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.

Hoopstad WestFert Fertilizers

Fertilizer company Westfert required a massive warehouse to take advantage of favourable global conditions in the market. The large-scale dome in Hoopstad that was built is described as the biggest in the southern hemisphere. The main objective of the structure was to create an inland fertilizer storage facility where various basic granular fertilizers can be blended and bagged for the specific needs of farmers. The structure is 116 meters wide and 152.25 meters in length and covers approximately two hectares.

There are no supporting pillars within the structure, which creates enough space for two Airbus 380s to fit inside the building. A triangular pipe frame structure was use for the trusses. A single 194mm diameter bottom cord pipe and two 140mm diameter pipes were used as top sections. The bracing is 76mm pipe and all the sections are 3mm thick.

Creating a structure of this scale wasn’t without its challenges, says project engineer Hentie Park. One of the main challenges was to ensure that all the trusses were rolled on a 96m radius. Secondly, all the welded connections were profiled with a CNC plasma cutter to ensure exact fit. Each truss consisted of 10 sections that were joined by specialised welding on site. Articulating joints were designed where the truss connected to the concrete plinth. Two halves of the trusses were lifted by two 25ton cranes and the centres were connected with three pins – one for each cord. The latter reduced the election time and costs significantly.

The unsupported span of this building is 116m. Global Roofing Solutions supplied approximately +-27000m2 of Klip-Tite and NuRib for the product and 127m long sheets were rolled on site and clipped into positionThe dome is the fourth largest such structure in the world and it will be able to house approximately 200 000 tons of fertilizer.  Thanks to the new dome warehouse, Westfert will now be able to buy input ingredients such as urea in bulk when exchange rates and prices are at their most favourable.

Cladding profile/ type used KlipTite & NuRib
Cladding area/ coverage +-27000m2
Cladding tonnage +-160 Tons

Project Team

Project Team Role Company
Nominator Global Roofing Solutions
Client/ Developer West Fertilizers
Structural Engineer Alliance Con Systems
Project Manager Alliance Con Systems
Main Contractor Alliance Conveying Systems
Steelwork Contractor Vic Engineering
Steel Erector Vic Engineering
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Alliance Conveying Systems

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.

Sun International Time Square Main Arena

The Sun Arena at Time Square in Menlyn Maine is the biggest live entertainment venue in Pretoria. The purpose of the arena is to create an event and performance space where some of the biggest music concerts in South Africa will be held.

The multi-faceted brief to the architect was to create a performance venue that could seat 8 500 people and could be adapted to accommodate 1300 banquet guests and up to 18000 delegates in a school room format. The client wanted a continuous roof span without any columns and the arena had to incorporate all of bells and whistles that would make it an arena of international standard. The fly tower height of the arena, which is the framing around the stage, is of international standard which means that many international performers will be able to perform at the Sun Arena.

The project wasn’t envisaged in steel from the start. The columns on which the edged gutter and roof wedges sit were originally conceived in concrete, but due to steel offering faster construction times, this was later changed to steel. The roof structure, which is a tubular truss frame roof, plus a large gutter were done in steel. The gutter of the roof has a steel construction tension ring and there is a compression ring in the center of the roof trusses.

The design team had to create an acoustic sandwich out of the cladding because the performance arena had to be insulated from noise from traffic and weather, and it also had to prevent interference from the concert to neighbouring facilities. The cladding also had to be watertight so that the arena would be kept dry during bad weather. Global Roofing Solutions supplied 86 tonnes of cladding to cover the 1300m2 cladding area for the project. The company’s widely popular KlipTite system was specified for the project.

The geometry of the cladding of the Sun Arena is particularly interesting because the roof was designed as a series of wedges. A curved gutter edge, however, meant that when an edge intersected with a curve, it would lead to a varying height at the bottom. During the project, the team had to resolve how they were going to marry the varying heights at the bottom of the cladding that resulted from the combination of curved gutter edges and roof wedges.

The roof has a 96m, column-free span, which is unusually large. While there are many long-span roofs in warehousing projects, the unique acoustic envelope that the team had to create makes it an exceptional project.

The entire project team worked together from the start to conceive the structure and decide on the appropriate materials for the arena. The main contractor was involved in all stages of the project so that the goal of creating an economic, structurally efficient and aesthetically pleasing structure could be achieved. The team also worked in a 3D modeling program called REVIT, which led to digital design-led decision making and information sharing.

The external box gutter of the Arena was originally planned in concrete, however looking at the complexity of building scaffolding, supporting of a concrete gutter and fixing re-bar at > 15m high levels and weight limitations, as well as programme, it was decided to re-design the concrete gutter to a steel lattice curved box gutter approx. 4m high, with internal 3mm plate, formed gutter, These items were fabricated as complete units from column to column and lifted into position using a 220-ton crane. Rest of the Arena roof the only possible way of spanning 100m was possible with the dome type steer of with compression ring in the center.

The Design was driven by three elements

  1. a) Client Budget
  2. b) Buildability with site constraints being the construction of 100m roof and seating structure on a complete basement structure as the footprint of the site
  3. c) The programme, with end dates not moving due to events already booked year in advance for the opening

Detailing was done in Tekla, hand-in-hand with the engineers to determine lifting sizes and weights to ensure the steel contractor could erect the steelwork using the most economical plant.

It was important to see the 3D model for details such as sheeting and cladding and to model the lifting procedure and method statement.

Tekla was used to colour in the lifting elements with element weights, which made it clear to the engineer when approving the loads on the slabs and determining the crane positions on the slabs.

Fabrication was done in complete assemblies as far as possible, due to CADCON premises close to site we could transport abnormal loads not having to travel to far on the main highways.

We detailed in Tekla temporary jigging structures to simulate real-life fit positions, with this we could ensure that the assemblies fit with high precision on site.

Complete gutters were, trusses in two sections, back section complete and front section bolted on site, was fabricated.

Trial assembly of all elements in the workshop was done before shipping to site.

A further requirement, all the reinforcement for the main oblong columns were installed in the steel contractor yard and we had to include the weight of the reinforcing in the overall lifting weight of the main columns when doing the crane studies.

Erection was the most critical element. The Steel roof was located on a complete basement three levels down and the main roof had to be erected in just over 3 months excluding sub-structures.

We had to design the elements to be lifted with cranes which the slab could handle from a design point of view.

The process was as follows:

  • Max. Lifting weights were determined for all main assemblies
  • Crane positions were pinned all around the structure taking concrete structures, lift shafts, roadways into consideration
  • Max radius for crane lifts determined, which determined sizes of cranes
  • Back propping of the slabs had to be designed for each and every position
  • Back propping was erected in sequence to synchronize with steel erection programme, we could not back prop the whole basement due to the costs involved.
  • As we erected, the back propping was moved in the same sequence
  • Temporary cabling was used to stabilize elements where the complete structure not yet working as a whole
  • The biggest challenge was to have fabricated elements of this size off-site, bring to sit in sequence and have a civil contractor aligning them 100% with the steelwork methodology and giving their support throughout and all trusses between the gutter and main compression ring fitting perfectly with only a 50mm tolerance gap over a 100m span.

Main Arena, a total of 1375.699 tons and a bolt count of 17 939.

      • An internal diameter of 93.4m
      • External diameter 96.0m
      • Total roof tonnage 570.510 tons
      • Outer tension ring ‘box gutter’ size 2.5m wide x 3.9m deep with segment lengths of 15.5m and oblong steel column ‘hammerhead’ being 2.5m wide x 3.9m deep x 4m in length. Total of 16 segmented sections of 19.4m. Total tonnage 215.216 tons.
      • Internal cylindrical ‘compression’ ring; 7.95m x 5.975m high at 20.469 tons
      • Main arena and staging sub-grids and catwalks/cat ladders at 132.877 tons
      • Main arena plate girders and raking seating support beams with a total of 143.844 tons
      • 16 number of Oblong tube steel / concrete composite columns and tension ring ‘hammerhead’ at 292.783 tons

Mobilisation and erection challenges: While continuing with the main concrete superstructure, structural steel erection had to overlap with the concrete works in order to keep to the very challenging and demanding programme. This entailed back-propping of the newly constructed lower ground concrete floors down to the –B3 level, to allow access for multiple construction laydown zones and mobile cranes in excess of 80 ton, and in some instances 220 ton, to be positioned on the concrete floors for assembly of the compression ring, tubular space frame roof trusses, rigging sub-grids, catwalks, stage mechanics support structure and the placement of the raking steel beam structures to facilitate the final finished bond-dek seating structures.

  • Erection Methodology and Sequence of ARENA Roof and Seating: The steel contractor developed his Erection Methodology and Sequence to suit the main contractors concrete programme, concrete pour sequence, striving for minimum radius of lifting weights, maximum permissible slab loads using the minimum amount of back propping to determine the most economical choice of cranes to lift the Main Roof assemblies.
  • The Main Roof Assemblies included the following heavy lifts to be erected in the most economical way:
  1. 16 No Oblong Columns
  2. 16 No Radial Plate Girders > 1m deep
  3. 32 No Hammer Head Lattice Box Girders
  4. 16 No Radial Box Gutter Girders with 3mm Internal folded Gutter plate
  5. 1 No Central Compression Ring approx. 6m high rigged as one assembly
  6. 16 No Main Trusses spanning over 40m (this was spliced in 1/3 and 2/3 sections due to lifting weights)’

Originally two erection philosophies were considered:

  • Philosophy 1: Erection of all heavy lift assemblies as above being lifted from external lifting positions outside the Arena perimeter with a 600-ton crane.

This option was very costly, for the following reasons:

  1. Standing time in between the heavy lifts whilst waiting for infill steelwork to be installed using two tower cranes before next heavy lift.
  2. Transport logistics involved removing and re-installing mega cranes’ counterweights each time crane repositioned to new lifting position.
  3. Establishment and de-establishment of mega crane.
  • Philosophy 2: Erection of all heavy lift assemblies at a shorter radius from inside the Arena perimeter, but off the concrete slabs.

Advantages of this option:

  1. Majority of lifts were possible using an 80-ton crane
  2. Shorter radius lifts possible due to cranes standing inside Arena perimeter.
  3. Hook time of 80-ton crane vs 600-ton crane is much quicker during lifting operations.
  4. Back propping of the internal Arena slabs was required, which ensured heavier lifts being done using maximum 220-ton crane where 80-ton crane lifting capacity limited.
  5. All 220-ton crane lifts were sequenced as 1st priority, after which back propping could be removed and use of this crane time limited as far as possible.
  6. Infill steelwork was done again using two tower cranes.
  7. Main assemblies were also spliced in such a way to limit lifting weights and temporary props designed to support the assemblies at the spliced positions. i.e. Main trusses spliced as a welded back segment 3rd of truss and front segment 2/3rd as bolted assembly on site.

Erection Philosophy 2 proved to be the most advantageous in terms of cost and time for contractor and client.

Main Challenges – Fabrication and Erection:

Planning had to be done from shop detailing stage, to ensure complete assemblies fit on site and erection weights being considered taking into account the crane/ lifting philosophy followed to limit erection costs and back propping as far as possible.

CADCON designed temporary workshop jigging, which was detailed in X-steel and built to make sure when the complete gutters girders, hammerhead structures and roof trusses built, it would fit x 100% on site.

In essence, the complete roof assemblies built in workshop, and bolted spliced where the assemblies suited best the transport route from Centurion to Menlyn, whilst also considering each assembly maximum lifting weights. Weights were pre-determined in Tekla and indicated on the Erection Methodology, also indicating maximum crane lifting radius.

This ensured that slabs and cranes were not overloaded on slabs where activity were 24/7 with labour and surrounding main contractor plant, tower cranes, etc.

Further challenges:

  1. Oblong columns

The external perimeter columns – “oblong columns” consisted of 1,2m high oblong rolled plate, welded together in segments to form the external plate columns 13m-16m high. The oblong columns were fabricated from 16mm plate and internally fitted with 120 x 60 RHS sections to prop the external face of the columns to ensure all stay aligned when the 16mm plate welded and the heat added. Studs and mesh were welded internally to provide the working of a composite column.

The oblong columns were fitted with rebar internally. The steel contractor fitted with the help of the steel re-bar supplier the reinforcement inside the workshop, to avoid this activity not possible to fix if the oblong columns already erected. From a practical and programme point of view, it made sense to fit the reinforcement in the workshop.

HD- bolts were designed to receive the oblong columns and a cable/prop stay system was also developed and designed by the steel contractor and main contractor to support the oblong columns after erected and the trusses not yet installed.

 It was a requirement that the full circle had to be erected, after which the cable/ prop system would remain in place during the concrete pumping of the oblong columns. To assist the pumping of the oblong columns with concrete, the steel contractor fitted nipples to each Oblong column, which used to pump concrete from bottom up in each oblong column

  1. Compression Ring

The Compression ring was completely built as a bolted assembly standing over 6m tall in the workshop.

After The compression ring pre-assembled x 100%, it was dismantled and sent to site in loose elements.

The compression ring had to be installed x 100% centrally to the Arena and at the correct level to ensure the roof trusses fit. To achieve this, a central scaffold tower was designed by Form Scaff in conjunction with the WSP and the main contractor.

The arena slab receiving the scaffold tower had to be back propped 3 floors down to the lower level surface bed.

At the base of the scaffold tower, sand release jacks were built and positioned under each scaffold prop by CADCON.

Main roof trusses were installed in segments supported from temporary designed columns to limit truss lifting weights and limit crane loadings on the slab.

Once all the trusses were installed in opposite sequence segments and all infill steelwork complete, the scaffold tower had to be lowered. Releasing the scaffold was done by washing the sand from, the sand jacks systematically, after which the roof lowered by approximately 80mm over the 95m spanned roof.

The engineer calculated the roof under full load with sheeting and stage sub-grids, the roof would settle 150mm lower from the compression ring scaffold platform level.

A remarkable achievement of this Arena installation, that it took only 2,5 months to install all roof and infill steelwork after the compression ring was installed and leveled on the central scaffold support tower.

The Overall Arena installation from 1st steelwork being the oblong columns to the release of the compression ring – 19th of October 2016 to 15th of May 2017, approximately 6 months.

After the main roof was released, supported off the compression ring scaffolding platform, the following installations proceeded.

  1. Roof Sheeting
  2. Main sub-grid suspended with hanger system off roof
  3. Lower and upper stages

What made this exceptional, was the teamwork required between the steel contractor, main contractor and engineers which all had to work in harmony, trusting each other views and coming up with the best plans to execute such a complex roof and sub-structures of over 1500 tons in this short period of time, with a client which gave their backing in all circumstances during the process to ensure the end goal achieved to open to the public on time and produce revenue.

STRUCTURAL STEELWORK
Tons of structural steel used Approx. 1 800 tons
Structural profiles used Tubular Steelwork up to 1000mm diameter in roof,  Hot rolled in Sub-grid and Seating

Project Team

Nominator CADCON (Pty) Ltd
Client/ Developer SUN INTERNATIONAL
Architect LYT Architects
Structural Engineer WSP
Quantity Surveyor MLC
Main Contractor WBHO
Steelwork Contractor CADCON (Pty) Ltd
Steel Erector On Par
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Chartwell Roofing
Corrosion Protection
Paintwork Contractor
Dram Industrial Coatings

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
.

Graskop Gorge Lift Structure

What is the purpose of the structure/ project?

To create an exciting and popular tourist stop over point on the Panorama Route at Graskop, Mpumalanga. The gorge has established itself as an adventure destination through the Big Swing, which is a well-known operation, so there had been some “human footprint” in the gorge for a while. The client wanted to expand on the adventure concept and added the lift and interactive walking trail in the rain forest below. The purpose of the structure is to accommodate the glass viewing panoramic lift taking visitors 51m down the face of the Graskop Gorge into the forest below, where wooden walkways and suspension bridges meander along a 600 metre trail through the indigenous forest with interactive exhibits.

What was the brief to the architect?

To design a lift shaft structure to accommodate the panoramic glass viewing lift for the Graskop Gorge Lift Company, as well as the buildings around the panoramic lift at the Graskop Gorge Adventure Centre. The site was chosen adjacent to a structure for informal curio traders and a protruding rock outcrop which had been a viewing point with a small pub. This was the ideal position for the lift shaft. The brief was to incorporate the traders into the adventure tourism complex and upgrade the existing structure. The centre should accommodate the ticketing office, shops of various sizes, a restaurant and general viewing areas for the public. Support services for the centre also had to be included. The servicing of the lift required easy access to the lift motor room. A viewing platform was subsequently added around the lift motor room as an extension to the public deck.

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

Yes. Structural Steel was the choice of material for the Lift Shaft Structure from the beginning. Reasons include compatibility with the lift installation, and the open truss-like nature of the shaft structure to simulate the waterfall on the opposite side of the gorge.

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

The distance from the base to the top of the shaft is 60m, with the total vertical lift travel distance of 51m. The shaft structure was designed as a vertical structure with two top fixing points apart from the fixing at the concrete base. UC 305x305x97 H-profiles were used for the 6 main shaft columns, because adequate l/r ratios were required for 10m segment lengths. Each segment was fully braced using 63,5×3 and 88.9×2,5 Circular hollow sections cross bracing between 203x133x25 UB lateral stiffness beams. 305x165x46 UB profiles were used for the access platform beams at the top of the shaft with 80x80x6 Angles for bracing. UC 152x152x23 profiles were used as knee brace elements to support and fix the top viewing platform to the main shaft structure.

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

Cladding formed a minimal part of the Shaft Structure itself, only the top machine room side walls and roof received IBR cladding after the access platform to the machine room 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.

A national shortage of 305x305x97 H profiles, required the design to be altered to use 254x254x73 in the top part of the shaft. For the erection of the shaft a 70 tonne crane was planned, but it would require the crane to be too close to the edge of the cliff, and the crane cables were too short to reach the 51m deep bottom.. Instead a 9 tonne Spierings Mobile Tower Crane had to be hired that could lift 2.5 t per lift at a 27m reach, with adequate cable length to reach down to the bottom.

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

The exquisite setting of the lift shaft structure opposite the Panorama Waterfall forms a truly aesthetic pleasing view from a distance, with the natural waterfall at one side of the gorge and the grey coloured, open truss-like lift shaft structure simulating the waterfall on the opposite side of the gorge, forming a beautiful parallel with each other.

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

Two weekly formal project meetings were conducted with a formal “Request for Information” procedure that were frequently communicated and updated per email between the various team members.

Tons of structural steel used 110 t
Structural profiles used Hot rolled H-profiles, hot rolled I-profiles, Angle profiles, circular hollow sections
Cladding profile/ type used IBR
Cladding area/ coverage and tonnage 1100m2    2.8 tons

Project Team

Project Team Role Company
Nominator Fourie Consulting Engineers
Client/ Developer

 

 

Graskop Gorge Lift Company

In partnership with the NEF

(National Empowerment Fund)

Architect Förtsch and Associates Architects
Structural Engineer LEW Consulting Engineers (Pty) Ltd
Engineer LEW Consulting Engineers (Pty) Ltd
Quantity Surveyor Siyakha Quantity Surveyors (Pty) Ltd
Project Manager Purlin Consulting
Main Contractor ENZA Construction (Pty) Ltd
Steelwork Contractor Quality Steel Construction (Pty) Ltd
Steel Erector Quality Steel Construction (Pty) Ltd
Cladding Manufacturer Safintra (part of the Safal Group)
Cladding Supplier Safintra Roofing Nelspruit (part of the Safal Group)
Cladding Contractor Roofing Solutions CC
Corrosion Protection
Galvanising
Babcock Nthuthuko Powerlines (Pty) Ltd
Photographer, Photo competition Förtsch  and Associates Architects
Photographer, Other submitted images Förtsch and Associates Architects

ENZA Construction (Pty) Ltd

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.

Club 2

The new Club 2 Building in Hazelwood, Pretoria, is set to become a landmark property in the city. The modern, industrial yet retro look and feel, combined with the striking curved roof, has made it a hotspot for local tenants.

In 2015, Atterbury Properties appointed Hofman Architects to design a space that would accommodate a gym as well as office spaces. Situated on the corner of Pinaster Avenue and 18th Street in Pretoria, Club 2 builds on the prestigious Club One office building that was designed and completed in 2011. The five office floors of Club One are leased to the University of South Africa, with popular retail areas such as Hogshead Craft Beer and Hudsons The Burger Joint occupying the ground floor section.

The brief from the client to the architect evolved over time.  Initially, the brief was to design a building for Planet Fitness on the intersection South of the precinct, with an office component to make up the bulk on the Northern end of the property.  When the design was presented, Atterbury was so impressed that they decided to move their head office to the new building. 

This decision changed the brief to the architect in a few ways. The office component had to mirror the design of the client’s offices and it had to move to the prominent South corner of the building. The gym, in turn, had to move to the Northern section of the property without it losing visibility and exposure from passers-by.

The ideal design for a gym of this magnitude is a “warehouse” type structure.  With this in mind, the design was always envisaged as a steel structure. The office component has a beautiful, industrial theme, which can easily be accommodated by steel structures.

The building is constructed of a curved portal frame structure with large I-beam sections. 

The roof cladding that was specified for the project is KlipTite by Global Roofing Solutions. The cladding was cranked around the curves of the portal frames with custom made flashing detail to accommodate the curved roof.  The walls were constructed out of a combination of brickwork and the Imison lightweight wall system.

One challenge that the design team encountered was cladding the curved radius of the large section I-beams.  To overcome this challenge, these sections were manufactured and not rolled. Ensuring that the exact placing of these sections aligned with the columns on site was challenging, as were the flashings that were needed. The design team had a few flashing prototypes made and in the end a custom designed flashing had to be created to accommodate the curved roof.

The curved portals on the property are particularly unique, innovative and aesthetic. The portals step up and down over box gutters to let natural light into the interior spaces, and they step in and out over the façade to create deep overhangs to accommodate shaded public spaces over the entrances of the building.  This design element is what gives the building its unique appearance. 

When working on a steel structure, attention to detail is of paramount importance as any design flaws and errors can be quite unforgiving. The contractors, engineers and architects worked well together to resolve any details as and when they arose. Ongoing inspections of the steel work and a culture of collaboration and innovation led to the successful outcome of Club 2.

Cladding profile/ type used Klip-Tite
Cladding area/ coverage 3400m2
Cladding tonnage 18 Tons

Project Team

Project Team  Role             Company
Nominator Global Roofing
Client/ Developer Atterbury
Architect Hoffman Architects
Structural Engineer DG Consulting
Quantity Surveyor
GK Project and Cost Engineering
Main Contractor Wilson Bayly Holmes Construction
Steelwork Contractor LTS Steelwork
Steel Erector LTS Steelwork
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Cladco

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.

Shoprite Climor Distribution Centre

The Shoprite Cilmor Distribution Park is the latest installation of the national distribution center rollout for the owner/operator client, Shoprite Checkers. The project comprises more than twenty buildings, the largest of which are three warehouses serving as the core of the development. The biggest is the 76,000m2 Dry Goods warehouse, followed by the 18,000m2 Refrigerated Building and the 12,000m2 Returns Centre.

The architectural brief was to deliver purpose-fit infrastructure that is aesthetically pleasing, given the facility’s prominence from the adjacent freeway and surrounding neighbourhoods, while also maximising the value of the client’s investment. The architectural and structural teams collaborated closely to allow function to define form, yet ensure refined aesthetics and a wow-factor to the overall appearance.

Structural steel was the natural choice to realise the large open span roof structures and curved architectural features. The operational design required a 32x32m internal grid for the ambient warehouses and 24x24m for the refrigerated warehouse. No construction material other than structural steel could achieve the same construction economics for these light-weight, large-span roof structures under the given programme constraints.

The design of the buildings and the subsequent construction methodology were all centered around safe and fast erection on site, delivering a light yet failure-tolerant structure. The buildings are stabilized by large cantilevering concrete tilt-up columns that were constructed during the fabrication period of the steel. The largest of these columns was 24.3m tall, weighing more than 44tons. Starting off with a stable structure greatly reduced the risk during the erection of the long-span structural steel girders and trusses.

The girders were built-up from horizontally orientated UB chords laced with double equal angle web members. This configuration allowed optimized utilisation of the material and produced a girder that was easier to handle on site due to the lateral and torsional stiffness of the box-shaped assembly. The trusses for the ambient warehouses were classic lattices made from equal angle chords and web members. To provide a flat fixing surface for the refrigeration panels, the trusses for the refrigerated buildings were also boxed lattices with channels as chords.

The connection design and detailing, especially for the girder-to-column and truss-to-girder nodes, also aimed at a reduction of risk during the erection process. All major connections are first seated and secured, after which the main structural bolts or plates are fastened. This greatly reduced handling of heavy bolts and plates while girders or trusses were suspended from cranes.

The appointed specialist steel contractor, Mazor Steel, delivered 2963 tons of structural steel on time and to highest quality standards following a strict safety plan under constant scrutiny by main contractor, Stefanutti Stocks, who achieved over one million lost-time injury free man-hours on this project.

The size of the building and the resulting rainwater run-off lengths of the Dry Goods building supported the choice of a curved roof structure for these buildings. As a result of the curve, the roof angle increases with increasing run-off length, thus improving run-off performance of the roof. A jointless sheet transition from -0.5° to 0.5° was incorporated at the apex of the roof in order to avoid a large flat zone. Typical step laps were detailed to facilitate watertight installation and minimise the effects of temperature strain with the first sheeting laps occurring at slopes of more than 2°.

In order to ensure transparency of the sheeting tender, all tenderers were required to submit test compliance data as an entry criterion to the bidding process. This data was to be derived using the methods of the draft cladding code, SANS10237, which is in development by the South African Metal Cladding and Roofing Association.

Scheltema won the sheeting tender with GRS KLIP-TITE as the product of choice, rolled from Safal’s Colorplus Matte AZ150. Similar to the structural steel erection, the contractor deployed safe erection methods far above industry standard while tight collaboration between Safal, GRS, and Scheltema ensured a high-quality installation with an uncompromised guarantee for the client.

The project was completed on time and within budget while impressing with outstanding design and way-leading quality of works.

Tons of structural steel used ± 2 963 tons
Structural profiles used UB, UC, C, EA, CFLC, CHS, SHS, RHS
Cladding profile/ type used GRS KLIP-TITE™ roof sheeting, IBR side cladding
Cladding area/ coverage 118,140m2 roof surfaces, 19,914m2 side cladding
Cladding tonnage ± 787 tons

Project team

Project Team Role Company
Nominator WSP Group Africa (Pty) Ltd
Client/ Developer Shoprite Checkers Properties
Architect Steyn le Roux Truter
Structural Engineer WSP Group Africa (Pty) Ltd
Engineer WSP Group Africa (Pty) Ltd
Quantity Surveyor iQS
Project Manager SiVEST
Main Contractor Stefanutti Stocks
Steelwork Contractor Mazor Steel
Steel Erector Mazor Steel
Cladding Manufacturer Global Roofing Solutions (Pty) Ltd
Cladding Supplier Safal Steel
Cladding Contractor Scheltema
Corrosion Protection
Galvanising
Advanced Galvanising (Pty) Ltd
Corrosion Protection
Paintwork Contractor
Nu Nation Protective Coatings
Photographer
Photo competition
WSP Group Africa (Pty) Ltd
Photographer
Aerial photographs
Subiaco Photography

 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.

Campus Square

Campus Square is a convenience centre situated on the corner of Kingsway and University Road, Melville. Anchor tenants include Pick ‘n Pay, Woolworths and a new Dischem, while the restaurant offering includes an upgraded Dros, RoccoMamas, enlarged Wimpy and a new Nandos. The Centre offers food, shopping, and convenience all under one roof and it is loyally frequented by students of the nearby University of Johannesburg.

The centre was recently extended and the brief to the architect was to create a very lightweight steel roof, with sidelights facing south to avoid heat gain.  A curved aspect was required on the sidelights to create a unique appearance. 

The extension of Campus Square was envisaged in steel from the start. Structural steel trusses (consisting of angles) at an average depth of 1m were used to span between 12 – 25m. I-beams were used where the roof span was less than 12m.

When tying into an existing building, there are usually unforeseen challenges that arise. With the extension of Campus Square, the existing building dimensions were not exact and the on-site dimensions weren’t measured prior to fabrication, which lead to the design team requiring additional brackets that had to be designed to enable the elements to span from column to column.

Another challenge that arose was that the designed steel members weren’t always available when they were needed, which delayed the construction process. To overcome this challenge and meet the deadline, a similar sized element was then identified and specified for the project.

A further challenge was dispensing of water off the existing roof which had a large number of steps and angles and new roof which was higher, a large concrete gutter had to be created between the two roofs, which in turn was used to support the steel structure.

The roof is undoubtedly an innovative aspect of the project. The roof was designed according to the minimum requirements as specified by the code, which resulted in a very light weight roof. Klip Lok 700 by Global Roofing Solutions was specified for the 8000m2 roof.

Fortnightly meetings were held where the professional team and contractor would discuss issues, progress and program to ensure the project runs smoothly. The end result is a successful extension of a widely popular convenience centre in Johannesburg.

Cladding profile/ type used KlipLok 700
Cladding area/ coverage 8000m2
Cladding tonnage 4,8 Tons

Project Team

Project Team Role Company
Nominator Global Roofing Solutions
Client/ Developer Key Stone properties
Architect Hammerhead Designs
Structural Engineer Axiom Engineers
Main Contractor Gothic Construction
Steelwork Contractor Nance Engineering
Steel Erector Nance Engineering
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Chartwell Roofing (Pty) Ltd

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.

Bosch Warehouse

Bosch is a prominent supplier of home appliances in South Africa. The company required a new factory and warehouse facility and appointed Empowered Spaces to design a facility that would ‘wow’ their staff and guests. The brief to the architect for the new facility, which is located in Witfontein opposite the Serengeti Golf Estate, was to design a factory and warehouse that ties in with the company’s corporate standards.

The warehouse was envisaged as a steel structure clad in sheeting from the start as this is renowned as the most efficient and cost-effective way to construct a warehouse. The structural framing consists of grinder trusses and a steel column structure which is supported by precast concrete columns.

What makes the new Bosch warehouse and factory unique is the use of corrugated iron sheeting, as this isn’t often specified for large warehouse structures. 125 tons of cladding was supplied to cover the 20 574m2 of warehouse area. Global Roofing Solutions’ Klip-Tite was the chosen steel sheeting for the project.

To speed up the construction process on site, the project team was appointed far in advance. This enabled the design team to issue the contractor with appropriate information ahead of schedule, which led to quick and efficient construction on site. The result is world-class warehouse that fits with the Bosch’s corporate brand and profile.

Cladding profile/ type used Klip-Tite
Cladding area/ coverage 20574
Cladding tonnage 125 Tons

Project Team

Nominator Global Roofing Solutions
Client/ Developer Bosch
Architect Empowered Spaces
Structural Engineer Kantey & Templer Engineers
Quantity Surveyor IBP Construction
Main Contractor Bantly Construction
Steelwork Contractor Steel Band
Steel Erector Steel Band
Structural Steel Detailer KRU Detailing
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding Contractor Roofline

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 Paint Shop re-roof

What is the purpose of the structure/ project?

Refurbishment of current paint shop.

What was the brief to the architect?

Remove leaking paint shop roof and replace with a thermally efficient built up roof system.

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

Innovation, twin skin built up metal roof system with uncompressed insulation, to correctly and   accurately provide the desired R value.

Difficulty short duration on project, over Christmas period in JHB’s rainy season, no extension of times were allowed, so continuous project acceleration was required.

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

Double skin, and larger than normal flashings. Over 75 penetrations in the roof with no back flashings.

Cladding profile/ type used Tufdek IBR Saflok 700
Cladding area/ coverage and tonnage 24000m²

Project Team

Project Team Role Company
Nominator Safintra
Client/ Developer BMW
Structural Engineer Nyletti Structural

Engineers Pretoria

Main Contractor MRC Group
Cladding Manufacturer Safintra South Africa
Cladding Supplier Safintra South Africa
Cladding Contractor MRC Group
Photographer, Photo competition Sublime Film

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.

33 Baker Street

What is the purpose of the structure/project?

 To upgrade a very old building, to accommodate multiple tenants of which the main tenant is Standard Bank.

What was the brief to the Architect? 

To convert the existing building into a contemporary design with a status commensurate with the expectations of Sasol Pension Fund and Standard Bank as a tenant.

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

The curtain wall application to an existing concrete structure demanded a steel frame to achieve a modulated façade.

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

 Mostly I-Beams with angular trusses was used to hold the roof.

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

In view of the fluctuating conditions inherent to the existing concrete structure, it was required that steel substructures be designed which would have sufficient adaptability to address the different conditions whilst being able to achieve a modulated curtain wall design.

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.

Baker Street at its core was an upgrade of a current concrete building that was to be equipped with new structural steel to accommodate impressive looking glass and facades with paneling on the exterior. Essentially the overall appearance of the building was to be modified. The problem was getting accurate and existing concrete dimensions from site to work with the new Engineering/Architectural changes.

The Engineering drawings which was received had rugged ideas of what was required, in terms of the structural steel and, for a job like this, accurate measurements were of utmost importance.

In the end consultation and coordination between the Architects, Engineers, Glass-and Curved Façade team members, and Sheeting members had to work inwards from the outer most edges of the sheeting and glasswork.

However, the information provided by SVA, with regards to where everything had to be, completed, and getting the required support structures in design form, from the Engineers, allowed the Structural Steel Detailers to reconstruct what was needed from the ground up. The required structural steel did fit in, although tightly in places, but worked. Coordination on this level made everybody sure that everything would accurately fit in the end, especially using the exact three-dimensional (3D) Tekla models as well as proper DWG drawings, where everyone was able to double-check everything on their end. What followed from the new type of coordination with the Structural Steel Detailers leading the way was:  Problems being sorted out quickly in meetings, with nothing left unanswered where after it was checked and updated after meetings between all parties.

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

The steel frame principle allowed sufficient flexibility to achieve a curtain wall cladding accentuated with aluminum solid elements as well as utilizing the steelwork at roof level to support a balcony structure. The essential idea was to achieve a simplicity of structures that could be erected within a limited time.

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

The design demanded a meticulous coordination of the Engineer’ requirements, the curtain wall shop drawings and the detailing of the solid aluminum elements during the pre-contract documentation stage and on-site construction. The coordination of the various disciplines, as well as management of the process on-site, proved to be efficient.

Tons of structural steel used 210 Tons
Structural profiles used Hot Rolled I-sections, Angles & CFLC

Project Team

Project Team Role Company
Nominator KRU Detailing CC on behalf of Central Welding Works
Client/ Developer Redefine- Sasol Pension Fund
Architect SVA Architects
Structural Steel Detailer KRU Detailing CC
Engineer Sutherland
Quantity Surveyor Matla
Project Manager TPM project management
Main Contractor WBHO
Steelwork Contractor Central Welding Works
Steel Erector Central Welding Works
Cladding Manufacturer Hunter Douglas (Fancy Facades)
Cladding Supplier Hunter Douglas
Cladding Contractor Hunter Douglas
Glass Facades Diri Glass (Glass Facades)
Rigging/Cleaning Rails Gravity Access
Photographer, Other submitted images Central Welding Works

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.