Cummins Johannesburg Relocation Program Waterfall

What makes the Cummins project unique from a structural perspective, specifically the structural steel design is the intricacies linked to the architectural aesthetics of the manufacturing facility. The brief was to design a manufacturing and assembly facility with multiple workshops and testing centers, which would from the outside not look that way. This is by no means a standard mechanical engineering, testing, and assembly facility, as the clean curved lines give the building a sophisticated yet functional envelope.

Engineers Motivation:

The steel design had to suit the architect’s vision, whilst keeping the structure light and within budget.  Behind all the curved sweeping lines is a steel structure made up of large span girder trusses supporting trusses in the opposite direction. The trusses are all made up of angle sections of varying sizes which form the truss chords and lacing members. This allows for a light and economic design, easy to transport and assemble on site, also allowing for the installation of solar panels over the entire roof area. Inside the facility, all services such as fire protection, electrical cable trays, and lights are suspended from the roof structure. There is a separate gantry crane steel structure inside the warehouse, suspended on top of reinforced concrete columns, which allows three gantry cranes to services about 75% of the floor area inside the facility. This is for the numerous operations taking place on floor level such as servicing and assembly of large engines and generators.

All offices inside the facility have lightweight steel structure designed to support low-level ceiling and services

Steelwork Contractor Interview:

As steel contractors, we were challenged on this project from the very beginning stages. This was no regular warehouse. The workshop drawings were very complex. Having to detail the steel facades with different levels, different elevations, Cladding stepping in and out, raised monitors, cantilever “Pop-Out” Monitors.

Once all of this was modelled using Tekla Structures, The fabrication had to begin. With the extremely tight program required by the client we had to produce the steelwork in record time but at the same time give the highest attention to our quality.

Erection on site is something to give special commendation to. To implement what the architect envisioned, to accomplish what the engineer required, and to do this in the time that the client needed was a feat to accomplish.

As the structure was a combination of concrete and steel much effort was needed to ensure that the steel facades are installed straight, level and with the correct steps in the façade to give the perfect final picture once cladded.

The main roof structure also required much attention, with the raised centre portion creating the roof monitor allowing for ventilation and natural light.

Inside are crane gantries that sit on Concrete Columns. Here we had a challenge to hand over the crane beams to the correct tolerances required by steel construction and crane beam specifications, as concrete tolerances are far larger that these. But with good detailing and accurate installation, this was accomplished to client satisfaction!

As Ferro Eleganza we are very proud to have been part of the team that constructed one of the Flagship and most attractive Warehouses next to the N1 Highway!

STRUCTURAL STEELWORK
Completion date of steelwork November 2018
Completion date of full project December 2018
Tons of structural steel used 258 Tons
Structural profiles used H/R sections / C/R Lipped channel
PROJECT TEAM COMPANY
Nominator Ferro Eleganza (Pty) Ltd
Steelwork Contractor Ferro Eleganza (Pty) Ltd
Steel Erector Ferro Eleganza (Pty) Ltd
Corrosion Protection
Paintwork Contractor
IPS Industrial Painting Services
Cladding and Roofing Global Roofing Solutions

Comair Simulator 3 Building

The client requested a space/building to accommodate the training facility for pilots. This building should also have all the necessary rooms and additional services to support the facility. Training halls, lecture rooms, and the brief and de-briefing rooms were part of this complex. In this facility, the pilots are getting training in the theory and practical aspects.

What was the brief to the architect?

The client’s brief was to provide a building, housing two mobile training units, and two static training units with their supporting rooms around and close by. The provision of lecturing rooms, a computer room, board rooms, a cafeteria, and open plan offices was included in the brief. The building should fit in with the other existing buildings on the site and also designed to allow the maximum natural light into the main core of the building.

Was the project envisaged in steel from the start? If not – why was it built in steel in the end?

Yes, the original design was definitely in steel. The flexibility of steel was the only answer to the curved structure of the building. The curved outline of the building simulates the hull form of an aeroplane. The curved spaces inside the building allow for the correct height in the centre of the building to accommodate the total envelope of the simulators to move freely in all directions. Both sides the building is lower to host the training rooms and other service rooms to support the operation of the simulators.

Steelwork contractor interview:

The roof structure consists of a few steel portal frames. These frames are curved trellis trusses, about 900mm deep. The space between the roof sheets and the curved ceiling was used for services like HVAC, Electrical trays, fire detection, IT cables and data lines. The ceiling follows the curved trusses and consists of different layers of material to achieve the necessary insolation towards the control of the heat gain and also for sound absorption. The ceiling is a suspended ceiling with stainless steel, 20×20 mm mentis grid, then a 40mm thick black cineplex insulation batting with fibre cement ceiling boards on top of that and then fixed to the underside of the curved trellis trusses.

Were there any challenges in the fabrication of the project from the engineer’s design – if yes, please tell? Tell more about the fabrication and erection process if it was complex, difficult, innovative etc.

Yes, due to the size of the steel portal frame it had to be manufactured in four parts to ease the transport and also the erection of the frames. The rolling of the roof sheets was very difficult and a complexed operation.  The rolling of the sheets was done on site and had to be 100% accurate to follow the curve of the steel frame.

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding in this project?

The brown built roof sheets followed the curved steel trusses and were also extended along the curved structure downwards to form at the time the wall cladding. The roof sheets rapped the building to enhance the feeling of an aeroplane. 

As Ferro Eleganza having built all the previous buildings (Except for building 1) it was a great privilege to be part of this project once again.

The iconic curved buildings housing the Com Air Flight simulators have become a landmark known by all across the R21 from OR Tambo International airport.

These beautifully shaped buildings based on the shape of a large aircraft could only have been done by the use of steel. 

The structure consists of curved CHS pipe lattice trusses and lipped channel sheeting support rails. Where the structure is closed with ceilings the truss sections are made out of Hot Rolled angle sections in order to save costs for the client. Once the steel becomes exposed again it changes back to CHS pipes.

Both gable ends of the building are complete glass and steel facades. Comprising of Shaped “Plate Girder Fins” and Large RHS members between carrying the glass. Here much effort was required as no bolts were allowed at the connections so as to keep the look and not to clash with the glass.

This was accomplished by using locating lugs inside the sections and then careful site welding and polishing to create the required finish and look.

The erection of this building was a great challenge in its self.

Due to the curved shape of the trusses and the fact that they are only connected to the concrete bases with a single Pin on both ends these trusses cannot stand on their own.

Therefore the entire truss was assembled on the ground and then using two mobile cranes the first two trusses were lifted into position and then held there while the bracing and purlins were installed so that the structure could stand on its own.

Another challenge has always been the link tunnels between the buildings. These are narrow tunnels that give the idea of the tail end of the aeroplane.

 Here the curved pipes needed to be rolled at much smaller radiuses and much effort was needed to ensure that the steel structure could receive the curved sheeting.

To crank the sheeting to the correct radius and then fit it to the steel structure required much effort and the combined efforts of Steel and Sheeting Contractor together.

It was a great challenge to create what the architect envisioned, to accomplish what the Engineer required, and produce this beautiful building that could only have been done with steel.

The roof super-structure radiated from the internal circular ring beam to the oval-shape external ring beam using a combination of gusseted rafters for the shorter spans to I beam/angle-iron type trusses for the longer sections.

STRUCTURAL STEELWORK
Completion date of steelwork June 2018
Completion date of full project September 2018
Tons of structural steel used 70 Tons
Structural profiles used CHS, H/R Sections, C/R Lipped Channel
PROJECT TEAM COMPANY
Nominator Ferro Eleganza (Pty) Ltd
Steelwork Contractor Ferro Eleganza (Pty) Ltd
Steel Erector Ferro Eleganza (Pty) Ltd
Corrosion Protection
Paintwork Contractor
Industrial Painting Services (Pty) Ltd
Cladding and Roofing Global Roofing Solutions
Architects WMS 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.

Peech Hotel

The Peech Hotel is a garden boutique hotel located in Melrose, Johannesburg. Meshworks was tasked with extending the hotel onto the newly acquired neighbouring property, designing an addition that respected the existing hotel and built upon its best features.


Specifically, we were asked to:

Increase the hotel’s accommodation by sixteen rooms of approx 45m2 each;
Apportion a reasonable garden space to the existing residence on the south half of the new property;
Retain the feel of private pavilions floating in a garden;
Consider the provision of circulation and an enlarged pool area.
Respond to but not necessarily match the existing aesthetic; and

Were there any particular innovations you were looking to achieve from the steel cladding?

Firstly, the planted steel mesh of the wrap-around balconies was an important element in the kit of parts we used to craft the articulated facades of an urban village. Together with the expressed steel framework of the buildings, it creates a play of layers, materials, light and shadows. The mesh provides a contrast with the impermeability of the masonry surfaces as well as comprising a changing organic screening device. This ‘wrapping’ allows for an adaptability, depending on the particular siting conditions and orientation of the units. The expressive repetition of vertical steel members creates a rhythm across the site, supporting a cohesive visual language.

Beyond this expressive role, the steel cladding was essential in establishing privacy gradients, in ensuring that there was a considered relationship between the units, and in developing a language of visual connection and shielding. The steelwork allows guests to experience and control various degrees of visual permeability into and out of the units and their zones. This layering means that balconies can become private outdoor courtyards, that guests can sleep with their sliding doors open, that different thresholds reveal different spaces which open up with movement through the unit. Steel is used at all these points to express a layered architecture of lightness.

Lastly, because of its planted nature, but also because of the way it could direct and orientate each unit, the cladding became a tool in the integration of built form with landscape, expressing the passage of light and shadow, and significantly contributing to the ‘garden urbanity’ embodied in the project.

Any specific other details you would like to mention that you feel would help the submission?

The articulation achieved through the various steel elements in the design palette created visual and spatial diversity, restructuring the traditional uniform scripting of a hotel typology. Hotels are complex sites in which the public and the private must be constantly negotiated and the steel screening solutions allow for a filtered experience that is still spatially interesting and dynamic. The steelwork is not only rational and functional, but becomes poetic too.

CLADDING
Completion date of cladding June 2018
Cladding profile/ type used Safintra Saflok 700
Cladding area/ coverage and tonnage 550m²
PROJECT TEAM COMPANY
Nominator Safintra
Client/ Developer The Peech Boutique Hotel
Architect Meshworks
Structural Engineer EVH Consulting
Quantity Surveyor Viking Construction
Steelwork Contractor Jaru Design
Cladding Contractor Monro Sheeting

Sky City Mall

Sky City – 17000m2. Along with the load of the roofs, the steel structure also supports the vast amounts of solar panels fixed with specially made aluminium steel brackets. The use of compatible steel products ensure that the lifespan of the building materials are not affected due to bimetallic corrosion processes.

Benefits achieved by using steel construction

As locally manufactured steel products are readily available the project could be completed in a timely fashion and the versatility of steel flashings meant that the design features could be rounded off and sealed to be watertight.

Aesthetic appeal

The big facades and overhanging canopies are a showcase of what can be achieved using steel cladding and structural steel materials.

Walking around the mall at Sky City it is evident that steel is no longer only a cold material used for it strength but also its attributes as a design feature.

Environmental/ Sustainability consideration

Steel is 100% recyclable and is an environmentally friendly product.

Innovation in Design Fabrication or construction

The large roof design along with the long spanning and good load bearing properties of ProLok 700 roof sheets accommodate the solar panels on the roof that assist with the ever growing demand for alternative power sources.

Technical process required for realizing the project

Due to various roof angles and heights, not only was the support systems and sheeting important, but more important was the special flashing designs to ensure the roof is water tight.

What is the purpose of the structure/project?

The project will service a large catchment area and provide a first of its kind retail experience to the local community.

Was the project envisaged in steel from the start? If not, why was it built in steel in the end?

Steel was the material of choice from the start.

 Give a brief description of the cladding process (complexity, difficulty, innovation etc).

Roll forming of the cladding was done in phases to accommodate each roof section and its canopy if applicable. Due to weather causing delays with manufacturing, the mobile mill

would start and stop numerous times during a day to complete a single section.

With high winds blowing in from the open land around the site, getting the sheeting

onto the roof proved difficult but once on the roof the cladding could be installed without difficulty.

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding in this project?

At the front of the building a massive canopy spans outward almost the entire length of the mall.

STRUCTURAL STEELWORK
Completion date of steelwork February 2019
Completion date of full project April 2019
Tons of structural steel used 385 tons
Structural profiles used 254×146 I Beam, angles and Lip Channels
CLADDING
Completion date of cladding March 2019
Cladding profile/ type used Prolok 700 for Roof
Cladding area/ coverage and tonnage 17000m2 / 91 Tons
PROJECT TEAM COMPANY
Developer GMI Property Group
Architect Rossouw Argitekte
Structural Consultants Proficient engineering
Quantity Surveyor SM Marè & Associates
Main Contractor Central Development Projects
Roof Sheeter Rainbow Sheeters
Structural Steel Quality Steel and fencing
Cladding Supplier Pro Roof Steel & Tube
Corrosion Protection Paintwork Contractor IPS Industrial Painting Services

Tibani Shopping Centre

The building is designed around a steel structure that supports the vast steel roofs along with the glass window feature surrounding the inside of the walkways. Tibane Mall – 18000m2. The weight bearing properties of steel allows for unobtrusive canopies and unique designs throughout the building.


Benefits achieved by using steel construction

Benefits include cost savings, ease of installation and with the ProLok 700 Sheeting system, sheeting could be rolled on site in various long lengths to accommodate the design. Small adjustments that can be made on site (especially in such a remote location) and the bolt on features make steel the obvious material choice for a project of this size and design.

Aesthetic appeal

With the availability of different roof sheeting colours the client has the ability to match colours to suit and add appeal to the design. With the versatility of steel, an aesthetically pleasing design could be achieved.

Environmental/ Sustainability consideration

Steel is 100% recyclable and is an environmentally friendly product.

Innovation in Design Fabrication or construction

Accommodating the unique design that gives a feeling of an open air experience even inside the mall the fabrication of the steel support systems is unique to this project.

Technical process required for realizing the project

With the remote location of the project all manufacturing had to be perfect to stay within budget.

  • Having the ProLok 700 mobile mill on site improved the logistical process and ensured that the process was achieved in a timely and cost effective manner.

What is the purpose of the structure/project?

The Tibani Shopping centre will give a much needed boost to the economy of the rural Tibani area. Creating jobs for the local community and giving access to a modern retail experience.

Was the project envisaged in steel from the start? If not, why was it built in steel in the end?

Steel was the material of choice from the start.

 Give a brief description of the cladding process (complexity, difficulty, innovation etc).

The use of concealed fix roofing profiled on site in long lengths gives a massive advantage to any project and roof sheeter, however, working with long single lengths of sheets can also be troublesome and in some conditions dangerous. In the case of the cladding at Tibani, the wide open surrounds allowed for high winds to ensue over the building area and made the manufacturing as well as moving of long length sheets difficult. At some stages manufacturing as well as installation was halted due to high wind gusts. Perseverance during good conditions was key to getting the cladding done on time and installed to standard.

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding in this project?

The building design raised the walkway roofs from the front to back on both the entrance ways throughout the inside of the mall creating large amounts of natural light,

the steel structure used flows seamlessly with the glass borders making it not only functional but attractive as well.

How did the project team work together

The whole team worked very closely together, whenever a problem or a snag occurred the communication between all parties involved was prompt and solutions were put in place.

CLADDING
Completion date of cladding October 2018
Cladding profile/ type used ProLok 700 for roof
Cladding area/ coverage and tonnage 18000m2 / 110 Tons
Structural Profiles used Beams, Angles and Channels
PROJECT TEAM COMPANY
Architect Rossouw Argitekte
Structural Consultants Proficient engineering
Quantity Surveyor SM Marè & Associates
Main Contractor Robert Skinner Konstruksie
Roof Sheeter Rainbow Sheeters
Structural Steel Quality Steel and fencing
Cladding Supplier Pro Roof Steel & Tube
Corrosion Protection Paintwork Contractor IPS Industrial Painting Services

 

Raincoat office building – Ghana

4 Storey hybrid office building, consisting of a combination of heavy structural steel and LSF

  • Structure had to be installed over an existing single storey building
    • Existing structure must be re-used after construction of new building
    • Foundations of new structure had to be designed in such a way that it does not influence existing structure’s foundations
  • Client Scope/ Focus points
    • Design a cost-effective steel framed 4 storey building
    • Large open plan areas required for office space
    • Aesthetically pleasing structure to showcase the use of steel
    • Speed of construction
    • Limited site access

 Designing a cost-effective solution

To reduce the overall weight of the structure, the first 3 floors were designed from heavy structural steel elements. In order to reduce overall structural weight, the top (level 4) floor was designed and constructed from LSF.

By using welded beam technology, where webs and flanges are joined together with a sub arch weld to only one side of the web and flange, we were able to design and make up our own sections. Overall dimensions of columns were kept the same, but flange and web thicknesses were reduced as overall structural loads reduced from ground floor to higher levels, as indicated on drawings.

Creating large open plan floor areas

Large open floor spaces were created by using composite action between welded beams and a 170mm thick concrete floor. The depth of the main floor beams was determined by deflection limits on the floors, rather than overall moment capacity of the beams. Again, flange and web thicknesses on the steel beams varied, depending on the moments that had to be resisted. Shear connection between steel beams and concrete floor was achieved by using Hilti Shear studs that were attached through the Bondek system into the top flanges of the steel beams.

Moment fixity was used between the columns and main floor beam connections. This ensured overall structural stability in one direction. In the other direction, vertical cross bracing was introduced

Using the above design enabled us to achieve clear spans of 14m on the floor system

Aesthetically pleasing structure

It was important to create more than just a square box that is functional, but not nice to look at. With this in mind, a staircase was designed that is supported by 2 large centre columns. Landing areas and as well as stringers were supported by small beams cantilevering from centre columns

Speed of construction

Using a steel framed building enabled erection of the heavy steel as well as placement of permanent shuttering and casting of concrete slabs in 4 weeks. Using LSF for the construction further reduced the overall construction time drastically.

Limited site access

The new office block had to be constructed between existing buildings, with a production plant on one side that must always remain operational.

Due to limited site access and the fact that the new building was almost surrounded by other structures it was not possible to use big mobile cranes on site. All these factors had to be considered when element lengths and splice positions were determined.

Conclusion

Concrete construction in Africa is normally quite expensive. By thinking outside the box and utilising different steel fabrication/ construction technologies, we were able to design, deliver and erect a cost effective and functional structure to our client. This project again showcase the advantages of steel construction and its ever-growing appeal in the office and residential space.

STRUCTURAL STEELWORK
Completion date of steelwork July 2018
Completion date of full project Dec 2018
Tons of structural steel used 28t
Structural profiles used Welded beams/ Plate girders
SA content – if this is an export project Structural steel – 100% SA content
LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work Dec 2018
Completion date of full project Dec 2018
Span of trusses and Kg/m2 (if applicable) 14m
Profiles used   

Bluescope Truecore material. 0.8mm G550 – Supplied by Raincoat Roofing in Accra, Ghana

Type of cladding Combination of Standing seam roof sheeting and fibre cement wall cladding
PROJECT TEAM COMPANY
Nominator Clotan Building Systems
Client/ Developer Raincoat Roofing Systems Ltd Ghana 

 

Architect David Bass Architects 

 

Structural Engineer Clotan Building Systems 

 

Engineer Clotan Building Systems 

 

Structural Detailer Steelinx Cape Town 

 

Quantity Surveyor Clotan Building Systems 

 

Project Manager Clotan Building Systems 

 

WAGS Warehouse

The project features a two-story office block and a mezzanine office within the warehouse. The warehouse was designed for dolomitic conditions with a post-tensioned surface bed (FM2 finish). The warehouse steel structure consists of 3 girder trusses with a 32m span that supports a total of 27 portal trusses spanning 32m each. The average span for the purlins was 8m. The warehouse is roughly estimated at 28000 m² (excluding canopy area) with a total tonnage of 630t. The steel rate of the warehouse is 22.5kg/m2.

The steel structure was divided into 3 phases. The spring height for the warehouse is approximately 13.5m high. The portals are supported by reinforced concrete columns extending 12m above the surface bed with 305x165x40 Universal Beams which range between 3 and 7m in height.

The challenges faced during the erection of the steel structure were mostly natural causes such as rain and wind that made working conditions difficult and thorough safety precautions were adhered to

What is the purpose of the structure/ project?

Distribution warehouse

Was the project envisaged in steel from the start? If not – why was it built in steel in the end?

Yes

Give a brief description of the structural framing. What type of sections were used (e.g. hollow, cellular, I beams etc) and why?

The steel structure is a combination of I-sections, angles, hollow sections, cold formed sections, METSEC Z & C sections, T- sections. All these different sections were used for their different qualities to ensure the structural integrity of the large warehouse was met.

Were there any challenges in the fabrication of the project from the engineer’s design – if yes, please tell? Tell more about fabrication and erection process if it was complex, difficult, innovative etc.

The structural engineer made use of the lightest structural members without compromising the aesthetic and function required by the Architect and Client.

5What is special/ unusual/ innovative/ aesthetic about the steelwork in this project?

In terms of architectural – horizontal and diagonal steps were created to form shadow lines within the façade to break down the big-box aesthetic.

STRUCTURAL STEELWORK
Completion date of full project 30 April 2018
Tons of structural steel used 630 Tonnes
Structural profiles used I-sections, angles, hollow sections, cold formed sections, METSEC Z & C sections, T- sections
CLADDING
Cladding profile/ type used Craft-lock
Cladding area/ coverage and tonnage 30 000 sqm Craft-lock roof 

Colourplus® material 0.55 Deep Ocean

10 000 sqm IBR Side cladding

PROJECT TEAM COMPANY
Nominator Clotan Steel
Client/ Developer Fortress Property Fund
Architect ICM Architecture
Structural Engineer Sotiralis Consulting Engineers
Quantity Surveyor Quanticost Quantity Surveyors
Main Contractor Archstone Construction
Steelwork Contractor SE Steel
Cladding Manufacturer Clotan Steel Pty Ltd
Cladding Supplier Clotan Steel Pty Ltd
Cladding Contractor GM Roofing

We Buy Cars Warehouse

Providing a world-class roofing solution for a world-class facility. The client and developer’s brief were to use a concealed fix roof sheet that would minimise risk of leaks as well as prevent any end lapping on sheeting, that would furthermore increase risk of early corrosion on sheeting system.

Due to its profile shape, Craft Lock® sheeting has one of the highest capacities against wind uplift, when compared to other concealed fix profiles in South Africa. The depth of the profile furthermore ensures effective drainage of water from the roof, even on roof slopes as low as 1-degree pitch.

Craft lock® sheets were site rolled with a mobile mill, directly onto the roof by means of constructing scaffolding between the roll former and mobile mill. Continuous sheets in excess of 95m were roll formed and placed on the roof through this method.

The fact that sheets were roll formed and moved to the roof structure directly reduced handling of sheets, which mitigated damages to the profile. Once sheets were pushed to the roof by the mill, installers could place the sheets close to or in their final position. The above way of construction ensured minimal damages or scratches to sheeting, therefore providing a top-quality finished product.

23 500m2 Warehouse facility with 16m clear height at eaves. Effective use of combination of concrete and steel columns to reduce overall weight of steel structure. Addresses issue of long slender steel columns that would lead to unnecessary heavy elements. Effective Engineering design lead to light steel structure. Column free areas of 27x32m girds. Main girders designed from a combination of H sections as top and bottom cord with angle sections as vertical and diagonal members Secondary trusses all from angle sections.

STRUCTURAL STEELWORK
Completion date of steelwork 2017-08-30
Completion date of full project 2018-01-31
Tons of structural steel used 539 tons
Structural profiles used Col’s      –  U-beams + castellated  

Trusses  –  angles

Girders   –  U-beams + angles

CLADDING
Cladding profile/ type used Craft-lock® concealed fix (roof)  

IBR profile sheeting for cladding

Chromadek®, 0,58 Fish Eagle White & Dark Dolphin

Cladding area/ coverage and tonnage 28 000sqm Craft-lock® concealed fix (roof)  

Chromadek®, Fish Eagle White & Dark Dolphin

11 000 sqm IBR sheeting (cladding)

PROJECT TEAM ROLE COMPANY
Nominator Clotan Steel Pty Ltd
Client/ Developer Fortress Property Fund
Architect Trilogy Architects and Interior Designers
Structural Engineer Sotiralis Consulting Engineers
Quantity Surveyor Quanticost Quantity Surveyors
Project Manager Fortress Property Fund
Main Contractor M&T Developments
Steelwork Contractor B&T Steel
Cladding Manufacturer Clotan Steel Pty Ltd
Cladding Supplier Clotan Steel Pty Ltd
Cladding Contractor GM Roofing
Corrosion Protection Paintwork Contractor IPS Industrial Painting Services

Shell Ultra City Kroondal East and West

The Shell Ultra City Kroondal East and West is a Greenfields project. It included the completed construction of two new Shell Ultra City service stations on the N4 highway close to the established town of Kroondal in the North West province. Each service station is just over 1000m2 under roof and incorporates a convenience store and two quick service restaurants.

The completed project is unique as it is the first Lightweight Steel Retail fuel station that has been introduced in the Shell network and could potentially be the first of its kind Lightweight Steel Retail fuel site in Africa.

The designer on the project moved away from the traditional idea of a service station being in the shape of a modular oblong box. The prominent architectural feature of the Shell Kroondal service station is its curved lightweight steel roof, to match the contours of the surrounding landscape. The boundaries were further pushed by uniquely designing a curved forecourt canopy moving away from the flat forecourt canopy as is synonymous with retail fuel sites all over the world.

The project specifically targeted sustainability initiatives. The initiatives encompass locally sourced materials, community facilities, indigenous planting, recycling of construction waste, a structure that can be disassembled and reused, ensuring a reduced embodied energy and resource depletion through the concrete mix, and low VOC interior finishes, among others. All grey and blackwater on-site are filtered and reused in the toilets and urinals. and water data are displayed in the shop area.

STRUCTURAL STEELWORK
Completion date of steelwork April 2018
Completion date of full project October 2018
Tons of structural steel used 7.5 Tons
Structural profiles used See Attachment
SA content – if this is an export project 100%
LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work April 2018
Completion date of full project October 2018
Tons of LSF used 62.4 Tons
Span of trusses and Kg/m2 (if applicable) 13m unsupported, 26m supported
Profiles used Framecad C – section , 30 mm Battens , 20mm Battens
Type of cladding G 550 ,  Z200 / Z275 , 0.8mm and 0.58mm steel
CLADDING
Completion date of cladding June 2018
Cladding profile/ type used F/Cement Boards  12mm x 1,2m x 2,4m 

F/Cement  Boards 12mm x 1,2m x 2,7m

F/Cement  Boards 12mm x 1,2m x 3,0m

Gypsum Boards – Moisture Resistant  Boards 15mm x1,2m x 3,0m

Gypsum Boards – Habito Boards 12,5mm x1,2m x 3,0m

Cladding area/ coverage and tonnage 3756m2 /  127 tons
PROJECT TEAM COMPANY
Nominator AECOM SA (Pty) Ltd
Client/ Developer Shell Downstream South Africa
Architect AECOM SA (Pty) Ltd
Structural Engineer AECOM SA (Pty) Ltd
Engineer  
Quantity Surveyor  
Project Manager AECOM SA (Pty) Ltd
Main Contractor Razorbill Eco-Construct
Steelwork Contractor Marboe & Sons (Pty) Ltd
Steel Erector Marboe & Sons (Pty) Ltd
Cladding Manufacturer Terraco 

Saint Gobain

Everite

Cladding Supplier Terraco 

Saint Gobain – Triangle Sourcing

Everite – Global Innovations

Cladding Contractor Razorbill Eco-Construct

 

Hazendal Wine Estate – New Administration Center

The new administration wing at the Hazendal wine estate in Stellenbosch is one part of a much larger redevelopment of this historic wine estate. This new building is set out in line with three historical barn structures of a similar scale. This long line of buildings forming the werf edge to this historical farm. Intensive consultations with the Western Cape heritage bodies suggested that this new structure, like the new Edu -Play Center, should be sensitive to the scale of the historical buildings adjacent to it. An added complexity is the close proximity of the new admin wing to the old historical homestead. This resulted in an understated, simple and elegantly detailed building which forms a backdrop to the historical homestead. Clad in all ‘white’ the building was imagined as a modern interpretation of an old cape barn.


Why steel?

Two reasons informed our decision to use steel for the construction for this project. Firstly, the fast-tracked nature of the project and secondly the cladding system called for a light weight steel and timber framing methodology for this double storied structure. The cladding material is a 10mm through-coloured fibre cement panel which forms a ventilated façade on both the wall and the roof. The wall and roof sandwich beneath this cladding is a galvanized steel portal structure of IPE-200 sections with a cold formed section grid supporting waterproofed OSB board as a sealed building envelope on the outside and insulation and drywalling on the inside.

Architect Interview:

Engineer Interview:

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 February 2018
Completion date of full project January 2019
Tons of structural steel used 16
Structural profiles used PF I-sections, CFLCs, CHSs
PROJECT TEAM ROLE COMPANY
Nominator Meny-Gibert and Associates
Client/ Developer Hazendal Wine Estate
Architect Michael Hackner Architects
Structural Engineer Meny-Gibert and Associates
Quantity Surveyor Prodigious
Main Contractor R + N Master Builders
Steelwork Contractor TGS Concepts
Steel Erector TGS Concepts
Cladding Manufacturer Marley Building Systems
Cladding Supplier First African Claddings
Cladding Contractor First African Claddings
Corrosion Protection
Galvanising
Galvatech

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.