Nike – Pulse

The Brief

A ‘linear sculpture’ fabricated in Grd 316 stainless steel and consisting of approximately 200 vertical members all supporting triangular, faceted panels which may interconnect in some instances.The entire sculpture to be assembled in Johannesburg and then dis-assembled and packed for shipping to Oregon USA.

Planning

Being able to interpret one mans abstract vision into a physical entity is a skill few people would possess.So, begun an intense series of planning meetings, idea swopping, mock up builds and lot of trial and error.Once again technology played an important key role as ideas became drawings and concepts began to take physical shapes. A strong partnership between the design team and the fabricator very quickly saw practicalities being introduced to the various mock ups and the individual shapes started to become recognizable as multi-dimensional sculpture began to form.

The Build

Several weeks of extremely detailed planning coupled with many hours of highly intricate detail drawing saw over 400 completed parts arriving at the fabrication shop. Each part an individual shape or cut and all carefully numbered were subjected to an intense polishing process before being set out in carefully prioritized sequences ready for assembly.

Each assembled component was certified by a member of the design team as he checked every angle, position and assembly order, before once again being processed through the polishing systems. The base, in total over 20mts long, was constructed in 8 individual sections consisting of 2 lasers cut 5mm plates separated by 150mm spacers, and fitted with tubular sleeves at specific angles, which would support the vertical members. The base sections were bolted together to from a waving ‘snake like’ platform which would be positioned into a water feature at the site.

The 180 vertical members are Ø38 tubular sections each with uniquely laser cut slots to accept the faceted plates. Each of the 300-laser cut 3mm plates were uniquely shaped and precision bent at various positions and welded into slots on the vertical posts.The vertical members are then slot guided into the sleeves in the base unit and the faceted plates form a multi- dimensional figure of a runner, which morphs into another figure as one moves along the length of the structure.

Packaging

The components, after a final touch up polish, were wrapped in bubble wrap and carefully tied down into timber crates, with great care being taken to avoid the possibility of chaffing on a long sea journey.

Intricate packaging lists were compiled indicating every position of each component in the crate, which would assist when unpacking in Oregon. Crates were sealed at the fabrication shop before travelling by road to Durban, by sea to New York and then by train to Oregon before a final road trip to the site, Nike’s new World Head Office. Spiral Engineering’s commitment to quality and professionalism have once again been recognized and we are honored to have been appointed as a partner on this prestigious International project.

STRUCTURAL STEELWORK
Tons of structural steel used 5 Tons
Structural profiles used All Grade 316 Stainless Steel Structure, Base Plates 6 thk, CHS Posts at angles, and 3mm bent shaped plates at precise angles and positions. All components CNC Laser Cut and bent to fit in exact position and angles.
SA content Design, supply, fabrication, polishing and Packaging 
Cost of steelwork Fabrication and packaging R 2 million.

Stortemelk Hydropower

Architect’s Motivation
Situated in the rolling foothills of the Drakensberg Mountains, along the banks of the Ash River, the Stortemelk Hydroelectric Plant attempts to celebrate the importance the plant holds in producing clean, responsible electricity in South Africa.

Comprised of a number of building skins, the design approach intended to create different experiences of the plant from the exterior, & from within the interior. Clad in Corten Steel & Polycarbonate sheeting, the architecture is intended to be of its landscape, while still allowing for good light quality to penetrate into the plant interior. Articulating the façade with slotted window openings allowed for the perception that the electrical production of the plant is spilling out into the surrounding environment, creating a beacon in the landscape.

On approach to the site, the Corten Sheeting reaches up into the skyline, announcing the building & adjacent river from a distance. The lightness of the steel construction is then contrasted by the far more stereotomic design of the rest of the plant, which protrudes from the river bank as a plinth.

The challenge in the project was to create spaces for production, with minimal human interaction. Working hand-in-hand with an exceptional client made the realization of this celebration of production possible, creating architecture with respect for the responsible electrical generation the client creates.

Client motivation:
Our company carries a certain ethos that is core to every enterprise we undertake, namely the responsible production of energy in a South African context.

Our brief for the Ash River site was to create a housing for a hydro-electric plant that blended seamlessly with the surrounding landscape while also celebrating the responsible production of electricity. Many of our hydroelectric sites have been in operation for decades, which therefore require an approach that does not become a burden on the landscape or surrounding community.

The response to this brief from the architect achieved every aspect that we required, succeeding in both blending into the landscape, while also celebrating the plant’s functions. Beyond this, the design managed to create a spectacular light quality in the work areas of the plant through the use of polycarbonate sheeting.

The plant stands as the perfect mediation between the production of electricity from the river, & a well-considered addition to the Golden Gate landscape. In its entirety we believe this piece of production architecture fits wholly within our ethos of responsible creation, standing as a testament to what can be achieved without negatively affecting our unique countryside.

Profiles used 406 x 140 x 46mm galvanized steel I-Beams & Columns, IPE-AA 120 galvanized, IPE 200
Type of cladding 3mm Corten sheet panels & polycarbonate sheeting

Project Team

Project Team Role Company
Nominator earthworld architects & interiors
Client/ Developer REH Group
Architect earthworld architects & interiors
Structural Engineer Aurecon
Main Contractor Eigenbau
Photographer, Photo competition CHARLES CORBETT PHOTOGRAPHY
Photographer, Other submitted images earthworld architects & interiors

 

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 events 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 roofspan 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 centre 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 modelling program called REVIT, which led to digital design-led decision making and information sharing.

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

Project Team Role Company
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 Contractor Chartwell Roofing
Corrosion Protection
Paintwork Contractor
Dram Industrial Coatings
Photographer, Photo competition SUN INTERNATIONAL

 

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

 

GO DURBAN INTERGRATED RAPID PUBLIC TRANSPORT NETWORK (IRPTN)(BUS STATIONS)

What is the purpose of the structure/ project?

Construction of Prototype bus station for as part of Integrated bus rapid transport system

What was the brief to the architect?

To design and create a visually pleasing structure with Universal access, be Energy efficient, be ahead of current times, and take Durban Integrated rapid transit into the future.

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

Generally square hollow tubing was used on most structural members, due to its light weight and excellent structural strength properties. Custom made hollow tubes had to be manufacture for the front and exit canopy legs, for aesthetic requirements.

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

The project does not consist of any radically new innovation, but rather a creative way of using some common construction materials to create a homogeneous and appealing structure, which involved the erection of a structurally stable steel frame, which was then covered with steel roof and clad with a glass façade.

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

Internally the roof has been insulated and the profile of the structure followed with an aluminium ceiling. This ceiling houses the light fixtures, and other emergency services required for puplic buildings.

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 detailed coating spec was required for long term protection of the structural elements, due to the proximity to the ocean and industrial fallout in the area. This required all structural steel member to be galvanised and coated with a duplex paint coating system. The initial project specification required frame member be continuously welded and no bolted joints allowed.  Due to the length (slenderness) and shape(U) of the portal frame members, and possible distortion of structural member during the galvanising process, full galvanising of the originally designed members proved to be impossible without possible areas of coating weakness due to site welding. It was recommended to the engineer that a bolted joint be placed in the structural elements, hidden from view, in the ceiling/roof area. Thus reducing the size of the elements and improving handling of the elements, the ability to fully apply the specified coating systems, this would all  could be achieved without disturbing the long slender appearance of the legs, that the architect required.

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

The construction of project specific box sections for the front and exit canopies, to achieve the correct angle and shape required. Using 3D software non-standard box section were created to support the front and exit canopies

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

The project team had to work closely with the architect, numerous changes were made to the structure initially (front and exit canopy) due to the specific planes and angles required to match the anticipated glass façade structure. 3D software was used to create the structure and ensure that the finer details could be achieved.

Tons of structural steel used 25 TONS
Structural profiles used CFLC 125x50x2.5 ; CFLC 100X50X2.5 ; UB 203X133X25

SHS 200X200X4.5 ; SHS 150X150X4.5 ; SHS 60X60X4.5

RHS 200X100X6.0 ; RHS 160X80X5.0 ; PLATES – 20MM;

16MM; 8MM; 6MM; 3MM; ANGLE 150X150X10 ;

UNEQUAL ANGLE 150X75X10 ; ANGLE 70X70X6 ;

ANGLE 40X40X3 ; FLAT BAR – 25MM, 20MM, 12MM;

8MM, 6MM, 5MM ; ROUND BAR – 60 DIA.

Tons of LSF used 5.257 TONS
Span of trusses and Kg/m2 (if applicable) 200 Meters of Balustrading
Profiles used 75×3 CHS S/S ; 80x40x2.5 RHS ; 20 RB ; 50×3 CHS S/S ; 10 RB ; 60x60x4.5 SHS ; 100x50x4.5 RHS ; 60×10 FL BAR
Type of cladding Hunter Douglas – Ceilings and Louvers
Cladding profile/ type used Brownbuilt Klip-Lok 406 (roof)
Cladding area/ coverage and tonnage Area 466m2

Project Team

Project Team Role Company
Nominator Shesha Engineering
Client/ Developer eThekwini Municipality
Architect Iyer
Structural Engineer Linda Ness Associates
Engineer (Site) MCA
Quantity Surveyor LDM
Project Manager MCA
Main Contractor Phayindani J.V
Steelwork Contractor Shesha Engineering
Steel Erector Shesha Engineering
Cladding Manufacturer HB Interiors

MJ Cheater Roofing

AGS Glass fibre

Cladding Supplier Hunter Douglas

City glass

Global roofing

Cladding Contractor HB Interiors

MJ Cheater Roofing

AGS Glass fibre

Corrosion Protection
Galvanising
Pinetown Galvanising
Corrosion Protection
Paintwork Contractor
Scott Clean
Photographer, Photo competition Lisa Woest Photography
Photographer, Other submitted images Qanza construction

New Facilities Centre for Durban Girls High School

PURPOSE OF THE STRUCTURE:

To house a large indoor, multi-function space as a major educational facility for a premier girls high school and to increase their hall accommodation from 400, built in 1938, to 1400.

BRIEF TO THE ARCHITECT:

To create an indoor space capable of housing:

  • The school assembly hall and exam
  • An indoor playing field to comply with Olympic specifications for indoor
  • Use for indoor basketball, volleyball, badminton and
  • Multifunction venue for dramas, dances, fashion shows and
  • Stepped viewing terraces to seat 250 persons. Form of Building:
  • Essentially an industrial “shed” with various beautiful “diamonds” on it, as per the Porte’ entrance, stonework, raw hardwood terraces, facebrick, frameless glazing panels and timber movable ventilation
  • Elements of “African” identity are introduced as per curved walls, raw circular stonework, with chevron truss lattices reflected in side cladding polycarbonate V shaped
  • Main entrance Porte’ celebrates the existing outdoor court, and acts as a visual focus and entry inducement into the main space using tubular “tree”
  • Curved facebrick walls guide the ingress into the “shed” under the curved Porte’
  • Off shutter concrete, coated steel, raw hardwood timber and facebrick finishes are juxtaposed in achieving a low maintenance and a “raw” material
  • Environmental conservation to achieve a “green” building was applied where possible. eg. Water harvesting, no mechanical ventilation and utilising roof light daylight

BRIEF DESCRIPTION OF THE STRUCTURAL FRAME:

  • An aesthetic decision was made to express the dynamics of a steel clear span structure, integrated with the translucent sheeting panels of the gable frames and south
  • The roof trusses feature tubular sections with profiled gussets framing into H section top
  • The purlins are standard cold rolled lipped channel
  • The terrace seating, stairs and handrails express

CHALLENGES IN THE FABRICATION OF THE PROJECT:

  • Approximately a third of the truss was erected as a temporary roof at first floor hall level during an earlier
  • To complete the Project the new roof was site connected to the existing structure and re- erected at the higher new roof
  • This required challenges in the site fabrication and restricted erection

INNOVATIVE AESTHETICS ABOUT THE STEELWORK AND CLADDING:

  • The Porte’ and main roof have intersecting curves on the main roof
  • Gable sheeting girts reflect truss V forms with silver heat polycarbonate sidelights which create a chevron lit graphic inside in the day, and externally at

THE PROJECT TEAM CHALLENGES:

  • Due to limited access to the site, being within a wooded suburban area adjacent to a swimming pool, the methodology of construction and erection required a team
  • The Main Contractor further shortened the steel construction critical path by 3 months, necessitating close co-ordination between Architect, Engineer and Steel

It is considered that the integrated aesthetic form of the tubular section roof structure, exemplifies the use of steel construction in public facility buildings, in an urban environment.

STRUCTURAL STEELWORK
Completion date of steelwork September 2017
Completion date of full project February 2018
Tons of structural steel used 46 tonnes
Structural profiles used Tubular, Hot and Cold Rolled
SA content – if this is an export project 100%
 Cost of steelwork R3685000.00

 

CLADDING
1.    Completion date of cladding October 2017
2.     Cladding profile/ type used Colour Coated Saflok 700
3.     Cladding area/ coverage and tonnage 2650sqmeters, 16 tonnes
4.     Cost of cladding R1003250.00

 

Project Team

Project Team Role Company
Nominator Young and Satharia
Client/ Developer DBN Girls High School Governing Body
Architect Neil Hayes-Hill Architect
Quantity Surveyor Edgecomb & Hayes-Hill
Main Contractor Nichol Projects (Pty) Ltd
Steelwork Contractor Ogilvie Engineering (Pty) Ltd
Cladding Manufacturer SAFINTRA
Cladding Supplier SAFINTRA
Cladding Contractor Four Seasons Roofing (Pty) Ltd

Discovery Head Office

The Project entails the development of the new Head Office for Discovery Health in the Sandton Precinct and consists of three towers with glass façades and large skylight roofs on the two larger towers and required extensive steelwork support for the facades at roof level and between the three towers.

ARCHITECTS PERSPECTIVE:

There were two key factors within Discovery’s brief.

First was to create an architectural statement that captured the essence of the Discovery brand, and that it could be identified with going forward.  They wanted a building that embodied their core values.

The second factor, that follows on from the first was to improve efficiencies in the day to day working of the company. 

The Discovery building was conceived from the inside out. This concept resolved itself into two large, sun filled internal atria around which the open floor plates were arranged.  The atria are enclosed by 2800sqm of glazed roof, with all pause areas and agile spaces opening into them.  Connecting these atria to one another is a central concourse, within which a stack of escalators links double volume bridges that stitch the floorplates together.  The concourse space was conceived as a “grand central station”, a literal and figurative interchange between the company and its clients.
The roof of the building is a landscaped retreat, accessible to all employees, where the philosophy of holistic approach to health, an integral part of the company’s core values, is physically expressed.

A key feature of the building is the floating “nose” of the west tower which projects over the Katherine/ Rivonia intersection.  To make a statement that fitted with the scale of the building, we needed to cantilever 17.5m over 6 floors.  This posed a significant structural challenge that was eventually solved with the introduction of 3 massive concrete beams that project over the length of the cantilever.  The floors are then suspended from these beams on steel, concrete filled, columns.

Another challenge was the large atrium roofs.  We wanted these to provide as much light as possible which meant the engineering of a bespoke support solution that was visually unobstructed, but structurally stable.  The solution from the façade engineers is an elegant tension truss lattice that supports both the weight of the glazing as well as resisting the up forces created by the movement of air over the top of the glazed panels.

STRUCTURAL PERSPECTIVE:

There are a number of separate steelwork structures on the Project many of which are worthy of exposure and as such a brief description of the major elements is covered below.

SkyLight Roofs:

The Skylight Roofs are probably the most iconic and interesting structures within the development and encompass an extremely innovative design concept allowing them to convey a minimal structural expression of openness.

The major construction challenge presented by the design was the requirement to effectively pre-stress the Main and Secondary (‘so called ‘Glass) Trusses post installation to ensure their bottom chords remain in tension under all loading conditions. The pre-stress is achieved by the incorporation of ‘ so called ‘ light pull-down bars which were then post tensioned on the main support trusses after installation using purpose made tensioning brackets and permanently installed strain gauges to ensure correct tensioning was applied. The ‘ Glass ‘ trusses were post tensioned using a much simpler ‘ nut turning ‘ method on their pull-down bars.

The bottom chords on the Main Support Trusses plus pull-down bars are all imported high tensile KINEX Bars from China with aesthetically pleasing end connection clevises and couplers. The Glass Trusses utilise normal structural steel round bars throughout.

The Fabrication of the steelwork had its own challenges particularly with respect to the Main Support Trusses which are of tubular construction with high tensile KINEX Bar bottom chord members. The main challenge here was in the design of the truss intersections which involved many hours with the design Engineers and careful component fabrication and fit-up in the workshop to achieve the required result.

Cantilevered Floating ‘Nose’:

The Cantilever floating ‘nose’ is a stunning architectural feature and an engineering marvel which enables the large cantilevered six storeys to be supported by the massive post-tensioned concrete beams at roof level.

This steelwork needed to be accurately manufactured with beams rolled to seven different radii seamlessly butt welded together to form the perimeter of the floors which supports the façade which follows the ever changing curvature of the building. The six floors were assembled and supported on five temporary columns at ground level, each floor has five 508mm diameter CHS columns which are concrete filled and hang from three massive post-tensioned concrete beams at roof level. After all the floors had been erected and the top of the CHS columns cast into the concrete beams, the temporary columns at ground level were slowly and methodically cut out while the structure was closely monitored for settlement deflection. This steelwork was on the critical path with a very tight programme. The final result talks for itself.

Façade Support Structure at Roof Level:

The façade support structure requires a 200x200x4.5 SHS to follow the three dimensional curvature of the top edge of the buildings, as this member could not be successfully rolled to the required radii with the required finish we opted for a purpose made curved SHS using plates which were laser cut to the required radius and shop welded to form the 200x200x4.5mm curved SHS which is curved in plan and segmented in elevation. The entire structure was erected to tight tolerances required by the façade glazing contractor and finished to the high standard required by the architect.

STAIRS – PERGOLAS – GREEN WALL:

When asked to write a report upon the above-mentioned project, immediate feeling of pride and achievement come to mind. This undoubtedly is one of Spiral Engineering’s finest sets of stair ever produced. The project team management and general site feel was on another level of professionalism and hence the success of the project.

We were set out the task of creating 11 features Spiral stairs which created an illusion of stairs which are ‘falling’ through concrete voids combining glass and plate balustrades. Together with this, we had 4 additional sweep stairs (2 in either atrium) to complete the access to the lower floors. Other works completed were the Executive Pergola and Smokers Canopy at Roof level, all boasting subtle curves in plan and elevation to the highest quality standards. Added to this was the design supply of the reception Green wall spanning over 6 floors creating a magnificent welcome to the Discovery staff and guests.

Feature Spiral stairs. (88 tons)

Each one of these stairs were double box stingers 600mm deep which alternated between glass and plate balustrades. The stairs spanned from floor to floor with no intermediate support thus the requirement for full penetration site welding to cast in channel systems to handle the eccentric loads. The handling of these stairs posed challenges in the accuracy and the very strict structural welds were required. Due to program restraints the stairs were hoisted using block and tackle off specially designed structural scaffold systems and were positioned to within very tight tolerance requirements. Full penetration site welding was carried out with every weld preparation and weld inspected and tested by Sotiralis Consulting Engineers.  It was a complete team effort from the Contractor, Sub Contractor, Engineer, Quantity Surveyor, Architect and Project Manager to achieve the desired effect. The real challenge was to perfect the flawless smooth white look that the Architects were looking to achieve. Special attention was placed on weld preparation as well as high quality welding and dressing thereof. The final product having the sense of multiple floating steel stairs throughout the Atriums. This really created the WOW FACTOR which you experience when entering these amazing spaces. The stairs were finished off with 16mm laminate full frameless glass and stainless steel grab rail. The sweep stairs on the lower level also consisted of the same high quality finish. Special attention to the tapering entrances and exits did add to detail during fabrication but the smooth clean look was definitely achieved. The full package was completed on time and a great experience for all parties involved.

Jakob green wall (1 Ton Stwk, 2400m Jakob Rope, 3750 No Jakob components)

This unmistakable green wall greets you at the entrance of Discovery Sandton.  The green wall spans over 6 floors and primarily comprised of grade 316 stainless steel 10mm cables, fittings, climbing ladders all fixed to slimline bracketry spreading the loads and minimizing any further stresses to the already loaded slab edges. The Green wall follows the curve of the slab edges and spans in length sections suitable to accommodate a dynamic green wall loads throughout the Growth formations. There are curved supporting channels which are staggered between floors which are perfectly set out creating a continuous slim look. This one of a kind green wall did come with its own challenges. Testing of the plant growth as well as a full pre made mock up off site were carried out to ensure the forces, loads and greenery were all covered to ensure the best possible quality for the client. There was no second chance as this installation was scheduled to be installed as a finishing trade, hence the fit first time and mockup requirements were critical to the success of the installation.

Pergola and Canopy (22.5 Tons)

Similar to the Stair structures these were high class fabrication with subtle curves in plan and elevation assembled and installed on the roof without overhead crane access.  The attention to detail by the Architect on these structures was exemplary and was cause for much consternation for our finishing teams. There was no shortcut and every curve and detail were thought of by the professional team and placed as much of a challenge as the Atrium stairs in that these were not just secondary structures and we were expected to maintain all the quality and fabrication standards as we had done for the stairs.

1.     Completion date of full project ± NOVEMBER 2017
2.     Tons of structural steel used TASS – 700 TONS

SPIRAL – 112 TONS

NANCY – 500 TONS

TOTAL = 1350 TONS

3.     Structural profiles used UB/UC, ANGLES, CHANNELS, CHS, SHS, RHS, PLATE AND PURPOSE MADE SHS.

 

Project Team

Project Team Role Company
Nominator TASS Engineering
Client/ Developer Growthpoint / Zenprop JV
Architect Boogertman & Partners
Structural Engineer, Skylight Pure Consulting
Structural Engineer, Main Building Sotiralis Consulting Engineers
Quantity Surveyor RLB Pentad Q.S.
Project Manager Morta Project Managers
Main Contractor Tiber / WBHO JV
Steelwork Contractor TASS Engineering
2nd Steelwork Contractor Spiral Engineering
3rd Steelwork Contractor Nancy Engineering
Steelwork Erector Onpar Steelwork Erection
Corrosion Protection
Paintwork Contractor
DRAM Industrial Painters
Photographer, Photo competition Megapix Digital

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

Shoprite Climor Distribution Centre

The Shoprite Cilmor Distribution Park is the latest installation of the national distribution centre 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 centred 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 AZ150 Colorbond. 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

 

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