MacEdwards House Extension

Finding himself pressed for time, Dr S. Albanis from AIS-CE Consulting Engineers, the Engineer of Project Mc Edward’s-House Extension in Midrand Kyalami, evaluated alternative options for a flooring system, i.e. reinforced / prestressed / prefabricated or in-situ concrete.

The main requirements he considered to tackle the looming December crunch in the construction industry, where

  • Structural performance to meet the load criteria
  • Speed of construction / erection
  • Avoid “hidden” later unavoidable time-consuming activities such as screed, structural topping, ceiling, etc.
  • Aesthetics of the final product

At a meeting with Aura Entle, the Deep Flute Floor System was presented to the Engineer.

Aura Entle was delighted upon the announcement by Dr. S. Albanis that the Deep Flute Floor System was selected amongst all other candidate alternatives as it was satisfying the stringent criteria for the assessment.

The Deep Flute Floor System is a floor system characterized by its steel permanent formwork. The steel acts alone to carry the construction loads – without any support within its span.The steel formwork also serves as the mould giving the concrete the shape required of it to act as part of the Engineered floor system.

Significantly less concrete is required in the Deep Flute Floor System – than traditional floor systems -thanks to the steel. As a result, a Deep Flute floor is much lighter than other floors. The Engineer was well pleased with the system as it meant he would not have to redesign his existing walls and foundations to carry additional loads from the slab.

The Deep Flute Floor System does not require the use of any cranes in order to be deployed, and even then the team at Aura Entle was confident that they would deliver the completed 100 square meter floor in under three and a half days of site work.

The folds of steel on the underside of the floor create spacious cavities where services can be placed. The cavities are intentionally kept clear of concrete thus making the services carried out asaccessible for future maintenance and upgrades. Yet another benefit to the Client. The electrician and plumber made use of these spaces to neatly hide away their wires and pipes in the floor.

Finally, armed with the knowledge that the Deep Flute Floor System would not require any props, the Project Engineer saw an opportunity to realize more savings in time, hassle and money. This he would accomplish by taking full advantage of the space available to him on the ground floor – the space that would be free of props. The preparations of the ground slab were run simultaneously with those of the 1st floor slab with the aim of pouring both slabs at the same time. The Engineer’s plan was carried out successfully.

The advantages of the steel formwork floor solution stretched beyond the construction phase. Even though it rained, the kitchen, on top of which was a freshly poured slab, was used by the family on the very day of the pour.

The project represented everything Aura Entle aimed to achieve – delivery on time, within budget and ultimately to see convenience passed down to the Client

Tons of structural steel used 1.53 Tons
Structural profiles used Deep Flute Floor System

Project Team

Project Team Role Company
Nominator AURA ENTLE
Client/ Developer FTT@580 (Pty)Ltd
Architect KTE Trading Enterprise cc
Structural Engineer AIS_CE Consulting Engineering (Pty)Ltd
Engineer Not provided by nominator
Quantity Surveyor Not provided by nominator
Project Manager Not provided by nominator
Main Contractor Goldee Trading
Steelwork Contractor AURA ENTLE
Steel Erector AURA ENTLE
Cladding Manufacturer Not provided by nominator
Cladding Supplier Not provided by nominator
Cladding Contractor Not provided by nominator
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition AURA ENTLE
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.

Rissik Street Post Office

What is the purpose of the structure/ project?

The structural steel is intended to act as a supporting frame of the existing building as it was previously damaged by fire in 2009.

What was the brief to the architect?

To restore the post office landmark to its former glory.

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

Yes as this was the most effective way of achieving the desired support within the existing structure.

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

305*305*97 UC was used for the supporting columns that tied into the existing brickwork. Channels and angles made up the girders that support the floors in the upper levels of the building.

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 greatest challenge on this project was the allowed space to conduct the works in a safe and secure manner. As this was a restoration project great care had to be taken in the erection of the structural steel as these were to create support for the entire structure. Each of the structural members had to be measured on site to allow for precision fabrication further to the installation each section had to be monitored due to the damage caused by the fire in 2009 – special care had to be taken with the installation of the steel members and the connections to ensure sufficient and strong support. 

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding

in this project?

The post office was constructed in 1897 and has survived several disasters over the years, implementing the structural steel as a support structure within the existing building allows for the building to be structurally sound and prevents previous damage from compromising the integrity further. 

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

All parties from start to finish worked in an orderly and disciplined manner allowing each trade to follow the other. Also allowing for multiple trades to conduct works simultaneously within a confined space.

Tons of structural steel used 130 TONS
Structural profiles used UB, UC, ANGLES

Project Team

Project Team Role Company
Nominator MPW STEEL CONSTRUCTION
Client/ Developer CITY OF JOHANNESBURG
Architect PARADIGN ARCHITECTS
Structural Engineer ASAKHENI CONSULTING ENGINEERS
Engineer Not provided by nominator
Quantity Surveyor Not provided by nominator
Project Manager Not provided by nominator
Main Contractor INKANYELI
Steelwork Contractor MPW STEEL CONSTRUCTION
Steel Erector MPW STEEL CONSTRUCTION
Cladding Manufacturer Not provided by nominator
Cladding Supplier Not provided by nominator
Cladding Contractor Not provided by nominator
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition MPW STEEL CONSTRUCTION
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.

Ngezi Lounge

When brothers Moses and Selby Mdaka approached Aura Entle to install a floor for their restaurant the team saw the project as an opportunity to carry out its practice of giving opportunity to unemployed youths. The Ngezi Lounge Project is located in the township of Letlhabile, in the North West Province.

South Africa is a country plagued with high levels of unemployment. Residing in it are multitudes of young people who need access to skills development. Aura Entle understands this and attempts to address the problem by decreasing the level of skill required for an inexperienced individual to enter a construction site and make a meaningful contribution.

Aura Entle holds the belief that this can be done by developing technologies that consider the unskilled labourer. With such technologies Aura Entle hopes to deliver projects that would typically be done using heavy machinery and highly trained personnel – with only the help of dedicated workers using simple had-held tools. We believe that this model can be used to deliver high quality projects, and at greater speeds than highly mechanised sites.

The Deep Flute System is a modular floor system characterized by its steel permanent formwork. The Deep Flute is made up of standard light steel components that can be carried and put in place speedily by two people. Simple tools are then used to join everything together to form the complete steel skeleton.

Then steel formwork is designed to carry all the construction loads. The steel also serves as a mould

for the layer of concrete which forms part of the engineered system. For this project the floor was engineered to safely carry 3kN/m2 over 6m long spans.

Aura Entle bravely assigned only two pre-trained workers to the project – with the intention of making up the rest of the team through the involvement of young people from the community. Amo, William and Michael were locally available and eager to get to work.

The trio was introduced to Aura Entle’s team upon our arrival. The team planned to deliver the project in three days – with the concrete pour being completed on the third. Three days was enough to install 100 square meters of flooring area with the pre-trained workers and the young South Africans from the community.

The floor was delivered in the expected time and quality to the joy of the team and to the satisfaction of the Clients.

Tons of structural steel used 1.7 Tons
Structural profiles used Deep Flute Floor System

Project Team

Project Team Role Company
Nominator AURA ENTLE
Client/ Developer MDK Business Solutions
Architect Not provided by nominator
Structural Engineer Arrow Point Engineering
Engineer Not provided by nominator
Quantity Surveyor Not provided by nominator
Project Manager Not provided by nominator
Main Contractor Ostafoghest (Pty)Ltd
Steelwork Contractor AURA ENTLE
Steel Erector AURA ENTLE
Cladding Manufacturer Not provided by nominator
Cladding Supplier Not provided by nominator
Cladding Contractor Not provided by nominator
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition AURA ENTLE
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.

Kusile power station: absorber strakes: specialised fabrication and transportation

NATURE OF PROJECT

The purpose of the project was to decrease “Time to Site” as well as “Time on Site” as well as to ease onsite erection and improve quality of fabrication by manufacturing the Absorber Strakes to be installed at Kusile Power Station in the largest possible assemblies.The largest components to be moved were 120o segments of a 20m diameter, 9m high, circular absorber tower section, fabricated from 14mm steel plate.

The following considerations came into play when determining the feasibility of the “Large Assembly Transport”:

POSITIVE CONSIDERATIONS

Conditions inside the fabrication workshop at Genrec are controllable and assembly could take place without interference from the elements.Quality control is easier, and automated welding methods could be used.Time to/on site (read SITE COSTS) was drastically reduced.

NEGATIVE CONSIDERATIONS

Bespoke transport cradles, as well as lifting equipment would have to be designed and fabricated. This was mainly due to the flimsy nature of the 120o segmentsDue to the highly specialised nature of the design, specialist design expertise would have to be outsourced.It was decided that the positives outweighed the negatives and LSL Consulting Engineers were appointed to design the lifting and transportation equipment.

DESIGN PROCESS

Since the absorber towers are not constant in diameter, some sections were reducer sections and some were smaller sections. Therefore, a “one size fits all” system could not be used. All in all 4 different lifting arrangements and transportation cradles were used.However, due to a design process involving people from management right down to the factory floor, it was possible to design the different cradles and lifting beams in such a way that they could be disassembled and modified to suit the specific requirements of the particular component to be moved. Thus the same cradle components could be re-used.

As far as possible, standard hot-rolled structural sections were used (I-beams and H-profiles) due to ease of availability. Specialised spreader beams were however required to carry out the “top-and-tail” operations required to rotate the absorber segments from a vertical manufacturing position, to a horizontal transportation position. The spreader beams were manufactured using bespoke box girders due to considerations of lifting capacity.The most interesting” part of the process was that the spreader beams, as well as the lifting beams which clamped onto the shells, had to be positioned in such a way that the Centre of Gravity of each shell would act as the rotational pivot point.

FABRICATION & TRANSPORTATION

Fabrication of the cradles were done partly in-house and partly outsourced, and transportation and transport co-ordination was outsourced to a specialist contractor.

Tons of structural steel used 309
Structural profiles used Box Girders, I-beams, H-sections

Project Team

Project Team Role Company
Nominator GENREC
Client/ Developer GE (at time of project)
Structural Engineer LSL Consulting
Engineering Manager GENREC
Main Contractor GENREC
Steelwork Contractor Burger & Company
Steelwork Contractor Nessa Engineering
Steelwork Contractor One Steel

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.

City Logistics Ceiling

Purpose of the structure/project?

The structure was designed and installed as a ceiling to bring the existing facility into spec as a functioning ESFR (Early Suppression Fast Response) warehouse. Due to the new tenant’s requirements to store tyres, the ESFR system requires the sprinklers at a precise height above the stored product, and consequently a ceiling within a specified ASIB range thereafter to optimise early warning parameters from smoke and heat.

Due to the underside of sheet being too high in approximately 8,800sqm of the warehouse, and the existing steelwork not being able to cope with the new sprinkler loads, the only option was to strengthen the existing steelwork insitu and thereafter provide a ceiling at the required height.

What was the brief to the architect?

To get the existing facility, recently vacated by the Mr Price group into spec for the new tenant, Goodyear.

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

Not necessarily. There were investigations into using traditional ceiling boards and droppers. It was deemed due to the sprinkler weight that truss and girder strengthening was required in either regard, and the subsequent steel roof would be lighter and quicker. The entire project was on a compact and tricky program with significant pressure from the tenant for occupation dates.

Give a brief description of the structural framing. What type of sections were used and why?

Hot-rolled: Angles, tubes, and plate.
Cold-rolled: 300mm purlin section and 302 Metsec Z-sections

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

All structural steel and cladding was retrofitted to the existing (strengthening) and new (ceiling) steelwork from inside the warehouse, off cherry pickers and scissor lifts. Due to the installation limitations and material handling the sheets were delivered in 4m lengths, as before, all off scissor lifts. Cladding had to span across 78m, in-between sprinkler droppers, lights, electrical cable trays, and at times in-between the existing lattice trusses.

Were there any challenges in the fabrication from the engineer’s design. Tell more about fabrication and erection process if difficult, complex, innovative

Large steel plates to carry the Metsec sections were cumbersome and difficult to install. Wind bracing and box sections (made from 300mm purlins) were installed above the existing truss beneath the existing roof. These were 11.2m in length and had to be lifted off access machines to over 13m and installed in highly restrictive conditions.

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

The steelwork was used to both strengthen the existing structure and provide a solution to the client/tenant’s need to successfully achieve the desired result and make this facility unique and superior to both parties.

How did the project team work together (contractor involved early, challenges, ease of communication)

Excellent. With numerous contractors on site working weekends, night shifts, and in confined areas the project team worked exceptionally well under improbable timelines.

STRUCTURAL STEELWORK
Tons of structural steel used 110 tonnes
Structural profiles used Z – Sections, Angles, Plates
CLADDING
Cladding profile/ type used 0.50 IBR 686 Zincal AZ150
Cladding area/ coverage and tonnage 8800m2

Project Team

Project Team Role Company
Nominator Cousins Steel International
Client/ Developer City Logistics
Architect RHA
Structural Engineer Sotiralis Consulting Engineering
Engineer Cousins Steel International
Quantity Surveyor Quantil
Project Manager Quantil
Main Contractor Cousins Steel International
Steelwork Contractor Cousins Steel International
Steel Erector Cousins Steel International
Cladding Manufacturer SAFAL
Cladding Supplier SAFINTRA
Cladding Contractor Cousins Steel International
Corrosion Protection
Galvanising
Cousins Steel International
Corrosion Protection
Paintwork Contractor
Cousins Steel International
Photographer, Photo competition Cousins Steel International

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.

BMW H-EMS Roof Lift

All Projects
Factory/ Warehouse
Metal Cladding