Cummins Johannesburg Relocation Program Waterfall

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

Engineers Motivation:

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

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

Steelwork Contractor Interview:

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

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

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

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

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

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

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

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

Amka Products (Pty) Ltd Campus Development

Amka products was a challenging and diverse project. A production plant of the many products that AMKA produces, required many different areas and facets of steelwork. The steelwork mainly consists of a large warehouse roof and a few smaller factory roofs. Then Staircases, Gantries, Canopies, Mezzanine Floors and over 2500m of Stainless steel balustrading went into this Plant.

With many areas and sections being constructed at the same time keeping up with the demands of the program needed good communication and planning from the team. The project team worked well together from the Client, professional team to the contractors. This resulted in a very successful project as a whole.

Steelwork Contractor Interview:

In a market where we are seeing more warehousing going up than factories or production plants, it was great to see a project of this size being built. There is not much more we can say as steel contractor except that the project really speaks for itself in its size and quality of workmanship overall.

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 December 2018
Completion date of full project December 2018
Tons of structural steel used 700 Tons
Structural profiles used H/R Sections, C/R Lipped Channel
PROJECT TEAM ROLE COMPANY
Nominator Ferro Eleganza (Pty) Ltd
Steelwork Contractor Ferro Eleganza (Pty) Ltd
Steel Erector Ferro Eleganza (Pty) Ltd
Corrosion Protection
Paintwork Contractor
Dram Industrial Painting Contractors

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.

Otto Volek

Otto Volek was built as a production and distribution hub for Pioneer Foods. They are a company that sells a diverse range of food, beverages and related products nationally and globally.

This facility is being used to store and distribute edible goods; therefore, the initial brief was to design a warehouse component which could store various food products and also manage to be a distribution facility from a central location. There are also various office components around the site of varying scales allowing for the management and control of this massive facility.

The warehouses being approximately 26 000m2 in total, was envisaged to be done in steel with sheeting as it was designed around the possibility of future racking and stacking heights. The most optimum type design or structure was for this to be a sheeted and structural steel warehouse. Hot rolled I beam sections, lattis girder trusses, cold formed purlins, and girts were used in the construction of this warehouse.

The sheeting for the structures is Safintra’s Saflok 700 0.53mm AZ200 Seaspray on the roof, and Widedek 0.50mm AZ200 Seaspray for the cladding. Due to the 60m sheeting lengths that were required for the roof , on-site rolling had to be done with Safintra’s Saflok 700 Mobile Mill. This required both space, planning and lifting onto the roof from ground level. Different sections were milled at different areas of the site so as to help with eased of erection, traffic requirements on a congested site and to minimise double handing of the sheets on site. The sheeting was hoisted to the roof from the inside of the building, as the building was erected almost on the boundary lines. This left no area for the cladding contractors to work and they had to improvise.

Standard warehouse type truss and girder design to meet fast track requirements for the client. The entire site was built in 7 months. The design was based around as fewer columns internally as possible and externally to follow the curve of the site boundary edge which made the structure unusual in shape but to maximise the space usage of the site.

A design that makes the building stand out, is that of a façade that separates the buildings and creates a unique look. This was one the main innovative and aesthetics that the roof contractors had to work around and clad.

Overall the team of professionals working on the Runway Business Park project worked well together, and had a great understanding with each other. With this it helped achieve what was set out to be done, and provide a suitable working environment for the client.

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.

CLADDING
Completion date of cladding July 2018
Cladding profile/ type used Roof:        Saflok 700 AZ200 0.53 Sea Spray Cladding:  Widedek AZ150 0.50 Sea Spray
Cladding area/ coverage and tonnage 257 000 Tons
PROJECT TEAM COMPANY
Nominator Safintra South Africa
Client/ Developer Newlyn Group
Architect Siza Architects
Structural Engineer Kantey & Templer
Main Contractor Spearville Trading
Steelwork Contractor Cadcon (Pty) Ltd
Steel Erector Cadcon (Pty) Ltd
Cladding Manufacturer Safintra South Africa
Cladding Supplier Safintra South Africa
Cladding Contractor Browndeck 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.

https://youtu.be/jiI_doPtQ2I

Southern African Fruit Terminals

SAFT is a cold storage facility for fruit. Fruit is brought in from various producers in South Africa where it is kept at an optimal temperature until it is exported to Europe.

What was the brief to the architect?

The brief to the architect was to create a visually pleasing exterior within the constraints of the industrial nature of the building and without adding too much to the cost of the project. The architect aimed at a solution which would not necessitate amendments to the original building envelope which was designed to accommodate the cold stores. The only structural change was the addition of a large fascia over the off-loading bay to give the building a strong presence on the M12 where the different sheeting panels and backlit polycarbonate is very visible to passing traffic. 

Architect Interview:

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

The cold store section was originally intended  / planned as a steel structure.

Engineer interview:

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

The cladding process was not much more difficult or complex than usual, except that additional angled sheeting rails had to be incorporated in order to achieve the angles and the change in level between the two different colours of sheeting. The flashing details were also more complex as the stepped (raised and recessed sheeting) had to be accommodated.

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

The architect’s approach to the brief was to incorporate two sheeting colours (light grey and darker grey) to articulate the facade. In addition to this the two different colours of sheeting are installed in different planes, i.e. the darker sheeting panels are raised 125mm above the lighter sheeting panels. This has the added effect of throwing shadows on the facade where the panels step. At night the recessed lighter coloured panels are washed from below by means of LED strip lights mounted at drip flashing level. This will ensure a striking effect at night. The office building components which are attached to the main steel structure are articulated with paint colours which closely match the sheeting colours on the steel structure. There are also portions of the facades on the office buildings which consist of LED backlit S-profile polycarbonate sheeting. Some sections of the main steel structure also have LED backlit polycarbonate sheeting to complete the whole and to complement the steel sheeting panels. The final effect will be striking, yet cost effective.

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

The engineer was consulted early on and assisted by detailing the raised and angled sheeting rails. and the cladding contractor were involved.

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 Main superstructure  February 2019.  Forced cooling tunnel racking    April 2019.
Completion date of full project June 2019
Tons of structural steel used Main superstructure including ancilliaries and  walkways  500 tons       Forced cooling tunnel racking steel  230 tons
Structural profiles used I-beams up to 305×165   H-columns up to 254×254 structural T ex 254×146. Angles from 60×60 to 100×100.  PF Channels. Cold rolled channels 150 x75 x20x2,5  
CLADDING
Completion date of cladding February 2019
Cladding profile/ type used Saflok 410, Armor Grey AZ150 0.53mm
Cladding area/ coverage and tonnage 20,000 m2
PROJECT TEAM ROLE COMPANY
Nominator Safintra
Client/ Developer SAFT (PTY) LTD (Southern African Fruit Terminals Pty Ltd)
Architect Joe de Villiers Architects
Structural Engineer MH&A Consulting Engineers
Engineer MH&A Consulting Engineers
Quantity Surveyor Du Toit Pienaar Quantity Surveyors
Project Manager Abland
Main Contractor Isipani Construction (Pty) Ltd
Steelwork Contractor Union Steel
Cladding Manufacturer Safintra Roofing CPT
Cladding Supplier Safintra Roofing CPT
Cladding Contractor Cladco Projects

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.

SA Steel Mills

Steel is the backbone of our industry, and it follows suit as a backbone of infrastructure. Steel provides the strength to keep a building and its components standing from the ground up. SA STEEL MILLS –  I 00 000m2

Benefits achieved by using steel construction

Steel can be used in diverse arrays of applications, both domestic and industrial. The strength to weight ratio assists in cost savings and ensures that the structure will stand the test of time. Quick installation allows for time conservation and readily available labour. Quality is ensured with various guarantees and via the durable nature of steel. Steel is the very DNA of Strength.

Aesthetic appeal

Steel, dependent on the design and customer’s requirement, can be shaped to fit any mould. The versatility, design, and application can make a structural art piece that is appealing to the eye.

Environmental/ Sustainability consideration

Steel is a recyclable resource and can be recycled over and over. By observing the 3 R’s, we reduce, reuse and recycle steel and ensure that our activities are Green, which will, in turn, lower greenhouse gas emissions. Building design & process can harvest maximum sun / solar energy and rain & groundwater that will enable us to use transformative technology to produce steel differently from the global players and make SA Steel Mill the second player in the world to make green steel without (GHG ) greenhouse gases. The steel buildings are designed to create 90,000 sq meter rooftop to place photovoltaic panels on 24degrees to tap solar irradiation. The roof space is enough to produce 55 MVA lowest cost renewable solar power without any Carbon dioxide CO2. The renewable solar power can be stored in large environmentally friendly containerized batteries developed and commercialized by MIT professor. 55 MVA power will enable SA Steel Mill to produce 400,000 tons of green steel by using eco-friendly technology. The plant is operating off the grid for electricity and water supply, where we will ensure that energy is used conservatively and waste is managed by up to 75%.

Innovation in Design Fabrication or construction

Lightweight and high tensile sheeting have been used in the structure. The use of translucent sheeting harnesses daylight and reduces the need for artificial light sources. The total roof area spans across 66 000m2 which allows for rainwater harvesting into our reservoirs. The Plant is a redesign of a standard mill, such that logistical transfer of product converges at a common area of dispatch. This redesign has maintained functionality while lowering overall project costs.

Technical Process Required for Realising the Project

In the execution of construction, we have used LEAN principles from a process standpoint. We have been able to generate value, continually improve and manage our processes and waste, while optimising the entire project from a capital perspective. The Project will then yield a fully automated plant, which employs state of the art technology and reduces human error in the steel manufacturing process.In maximising efficiency, the mill utilises a central Melt Shop, where molten metal is transferred into four mills, obtaining their own applications.

What is the purpose of the structure/project?

This is a steel production plant. Used to house ovens, mills and finished goods.

What was the brief to the Architect?

Design a steel  mill  manufacturing  plant in the   most cost effective way.

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

Yes, as we are a company grounded in the steel industry.

Give a  brief  description  of  the  structural  framing. What type  of  sections were  used I Beams of various weights have been used, namely the following:

  • 533 X 210 • 406 X 140 • 356 X 171 • 305 X 165 • 305 X I 02 • 254 X 146 • 203 X 133

305 x 305 H Beams • 203 x 203 H Beams • 152 x 152 H Beams

300 x  I 00     Channels  • 152 x 75 Channels

2000 x I 00 Lipped Channels • 150 x 75 Lipped channels • I 00 x 50 Lipped Channels

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

All internal and light-framed buildings are built with a combination of brickwork and steel.

Were there any challenges in the fabrication of the project from the Engineer’s design

As we are a steel company, we have an inventory and supply of steel from other branches in house. We challenged the engineer to construct buildings using the inventory on hand. This task has allowed for us to repurpose old stock and really maximize existing materials. The challenge posed revolved around the load-bearing capacities of the steel from inventory. We have therefore designed the buildings stronger for their applications

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

We have used lightweight, high tensile sheeting. We have made use of translucent roof sheeting, which allows for daylight to enter the plant

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

We have a team of dedicated individuals who mind the time and cost constraints of the project. The team is sensitive to work ethic and commitment to doing what is right, rather than what is pleasing. Contractor involvement sought to source the best price, along with the best quality.No project is perfect, nor will they run smoothly, we have certainly had our share of project hiccups, however, we abide by the motto that: “teamwork makes the dream work”.

STRUCTURAL STEELWORK
Completion date of steelwork September 2018 (Phase 1)
Completion date of full project December 2019
Tons of structural steel used 500 tons
Structural profiles used 254×146 I Beam, angles and Lip Channels
CLADDING
Completion date of cladding December 2018 (Phase 1)
Cladding profile/ type used 0.58mm G550 IBR 686 for Roof and Side Cladding
Cladding area/ coverage and tonnage 100 000m2 / 515 Tons
PROJECT TEAM COMPANY
Developer Changing Tides
Architect Changing Tides Architects
Structural Engineer Cassiem Hanse and Associates
Main Contractor Changing Tides 74
Roof Sheeter Changing Tides 74
Quantity Surveyor Changing Tides 74
Cladding Supplier Pro Roof Steel & Tube
Structural Steel Erector Changing Tides 74

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.

WAGS Warehouse

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

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

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

What is the purpose of the structure/ project?

Distribution warehouse

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

Yes

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

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

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

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

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

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

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

Colourplus® material 0.55 Deep Ocean

10 000 sqm IBR Side cladding

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

We Buy Cars Warehouse

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

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

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

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

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

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

Trusses  –  angles

Girders   –  U-beams + angles

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

IBR profile sheeting for cladding

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

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

Chromadek®, Fish Eagle White & Dark Dolphin

11 000 sqm IBR sheeting (cladding)

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

Westlake Warehouse Erf 50

The warehouse structure consists of a 23000 m² warehouse structure with a two-storey office block a concrete roof slab and a warehouse mezzanine floor. The warehouse is clad in pre-cast concrete tilt-up wall panels and steel cladding. Internal columns are provided at 32 m centres with lattice girders spanning in between. The portal consists of trusses centred at 8 m centres, with end spans of 24 m and an internal span of 32 m. Concrete columns were cast to 13.5 m above the finished floor level with steel columns to the roof height. The warehouse floor was cast to FM2 surface regularity.

Externally 5m cantilever canopies were provided over the loading docks with an 11 m cantilever canopy required over the side loading bays. The total steel tonnage for the project was 485Tons.

The challenges faced on this project was the fast-tracked construction programs and working at heights with these tall warehouse structures. The fast-tracked construction program resulted in detailing done within 2 weeks by KRU Detailing to give SE Steel Fabrication the edge in the market.

STRUCTURAL STEELWORK
Completion date of steelwork June 2018
 Completion date of full project 12 December 2018
Tons of structural steel used 485 Tons
Structural profiles used Member sizes :Columns=UB245*146*31 Truss top chord=100*100*8 Angle Truss bottom chord=90*90*8 Angle; Top & bottom chord of Girder=UB254*146*31; Roof bracing 70*70*6 & 80*80*8 Angle; Sag angle=45*45*3 Angle; Purlins=250*75*20*2.0 & 250*75*20*2.5 CFLC; Girts= 200*75*20*2.0 

CFLC; Vertical bracing=165*3.5 CHS; Louver Frames= 200*15*4.0 RHS & 150*150.4.0 SHS. Die langste span op die gebou is 252 meter die gebou self.

CLADDING
 Completion date of cladding October 2018

Ultimate Heliport

A new Heliport for Ultimate Heli has been developed next to the N1 highway opposite the Mall of Africa, in Waterfall. The major structural steel aspects of the Waterfall Heliport are the roof structures and gantry crane beams for the two helicopter hangars positioned in Portion 2 and Portion 4 of the heliport.

Portion 2

Roof Structure

The roof structure of the hangar at Portion 2 of the Heliport consists of trusses occurring every 6.65 m or 6.60 m apart and spanning distances ranging from 23.66 m to 28.31 m. The trusses support purlins, roof sheeting and insulation. A portion of the hangar roof in one area is raised to a higher level in order to provide enough clearance for an overhead traveling crane to operate beneath the roof and above the helicopters. This portion of the hangar is used for maintenance of the helicopters.

At the western side of Portion 2, next to the N1 highway, reinforced concrete columns occur at every 6.65 m or 6 m whereas on the eastern side of the hangar, four reinforced concrete columns are separated by distances of 19.8 m,19.95 m and 19.8 m respectively. The large openings between the columns on the eastern side of Portion 2 is to provide enough clearance for the helicopter rotors when these are towed in and out of the hangar. Due to the large opening over these hangar doors, three structural steel girders spanning nearly 20m each have been provided to support the trusses between the columns. These girders also support the heavy Techentrup roller shutter doors which roll up vertically and weigh 1.4 tons each. The vertical deflection of these girders is limited to 10mm to ensure the smooth operation of the roller shutter doors.

The roof structures for the hangars (Portion 2 and Portion 4) were analyzed using the Prokon frame analysis program with loading modelled in 9 different factored combinations. All the structural steel trusses and girders which form part of the roof structures are manufactured using circular hollow sections of varying sizes. The trusses consist of a horizontal bottom chord and a radiused top chord which follows the shape of the curved profile of the roof sheeting. The shape of the roof has been designed by the architects in the shape of an aero foil and the steel structure has been designed accordingly. The depth of the trusses at their deepest point is roughly 2.4 m. Vertical and diagonal chords connect the top and bottom chords spaced at 1.49 m along the length of the truss. The girder trusses comprise of horizontal top and bottom chords with vertical and diagonal chords connecting the two along its length.

Gantry Crane Beams

The gantry crane beams in the Portion 2 hangar under the raised section of the roof are designed to carry an overhead travelling crane with a capacity of 5 tons. This crane is necessary for the removal of heavy helicopter components such as engines and gearboxes. At the eastern side of the building the gantry crane beam spans 19.8 m and on the western side of the building the gantry crane beam is continuous and spans three lengths of 6.6 m each. The eastern gantry crane beam is made up of an 850 mm deep (16 mm thick) web plate and two 500 mm wide (20 mm thick) flange plates, with stiffener plates occurring every 825 mm along its length. The western gantry crane beam is made up of a 254 x 146 x 43 I-beam capped with a PFC200 x 75, with stiffener plates occurring every 510 mm along its length.

Portion 4

Roof Structure

The roof structure of the Portion 4 hangar is similar to that of Portion 2, except that the roof height remains constant along its length, at a similar height to the raised section of Portion 2. Trusses which support purlins, roof sheeting and insulation, occur at each gridline which are roughly 5.6 m apart and span 30 m.

At the western side of the hangar, reinforced concrete columns support each truss on a gridline, while at the eastern side (air side) of the hangar, four reinforced concrete columns are placed roughly 16.7 m apart. Due to these large spans between columns, three structural steel girders spanning nearly 16.7 m each have been provided to support the trusses between the columns.

As with Portion 2, large roller shutter doors which open vertically between each of the columns on the eastern side of the hangar provide enough clearance for the helicopter rotors when they are towed in and out of the hangar. However, since the roof is raised to allow for the operation of the overhead travelling crane beneath, the same girder trusses which support the roof trusses are not able to support the heavy roller shutter doors too. Therefore, an additional steel girder has been provided between each of the columns at a lower level to support the heavy Techentrup roller shutter doors which roll up vertically and weigh 1.3 tons each. The vertical deflection of these girders is limited to 10mm to ensure the smooth operation of the roller shutter doors.

Gantry Crane Beams

Similar to the Portion 2 hangar, Portion 4 was also designed to accommodate an overhead travelling crane with a capacity of 5 tons. The crane in Portion 4 however has been designed to reach the entire floor space and therefore gantry crane beams span across the interior of both the eastern and western perimeters of the hangar and are supported by the reinforced concrete columns. These cranes will in future be used for the removal of heavy helicopter components such as engines and gearboxes.

The gantry crane beam on the western side of the building spans roughly 5.6 m and is continuous along its length. Due to the small span between columns, this beam is made up of a 254 x 146 x 43 I beam capped with a PFC 200 x 75 and stiffener plates occurring every 510 mm along its length. On the eastern side (air side) of the hangar, the gantry crane beams have to span over the hangar door openings of 16.7m, and are made up of a 533 x 210 x 122 I- beam, capped with a PFC 300 x100 and stiffener plates occurring every 1000 mm.

STRUCTURAL STEELWORK
Completion date of steelwork September 2018
Completion date of full project November 2018
Tons of structural steel used 130 Tons
Structural profiles used All Types of Profiles
SA content – if this is an export project All Types
CLADDING
Completion date of cladding November 2018
Cladding profile/ type used Kliptite 700 – 0.58mm thick Z200 C1S roof sheeting and side cladding
Cladding area/ coverage and tonnage Roof – 4454 m2 – 29397 kg
PROJECT TEAM COMPANY
Nominator KRU Detailing
Client/ Developer Ultimate Heli
Architect Liquid Spaces
Structural Engineer Fortem
Engineer C-Plan
Quantity Surveyor CDL Quantity Surveyors
Main Contractor Liviero
Steelwork Contractor Central Welding Works
Steel Erector Central Welding Works
Cladding Manufacturer Pinnacle cladding
Cladding Supplier Pinnacle cladding
Cladding Contractor Pinnacle cladding
Corrosion Protection Paintwork Contractor Dram Trading
Roofing and Cladding Global Roofing Solutions
Nomination Document Submission KRU Detailing CC
Structural Steel Detailer KRU Detailing CC

Omnia Nitrophosphate plant

Omnia is a diversified chemicals Group that supplies chemicals and specialised services and solutions for the agriculture, mining, and chemical application industries. Differentiation is ensured through using innovation combined with intellectual capital, whereby Omnia adds value for customers at every stage of the supply and service chain. With its vision of leaving a “better world” the Group’s solutions promote the responsible use of chemicals for health, safety and a lower environmental impact, with an increasing shift towards cleaner technologies.

A new Quality Control system was implemented internally at SE Steel Fabrication. All fabrication had to be done with a high level of accuracy, this was essential to prevent steelwork arriving on site and possibly requiring additional remedial work before installation, so a best-fit approach was adopted. Any remedial work may have placed the integrity of the anti-corrosive paintwork at risk in an already corrosive environment.

Limited space was available for steelwork, so a laydown area for steelwork was created approximately one kilometer from the actual site. This being the situation, we placed a 20-tonne crane and a horse and trailer permanently on site while the project was running, to ensure the correct sections and steelwork were being fed to the site. Ultimately to prevent delays, there was a need to plan for tomorrows erection, today, to avoid unnecessary standing time. Executing advanced planning on site allowed us to remain on program.

Full penetration welded, purpose made columns, were used on the Main Plant. 3CR12 was selected for the purlins and girts. The paint specification was a complex sand blasted, epoxy corrosion specification, to ensure the longevity of the steelwork on site.

Numerous safety challenges were faced during the tight deadline to complete erection on this 1200 tonne project. A dedicated Safety Officer was permanently placed on site to ensure all safety compliance was met on our part. This proved effective with a less than 1% accident rate during the entire span of the project, including all trades. This number needs to be taken into consideration, knowing, that there were numerous trades working on multiple levels of the structure, at the same time, the whole time. Up until the full height of +-46m.

Tight spaces as viewed in the pictures submitted, meant that cranes and cherry pickers had to be strategically placed in order to reach all necessary corners and the required heights, again often while other trades were working and the various levels of the structure. This also meant that work was halted while wind condition worsened during the erection process. In total, we had two 44m articulate boom cherry pickers, a 220-tonne, 160-tonne and a 50-tonne crane on site the full duration of the project (this excludes the laydown area machinery as listed above)

Planning, erection and project program was cast in stone with a strict deadline, regardless of the weather that there was no time to be wasted all had to be done in one year from design to fully operational. Installation crews and machinery from Europe were due to install their scope of work to ensure that this strict program was implemented, so we had no choice but to meet each deadline.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

STRUCTURAL STEELWORK
Completion date of steelwork February 2019
Completion date of full project March 2019
Tons of structural steel used 1200 Tons
 Structural profiles used UB/UC Columns and Beams Truss and Girder Systems Crane and Crawl Beams Channels   

Tubing

3CR12 CFLC Purlin and Girts 3CR12 Sag Angles

304 S/S CFLC Girts 304 S/S Sag Angles

CLADDING
Completion date of cladding January 2019
Cladding profile/ type used 304 Stainless Steel
Cladding area/ coverage and tonnage ± 18,000m²

 

Project Team Role Company
Nominator SE Steel Fabrication (PTY) Ltd
Client/ Developer Omnia Fertilizer a division of Omnia Group Pty Ltd
Structural Engineer Omnia Group Pty Ltd – Group Technical Projects
Engineer Omnia Group Pty Ltd – Group Technical Projects
Project Manager Omnia Group Pty Ltd – Group Technical Projects
Project Manager SE Steel Fabrication (Pty) Ltd
Main Contractor Omnia Fertilizer a division of Omnia Group Pty Ltd
Steelwork Contractor SE Steel Fabrication (Pty) Ltd
Steel Erector SE Steel Fabrication (Pty) Ltd
Cladding Supplier M.R.G
Cladding Contractor M.R.G
Corrosion Protection Paintwork Contractor Dram Trading
Corrosion Protection Paintwork Contractor Rand Sandblasting Projects
Nomination Document Submission KRU Detailing CC
Structural Steel Detailer KRU Detailing CC
Photographer, Photo competition Photography by Micaela
Photographer, Other submitted images Cedric Brender-A-Brandis
Videographer Cedric Brender-A-Brandis
Piping contractor Goss & Balfe

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.