Hoenderhok (Light Poultry House)

Nominator Siteform
Main Contractor SS Silo Konstruksie
Tons of LSF used 8.8 Ton
Span of trusses and Kg/m2 (if applicable)  
Profiles used C-Channel

 

Type of cladding Widespan & flatsheet

 

Wilcox Jones

External cladding Marley FC Boards with OSB, Tyvec membrane and ISOVER Cavitybat fitted internally with 15mm Marley Gypsum boards and fully skimmed.  Joist mezzanine floor system of span of 6.5 meters with 15mm FC Boards and special 50mm x 2 Genises sound mats inside the cavity of the joist system.

Light steel frame roof on the on side of the project and Timber rafter on the Lounge section which was double volume.

Allocation:   Knysna
Square meters:   168sq
Duration:  10 Weeks

Nominator: Rancor
Steel supplier:  Pholaco
Main contractor:  Rancor
Structural Engineering:  EMC Engineering

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.

Van Rooyen

This project was originally designed as a brick and mortar house.   Reasons why this customer has chosen LGS was due to speed, we completed the project turn key in 5 months as suppose to 9 months on brick and mortar.    The insulation factors also has a impact on the customers decision.

Marley smooth external shiplap boards with OSB 12mm and Tyvec membrane with ISOVER cavitybat, fitted internally with 15mm Marley Gypsym boards fully skimmed.

1st floor was done with LGS joist spaced 300mm and 350mm deep with IBR and 25 MPA 80mm concrete slab with ref 193.    ISOBOARD Ceilings with additional 40mm ISOVER green roof insulation was fitted between purlins and rafters.

Allocation:   Cape Town
Square meters:   480sq
Duration:  5 Months

Nominator: Rancor
Steel supplier:  Pholaco
Main contractor:  Rancor
Structural Engineering:  EMC Engineering

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.

 

Schmidtz

Previous house was on stilts and build with Timber – our customer was not happy with the previous house insulation and with a North Facing site, to hot in summer.

We had a fall of slope of 10 meters and secured this with filling and eventually built a raft foundation with light steel frame house.   Cladding externally Envirdeck composite cladding with OSB 12mm boards, Tyvec membrane and cavity bat with 20mm steel purlines to create a cavity for airflow.    Internal boards Marley Gypsum boards 15mm with full skim.    Panel roof was fitted with two joist beams (joists) to support the spans.  

Allocation:   Knysna
Square meters:   175sq
Duration:  11 Weeks

Nominator: Rancor
Steel supplier:  Pholaco
Main contractor:  Rancor
Structural Engineering:  EMC Engineering

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.

Pienaar

This project had a slope of 4 meters and a huge water table – we had no option but to improvise on a special foundation system called Surefoot Africa.  We have drilled steel tubes 2 meters into the ground and added the mezzanine floor on top of brackets, this allowed us to freely secure the footings and to have a stable foundation system in the water table conditions.   Walls are clad externally with Enviro deck composite cladding, Tyvec, OSB 12mm with ISOFER Cavitybat and 15mm Firestop Gypsum boards internally.

Roof has been done with Insulated polystyrene panel with 0.8mm Zink Alum cladding internally and roof covering the Diamond Deck 0.53mm Colorbond.

Duration:  12 Weeks
Allocation:   Kleinmond
Square meters:   190sq

Nominator: Rancor
Steel supplier:  Pholaco
Main contractor:  Rancor
Structural Engineering:  EMC Engineering

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.

Limpopo Mall – Pick n Pay Entrance

What is the purpose of the structure/ project?

This is going to be the new entrance to the Pick a Pay in the centre of the mall.  A concrete floor was removed in order to accommodate this changes.

In order to get the trusses to the designated area where the work was done, we’ve designed and constructed a walk way out of Ultra Span trusses. This was used by all of the construction teams to get to the working site without damaging the existing roof.

What was the brief to the architect?

A model was built of parts of the projects that the architect used to explain to all parties involved what the look was that they were going for.  There were constant communication with the architect to address the challenges.

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

Light gauge steel was mentioned by the project Engineer.  The reason for this was the location of the site within the mall, time frame to close the roof, flexibility with the change of dimensions (should something change).  The walk way was proposed to the contractor and customer as a precaution and to speed up the project.

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

The bulk of the main truss were made from the 140×1.2 chord and the webs were 76 x 0.8mm material.

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

The roof structure had to be constructed over a live mall.  The location of the structure was the next challenge. The opening was close to the centre of the mall and no crane could reach this from the outside.  The use of a crane from the inside was impossible as this would obstruct the doors of Pick n Pay and other major stores in the mall.  The open roof area was a concern as well.  The whole job was done during night shift not to interfere with the normal trade of the shops in the mall. See picture of the Ultra Span walk way that was constructed on the existing roof.  The design was done inhouse and then chedked by MiTek. This walk way made it possible to carry all the Ultra Span material to the working area for erection.  This was the first time the mall owner could see the roof from the top.  The walkway also remained on the roof as the Mall owners now use this for their routine maintenance on the roof.

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

The main truss were made in 2 parts to transport the truss to site and to be able to carry the truss on the roof using the walk ways. Work on the roof could only be done from 19:00 to 06:00 at night as the mall was still trading during normal working hours. The Ultra Span Trusses had to clear the existing heavy steel truss apex.  These trusses were removed after the Ultra Span trusses were in place.  The trusses were boxed (brace-frame) between trusses so that they could be moved as a unit.

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.

Initially the steel trusses would be left exposed but a ceiling was later requested. Two frames (Ultra Span) were made that would be attached to the main Ultra Span Truss. This was then finished by the cladding specialist on site. This gave a finished look with the steel trusses still partly visible. (see pictures)

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

The customer and contractor had a tight time line to complete the project. The quick assembling of the Ultra Span Trusses helped them to stay on track and the additional Ultra Span Walkway had a big impact on the movement of the teams on this part of the project.

Tons of LSF used 4.7 Tons
Span of trusses and Kg/m2 (if applicable) 15m
Profiles used Ultraspan Profiles

 

Type of cladding Widedek (Safintra)

Project Team

Project Team Role Company
Nominator Martek Roofing
Client/ Developer Nitruco
Architect Piet Tempel & Associates
Structural Engineer Enducon
Engineer Not provided by nominator
Quantity Surveyor Not provided by nominator
Project Manager Not provided by nominator
Main Contractor Nitruco
Steelwork Contractor Martek Roofing
Steel Erector Martek Roofing
Cladding Manufacturer Not provided by nominator
Cladding Supplier Select Projects
Cladding Contractor Select Projects
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition Sakkie Maritz
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.

Labus

The prevous house was Timber and our new customer insisted on LGS.   We have done the foundations with timber poles and footings, a concrete deck with LGS joist, IBR sheeting with 80mm 25MPA Concrete system fitted with a 40mm EPS Polystyrene for additional R Value on insulation.   Cladded with Marley shiplap Fibre cement boards and OSB with Tyvec membrane and ISOVER Cavitybat.  Internal boards was Marley 15mm firestop boards.

Lgs trusses on mono pitch with Diamond deck.

Allocation:   Knysna
Square meters:   162sq
Duration:  11 Weeks

Steel supplier:  Pholaco
Main contractor:  Rancor
Structural Engineering:  EMC Engineering

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.

 

Kaap Agri Building

The beautiful and functional Kaap Agri building in Paarl, Western Cape symbolises the professionalism and success of an organisation that has been operating for more than 100 years.

Recently Charl van Zyl, CEO of Rancor, leading light steel frame (LSF) construction company, was asked for a solution to add a mezzanine floor to the Kaap Agri’s existing building leaving its original dimensions unchanged.

The stipulations for the new structure were clear: it had to be cost-effective; it had to be strong and safe; completely sound proof; energy efficient and built in double-quick time.  “Taking all these into account, a light steel frame solution was certainly the most appropriate,” van Zyl says.

The initial design – before Rancor was called in – was based on brick and mortar with concrete beams but after the foundation footings were opened, it was immediately apparent that additional footings would add so much cost and time to the project the design was an unviable option.

Rancor was then invited by Loutjie van Deventer and Hannes De Kock from architect/engineering firm De Kock & Vernote to provide a solution in LSF that would do the job.

This was done successfully. “LSF met all the requirements and, in addition, put less stress and weight on the existing walls,” van Zyl says adding that Jaco Kotze of Stahlbau Construction, the main contractor, accepted the solution without hesitation.

Scope of Works Description

Light Steel Frame was used for the trusses, which spanned 17 meters with large openings opening on the front deck of 10 meters free span over the exterior window stagger doors.  

Marley fibre cement boards were used for flooring on the joists, with special sound mats between the joists to reduce sound transmission, which was further reduced by acoustic ceilings and the   additional height achieved through the design.

Internal board 15mm Marley Gypsum boards with full skim of 3mm and cavitybat from ISOVER, with Fibre cement boards Marley supplied with top 20mm galvanised battens and cladded with Diamond deck externally and roof.  Some sections was clad with Enviro cladding.

We were on time and in budget and the new Paarl Kaap Agri head office was occupied with great enthusiasm and satisfied customer.  

Efficiency is the name of the game

John Barnard, Southern African Light Steel Frame Building Association (SASFA) director, says it is encouraging that an increasing number of construction professionals are recognising the environmental benefits and long-term cost savings of LSFB. He says that sustainability with regard to buildings is essentially based on three criteria: social acceptability, affordability and energy efficiency and that LSFB rates highly on all of the sustainability considerations:

  • LSF buildings appear no different to ‘conventionally’ built structures, except that the quality of finishes is typically better with the former. It has found rapidly growing acceptance for ‘affordable’ as well as up-market buildings in South Africa.
  • It is a cost-effective building method, with financial savings emanating mainly from significant time savings to complete building projects, less rework, reduced logistical costs –which are of growing importance due to the escalation of fuel prices and general construction inflation – and a drastic reduction of rubble on building sites, when compared with the brick-and-mortar alternative.
  • LSF building is significantly more energy efficient than heavy construction methods – both with regard to ‘embodied energy’ of the materials and components, as well as ‘operational energy’ relating to heating and cooling of the building over its design life.

All three of Barnard’s criteria are met on the Kaap Agri project. In fact, as far as energy efficiency is concerned, the R-value (the measure of thermal insulation) of the Kaap Agri external walls is 2.78 which is more than a 1000% better insulation than if it had been built with conventional building materials and significantly more sound proof.

Barnard says that the Kaap Agri project is indicative of an area of construction where LSF is increasingly playing an important role. “It is not only perfect for renovation-type work on existing structures, but, also, LSF building is in general becoming increasingly relevant in a construction environment that is facing rising costs in materials and transport and in an end-user environment where energy costs are soaring and environmental issues are paramount,” Barnard concludes.

So successful was the solution brought by Rancor to Kaap Agri, Rancor was asked asked to assist with a solution to the Kaap Agri Simonduim project, about halfway through the Paarl Head Office construction period.  

Both projects were finished on time and within budget.

Kaap Agri

Kaap Agri began formally with the establishment of De Westelike Graanboeren Koörporatiewe Vereniging (Wesgraan) in 1912 as a cooperative. Over the years the company expanded with a branch and silo network in the Swartland and the Boland. From 1930 to 1950 various other cooperatives were established in neighboring towns and areas. They all basically delivered the same services as Wesgraan. In 1981 the first large amalgamation took place when Western Province Fruitgrowers and Wesgraan joined forces to form WP (Koörperatief) Beperk. Since then further amalgamations have taken place with Drakenstein Vrugtekwekers and Wynland Koöperasie.

In 1995 WP (Koörporatief) was converted to a public company, WPK Landbou Beperk. This was the first of the former cooperatives that converted from a cooperative to a company. In the meantime, Porterville Landboukoöperasie and Noord-Boland Koörporasie amalgamated to form Boland Agri. The current Kaap Agri had its origins when WPK and Boland Agri amalgamated in 2005.

Today the Kaap Agri area of operation includes the Swartland, Boland, Wynland, Overberg, Langkloof, Namaqualand, Orange River, Sundays River Valley, Namibia, and the areas in between, as well as Limpopo, Mpumalanga and Gauteng.

Rancor

Charl van Zyl  (CEO and Founder of Rancor) has more than 25 years of international business experience and has been specializing for the last 10 years in the Light Steel Frame Industry. He started his own company in South Africa in 2007 beginning with delivering roof truss systems to the local market.  Within 8 months his business became the largest LGS roof truss business in the province.  After specializing in LSF roof truss systems, Charl developed his business to residential and commercial building projects with much success. Charl started Rancor after selling his previous company in 2016 and brings with him the experience of more than 500 individual projects in LSF, where he has been involved in all aspects of design, project management, pre-planning, and the construction of projects – always with a hands-on approach to projects, leading to successful completion.

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.

Gilson

We had to design special box sections for the heavy duty trusses to fit into as the rafters weight was 320kg per rafter and with special ridge beams to be fitted.  Flooring was done with light steel frame joist spaced 300mm with 12mm fibre cement board (Marley) with structural screed of 90mm and special sound mats of 50mm each inside the joist which also allowed for all services to easily run in between the joists to be sound proof wall assembly system.

External cladding supplied by Marley Handyplank with OSB boards 12mm and tyvec moisture membrane, 20mm tophat steel battens and then Hanyplank.

We had to create an brick look white wash internal wall in lounge which has been done with Brick.

Timber trusses was specially designed as solid rafters open exposed trusses.

We created an unsupported span of 11 meters for the lounge section going out to the deck and pool which has been done with special engineering design on truss beam plated with 1.2mm galvanized plating and special bolts as additional strength.

Square meters:   750sq
Duration: 
8 Months

Nominator: Rancor
Steel supplier:  Pholaco
Main contractor:  Rancor
Structural Engineering:  EMC Engineering

No additional project team information provided by the 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.