtt Structures Steel Erector Tensile Mtt Structures Cladding Manufacturer Sheeting Global Roofing Solutions Cladding Supplier Sheeting Global Roofing Solutions Cladding Contractor Sheeting Impact Engineering Cladding Manufacturer Panels Façade Solutions Cladding Supplier Panels Façade Solutions Cladding Contractor Panels Façade Solutions If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.