Construction Designer Magazine (Sept Issue)

CONSTRUCTION design magazineR50.00 Other Countries $10.00 Issue 10/08 Top Billing Dream HomeKenako Mall Port Elizabeth Top Billing Dream Home Industrial Control Transformer

76Developed in Australia, and manufactured around the world, the ENDUROFRAME® buildingsystem has a long track record in manufacturing efficient steel trusses and wall frames.The ENDUROFRAME® building system can be used to design, detail, and manufacture steelframes for the residential and light commercial markets using the ENDURO® all-in-one rollformer.

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Top Billing Dream Home The Mirage, De Waterkant, Cape TownANTONI ASSOCIATES is the Interior Design and Décor The design of the duplex apartment expresses a distinctly modern division of the iconic architectural firm SAOTA. Led by Mark African attitude that is current with today's demands of fast paced Rielly and Adam Court, ANTONI ASSOCIATES has become city living. The apartment is a space of calm and serenity for re-known for creating some of the most exclusive interiors in South energising, relaxing within, floating above the city streets of itsAfrica as well as international locations including Paris, Moscow, location. Using these criteria as the foundation of the designLondon, New York, Dubai and Geneva. This dynamic and direction, the interior is a stylised and dynamic clutter free spaceinnovative practice conceptualises and creates contemporary that is a forward thinking, contemporary luxury urban space thatinterior spaces and bespoke décor for the full spectrum of interior maximises spatial use, cutting edge design and technology.design briefs which includes domestic, hospitality, retail, corporateand leisure sectors. Their interiors meet the international standard The spatial constrictions of the space have influenced the designof being modern, luxurious and seductive while at the same time and careful consideration to ergonomic planning, have influencedremaining understated and timeless and in tune with the delights of the design process. The requirements of the modern urban couple,quality living demanded by their discerning clients. that desire to live a streamlined, fluid and finely focused existence and the need to express one's individuality have been at theThe brief was to transform a duplex apartment shell in the new forefront in the conceptualisation of the apartment. The designMirage Development, being constructed in De Waterkant. This takes advantage of the small space to highlight clever functionalitytrendy suburb is located in the heart of Cape Town and in the day, and wherever possible spaces double-up in function.hosts cool-hunting hipsters frequenting impossibly quaint eateriesand in the evening it becomes the urbanites playground as fashionand art champion the nights. The brief to the Design Dream Teamwas to create a sanctuary for these city slickers, and to create aspace that captures the 'urban chic,' combining contemporary livingwith high design.2

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The largest challenge was that the designers had a small narrow The lower living level features a seamless spatial flow betweenspace with high double volume walls to work with as well as an the kitchen and living room on to the terrace with uninterruptedextensive brief requiring the inclusion of a number of living views of Cape Town's cityscape and Table Mountain. The featureelements. The total internal floor area of the existing shell was black steel staircase slices through the apartment and creates aonly 65 square meters. To define the bare spaces Mark Rielly strong focal point linking to the private bedroom suite upstairs.and Michele Rhoda conceptualised a black and white colour The kitchen design incorporates a Careline kitchen finished inpallet as the base fabrics for the walls, floors and ceilings. white duco which has been matched with white Miele appliances. By cleverly tucking the kitchen underneath theThe concept was to create a light living space with a dark staircase and having the centre kitchen island double up as a barbedroom cubicle cantilevered overhead. This theme of day and and a dining table, the multi-functional lower level can be usednight was introduced to reflect the way in which the apartment both practically and for entertainment.functions differently at various times of the day. To break up the'box space' angular and facetted elements were introduced in The brief also required that the Design Team create a masterthe stair and ceilings to create drama and interest. The large dressing room. Due to the size of the apartment, the designersdouble volume vertical walls were broken up by the feature black combined the master dressing room and en-suite bathroom intostair on the one side and on the opposite wall a cantilevered one and created a dark, 'moody' sanctuary for bathing andwhite glass bridge. The glass bridge extension adds additional dressing.floor area to the apartment and functions as a library platform. Tokeep the apartment spacious, and to accentuate additional floorspace, a number of the design elements such as the joinery,kitchen counters and the TV wall ledge float. Concealed lightinghas been added to these elements for more dramatic lightingeffects.4

There is a strong emphasis on rhythm, geometric forms and graphic furniture is modular, allowing the layout to be re-configured as needelements that are reflective of modern patterns. The general colour be. As the interior needed to be a place of calm and serenity, 'less ispallet is kept crisp and monochromatic for a clean and uncluttered more' was the design rule but still allowing for personal expressionlook and feel. This is warmed up with a beautiful dark wood parquet and individuality to have its place.flooring and again the warm timber is picked up in the angulargraphic timber screen used behind the bedroom wall to separate Renowned for its contemporary take on African luxury, Antonithe dressing room en-suite. The parquet flooring, concealed LED Associates' distinctive style paired with the unique pieces designedlighting and décor items bring the added dimension of warmth into by OKHA, sets this apartment in a category of its own.the space.The Design Team wanted the interiors and artwork to explore theavant gardist graphic of the interior architecture and to introducecolour. Adam Court played with a fusion of modern African graphicand colour to juxtapose the lean,monochromatic interior. Artist DanielOrme was commissioned for the onemajor artwork hung above the staircase.Some of the furniture has multiple uses,i.e. tables that also provide storage, thebookshelves that act as an installationartwork, plus all the furniture wascustom designed to fit in the availablespace allowing enough circulation. TheProject TeamClient: Top BillingProject Manager: AJC ArchitectsInterior Architects: AA InteriorsInterior Décor: OKHA Interior 5

The new face of Lenmed's Public access to quality healthcare, whether Zamokuhle Private Hospital private or public, is a challenge for all stakeholders in the healthcare sector. The in Tembisa - Gauteng revamping of Lenmed's Zamokuhle Private Hospital in Tembisa on Gauteng's East Rand, from a small privately run hospital to a 110 bed facility going a long way in the provision of quality hospital and medical care to the Tembisa community. The extension and establishment of the Zamakuhle Private Hospital is located on Flint Mazibuko Drive and Dr Mahomo Street (Abram O Tiro Crescent), Tembisa Extension 1, Gauteng. The hospital is is owned by the Lenmed Group. Zamokuhle Hospital is a private hospital currently being expanded to a four-floor, 110 bed facility, occupying some 20,000 square meters. This expansions include general wards, operation theatres, ICU, surgical ward, maternity ward, casualty and all related site works. Murray and Dickson Construction Building Division was awarded to be a main contractor and commenced earthworks in October 2014 also they were given additional work on this project to do all the Brickwork, Plaster and Screeds on the Second floor of the Hospital. This area is to be future wards and was to be finished as a shell but the Client decided to finish off all the Wet works as well. Ocon Brick were contracted to supply 750,000 clay stock bricks for the hospital. Often on projects of this calibre, storage space for brick deliveries is limited, making it important that Ocon Brick worked jointly with Murray and Dickson Construction to avoid an overflow of stock at site, which they did.6

Ocon Brick were aware of storage challenges on sitefor some of the projects that they are involved withbefore. They do try to ensure that their products isdelivered to site when required by Site Agents, andthat the amount of clay stock bricks can be stored notonly optimally but securely as well. Ocon Brickmanufacturing capability is so large that can fill ordersfor large quantities of clay stock bricks at relativelyshort notice. This fact greatly assists them in workingclosely with their customers and meeting their deliveryrequirements.This project completed in first quarter of 2016Professional TeamClient: Lenmed ClinicArchitect: SC RouxArchitectsQuantity Surveyor: Koor Dindar Mothei QSElectrical Engineer: JH Systems EngineersCivil Engineer: DNS Consulting Engineers 7

AIRCYCLE Aircycle Engineering is specialised in air-conditioning, refrigeration, compressors and plant maintenance. Engineering342 Soutter Street, Pretoria West, 0117 PO Box 12530, Die Hoewes, 0163 Tel: (012) 327 1414/ 5152 Fax: (012) 327 2420We are proud to be involved in ZAMOKUHLE PRIVATE HOSPITAL PROJECT BWK ENGINEERING SERVICES Consultants in hospital and building services Tel: 021 797 5266 Email:[email protected] 4 Lidford Road, Plumstead, 7800 Western Cape PROUDLY ASSOCIATED WITH THE NEW MEDI CLINIC, CENTURION PROJECT8



Modular building company contributes to major SouthAfrican dam wall Fire-proof project through the construction of fire retardant buildings buildings installed atKwikspace, Sub-Saharan Africa’s leader in prefabricated modular building Clanwilliamsolutions has delivered specialised site constructed fire-proof buildings, Damunique to Kwikspace’s 40mm polyurethane panel offering, to the ClanwilliamDam site. The dam, owned by the Department of Water Affairs, is a gravitydam that was built in 1935 and constructed from concrete to resist largevolumes of water pressure. The dam wall is set to be raised by 13 metres andis one of South Africa’s largest projects set to be completed in a five year roll-out plan.Kwikspace’s involvement has played an integral supporting role to thesuccess of the larger Clanwilliam Dam project and has erected two mainbuilding structures comprising two pre-fabricated office blocks next to eachother: the contractor’s block (952m²) with 40 offices and the engineer’s block(607 m²) providing 25 offices. The project includes five buildings in total, threeof which are workshops with portal frames and sheeted cladding and rollershutter vehicle access doors.The fire retardant feature of the buildings is comprised of panels that aremanufactured with a magnesium oxide portion sandwiched between theouter panels. This provides a fire safety feature where, in the event of fire, thepanels will resist burning for up to 30 minutes. All the walls are filled withinsulating material and lined on the inside with approved materials.The buildings will provide comfortable, air-conditioned office space with highquality finishes to engineering, design, management, administrative andconstruction supervision personnel. Attention to detail includes windows thatwere fitted with burglar proofing and mesh fly-screens, thermally insulatedceilings with air-conditioning/ heater units and flooring fitted to clientspecifications.10

Solar geyser and energy saving electric installations and theplanting of indigenous grasses were also part of the eco-friendlyturnkey solution provided by Kwikspace. A special rainwaterharvesting system was designed and implemented tosupplement normal water supply to the offices. Local labour andsemi-skilled personnel were employed throughout the course ofthe construction period.Comments Kwikspace Executive Manager, Con de Villiers: “Ourexpertise in rapid site setups in remote locations has ensuredthat the two-and-a-half month on-site construction deadline wassuccessfully met, all under challenging weather conditions and asevere sloping site.”Kwikspace is ISO 9001 certified and conforms to the SouthAfrican Bureaus of Standards (SABS) and SANS 10400 for alltheir building designs, unless otherwise specified by the client’slocal standards.Kwikspace Modular Buildings can be contacted on+27 11 617 8000www.kwikspace.co.za 11

No 5 SILO the new Office and Retail Development in the V + A Waterfront – Silo PrecinctThe Silo Precinct has taken shape around one of the city's most prominent industrial relics, the 1921 grain silo that has now been reinvented as the ZeitzMuseum of Contemporary Art Africa. The client, the V&AWaterfront, wanted to create a vibrant, mixed-use andsustainable district that would combine residential, office,leisure and retail opportunities as well as creating apedestrian-friendly link between the Waterfront and thecity.No 5 Silo is the third building in the Precinct to becompleted. The prime requirement was for new officespace to increase the client's rental stock, but also toextend the sustainable and public nature of the precinct.The precinct plan provided for an open shaft of publicurban space between No 5 and the future No 6, theBoulevard, starting from the south façade of the historicalsilo building and extending to South Arm Road. Entry forpedestrians was required from this open shaft of space tothe West of the building, but also from the basements (ashuttle lift) and from the South and East to the newlycreated external Urban Public Realm. This buildingtherefore became pedestrian permeable, with a publicStreet and Arcade allowing access to and through thebuilding from all sides. The intent is that the building beaccessible and public, but also easing access from thebus stop and from the harbour (including the cruiseterminal). This is further supported by retail and publicfacilities at ground level.The Street is not only an “urban” idea, but also becamepart of the Sustainability idea of the building. It is naturallyventilated with high level fans maintaining movement ofair. This becomes a new type of atrium, un-conditionedand public. The green agenda is furthered by otherinnovations such as a central sea-water cooling systemand solar panels on the saw-tooth roof over the street. AGreenstar rating is awaited.We sought design themes that suited the location of theprecinct as part of a working harbour, themes of fit-for-purpose, workman-like and dockside-warehouse.Expressed materiality and appropriate detailing wereconsiderations equally as important as resolving thefunctional and programmatic requirements of the brief.This reinterpreted and extended the ideas alreadyexplored at No 1 Silo.Materials chosen for the building consist of exposedconcrete, raw concrete block-work, unitised glass and tilecladding, glass curtain walling, rough cut timber panelling,exposed steel structural members, steel framing andgrillages, cobble and flagstone paving, bold 'warehousesignage' and 'street lighting'. The vast extract fans at highlevel at both street ends are consciously expressed inkeeping with the language of the design.The roof space is treated as a “fifth elevation” and a usablespace. It is landscaped and utilised as breakaway spacefor the Office users.12

It is the responsibility of every organisation to effectively manage health and safety in the working environment. OHSAS 18001 and ISO 22000 are theinternationally accepted and recognised standards that regulates Occupational Health , Food and Safety Management Systems.Benefits of implementing and adhering to these standards include but are not limited to:•Reduced risk of accidents and incidents by preventing and/ or eliminating workplace hazards.•The health and safety of employees is ensured, maintained and controlled.•Creates awareness of Occupational Health & Safety and Food Safety legislation and promotes compliance within the organisation.•It enhances the credibility of the organisation within the Occupational Health, Safety and Food sectors, and confirms its commitment thereto, to bothindustry and the general public.SHEM Consulting & Training (Pty) Ltd specialises in Occupational Health & Safety, Food Safety and Environmental Consulting Services to all industries,including Quality Management Systems (Implementation & Auditing). SHEM Consulting & Training (Pty) Ltd is accredited to provide the following trainingprograms (including various additional training courses not listed below).The Republic of South Africa: The Republic of Botswana:• OHSAS 18001 – Occupational Health and Safety Management Systems; • OHSAS 18001 – Occupational Health and Safety Management Systems;• ISO 9001 – Quality Management Systems; • ISO 9001 – Quality Management Systems; and• ISO 22000 – Food Safety Management Systems; • ISO 22000 – Food Safety Management Systems;• First Aid Level 1,2 & 3; and• Monitor Occupational Health and Safety (Safety Officer Training for all industries)Our Training Courses are accredited by the following Training Authorities:The Republic of South Africa: Enquiries: The Republic of Botswana:Tel: (+27) 012 808-3811 / +27 12 808 3811 Mobile: (+26) 077 214 1987 / +26 77 214 1987 orMobile: (+27) 071 689 7365 / +27 71 689 7365 or (+27) 082 200 7591 / +27 82 200 7591 (+27) 082 200 7591 / +27 82 200 7591Fax2email: (+27) 086 559 3307 / +27 86 559 3307 Email: [email protected] Website: www.shem.co.za 13

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New Military Health BaseDepot for the SAMHSThe Military Health Base Depot (MHBD) is a formation within sun protection for the large office windows. The advantage of the the South African Military Health Service (SAMHS) design is that one cantilevered HDG steel truss with suspended responsible for the acquisition, stockpiling and distribution of elements is used in place of individual cantilevers at many levels.medical supplies and pharmaceuticals. SAMHS required a larger, Columns could not be used at ground level because of vehiclemore secure and modern base to ensure optimum functioning of movement at the loading bays. Horizontal and vertical HDG steelthis crucial formation within the Department of Defence. channels have finely detailed connections to accommodate filigree and canopy roofs. The structure reads as a light and semi-An existing military property of 64 571m² in Thaba Tshwane was transparent vertical screen against the backdrop of the mass of theselected as the most suitable site.Anumber of the existing buildings industrial scale building. HDG steel provides an excellent durableon site were identified to have significant heritage value and had to and no-maintenance finish at heights that would be difficult to reachbe retained in the new design in future..Total gross building area of the development amounted to ±30 The HDG steel provided the designers with a lightweight structure000m² and the turnkey building cost is R480M (incl. VAT). to resolve aesthetic issues relating to sun control and covered spaces for pedestrians and vehicles. HDG steel provided answersRequirements were met through a campus type development with to resolving difficult architectural and engineering challenges.12 buildings of different sizes and functions, including 5 heritagebuildings being restored and creatively adapted for re-use. The Steel canopies and walkwaysmain functions housed on site are as follows: pharmaceutical Hot dip galvanised (HDG) steel canopies provide protection for thestorage, general storage, vehicle storage, specialist storage pedestrian walkways linking different buildings across the site. The(weapons, ammunition & medical containers), offices, recreation canopy roof in the heritage area is a lightweight structurefacilities, covered walkways & parking. cantilevered from a single line of columns to minimize the visual impact on the historic buildings and ensure free movement ofConstruction was split into 2 phases. The groundworks & demolition pedestrians. In other areas sturdy concrete stub columns supportcontract was 9 months, followed by a main building works contract the steel columns, emphasizing the structural strength and relativeof 30 months. Practical completion was reached in October 2013 lightness of steel. These light structures provide an unobtrusive and elegant physical link to the historic buildings. Their galvanized finishIndustrial aesthetic In keeping with the historic warehouse becomes a continuous visual element that binds the buildings andcharacter of the site and the storage function of the new buildings, site into a cohesive whole with a strong identity.the new design displays an industrial aesthetic. The existing hangarbuildings use steel structures and sheeting extensively. The design Ammunition storeexploits these aesthetics in the new buildings. Prepainted steel The existing ammunition store was identified to have high heritagesheeting on steel support structures is used as side and roof value as there are only a few remaining in the country. However, itscladding for the large warehouse buildings. brick walls were cracking badly and the concrete flat roof was in poor condition. Through creative design and the input of theSteel, especially hot dip galvanized (HDG) steel, is the material of engineer, a way was found to restrict further damage to the buildingchoice to provide structures that are low maintenance with a while still ensuring an aesthetically pleasing end-product thatdurable finish that remain attractive over time. preserves its historic integrity.Meticulous care was given to the detailing and construction of each HDG steel I-columns were wrapped up around the building (withoutbuilding element, including HDG steel. Two architectural clerk of touching it) to carry a new steel roof for protection of the existingworks and a structural resident engineer monitored construction concrete roof. HDG steel angle straps were aligned continuously toquality throughout the project. Quality of work was addressed with the inside and outside of walls with a connecting bolt in-between,the galvanizers, steelwork sub-contractors and the main contractor thus holding the existing walls tightly in position and preventingon a continual basis to ensure a quality product. further cracking. The external facebrick finish therefore remains untouched. The HDG steel straps are connected back to the I-Architectural, structural & workshop drawings were produced to colums for extra stability. Once again HDG steel provided andetail each HDG steel member for the hot dip process. All answer to resolving a difficult architectural and engineeringconnections (bolts, nuts, flanges, etc.) were detailed and challenge.constructed.Steel structure for sun control and loading canopiesFor the three largest buildings a HDG steel sun control grid is visibleone the northern and southern facades. A high level truss thatcantilevers three metres supports the HDG steel grid suspendedbelow it. The structure carries aluminium sun control filigree and asteel roof over the truck loading bays. The filigree provides effective16

Heritage: restoration & re-use required for the steel, preparation processes of the steelwork by theOf the existing buildings on site, two old Bellman type steel aircraft fabricator, logistical considerations and erection processes on site.hangars and one railway type platform building had to be retained A checklist was also put together to ensure that the processes andand restored as per heritage legislation. All were re-fitted internally procedures required for hot dip galvanising are met by both theto accommodate new functions. The doors of one of the hangars Design Engineer, Fabricator, Galvaniser and Erection team.were stripped of sheeting to expose its steel skeleton as a feature. Regular visits were made to both the Fabricator and Hot Dip Galvanisers to ensure that the specifications were being adheredThe steel structure skeleton of another hangar was retained and re- to.cladded with steel and translucent roof sheeting to create a coveredceremonial area. Complete steel structures of another four hangars Coating thicknesses were measured at each visit to ensure thatwere carefully dismantled, documented and re-erected elsewhere. they were within the tolerances required.Although HDG steel was not involved with these buildings, it was The above process ensured a consistent quality coating that willused as loose attachments in the form of walkways, balustrades & add value to the project for many decades to come. It adds the valuetree guards which further enhanced the contrast between old and of a consistent, no maintenance and extremely resilient finish thatnew will outlast any other component or finish available in the market.Steel detailing Professionalism, skills & dissemination of knowledgeDetails of HDG steel elements, their connections and their The project went a long way in ensuring that not only was hot dipconnections with other materials (e.g. aluminium filigree & galvanising specified as a protective coating, but that considerationaluminium ceilings) were carefully coordinated between architect is given to architectural design requirements. The synergy of aand engineer to ensure the final manufactured product fits the durable protective coating and aesthetic value had to be managedarchitects' design concept. with all role players playing a critical role in ensuring that this was achieved. The HDGASA ensured that role players were wellInnovation and the Promotion of Benefits conversed with the requirements of architectural hot dipAs indicated before the choice of finishes and building material was galvanising. Prior visits was arranged to Robor Galvanisers, anadvised by the need for low maintenance costs and durability. There association member, to learn about hot dip galvanising. This waswas also a need to balance the initial costs to the project budget. attended by the Design Engineer, the Fabricator and HDGASA.The project location being an inland area, the elements would notbe exposed to a harsh environment. The design philosophy was The Design Engineer also attended a workshop on thealso aimed at providing a landmark structure. A conscious decision improvements in hot dip galvanising technology which waswas made to provide protection that was environmental friendly and conducted at Robor Galvanisers by Professor Stephens Yeomansat the same time durable. Hot dip galvanized steel provided such of University of New South Wales, Canberra, Australia. This alsoprotection. It was therefore decided that all exposed structural steel showcased the extensive applications which hot dip galvanising iselements would be hot dip galvanised save for the refurbished being used for, e.g. galvanised reinforcing steel for durableelements since it would have been costly to dismantle and taken concrete structures. This assisted the Design Engineer in ensuringthem offsite for galvanising. that specifications and processes of implementing the project were met in line with international norms.The design approach to the facade elements was such that on-sitehandling of the materials would be functional. The elements, Celebration of Superiorityespecially the sunscreen steelwork, were designed in modular The New Military Health Base Depot is a high profile project for thesections to ensure ease of coating (consideration was given to the Department of Public Works and the Department of Defence. It is asizes of hot dip galvanizing tubs around) and erection procedures landmark project because of its size, quality and complexity. Theas well as storage on site. critical function that the Military Health Service fulfils in the South African Military increases its importance and visibility further. AThe Hot Dip Galvanizers Association of SA (HDGASA) was building cost of R 12 200/m² (including site works, excl. VAT) is veryapproached for technical assistance. A technical specification was impressive for high quality buildings like these and sets adrawn up which was approved by the HDGASA. Use of HDGASA benchmark for future state funded facilities of this nature.literature for hot dip galvanizing and SANS 121 was used in puttingtogether the specification. The specification considered addressing 17the coating thickness which would address the architectural finish

Market GrowthThe extensive use of hot dip galvanized components exposed a number of role players (i.e.architects, engineers and multiple sub-contractors and foremen) to its unique characteristicsand requirements. The scale and variety of application effectively showcases the material tolaymen and those in the building industry. It becomes a very clear point of reference to thosewho have not been exposed to HDG steel before.A total of 350 tons of carefully detailed hot dip galvanized steel elements is a notablecontribution to the galvanizing industry for a single project.Sustainable ResourcesThe use of a hot dip finish for the external steel elements impacts positively on the long termsustainability of the project. A strong and relatively lightweight material that requires noadditional paint finishing or maintenance has obvious financial and environmentaladvantages. When used in high or hard to reach places its advantages over other finishesbecome even more clear.Exceptional MeritThe project is unique in the way that galvanized steel is used across an extended site - not onlyas a modular building element in various buildings, but also as an aesthetic visual element thatjoin the buildings, circulation routes and site. Galvanized steel, due to its unique properties, isutilized as a key ingredient to bind other materials, i.e. concrete, brick, steel sheeting & glass,into a coherent whole.ConclusionThe new Military Health Base Depot is a unique project that posed many architecturalchallenges. Hot dip galvanized steel as building design element allowed the design team tocome up with creative solutions that are strong, practical, no-maintenance yet aestheticallypleasing. By carefully considering its properties and advantages, HDG steel was used as thebinding design element to create an industrial complex that is not only functional but alsoaesthetically appealing.Client The Liviero Group is proud to be associated withThe Department of Public Works: Pretoria Region and this prestigious project that received the SAPOAThe Department of Defence: South African Military HealthService Innovative Excellence Heritage Award.Architect & Principal AgentJeremie Malan Architects & Impendulo Design Architects JV Building v Civils v Plant v Mining v Drill & BlastQuantity SurveyorMokate Monk & Du Plessis Tel: +27(0)11 466 2644 Passionate about relationshipsCivil & Wet Services Engineers email: [email protected] Engineering Consultants www.liviero.comArchCADStructural EngineersCivil ConceptsEmzansi Consulting EngineersFire, Electronic & Mechanical EngineersMnjiya Consulting EngineersJP PartnershipElectrical EngineerUkhozi Consulting EngineersLogistics ConsultantFortnaLandscape ArchitectMarian Louw Landscape ArchitectAcoustic ConsultantJacques Rossouw Acoustic ConsultantOccupational Health & SafetySHEM Consulting & TrainingGreen Star Rating ConsultantWSP Green by DesignMain ContractorLiviero Building (Pty) Ltd18

The South African Military Health Base DepotSkilled pro-active management and creative design. 75 Department of Public Works Department of Defence / South African Military Health ServicesTel: 012-460 5388email: [email protected] JV - Impendulo Design Architects 19

EFFECTIVE WATER HARVESTINGThe need to save water has never been more paramount than with manhole access chambers, a sediment filtration system, now. Local municipalities are focusing on upgrading water velocity reducing inlet and outlet overflow structure. Top-up infrastructure systems to stem water wastage and to ensure systems, pumps electrical control system and safety switch can bewater supplies are hygienic for communities. Commercial and supplied by the installer.residential entities are looking to use grey water wherever possibleto cut back on water usage and the related costs. Essentially the system connects to roof downpipes and captures the water for underground storage. This captured water supply canTechnicrete and Rocla, part of the Infrastructure Specialist Group, be re-used for toilet flushing, laundry and gardening activities. It isboth offer water harvesting friendly options through permeable relatively easy to install, maintain, is durable and requires littlepaving solutions and concrete water collection tank systems. maintenance.Concrete Water Tanks Manna Hoogenboezem from Use-Rainwater, who partners withMany water harvesting systems are available for water catchment Rocla on the concrete tank solutions, said “At the moment, in Southand recycling, but one of the key requirements for water re-use is Africa the Rocla option is mainly being utilised by commercial'clean and hygienic' water storage facilities. Rocla, the South applications and in selected residential applications where theAfrican concrete specialists, offer underground, concrete rainwater customer requires a long-term, good quality investment”.harvesting solutions in the form of their ecoRain and ecoRain Plussystems. These systems, which have been applied successfully inAustralia, one of the driest regions globally, are considerably morehygienic when compared to above ground plastic alternativeswhere micro-organisms can grow due to warm, light conditions.The concrete tanks comprise underground precast tanks complete20

The concrete tanks comprise underground precast tanks complete Other benefits of the Rocla concrete tank are that concrete allows forwith manhole access chambers, a sediment filtration system, velocity minimal fluctuations in water storage temperature, which is ideal forreducing inlet and outlet overflow structure. Top-up systems, pumps captured rainwater, which requires a cool and dark environment forelectrical control system and safety switch can be supplied by the natural removal of most micro-organisms. Plastic has a limitedinstaller. lifespan whereas the concrete tank, if managed correctly, lasts a lifetime.Essentially the system connects to roof downpipes and captures thewater for underground storage. This captured water supply can be re- Hoogenboezem said “Use-Rainwater specialises in the design ofused for toilet flushing, laundry and gardening activities. It is relatively rainwater harvesting systems. We support and promote the Roclaeasy to install, maintain, is durable and requires little maintenance. concrete tank concept as it is compatible with many of our own solutions. We are currently preparing final layouts for installation of aManna Hoogenboezem from Use-Rainwater, who partners with Rocla concrete tank system in a residential dwelling in Pretoria. It will beon the concrete tank solutions, said “At the moment, in SouthAfrica the installed in the basement and will be used for potable rainwaterRocla option is mainly being utilised by commercial applications and in harvesting, as well as a back-up water system should the municipalselected residential applications where the customer requires a long- supply be interrupted. If one thinks about the water hygiene coupledterm, good quality investment”. with the storage and recycling capabilities, the Rocla tank is the way forward” he said.“This modular concept is a pre-manufactured tank that can becommissioned and installed within a few days with minimalinterruption at site. While plastic will always be cheaper, a majorbenefit offered by the concrete tank is that the lime in the tank naturallyneutralizes the slight acidity of water – with a plastic tank you have tomanage the water alkalinity, this is not required with the concrete tank.This is an issue that water harvesting users need to be educated on”said Hoogenboezem. 21

Permeable PavingHard landscaped paved walk-and-driveways in industrial andresidential developments are often the first areas under waterwhen heavy rains fall and the storm water dischargemanagement system is inadequate. Imagine being able toeasily remove AND harvest this water supply in anenvironmentally friendly way at source. This water can berecycled as gray water for non-potable or irrigation use.Sustainable Urban Drainage Systems (SUDS) offer preciselysuch opportunities.SUDS are used to prevent and alleviate flooding and unwantedwater run-off in areas that have of necessity hardscaped heavy-duty applications such as car parks, industrial estates, domesticdrives, airport service areas and such like. The TechnicreteAquaflow permeable paving allows heavy rain to infiltratethrough a permeable concrete block pavement via special slotsin the concrete paving blocks, into a special sub-base consistingof stone, where the storm water is then retained in the stonematrix. The water is then ready for re-use or for controlledrelease into sewers or gray water supplies, thereby eliminatingexcessive pressure on existing storm water systems.Heavy metals, hydrocarbons, rubber, dust, silts and other debriswhich are generally deposited on impermeable surfaces duringdry weather, are removed to treatment works, rivers or streamsduring rainfalls causing severe environmental damage andsevere secondary pollution. Technicrete's Aquaflow permeablepaving offers two unique solutions – superior water harvestingand environmental protection.Technicrete's Aquaflow permeable paving not only requires lessspace because of more efficient land use, it is also a more costeffective solution, with the permeable paving offering instantpollution control at source.Analysis of water exiting from the Aquaflow system has beenfound to be as clean as water from a modern sewage works andwith a pH of approximately 7.5, it makes sense to utilise theseunique SUDS philosophies and paving techniques in local waterharvesting operations. To date youth hostels and schools areusing water passed through and filtered by this system for non-potable purposes as lavatory flushing while garden centres areusing the technique to water plants and soft landscaped areas,where it has been found that the Aquaflow system is kinder toplants than ordinary tap water.The most popular usage of these systems is for storm-waterattenuation under large parking areas, thereby reducingdamage to natural waterways from rapidly flowing water.There are three basic designs available: a typical infiltrationsystem, atypical attenuation system with controlled reduceddischarge into the existing storm water management system,and a typical water attenuation and harvesting system, each ofwhich can be tailored to the customer's requirements.22

IRFUflex: An all-rounder for concrete compactionWith the internal vibrator IRFUflex, Wacker Neuson is presenting an extensive expertise in the project business as well as from a wideinnovation within the range of concrete compaction. range of units and special equipment for customer-specific application areas.Wacker Neuson expanded its product range of internal vibrators forconcrete compaction with the new IRFUflex. With a flexible system, Wacker Neuson:you can now cover a broad performance range for concrete Wacker Neuson – all it takes! Wacker Neuson makes this promise tocompaction. customers world-wide with a comprehensive product range of construction and compact equipment, spare parts and servicesWithin the range of concrete compaction, Wacker Neuson presented rendered. Among other things, the product range includes internal andthree high quality product lines of internal vibrators at Bauma. external vibrators for concrete compaction, rammers, vibratory platesCustomers can thus decide for themselves whether they opt for a and rollers for soil compaction, demolition and cutting equipment, lightproduct from the Basic line (HMS) with simple comfort, the Economy towers and generators, heaters and ventilation equipment, as well asline for standard applications (IE/IEC) or the Premium line for excavators, wheel loaders, telehandlers, skid steer loaders andcomprehensive comfort, maximum service life and the broadest dumpers in the field of compact construction equipment. Wackerperformance range (IRFU/IREN). Neuson has always owed its leading market position to unconditional customer orientation as well as the reliability and power of innovationThe modular premium system IRFUflex is entirely new to the product of its products. With its own sales and service organizations in morerange. It is part of the time-tested and proven IRFU series of the than 35 countries, 9 international production locations and numerousPremium line and combines many product advantages into one partner locations for sales and service, Wacker Neuson has a broadflexible system. Thanks to the innovative modular principle and the presence. In addition, Wacker Neuson offers services rendered thatsturdy coupling system, it allows the end user to operate various meet the diverse requirements of its customers. Companies from thevibrator heads with just one converter unit. Replacement is done in a main construction industry, gardening and landscaping, municipalitiesfew simple steps, which results in significant time savings. Vibrator and industry among other sectors therefore rely on the innovativeheads with diameters between 30 and 57 millimeters can be solutions of Wacker Neuson. The brand is supported by the Wackerconnected to a single converter unit. The protective hose belonging to Neuson Group, a corporation with more than 4,600 employees and athe vibrator head has standard lengths of 5 and 10 m, but can also be turnover of EUR 1.38 billion in 2015.manufactured in any length from 0.5 - 10 m at the customer's request.The uncomplicated change-over between the different vibrator heads Wacker Neuson SouthAfrica (Pty) Ltdmakes it possible for the end user of the IRFUflex to adjust the 1031 KatrolAvenue, Robertville Ext. 10, Florida 1710movement radius and to vary the action radius when working with www.wackerneuson.comreinforcing steel mesh of various mesh sizes.The IRFUflex offers particular advantages to rental park operators andlarge contractors. The modular system with just one converter unit andseveral vibrator heads saves costs for acquisition, maintenance andstorage.The appropriate unit can beindividually assembled for everyrental customer or any application.This offers maximum flexibility andincreases the economic efficiencyand utilisation.In 1937, the first internal vibrator forprofessional concrete compactionwas invented by Wacker Neuson.Today, the company's variousinternal vibrators are the most soldworld-wide. This is above all due tothe time-tested and proven qualityand the different possibilities thatonly Wacker Neuson offers with itsthree lines: Basic, Economy andPremium.With the concrete specialists of\"concrete solutions,\" WackerNeuson also offers expert advice forconcrete compaction as an additional service, which can be retrievedvia the Wacker Neuson sales network. Customers benefit from the 23

Mercedes-Benz Pinetwon DealershipThe Mercedes-Benz facility is a multi-level, 10 100m² building and is the firstdealership in the country to incorporate the latest Mercedes-Benz brandspecifications.The NMI Durban South Motors (Pty) Ltd, through their property Benz brand specifications. The Jeep facility also a multi-storey company Rapiprop, are currently in the process of developing building, ±3 500m² in extent and accommodate the Jeep, Fiat, Fiat new state-of –the –art Mercedes-Benz and Jeep showroom and Professional, and Abarth brands. Both buildings were designed toworkshop facilities on the property on the corner of Caversham and include the latest technology for Green Buildings and sustainableHagart Roads in Pinetown. The property previously housed a textile developments, from recycling the crushed material obtained from thefactory which burned down a few years ago, leaving derelict buildings previous buildings on the property to the latest technology inon the property for a number of years. Rapiprop has since acquired photovoltaic energy generation and water recycling and rainwaterthe property and demolished the derelict buildings and is in the harvesting.process of constructing the two facilities.The Mercedes-Benz facility is a multi-level, 10 100m² building and isthe first dealership in the country to incorporate the latest Mercedes-24

The total capital cost of the development and also facilitate glass and tyre fitment byis about R125 million and the project in house experts. CJD have 7 workshopgenerated approximately 250 short-term bays. This can to accommodate approx.jobs during construction, with the 70 cars a day for repairs, and servicing.emphasis on empowerment and a The Mercedes-Benz Showroomtargeted minimum Level 4 B-BBEE rating accommodate approx. 50 carsfor the entire project. Construction of the Chrysler, Jeep and Dodge would have thenew buildings commenced in March 2015, capacity for 30 Showroom vehicleswith the facilities became operational infirst quarter of 2016.The land size is 14500SqmThey have 2 dealerships on the oneproperty – Mercedes-Benz, and Chrysler,Jeep, DodgeAnd have used the latest in greentechnologies, energy savings, water andwaste recycling366 Parking baysThe Mercedes-Benz facility is 4 storiesand 14126sqm, CJD is 2 Stories 3500sqmThey moved into the new premises in firstquarter of 2016The project have employed approx. 110employeesThe building is one of the first in thecountry that shows the latest Mercedes-Benz Modern Luxury theme, and latest CIin both premisesMercedes-Benz have 21 workshop bays, 25

Industrial ControlTransformers SolutionsIndustrial Control Transformers provide a low and safe control meet rigid standards for mechanical durability as well as surpass voltage for the operation of electromagnetic devices such as Agency and Industry electric standards. The Finger/Guard line is motor starters, contactors, solenoids, timers or any other loads designed for all control applications and features integrallyrequiring above average voltage regulation when actuated. There installed, durable molded plastic terminations designed to protectare various types available for various conditions and requirements. against contact with live components with no slip-on plastic coversThe Dry-type step-down transformer Range has an open core and to be broken, lost or misplaced.coil design. These units are designed specifically for industrialcontrol applications where the energizing of electromagnetic Choosing the Correct Seriescomponents creates high in-rush current that must be There are a broad range of industrial control solutions for the mostaccommodated without sacrificing the voltage stability in the demanding industrial applications. Electro-magnetic controlsecondary circuit. They are usually available in series of up to 5000 components demand inrush currents of up to 10 times theVA. The products are offered with ratings from 50VA to 1000 VA; all transformer's nominal rating. While this inrush is occurring, theunits are 50/60 Hz rated. output side of the transformer must not fall below 85%. Using a transformer that does not meet these ratings may cause erroneousSome specifications require installation of large control shut downs of downstream processes. There are four seriestransformers, usually 1000 to 5000 VA outside of the control currently available in the market today to meet complete controlcabinet. This means the transformer must be in a sheet metal needs. The SBE series is available from 50 - 5000 VA, 55°C riseenclosure instead of the usual open core and coil construction and features copper windings and - encapsulation (through 1000method. Most companies meet this need by providing all of the VA) for longer life and protection from the environment. This low tempower, protection, regulation and performance of standard perfor- mance can mean smaller cabinet size or longer life for anyindustrial control transformers. These transformers are wound with electronic components that may be nearby. The SMT series arecopper magnet wire, deliver full nameplate capacity, and provide 115°C rise, aluminum wound and for applications where goodthe high regulation required in control applications. All units must be voltage regulation and higher power capacities (1000-5000 VA) arecertified and covered by warranty. required. The International series meets IEC requirements and IP20 (touch proof covers ordered separately for E models)Durability, Accuracy and Safety particularly for European applications. The HSZ series rounds outThere are various Industrial Control Transformers that have been the series available for control transformers from 1 - 10 KVA thatsynonymous with quality, precision and dependability. Industry- feature either an UL-3R, NEMA 4X or NEMA 4/12 enclosure. Thisleading warranties, expert technical assistance and product unique design, featuring copper windings and encapsulatedsupport ensure premier testing and measurement solutions. construction, can help system designers meet harsherDurability, accuracy and safety have to be the hallmark of Industrial environmental standards or design for a safer installation outside ofControl Transformers. Industrial Control Transformers are a control cabinet. The HSZ series is for applications where cost ordesigned specifically for machine tool control circuit applications. heat issues make mounting the transformer outside the controlThese transformers have the ability to handle potentially damaging panel necessary.high in-rush currents that occur when electromagnetic componentsare energized, without sacrificing the required stable outputvoltage. Designed to meet or exceed the demands of internationalstandards combined with the full breadth of product offering.There is a series designed to improve the dissipation of the heataway from the core and coil assembly providing cooler operation. Inaddition, they seal the transformer's windings and internalterminations within an epoxy encapsulated encased in a durablethermoplastic end cap, protecting them from potentially damagingmoisture, dirt and other ambient contaminants. Furthermore, thecompact design helps minimize the mounting footprint, providingmore flexibility in applications where space is a premium. TheFinger/Guard line of Touch-Protected Industrial ControlTransformers offers the most advanced and versatile designconcepts available to the marketplace today. They are designed to26

For proper transformer selection, three characteristics of the load 3. Add the inrush VA of all components that will be energizedcircuit must be determined in addition to the minimum voltage together. Be sure to include the sealed VA of components that don'trequired to operate the circuit. These are total steady state (sealed) have an inrush, (lamps, timers, etc.) as they present a load to theVA, total inrush VA, and inrush load power factor. Sealed VA - Total transformer during maximum in rush.steady state sealed VA is the volt-amperes that the transformer 4. Calculate selection inrush VAin one of the following two ways:must deliver to the load circuit for an extended period of time. B. A. Selection inrush VA = (VA sealed) 2 + (VA in rush) 2 alternatively,Inrush VA - Total inrush VA is the volt-amperes that the transformer you can use the B. VA sealed + VA inrush = Selection inrush Methodmust deliver upon initial energization of the control circuit. B will result in a slightly oversized transformer.Energization of electromagnetic devices takes 30-50 milliseconds.During this inrush period the electromagnetic control devices drawmany times normal current – 3-10 times nor mal is typical. C. InrushLoad Power Factor is difficult to determine without detailed vectoranalysis of all the load components. Generally such an analysis isnot feasible; therefore, a safe assumption is 40% power factor.Previously 20% PF was commonly used for transformercalculations; however, tests conducted on major brands of controldevices indicate that 40% PF is a safer default assumption.Selection Steps1. Determine the supply and load voltages. The supply voltage isthe available voltage to the control transformer. The load voltage isthe operating voltage of the devices that will be connected to thetransformer output.2. Calculate the total sealed VA by adding the VA requirements of allcomponents that will be energized together (timers, contactors,relays, solenoids, pilot lamps, etc.). Sealed VA data is availablefrom the control device manufacturer. Reliable Transformers Manufacture and supply of all types of transformers, chokes and reactors up to 3.5MVAReliable Transformers is a South African transformermanufacturer servicing the South African and Africanmarkets. Through some of our resellers our productshave been exported as far as Texas and Mexico.We also service the growing infrastructure needs ofSub-Saharan Africa. We regularly producetransformers for customers in Zambia, Angola,Mozambique and the DRC and have suppliedtransformers as far afield as Burkina Faso in WestAfrica.Our product range includes:Ÿ Single & Three phase Dry Type transformers.Ÿ Single & Three phase Oil Cooled transformers.Ÿ Auto TransformersŸ ReactorsŸ ChokesŸ RectiformersŸ Furnace transformersŸ Distribution transformersŸ Intermediate Voltage TransformersŸ Constant Voltage TransformersŸ Precipitator TransformersŸ Plasma Cutting Equipment Tel: +2711 421-2333 Fax: +2711 421-3446 E-Mail: [email protected] www.reltrans.co.za Address: Atlas Industrial Park, 17 Lincoln Road, Benoni South, Gauteng 1508 27

Kenako MallPort ElizabethSituated at the entrance corridor of the New Brighton known where one was if one read the signs, so to speak. By Township, which was established in 1903 and was the first breaking up the facade and by celebrating the entrances into legible officially black residential area in Port Elizabeth, Kenako components on strategic positions of the building that binds it allMall, valued at R195 million, made use of the industrial land that together, makes Kenako Mall a more meaningful, friendly andbecame available to establish itself as a very important retail node recognisable place to shop.that would serve the larger previously segregated community. The main entrance visible from Uitenhage Road and the secondaryInitially the dominant and utility structures of the existing warehouse entrance visible from Spondo Road, the structures constructed outthat constituted the old paint factory site, the emphasis was for the of concrete framework technology and infill face brick panels, in turndesign to enhance the experience of the pedestrian and patrons had a sensible and practical function through clearly defining whichthat would occupy the walkways and entrances between the tenants were positioned at each entrance, by lending the signageexisting buildings into pleasant retail malls. Faced, however, with opportunities for them and also housing the plant slabs for the linederelict buildings and a high demand for retail space, the onset was shops and food tenants requirements so they were not visible fromto sustainably demolish the existing structures by using the crushed the parking on main roads. The two welcoming entrance roofs hadmaterials by shaping the land into the required platforms the retail to be carefully engineered to stand up to the gale force speeds thatcentre required. are experienced in the so-called windy city and yet maintain a sense of elegance when viewed or experienced as one enters the centre.It gave rise to the opportunity to express the building to a very activeUitenhage Road, resulting in good retail principles being applied, Kenako Mall is ventilated and the roof overhangs were addressedsome of which are: that the entrances and parking must be visible by increasing them in length so to maximise the smoke extractionfrom the main roads, the parking has a natural flow and service requirements prescribed by building regulations but to avoid anyareas are hidden behind the building with separate access. The water ingress from driving rains the greater Port Elizabeth is facedoverall dynamic of the building is further scaled in relation to the with, subsequently becoming a roof that appears to loosely floatexisting surrounding industrial context with specific emphasis on over one’s head.the main entrances to the mall through large entrance porticos that,on one hand, mitigatethe scale of the existing surrounding industrialbuildings and, on the other, enhance the retail offering it provides.The distributions of different tenants, with an emphasis on foodtenants at strategic positions such as the main entrance, furtherenhance the experience of a pedestrianised retail node.Kenako Mall is anchored by Shoprite and other btenants includeHungry Lion, Shoprite Liquor, Pep, Mr Price, Truworths, Clicks, Jet,Identity, Legit, Edgars Active, Standard Bank, Fashion IQ, FNB,Cashbuild, Tekkie Town, OK Furniture’s, Morkels, Bears,Debonairs, Chesenyama, Cassies, Ellerines, the Post Office,McDonalds and many other smaller chains totalling a grossleasable area (GLA) of 20,000m², a dedicated taxi area and 995parking bays to satisfy the need for convenience shopping.The massing on site with its future phase 2 will eventually achieve amix of the required retail visibility and road edge definition. Duringthe design stages, the shed-like building typology, with its very longwalkway, created a loss of scale wherein it would have been difficultto identify with ones relevant location and one would only have28

All materials were used very efficiently; this does not onlymake for a building that cam in under budget but lessens itsimpact on the environment. The mall floors are white polishedsurface beds and the materials used are all maintenance-friendly with an industrial feel. The architects chose to use adark colour roof for its lessened visual impact on thepredominantly denser industrial developments around it andnatural light was carefully considered to highlight thestructural rhythm of the mall internally and create a sense ofplay on the brick patterns that were created.The natural light makes it possible to further lessen theenvironmental impact on the lighting requirements for atypical mall and the roof insulation was upgraded to achievemore than the required SANS specification. In the mall, theface brick detailing with its subtle patterns and overall qualityachieved by the contractor shows that there is still a skill to beadmired.DEVELOPERSShoprite Checkers, Prima Retail PropertiesARCHITECTSStauch VorsterArchitectsPROJECT MANAGERSMDSAQUANTITY SURVEYORSMLCSTRUCTURAL & CIVIL ENGINEERSEkconELECTRICAL & MECHANICAL ENGINEERS:SolutionStation Consulting EngineersMAIN CONTRACTORWBHO Fibsol (Fibre Reinforcing Solutions) is a South African based company specialising in alternative concrete reinforcement designs utilizing the latest technology to design cost effective fibre reinforced concrete solutions for a large number of applications. Steel and Polypropylene fibres conforming to the highest international quality standards (ASTM, EN & ISO) are used as a means of reinforcement as opposed to conventional rebar and welded mesh. In conjunction with our international partners/suppliers and our own extensive experience gained both locally and internationally we are able to provide cost saving fibre reinforced concrete alternatives to our clients. We maintain a Quality Management System developed to the requirements of ISO 9001:2008 within the organization ensuring we meet and exceed the expectations of our clients. Our Services: • Steel and Macro Polypropylene fibre reinforcing applications • Micro Polypropylene fibre applications •Alternative reinforcing designs for flooring (Saw cut floors, Jointless floors & floors on piles) •Alternative reinforcing designs for pre-cast products •Alternative reinforcing designs for sprayed (Shotcrete) concrete in mining and tunnels • Fibre reinforcement for slope stabilization • Fibre reinforcement for fire protection in concrete structures • Fibre reinforcement for impact resistant concrete structures • Fibre reinforcement for abrasion resistant concrete structures • Fibre reinforcement for cold rooms and sub-zero temperatures Alternative Services: As Manufacturers of Polypropylene, Steel and High Performance Polymer (HPP) reinforcing fibres, Fibsol is a unique single source for concrete fibres, specifically focused on offering innovative and unbiased Fibre Reinforced Solutions for concrete. Tel: + 27 82 494 0455 I Email: [email protected]/ [email protected] I www.fibsol.co.za 29

Steel, forming the futurefor house framing.Light gauge steel framing is rapidly gaining acceptance around the When deciding on which steel framing system to purchase, aworld as a preferred material for the construction of residential and potential customer should pose several questions to framinglight commercial buildings. Since their introduction around 70 years system providers:-ago, light gauge steel has grown in popularity with the introductionof complex software programs which can model and design steel · Can the framing system I am considering design and manufacturebuildings which are then manufactured by rollformers which form, frames that meet the needs of my target market?punch and inkjet mark steel frames. This can provide an exciting · What is the cost of steel, labour, and accessories to complete aopportunity for businesses looking to provide steel frames into their frame?local market. · Can the system be approved by local authorities in my market? · Does the system have all of the accessories that are required toBlueScope Steel is Australia's largest manufacturer of steel and complete the manufacture, assembly and installation of steelhas been involved with the design, development and manufacture frames?of steel house frames in Australia since the 1950s, and has become · Is training and support available to learn how to use the software,one of the largest suppliers of steel frames throughout Asia over the manufacture and install steel frames? Are there installationlast 15 years. The drivers for the growth have varied from region to manuals?region but common themes have been that steel framing has been · What support goes with the rollformer?cost competitive, is strong yet lightweight, provides a termite- · How well does the software work with the rollformer, and whoresistant alternative, and has not been subject to twisting or warping takes responsibility that the 2 work together smoothly?over time. All of these questions should be asked of a potential framing systemDrawing on its extensive experience with writing software, provider. Submitting a set of plans for the type of jobs that are beingoperating rollformers around the world, and in the manufacture, considered, and asking for a design including material take off tofabrication and installation of steel frames, BlueScope Steel has framing system providers is a good way to compare the pros andcreated the Enduroframe® building system. “We have seen that not cons of different systems.all steel framing systems are the same with many struggling to be Linked parts ensure small pieces don’t get lostcompetitive” says Business Manager, Paul Jones. “Steel framingsystems can vary dramatically in the types of buildings that can bedesigned, the amount of steel used, the cost to assemble, and thelevel of support provided to ensure that a manufacturer can besuccessful. Buying a steel framing rollformer is only a small part ofthe solution in setting up a successful steel framing business.”One of the key factors in determining the efficiency of a steelframing system is the software that drives the entire process. Notwo steel framing software packages are the same and can requiredifferent quantities of steel, and different amounts of labour in thedesign and construction process. In addition, the software is the keyfactor in determining whether the types of buildings in each marketcan be designed and manufactured.Packed and ready to go in complete knock down form. Ease and simplicity in manufacture, fully tested design software30

A steel framing manufacturer should also consider what their In Australia, it is the only steel framing package that can self-certifyfabrication and installation business model will be. There are frames for cyclonic and non-cyclonic regions, eliminating the timemultiple fabrication and installation models which can be and costs of external engineer certification.considered, and include:- The Endurocadd® software links in with the Enduro® rollformer, an. Supply components, manufacturing the frames and trusses in all-in-one machine, capable of producing all steel sections requiredcomplete knock down form for easy on site assembly. for steel trusses and wall frames.Enduro® rollformers are busily· Assemble in factory, Rollform in plant, assemble steel frames, manufacturing framing in Africa, Asia, and Australia. The Enduro®deliver to site. rollformer has been designed for high-speed rollforming , with 15· Outsource fabrication, Rollform in plant, send components to sub punching stations and a heavy duty 1.5 tonne SWL, powered, tilt-upfabricator to assemble and deliver to site. uncoiler, eliminating the need for overhead cranes.· 2D Pre fabrication, Rollform in plant, assemble steel frames, pre Conveniently BLUESCOPE STEEL have an office in Capetown.install external wall materials, deliver to site. To find out more, please contact the ENDUROFRAME® team:-· Full 3D Pre fabrication, Rollform in plant Assemble steel frame, Tel: +27(0)21 442 5420assemble building as a complete unit, deliver to site. Email: [email protected] Black River Park North, Block D Ground Floor, Fir Str,The choice of which model suits a business depends upon the Cape Town, South Africatarget market and mix of factory labour, site labour, and freight Email: [email protected], and a combination may be selected. Web: www.enduroframe.comThe Enduroframe® team has extensive experience in assisting 31clients set up operations and can provide advice on which optionscan be suitable for a business' needs.The Enduroframe® building system incorporates the Endurocadd®detailing software is a core component of the framing system. It isthe result of over 20 years of light gauge steel R&D and constructionfeedback from projects around the world. Using a combination oftest data to confirm actual failure points of frames, sectionsmanufactured with stiffening ribs, and the use of high strengthTRUECORE® 550MPa steel, it is capable of providing very efficientframes designs.TrueCore steel® manufactured by BlueScope Steel, can beshipped globally in slit coil form ready for you to just run it throughthe machine.

MOBILE RACKING IN SOUTH AFRICAN FRUIT STORES.Brought to you by Southern Storage Solutions-DEXIONSouthern Storage Solutions – DEXION, has installed numerous mobile rack Rail support stool. The excessinstallations in conjunction with Barpro Storage which has increased the storage threaded rod is removed when thecapacity of each facility without the expensive task of increasing the room size to rails have been levelled.cater for conventional pallet racking or drive in racking with all the associated extrarefrigeration and electrical costs. Rails can also be retrofitted in existing rooms provided the floor is suitable by levelling the railsTraditionally pallets of packed fruit were stored by securing steel corner posts to on the existing surface and pouring a 150mmeach pallet and then storing another level of pallets on top. While doubling store reinforced slab. A low ramp is needed at thecapacity, this form of block storage effectively prevented stock rotation, increased entrance. The mobile bases run on the rails andstock damage and in some situations prevented adequate cooling. As fruit support pallet racking which is specially designedpackaging became further differentiated, accessing stock quickly for an order for use in a mobile application.became practically impossible. The bases are motorised and energy efficient.Pallet racking was introduced into existing fruit stores to solve these problems. Maximum tonnage per base varies but should not“Drive-In” racking made better theoretical use of the chilled space and reduced exceed 360 tons. In larger stores mobiles areproduct damage. However the accessibility problem was not solved leading to arranged in banks of up to 10 bases, each with its“drive-in” lanes being only partially utilised for immediate access to individual own moving aisle. The bases are controlled eitherproduct lines. The alternative was to use fixed selective racking, giving immediate by push buttons, remote control, or by an interfaceaccess to every pallet but greatly reducing storage capacity. with the warehouse management system. An access aisle is created at the push of a button.Mobile racking was first used in 1997 in a fruit store outside Grabouw in theWestern Cape. Designed to take a combination of 2200mm and 2400mm palletswith a maximum weight of 1000kgs, the pallets were stored with the 1000mm sidefacing and the 1200mm side in the depth of the racks.WHAT IS MOBILE RACKING?Mobile racking consists of special rails that are laid in the floor during construction Mobile Rails with reinforcing before the concrete is poured. A Mobile Base32

Safety measures include photoelectric beams down the Recently, mobiles have been installed in smaller stores, 3 and 2 pallets in thelength of each base and across the front of each mobile height with capacities of less than 450 pallets. Moving aisles have beenbank with additional emergency stops. To move one or widened to allow for the use of counterbalanced trucks and pallet baysmultiple bases takes approximately one minute twenty extended allowing the placement of 3 pallets on the longer 1200mm side.seconds. Mobiles are designed to give lighting signals so Maximum pallet weights have increased to in excess of 1300kgs and storingthat the lights come on only in open aisles. This results in five pallets in the height is now quite possible.energy savings as each light produces heat which must beremoved by the refrigeration system. Barpro Storage are able to manufacture smaller systems locally in their Cape Town manufacturing facility which cuts costs and reduces lead times.The possibility of pallets breaking was removed by using a The racking superstructure supplied by Southern Storage – DEXION ispallet support or saddle beams in the middle of each pallet manufactured locally in Gauteng.slot. These were painted yellow to assist with palletplacement especially on higher levels and increase rackstrength. Another challenge arose when packed fruit storesremained in use for extended periods. Improved ventilationin the mobiles allowed packed fruit to be chilled and storetemperatures were reduced to around 0 degrees C. Frostheave, caused by moisture freezing under the floor, is notgood for mobiles and recent installations have under floorinsulation and heater mats to make sure this doesn'thappen.Pallet Support Beams are important as most Southern Storage Solutions – DEXION. For all your storageSouth African fruit pallets are disposable. requirements. Contact Ron BonthuysThe advantages of using mobiles in fruit stores have Tel: 021 552 0220become apparent over the years. More expensive than email: [email protected]“fixed selective” or “drive in”, mobiles can increase thepractical capacity of a store by up to 75 or 80% while still 33giving immediate access to every pallet. If the total cost of aproposed fruit store is divided by the practical palletcapacity the mobile option can be surprisingly competitive.



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Variable Refrigerant Flow TechnologyVRF systems are enhanced versions of ductless multi-split motorssystems, permitting more indoor units to be connected to each • Variable capacity indoor unitsoutdoor unit and providing additional features such as simultaneous • Better heat exchanger surfaces with multi-segmented coilsheating and cooling and heat recovery. VRF technology uses smart • Improved controls and diagnosticsintegrated controls, variable speed drives, refrigerant piping, and • R-22 to R-410Aheat recovery to provide products with attributes that include high • Better refrigerant charge and oil managementenergy efficiency, flexible operation, ease of installation, low noise, Other features include the addition of concealed ducted units andzone control, and comfort using all-electric technology. ceiling cassette configurations to the traditional wall-mounted units. Refrigerant piping runs of more than 200 feet are possible andDuctless space conditioning products, the forerunner of multi-split outdoor units are available in sizes up to 240,000 Btu/ hr.and VRF systems,were first introduced in the 1950s as splitsystems with single indoor units and outdoor units. These ductless The term “variable refrigerant flow” refers to the ability of the systemproducts were designed as quieter, more efficient alternatives to to control the amount of refrigerant flowing to each of thewindow units. Products have evolved from a few indoor units evaporators, enabling the use of many evaporators of differingoperating off each outdoor unit, to multisplit products with 4 units to capacities and configurations, individualized comfort control,8 units in the late 1980s, to 16 units in the early 1990s, to 32 units by simultaneous heating and cooling in different zones, and heat1999. Today’s advanced systems permit as many as 60 or more recovery from one zone to another. Most VRF condensers useindoor units to operate off one outdoor unit, enabling application in variable frequency drives to control the flow of refrigerant to thelarge commercial buildings. Electronically commutated motors, evaporators.inverter-driven/capacity modulated scroll compressors, multiplecompressors, versatile configurations and complex refrigerant and Refrigerant flow control lies at the heart of VRF systems and is theoil circuitry, returns, and controls have enabled this addition of up to major technical challenge as well as the source of many of the60 indoor units. Refrigerants have also changed. system’s advantages. In most cases, two-pipe systems can be used effectively (in VRF heat pump systems) when all the zones inThe early “mini-split” systems used R-22 refrigerant, then R-407C, the facility require cooling or all require heating during the sameand today’s systems rely on R-410A. Multi-splits offer some of the operating period. Three-pipe (a heating pipe, a cooling pipe and amajor advantages of VRF systems, such as zoning, capacity return pipe) systems work best when there is a need for some of thecontrol, ease of retrofit, low installation costs, and minimizing spaces to be cooled and some of them to be heated during the sameducting and use of secondary fluids and associated costs and period. (This often occurs in the winter in medium-sized to large-losses. On the other hand, their simpler piping results in longer total sized buildings with a substantial core.) One manufacturer has alength of piping compared to VRF systems. Similarly, multi-split two-pipe system than can be used to provide simultaneous heatingheat pumps do not have the opportunity for heat recovery between and cooling as well as heat recovery operations.units that are cooling and units that are heating. As such, multi-splitsystems should be considered for smaller, simpler buildings whereheat recovery is not a possibility and fewer numbers of zones needto be conditioned.How Does VRF Work?Multi-splits include multiple indoor units connected to a singleoutdoor unit. Ductless products are fundamentally different fromducted systems in that heat is transferred to or from the spacedirectly by circulating refrigerant to indoor units (evaporators orcondensers) located near or within the conditioned space. (Whenthe indoor units are in the cooling mode they act as evaporators andwhen they are in the heating mode they act as condensers.) Incontrast, conventional ducted systems transfer heat from the spaceto the refrigerant by circulating air (in ducted systems) or water (inchillers) throughout the building. VRF systems are enhancedversions of ductless multi-split systems, permitting more indoorunits to be connected to each outdoor unit and providing additionalfeatures such as simultaneous heating and cooling and heatrecovery. VRF heat pump systems permit heating in all of the indoorunits, or cooling of the all the units, not simultaneous heating andcooling. Heat recovery systems provide simultaneous heating andcooling as well as heat recovery to reduce energy use during theheating season.Over the years the technology has advanced in a number ofareas:• Standard compressors to variable speed and capacity modulatedscroll compressors• Direct driven outdoor fans to variable frequency drive, inverter-driven fans• Direct driven indoor coil motors to direct current or ECM-type36

Heat recovery can be accomplished by transferring heat between electronic expansion valves andthe pipes providing refrigerant to the cooling and heating units. One advanced controls contributes toway is to use heat exchangers to extract the superheat from the enhanced low temperatureunits in the cooling mode and route it into refrigerant entering a performance that can avoid orheated zone. One manufacturer sends the refrigerant first to the minimize the need for supplementaryunits that require heating, allows the refrigerant to condense, heat in many climates.collects it at a central point and then sends it to the indoorevaporators to do cooling. Most manufacturers have a proprietary Other non-energy advantagesdesign for the heat recovery plumbing and operation with special include:valving arrangements, heat exchangers, controls, receivers and • Better comfort. Since the systemdistribution boxes. can be modulated to follow the load, units can remain running to maintainAdvantages of VRF and Multi-Split Systems temperature within narrow limits,Some of the features of multi-split systems should provide energy assuring a comfortable temperaturesavings. These include: envelope.Good part load performance due to multiple compressor and • Low noise levels. Levels are 24 dBAvariable speed compressor systems permitting capacity for the indoor unit and 56 dBA for themodulation to serve 7% to 100% of the cooling or heating load. outdoor unit (Siddens, 2007).Many hours of HVAC system operation are spent between 30% and • Flexible and quick installation. Only70% of maximum capacity where the VRF system efficiency is high. a small (3” or so) opening is needed for the refrigerant piping.Good zone control, saving by not conditioning unoccupied zones • Low-profile, low space requirements and light weight make unitsand by providing capability to condition single zones off hours at a easier to fit into tight spaces and to avoid obtrusive terminal unitsreasonable cost. Figure 3 shows how VRF systems can provide that could spoil the esthetics of a space.zone control, including simultaneous heating and cooling. Modularity allows easy apportioning of energy costs among tenants or operations.Heat recovery is readily accomplished with the refrigerant when Increased useful building space is enabled by reducing floor to floorsome of the indoor units are heating and some of the units are height (12” ceiling void vs. 20”) and eliminating the need for acooling. According to one manufacturer’s published data, if a 50% machine room.demand for full cooling and a 50% demand for full heating exist, in • Avoids the need for an on-site, trained operator as might bethe heat recovery mode the compressor would only be 48% loaded. desirable with a large chiller based system.Duct losses are confined to the ventilation air which is normallyabout 1/5th of the airflow of a ducted system circulating and Some of the features of the VRF and multi-split systems mayconditioning both the ventilation air and the re-circulated air. (Since result in increased energy costs relative to some competitiveducts are often in unconditioned spaces, duct losses may not systems, and thus offset savings:contribute to building space conditioning). Less economizer cycle benefit may occur with the smaller ventilation system since the ducting is sized just for ventilation.Refrigerant is used directly as both the working fluid and the heattransfer fluid tending to make the VRF system more efficient than Use of supplementary heat may be required for quick recovery fromsystems that use air or water as a secondary heat transfer fluid for night setback. This can be avoided to a great extent by providingdelivering heating or cooling. sufficient time to allow the heat pump cycle to be used with the compressors running at maximum capacity to provide morningThe use of R-410A and other features such a variable speed warm up.compressors, multiple speed fans and blowers, refrigerant circuitry, Use of backup strip heat for space heating in cold weather would be a detriment to the efficiency of the system. However, as indicated above in the list of advantages, speed variation and other features help increase the heat pump capacity to offset some of the vapor compression cycle degradation with lower temperatures. This can avoid or minimize the need for backup heat. Integrated gas heating systems are not available as yet as a dual fuel option. It may be less economical to provide high efficiency components (such as fans, or filter systems) for many decentralized indoor units compared to the efficiency of these systems when installed in a single larger centralized system. 37

Other disadvantages include: spot cooling is needed. Historical buildings have benefited from theThe need for a separate ventilation system to satisfy code minimum alterations needed for the addition of a VRF system.requirements for delivery of outside air offsets some of the retrofit Retrofit situations where air conditioning may be anadvantages of the VRF system. addition/upgrade to the space can be good applications of ductless systems since additional duct work and conditioning needed forEach VRF indoor unit should be supplied with a condensate drain ventilation can be minimized with VRF systems compared to ductedthat needs to have access to a water collection system. systems. Other applications well suited to VRF systems include any case in which there is an advantage to delivering personalized,Long refrigerant runs and large numbers of connections could result compartmentalized comfort conditioning, such as: office buildings,in refrigerant leakage that could be significant, causing safety strip malls, hotels and motels, hospitals and nursing homes, banksissues and repair difficulties. One VRF manufacturer cautions not to and schools.install an air conditioner in a room where the limit density will beexceeded if refrigerant leaks. They assert that the refrigerant Offices and strip malls have occupants with different space(R410A) used by this system is itself a safe refrigerant; however, if conditioning requirements, making the zoning opportunities of VRFfor some reason the refrigerant leaks and the limit density is attractive for these applications. Hospitals and nursing homes canexceeded, there is a risk of injury to persons due to a lack of oxygen. be good candidates since the VRF system makes it easy to avoid zone to zone air mixing. Banks have favored the system for securityOil return (and refrigerant positioning) could be an issue but many because the egress paths into the bank are minimized due to thesystems employ special oil retrieving modes that are periodically, minimal smaller diameter duct work. Even in schools, whichautomatically activated to flush oil (or refrigerant liquid) out of any because of high occupancy often have a 100% outside airlocations where it has accumulated requirement, VRF units can be used (often with heat recovery ventilators) to meet the load.Best Applications for VRF SystemsInitial applications of VRF in commercial buildings have includedbuilding add-ons such as a new data center and situations whereThe latest generation of Daikin’s pioneering VRV heat pump This automatic adjustment means the system only uses the powerand soon to be launched Heat Recovery System has proven as required to meet the load, resulting in 28% less energy beingpopular as previous models, with thousands of new systems consumed and a drop in CO2 emissions of 28%, compared withinstalled across the world. previous generations of VRV. This performance not only meets but actually surpasses the EU’s overall 20/20/20 climate targets thatVRV IV was developed by Daikin Europe N.V.’s European demand 20% less CO2 emissions, 20% more renewable energyDevelopment Centre (EDC) in Ostend, Belgium. It is designed to use and 20% less primary energy use by the year 2020.meet the unique requirements of modern buildings, for everypossible climatic condition, as well as complying with the latest The benefits of this innovative feature were demonstrated during aenvironmental legislation on energy-using products. trial of VRV IV at a branch of a German fashion retailer in Unterhaching, near Munich, Germany, in 2013. The store’s climate“Winner of the 2013 Plus X Award” (World’s leading prize for control was originally provided by a 20HP VRVIII system,innovation in the fields of technology, sports and lifestyle) in comprising two outdoor units. These were replaced by a singlerecognition of its innovative technology, market leading efficiencies, 18HP VRV IV unit, with the rest of the system retained. The trialfunctionality and environmental credentials. showed that the VRV IV system consumed up to 60% less energy inIts great success in penetrating world markets can be explained by cooling and 20% less energy in heating, compared with the VRV IIItwo major enhancements to the already industry-leading system: system – without compromising on comfort.1. Variable Refrigerant Temperature technology2. VRV configurator, for simplified commissioning and servicing 2. VRV configurator, for simplified commissioning and servicing1. How does “Variable Refrigerant Temperature Technology” Another of VRV IV’s innovations is the VRV configurator. Thiswork? allows the remote configuration of settings that can be used atThe unique Variable Refrigerant Temperature technology allows multiple sites, so less time is required configuring outdoor units.VRV IV heat pumps to respond to heating or cooling requirements Ongoing maintenance is easier too, thanks to a graphical interfaceby continually monitoring the required capacity and weather that allows engineers to evaluate operational data and errors.conditions. It takes thermal energy from the outside air to provideroom heating and cooling, ventilation and hot water production from Daikin has been continuously setting the standard for climateone integrated unit (Applicable on air to- air models). control since it first introduced VRV technology in 1982. Innovations, such as inverter controlled compressors and heatIn mid-season, when little cooling is needed, the room temperature recovery, have improved efficiency and comfort and made VRV onewill already be close to the set-point, so a small difference between of the most commonly specified systems for commercial buildingsroom and refrigerant temperature is sufficient for the system to in Europe: about 40% of the VRF systems installed in Europe areoperate effectively. In automatic mode, the system will change the Daikin VRV systems.refrigerant temperature from 6°C (the current operating standard)to a higher temperature, resulting in reduced energy consumptionand significantly improving the seasonal efficiency.38

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