Rosebank Link

What is the purpose of the structure/project?

At 15 stories above the ground, the building consists of two basement parking levels, a ground floor or public/retail level, five parkade levels, and nine stories of offices from a podium level. It will allow everyday pedestrians to traverse without barriers from the Gautrain through to the adjacent malls.

What was the brief to the Architect?

As a building standing foremost in the center of a developing cosmopolitan area, the client wanted to have a unique building that served the needs of the client, its neighbors, as well as the public in a new, exciting, and smart way.

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

Yes, Meeting Pods, Atrium, and Media screen.

Meeting Pods:  The Meeting Pods can be viewed from the landscaped thoroughfare which forms part of the showpiece of the buildings. The architectural intent for the pods is to be as open as possible, embedded in the glass. These pods are also cantilevered from the concrete frame and was a retrofit.

Atrium:  The Atrium structure formed part of the glass façade, spanning over six stories, additionally it formed a part of the glass skylight structure on the Atrium roof. The structure spanned large distances and had to be as slender as possible while limiting deflection.

Media screen:  The LED panels required special connections at very particular points, while constrained by the removal time by the crane, steel allowed achieving these challenges.

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

Meeting pods:  Gravity loads were the main consideration; therefore, the loads were concentrated around one axis and normal I-section portals bolted to the concrete were the most efficient.

Atrium:  The inner–and bottom chord of the Atrium vertical truss and roof truss were determined by architectural constraints. The outer chord is braced by transom beams for the façade glass, however, the inner chord had a large unbraced length due to the omission of regular knee-bracing. Similarly, the bottom chord had a large effective length for the uplift load case, due to knee bracing not being able to pierce the bulkheads of the skylights butting up snug to the truss either side. This resulted in a relatively large PFC inner chord and large I-section for a bottom chord. The purlins (bracing for the top chord) of the roof had to step, due to the skylight glass line and sheeting line being on different levels. Additionally, the purlins form part of the skylight substructure. The load path was fairly two dimensional and an RHS section was used. For the Atrium glass transoms, large SHS were used due to the wind, and gravity load cases being very similar correlating the sections’ similar radii of gyration in each direction, it was also aesthetically preferred.

Media screen:  The screen consisted of a large SHS outer frame, as the facade and surrounding over cladding required a 200mm flat fixing face, it was also beneficial at the one end, as a part of the screen had to remain cantilevered to span across the crane void, which would only be filled later with structure. Considering hollow sections’ optimal spread of material away from the center of gravity it gave good results when relating stiffness/size ratios.

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 manufacturing was straightforward, the main difficulty was during erection, the site has virtually no laydown areas with very limited access. The internal cladding support was all done by hand, accurate setting out of beveled columns gave a suitable platform to fix the substructure at awkward angles and positions as per the Architect’s design. The main Atrium roof is very high, and tower cranes were relied on for erection, difficulties were accessed and space as well as supporting lattice columns until the trusses were fixed in place.

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

The final steelwork visual was not part of the architectural intent, therefore hiding it as effectively as possible while forming part of multiple systems and serving its purpose. To accommodate this architecture, it resulted in large unbraced lengths and a peculiar arrangement of members. There was also a large emphasis on keeping the tonnage down to accommodate the Green Star rating.

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

Design stage:   The Engineer and Architect liaised and correlated intent and final design with BIM level two, this was vital to ensure clash detection as the complex facade shapes where hard to interpret on two-dimensional drawings.

Shop drawing stage:  Even though detailed sheets were prepared, it was almost completely unused at this stage. Since such a large emphasis was placed on BIM, the model was an accurate reflection of the drawings. This allowed the Structural Steel Detailers to use the engineering model and import it straight into Tekla Structures software. Member lengths, connections, and positions translated from the model kept turnaround times for shop drawings and queries to a minimum. It also resulted in industry standard repercussions, where certain information pertaining to the length of the member can be omitted from engineering drawings and can technically only be used for design intent and setting out purposes.

Erection stage:  The Engineer worked directly with the Sub-Contractor to ensure the complexity of the information was carried over to the final item. BIM was also used on site, as the model was issued directly to the Sub-Contractor, allowing them to interrogate the model on site.

Tons of structural steel used 115 Tons
Structural profiles used All readily available profiles

Project Team

Project Team Role Company
Nominator KRU Detailing CC
Client/ Developer Redefine
Architect Paragon Group
Structural Steel Detailer KRU Detailing CC
Structural Engineer Sutherland
Engineer Sutherland
Quantity Surveyor MLC
Project Manager WBHO
Main Contractor WBHO
Steelwork Contractor Central Welding Works
Steel Erector Central Welding Works
Cladding Manufacturer Façade Solutions
Cladding Supplier Façade Solutions
Cladding Contractor Façade Solutions

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Our Lady of Lourdes – Rivonia Church

What is the purpose of the structure/project?

A new Roman Catholic Church with exceptional acoustics, despite the exterior weather conditions.

What was the brief to the Architect?

The brief to the project team was to design a long span octagonal roof, acoustically insulated from rain and hail sound effects.  The brief included the design of a complex shaped and vaulted ceiling below, also designed with specific acoustic properties.  A specialist Acoustic Consultant was employed  to assist in the form and specification of the roof coverings as well as ceiling below.  A Sound Reinforcement Consultant also advised on the church space and acoustic ceiling above.

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

Yes.  Early design options for a tiled roof were discounted at the inception of the project.

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

The roof design was made more complicated by the planned shape of the building itself, not being asymmetrical octagon but rather an adjusted one. This design could not rely on pure symmetry and a lot of effort was spent with the Structural Steel Detailers, KRU Detailing, to draw and detail all the components.

The fact that the springing point of the roof was at 6.95m above the slab level, and that the concrete work at roof level comprised of two complex rings of reinforced concrete “loops” supported on linked column frames, required planned tolerance between the steel/concrete face and much survey effort was undertaken by the builder and Sub-Contractors to ensure a first time fit at the high level.

The ceiling below was also required to be supported on a secondary structural steel grid.  The centroid and shape of the ceiling profile did not match the shape of the roof, with slopes and acoustic performance requiring support work, positioning the steel grid well away from trusses and cladding supports, considerably over-complicating the design and erection process.

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

The roof cladding, on the advice of a multidisciplinary team led by the Engineer, was for lightweight concealed fix roof cladding, designed around the partly asymmetrical octagonal roof, built tightly over a special taped gypsum sandwich layer, specified by the Acoustic Consultant, the sound damping system was to be tightly below the metal cladding.

This design was configured to damp excessive noise from rain and hail during the future church services.  The gypsum was in turn supported on its own metal gridwork, all fixed to the steel roof at the highest level.  Spans and spacings were critical, with the roof cladding requiring a different support work spacing from the gypsum layers below.

The acoustic ceiling below was designed to a complex shape, in turn requiring a different grid configuration and shape from the girders and supports above.

The ceiling required movement and control joints as part of the design specification, with the metal grid work between steelwork and the acoustic ceiling itself being “weakened” at the critical positions of the larger radial joints to ensure the performance of the actual ceiling joints below.  The ceiling would not be readily accessible from below for cleaning and maintenance purposes due to the configuration and layout of the seating for the congregation.

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 sheer complexity of the roof, the two independent levels of structure (at cladding level and much lower down at acoustic ceiling level), the substantially different shapes of the two structural elements, the moderately long spans, structural heights, moderate-high loads, and all design complicated matters.

The site of the new Church has a severe grade of around some eight percent, also had planned stepped terraces.  This required quite complex construction arrangements, affecting the delivery of materials, site storage and the steelwork erection process itself.

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

The roof cladding itself required to reflect the “look” of old weathered copper-roofed churches, and the complex vaulted and shaped acoustic ceiling below were conceived by a specialist experienced ecclesiastical Architect and executed by the project team, led by the Structural Engineer.

A specialist Acoustic Engineer was consulted to assist with shape and material of the roof cladding as well as the ceiling below.  The requirement for special acoustic cladding at roof level, with the unique acoustic shape and material at ceiling level below, provided quite a challenge that was successfully solved by the Designers and Contractors.

The rainwater goods and concealed downpipe pipes required intricate detailing and planning.  The gutters were designed as part of the external cladding shapes and the collection and vertical reticulation of stormwater integrated into the frame and cladding of the building.  The downpipes are hidden in the structural support columns but linked back to the gutters, which in turn, were provided with long life urethane coatings.  An overflow capability was built into the gutter design to cope with larger design storms and hail precipitation.

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

The Contractor was consulted immediately after tender.  The tender documents were especially drawn up by the Quantity Surveyor firm, Norval Wentzel Steinberg, around the complex shape, and working drawings were included in the documents (for the upper-level structures only – the ceiling supports were added post tender). A pre-tender qualification process ensured a trim tender pack of experienced steel contractors.

Prior to award of the contract, the Sub-Contractor, Central Welding Works, and their project team was interviewed about the project, complexities, ceiling support grid, and the tight programme.  The Engineer had prior significant experience of contracting work from Central Welding Works and this was a material condition of the award itself.

Close planning between the Engineers and Structural Steel Detailers, resulting in several important meetings, and then the presence of an impressive three-dimensional (3D) drawing back to the team (Employer, Architects, and Contractors), ensured a multilevel approval process, all done quickly due to a rapid and compact construction programme.

The team realized the complex and special requirements of the roof upfront and the need to get it right from all angles and stages, from start to finish.  The shaped vaulted acoustic roof and complicated ceiling elements are probably the most crucial part of a successful building and all aspects of this received priority attention from the whole team, including the Employer, Structural Steel Detailer, and Site Crews.

Tons of structural steel used  32 Tons
Structural profiles used All Sections
Cladding profile/ type used 0.58mm colored GRS Kliplok 700 concealed fix
Cladding area/ coverage and tonnage 1,120m²

Project Team

Project Team Role Company
Nominator KRU Detailing CC
Client/ Developer Rivonia Catholic Church

The Shopz Group

Architect AIB Architects
Structural Steel Detailer KRU Detailing CC
Structural Engineer Rouillard Consulting
Engineer Rouillard Consulting
Quantity Surveyor Norval Wenzel Steinberg
Project Manager Rouillard Consulting
Main Contractor Interbau
Steelwork Contractor Central Welding Works
Steel Erector Central Welding Works
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Tate & Nicholson
Cladding Contractor Tate & Nicholson
Corrosion Protection
Paintwork Contractor
Dram industrial painters

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.

RCL Foods Head Office, Westville

This project was undertaken in the framework of an extraordinary collaboration of the developer/landlord/contractor, tenant, architect, interior designer, branding alchemist and technical team. Somewhat of a ‘rescue operation’, we engaged by the developer to redesign a new corporate head office for RCL Foods after construction had commenced on the site in Westway Office Park. With a semi basement parking structure well underway for a generic commercial office block designed by another architect, the tenant decided that a bespoke design solution was imperative and the project entirely changed course. Key to advancing the conceptual approach for the workplace was an appreciation that the building was to be a pivotal part of creating a new culture for an amalgamated business of five individual corporate acquisitions. Driven by a desire to create Africa’s best and largest food company in the future, the directors of RCL Foods commenced weaving a non-corporate culture around the principles that people are the business and that the workplace environment should attract and retain the best human resource talent available. Working with the branding alchemist and the tenant engagement of our interior design company from the inception of the design proved to be an excellent decision as the stage was set for a fully integrated concept origination.

PROGRAMME

The new offices required to accommodate 700 people with an emphatic directive to create a bespoke environment exuding the culture of the business at every possible level. With growth and space planning flexibility demands being central to the physical programme, the need for a multiplicity of different meeting and collaborative spaces and a focus on food were imperatives. A desire for spatially connected workspaces with emphasis on providing a focal and legible public interface was expressed together with the need to create a variety of functionally usable external spaces.

APPLICATION + USE OF STEEL

The concept of the building delivers a significant linear atrium connecting all spaces and operations of the office building. This space is entirely given over to circulation, spatial connectivity and acts as the heart of the building. The application of steel, envisaged from inception, is expressly utilized in many primary and secondary components in the atrium space and is intended to be on show as the ‘theatrical’ material.

STEELWORK

CONNECTING ELEMENTS

The functional and visual focus of the atrium is the cascading staircase which extends from the entrance area to the uppermost floor and connects all levels. This is created from a single 450mm diameter tubular section which almost impossibly spans up to 13m between bridges which connect the floors on either side of the atrium. This stair displays cantilevered treads and is carefully crafted to connect to the bridges comprising universal beams and other sections to produce visually light elements in the space.

SECONDARY ELEMENTS

Steel is deployed variously through the building internally to produce an architecturally dynamic environment. Its sometimes subtle presence, is almost unperceived and this amplifies its extraordinary role in this building as both a ‘star actor’ and ‘cameo parts’!  The extensive balustrading is a composite of delicate perforated steel plate and both steel and stainless steel sections. This delivers a lightness and transparency which is rarely evidenced in such components. The exposed lifts in yellow lift shafts exhibit the workings of a standard lift and this displays the importance of steel components in a lift. The flush glazed atrium enclosure is neatly supported in slender universal beam sections set unconventionally to accommodate blinds.

SPECIAL INTERIOR APPLICATIONS

In an office which is unusual in nearly every way, all internal space divisions are unconventional.  Curvilinear glazed meeting pods, which precariously cantilever into the atrium, rely on curved steel tubular sections to support internal roofs and glazing, delivering a light and delicate support system. All internal meeting spaces and cellular office are created of freestanding steel framed structures where light tubular sections are deployed to support walls, glass and ceilings in many cases. Steelwork is seldom hidden and consistently treated in a dark charcoal colour, it demands both visual appreciation and indeed in its main roles, a ‘take your breath away’ awareness.

EXTERNAL APPLICATIONS

While RCL Foods is a fundamentally conventional wet-trades construction externally, many solutions to create the architectural outcome demand the use of steel. Hidden steel posts embedded in glazed enclosure, substructures for the signature perforated aluminium solar screens and giant tubular supports for impossible concrete cantilevers offer subtle and functional solutions through the building. Sporadic application of Corten is evident to selected and focal elements externally in the curved planters, gates and deck seating screens. This delivers a warm and crafted quality contrasting the cool grey and white exterior fabric.

CHALLENGES + TEAMWORK

This was a fast track project where the office building component was designed on a parking podium already under construction. So while the primary structure was being erected, decisions around methodologies to facilitate a near impossible completion date had to be made. Within the framework of a relatively conventional construction solution, the atrium usefully served as the concourse of construction. To allow efficient construction to proceed, the atrium roof demanded a soft roof using steel beams and lightweight sheeting as opposed to reinforced concrete. This decision, eliminating a forest of scaffolding then allowed the challenge of erecting a 70m long stair and series of connecting bridges to become manageable. Consistent and intense collaboration between Engineer, Architect, Interior Designer and Steel Fabricator became the hallmark of the design and construction process. Early involvement of the Contractor, Fabricator and Structural Engineer with significantly detail concept design at initial stages ultimately delivered a timeous and a remarkable outcome.

Tons of structural steel used      255 +

Structural profiles used Tubular and U.B.

Project Team

Project Team Role Company
Nominator EPA
Client/ Developer JT Ross
Architect EPA
Structural Engineer BPH Engineers
Engineer Not provided by nominator
Quantity Surveyor MLC Quantity Surveyors
Project Manager Not provided by nominator
Main Contractor JT Ross
Steelwork Contractor Rebcon Engineering
Steel Erector Rebcon Engineering
Cladding Manufacturer HB Interiors

 

Cladding Supplier HB Interiors
Cladding Contractor HB Interiors
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition Not provided by nominator
Photographer, Other submitted images Not provided by nominator

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.

PwC Tower – Triple Height Lobby

PwC Tower is PwC’s new head office in Johannesburg. The floor plates of the 28-storey building rotate by 1.2 degrees per floor, which results in a doubly-curved surface for the building’s façade and the structural line behind. The reception is housed in a triple volume lobby area at ground floor. This triple volume space flows into the adjacent meeting centre, and is used as a café and informal meeting space.

A steel and glass atrium roof covers the link between the tower and the meeting centre, whilst a steel link bridge with glazed balustrades connects the two floors at first floor level with a steel feature stair forming the principal link up to the second floor of the meeting centre. Whilst the majority of the tower floors are post-tensioned concrete, the first and second floors of the tower are formed in steelwork with bondek slabs and are hung from the third floor, to increase the column-free space in the lobby below. The northern part of the lobby features a triple volume steel and glass façade, gently following the twist of the tower. Within the atrium and outside the glass façade the sloping and spiralling columns of the building are encased in steel tubes to act compositely with the concrete inside; this increases the capacity of the reinforced concrete columns where they are unrestrained over the three floors and means that the overall section sizes can be similar to the rest of the tower which allows us to achieve the preferred architectural aesthetic. All of these components feature the use of steelwork in a complex geometric form and in the majority of cases the painted steel is exposed to form the finished surface.

Rectangular hollow sections were used on the skylight. The suspended floors were built out of BOND-DEK on cellular beams, with curved edge beams rolled horizontally. The hangers are circular hollow profiles. The bridge and stair are predominantly formed from welded plate with concealed connections and preformed slots for the cantilevered glazed balustrades. The façade mullions, spanning over three floors are I-sections, and are laterally restrained by circular hollow profiles. Rolled square hollow profiles are used over the main entrance doors. The structural columns in the tower are encased in large diameter circular hollow tubes.

The geometry of all this steelwork was generated by parametric scripts. The steel profiles were explicitly modelled in 3D by the design team. Conventional plans with all setting out information were produced for use on site but the 3D steelwork model was also issued to the contractor to use as the basis of their steel shop model and then later used to check the steel shop model.

Tons of structural steel used 250t
Structural profiles used RHS, CHS, UB, UC and plates

Project Team

Project Team Role Company
Nominator Arup
Client Attacq
Developer Atterbury
Architect LYT Architecture
Structural Engineer Arup
Quantity Surveyor Brian Heineberg & Associates
Main Contractor WBHO
Steelwork Contractor Cadcon
Steel Erector Cadcon
Cladding Manufacturer Geustyn & Horak (G&H Aluminium)
Cladding Supplier Geustyn & Horak (G&H Aluminium)
Cladding Contractor Geustyn & Horak (G&H Aluminium)

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.

Gateway West, Waterfall Kyalami

This is a landmark project, albeit small in tonnage terms. It illustrates what can be achieved using LSF!

The bi-axially curved façade walls give expression to the architect’s design, at a much lower cost than would have been the case had reinforced concrete been used. The rapid assembly and erection shaved weeks off the building programme. It provides a ventilated façade which translates into thermal insulation to the office building interior. The wall panels consist of (from the outside) aluminium cladding (thickness?), ETICS cladding (60 mm thick), vapour permeable membrane (?), 90mm LSF support structure, Cavity Bat insulation (?), Fire Stop gypsum board. Key for the success of the project was the meticulous 3-D design to facilitate integration of the curved LSF framework, the window schedules and the structural concrete.

What makes this project special? LSF allowed the designer to create a unique and striking building exterior, like no other. The insulated LSF walling provides excellent insulation (R-value …..) which will save electricity for heating and cooling over the design life of the building. It was executed at much lower cost than alternatives, and is said to be maintenance free. It is a prominent reminder on the Waterfall skyline of creative designs. A comment received from the USA sums it up – ‘in what galaxy is this building?’

Tons of LSF used 7 ton
Profiles used 90mm C section
Cladding profile/ type used Weber ETICS and 15mm Firestop Gyproc boards
Cladding area/ coverage and tonnage 1400 sqm

Project Team

Project Team Role Company
Nominator Ohlhorst LBS Pty Ltd
Client/ Developer Attacq Property Development
Structural Engineer HAGE engineers
Main Contractor Group 5
Steelwork Contractor Ohlhorst LBS Pty Ltd
Steel Erector Ohlhorst LBS Pty Ltd
Cladding

Manufacturer

Quinton
Cladding Supplier Quinton
Cladding Contractor Ohlhorst LBS Pty Ltd
Photographer, Photo

competition

Ohlhorst LBS Pty Ltd

 

Cornubia Mall

Cornubia Shopping Mall is an 85 000 m² regional shopping centre that offers a mix of food, fashion, lifestyle and sports, which are all integrated into an outdoor family-orientated shopping experience in KwaZulu-Natal. The brief to the architect was to create a differentiated shopping and leisure experience that would resinate with people in the region.

The shopping centre is an open-air development with various nodes that all have their own unique design elements and architectural language. The surrounding landscape and natural elements have been incorporated into the design and the various nodes are connected through sidewalks, bridges, landscaped walkways and park-like open areas where visitors can connect and relax. Moving through the walkways, pedestrians are shielded from nearby traffic through elevated walkways and parks that are surrounded by vegetation. The luscious leafy ring of landscaping creates a feeling of calm and relaxation for families and visitors. It has also achieved the goal of creating a recreational retail experience for shoppers.Sustainability was an important goal for the developers and the centre has achieved an environmental merit certification for its use of recycled rubber, one of the world’s most hazardous waste streams, in the manufacture of roof coping tiles equating to 6250 cubic meters of rubber not reaching landfill.The majority of the development was constructed with brick masonry with a steel roof and canopies. The structural profiles of the shopping mall include I-Beams, channel, cold rolled and angle profiles. 1300 tons of structural steel was used for the roof and Global Roofing Solutions supplied 72000m2 of Klip-Tite for the project.

Social transformation was another key goal of the project. During the course of design and construction, 1100 people received access to work readiness programmes that will help them obtain permanent employment and 2500 people received temporary jobs.The end result is a new regional shopping centre that creates a pleasurable experience for visitors and also achieves a triple bottom line for the developers. The social impact, economic measurables and sustainability goals has helped the centre achieve a balance of ecology community, financial feasibility to ensure that the development will of benefit to current and future generations.

Tons of structural steel used 1300 tons
Structural profiles used I-Beams, Channel, cold rolled , Angles
Cladding profile/ type used Klip-Tite, IBR 686
Cladding area/ coverage 72000m2
Cladding tonnage 408Tons

Project Team

Project Team Role Company
Nominator Global Roofing Solutions
Client/ Developer Investec Property Group
Architect Bental Ass
Structural Engineer Pure Consulting
Engineer CKR Consulting engineers
Main Contractor Wilson Bayly Homes
Steelwork Contractor Cadcon
Steel Erector Cadcon
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Chartwell Roofing

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Graskop Gorge Lift Structure

What is the purpose of the structure/ project?

To create an exciting and popular tourist stop over point on the Panorama Route at Graskop, Mpumalanga. The gorge has established itself as an adventure destination through the Big Swing, which is a well-known operation, so there had been some “human footprint” in the gorge for a while. The client wanted to expand on the adventure concept and added the lift and interactive walking trail in the rain forest below. The purpose of the structure is to accommodate the glass viewing panoramic lift taking visitors 51m down the face of the Graskop Gorge into the forest below, where wooden walkways and suspension bridges meander along a 600 metre trail through the indigenous forest with interactive exhibits.

What was the brief to the architect?

To design a lift shaft structure to accommodate the panoramic glass viewing lift for the Graskop Gorge Lift Company, as well as the buildings around the panoramic lift at the Graskop Gorge Adventure Centre. The site was chosen adjacent to a structure for informal curio traders and a protruding rock outcrop which had been a viewing point with a small pub. This was the ideal position for the lift shaft. The brief was to incorporate the traders into the adventure tourism complex and upgrade the existing structure. The centre should accommodate the ticketing office, shops of various sizes, a restaurant and general viewing areas for the public. Support services for the centre also had to be included. The servicing of the lift required easy access to the lift motor room. A viewing platform was subsequently added around the lift motor room as an extension to the public deck.

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

Yes. Structural Steel was the choice of material for the Lift Shaft Structure from the beginning. Reasons include compatibility with the lift installation, and the open truss-like nature of the shaft structure to simulate the waterfall on the opposite side of the gorge.

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

The distance from the base to the top of the shaft is 60m, with the total vertical lift travel distance of 51m. The shaft structure was designed as a vertical structure with two top fixing points apart from the fixing at the concrete base. UC 305x305x97 H-profiles were used for the 6 main shaft columns, because adequate l/r ratios were required for 10m segment lengths. Each segment was fully braced using 63,5×3 and 88.9×2,5 Circular hollow sections cross bracing between 203x133x25 UB lateral stiffness beams. 305x165x46 UB profiles were used for the access platform beams at the top of the shaft with 80x80x6 Angles for bracing. UC 152x152x23 profiles were used as knee brace elements to support and fix the top viewing platform to the main shaft structure.

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

Cladding formed a minimal part of the Shaft Structure itself, only the top machine room side walls and roof received IBR cladding after the access platform to the machine room was completed.

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 national shortage of 305x305x97 H profiles, required the design to be altered to use 254x254x73 in the top part of the shaft. For the erection of the shaft a 70 tonne crane was planned, but it would require the crane to be too close to the edge of the cliff, and the crane cables were too short to reach the 51m deep bottom.. Instead a 9 tonne Spierings Mobile Tower Crane had to be hired that could lift 2.5 t per lift at a 27m reach, with adequate cable length to reach down to the bottom.

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

The exquisite setting of the lift shaft structure opposite the Panorama Waterfall forms a truly aesthetic pleasing view from a distance, with the natural waterfall at one side of the gorge and the grey coloured, open truss-like lift shaft structure simulating the waterfall on the opposite side of the gorge, forming a beautiful parallel with each other.

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

Two weekly formal project meetings were conducted with a formal “Request for Information” procedure that were frequently communicated and updated per email between the various team members.

Tons of structural steel used 110 t
Structural profiles used Hot rolled H-profiles, hot rolled I-profiles, Angle profiles, circular hollow sections
Cladding profile/ type used IBR
Cladding area/ coverage and tonnage 1100m2    2.8 tons

Project Team

Project Team Role Company
Nominator Fourie Consulting Engineers
Client/ Developer

 

 

Graskop Gorge Lift Company

In partnership with the NEF

(National Empowerment Fund)

Architect Förtsch and Associates Architects
Structural Engineer LEW Consulting Engineers (Pty) Ltd
Engineer LEW Consulting Engineers (Pty) Ltd
Quantity Surveyor Siyakha Quantity Surveyors (Pty) Ltd
Project Manager Purlin Consulting
Main Contractor ENZA Construction (Pty) Ltd
Steelwork Contractor Quality Steel Construction (Pty) Ltd
Steel Erector Quality Steel Construction (Pty) Ltd
Cladding Manufacturer Safintra (part of the Safal Group)
Cladding Supplier Safintra Roofing Nelspruit (part of the Safal Group)
Cladding Contractor Roofing Solutions CC
Corrosion Protection
Galvanising
Babcock Nthuthuko Powerlines (Pty) Ltd
Photographer, Photo competition Förtsch  and Associates Architects
Photographer, Other submitted images Förtsch and Associates Architects

ENZA Construction (Pty) Ltd

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Go Durban Integrated 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

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.

New Facilities Centre for Durban Girls High School

PURPOSE OF THE STRUCTURE:

To house a large indoor, multi-function space as a major educational facility for a premier girls high school and to increase their hall accommodation from 400, built in 1938, to 1400.

BRIEF TO THE ARCHITECT:

To create an indoor space capable of housing:

  • The school assembly hall and exam
  • An indoor playing field to comply with Olympic specifications for indoor
  • Use for indoor basketball, volleyball, badminton and
  • Multifunction venue for dramas, dances, fashion shows and
  • Stepped viewing terraces to seat 250 persons. Form of Building:
  • Essentially an industrial “shed” with various beautiful “diamonds” on it, as per the Porte’ entrance, stonework, raw hardwood terraces, facebrick, frameless glazing panels and timber movable ventilation
  • Elements of “African” identity are introduced as per curved walls, raw circular stonework, with chevron truss lattices reflected in side cladding polycarbonate V shaped
  • Main entrance Porte’ celebrates the existing outdoor court, and acts as a visual focus and entry inducement into the main space using tubular “tree”
  • Curved facebrick walls guide the ingress into the “shed” under the curved Porte’
  • Off shutter concrete, coated steel, raw hardwood timber and facebrick finishes are juxtaposed in achieving a low maintenance and a “raw” material
  • Environmental conservation to achieve a “green” building was applied where possible. eg. Water harvesting, no mechanical ventilation and utilising roof light daylight

BRIEF DESCRIPTION OF THE STRUCTURAL FRAME:

  • An aesthetic decision was made to express the dynamics of a steel clear span structure, integrated with the translucent sheeting panels of the gable frames and south
  • The roof trusses feature tubular sections with profiled gussets framing into H section top
  • The purlins are standard cold rolled lipped channel
  • The terrace seating, stairs and handrails express

CHALLENGES IN THE FABRICATION OF THE PROJECT:

  • Approximately a third of the truss was erected as a temporary roof at first floor hall level during an earlier
  • To complete the Project the new roof was site connected to the existing structure and re- erected at the higher new roof
  • This required challenges in the site fabrication and restricted erection

INNOVATIVE AESTHETICS ABOUT THE STEELWORK AND CLADDING:

  • The Porte’ and main roof have intersecting curves on the main roof
  • Gable sheeting girts reflect truss V forms with silver heat polycarbonate sidelights which create a chevron lit graphic inside in the day, and externally at

THE PROJECT TEAM CHALLENGES:

  • Due to limited access to the site, being within a wooded suburban area adjacent to a swimming pool, the methodology of construction and erection required a team
  • The Main Contractor further shortened the steel construction critical path by 3 months, necessitating close co-ordination between Architect, Engineer and Steel

It is considered that the integrated aesthetic form of the tubular section roof structure, exemplifies the use of steel construction in public facility buildings, in an urban environment.

STRUCTURAL STEELWORK
Completion date of steelwork September 2017
Completion date of full project February 2018
Tons of structural steel used 46 tonnes
Structural profiles used Tubular, Hot and Cold Rolled
SA content – if this is an export project 100%
   
CLADDING
   
Cladding profile/ type used Colour Coated Saflok 700
Cladding area/ coverage and tonnage 2650sqmeters, 16 tonnes
   

Project Team

Project Team Role Company
Nominator Young and Satharia
Client/ Developer DBN Girls High School Governing Body
Architect Neil Hayes-Hill Architect
Quantity Surveyor Edgecomb & Hayes-Hill
Main Contractor Nichol Projects (Pty) Ltd
Steelwork Contractor Ogilvie Engineering (Pty) Ltd
Cladding Manufacturer SAFINTRA
Cladding Supplier SAFINTRA
Cladding Contractor Four Seasons Roofing (Pty) Ltd

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

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

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.