The Inoxa Manufacturing Facility project came about due to an international crockery manufacturer’s desire to open a manufacturing facility in South Africa. The facility manufactures products for the South African market, as well as for export.The client for this project was Shree Property Holdings (SPH), who developed the property for lease to Inoxa Manufacturing.

From the start of the project, SPH consulted with both Davgo and Steelkon Projects to find the most suitable structural steel solution for the specific site and client requirements. The tenant required a linear manufacturing process and product flow, which led us to the current design of a 50 metre wide by 350 metre long building.

The building is divided into 3 distinct zones, each with it’s own characteristics in terms of steel structure.The first zone is the Manufacturing Zone, which measures 50m by 143m. This zone comprises two 25ton overhead crane gantries, each with a span of 23m, both of which run the full 143m. The crane rail height is at 9.2m above FFL, and hence the eaves height is at

11.5 above FFL, to accommodate the gantry cranes. Lattice type columns were designed for this zone so as to mitigate against the horizontal deflections caused by forces induced by the cranes onto the rails. The crane beams were designed as compound members comprising I-section beams with parallel flanged channel section caps.

The second zone is the Polishing Zone, which an extent of 50m by 71.5m. Here the manufactured products are cleaned and polished before proceeding to packaging. This process requires ample headroom and the most uninterrupted floor space economically possible. For these reasons, the eaves height of 11.5 was retained, and a centrally located lattice transfer girder was designed to span 3 bays (18.5m), which meant only 2 internal columns were used over the entire 2,600sq.m footprint of the Polishing Zone.

The third zone is the Warehouse Zone, which an extent of 50m x 136m. This is where the finished products undergo QC, before being packaged, and then stored whilst they await distribution. Since the tenant did not require high level racking, the eaves height for this zone was reduced to 9m above FFL. The same roof design as the Polishing Zone was used to keep internal columns to a minimum.

Added to the main building, a semi-detached office structure was also designed and supplied to suit the tenant’s needs. The office structure comprised a suspended slab and roof, with floor area of both floors totaling 5,000sq.m. This was originally supposed to be designed as a concrete framed structure with a steel roof, however due to the tight time constraints the development faced, it was decided to rather use a steel framed structure to support the pre-stressed concrete T-beams & topping slab. The main load carrying beams had to be deep I-sections since the spans varied between 7.5m and 9m. These were compositely tied to the slab by means of Y12 shear connector bars.

The office roof also used a lattice transfer girder in the centre of the 35m span width, resulting in only 4 internal columns over the 2,500sq.m footprint.The steelwork and cladding portions of the job were completed on time and without any problematic incidents, mainly due to the meticulous design, detailing, and planning of the steelwork with one of the main objectives being to minimize the complexity of the rigging. One of the challenges faced was the interaction between the rigging of steelwork and the rigging of pre-cast concrete panels, since the latter required steel members to be temporarily removed so as to allow the concrete panels to be installed and plumbed with ease.

The end result of this project is a landmark building on the KZN North coast, which is both functional and aesthetically pleasing externally and internally. When standing inside the structure, one is not only struck by the pleasing geometry, vast uncluttered space, and striking yellow paintwork; but also by the beautifully detailed lattice columns and girders which create curious geometrical shapes as you move around within the building.

A very satisfied client also adds to the prestige of being involved with this project.

Tons of structural steel used 500 tonnes
Structural profiles used I-sections, H-sections, Angles, CHS, Crane Rails, CRLC
Cladding profile/ type used IBR 686 Colourplus AZ150
Cladding area/ coverage and tonnage Approx. 20,000 sq.m

Project Team 

Project Team Role Company
Nominator DAVGO Steel Construction
Client/ Developer Shree Property Holdings
Architect Zadar Studio
Structural Engineer Steelkon Projects
Main Contractor Shree Property Holdings
Steelwork Contractor DAVGO Steel Construction
Steel Erector DAVGO Steel Construction
Cladding

Manufacturer

Global Roofing Solutions
Cladding Supplier Future Steel
Cladding Contractor DAVGO 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.