Project Type

Innovation
Light Steel Frame Building
Metal Cladding

Project Team Zoom Interview Case Study

Project Case Study

13-Nelson-Mandela-Cruise-Terminal.pdf View

Steel Profiles Used

Date of Steelwork Completion

2023-11-30
Tonnage

302

Metal Cladding and Roofing Overview

Date of Cladding Completion

2021-11-30
Other Materials Used

Project Completed: PH 1 - December 2021/Ph 2 November 2023 Cladding Material Used: Mineralis Fibre Cement panels Cladding Profile: Flat sheet
Cladding Tonnage

302
Cladding Area Coverage (m2)

11533

Light Steel Frame Building Overview

Cladding Tonnage

1

Project Overview

The Nelson Mandela Cruise Terminal in South Africa is an impressive feat of steel engineering. Utilising over 3,200 tonnes of structural steel, the building features a complex roof design with a 105-metre unbalanced cantilever supported by an innovative "anvil" concrete structure. Slender circular columns, shear walls and a braced roof frame create the expansive 13-metre spans. Specialised steel sections like castellated beams add visual interest. Externally, a parametric facade of over 12,000 sq.m is clad in a bespoke steel-framed equitone system, wrapping the landmark building in a cohesive, sculptural envelope.

Project Details

Fabricating the terminal's intricate steel components demanded exceptional precision. Each truss and rafter was uniquely engineered, requiring specialised jigs to ensure accurate construction. Manoeuvring the complex box girders that supported the cantilever was a particular challenge, necessitating custom rigging aids to position them safely. Aligning the raking columns at varying angles also tested the fabricators' expertise. Throughout, meticulous attention to detail was essential, as any discrepancies could compromise the structure's integrity. Innovative manufacturing techniques and a high level of engineering know-how were vital in translating the architects' bold vision into a reality.

• Light steel frame 90x40x0,9m LSF sub grid 10 KM of steel 4500m2 The terminal's steel-intensive construction presented a host of logistical challenges. Installing the massive box girders that formed the cantilever required specialised rigging equipment and careful alignment to integrate with the concrete "anvil" structure. Positioning the raking columns, each at a different angle, demanded meticulous precision to ensure a seamless fit with the primary roof framing. At height, the team utilised extensive scaffolding and high-reach machinery to safely manoeuvre and secure the steel components. Throughout, the need for exceptional coordination between trades was paramount, as any misalignment could jeopardise the building's structural integrity and weatherproofing. Overcoming these complexities, the contractors delivered an impressive steel installation.

The terminal's complex geometry presented significant fabrication and installation challenges. Specialised jigs were required to accurately construct each unique truss and rafter. Aligning the raking columns and positioning the cantilever's box girders demanded innovative rigging solutions and meticulous coordination between trades. Overcoming these complexities, the team delivered an exceptional steel installation.

Project Brief

Fabrication

Erection / Construction / Installation

Challenges and Solutions

Benefits of Steel in this Application

Steel's inherent structural integrity and design flexibility were pivotal in realising the Nelson Mandela Cruise Terminal's ambitious architecture. Slender columns, expansive spans and a dramatic 105-metre cantilever were all achieved through innovative steel framing solutions. Specialised steel sections added visual interest, while a bespoke steel substructure supported the parametric facade's seamless, sculptural form. Meticulous coordination between contractors demonstrated steel's capacity for precision engineering, essential for executing the terminal's complex geometry. Ultimately, steel's versatility empowered the architects' bold vision, transforming this landmark building into an impressive showcase of the material's capabilities.

Testimonials

The project team take great pride in the Nelson Mandela Cruise Terminal, hailing it as a showcase of their expertise. The seamless integration of the steel structure, parametric facade and intricate interior finishes is a testament to their collaborative efforts. Overcoming the design's complexities, they have delivered an iconic, steel-intensive landmark

Nelson Mandela Cruise Terminal