Steel is the backbone of our industry, and it follows suit as a backbone of infrastructure. Steel provides the strength to keep a building and its components standing from the ground up. SA STEEL MILLS –  I 00 000m2

Benefits achieved by using steel construction

Steel can be used in diverse arrays of applications, both domestic and industrial. The strength to weight ratio assists in cost savings and ensures that the structure will stand the test of time. Quick installation allows for time conservation and readily available labour. Quality is ensured with various guarantees and via the durable nature of steel. Steel is the very DNA of Strength.

Aesthetic appeal

Steel, dependent on the design and customer’s requirement, can be shaped to fit any mould. The versatility, design, and application can make a structural art piece that is appealing to the eye.

Environmental/ Sustainability consideration

Steel is a recyclable resource and can be recycled over and over. By observing the 3 R’s, we reduce, reuse and recycle steel and ensure that our activities are Green, which will, in turn, lower greenhouse gas emissions. Building design & process can harvest maximum sun / solar energy and rain & groundwater that will enable us to use transformative technology to produce steel differently from the global players and make SA Steel Mill the second player in the world to make green steel without (GHG ) greenhouse gases. The steel buildings are designed to create 90,000 sq meter rooftop to place photovoltaic panels on 24degrees to tap solar irradiation. The roof space is enough to produce 55 MVA lowest cost renewable solar power without any Carbon dioxide CO2. The renewable solar power can be stored in large environmentally friendly containerized batteries developed and commercialized by MIT professor. 55 MVA power will enable SA Steel Mill to produce 400,000 tons of green steel by using eco-friendly technology. The plant is operating off the grid for electricity and water supply, where we will ensure that energy is used conservatively and waste is managed by up to 75%.

Innovation in Design Fabrication or construction

Lightweight and high tensile sheeting have been used in the structure. The use of translucent sheeting harnesses daylight and reduces the need for artificial light sources. The total roof area spans across 66 000m2 which allows for rainwater harvesting into our reservoirs. The Plant is a redesign of a standard mill, such that logistical transfer of product converges at a common area of dispatch. This redesign has maintained functionality while lowering overall project costs.

Technical Process Required for Realising the Project

In the execution of construction, we have used LEAN principles from a process standpoint. We have been able to generate value, continually improve and manage our processes and waste, while optimising the entire project from a capital perspective. The Project will then yield a fully automated plant, which employs state of the art technology and reduces human error in the steel manufacturing process.In maximising efficiency, the mill utilises a central Melt Shop, where molten metal is transferred into four mills, obtaining their own applications.

What is the purpose of the structure/project?

This is a steel production plant. Used to house ovens, mills and finished goods.

What was the brief to the Architect?

Design a steel  mill  manufacturing  plant in the   most cost effective way.

Was   the   project  envisaged  in  steel from  the  start?  If  not, why was  it  built  in  steel  in  the end?

Yes, as we are a company grounded in the steel industry.

Give a  brief  description  of  the  structural  framing. What type  of  sections were  used I Beams of various weights have been used, namely the following:

  • 533 X 210 • 406 X 140 • 356 X 171 • 305 X 165 • 305 X I 02 • 254 X 146 • 203 X 133

305 x 305 H Beams • 203 x 203 H Beams • 152 x 152 H Beams

300 x  I 00     Channels  • 152 x 75 Channels

2000 x I 00 Lipped Channels • 150 x 75 Lipped channels • I 00 x 50 Lipped Channels

Give a brief description of the cladding process (complexity, difficulty, innovation etc).

All internal and light-framed buildings are built with a combination of brickwork and steel.

Were there any challenges in the fabrication of the project from the Engineer’s design

As we are a steel company, we have an inventory and supply of steel from other branches in house. We challenged the engineer to construct buildings using the inventory on hand. This task has allowed for us to repurpose old stock and really maximize existing materials. The challenge posed revolved around the load-bearing capacities of the steel from inventory. We have therefore designed the buildings stronger for their applications

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding in this project?

We have used lightweight, high tensile sheeting. We have made use of translucent roof sheeting, which allows for daylight to enter the plant

How did the project team work together (e.g. Contractor involved early, challenges/ease of communication etc.)?

We have a team of dedicated individuals who mind the time and cost constraints of the project. The team is sensitive to work ethic and commitment to doing what is right, rather than what is pleasing. Contractor involvement sought to source the best price, along with the best quality.No project is perfect, nor will they run smoothly, we have certainly had our share of project hiccups, however, we abide by the motto that: “teamwork makes the dream work”.

STRUCTURAL STEELWORK
Completion date of steelwork September 2018 (Phase 1)
Completion date of full project December 2019
Tons of structural steel used 500 tons
Structural profiles used 254×146 I Beam, angles and Lip Channels
CLADDING
Completion date of cladding December 2018 (Phase 1)
Cladding profile/ type used 0.58mm G550 IBR 686 for Roof and Side Cladding
Cladding area/ coverage and tonnage 100 000m2 / 515 Tons
PROJECT TEAM COMPANY
Developer Changing Tides
Architect Changing Tides Architects
Structural Engineer Cassiem Hanse and Associates
Main Contractor Changing Tides 74
Roof Sheeter Changing Tides 74
Quantity Surveyor Changing Tides 74
Cladding Supplier Pro Roof Steel & Tube
Structural Steel Erector Changing Tides 74

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