Purpose of the structure/project?

The structure was designed and installed as a ceiling to bring the existing facility into spec as a functioning ESFR (Early Suppression Fast Response) warehouse. Due to the new tenant’s requirements to store tyres, the ESFR system requires the sprinklers at a precise height above the stored product, and consequently a ceiling within a specified ASIB range thereafter to optimise early warning parameters from smoke and heat.

Due to the underside of sheet being too high in approximately 8,800sqm of the warehouse, and the existing steelwork not being able to cope with the new sprinkler loads, the only option was to strengthen the existing steelwork insitu and thereafter provide a ceiling at the required height.

What was the brief to the architect?

To get the existing facility, recently vacated by the Mr Price group into spec for the new tenant, Goodyear.

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

Not necessarily. There were investigations into using traditional ceiling boards and droppers. It was deemed due to the sprinkler weight that truss and girder strengthening was required in either regard, and the subsequent steel roof would be lighter and quicker. The entire project was on a compact and tricky program with significant pressure from the tenant for occupation dates.

Give a brief description of the structural framing. What type of sections were used and why?

Hot-rolled: Angles, tubes, and plate.
Cold-rolled: 300mm purlin section and 302 Metsec Z-sections

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

All structural steel and cladding was retrofitted to the existing (strengthening) and new (ceiling) steelwork from inside the warehouse, off cherry pickers and scissor lifts. Due to the installation limitations and material handling the sheets were delivered in 4m lengths, as before, all off scissor lifts. Cladding had to span across 78m, in-between sprinkler droppers, lights, electrical cable trays, and at times in-between the existing lattice trusses.

Were there any challenges in the fabrication from the engineer’s design. Tell more about fabrication and erection process if difficult, complex, innovative

Large steel plates to carry the Metsec sections were cumbersome and difficult to install. Wind bracing and box sections (made from 300mm purlins) were installed above the existing truss beneath the existing roof. These were 11.2m in length and had to be lifted off access machines to over 13m and installed in highly restrictive conditions.

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

The steelwork was used to both strengthen the existing structure and provide a solution to the client/tenant’s need to successfully achieve the desired result and make this facility unique and superior to both parties.

How did the project team work together (contractor involved early, challenges, ease of communication)

Excellent. With numerous contractors on site working weekends, night shifts, and in confined areas the project team worked exceptionally well under improbable timelines.

Tons of structural steel used 110 tonnes
Structural profiles used Z – Sections, Angles, Plates
Cladding profile/ type used 0.50 IBR 686 Zincal AZ150
Cladding area/ coverage and tonnage 8800m2

Project Team

Project Team Role Company
Nominator Cousins Steel International
Client/ Developer City Logistics
Architect RHA
Structural Engineer Sotiralis Consulting Engineering
Engineer Cousins Steel International
Quantity Surveyor Quantil
Project Manager Quantil
Main Contractor Cousins Steel International
Steelwork Contractor Cousins Steel International
Steel Erector Cousins Steel International
Cladding Manufacturer SAFAL
Cladding Supplier SAFINTRA
Cladding Contractor Cousins Steel International
Corrosion Protection
Cousins Steel International
Corrosion Protection
Paintwork Contractor
Cousins Steel International
Photographer, Photo competition Cousins Steel International

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