IRPTN Pedestrian Bridges

In 2013, the City of Ekurhuleni Metropolitan Municipality embarked on an upgrade of their existing transportation route planning and infrastructure in the form of an Integrated Rapid Public Transport Network (IRPTN). The City is now set to kick off the first official run of its IRPTN service, Harambee, as part of the implementation of its Phase lA operations.  The limited service will run eight buses in mixed traffic along the 38 km service route, with 33 kerbside stops, between Tembisa and Isando.


The full roll-out of the Harambee Phase lA service includes the introduction of new elements into the system until it is ready to operate as a fully-fledged BRT (Bus Rapid Transit) scheme. Integral to the project is the construction of nine new BRT Bus Stations (see the Station layout in Figure 1 below) which run into the heart of Tembisa. These new Bus Terminals and pedestrian bridges are the projects submitted here for consideration.

The overall project scope includes the upgrade of the existing road facilities, to add new BRT lanes with sidewalk and median, as well as the construction of nine new station facilities. Due to the overall road width increase, several structures are required to be extended and upgraded – these include a road culvert water crossing and several rail culverts that cross the main road (Andrew Mapheto drive) that traverses through central Tembisa.

With the exception of the pedestrian bridges, the typical layout model that has been deployed throughout the project is similar to that which has been used in the Johannesburg CBD and Cape Town BRT systems. The Stations represent central node points that facilitate the easy access of pedestrians into the BRT system, and the brief to the Architect was to design an aesthetically pleasing solution that provided such access.

The elements generally incorporated into a typical Station are the following:

  • A median area where passengers are noused in a dedicated enclosed structure that provides direct access to the bus route and BRT lane,
  • the pedestrian bridges that cross over the road intersections, allowing pedestrians the ability to gain safe access to the median area,
  • the various interlinking walkways and stairs,
  • the lift shafts that allow users to transition from the Ground level to the First-Floor level and back

The original concept developed by the Architect and Structural Engineer is very similar to the final design that is currently under construction, which involves a curved steel truss type arrangement, made out of mostly circular hollow sections. Structural steelwork was envisaged on this project due to its ease of use for the required spans, the ability for easy erection over existing roads, as well as the overall slim look and feel that arises out of its use in the design.

The bridges incorporate a composite structural steel/reinforced concrete slab design. The top and bottom girder chords are constructed from circular hollow sections and the design has a curved top chord that is set at an angle relative to the main floor structure, making the bridge took “open” as one travels from one end to the other. Due to deflection requirements, the bridges are given a slight vertical preset to allow the deflections to normalise under dead and live load conditions. The vertical girder members are given outward curved radi, and a similarly radiused plexiglass f de is attached using aluminium mullions – the fac;ade envelops the entire truss frame, giving the bridge an aesthetically appealing look and feel, To facilitate drainage on the bridges, a longitudinal fall is provided between deck interface platforms and full-bore outlets are used on the bridge ends to facilitate the discharge.

The longest pedestrian bridge has a span of 36m and therefore it is long enough for vibration considerations to play a role. A LUSAS model was therefore developed to simulate the effects of pedestrian crowds as well i:IS single dynamic pedestrian users moving over the bridge. The analysis showed that that the maximum accelerations developed on the bridges are not in excess of the 0.5m/ s2 allowed by the relevant Codes. Acceleration results were further compared with the SETRA Pedestrian Bridge design guide as well as the TMH7 guidelines.

The Lift Tower shafts and their supporting structure represent key structural elements that directly interface with an unusual curved supporting element that takes the bridge load directly down to the foundation level after first wrapping its way around the Lift Shaft Tower. The lift shaft itself is also enclosed in an aesthetic plexiglass facade, providing cover to users of the lift as well as protection for the lift equipment. Louvered vents through the facade are also required due to the heat-build inside the Lift Shaft Tower structure.

From a design point of view, the interfacing of the plexiglass facade with the bridge structure required several Iterations to ensure that a robust and workable solution was arrived at. One of the challenges of designing with plexiglass material is that all the connections to the structure need to include a gasket sealing material and gaps are required in connections to allow for a certain degree of plexiglass movement. Interfacing with the 11ft contractor also required a thorough understanding of the details of the levels and falls on the site to ensure that the lift exit and entry points corresponded with the deck slab and ground levels.

The open frame design of the bridge girder members meant that careful attention had to be paid to the stability of the main girder structure in the transverse direction –  this meant that any member splicing along the lines of the main transverse framing action required the use of stiff moment connections.

A significant number of Shop drawings were required to be generated for the entire project. 3-D Tekla models were used by the steelwork contractor to facilitate the rapid development and approval of shop drawings. Due to aesthetic requirements, welding for the splicing of main longitudinal members was done on site under carefully controlled conditions.

For each bridge site, road closures were required for the erection of each bridge – this required a significant amount of coordination with the local traffic authorities who were fortunately very obliging. Some 32 tonnes per 36m span were lifted, and a typical station involved the erection of approximately 115 tonnes (Including the Lift Towers) per station.

For this project, the two main Contractors on the project (Stefanutti Stocks and King Civils) were required to think of solutions to the problem of how and when to  Install the concrete deck slabs whilst allowing for the concrete creep and shrinkage to occur. This produced a set of interesting and varying opinions, and ideas suggested varied from precast concrete to  in­ situ concrete with permanent formwork.

The design of the Station Bridge structures that are required to harmonize with Lift Shaft Towers presented an interesting challenge to the SMEC South Africa bridges design team. The project demonstrated that there is still a significant preference for the use of structural steel for pedestrian bridges in this country.

STRUCTURAL STEELWORK
Completion date of steelwork ± September 2018
Completion date of full project ± April 2019
Tons of structural steel used 725 Tons
Structural profiles used Chs, Ub, Uc, [, Angle
PROJECT TEAM COMPANY
Nominator Khombanani
Client Ekurhuleni Metropolitan Municipality
Structural Engineer Smec South Africa
Engineer Lte Consulting
Engineer/Project Manager Lte Consulting
Main Contractor Stefanutti Stocks / Khombanani Steel JV
Main Contractor King Civils
Steelwork Contractor Khombanani
Steel Erector Onpar Steel
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Roofline
Corrosion Protection
Paintwork Contractor
Dram Industrial Painters
Corrosion Protection
Paintwork Contractor
RSC

UKZN – School of Engineering Dining Hall

The building is around 250m² with lots of shopfront opening divided by 220mm wall fins. LSF wall panels and trusses and roof panels. The most changeling was the soffit boxes above NIB wall to take the trusses. Roof overhang cantilever of 1200mm.

The cantilever entrance soffits and horizontal beams to look like cast concrete. The support structure for these needed to protrude into the truss void by approximately 2.0m to allow for the cantilever.


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

Yes, the architect has previously worked with LSF.

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

A standard frame-cad LSF lip channel section was used for all walls and roof structures. 90 x 40 x 0.8mm LSF Section.

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

The cladding process is standard flat fibre cement, however, most of the building consists of glazed shopfronts. The entrance canopy’s and soffits were a bit challenging

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.

Roof overhangs on the sides needed extra support in the roof, panels on 4 corners as well. This made them quite heavy.

The cantilevered soffit beam detail at entrances required some extra design and solutions to achieve this.

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

The interesting boxing to entrances and soffit beams.

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

Shospec priced as a sub-contractor at tender stage, we had no involvement in the original design process.

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work December 2018.
Completion date of full project March 2019.
Tons of LSF used 4 762 Tons
Span of trusses and Kg/m2 (if applicable) 12.3 meters
Profiles used Frame Cad – C Section
Type of cladding 10mm Fibre cement board and 12mm OSB Board
PROJECT TEAM COMPANY
Nominator Shospec (Pty) Ltd
Architect Artek 4 Architecs
Structural Engineer Martin & Associates
Engineer Martin & Associates
Main Contractor Go Plan Homes
Steelwork Contractor Shospec (Pty) Ltd
Steel Erector Shospec (Pty) Ltd
Cladding Manufacturer SHERA
Cladding Supplier CAPCO
Cladding Contractor Shospec (Pty) Ltd

Department of Health – Townhill Office Park

The employer’s objective was to construct a new office park for the Department of Health infrastructure development and technical support at Townhill hospital, Pietermaritzburg. The expected outcome was the completion of 3 office blocks, complete with furniture, fittings, landscaping and road works. IE a full turnkey project. 


The KwaZulu-Natal department of health head offices occupied two rented buildings of which their leases expired. In line with cost-cutting imperatives, the department of health had decided to invest in a state-owned facility rather than paying annual rent.

What was the brief to the architect?

Professional and management services for the design, development, documentation supervision and construction of a new office park for the department of health, infrastructure development and technical support at Townhill hospital, Pietermaritzburg, KwaZulu-Natal.The department of health supplied a general draft specification and requirements at Tender stage including a layout and footprint for the development.

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

Yes, steel was envisaged from the start

“The project comprises of three buildings, to be constructed in a short time frame and to be fitted and furnished at completion. The construction of the building may compromise of any certified (S.A bureau of standards) or accredited (Agreement S.A) construction method and must comply fully with the National Building Regulation and the SANS 10400. The buildings must be low maintenance, single story structures and be aesthetically pleasing. Potentially severe weather must be considered.

Design, supply, fabricate and erect the following structural steel roof and wall framework, wall cladding, completed as installed with SANS 517:2009 and SASFA association. “ – [ Extract from Tender Document]

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

A standard FRAMECAD LSF lip channel section was used for all walls and roof structures. – 90 x 40 x 0.8mm LSF Section.

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

  • Wall Cladding – 90% of the walls where clad externally with OSB board, Tyvek vapor barrier and Shera planks.
  • Internal Cladding – Is 102mm Isover Cavity Batt insulation and 15mm Gyproc fire stop boards.
  • Entrance’s – All were clad with Flat fibre cement boards and expressed joints.
  • Roof Cladding – 100mm Factory-lite bulk insulation and SAFLOK 700 roof sheeting.

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

  • The buildings comprised of 4 x Flanks and a center core section.
  • Flank walls varied in height from 3m to 3.6m.
  • Centre core walls varied in heights from 5m to 6.2m
  • Truss spans of approximately 11.5m between walls and 900mm overhang all around.
  • Approximately 45 Tons of LSF was used
  • A notable achievement was the speed of construction using LSF, erected LSF, cladding, roofing, ceilings and window installation was completed in 10 – 11 months for 3 office blocks.
  • 2 x 1280m² and 1 x 900m² with a total area of ± 3500m².

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.

No changes from the engineer as the project scope was “design, develop and construction” of an office park.

Shospec was very involved with the design from the onset as the specialist LSF contractor and member of TOP JV.

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

  • Wall cladding is a standard Shiplap plank and flat sheets with express joints.
  • The four side entrances protrude from the building flanks and stand out from the main cladding due to the texture of the finish and colour.
  • The same applies to the two center core entrances of approximately 5.2m high. These comprised of a lightweight slab as the roof. This is to accommodate the air-conditioning plant hidden behind a parapet wall and two Louver screens and doors on the sides.
  • The speed of construction was critical for achieving the clients intended programme; originally planned at 19 months and accelerated by 4 months as per the client’s request to achieve occupation within 14 month’s

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

The clients’ brief and tender specification was for a full turnkey professional and management services for the design development, documentation supervision and construction of new office park for the department of health.

The successful bidders were TOP JV (Townhill Office Park J.V), our team consisted of;

  • Shospec (Pty) Ltd       Light Steel Frame
  • D-Construction       Wet works and other trades
  • SMS Design Architects Lead professional

All other professionals were employed as sub-consultants by the Joint Venture.

  • It was critical at tender stage to have a design philosophy for costing purposes and submitting a fixed price. Once the tender was awarded it was imperative that the contractors were involved with the projects team to ensure the building was designed and constructed within the budgets and allowables submitted at tender stage.
  • We were handed over a green lawn of around 15 000m² to develop the full turnkey office park comprising of around 3600m² of LSF Buildings.
  • Most sub-consultants had previous experiences working on similar LSF projects.
LSFB / LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work November 2018.
Completion date of full project 08 March 2019.
Tons of LSF used 45 Tons
Span of trusses and Kg/m2 (if applicable) 11.4 meters
Profiles used Frame Cad – C Section
Type of cladding 8mm Shera Plank Teak Wood grain, And 12mm OSB Board
CLADDING
Completion date of cladding ± July 2018.
Cladding profile/ type used SAFLOK 700
Cladding area/ coverage and tonnage 3400m²
PROJECT TEAM COMPANY
Nominator Shospec (Pty) Ltd
Client/ Developer Dept Of Health
Architect Sms Design Architects
Structural Engineer Martin & Associates
Engineer Martin & Associates
Quantity Surveyor TMS
Project Manager D-Construction / TOP JV
Main Contractor TOP J.V
Steelwork Contractor Shospec (Pty) Ltd
Steel Erector Shospec (Pty) Ltd
Cladding Supplier Four Seasons
Cladding Contractor Four Seasons

UNi4 EdTech Centre

The Architectural concept required a continuous vertical regular screen element, suspended up to 3.5 metres from the external façade, about an irregular 3 storey building. Considering all options, galvanised expanded metal cladding was chosen, made up in the order of 2.1 meters by 1.2-metres panels fixed to a supporting peripheral framework.


Supporting frames, comprising braced tubular and hot rolled sections were fixed at convenient structural locations about the perimeter, to the columns and floors slabs, at up to 9.0-metre centres.

Sheeting rails comprising “T” sections fabricated from hot rolled H and I sections, span between the frames, with the mesh angle edged panels connected to the rails.  All sections were hot dipped galvanised and connections site bolted.

All steel elements being viewed from within the building were carefully detailed to achieve an aesthetic industrial appearance of featured steelwork sections.

it is considered that the design and detailing efforts, in conjunction with the input from the fabricator and erector, under the Architect’s directive, achieved a unique and noteworthy building steel cladding system.

ARCHITECT ASPECTS

A few decades ago the construction of the new N3 freeway cut off and isolated the site from its residential context. With freeways on two sides and a suburban access road on the third, the site was now characterised by both second-to-none visibility from the main vehicular accesses into and out of the city, and the related 24/7 freeway noise.

Initially, a single storey free-standing house was built on the site. With the irreconcilable conflict between domesticity and the freeways, it took a few years for residential use to be abandoned. The house was demolished and a compact two-storey office building was constructed above one level of parking.

Although typologically a courtyard layout, the void was filled with meeting rooms, effectively reducing it to a fragmented light-well. The plan arrangement, exterior form and decoratively expressed structure were typical of post-modern geometric and iconographic complexity popular at the time.

In the site’s third iteration to accommodate a UNi4 Institute, our approach was to strip the building to its bare bones, first to enable the development of a  generous, acoustically protected interior patio around which all programmed education and support activities are arranged. And second to shade the building at the same time as radically transforming the exterior in response to the 120km/hr freeway context.

Full of natural light, covered but not enclosed, central to all movement, part garden and part ‘piazza’, the patio is the primary social setting for both incidental and planned interaction at the core of contemporary learning thinking and practice.

Both ground and first levels are conceived as verandahs opening into and overlooking the patio. Very few activities require visual and acoustic privacy. Apart from a raked auditorium, these are located in freestanding enclosures on the ‘verandah’ floors like objects on a terrain.

An industrial version of a trellised verandah, a primary purpose of the free-floating expanded-metal screen is, with one solution, to shade existing highly solar-exposed glazing on all orientations while retaining optimal internal light levels. At the same time, the screen transforms the undefined geometric complexity of the pre-existing external envelope into a smooth, blind, homogenous surface that mediates between the technological and the human, generating an imageable and memorable landmark at the confluence of the freeways. And between these two geometries, a range of open shaded perimeter office and student break-out terraces became possible as more privately accessible versions of the interior courtyard.

Although accommodating parking, the unbuilt area of the site will develop into an endemic sub-tropical landscape, the screen and vegetation together integrating the building and site into its accidental context.

STRUCTURAL STEELWORK
Completion date of steelwork July 2018
Completion date of full project July 2018
Tons of structural steel used Support Frames, 24 Tonnes
Structural profiles used Tubes/Hot Rolled Sections
SA content – if this is an export project 100%
CLADDING
Completion date of cladding July 2018
Cladding profile/ type used Mentis Expanded Metal – Ref 38
Cladding area/ coverage and tonnage 3 000 Sq Metres/16 Tonnes
PROJECT TEAM COMPANY
Nominator Young + Satharia (Pty) Ltd
Client/ Developer Educor Property Holdings
Architect Design Workshop
Structural Engineer Young + Satharia (Pty) Ltd
Engineer – Civil Young + Satharia (Pty) Ltd
Main Contractor Linear Construction (Pty) Ltd
Steelwork Contractor STS Steel Projects
Cladding Manufacturer Danjay Fabrication
Cladding Supplier Andrew Mentis (Pty) Ltd Trading As Mentis Sales
Cladding Contractor STS Steel Projects
Corrosion Protection
Galvanising
Pinetown Galvanising

 

Form-Scaff Distribution, Phase 2 (Warehouse & Office Block)

Futurecon did a complete turnkey project which consisted of a new head office & workshop for Form-Scaff. The project was done at Lordsview Industrial Park in Chloorkop, Gauteng. The office is two storeys at 530m² per floor and 1060m² in total. The workshop is 1206m² ground floor with a 397m² first floor mezzanine area and total 1603m². The total project is 2663m² and only took 6 months to complete.

 

The client wanted the building to be occupied as soon as possible, temporary offices were hired for the tenant to use while construction was going on. We offered a turnaround time off less than half of traditional building methodology. In the end we handed over the workshop in just over 5 months & the office in 6 months and includes the snag period.

The building construction consists of

  • Internal walls: LFS with 15mm fire board on both sides. Skimmed and painted
  • External walls: LFS with 15mm fire board on the inside. External cladding with a scratch and smooth plaster finish.
  • Concrete floors: 255mm Voidcon system on concrete columns to first floor slab.
  • Roof & Cladding: 150x50x20x2mm CFLC purlins 1100mm c/c with Safintra 0.5mm Zincal Saflok interlocking roof sheeting & 716m² side cladding

With all the experience Futurecon built up over the course of 18 years we didn’t experience any problems aside from your normal building related issues. This project went exceptionally well from the beginning. The biggest factor is to have a reliable and experienced project manager as well as staff that’s well trained in the LFS industry. We also rely on our sub-contractors that’s been with us for many years now.

The owner, architect, QS firm and tenant are extremely happy with the result.  They commented on the neatness of the building, the speed it was erected, as well as the high class of finishing that was reached. They also enjoyed the fact that the building site during the project was always neat.

STRUCTURAL STEELWORK
Completion date of steelwork November 2019
Completion date of full project Feb 2019
Tons of structural steel used 2.8t
Structural profiles used 152x152mm x23kg/m I-sections
LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work November 2019
Completion date of full project Feb 2019
Tons of LSF used 27 tons
Span of trusses and Kg/m2 (if applicable) 30 meters
Type of cladding KlipLok / Plaster
CLADDING
Completion date of cladding January 2019
Cladding profile/ type used Klip-Lok / Plaster
PROJECT TEAM COMPANY
Nominator Futurecon
Client/ Developer Wealthgate Investments 45 (Pty) Ltd  
Architect Boogertman and Partner  
Structural Engineer J3 Engineering
Quantity Surveyor Henry Riley Construction Consultants (Pty) Limited  
Project Manager Henry Riley Construction Consultants (Pty) Limited  
Main Contractor Futurecon
Steelwork
Contractor
Futurecon
Steel Erector Futurecon
Cladding
Manufacturer
Hollyberry Roofing (PTY) Ltd
Cladding Supplier Hollyberry Roofing (PTY) Ltd
Cladding
Contractor
Hollyberry Roofing (PTY) Ltd
Roofing and
Cladding
Global Roofing Solutions

Fezile Dabi Stadium, Parys

The roof structure provides protection from the elements to the main grandstand and adjoining stands.  The stadium was officially opened in 2013 but without a roof. As part of the upgrade of the stadium, a new roof was proposed.


What was the brief to the architect?

Provide a roof on the existing stands that is both practical as well as aesthetically pleasing on the eye.

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

Yes proposed as steel from the beginning

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

The roof trusses and supporting columns are made entirely from Circular Hollow Sections (CHS)

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

The bull-nose on the stadium roofs were a concern. A mock-up was carried out at the steelwork fabricator’s premises and approval was given to continue as planned

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 fabrication process required several fabrication jigs to be made up to accommodate the 84-no trusses required for the project. The tubular sections were rolled into various radii and the cross bracing were individually profiled cut to allow a stub-on connection to the main truss struts. The challenges faced during erection involved fitting a new roof onto an existing structure. Interface connections that were not in the envisaged locations, resulted in modifications having to be carried out on new steelwork.

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

The project is aesthetically appealing in that a previous stadium is now provided with a roof which enables the spectators to have some protection from the elements.

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

Constant communication between the Steelwork Contractor and the Structural Engineer was critical to get agreement on being able to fit the new roof to the existing stadium stands.

STRUCTURAL STEELWORK
Completion date of steelwork March 2019
Completion date of full project April 2019
Tons of structural steel used Approx. 300 tons
Structural profiles used Tubular Steelwork up to 220mm diameter in roof
CLADDING
Completion date of cladding March 2019
Cladding profile/ type used 0,58mm IBR Chromadek Sheeting
Cladding area/ coverage and tonnage 7920 m2
Nominator CADCON (Pty) Ltd
Structural Engineer Aecom
Quantity Surveyor WBHO
Main Contractor WBHO
Steelwork Contractor CADCON (Pty) Ltd
Steel Erector CADCON (Pty) Ltd
Steel Detailer MONDO CANE
Cladding Supplier Clotan Steel
Cladding Contractor CADCON (Pty) Ltd
Corrosion Protection
Paintwork Contractor
Dram Industrial Coatings

Chilleweni Cold Storage Solutions

Chilleweni Cold Storage Solutions provides cold storage and refrigerated logistics services to several of South Africa’s largest brands within the frozen food market.  Their new, larger and more improved home in the Randport Industrial Park is strategically located adjacent to the Elands Interchange, a major transport node situated in the well-established industrial hub of Gosforth Park, Germiston.

 A fresh design approach has given rise to a unique building which compliments the strategic and locational benefits of the building. The harmonious choice of structural elements combined with technology, technical aesthetics, colour, and material has resulted in a visually appealing industrial building fit for purpose. It is a building which enhances the experience of the user and adds value to the immediate context.

 

Why steel was chosen for this project

Steel speeds up the construction period and is highly recyclable, meaning it can be capitalized on by future generations. It also limits the operational costs during construction.  Further reduction in operational costs was achieved through careful selection of material colour, insulation and use of Low-emissivity glass.  Office HVAC system designed with reduced chilled glycol supply temperatures to optimise HVAC equipment capital cost and utilize highly efficient primary ammonia plant operating at a Coefficient of Performance of 4.93. Waste heat from compressor discharge used to mechanically dehumidify the receiving and despatch area. All condensate from blower coils harvested and re-utilized for heat rejection in condensers. Highly efficient, two-stage ammonia plant operating at a Low-Temperature Coefficient of Performance of 5.62 and a Medium-Temperature Coefficient of Performance of 4.93. Decreased TEWI (Total Equivalent Warming Impact) vs synthetic and other natural refrigerant options evaluated due to reduced primary and secondary emissions. All-natural refrigerant designed with zero Ozone Depletion Potential and Global Warming Potential. Integral compressor oil cooling providing waste heat for underfloor glycol to prevent frost heave.

Notable elements of the project include

  • Longest known freezer in SA, possibly Africa with single throw fans: 55.95m
  • Integral compressor oil cooling providing waste heat for underfloor glycol to prevent frost heave.
  • Bespoke in-rack blast freezers installed inside the main freezer chambers allowing for integrated blast freezing utilising primary room coils as opposed to dedicated blast freezer room.
  • Construction period of 8 months. Most facilities this size take 10 months to a year to complete.

Industrial buildings are characterised by standard ‘archetypal features’ such as large unbroken facades, blank walls, large spans of repetitive faces and materials which integrate various engineering structures and equipment.  Through careful artistic treatment, systematic arrangement and sensible proportioning of these main and pronounced features, the repetitive appearance of a ‘standard’ industrial building was avoided.  Instead, the harmonious choice of structural elements combined with technical aesthetics, colour and materials resulted in a visually appealing industrial building fit for purpose, one which enhances the experience of the user while adding value to its immediate context.

Chilleweni Cold Storage Solutions provides cold storage and refrigerated logistics services to several of South Africa’s largest brands within the frozen food market. Through well thought out spatial arrangements coupled with quality finishes and design, the user experience is positively enhanced. Low emissivity glazing and strategically positioned windows allow natural light to filter deep into the office space.  It connects the user to the amazing vistas surrounding the site. The office HVAC system is designed with reduced chilled glycol supply temperatures to optimise HVAC equipment efficiency and performance to create a comfortable climate at a reduced operational cost while reducing environmental impact. The staff/ back of house facilities share the same amenity and are not segregated from the main office portion.

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 October 2018
Completion date of full project September 2018
Tons of structural steel used 210
Structural profiles used Hot and cold rolled profiles
CLADDING
Completion date of cladding October 2018
Cladding profile/ type used GRS Klip-Tite and GRS Klip-Lok 700
Cladding area/ coverage and tonnage 11 002m² / 58.310 tons

PROJECT TEAM

COMPANY

Nominator

Global Roofing Solutions

Client/ Developer

Zenprop Property Holdings

Architect

Empowered Spaces Architects

Structural Engineer

DG Consulting Engineers

Engineer

DG Consulting Engineers

Quantity Surveyor

Schoombie Hartmann

Project Manager

Capex Projects

Main Contractor

Akhane Construction

Steelwork Contractor

Steel Band

SE Steel Fabrication

Steel Erector

Steel Band

SE Steel Fabrication

Cladding Manufacturer

Global Roofing Solutions

Cladding Supplier

Global Roofing Solutions

Cladding Contractor

Cladco

Cladding and Roofing

Global Roofing Solutions

Steel Detailer

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.

Protea Glen Secondary School 2

The Gauteng Department of Education gave out 9 Alternative Building Technology (ABT) Schools in 2018, with the aim to adjudicate the various building systems and see if there were advantages to be had using any of the systems.

Abacus Space Solutions was awarded one school, Protea Glen Secondary school no. 2; following their submission of a SANS 517:2013 based school. Local studio Architects, who have a number of Light Steel Frame projects to their name, including the well-accredited Hillbrow Outreach Program, were appointed as the Architect.

The structure and space requirements for the GDE are laid out in their previous project designs, so the brief to the Architect was to work within those parameters, but to create flow and harmonious structures conducive to learning.

Local Studio set about tailoring the generic GDE drawings to suite the site and designing a school layout and buildings that would be the best for the site. SMC Africa where tasked with the detailing and construction portion of the project. Craig Tyndall from the Structural Workshop, who is well experienced in Light Steel Frame construction was responsible for structural engineering.

Hennie Snyman of Luleka, was appointed the Civil Engineering Consultant and was responsible for slab design, and handling of, amongst other things, the dolomitic area. The site was classified as a type 3 dolomitic area, requiring ring- beams and raft foundations.

The advantages of LSF framing to be capitalized on for this project were:

  • Speed – the project started in August with the structures (3421m2) being completed by the 15th December. This was the first of the 9 schools to achieve works completion.
  • Acoustics– this is particularly important in a school and the superior acoustic properties of the walls stop sound transmission between classrooms.
  • Temperature – the rooms are temperate and noticeably cool in hot ambient temperatures.
  • The flexibility of design- Local Studio was able to capitilise on the flexibility of the building system to create lofted ceilings and acentric roof lines to create unique aesthetic structures

A variety of ABT technologies were chosen by the client, in order to evaluate them.  Abacus space solutions chose LSF  due to their experience in it, and their knowledge that the product is superior to other building methods.

A brief description of the structural framing and use of LSFB

The structure is a Framemaster 90mm by 38mm cold rolled section in 0.8mm galvanised steel. The roof structures are Structural Insulating Panels with Chromadek finish. Walkways are mild steel C, and rectangular hollow sections.

The LSF system is in line with the requirements of SANS 517:2013. The inner skin is 15mm Gypsum, with a 110mm cavity batt, Tyvec, building wrap, 21mm shutterply runners and 12mm fibreboard external sheeting. The joints are treated with a two-part epoxy, with expansion joints where detailed. The external paint is Weatherguard PVA.

As there are a number of repeated building elements, or minor variations, there is a huge advantage in using LSF, as the rollformer needed to merely manufacturer multiple of the same buildings, thus saving on detailing time.

The large span capacity of the 125mm SIP panels, in conjunction with LSF beams, allows for elevated internal spaces that create open light classrooms.

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

The inclined wing walls on the buildings would not have been as easily achieved with conventional building methods. The design choice of the inclined Chromadek clad Structural Insulating Panel roofs provided unique Architectural features.

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

The experience of the Architect and LSF Contractor in using LSF, as well as the quick feedback loop allowed for accurate design and detailing work to be done relatively easily. The in-house 3d detailing done by the LSF Contractor improved communications between all of the relevant professions.

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.

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work November 2018
Completion date of full project February 2019
Tons of LSF used 40t
Span of trusses and Kg/m2 (if applicable) 8m
Profiles used   

Framemaster 90mm

Type of cladding Fibre Board and render
PROJECT TEAM COMPANY
Nominator SMCAfrica
Client/ Developer GDE
Architect Local Studio
Structural Engineer The Structural Workshop
Engineer Luleka Consulting Engineers
Quantity Surveyor Diva Sync
Project Manager Proplan
Main Contractor Abacus Space Solutions
Steelwork Contractor Emkay
Steel Erector SMCAfrica
Cladding Manufacturer Marley
Cladding Supplier Marley
Cladding Contractor SMCAfrica

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.

CMH Kempster Ford Dealership

The elliptically shaped building with an asymmetrically placed circular inner core was designed for BMW Umhlanga in 2000 and the roof consisted of a concrete ring beam with a tensile tent-type structure attached to it. CMH Kempster Ford, the building owners decided to convert the building into their new flagship dealership that would satisfy Ford international’s CI. The original building had no thermal qualities and it was only projected by a 2mm membrane. Needless to say, the internal thermal comfort was not great and had to rely on mechanical cooling.

Steel was the obvious choice due to its flexibility, durability and aesthetic value. The steel members allowed for great long and shallow spans and also for it to be extended beyond the building façade for greater solar protection. Braced roof overhangs of 4,0m were achieved and bring with it an added aesthetic dynamic.


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.

Due to the geometry of the structure very careful consideration design innovation had to be given to the roof and side cladding. The roof structure was a series of overlapping circular rings and GRS recommended Ziptec due to its ability to be tapered around the circular roof-scape. Another reason for choosing Ziptec was due to its high wind-loading capabilities as the sheeting was laid on a six-degree pitch. Horizontally laid IBR sheeting was used on the vertical face of the elliptical building and each every sheet had to be specifically rolled to the correct radius to fit each segment of the façade. The balance of the building façade was a combination ColorPlus – S Profile sheeting fixed horizontally to large parts of the building as well as Hulabond HBS Aluminium System Panels attached to a curved steel sub-structure. The latter work was done by Façade Solutions and the Colorplus sheeting was prepared and supplied by GRS

Due to the complex and intricate nature of the design and installation of the project, it was imperative that all the stakeholders be involved from inception. Experience played a major role in the ultimate success of the project and the client employed two key professionals that were involved in the project when first constructed in 2000- 2001. The Engineer, Linda Ness from NJV Consulting Engineers and the Architect from Hans Coetzee Architect. Linda Ness nominated Impact Engineering for the work at hand and their input and manufacturing abilities proved to be a catalyst of the ultimate success of the project. Their only recommendation was that GRS be involved due to their ability to provide the correct sheeting and cladding products from a design and supply point of view. The timelines were manic due to the clients trading requirements but all parties got stuck in and delivered an awesome new building to CMH Kempster Ford. Hans Coetzee Architect provided the services of Project Manager and Principal Agent.

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 30 MARCH 2018
Completion date of full project 30 MARCH 2018
Tons of structural steel used UNKNOWN
Structural profiles used I-BEAM / CHANNEL / COLD ROLLED ANGLES
SA content – if this is an export project LOCAL SUPPLIER:  IMPACT ENGINEERING
CLADDING
Completion date of cladding 26 JULY 2018
Cladding profile/ type used ZIPTEK 420      0.8MM GR9017 HAZY GREY N/F  

IBR 686            0.53MM AZ200 SLATE  N/F

KLIPTITE          0.53MM AZ200 RAIN CLOUD N/F

Cladding area/ coverage and tonnage ZIPTEK 420      2326m²             7.310 TONS  

IBR 686            359m²               2.900 TONS     

KLIPTITE           159m²               830 KG

PROJECT TEAM ROLE COMPANY
Nominator Global Roofing Solutions
Client/ Developer CMH
Architect Hans Coetzee Architect
Structural Engineer NJV Consulting Engineers
Project Manager Hans Coetzee Architect
Main Contractor Impact Engineering
Steelwork Contractor Impact Engineering
Steel Erector Impact Engineering
Roofing and Cladding Global Roofing 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.

Cummins Southern Africa Regional Office Project

Sitting between Johannesburg and Pretoria, Waterfall is one of the largest urban developments, housing a concept which connects and integrates lifestyle and business.  Featuring high-quality purpose-designed buildings with a focus on mixed-use precincts, this area is already home to notable corporate beacons such as PwC, Deloitte, Dimension Data, Amrod and the BMW Group SA.

In the heart of the Waterfall Logistics Precinct, the new Cummins Southern Africa Regional Organization building rises from its prominent site alongside the N1 Highway off Allandale Road.

The aim for this mixed-use site was to deliver a unique and iconic modern design, which not only functions with integrity, flexibility and efficiency within the warehouse and office structures but also delivers a visual and fascinating experience for vehicles on the N1 as an iconic structure from all elevations. While every aspect of the facility was guided by the Cummins International Design standards with local adaptations, Empowered Spaces Architects has adapted and moulded these ideas into a marvel of design, making use of different colours and materials to accentuate the profile of the office and warehouse structures.


What was the brief to the architect?

To Create / Design a New Idea & Concept

The fluidity of the geometric forms was important in the massing of the structures, creating a regular gridded planning that was extrapolated into usable spaces which are seen in various progressive arrangements throughout the design. The combination of structural architectural elements grounded on a base format sets the tone for the overall three-dimensional form, the play and juxtaposition of heights and colour arrangement allowed for the desired architectural forms.

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

The structure is supported by 320 Tons of steel and roofed with GRS Klip-Tite steel sheeting, whereby sheeting accommodated the Architectural concept of the building.

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

Hot & Cold Roll Profiles

Cranes will be installed in the building, as car/truck motors shall be assembled in the warehouse. Heavy steel was needed to support the structure. 

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

To accommodate the design, cranking a sheet either side, GRS assisted to design a step-lap to accommodate the aesthesis of the design.   

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

To create a visually exciting but functional building envelope that captured all the required amenities set out by the client without disrupting work efficiency. To create a model of visual and functional architecture that house numerous advanced design technics and construction but still allows universal access.

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

All teams worked well towards the end goal. The integration and support from GRS, the suppliers or roofing and cladding worked well with the roof installer and Architect on site constantly to achieve a stunning profile. Support from Alubond (Stalcor) was greatly appreciated when they supplied the Aluminium composite panels.

STRUCTURAL STEELWORK
Completion date of steelwork 23/11/2018
Completion date of full project 2019/01/28
Structural profiles used Hot and cold rolled profiles
CLADDING
Completion date of cladding 31st October 2018
Cladding profile/ type used Klip-Tite, Nu-Rib
Cladding area/ coverage and tonnage 11750m2 Roof, Cladding 7000m2 (Total of 112 Tons)
PROJECT TEAM COMPANY
Nominator Global Roofing SA
Architect Empowered Spaces
Civil Engineers DG Consulting Engineers
Quantity Surveyor Schoombie Hartmann
Project Manager CAPEX Projects
Structural Engineers DG Consulting Engineers
Mechanical Engineers WSP Group Africa
Other Consultants Daniel Rebel Landscape Architects
Principal Contractors Group Five Building
Roofing and cladding manufacturer Global Roofing SA
Electrical Engineers QUAD AFRICA Consulting
Fire Consultants WSP Group Africa