Van Rooyen

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

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

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

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

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

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

 

Schmidtz

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

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

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

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

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

Pienaar

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

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

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

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

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

Limpopo Mall – Pick n Pay Entrance

What is the purpose of the structure/ project?

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

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

What was the brief to the architect?

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

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

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

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

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

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

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

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

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

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

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

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

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

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

 

Type of cladding Widedek (Safintra)

Project Team

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

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

Labus

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

Lgs trusses on mono pitch with Diamond deck.

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

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

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

 

Kaap Agri Building

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

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

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

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

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

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

Scope of Works Description

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

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

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

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

Efficiency is the name of the game

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

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

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

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

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

Both projects were finished on time and within budget.

Kaap Agri

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

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

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

Rancor

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

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

Gilson

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

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

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

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

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

Square meters:   750sq
Duration: 
8 Months

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

No additional project team information provided by the nominator 

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

Wupperthal Pedestrian Bridge

Safe and reliable pedestrian access is a frequently neglected aspect of rural life in South Africa. In many areas, adults and children are forced to traverse rivers via unsafe paths along river courses, low level bridges prone to flooding, or unmaintained and dangerous pedestrian bridges. The Western Cape Department of Rural Development and Land Reform has identified this as an area requiring intervention after numerous accidents and fatalities caused due to unsafe river crossings and poorly designed and maintained infrastructure.

Near Clanwilliam in the Cederberg Mountains is the small town of Wupperthal, located in a pristine valley in an unspoilt part of the Country. Wupperthal is split by the Dassieboskloof River.  The existing pedestrian bridge over the river was poorly maintained and is no longer in a usable condition. For most of the year, the river is easily traversed on foot, however, during heavy rains, the river floods and crossings are no longer safe. The Western Cape Department of Rural Development and Land Reform appointed iX Engineers (Pty) Ltd to assess whether the existing bridge was adequate to meet its intended purpose. It was found that the bridge was not safe and a new bridge was required.

SMEC South Africa (Pty) Ltd were appointed as a sub-consultant to iX Engineers (Pty) Ltd to propose  possible replacement options for the existing bridge and to provide the detailed design of the approved proposal.

The aim of the new crossing was to provide a simple structure that would blend in with the natural surroundings. It was decided to traverse the river with a single span, preventing the need for piers within the river course and the consequent environmental disturbance which could arise as a result there of. A concrete beam bridge was judged to be too heavy to span the long distance, which might have appeared out of place in the natural setting. Steel provided the perfect solution to enable a simple and slender structure, yet still robust enough to withstand debris impacts during flood events. The applicability of the use of steel in rural and remote contexts was illustrated by the fabrication of the structure in Cape Town and subsequent transport to the site. The colour of the steelwork, which was chosen through a participative process with the local community, ensured that the bridge blended in with the local surroundings, and to create stewardship for the bridge among the community. A steel solution also presented the opportunity to be innovative with the design and sculpt a unique and creative form. 

The chosen solution is a tapering, 36 m single span, steel plate through girder bridge.

The deck superstructure consists of two girders created from an assembly of welded plates to form a varying depth beam.  A semi-circular void in the girders was introduced at mid span to give the bridge an arch feel, a natural form that suited the setting. A compression box was provided on the top flange at mid span to prevent buckling of the compression fibre. The transverse members are steel I-beams with diagonal circular hollow section plan bracing, both of which are bolted to the longitudinal plate girders.

The bridge is a simple and basic structural solution, consisting of a simply supported beam. However, the open form and intricate geometry required a complicated analysis and design process. A three-dimensional finite element plate model was created to perform a detailed buckling analysis and stress check on the plate elements.

The Contractor appointed for the construction of the bridge was Guerrini Marine Construction, who were responsible for the construction of the bridge substructure and transport and erection of the superstructure. The deck superstructure was fabricated in Milnerton by Just Engineering and transported to site in three separate parts with a maximum length of 13.7 m. The three parts were erected on temporary supports on the river bank where they could be spliced together. The splice joints consisted of a temporary bolted connection used to secure and position the structure. A full penetration weld could then be performed to conclude the permanent connection. The completed 36 m long deck could then be lifted and rotated into position on top of the reinforced concrete supports.

The handrail consists of an 80 mm diameter circular hollow section, with a custom-made mesh of 8 mm diameter solid bars, which could be bolted onto the bridge in modules on site. This unobtrusive design was chosen so that the handrail does not detract from the elegant lines created by the aesthetically pleasing form created by the steel plate girders below.

The bridge was positioned with a 0.5 m freeboard above the 1:100 year flood line to reduce the risk of debris impacts during a flood event on the lightweight steel superstructure. A timber walkway was provided to link the bridge with the 1:5 year flood line to ensure that the river could be safely crossed even in minor flood events. The total construction cost of the project was R5.265 million.

The bridge in Wupperthal highlights the potential for steel to be used in an innovative way to achieve social and developmental objectives for the community, combining function and aesthetics, without impacting on the environment. The steel bridge provides a positive landmark to the small town that the local community and Client can be proud of.  

Tons of structural steel used 37 tons
Structural profiles used Plates, I Beams, CHS

Project Team

Project Team Role Company
Nominator SMEC South Africa (Pty) Ltd
Client/ Developer Department of Rural Development and Land Reform
Architect Not provided by nominator
Structural Engineer SMEC South Africa (Pty) Ltd
Engineer SMEC South Africa (Pty) Ltd
Quantity Surveyor Not provided by nominator
Project Manager iX Engineers (Pty) Ltd
Main Contractor Guerrini Marine Construction
Steelwork Contractor Just Engineering
Steel Erector Guerrini Marine Construction
Cladding Manufacturer Not provided by nominator
Cladding Supplier Not provided by nominator
Cladding Contractor Not provided by nominator
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition SMEC South Africa (Pty) Ltd
Photographer, Other submitted images SMEC South Africa (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.

 

Woolworths DC/ Communications Park

The purpose of the Distribution centre is to manifest in the hardware of the design, the most economical structure, and spatial format that is a combination of built budget, robustness and efficient product flow. The spatial make-up of the entire campus must both serve the myriad of possibilities in terms of vehicle use externally and internally, but also in terms of product storage, staging, incoming goods and out-going goods. Future proofing is a heavily considered aspect. The logistical design is the intertwined set of flows, identifying efficiencies and exploiting them as well as any overlapping synergies and putting this into reality. The architecture needs to respond to all of these.

The brief to the Architect was to co-ordinate the considered logistics, to build to a set budget in the most robust manner and to future proof in terms of a 5 year, 10 year and 15 year vision with multi campuses in mind. The DC also needed to be as vermin proof as possible and simple in terms of upkeep and cleaning.

The project was always going to incorporate steel into the design, as this becomes the most economical and column free way to extend a “shed” type space over a vast span, allowing free flow and staging areas for numerous product flows.

The structural framing is a simple truss and girder configuration, all connected down by steel columns onto what essentially is a vast concrete ring beam that surrounds and protects all the low level docking stations. The economy and design principle that makes this otherwise semi-unconventional, is that 2 separate grid structures were used throughout the build; one below for the concrete portals and one above for the steel. The concrete responds to the most efficient dimensions for maximising docking stations, being extremely robust, and the second grid responding to the steel structure above in the making of the most economical spanning steel structure above. The steel structure is a combination of I-sections, H-sections, Channels, Angles, Circular hollow sections, and Cold formed lipped channels. All these different sections were used for their different qualities to fulfil specific functions whether it’s a sag bar or a bearer beam.

The cladding was a simple vertical clad design, the IBR sheeting was fixed broad flute out with a Colourplus AZ 200 material. The upper 1100mm of the vertical cladding is a continuous polycarb sheet which tucks behind a large structural gutter, then Lapps onto the Colourplus AZ 200 sheeting below. The cladding starts here and is fixed as a single span extruded sheet to the drip trim slightly above the brickwork on top of the continuous concrete ring beam. The resultant gap between the sheet and the brickwork is closed with flashing. The polycarb sheeting to the top, allows natural light to filter into the warehouse and at a level where the building enjoys air extraction, thus allowing the light without contributing to the heat loading of the space. The natural light contributes to our green points in terms of access to the outside, humanising the space, and saving on the day time lighting.

In terms of the fabrication, the major issue we experiences was in terms of the steel accuracy and the cladding and roofing sub-contractors’ challenges with the system implemented. In a building of this scale it is virtually impossible to survey and hand over with everything level and true. We found the implemented cladding and roofing systems were able to deal with the challenges, but with special focus from the design and sub-contracting team. The resultant meetings met with agreement in terms of getting the structure and the covering membranes to work together, especially when fast track is integral to the project. The systems we have developed will certainly be used as a template going forward and improving these aspects of implementation.

The first major aesthetic consideration in terms of the roofing and the cladding, was to use conventional roofing in terms of budget, but to interchange with different colours so as to realise the client’s corporate identity. These simple colour changes brought focus and visual dominance to the office and important ancillary functions of the large scale warehouse complex. This also acts as an intuitive architectural signage within the functionality. The complex can immediately be identified to be owned and run by the client we represent regardless of the specific corporate signage hung from various locals.

The second aesthetic consideration was for the ancillary office buildings to have exaggerated clad elements as barge boards, so as to conceal the guttering, RWDP’s and steel structures behind, without necessarily extending the structure unnecessarily. This also served to neaten the appearance and contributing to the corporate image as mentioned above.

The project teams worked extremely well on this project, as we engaged with logistical experts prior the tender and had advanced the design to such an extent before tender. The building inspector had also commented that in all his years he had never seen such an accurate and finished building as compared to the approved council drawings he was walking with. We are extremely proud of this.

We enjoyed working closely with the contractor, the sub-contracting parties, the suppliers as well as the design team in terms of reaching our goal, well. We were pleased in developing an extensive set of documents handed to the client, dealing with guarantees, warrantees, assembly guarantees, snag remedy documentation and schedules identifying repair materials, repair details, anti-weathering agents and a comprehensive maintenance plan in relation to all that was done. This was also done with regard to the surrounding air as industrial fall out.

Tons of structural steel used 835.5 Tonnes
Structural profiles used I-sections, H-sections, Channels, Angles, Circular hollow sections, Cold-formed lipped channels
Cladding profile/ type used IBR sheeting
Cladding area/ coverage and tonnage 7653m2

 Project Team

Project Team Role Company
Nominator Safintra
Client/ Developer Woolworths (Pty) Ltd
Architect R&L Architects (Pty) Ltd
Structural Engineer Aurecon Engineers
Engineer Aurecon Engineers
Quantity Surveyor iQS Quantity Surveyors
Project Manager MDSA Project Managment
Main Contractor Stefanutti Stocks
Steelwork Contractor Mazor Steel
Steel Erector Mazor Steel
Cladding Manufacturer Safintra
Coil Manufacturer (Cladding Supplier) Safal Steel
Cladding Contractor Chartwell Roofing
Photographer, Photo competition Fourth Wall 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.

 

Woodlands Dairy – Uht Warehouse

The purpose of the project was to provide a new warehouse facility which would serve as a central distribution center for Woodlands Dairy UHT products.

Our Clients brief was to design a warehouse of 18000sqm which they would need to occupy on a specific date. An important requirement was that the facility would need to be sufficiently sealed to eliminate any dust ingress and the height needed to accommodate a pallet raking system.

The warehouse was to link onto an existing warehouse and had to maximize the site and would need to be able to accommodate future expansion.

The structure was always envisaged as steel. Due to the extremely tight programme and budget, the  appointed main contractor was requested to investigate alternative methods which could be a cost saving and accelerate his programme. The option of concrete columns where looked at. In the end steel was chosen due to the speed of erection and flexibility of construction. All steel was required to be hot dipped galvanized. Due to the lead time of galvanizing and limitations on steel section lengths, all internal steel was to receive a Sigma coating.

The columns supporting the building was a combination of minimal reinforced concrete internally and hot rolled structural steel I sections and H sections along the perimeter of the building. The roof was supported by structural steel trusses comprising hot rolled angles with hot rolled T-sections used as top and bottom chords. The trusses spanned onto structural steel girders of a similar construction than the trusses. Bracing members were circular hollow sections.

The sites irregular shape and conditions as well as the Clients request to maximize the site, meant the warehouse required to change in angle along its length as well as a change in level due to the site slope. This all made for some challenging structural junctions and sheeting interfaces.

Dust proofing the warehouse was challenging. Junctions between different sheeting profiles of roof bullnose, side cladding and gutter interface as well as where the side cladding terminated at the concrete floor perimeter upstand. The structure had to be enclosed prior to the concrete floor being cast.

If it were not for the fact that we were a well-established project team we would never have achieved the quality of facility provided in the extremely tight time frame given.

Tons of structural steel used 572 Tonnes
Structural profiles used I-sections, H-sections, T-sections, Circular hollow sections
Cladding profile/ type used Saflok 410/TUFDEK
Cladding area/ coverage and tonnage Roof Sheeting 20 140m2

Vertical Cladding 6 443m2

Project Team

Project Team Role Company
Nominator Safintra
Client/ Developer Woodlands Dairy
Architect MMK Architects
Structural Engineer Sigma Consulting
Engineer Not provided by nominator
Quantity Surveyor Johnston & Rosser
Project Manager MMK Architects
Main Contractor WBHO Construction
Steelwork Contractor USS (Uitenhage Super Steel)
Steel Erector USS (Uitenhage Super Steel)
Cladding Manufacturer Safintra
Cladding Supplier Safintra
Cladding Contractor Cladall
Corrosion Protection
Coating
PPG Protective & Marine Coatings
Corrosion Protection
Paintwork Contractor
USS (Uitenhage Super Steel)
Photographer, Photo competition Impact Studio
Photographer, Other submitted images Impact Studio

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.