Renish Girls High Stellenbosch

The purpose of the project was to replace the existing timber structure that is deflecting and collapsing after 70 years service.


What was the brief to the architect?

To comply with the heritage of the building and new building regulations, to keep the appearance the same as the existing structure.

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

Timber was an option as the existing structure is of timber, LWS was chosen as a new material that will give a long service period in a public building and complies with all regulations.

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

LWS profiled sections where used, the profiles differ according to the strength required for each truss design.

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

The 60 degree pitch was a challenge for safe working conditions with long sheet lengths.

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

The entire roof was assembled on ground level in sections and then hoisted to roof level with a mobile crane.

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.

With the entire roof structure assembled on floor level it was easier to handle, this was made possible by creating a wallplate level replica of the building at a lower more easily accessible platform.

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

All teams communicated from the start, as the existing roof had asbestos slate that needed to be removed first. At a public school this poses many challenges to co-ordinate the time of removal without interfering with the day to day school process. During the construction phase areas had to be hoarded off to prevent access as overhead hoisting was occurring for installing large sections of the LWS roof structure

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work 03 DEC 2018 – 31 JAN 2019
Completion date of full project 05 OCT 2018 – 30 APRIL 2019
Tons of LSF used 15.162 TON
Span of trusses and Kg/m2 (if applicable) 6350 – 18600mm
Profiles used  MITEK ULTRA-SPAN
Type of cladding METAL SHEETS
   
CLADDING
Completion date of cladding 30 APRIL 2019
Cladding profile/ type used 0.53 AZ200 SAFLOK 700 – RAINCLOUD COLORPLUS
Cladding area/ coverage and tonnage 1790M2
   
PROJECT TEAM COMPANY
Nominator Elegant Roofing
Client/ Developer Western Cape Education Department
Architect R&L Architects
Structural Engineer Nadeson Consulting Serv
Engineer Mitek Industries SA
Quantity Surveyor Aveng Grinaker-LTA
Project Manager Aveng Grinaker-LTA
Main Contractor Aveng Grinaker-LTA
Steelwork Contractor Elegant Roofing
Steel Erector Elegant Roofing
Cladding Manufacturer SAFAL Group
Cladding Supplier Safintra Roofing
Cladding Contractor Elegant Roofing

 

Shell Ultra City Kroondal East and West

The Shell Ultra City Kroondal East and West is a Greenfields project. It included the completed construction of two new Shell Ultra City service stations on the N4 highway close to the established town of Kroondal in the North West province. Each service station is just over 1000m2 under roof and incorporates a convenience store and two quick service restaurants.

The completed project is unique as it is the first Lightweight Steel Retail fuel station that has been introduced in the Shell network and could potentially be the first of its kind Lightweight Steel Retail fuel site in Africa.

The designer on the project moved away from the traditional idea of a service station being in the shape of a modular oblong box. The prominent architectural feature of the Shell Kroondal service station is its curved lightweight steel roof, to match the contours of the surrounding landscape. The boundaries were further pushed by uniquely designing a curved forecourt canopy moving away from the flat forecourt canopy as is synonymous with retail fuel sites all over the world.

The project specifically targeted sustainability initiatives. The initiatives encompass locally sourced materials, community facilities, indigenous planting, recycling of construction waste, a structure that can be disassembled and reused, ensuring a reduced embodied energy and resource depletion through the concrete mix, and low VOC interior finishes, among others. All grey and blackwater on-site are filtered and reused in the toilets and urinals. and water data are displayed in the shop area.

STRUCTURAL STEELWORK
Completion date of steelwork April 2018
Completion date of full project October 2018
Tons of structural steel used 7.5 Tons
Structural profiles used See Attachment
SA content – if this is an export project 100%
LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work April 2018
Completion date of full project October 2018
Tons of LSF used 62.4 Tons
Span of trusses and Kg/m2 (if applicable) 13m unsupported, 26m supported
Profiles used Framecad C – section , 30 mm Battens , 20mm Battens
Type of cladding G 550 ,  Z200 / Z275 , 0.8mm and 0.58mm steel
CLADDING
Completion date of cladding June 2018
Cladding profile/ type used F/Cement Boards  12mm x 1,2m x 2,4m 

F/Cement  Boards 12mm x 1,2m x 2,7m

F/Cement  Boards 12mm x 1,2m x 3,0m

Gypsum Boards – Moisture Resistant  Boards 15mm x1,2m x 3,0m

Gypsum Boards – Habito Boards 12,5mm x1,2m x 3,0m

Cladding area/ coverage and tonnage 3756m2 /  127 tons
PROJECT TEAM COMPANY
Nominator AECOM SA (Pty) Ltd
Client/ Developer Shell Downstream South Africa
Architect AECOM SA (Pty) Ltd
Structural Engineer AECOM SA (Pty) Ltd
Engineer  
Quantity Surveyor  
Project Manager AECOM SA (Pty) Ltd
Main Contractor Razorbill Eco-Construct
Steelwork Contractor Marboe & Sons (Pty) Ltd
Steel Erector Marboe & Sons (Pty) Ltd
Cladding Manufacturer Terraco 

Saint Gobain

Everite

Cladding Supplier Terraco 

Saint Gobain – Triangle Sourcing

Everite – Global Innovations

Cladding Contractor Razorbill Eco-Construct

 

Razorbill Eco Construct – Shell Kroondal

Aecom was appointed by Shell to design, oversee and build the first green star rated Shell Ultra City in South Africa. Aecom saw the value of Light Weight Steel Frame building and appointed Razorbill who has 12 years’ experience in design, production, and construction of Light Weight Steel Frame. Razorbill’s design department transformed Aecom’s design into a lightweight steel frame structure. Shell /Aecom see the value of Light Weight Steel Frame constructionDeveloping the Light Weight Steel Frame steelwork designs to express the architect’s concept was a challenging exercise that would have been difficult to re-create in brickwork or in concrete whilst still meeting the parameters set out by the client.

The underlying drivers of the Shell Kroondal project on the N4 North West were cost, speed and environmentally friendly building methods which are especially apparent in the project promoting alternative building technology (ABT) and the role it could play in innovative development in South Africa. The project is notable for its lightweight steel structure featuring exposed lightweight steel trusses

Part of the requirement was to ensure that work opportunities were created for members of the local community and that there would be no impact due to the construction of the buildings on the adjoining wetland area.

The use of LWSF resulted in a significant reduction of transporting building materials as well as the use of materials that can be recycled at end of life.

World class Health, Safety, Environment and quality control measures were to have complied with that met the standards as required by Shell, Aecom and Pragma. In this Razorbill utilized a Health and Safety program that was tailor-made for the project and which was designed by an expert engineer with a vast experience in the mining, manufacturing and construction industry.

Razorbill utilised renders and finishing materials from Terraco which is proven worldwide and backed by a company with experience in all climate zones over the world. Extreme satisfaction was expressed by Shell International on the product and the speed of construction during their visits to the site during and after the construction of the buildings.

This is the future of building in South Africa and Africa, lightweight steel buildings have a much lower impact on the environment, rehabilitation of land is much cleaner and faster to achieve than with brick and mortar buildings.

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work Aug 2018
Completion date of full project Oct 2018
Tons of LSF used 32.4 tons
Span of trusses and Kg/m2 (if applicable) 13 mtr unsupported / 26 mtr supported
Profiles used Framecad C-sections, 30mm and 20mm battens 

 

Type of cladding Exterior: 

. 12mm fibre cement boards

. Terraco exterior wall products

 

Interior:

. Gypsum 15mm firestop and moisture resistant boards

. Terraco interior wall products

 

 

CLADDING
Completion date of cladding Sep 2018
Cladding profile/ type used Exterior: 

. 12mm fibre cement boards

. Terraco exterior wall products

 

Interior:

. Gypsum 15mm firestop and moisture resistant boards

. Terraco interior wall products

 

Cladding area/ coverage and tonnage 3756m2, 36.379tons
PROJECT TEAM ROLE COMPANY
Nominator Razorbill
Client/ Developer Aecom
Architect Aecom
Structural Engineer Donnic Engineering
Engineer Razorbill
Project Manager Aecom
Main Contractor Aecom
Hot rolled Steelwork Contractor Marboe & Sons (Pty) Ltd
Hot-rolled Steel Erector Marboe & Sons (Pty) Ltd
LW Steel Contractor Razorbill
LW Steel Erector Razorbill
Cladding Manufacturer St Gobain/Marley/ Everite
Cladding Supplier Triangle Sourcing
Cladding Supplier Global Innovations
Cladding Supplier Terraco
Cladding Contractor Razorbill

6 Sidmouth Avenue Oranjezicht

6 Sidmouth Avenue is the remodelling of an existing old Oranjezicht home. Oranjezicht is an old suburb in the Cape Town city bowl, situated on the slopes of Table Mountain.

Most of these old homes face north, look over the city below and have imposing but spectacular mountain views at their rears.

The existing old home was a typical 50’s ‘box’ type double story home but lacking real architectural merit. The brief called for a complete renovation and make-over. This involved adding a floor for a new main bedroom suite as well as gutting, re-planning and enlarging the living and kitchen areas on the lower levels. In addition, the landscape was reshaped with new outside living areas. Only what now is the middle level was retained in a planning sense.


The existing kitchen (at the rear) had to be opened to take advantage of the mountain views. By introducing a 1x8m steel girder weighing about a ton were we able to support the weight of the structure above and bring the views into the kitchen. This girder had to be craned over the house to get it in place. A new steel cranked roof, forming a kitchen living space was clipped onto the front of this girder. The cranked angle of this roof allowed unimpeded views into the kitchen and maximized the views from its adjacent living space. This room, in turn, opens up onto the pool area at the rear of the property.

The use of reversed IBR profile cladding on the verticals was used as a device to tie in the new roof conversion with the old walls below. The result is a homogenous blend of the old and new, pulling the whole design together. We wanted to avoid the extension looking like an afterthought. One other innovation was the use of powder-coated steel window boxes which project from the façade. These have a dual role of being the main window flashing element in the lightweight walls and the finishing gasket against the IBR sheeting. This was used in lieu of the standard wide steel flat profile normally used around sheet façade openings.

Due to the old structure, there was uncertainty around the bearing capacity of the old walls, and it was decided very early on in the project to propose LSF. Many existing and critical ground floor support walls and beams were removed. To compensate, hot rolled structural steel elements had to be introduced under the existing first-floor slabs. The lightweight nature of LSF above was critical to the success of these supports. The nature of the steel cladding also lent itself perfectly to the use of LSF. A further challenge was to connect and combine the LSF roof elements with some long span timber laminated beams which spanned the entire length (gable to gable) of the upper level. 

I was already familiar with LSF technology, having used it on two prior projects. The prior experience I gained using LSF had introduced me to the key players in the industry, namely the structural engineer and the LSF contractor. I had also worked with the main contractor so that there was a familiarity in the professional team, and we had a good working relationship. Unfortunately, the LSF contractor ran into financial difficulty early on during the erection of the LSF. He abandoned the project leaving the client and the professional team to pick up the pieces. Our main challenge was that the budget did not allow us to re-tender the LSF and cladding and so the main contractor, client and myself project-managed the LSF. One of the LSF Contractor’s former erectors, a Zimbabwean named Para Chimimba, was brought in to complete the works. We, therefore, lost the time-saving benefits of using LSF. The project was delayed causing enormous financial pressure for the client and created a challenging working environment. Despite this challenge, we managed to pull it off – and the proof is in the result.

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work March 2017
Completion date of full project January/February 2018
Tons of LSF used 3 Tons
Profiles used 89mm .75 lip channel 

 

CLADDING
Completion date of cladding June 2017
Cladding profile/ type used IBR – inverted
PROJECT TEAM COMPANY
Nominator Chris Wood Architect
Architect Chris Wood Architect
Structural Engineer By Design Consulting Eng
Main Contractor Arba Construction
Steelwork Contractor Arba Construction
Cladding Manufacturer Youngman Roofing
Cladding Supplier Youngman Roofing

UKZN – School of Engineering Dining Hall

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

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


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

Yes, the architect has previously worked with LSF.

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

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

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

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

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

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

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

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

The interesting boxing to entrances and soffit beams.

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

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

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work December 2018.
Completion date of full project March 2019.
Tons of LSF used 4 762 Tons
Span of trusses and Kg/m2 (if applicable) 12 365 meters
Profiles used Frame Cad – C Section
Type of cladding 10mm Fibre cement board and 12mm OSB Board

 

Department of Health – Townhill Office Park

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


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

What was the brief to the architect?

Professional and management services for the design, development, documentation supervision and construction of a new office park for the department of health, infrastructure development and technical support at Townhill hospital, Pietermaritzburg, KwaZulu-Natal.

The department of health supplied a general draft specification and requirements at Tender stage including a layout and footprint for the development.

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

Yes, steel was envisaged from the start

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

  • It was critical at tender stage to have a design philosophy for costing purposes and submitting a fixed price. Once the tender was awarded it was imperative that the contractors were involved with the projects team to ensure the building was designed and constructed within the budgets and allowables submitted at tender stage.
  • We were handed over a green lawn of around 15 000m² to develop the full turnkey office park comprising of around 3600m² of LSF Buildings.
  • Most sub-consultants had previous experiences working on similar LSF projects.
LSFB / LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work November 2018.
Completion date of full project 08 March 2019.
Tons of LSF used 45 Tons
Span of trusses and Kg/m2 (if applicable) 11.4 meters
Profiles used Frame Cad – C Section
Type of cladding 8mm Shera Plank Teak Wood grain, And 12mm OSB Board
CLADDING
Completion date of cladding ± July 2018.
Cladding profile/ type used SAFLOK 700
Cladding area/ coverage and tonnage 3400m²

Artek 4 Architects Office Expansion – Durban

The project entailed the development of ground and first-floor extension to Artek 4 Architect offices. New open plan drawing office to the first floor constructed with Light steel frame. Garage and storerooms to the ground floor in brick.


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

Yes, it was envisaged in LSF from the start. The client had previously worked with LSF building method and chose this option for speed of construction, green building attributes and wanting a mix of construction methods at their office expansion.

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

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

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

  • The building exterior cladding comprised of a OSB sub-board, Tyvek vapour barrier and 12mm fibre cement sheets. This was painted to seal the boards.
  • Thereafter timber cladding was used, comprising of Timber battens running vertically at 400m centres. The final clad finish is Siberian larch in a T+G profile. All to create a stunning finish to the building.

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

  • Light steel frame was used for the floor joists, wall panels and roof trusses.
  • Due to the lightweight structure, the client was able to use the existing foundations. The big glass shopfront opening and canter lever LSF floor required some additional design input and steel plating.

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

No colossal challenges as the versatility of the LSF system provided some simple solutions.

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

The timber T+G cladding creates an awesome finished product and effect.

It was quite exciting for us to use this cladding as this was our first contract cladding a building in timber. The finished result we found was stunning.

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

  • All worked smoothly, Shospec were the LSF specialists and other sub-trades were done by the architect.

A brief summary from the project given by the client “Somer Govender”.

  • “Artek 4 Architects Durban office is in the process of becoming part of a precinct named Green Houses located at 44 & 46 Lena Ahrens Road, Glenwood. The buildings constructed in the early 1920s are Edwardian Period in Vernacular style and Union Period, Berea Style house. The properties are neighboured by three historic “listed” double storey houses of Edwardian Period in Vernacular style, creating a mini-precinct of heritage buildings. The proposed additions are modest “clip on” lightweight steel and timber clad (FSI rated Siberian Larch) structures so as to not compete with the original dwelling and can be easily removed to bring the building to its original state. The intervention is based on minimal simplicity and honest materials of the period correct Bauhaus movement. When juxtaposed, the period styles enhance the character of the historic buildings but is also inclusive of the origins of modern architecture.

An inclusive process to ensure that the very essence that makes the historic building special is not lost. For the effective transformation from house to office, the design has considered the actual users which consist of a multitude of cultures endemic to our society. A variety of cultural inclusiveness is adopted in materials, patterns, colours and style in the building fabric. Much attention is paid to energy efficiency, water conservation/management and use of renewable materials and a Green Star process has been adopted.”

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work June 2018.
Completion date of full project August 2019.
Tons of LSF used 2 173 Tons
Span of trusses and Kg/m2 (if applicable) 7 766 meters
Profiles used Frame Cad – C Section
Type of cladding 18mm OSB tongue and groove,12mm Fibre cement and Timber T&G planks.
CLADDING
Completion date of cladding July 2018.
Cladding profile/ type used SAFLOK 700
Cladding area/ coverage and tonnage 78m²

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

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

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

The building construction consists of

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

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

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

STRUCTURAL STEELWORK
Completion date of steelwork November 2019
Completion date of full project Feb 2019
Tons of structural steel used 2.8t
Structural profiles used 152x152mm x23kg/m I-sections
LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work November 2019
Completion date of full project Feb 2019
Tons of LSF used 27 tons
Span of trusses and Kg/m2 (if applicable) 30 meters
Type of cladding KlipLok / Plaster
CLADDING
Completion date of cladding January 2019
Cladding profile/ type used Klip-Lok / Plaster
PROJECT TEAM COMPANY
Nominator Futurecon
Client/ Developer Wealthgate Investments 45 (Pty) Ltd

 

Architect Boogertman and Partner

 

Structural Engineer J3 Engineering
Quantity Surveyor Henry Riley Construction Consultants (Pty) Limited
Project Manager Henry Riley Construction Consultants (Pty) Limited
Main Contractor Futurecon
Steelwork Contractor Futurecon
Steel Erector Futurecon
Cladding Manufacturer Hollyberry Roofing (PTY) Ltd
Cladding Supplier Hollyberry Roofing (PTY) Ltd
Cladding Contractor Hollyberry Roofing (PTY) Ltd

Protea Glen Secondary School 2

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

Abacus Space Solutions was awarded one school, Protea Glen Secondary school no. 2; following their submission of a SANS 517:2013 based school.

Local studio Architects, who have a number of Light Steel Frame projects to their name, including the well accredited Hillbrow Outreach Program, were appointed as the Architect.

Local Studio set about tailoring the generic GDE drawings to suite the site and designing a school layout and buildings that would be the best for the site.

SMC Africa where tasked with the detailing and construction portion of the project.

Craig Tyndall from the Structural Workshop, who is well experienced in Light Steel Frame construction was responsible for structural engineering.

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

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

  1. Speed – the project started in August with the structures (3421m2) being completed by the 15th December. This was the first of the 9 schools to achieve works completion.

2. Acoustics– this is particularly important in a school and the superior acoustic properties of the walls stops        sound transmission between classrooms.

3. Temperature – the rooms are temperate and noticeably cool in hot ambient temperatures.

4. Flexibility of design- Local Studio was able to capitilise on the flexibility of the building system to create lofted ceilings and acentric roof lines to create unique aesthetic structures

  1. What is the purpose of the structure/ project?

       a. The Building is a school In Protea Glen, Soweto. It is part of the Gauteng Department of Education’s (GDE) alternative                 building system orders for 2018

  1. What was the brief to the architect?

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

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

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

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

       a. The structure is a Framemaster 90mm by 38mm cold rolled section in 0.8mm galvanised steel.

       b. The roof structures are Structural insulating panels with Chromadek finish.

       c. Walkways are mild steel C, and rectangular hollow sections.

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

       a. The LSF system is in line with the requirements of SANS 517:2013.

       b. The inner skin is 15mm Gypsum, with a 110mm cavity batt, Tyvec, building wrap, 21mm shutterply runners and 12mm                    fibre board external sheeting. The joints are treated with a two part epoxy, with expansion joints where detailed.

       c. The external paint is Weatherguard PVA.

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

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

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

        a. The inclined wing walls on the buildings would not have been as easily achieved with conventional building methods.

        b. The design choice of the inclined Chromadek clad Structural Insulating Panel roofs provided the unique Architectural                     features.

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

        a. The experience of the Architect and LSF Contractor in using LSF, as well as the quick feedback loop allowed for accurate              design and detailing work to be done relatively easily.

        b. The in-house 3d detailing done by the LSF Contractor improved communications between all of the relevant professions.

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

Framemaster 90mm

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