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.