Comair Simulator 3 Building

The client requested a space/building to accommodate the training facility for pilots. This building should also have all the necessary rooms and additional services to support the facility. Training halls, lecture rooms, and the brief and de-briefing rooms were part of this complex. In this facility, the pilots are getting training in the theory and practical aspects.

What was the brief to the architect?

The client’s brief was to provide a building, housing two mobile training units, and two static training units with their supporting rooms around and close by. The provision of lecturing rooms, a computer room, board rooms, a cafeteria, and open plan offices was included in the brief. The building should fit in with the other existing buildings on the site and also designed to allow the maximum natural light into the main core of the building.

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

Yes, the original design was definitely in steel. The flexibility of steel was the only answer to the curved structure of the building. The curved outline of the building simulates the hull form of an aeroplane. The curved spaces inside the building allow for the correct height in the centre of the building to accommodate the total envelope of the simulators to move freely in all directions. Both sides the building is lower to host the training rooms and other service rooms to support the operation of the simulators.

Steelwork contractor interview:

The roof structure consists of a few steel portal frames. These frames are curved trellis trusses, about 900mm deep. The space between the roof sheets and the curved ceiling was used for services like HVAC, Electrical trays, fire detection, IT cables and data lines. The ceiling follows the curved trusses and consists of different layers of material to achieve the necessary insolation towards the control of the heat gain and also for sound absorption. The ceiling is a suspended ceiling with stainless steel, 20×20 mm mentis grid, then a 40mm thick black cineplex insulation batting with fibre cement ceiling boards on top of that and then fixed to the underside of the curved trellis trusses.

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.

Yes, due to the size of the steel portal frame it had to be manufactured in four parts to ease the transport and also the erection of the frames. The rolling of the roof sheets was very difficult and a complexed operation.  The rolling of the sheets was done on site and had to be 100% accurate to follow the curve of the steel frame.

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

The brown built roof sheets followed the curved steel trusses and were also extended along the curved structure downwards to form at the time the wall cladding. The roof sheets rapped the building to enhance the feeling of an aeroplane. 

As Ferro Eleganza having built all the previous buildings (Except for building 1) it was a great privilege to be part of this project once again.

The iconic curved buildings housing the Com Air Flight simulators have become a landmark known by all across the R21 from OR Tambo International airport.

These beautifully shaped buildings based on the shape of a large aircraft could only have been done by the use of steel. 

The structure consists of curved CHS pipe lattice trusses and lipped channel sheeting support rails. Where the structure is closed with ceilings the truss sections are made out of Hot Rolled angle sections in order to save costs for the client. Once the steel becomes exposed again it changes back to CHS pipes.

Both gable ends of the building are complete glass and steel facades. Comprising of Shaped “Plate Girder Fins” and Large RHS members between carrying the glass. Here much effort was required as no bolts were allowed at the connections so as to keep the look and not to clash with the glass.

This was accomplished by using locating lugs inside the sections and then careful site welding and polishing to create the required finish and look.

The erection of this building was a great challenge in its self.

Due to the curved shape of the trusses and the fact that they are only connected to the concrete bases with a single Pin on both ends these trusses cannot stand on their own.

Therefore the entire truss was assembled on the ground and then using two mobile cranes the first two trusses were lifted into position and then held there while the bracing and purlins were installed so that the structure could stand on its own.

Another challenge has always been the link tunnels between the buildings. These are narrow tunnels that give the idea of the tail end of the aeroplane.

 Here the curved pipes needed to be rolled at much smaller radiuses and much effort was needed to ensure that the steel structure could receive the curved sheeting.

To crank the sheeting to the correct radius and then fit it to the steel structure required much effort and the combined efforts of Steel and Sheeting Contractor together.

It was a great challenge to create what the architect envisioned, to accomplish what the Engineer required, and produce this beautiful building that could only have been done with steel.

The roof super-structure radiated from the internal circular ring beam to the oval-shape external ring beam using a combination of gusseted rafters for the shorter spans to I beam/angle-iron type trusses for the longer sections.

STRUCTURAL STEELWORK
Completion date of steelwork June 2018
Completion date of full project September 2018
Tons of structural steel used 70 Tons
Structural profiles used CHS, 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
Industrial Painting Services (Pty) Ltd
Cladding and Roofing Global Roofing Solutions
Architects WMS Architects

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.

Mill Road Industrial Park – Phase 1

 

The unusually shaped brownfield site proved a challenge to provide feasible development coverage while accommodating onerous vehicular access requirements from the municipality. The architects tested numerous speculative and tenant-specific designs on the site before the client settled on a phased speculative development for the park. 
The initial phase of the development provides the largest warehouse of the park, a sub-divisible building offering three 3,800m² units and one 7,125m² unit capable of consolidation into larger units. Utilising the natural gradient across the property, units with either on-grade or docked loading are offered for marketability. 

Architect interview:

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

Isections – Girders top – internals back to back equal angles – Trusses – Longleg horizontal angles – top chord equal angles – internals used equal angles – Horizontal Bracing equal angles chs struts – vertical bracing equal angles CHS strutts. – Sheeting roles cold form lip channels c sections and purlins – Colums were Isections. – Innovation – Movement joint in steel structure

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

Innovation – Movement joint in steel structure

A cost-efficient and simple, but innovative roof light detail was developed to minimise on the amount of flashings installed (typically the point of water ingress on shallow pitched roofs in the Cape).  Polycarbonate sheeting was installed in 800mm lengths (mitigating expansion concerns) draining perpendicular to the fall of the roof on lipped channels fixed on top of the purlins.  This facilitated the speed of installation as the roof lights could be retro-fitted after the roof sheeting was completed. 

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

No. The steelwork design was developed in conjunction with the fabricator (Mazor) to facilitate speedy erection. The principal concern with fast-track industrial construction is to erect the steelwork as quickly as possible to allow for the roof sheeting and vertical cladding to be completed thus allowing for the casting of the concrete warehouse floors. The pouring of super-flat concrete floors cannot be done until the warehouse is fully enclosed.

The architect also worked closely with the engineer and fabricator to develop the canopy hanger detail as a feature. Where possible exposed steel structure was also painted red to celebrate structural elements often overlooked.  

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

The lightest colour sheet was selected to mitigate heat gain.

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 August 2018
Completion date of full project 20 October 2018
Tons of structural steel used 480 tons
Structural profiles used I-Sections 203 133 x 2.5 – 305 x 102 x 25- c140 c160 – 254 x 136

CLADDING

Completion date of cladding

July 2018

Cladding profile/ type used

Saflok 700 0.53mm AZ150 Colorplus Seaspray

Cladding area/ coverage and tonnage

19,450 sqm roof, 5950 sqm vertical
sheeting

PROJECT TEAM COMPANY
Nominator Safintra
Client/ Developer Growthpoint Properties
Architect Loudon Perry Anderson
Structural Engineer Aurecon
Quantity Surveyor MLC
Main Contractor Group 5 Coastal
Steelwork Contractor Mazor Steel
Steel Erector Mazor Steel
Cladding Manufacturer Safintra Roofing
Cladding Contractor Chartwell Roofing


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

Tibani Shopping Centre

The building is designed around a steel structure that supports the vast steel roofs along with the glass window feature surrounding the inside of the walkways. Tibane Mall – 18000m2. The weight bearing properties of steel allows for unobtrusive canopies and unique designs throughout the building.


Benefits achieved by using steel construction

Benefits include cost savings, ease of installation and with the ProLok 700 Sheeting system, sheeting could be rolled on site in various long lengths to accommodate the design. Small adjustments that can be made on site (especially in such a remote location) and the bolt on features make steel the obvious material choice for a project of this size and design.

Aesthetic appeal

With the availability of different roof sheeting colours the client has the ability to match colours to suit and add appeal to the design. With the versatility of steel, an aesthetically pleasing design could be achieved.

Environmental/ Sustainability consideration

Steel is 100% recyclable and is an environmentally friendly product.

Innovation in Design Fabrication or construction

Accommodating the unique design that gives a feeling of an open air experience even inside the mall the fabrication of the steel support systems is unique to this project.

Technical process required for realizing the project

With the remote location of the project all manufacturing had to be perfect to stay within budget.

  • Having the ProLok 700 mobile mill on site improved the logistical process and ensured that the process was achieved in a timely and cost effective manner.

What is the purpose of the structure/project?

The Tibani Shopping centre will give a much needed boost to the economy of the rural Tibani area. Creating jobs for the local community and giving access to a modern retail experience.

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

Steel was the material of choice from the start.

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

The use of concealed fix roofing profiled on site in long lengths gives a massive advantage to any project and roof sheeter, however, working with long single lengths of sheets can also be troublesome and in some conditions dangerous. In the case of the cladding at Tibani, the wide open surrounds allowed for high winds to ensue over the building area and made the manufacturing as well as moving of long length sheets difficult. At some stages manufacturing as well as installation was halted due to high wind gusts. Perseverance during good conditions was key to getting the cladding done on time and installed to standard.

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

The building design raised the walkway roofs from the front to back on both the entrance ways throughout the inside of the mall creating large amounts of natural light,

the steel structure used flows seamlessly with the glass borders making it not only functional but attractive as well.

How did the project team work together

The whole team worked very closely together, whenever a problem or a snag occurred the communication between all parties involved was prompt and solutions were put in place.

CLADDING
Completion date of cladding October 2018
Cladding profile/ type used ProLok 700 for roof
Cladding area/ coverage and tonnage 18000m2 / 110 Tons
Structural Profiles used Beams, Angles and Channels
PROJECT TEAM COMPANY
Architect Rossouw Argitekte
Structural Consultants Proficient engineering
Quantity Surveyor SM Marè & Associates
Main Contractor Robert Skinner Konstruksie
Roof Sheeter Rainbow Sheeters
Structural Steel Quality Steel and fencing
Cladding Supplier Pro Roof Steel & Tube
Corrosion Protection Paintwork Contractor IPS Industrial Painting Services

 

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
Steel Detailer KRU Detailing cc

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.

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 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

 

Project Team Role Company
Nominator KRU Detailing
Client/ Developer Fortress Property Fund
Architect ICM Architectural Studio
Structural Engineer L&S Consulting (Pty) Ltd
Engineer L&S Consulting (Pty) Ltd
Project Manager Abbeydale Building and Civil (Pty) Ltd
Main Contractor Abbeydale Building and Civil (Pty) Ltd
Steelwork Contractor SE Steel Fabrication (PTY) Ltd
Steel Erector SE Steel Fabrication (PTY) Ltd
Cladding Manufacturer Roofing Solution
Cladding Supplier Roofing Solution
Cladding Contractor Roofing Solutions
Corrosion Protection Paintwork Contractor Dram Trading
Nomination Document

Submission

KRU Detailing CC
Structural Steel Detailer KRU Detailing CC
Photographer, Photo competition Photography by Micaela

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.

Mega Shed

First and foremost, the space was intended to be practical and utilitarian. It had to accommodate four cars and a workshop on the ground level, and a space in which the client could work, entertain and relax – a multi-use mezzanine level was incorporated for this purpose. Notwithstanding this functional focus, it was also intended for the structure to assume an interesting and visually pleasing form.


Background:

On a trip to Iceland in 2017 the client was struck by the number of buildings, both traditional
residential and modern commercial/mixed use, which were constructed in, or at least clad by,
steel. Furthermore, the clean lines and stark simplicity of Scandinavian design were greatly
appealing. Inspired by this, the client undertook a few concept sketches for a garage/workshop
which he thought would be an interesting project to undertake. He also wished to experiment with using steel as a building material, with a view to possibly employing the materials and methods in a house-build in the future.

Brief:
The brief from the client was to design a multi-use garage-workshop-studio in a Scandinavian minimalist style, based on the concept sketches and imagery provided. The client felt strongly that the structural materials used in the construction were to be celebrated and presented as feature elements, not concealed by plaster, paint, etc. Steel I-beams are left exposed throughout the structure and all the internal walls and ceilings are clad in raw Oriented Strand Boards (OSB), a material not often considered a finishing.

The client always envisaged using steel for the exterior cladding. The one inherent challenge was that the structure might appear too ‘industrial’ for a suburban setting. This was mitigated by the use of timber externally (both on the double sectional garage doors and the cladding on the underside of the roof overhang) and internally (with the use of OSB cladding throughout).

Structural framing:
The structural framing consisted of I beams and lip channels mostly to keep the costs to a
minimum as well as keeping the main framing as basic as possible. The I beams were used for
the main portal frame to also allow the internal timber cladding to terminate into the top flange of
the beam while leaving the rest of the beam exposed as a feature. The I beam for the mezzanine also allowed for the structural timber beams to be supported within the flange of the beam.

Cladding:
The cladding seemed a standard application, specialized workmanship was required in aligning the rib lines from the roof cladding down onto the side cladding, further, the complexity ensued in the flashing details, whereby the eaves flashing had to conceal the edge of the roof cladding and the flow of the water. The barge and corner flashing were made up to suit the rib lines of the cladding. A specially designed gutter and cover flashing were required on the splayed end of the roof cladding ensuing a concealed edge and conforming with the eaves flashing, further all cladding troughs covered by flashing were sealed with serrated closers.
.
Challenges:
The design incorporated an asymmetrical roof overhang detail, which was to be clad in timber on the underside, to match the garage doors. AS mentioned above the overhang required a concealed gutter and flashings which had to be custom-fabricated. Furthermore, all flashings on the front side of the structure were custom-fabricated in a slimmer profile than standard, to attain the level of aesthetics required by 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.

STRUCTURAL STEELWORK
Completion date of steelwork 5 September 2018
Completion date of full project 1 March 2019
Tons of structural steel used +/- 4 tons
Structural profiles used 203x133x25 I Beams, 254x146x31 I beams , 356x171x51 I beam and 125x25x2.5 steel purlins
CLADDING
Completion date of cladding 18 October 2018
Cladding profile/ type used 0,55mm C1S Colorplus  “Thunderstorm” Nu-Rib roof, side and gable cladding

 

Cladding area/ coverage and tonnage 245 sqm/ 840 kg
PROJECT TEAM COMPANY
Nominator Global Roofing Solutions
Architect MWA Architecture
Structural Engineer Galatis and Associates
Roofing Contractor Vivace Roofing CC
Roofing and cladding supplier Global Roofing Solutions
Main Contractor Prodevcon Construction

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

Shell Ultra Escourt (North And South)

The purpose of the project is to provide a new customer experience different from a conventional fuel station. To align with the client’s vision of a more retail orientated experience.


What was the brief to the architect?

To design a building fit for purpose and to embrace the client’s brand.

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

It was originally conceptualised as a concrete frame building. A redesign of the look and feel of the building occurred to align with the context of 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?

I-beams, H-columns, angles for bracing, circular hollow sections (tapered) used as features and lip channels for roof sheeting and side cladding support. Due to the low pitch of the double pitch roof of the main building and also the arch shape of one end of the mono-pitch roofs over the quick service restaurant area and part of the main building, a portal frame type of structure was adopted.   

CLADDING
Completion date of cladding November 2018
Cladding profile/ type used Klip-Tite 0.53mm Az150 C1s Slate
Cladding area/ coverage and tonnage Ibr 0.50mm Az150 C1s Slate
PROJECT TEAM COMPANY
Nominator Global Roofing Solutions
Architect AECOM
Structural Engineer AECOM
Quantity Surveyor AECOM
Project Manager AECOM
Main Contractor Bartlett
Roofing and Cladding Global Roofing Solutions
Corrosion Protection Paintwork Contractor IPS Industrial Painting Services