GO DURBAN INTERGRATED RAPID PUBLIC TRANSPORT NETWORK (IRPTN)(BUS STATIONS)

What is the purpose of the structure/ project?

Construction of Prototype bus station for as part of Integrated bus rapid transport system

What was the brief to the architect?

To design and create a visually pleasing structure with Universal access, be Energy efficient, be ahead of current times, and take Durban Integrated rapid transit into the future.

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

Generally square hollow tubing was used on most structural members, due to its light weight and excellent structural strength properties. Custom made hollow tubes had to be manufacture for the front and exit canopy legs, for aesthetic requirements.

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

The project does not consist of any radically new innovation, but rather a creative way of using some common construction materials to create a homogeneous and appealing structure, which involved the erection of a structurally stable steel frame, which was then covered with steel roof and clad with a glass façade.

Give a brief description of the Light Steel Frame Building element of the project. (Notable features/ achievements made possible by LSFB)

Internally the roof has been insulated and the profile of the structure followed with an aluminium ceiling. This ceiling houses the light fixtures, and other emergency services required for puplic buildings.

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. 

A detailed coating spec was required for long term protection of the structural elements, due to the proximity to the ocean and industrial fallout in the area. This required all structural steel member to be galvanised and coated with a duplex paint coating system. The initial project specification required frame member be continuously welded and no bolted joints allowed.  Due to the length (slenderness) and shape(U) of the portal frame members, and possible distortion of structural member during the galvanising process, full galvanising of the originally designed members proved to be impossible without possible areas of coating weakness due to site welding. It was recommended to the engineer that a bolted joint be placed in the structural elements, hidden from view, in the ceiling/roof area. Thus reducing the size of the elements and improving handling of the elements, the ability to fully apply the specified coating systems, this would all  could be achieved without disturbing the long slender appearance of the legs, that the architect required.

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

The construction of project specific box sections for the front and exit canopies, to achieve the correct angle and shape required. Using 3D software non-standard box section were created to support the front and exit canopies

How did the project team work together (e.g contractor involved early, challenges/ ease of communication etc.)

The project team had to work closely with the architect, numerous changes were made to the structure initially (front and exit canopy) due to the specific planes and angles required to match the anticipated glass façade structure. 3D software was used to create the structure and ensure that the finer details could be achieved.

Tons of structural steel used 25 TONS
Structural profiles used CFLC 125x50x2.5 ; CFLC 100X50X2.5 ; UB 203X133X25

SHS 200X200X4.5 ; SHS 150X150X4.5 ; SHS 60X60X4.5

RHS 200X100X6.0 ; RHS 160X80X5.0 ; PLATES – 20MM;

16MM; 8MM; 6MM; 3MM; ANGLE 150X150X10 ;

UNEQUAL ANGLE 150X75X10 ; ANGLE 70X70X6 ;

ANGLE 40X40X3 ; FLAT BAR – 25MM, 20MM, 12MM;

8MM, 6MM, 5MM ; ROUND BAR – 60 DIA.

Tons of LSF used 5.257 TONS
Span of trusses and Kg/m2 (if applicable) 200 Meters of Balustrading
Profiles used 75×3 CHS S/S ; 80x40x2.5 RHS ; 20 RB ; 50×3 CHS S/S ; 10 RB ; 60x60x4.5 SHS ; 100x50x4.5 RHS ; 60×10 FL BAR
Type of cladding Hunter Douglas – Ceilings and Louvers
Cladding profile/ type used Brownbuilt Klip-Lok 406 (roof)
Cladding area/ coverage and tonnage Area 466m2

Project Team

Project Team Role Company
Nominator Shesha Engineering
Client/ Developer eThekwini Municipality
Architect Iyer
Structural Engineer Linda Ness Associates
Engineer (Site) MCA
Quantity Surveyor LDM
Project Manager MCA
Main Contractor Phayindani J.V
Steelwork Contractor Shesha Engineering
Steel Erector Shesha Engineering
Cladding Manufacturer HB Interiors

MJ Cheater Roofing

AGS Glass fibre

Cladding Supplier Hunter Douglas

City glass

Global roofing

Cladding Contractor HB Interiors

MJ Cheater Roofing

AGS Glass fibre

Corrosion Protection
Galvanising
Pinetown Galvanising
Corrosion Protection
Paintwork Contractor
Scott Clean
Photographer, Photo competition Lisa Woest Photography
Photographer, Other submitted images Qanza construction

Club 2

The new Club 2 Building in Hazelwood, Pretoria, is set to become a landmark property in the city. The modern, industrial yet retro look and feel, combined with the striking curved roof, has made it a hotspot for local tenants.

In 2015, Atterbury Properties appointed Hofman Architects to design a space that would accommodate a gym as well as office spaces. Situated on the corner of Pinaster Avenue and 18th Street in Pretoria, Club 2 builds on the prestigious Club One office building that was designed and completed in 2011. The five office floors of Club One are leased to the University of South Africa, with popular retail areas such as Hogshead Craft Beer and Hudsons The Burger Joint occupying the ground floor section.

The brief from the client to the architect evolved over time.  Initially, the brief was to design a building for Planet Fitness on the intersection South of the precinct, with an office component to make up the bulk on the Northern end of the property.  When the design was presented, Atterbury was so impressed that they decided to move their head office to the new building. 

This decision changed the brief to the architect in a few ways. The office component had to mirror the design of the client’s offices and it had to move to the prominent South corner of the building. The gym, in turn, had to move to the Northern section of the property without it losing visibility and exposure from passers-by.

The ideal design for a gym of this magnitude is a “warehouse” type structure.  With this in mind, the design was always envisaged as a steel structure. The office component has a beautiful, industrial theme, which can easily be accommodated by steel structures.

The building is constructed of a curved portal frame structure with large I-beam sections. 

The roof cladding that was specified for the project is KlipTite by Global Roofing Solutions. The cladding was cranked around the curves of the portal frames with custom made flashing detail to accommodate the curved roof.  The walls were constructed out of a combination of brickwork and the Imison lightweight wall system.

One challenge that the design team encountered was cladding the curved radius of the large section I-beams.  To overcome this challenge, these sections were manufactured and not rolled. Ensuring that the exact placing of these sections aligned with the columns on site was challenging, as were the flashings that were needed. The design team had a few flashing prototypes made and in the end a custom designed flashing had to be created to accommodate the curved roof.

The curved portals on the property are particularly unique, innovative and aesthetic. The portals step up and down over box gutters to let natural light into the interior spaces, and they step in and out over the façade to create deep overhangs to accommodate shaded public spaces over the entrances of the building.  This design element is what gives the building its unique appearance. 

When working on a steel structure, attention to detail is of paramount importance as any design flaws and errors can be quite unforgiving. The contractors, engineers and architects worked well together to resolve any details as and when they arose. Ongoing inspections of the steel work and a culture of collaboration and innovation led to the successful outcome of Club 2.

Cladding profile/ type used Klip-Tite
Cladding area/ coverage 3400m2
Cladding tonnage 18 Tons

 

Project Team

Project Team  Role Company
Nominator Global Roofing
Client/ Developer Atterbury
Architect Hoffman Architects
Structural Engineer DG Consulting
Quantity Surveyor
GK Project and Cost Engineering
Main Contractor Wilson Bayly Holmes Construction
Steelwork Contractor LTS Steelwork
Steel Erector LTS Steelwork
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Cladco

Shoprite Climor Distribution Centre

The Shoprite Cilmor Distribution Park is the latest installation of the national distribution centre rollout for the owner/operator client, Shoprite Checkers. The project comprises more than twenty buildings, the largest of which are three warehouses serving as the core of the development. The biggest is the 76,000m2 Dry Goods warehouse, followed by the 18,000m2 Refrigerated Building and the 12,000m2 Returns Centre.

The architectural brief was to deliver purpose-fit infrastructure that is aesthetically pleasing, given the facility’s prominence from the adjacent freeway and surrounding neighbourhoods, while also maximising the value of the client’s investment. The architectural and structural teams collaborated closely to allow function to define form, yet ensure refined aesthetics and a wow-factor to the overall appearance.

Structural steel was the natural choice to realise the large open span roof structures and curved architectural features. The operational design required a 32x32m internal grid for the ambient warehouses and 24x24m for the refrigerated warehouse. No construction material other than structural steel could achieve the same construction economics for these light-weight, large-span roof structures under the given programme constraints.

The design of the buildings and the subsequent construction methodology were all centred around safe and fast erection on site, delivering a light yet failure-tolerant structure. The buildings are stabilized by large cantilevering concrete tilt-up columns that were constructed during the fabrication period of the steel. The largest of these columns was 24.3m tall, weighing more than 44tons. Starting off with a stable structure greatly reduced the risk during the erection of the long-span structural steel girders and trusses.

The girders were built-up from horizontally orientated UB chords laced with double equal angle web members. This configuration allowed optimized utilisation of the material and produced a girder that was easier to handle on site due to the lateral and torsional stiffness of the box-shaped assembly. The trusses for the ambient warehouses were classic lattices made from equal angle chords and web members. To provide a flat fixing surface for the refrigeration panels, the trusses for the refrigerated buildings were also boxed lattices with channels as chords.

The connection design and detailing, especially for the girder-to-column and truss-to-girder nodes, also aimed at 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.

The appointed specialist steel contractor, Mazor Steel, delivered 2963 tons of structural steel on time and to highest quality standards following a strict safety plan under constant scrutiny by main contractor, Stefanutti Stocks, who achieved over one million lost-time injury free man-hours on this project.

The size of the building and the resulting rainwater run-off lengths of the Dry Goods building supported the choice of a curved roof structure for these buildings. As a result of the curve, the roof angle increases with increasing run-off length, thus improving run-off performance of the roof. A jointless sheet transition from -0.5° to 0.5° was incorporated at the apex of the roof in order to avoid a large flat zone. Typical step laps were detailed to facilitate watertight installation and minimise the effects of temperature strain with the first sheeting laps occurring at slopes of more than 2°.

In order to ensure transparency of the sheeting tender, all tenderers were required to submit test compliance data as an entry criterion to the bidding process. This data was to be derived using the methods of the draft cladding code, SANS10237, which is in development by the South African Metal Cladding and Roofing Association.

Scheltema won the sheeting tender with GRS KLIP-TITE as the product of choice, rolled from Safal’s AZ150 Colorbond. Similar to the structural steel erection, the contractor deployed safe erection methods far above industry standard while tight collaboration between Safal, GRS and Scheltema ensured a high quality installation with an uncompromised guarantee for the client.

The project was completed on time and within budget while impressing with outstanding design and way-leading quality of works.

Tons of structural steel used ± 2 963 tons
Structural profiles used UB, UC, C, EA, CFLC, CHS, SHS, RHS
Cladding profile/ type used GRS KLIP-TITE™ roof sheeting, IBR side cladding
Cladding area/ coverage 118,140m2 roof surfaces, 19,914m2 side cladding
Cladding tonnage ± 787 tons

 

Project team

Project Team Role Company
Nominator WSP Group Africa (Pty) Ltd
Client/ Developer Shoprite Checkers Properties
Architect Steyn le Roux Truter
Structural Engineer WSP Group Africa (Pty) Ltd
Engineer WSP Group Africa (Pty) Ltd
Quantity Surveyor iQS
Project Manager SiVEST
Main Contractor Stefanutti Stocks
Steelwork Contractor Mazor Steel
Steel Erector Mazor Steel
Cladding Manufacturer Global Roofing Solutions (Pty) Ltd
Cladding Supplier Safal Steel
Cladding Contractor Scheltema
Corrosion Protection
Galvanising
Advanced Galvanising (Pty) Ltd
Corrosion Protection
Paintwork Contractor
Nu Nation Protective Coatings
Photographer
Photo competition
WSP Group Africa (Pty) Ltd
Photographer
Aerial photographs
Subiaco Photography

 

Campus Square

Campus Square is a convenience centre situated on the corner of Kingsway and University Road, Melville. Anchor tenants include Pick ‘n Pay, Woolworths and a new Dischem, while the restaurant offering includes an upgraded Dros, RoccoMamas, enlarged Wimpy and a new Nandos. The Centre offers food, shopping, and convenience all under one roof and it is loyally frequented by students of the nearby University of Johannesburg.

The centre was recently extended and the brief to the architect was to create a very lightweight steel roof, with sidelights facing south to avoid heat gain.  A curved aspect was required on the sidelights to create a unique appearance. 

The extension of Campus Square was envisaged in steel from the start. Structural steel trusses (consisting of angles) at an average depth of 1m were used to span between 12 – 25m. I-beams were used where the roof span was less than 12m.

When tying into an existing building, there are usually unforeseen challenges that arise. With the extension of Campus Square, the existing building dimensions were not exact and the on-site dimensions weren’t measured prior to fabrication, which lead to the design team requiring additional brackets that had to be designed to enable the elements to span from column to column.

Another challenge that arose was that the designed steel members weren’t always available when they were needed, which delayed the construction process. To overcome this challenge and meet the deadline, a similar sized element was then identified and specified for the project.

A further challenge was dispensing of water off the existing roof which had a large number of steps and angles and new roof which was higher, a large concrete gutter had to be created between the two roofs, which in turn was used to support the steel structure.

The roof is undoubtedly an innovative aspect of the project. The roof was designed according to the minimum requirements as specified by the code, which resulted in a very light weight roof. Klip Lok 700 by Global Roofing Solutions was specified for the 8000m2 roof.

Fortnightly meetings were held where the professional team and contractor would discuss issues, progress and program to ensure the project runs smoothly. The end result is a successful extension of a widely popular convenience centre in Johannesburg.

Cladding profile/ type used KlipLok 700
Cladding area/ coverage 8000m2
Cladding tonnage 4,8 Tons

Project Team

Project Team Role Company
Nominator Global Roofing Solutions
Client/ Developer Key Stone properties
Architect Hammerhead Designs
Structural Engineer Axiom Engineers
Main Contractor Gothic Construction
Steelwork Contractor Nance Engineering
Steel Erector Nance Engineering
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Chartwell Roofing (Pty) Ltd

Bosch Warehouse

Bosch is a prominent supplier of home appliances in South Africa. The company required a new factory and warehouse facility and appointed Empowered Spaces to design a facility that would ‘wow’ their staff and guests. The brief to the architect for the new facility, which is located in Witfontein opposite the Serengeti Golf Estate, was to design a factory and warehouse that ties in with the company’s corporate standards.

The warehouse was envisaged as a steel structure clad in sheeting from the start as this is renowned as the most efficient and cost-effective way to construct a warehouse. The structural framing consists of grinder trusses and a steel column structure which is supported by precast concrete columns.

What makes the new Bosch warehouse and factory unique is the use of corrugated iron sheeting, as this isn’t often specified for large warehouse structures. 125 tons of cladding was supplied to cover the 20 574m2 of warehouse area. Global Roofing Solutions’ Klip-Tite was the chosen steel sheeting for the project.

To speed up the construction process on site, the project team was appointed far in advance. This enabled the design team to issue the contractor with appropriate information ahead of schedule, which led to quick and efficient construction on site. The result is world-class warehouse that fits with the Bosch’s corporate brand and profile.

Cladding profile/ type used Klip-Tite
Cladding area/ coverage 20574
Cladding tonnage 125 Tons

Project Team

Nominator Global Roofing Solutions
Client/ Developer Bosch
Architect Empowered Spaces
Structural Engineer Kantey & Templer Engineers
Quantity Surveyor IBP Construction
Main Contractor Bantly Construction
Steelwork Contractor Steel Band
Steel Erector Steel Band
Structural Steel Detailer KRU Detailing
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Roofline