Aecom was appointed by Shell to design, oversee and build the first green star rated Shell Ultra City in South Africa. Aecom saw the value of Light Weight Steel Frame building and appointed Razorbill who has 12 years’ experience in design, production, and construction of Light Weight Steel Frame. Razorbill’s design department transformed Aecom’s design into a lightweight steel frame structure. Shell /Aecom see the value of Light Weight Steel Frame constructionDeveloping the Light Weight Steel Frame steelwork designs to express the architect’s concept was a challenging exercise that would have been difficult to re-create in brickwork or in concrete whilst still meeting the parameters set out by the client.

The underlying drivers of the Shell Kroondal project on the N4 North West were cost, speed and environmentally friendly building methods which are especially apparent in the project promoting alternative building technology (ABT) and the role it could play in innovative development in South Africa. The project is notable for its lightweight steel structure featuring exposed lightweight steel trusses

Part of the requirement was to ensure that work opportunities were created for members of the local community and that there would be no impact due to the construction of the buildings on the adjoining wetland area.

The use of LWSF resulted in a significant reduction of transporting building materials as well as the use of materials that can be recycled at end of life.

World class Health, Safety, Environment and quality control measures were to have complied with that met the standards as required by Shell, Aecom and Pragma. In this Razorbill utilized a Health and Safety program that was tailor-made for the project and which was designed by an expert engineer with a vast experience in the mining, manufacturing and construction industry.

Razorbill utilised renders and finishing materials from Terraco which is proven worldwide and backed by a company with experience in all climate zones over the world. Extreme satisfaction was expressed by Shell International on the product and the speed of construction during their visits to the site during and after the construction of the buildings.

This is the future of building in South Africa and Africa, lightweight steel buildings have a much lower impact on the environment, rehabilitation of land is much cleaner and faster to achieve than with brick and mortar buildings.

LSFB /  LIGHT STEEL FRAME BUILDING WORK
Completion date of LSFB work Aug 2018
Completion date of full project Oct 2018
Tons of LSF used 32.4 tons
Span of trusses and Kg/m2 (if applicable) 13 mtr unsupported / 26 mtr supported
Profiles used Framecad C-sections, 30mm and 20mm battens 

 

Type of cladding Exterior: 

. 12mm fibre cement boards

. Terraco exterior wall products

 

Interior:

. Gypsum 15mm firestop and moisture resistant boards

. Terraco interior wall products

 

 

CLADDING
Completion date of cladding Sep 2018
Cladding profile/ type used Exterior: 

. 12mm fibre cement boards

. Terraco exterior wall products

 

Interior:

. Gypsum 15mm firestop and moisture resistant boards

. Terraco interior wall products

 

Cladding area/ coverage and tonnage 3756m2, 36.379tons
PROJECT TEAM ROLE COMPANY
Nominator Razorbill
Client/ Developer Aecom
Architect Aecom
Structural Engineer Donnic Engineering
Engineer Razorbill
Project Manager Aecom
Main Contractor Aecom
Hot rolled Steelwork Contractor Marboe & Sons (Pty) Ltd
Hot-rolled Steel Erector Marboe & Sons (Pty) Ltd
LW Steel Contractor Razorbill
LW Steel Erector Razorbill
Cladding Manufacturer St Gobain/Marley/ Everite
Cladding Supplier Triangle Sourcing
Cladding Supplier Global Innovations
Cladding Supplier Terraco
Cladding Contractor Razorbill