The Bus Rapid Transport Stations for the Rea Via is an architecturally pleasing steel structure, designed as a steel structure with glass facades.

Structural Framing

The project makes use of a wide variety of steel sections. The Columns are shaped plate girder sections, sloping or leaning over.

The rafters are Tee-Section rafters cut from I beam sections. Also shaped from wider to thinner at the furthest point.

These are hanging from CHS hangers. With CFLC sections as purlins to receive the sheeting.

The Façade steelwork is a complex design, with a curved CHS pipe rolled on the two ends creating and oval façade to receive the glass. Welded to this top cord of the pipe are plate support brackets which support a large CFLC which acts a support to all the information boards that are required inside the station.

This entire façade sits on shaped plate brackets which are fixed to the concrete floor.  



Challenges

There were definitely many challenges in both fabrication and erection of these structures. The final product looks lovely but there many technical issues that needed to be overcome to be able to achieve this finished product.

Fabrication

As all the steel is exposed all welding on the shaped plate girder columns had to be done to the greatest of care. To achieve an aesthetically pleasing finish.

The splitting of the Tee-Section rafters causes distortion to the sections. Which needed to be straightened before fabrication could proceed.

The façade steelwork pipe and support brackets had to be fabricated to the greatest of accuracy. If the brackets were out by just a few millimetres the effect on the straightness of the CFLC would become very noticeable.

Erection

The design of this structure required very precise and accurate erection procedures. Which needed to be adhered to from the very first part. And that would be placing the columns on the HD bolts.

The sloping columns receive all the steelwork, and the interface between the final façade steelwork and the concrete interface is of the utmost importance.

So these columns needed to be erected at exactly the correct level, and at exactly the correct slope. This was done and confirmed by using an electronic slope spirit level.

The roof rafters, purlins and hangers were fairly straight forward to erect.

Much time went into installing the façade steelwork.

This curved pipe structure then bolted between the sloping columns. Which spacing had to be exact otherwise these pipes would not fit.

The levels of this façade pipe could only be adjusted by the levels of the columns.

Once the top pipe was perfectly aligned the bottom pipe could be installed onto the concrete floor.

The shaped brackets below the bottom façade pipe had ten to be measured on-site and be fabricated to ensure the perfect interface between the concrete floor and the bottom pipe. No large grouting was accepted by the architect. 

Apart from the technical aspects mentioned above. These stations needed to be erected in the middle of the most busy JHB streets. Only the island which became the “site” was cordoned off. So space was very limited.

This was accomplished by using small spider cranes, and bringing the steel to site in the correct sequence as required by the erectors.

How this project demonstrates the benefits of steel

Accomplishing what was required by the architect, the look, constructability and finish would only have been done by using steel.

How did the project team work together?

As this design was so complex, there was good communication required between Concrete and steel contractors. Surveys of concrete was done before workshop drawings were completed.

Between steel and glass contractors, many hours of our teams working together to make sure all the details work.

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 

 

 

 

 

 

249-253 M11, Orange Grove 

Johannesburg 

Gauteng 

Google Maps link  https://goo.gl/maps/wgJKWXPCDL14HBrQ9  

 

STRUCTURAL STEELWORK 
Completion date of steelwork  Currently Still Busy 
Completion date of full project  2021 
Tonnage and steel profiles used  360t – Cold Formed and Tubular 
Project Team RoleCompany
NominatorFerro Eleganza (Pty) Ltd
Client/ DeveloperJDA
ArchitectDelta
Structural Engineer WSP Group Africa (Pty) Ltd
Engineer  
Quantity Surveyor (PQS)Aecom
Project Manager/Principal AgentAOS
Main ContractorStefanutti Stocks A Re Shomeng JV
Steelwork ContractorFerro Eleganza (Pty) Ltd
Steel ErectorFerro Eleganza (Pty) Ltd
Cladding Manufacturer 
Cladding Supplier 
Cladding ContractorDoublejack Construction (Pty) Ltd
Corrosion Protection 
Galvanising 
Corrosion Protection 
Paintwork ContractorDram Industrial Painting
Photographer, Photo competitionFerro Eleganza (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.