The Rotek Modular Spares Facility houses critical interchangeable spares for the country’s power generation facilities. The building consists of a +-6750m2 warehouse with a double story office block attached. The building is by no means a standard warehouse. There are two primary longitudinal bays that house 2 x 60t cranes each. These cranes are to be able to lift 100t in tandem in each bay. The high building eaves height of 18m has been governed by the required hook height of 13m for the 60t cranes. On a lower level, there are 4 assembly bays with each having a 10t crane overhead which run transverse to the primary overhead cranes. The number of cranes and the requirement for tandem lifting resulted in a complex design with several load combinations that had to be considered.

Due to the clients requirements to house stock that was already scheduled for delivery, the contractor was asked to accelerate the project. This required great co-ordination between the fabrication process and enabling the site to erect the structure systematically.

The structure consists of Lattice columns, supporting the roof structure with roof legs, also supported on the lattice columns are large plate girders carrying the four 50ton cranes. Steel would always be the preferred material for a building of this nature. 

The welding to the plate girders was done under the highest level or NDT testing for full penetration welding conforming to cyclically loaded charts. Allowing the client to have peace of mind that no fatige caused by the constant movement of the cranes would result in any maintenance in years to come.

With good planning, and effort the team was able to erect the 470t warehouse (excluding the plate girders) within six weeks. To enable the rest of the trades to follow and allowing the contractor to meet his project deadline.

Project Team Role Company
Structural Engineer Aurecon
Main Contractor Tyris Construction
Steelwork Contractor Ferro Eleganza
Structural Steel Detailer Ferro Draughting
Steel Erector Ferro Eleganza