SAB Miller, prior to its takeover by ABInBev, identified the need for a new brewery in Nigeria and selected a site in Sagamu located approximately 60 km north-east of Lagos.  The initial brewery size was for 1.8 mega hectolitres, however, shortly after commencing with the design work, the decision was made by ABInBev to proceed with design work for a revised capacity of 3.2 mega hectolitres.   

 

Structural steel as choice of building material

The 3.2 mega hectolitre brewery is approximately 41 000 m² in building area consisting of a number of different buildings, e.g. packhall, brewhouse, engine room, CHP & boiler house, full-bottle store, administration buildings.

With the inherent flexibility that structural steel offers, combined with the main buildings all having requirements for large clear spans, some in excess of 32m, in order to accommodate the respective equipment, steel was the clear choice of construction material. Structural steel provided the various buildings on the project with an ability to absorb inevitable late design changes associated with a project of this type. In particular, the structural steel facades of four of the buildings, earmarked for future expansion at the outset of the project, provided the perfect flexibility required in the structure at the time of various expansions.

The steel grade that was available locally was 275 MPa and prior to commencement of the revised design, a list of section sizes available from the Nigeria market was obtained and utilised in the design.  During the review of shop drawings, some of the section sizes were no longer available requiring a design check of the structural elements to find suitable alternatives.  In most instances, the result was a heavier section having to be used. 

Value engineering was a key consideration in the design and fine-tuning was required wherever savings could be realised. For example, a decision was taken to provide additional columns in one section of the packhall building, which meant that instead of a girder with trusses connecting to the girder as per the main design rationale, the girder could be removed and the trusses then connected directly to the columns.  This resulted in a significant saving in the overall steel weight of the structure.

Other steel buildings and components include:

  • 240 m2 four-storey malt intake tower consisting of steel composite floors
  • 875 m2 five-storey sorghum intake tower consisting of steel composite floors
  • 2016 m2 seven-storey mill tower consisting of steel composite floors
  • Covered gatehouse entrance in steel approximately 890 m²
  • 600 m of steel pipe bridges
  • 400 m of covered pedestrian walkways
  • 56 m2 tyre store
  • 787.5 m2 keg Store
  • 387.5 m2 hops store
  • 2326 m2 generation and boiler warehouse
  • 4950 m2 brew house and cold block
  • 1575 m2 engine room
  • 480 m2 forklift workshop
  • 1335 m2 amenities building
  • 155 m2 induction building
  • 477 m2 empty bottle store canopy
  • 351 m2 water treatment plant
  • Steel supporting members for safety lines, which became a requirement from ABInBev during the construction stage of the project.

Conclusion

In spite of its limited local availability, structural steel was the ideal choice for the Sagamu Brewery project, providing the flexibility to deal with various design expansions and the solutions for large clear span elements.

The use of steel, combined with good collaboration between the architect, the structural engineer, the rest of the professional team and the contractor, has created a structure that will be economically efficient and meet the requirements of the client for resilient, sustainable design.  Aurecon is proud to be associated with a project of this calibre.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

PROJECT OVERVIEW
Physical address of the project
Street Address
Town
Province
Abeokuta-Sagamu Expressway
Sagamu
Ogun State
Google Maps link https://goo.gl/maps/efxexzkL6eEKEpG27

STRUCTURAL STEELWORK
Completion date of steelwork Feb 2019
Completion date of full project May 2019
Tonnage and steel profiles used 2900 tons
Cost of steelwork   NGN 1,795,735,245.00 = 4.9 Million USD

Project Team Role Company
Nominator Aurecon Consulting Engineers
Client/ Developer ABInBev
Architect PPS Architects (Pty) Ltd
Structural Engineer Aurecon Consulting Engineers
Quantity Surveyor De Leeuw Group
Main Contractor Vita Construction
Steelwork Contractor Vita Construction
Steel Erector Vita Construction
Cladding Manufacturer Vita Construction
Cladding Contractor Vita Construction
Galvanising Vita Construction
Paintwork Contractor Vita 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.