Makro Riversands

What is the purpose of the structure/ project?

The structure serves as a retail centre.

What was the brief to the architect?

To maximize space utilization and minimize construction time.

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

The main roof structure consists of girders and castellated rafters. Castellated beams were used for aesthetics and to reduce the overall weight of the sections along the span. Also to increase the spanning capabilities.CHS were used in the barrel vaults as an architectural feature.

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

The fabrication of the barrel vault needed to be completed to a tight tolerance in order to ensure correct fitment of barrel vault sky –lights.

It was complex due to the fast-track nature of the project. Whereby close coordination was required between the civil contractor, steel contractor, building contractor, sheeting contractor, fire services, mechanical services in order for the works to be completed in the required sequence within the building footprint.

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

The structural steel barrel vault arches on Makro structures have become a nationwide symbol of the Makro brand.

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

MPW detailing office worked in close communication with the engineering and architecture team in order to ensure discrepancies were picked up within the detailing phase, to allow for adjustments to be made prior to fabrication. This resulted in a structural system which very closely resembled a Mecano set. Therefore it allowed us to reduce erection time on site. All contractors on site worked in close unison moving from section to section ensuring all the requirements were met timeously.

Tons of structural steel used 480 TONS
Structural profiles used CASTELLATED, TUBING, UC, UB

Project team

Project Team Role Company
Nominator MPW Steel Construction
Client/ Developer Makro / Century Properties
Architect R&L Architects
Structural Engineer L&S Consulting
Engineer Not provided by nominator
Quantity Surveyor Not provided by nominator
Project Manager MPW Steel Construction
Main Contractor Concor
Steelwork Contractor MPW Steel Construction
Steel Erector MPW Steel Construction
Cladding Manufacturer Grs
Cladding Supplier Grs
Cladding Contractor Roofing Guarantee 
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Not provided by nominator
Photographer, Photo competition MPW Steel Construction
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.

Time Square Maslow Hotel

 

Tons of structural steel used 700 tons
Structural profiles used Structural Hot Rolled, Tubular Steelwork up to 1000mm diameter, etc.

Project team

Project Team Role Company
Nominator Cadcon (Pty) Ltd
Client/ Developer Sun International
Architect LYT Architects
Structural Engineer WSP
Engineer WSP
Quantity Surveyor MLC
Project Manager Not provided by nominator
Main Contractor WBHO
Steelwork Contractor Cadcon (Pty) Ltd
Steel Erector On Par
Cladding Manufacturer Not provided by nominator
Cladding Supplier Not provided by nominator
Cladding Contractor Chartwell Roofing
Corrosion Protection
Galvanising
Not provided by nominator
Corrosion Protection
Paintwork Contractor
Dram Industrial Coatings
Photographer, Photo competition Sun International
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.

PwC Tower – Triple Height Lobby

PwC Tower is PwC’s new head office in Johannesburg. The floor plates of the 28-storey building rotate by 1.2 degrees per floor, which results in a doubly-curved surface for the building’s façade and the structural line behind. The reception is housed in a triple volume lobby area at ground floor. This triple volume space flows into the adjacent meeting centre, and is used as a café and informal meeting space.

A steel and glass atrium roof covers the link between the tower and the meeting centre, whilst a steel link bridge with glazed balustrades connects the two floors at first floor level with a steel feature stair forming the principal link up to the second floor of the meeting centre. Whilst the majority of the tower floors are post-tensioned concrete, the first and second floors of the tower are formed in steelwork with bondek slabs and are hung from the third floor, to increase the column-free space in the lobby below. The northern part of the lobby features a triple volume steel and glass façade, gently following the twist of the tower. Within the atrium and outside the glass façade the sloping and spiralling columns of the building are encased in steel tubes to act compositely with the concrete inside; this increases the capacity of the reinforced concrete columns where they are unrestrained over the three floors and means that the overall section sizes can be similar to the rest of the tower which allows us to achieve the preferred architectural aesthetic. All of these components feature the use of steelwork in a complex geometric form and in the majority of cases the painted steel is exposed to form the finished surface.

Rectangular hollow sections were used on the skylight. The suspended floors were built out of BOND-DEK on cellular beams, with curved edge beams rolled horizontally. The hangers are circular hollow profiles. The bridge and stair are predominantly formed from welded plate with concealed connections and preformed slots for the cantilevered glazed balustrades. The façade mullions, spanning over three floors are I-sections, and are laterally restrained by circular hollow profiles. Rolled square hollow profiles are used over the main entrance doors. The structural columns in the tower are encased in large diameter circular hollow tubes.

The geometry of all this steelwork was generated by parametric scripts. The steel profiles were explicitly modelled in 3D by the design team. Conventional plans with all setting out information were produced for use on site but the 3D steelwork model was also issued to the contractor to use as the basis of their steel shop model and then later used to check the steel shop model.

Tons of structural steel used 250t
Structural profiles used RHS, CHS, UB, UC and plates

Project Team

Project Team Role Company
Nominator Arup
Client Attacq
Developer Atterbury
Architect LYT Architecture
Structural Engineer Arup
Quantity Surveyor Brian Heineberg & Associates
Main Contractor WBHO
Steelwork Contractor Cadcon
Steel Erector Cadcon
Cladding Manufacturer Geustyn & Horak (G&H Aluminium)
Cladding Supplier Geustyn & Horak (G&H Aluminium)
Cladding Contractor Geustyn & Horak (G&H Aluminium)

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.

JRA Gantry

What is the purpose of the structure/ project?

Designed to be a traffic intersection regulator.

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

Yes.

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

The gantry consisted of only circular hollow sections from the main frame and bracing to the support columns.

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.

All the connections on the CHS had to be profiled and the girder section had to be pre-cambered. Fabrication had to allow for safe transportation as the sections were abnormal loads delivered in Johannesburg CBD. Assembly of the bridge had to be carried out in an allocated area in close proximity to the site, in order to minimise road closure time. Once the main gantry was assembled it was moved into place with a truck and dolly and the erection began in the allocated 1 day road closure.

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

Traffic was cordoned off for about 6 hours to allow the tandem lift of the bridge into its final position. Pre assembly was done approximately 1Km away from the actual site. This intersection is highly populated and carries heavy traffic during the day. The project will aid in reducing intersection confusion due to lack of robots and appointed personal to direct traffic. 

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

Like a well-oiled machine – Close coordination between MPW Steel construction, JRA and JMPD was essential to ensure the erection process was completed in a safe and efficient manner. Traffic was diverted around the designated area between Empire road and Clarendon.

Tons of structural steel used 19.4 TONS
Structural profiles used ONLY CHS

Project Team

Project Team Role Company
Nominator MPW STEEL CONSTRUCTION
Client/ Developer JOHANNESBURG ROAD AGENCY
Structural Engineer JG AFRIKA
Main Contractor MPW STEEL CONSTRUCTION
Steelwork Contractor MPW STEEL CONSTRUCTION
Steel Erector MPW STEEL CONSTRUCTION
Photographer, Photo competition MPW STEEL CONSTRUCTION

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

Heineken Warehouse

What is the purpose of the structure / project?

The approximate 18 800m2 of warehouse area was constructed to provide the client with additional storage capacity for finished product due to increase demand and new logistics strategy implemented by the client.

What was the brief to the architect?

Expansion of the existing warehousing and supporting infrastructure to accommodate market growth and centralise logistic facilities for more cost effective and efficient operations. The project had to be completed in record time (5 months) as the client intended not to renew current rental agreements for existing warehousing, and the new warehousing had to be in operation before the client’s peak sales period over the December holidays.

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

The warehousing was initially envisaged by the client as imported tent structures cladded with canvas due to financial considerations. The professional team however showed that new predominant steel structure warehousing with IBR cladding built in similarly configuration to the existing predominant concrete structure warehousing proofed more cost effective and more suitable to the client’s environment and needs. Various reinforced concrete components of the existing warehousing were replaced with light weight structural steel components in the new warehousing, which resulted in significant functional and aesthetic improvements and at least 30% savings in building costs. 

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

After careful design considerations, the structural engineer identified opportunities to further optimize the new structural members by deviating from the heavy original structure which had been designed for European snow loads.  As a result hot rolled I-sections were used instead of cellular beams.  The original concrete box gutters were also replaced with steel girders and gutters in order to reduce cost and increase the speed of construction.  This demonstrated the versatility of structural steel as a construction material. The steel also provided the benefit of acceleration by not having to endure a curing period before the structural members could be loaded.

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

The cladding was specified as 0.58mm thick IBR Chromadek Z200 to suite existing warehouses. The cladding was supported by standard galvanized cold formed steel sections.

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

Although the new optimized design showed an approximate 30% saving in weight, no light weight steel members (aluminium) were used on the project.

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

The construction programme necessitated the complete construction of the 18 800m2 warehouse inclusive of concrete raft foundations in a period of 5 months with 3 partial completion dates for sections of the construction.  This resulted in an extremely tight schedule for manufacturing and erection of the steel. Space frame steel trusses were constructed as cantilever canopies over loading bays. Overhead steel beams were used to increase span lengths between supports and subsequently reduce the number of internal steel columns to optimise floor stacking area. Historically concrete beams were used to support roof structures and box gutters, which were replaced with light weight steel girders in the new warehousing.

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

Light weight structural steel components replaced historic reinforced concrete elements resulting in more efficient and cost effective warehousing. Space framed steel truss canopies is more functional and aesthetically pleasing. Steel girders were also used in lieu of the original concrete box gutters.  Circular hollow sections were used for the loading bay canopies to compliment the warehouse aesthetically and also proved to be the most effective structural members that could accommodate the excessive cantilever requirements (12.5m).  Steel was also ordered early based upon workshop approval of certain components in order to speed up delivery and manufacturing.

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

The 5 months construction period was initially considered unrealistic with inherent risks to all parties involved. The new warehousing was however completed on time and within budget, which proofed to be a huge success. This achievement is attributed to the pro-active solution driven approach adopted by all team members from the start of the project.  Good governance, management, site control, communication, support and cooperation between all team members ensured that challenges were resolved timeously. 

Tons of structural steel used 692 tons
Structural profiles used Various I-Sections, PFC Channels, Equal Angles, CFLC and Circular Hollow Sections (CHS)
Cladding profile/ type used 0.58mm IBR Chromadek Z200 roof sheeting and cladding
Cladding area/ coverage and tonnage 27 135m2

Project Team

Project Team Role Company
Nominator ESABA Consulting Engineers (Pty) Ltd
Client/ Developer Heineken South Africa
Architect Designdex Architect
Structural Engineer ESABA Consulting Engineers (Pty) Ltd
Engineer ESABA Consulting Engineers (Pty) Ltd
Quantity Surveyor ESABA Consulting Engineers (Pty) Ltd
Project Manager ESABA Consulting Engineers (Pty) Ltd
Main Contractor AVENG Grinaker LTA
Steelwork Contractor BOKSAN Projects CC
Steel Erector BOKSAN Projects CC
Cladding Manufacturer Chartwell Roofing (Pty) Ltd
Cladding Supplier Chartwell Roofing (Pty) Ltd
Cladding Contractor Chartwell Roofing (Pty) Ltd
Corrosion Protection
Galvanising
BOKSAN Projects CC
Corrosion Protection
Paintwork Contractor
BOKSAN Projects CC
Photographer, Photo competition ESABA Consulting Engineers (Pty) Ltd
Photographer, Other submitted images ESABA Consulting Engineers (Pty) Ltd
  Fowlds 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.

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.

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 centre.

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 levelled 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

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

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.

Go Durban Integrated 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

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.

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%
   
CLADDING
   
Cladding profile/ type used Colour Coated Saflok 700
Cladding area/ coverage and tonnage 2650sqmeters, 16 tonnes
   

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

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.