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JUly 2013 Issue: 51
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WE SET THE STANDARD (SANS1273 – 2009
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JULY 2013
Trademax Publications
ISSUE: 51
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EDITOR’S COMMENTs....................................................................................................... 2 steel awards..................................................................................................................4-5 Energy Efficiency......................................................................................................6-7 Refurbishment........................................................................................................... 8-11 hot dip Galvanizing........................................................................................... 12-15 Architecture........................................................................................................... 16-17 Solar.............................................................................................................................. 18-19 Architecture........................................................................................................... 20-21 Waterproofing...................................................................................................... 22-23 Case study.................................................................................................................. 26-27 energy efficiency................................................................................................. 28-29 paints & coatings....................................................................................................... 30 fastening systems....................................................................................................... 32 news............................................................................................................................... 34-35 news............................................................................................................................... 36-37 news............................................................................................................................... 38-39 news............................................................................................................................... 40-41 advertorial.............................................................................................................. 42-43 Product Profile..................................................................................................... 44-45 Cement & Concrete............................................................................................. 46-47 Cement & Concrete................................................................................................... 48
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Publisher: Billy Perrin billy@trademax.co.za 0861 727 663 Editor: Jennifer Rees editor@trademax.co.za 0861 727 663
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DISCLAIMER The views expressed herein are not necessarily those of Trademax Publications. Although we have done our best to ensure the accuracy of our content, neither Trademax Publications nor SA Roofing magazine will be held liable for any views expressed or information disseminated in
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this issue.
22 J U LY 2 0 1 3
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EDITOR’S commentS
On the subject of learning Welcome to the July issue of the SA Roofing magazine.
O
ur 51st issue covers a range of topics relating to the principle of learning; from a case-study on the benefits of insulation on a school environment to one of the 2013 SAISC Steel Awards entries, the UNISA extension project, whose purpose is to accommodate more students to the university in a way that is environmentally responsible. We take a look at case-study of the impact insulation has had on the teaching and learning processes taking place at a Cape Town school. The school in question had built a new extension to the existing building and, with that, installed insulation for thermal stability and acoustic control. This installation took place three years ago and the results, according to the teachers, of the insulation on the learning environment have been telling. Read more about this on page 26.
The UNISA extension project, which is one of the many exceptional entries to this year’s SAISC Steel Awards is an example of intelligent, considered design that takes a number of aspects into account to produce a local work of architecture that houses a growing student population in a highly flexible and adaptable learning environment. Spencer Erling, SAISC education director remarks that he is “constantly amazed how the standard of entries seems to improve each year. Considering the history of high-level work that has been entered into Steel Awards over the years, it is most encouraging that the bar is raised on such a consistent basis.” Read more about this on page 4.
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On the subject of learning, we are also happy to share with our readers that the newly formed Concrete Institute has a busy year ahead with a great line-up of concrete technology training courses scheduled for the year. Also, the new SAPMA/SAPITI Centre of Excellence training facility for the coatings industry is now officially open and will offer training programmes accredited by the Chemical Industries Education and Training Authority (CHIETA) and endorsed by the Department of Labour, as well as the Department of Higher Education and Training. Here’s to learning! Enjoy the read! Jen Please forward your comments, suggestions and contributions to editor@trademax.co.za.
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ste e l awa r d s
UNISA building one of the many
exciting entries in Steel Awards 2013 The extension project at the existing UNISA Cape Town Campus, situated in Parow, Cape Town, is one of several exciting entries to this year’s Steel Awards. This is according to Spencer Erling, Southern African Institute of Steel Construction education director.
“I am constantly amazed how the standard of entries seems to improve each year. Considering the history of high-level work that has been entered into Steel Awards over the years, it is most encouraging that the bar is raised on such a consistent basis,” Erling says.
The design brief included additional administrative space, contact classrooms and examination halls and the creation of social spaces where the distance learning students could interact with each other and sample campus life that hitherto was not possible.
He adds that the work at the UNISA Cape Town Campus is certainly an example of this ongoing quality and innovation in local structural steel design and construction. “An aspect of this year’s theme is ‘proudly South African’ and the UNISA project amply displays the power of local ingenuity for an institution that ranks among the greatest of its kind in the world,” Erling said.
The architects were tasked with designing a building that was environmentally responsible. “This meant that energy conservation, material selection, natural lighting and ventilation and the conservation and recycling of natural resources consistently informed every aspect of the building from inception to detail resolution,” said Michele Sandilands of MSa michele sandilands architects.
Located within a light industrial urban context, the previous UNISA facilities consisted of a combination of new educational and converted industrial buildings. The increase in student numbers and the subsequent burden on the facilities had compelled UNISA to rent nearby factory space, resulting in a sprawling and disparate campus. A decision was made to assimilate all these needs back onto the main campus by erecting a significant extension to the existing building.
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Innovation and the use of steel Because of the need to build as quickly as possible and with as little disruption as possible to the existing campus life a steel frame was, according to the project team, the “optimum way to go.”
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ste e l awa r d s
The extension project at the existing UNISA Cape Town Campus, situated in Parow, Cape Town, is one of several exciting entries to this year’s Steel Awards. “Steel framing and the use of the innovative Cobiax system enabled flexible, unbroken and highly adaptable teaching spaces. The combined use of the steel frame and the Cobiax slab enabled the steel to span even further. With a significant weight reduction of up to 35% of a standard flat slab, there was a significant decrease in the number of columns required with uninterrupted spans of 10m x 20m, which could be demarcated into teaching spaces and examination halls with ease,” they said. Furthermore, the entire building is designed for adaptation. All cross-walls are dry walls so they can be positioned in different combinations, allowing for smaller or larger spaces. Every module has dry jointed door openings with lintels in place to enable an instantaneous knock-out when required. Significantly, the architects wanted a building system that, in its simplest form, was devoid of ‘artificial ornamentation,’ and would still provide key articulation elements and rhythm to the façade. “This desire for an honest and clear building system was well met with the use of steel. Important too was the way in which the building related to its semi-industrial environment adjacent to the major railway line. The use of steel framing and detailing was perfect and tied the building back to its surrounding environment with ease,” concluded the project team. The main sponsor of Steel Awards 2013, which will be held simultaneously in Johannesburg, Cape Town and Durban on the 19th of September, is Aveng Trident Steel. Other sponsors are: Macsteel (Table Décor); Cadex SA (Photo Competition); The Association of Steel Tube and Pipe Manufacturers of South
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Africa (Tubular Award); Stewarts & Lloyds (Light Steel Frame Award) and partner sponsors: ArcelorMittal SA; B&T Steel; Eazi Sales & Service; Genrec Engineering; NJR Steel; Peddinghaus; Tubular Holdings; Vital Engineering.
Project Team Developer/ Owner: University of South Africa (UNISA) Architect: MSa michele sandilands architects cc Structural Engineer: Nadeson Consulting Quantity Surveyor: BTKM Quantity Surveyors Main Contractor: Filcon Projects Steelwork Contractor: Raven Steel Steelwork Contractor (secondary elements): Olympic Steel Mechanical and Electrical Engineers: BVI Consulting Engineers Landscape Architect: TK Landscape Architects
For more information on Steel Awards 2013 please go to www.saisc.co.za
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E n e rgy Effi c i e n cy
Rational energy design Experience in applying the rational assessment path to compliance for the SANS 10400 Part XA energy regulations. Article supplied by Warren Gray, a sustainable design engineer at Solid Green Consulting.
I
t has been over two years since the new SANS 10400 Part XA energy efficiency regulations for buildings were introduced to the market. Building councils are starting to get up to speed and professionals are gaining experience in applying the code. Supporters argue that in the absence of energy regulations, running costs are passed onto consumers and further strain is placed on the already-struggling national grid. Critics reply that significant costs are levied on to the initial build price tag. Others are concerned about the restrictions placed on the architect in the use of glazing as an element in the design. The existing accreditation training courses deal almost exclusively with the prescriptive path to compliance. That is, how to calculate the glazing and insulation properties required to pass at council. Few professionals know that an alternative to the prescriptive path exists.
The prescriptive path The deemed-to-satisfy, also known as the prescriptive path to compliance, requires that physical properties of the building meet a set of minimum criteria. This operates under the assumption that building fabric and geometry reliably correlate with building energy use. There is no requirement that actual systems in the space – lighting, heating and cooling – meet any efficiency standard comparable to that against which the fabric and geometry are judged. As professionals familiarise themselves with the code, many are starting to ask questions about the prescriptive path to compliance. Are highly insulated roofs beneficial in all cases? Are thermally broken frames and double-glazing the best places to spend budget if saving energy is the goal? Given that buildings are not mass-produced and rather vary vastly in their uses and forms, a one-size-fits-all approach is unlikely to fit anyone well.
The performance path The rational assessment, also known as the performance path to compliance, requires that the design team prove that the building is designed to meet actual energy and peak demand limits. This is analogous to the method in which automobile efficiency is regulated. Motor manufacturers need to meet certain minimum fuel consumption numbers. They may achieve this in whichever way is most rational in delivering all the other performance criteria required by the consumer. There is no requirement for motor companies to change car geometry or engine size to achieve this. They are free to arrive at the solution that suits them best, provided they directly address that which is being regulated, fuel consumption and CO2 emissions.
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In the case of buildings, the regulation refers to peak demand and annual energy consumption. Design teams may do whatever they like, provided they achieve these targets as codified in the regulation. In other words, the minimum requirements in glazing and insulation of the prescriptive path do not need to be met if a rational assessment is done. Arguments for and against both paths to compliance exist at the policy level. The legislative process has arrived at different solutions in different parts of the world. The UK, Australia and the United States all offer performance paths to compliance. The UK has done away with the prescriptive path to compliance and the Australians are in in the process of doing the same.
Choosing a path to compliance What building professionals are really interested in boils down to the most cost-effective and functional way to meet regulations. This holds true when referring to fire, fresh air, energy efficiency or any other parts of the building code. Whether or not the best way to achieve this lies in the prescriptive or the performance path to compliance is dependent entirely on the building type and size. If the building in question is a traditional ranch-style house with punch windows, then the prescriptive path to compliance will almost certainly be the best value. The glazing ratio will be low enough such that regulations will require no changes to the glass or frames. High amounts of insulation will be required for the roof, more than would be applied if the design were to be rationalised, but the extra cost will be lower than the cost of rational assessment. This of course assumes that the architect levies no additional fees in the calculation and reporting of the deemed-to-satisfy requirements. In the case of a highly glazed office building, the prescriptive path to compliance is certain to increase the cost of the glazing system substantially. In the design of office buildings, budget used on energy efficiency is not limited only to glass and insulation. A given sum of money may be more effectively spent on more efficient heating and cooling equipment or lighting control, as opposed to thermally broken frames. This is the principal aim of the rational assessment; to allow design teams to show that their rational design achieves the minimum energy efficiency thresholds while maintaining commercial and technical viability. In an application such as a large retail complex with vast roof area, the cost difference between a rationally designed thickness of roof insulation and the amount needed to meet the prescriptive requirement can amount to a significant cost over the project. In this case, the rational assessment may provide a cheaper alternative.
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Building type
Estimated cost of XA rational assessment
Free standing house
R10,000 - R20,000
Multi unit residential complex
R30,000 - R60,000
Small commercial office building (<4000m²)
R25,000 - R50,000
Large commercial office building (> 4000m²)
R30,000 - R60,000
Large retail complex
The simulation model is aimed at predicting the energy use of the building, and is of little comfort if results do not correlate with reality. Fortunately, metering data confirms what the models predict â&#x20AC;&#x201C; that the energy allowances are higher than what new buildings are using.
E n e rgy Effi c i e n cy
In order for the rational assessment to bring about change in the industry requires reasonable energy allowances to be defined in the code. If allowances are too strict, no one would use it as an option. As it currently stands, however, the rational assessment path to compliance is very difficult to fail. The energy allowances for all building types are higher than most business-as-usual modern designs will use. The reality of this is that the vast majority of buildings will need to make no changes to their initial design, and only require having a rational assessment done. Users of the code performing rational assessments question the quantum of the energy allowances. Schools, for example, are allowed to use double the amount of energy per year than commercial offices, despite being a far less energy intense space.
Up to R75,000
What the rational assessment involves If done correctly, the rational assessment begins with the construction of a 3D computer model of the building from architectural plans. Material properties, operational profiles and heating, cooling and lighting system data are entered into the model. The details entered into the model must match those that will be built in the actual building. An annual energy simulation is then run in the context of the climate. Peak demand and annual energy use must then be reported. An energy performance summary and details of the simulation process are submitted to council in the form of a modelling report. Details showing how the model exactly reflects the design are shown in this report for assessment.
From the policy level, the advantage of the rational assessment path to compliance is that legislators may slowly reduce the energy allowances over time to push the market towards quantifiable energy savings. Right now the high allowances place no pressure on design teams to change their existing energy efficiency practices. Feedback from industry will hopefully bring down the energy allowances in future revisions of the code, such that new buildings will be driven toward an efficient future.
About the author Warren Gray is a sustainable design engineer at Solid Green Consulting. He has presented on the topic of the rational assessment path to compliance with SANS 10400 Part XA at the Gauteng Institute for Architects, Durban City Building Council and various universities.
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Ashgrid ‘Raises the Bar’ in Roof Refurbishment
R e fu r bi s h m e nt
TM
The revolutionary Ashgrid™ Spacer System offers a simple, costeffective and safe solution to the refurbishment of asbestos-cement and steel roofs in Southern Africa. Words: Dion Marsh
T
raditionally in South Africa, roof refurbishment has been tackled by simply replacing the old roof covering with new. Repairs are, in most cases, a short-term solution and thus not cost-effective over the life cycle of the building. Excessive foot traffic during repairs of a roof that has reached its life expectancy can often result in additional water ingress problems rendering this option counter-productive and risky for both the customer and the contractor. Roof replacement has serious cost, safety, and logistical implications, especially when dealing with asbestos-cement roofs. It is widely accepted internationally that the removal of asbestos-cement roof sheets poses the highest risk of releasing asbestos fibres. The Asbestos Information Centre of the United Kingdom (www.aic.org.uk) states: “Asbestos materials, which are sound, undamaged and not releasing fibres, should not be disturbed. Their condition should be monitored on a regular basis. Removal should only be performed where repair is not possible or the material is likely to be disturbed.”
OVER-ROOFING ASBESTOS ROOFS
Some of the benefits of overroofing asbestos-cement roofs are: • Over-roofing eliminates the costly and invasive procedure of stripping and removing the old asbestos roof sheets. • Over-roofing the existing asbestos roof sheets prevents deterioration commonly caused by weathering and exposure to the elements. • Leaving the existing asbestos sheets in position poses less danger to both the contractor and occupants of the building than removal. Asbestos fibres are at most risk of being released when the roof sheeting is removed. These fibres can find their way into inaccessible areas within the building, such as air-conditioner ducting and cavity walls. • Over-roofing asbestos roofs is less harmful to the environment than removal and disposal. • Over-roofing improves the overall energy efficiency of the entire building. • Over-roofing reduces labour and haulage costs considerably. • Over-roofing improves site safety.
OVER-ROOFING STEEL SHEETED ROOFS Over-roofing of steel sheeted roofs may not be as costeffective in comparison to asbestos over-roofing, but the benefits far outweigh the cost savings. Over-roofing with the Ashgrid™ Spacer System creates an engineered and tested, structurally defined cavity between the old and new roof coverings. When insulated, this cavity dramatically improves the overall energy efficiency of the entire building. With ever increasing electricity prices in South Africa, energy consumption has become a big concern for most property owners and tenants. Significant financial savings are possible over the life cycle of the new roof covering when insulated appropriately. Over-roofing is a non-invasive form of refurbishment and the occupants of the building can continue with business whilst the work is being carried out. Disruption of trade, security and safety problems associated with conventional re-roofing are completely averted when over-roofing.
Enclosure of asbestos-cement roofs by means of over-roofing is widely recognised internationally as a safe, cost-effective and non-invasive alternative to removal. The Ashgrid™ Spacer System has been used extensively over the last 15 years to over-roof in excess of 10 million square metres of asbestoscement roofs in the United Kingdom alone.
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R e fu r bi s h m e nt
STEENBRAS DAM PROJECT
accommodate the specialised ThermocousTex blanket which was supported by steel straining wires laid over purlin. The Ashgrid™ System then provided the structural interface between the new Saflok 410 concealed fix roof sheets and the underlying steel purlins whilst preventing compression of the insulation blanket. By installing the insulation blanket overpurlin a continuous layer was achieved, eliminating thermal bridging and improving acoustic performance.
AL-GHAZALI SCHOOL
Location: Gordons Bay, Western Cape Client: Cape Town City Council Roofing Contractor: Indawo Project details: Refurbishment The building houses the main control centre and three sixstorey shafts containing the pump turbines. There was particular concern regarding the safety of the contractors, the building’s occupants and the high-tech equipment housed within the building. The removal of the old roof sheets above the turbine shafts would have presented numerous safety challenges and a further risk of falling debris causing damage to the turbines and electronic equipment. Over-roofing with the Ashgrid™ System allowed the contractor to completely refurbish the roof, whilst leaving the existing roof sheets in position. The old roof covering served as the perfect fall protection and prevented any falling debris from entering the turbine shafts. The normal day-to-day operations continued within the building, without disruption, whilst the new roof covering of Diamondek 407 was being installed.
NO 1 SILO PROJECT
Location: Pretoria West, Gauteng Client: Al-Ghazali School Architect: Alet Bredenkamp, Ekis Architects Roofing Contractor: LeCool Construction Project details: New Build To comply with the new SANS 10400XA legislation the Ashgrid™ System was specified to create a defined cavity above the conventional steel purlins to accommodate the fibreglass insulation which was supported by a profiled steel liner sheet. The Ashgrid™ System then provided the structural interface between the new roof sheets and the underlying steel purlins, whilst preventing compression of the insulation blanket. By installing the insulation blanket and liner sheet over-purlin, a continuous layer was achieved, eliminating any risk of thermal bridging. The profiled steel liner sheet was used as a finish with exposed steel trusses.
OTHER PROJECTS NEW YOUNGMAN ROOFING FACTORY, MAITLAND WESTERN CAPE (NEW BUILD)
Location: V&A Waterfront, Western Cape Client: V&A Waterfront Roofing Contractor: Scheltema Roofing Project details: New Build This 6 Star Green Rated project (Awarded by the Green Building Council of South Africa) had very specific requirements regarding energy efficiency and acoustic performance. The Ashgrid™ System was used to create a defined cavity above the conventional steel purlins to
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The Ashgrid™ System was used to seamlessly to integrate various forms of rigid and blanket type insulation into the roof space to showcase their product range in their new sales office whilst complying with the requirements of the new SANS 10400XA Energy Efficiency Legislation. The cavity created by the Ashgrid™ System also served as a void to hide the electrical services. The Ashgrid™ System provided a structurally sound interface between the existing steel structure and the Diamondek 407 concealed fix roof sheeting.
This particular domestic dwelling with cathedral-type ceilings was unbearably hot during the summer months and very cold in winter. The roof had reached the end of its serviceable life and required replacement. The Ashgrid™ System was used to over-roof the existing roof covering. The defined cavity created by the Ashgrid system was insulated with 160mm of blanket type insulation. The overall thermal reductions in summer and the retention of heat in winter resulted in a far more comfortable and energy efficient living space.
R e fu r bi s h m e nt
Contractor: Lemco
Comprehensive photographic case studies are available at www.facebook.com/AshgridSouthAfrica
HEIDI ZOLLNER ARCHITECTS, DEVILS PEAK, WESTERN CAPE (OVER-ROOF)
Dion Marsh General Manager Mobile: 082-852 3424 Fax: 086-610 5441 Email: dion@ashgrid.co.za Web: www.ashgrid.co.za www.facebook.com/AshgridSouthAfrica
Contractor: Metro Roofing
CLASS 3 AND CLASS 4 SCREWS CORROSION PROTECTION
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WARRANTY
Double Conventional Class 4
DURABILITY
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DRILL DRIVE PERFORMANCE 28% Faster than Conventional Class 4
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CONFORMANCE
Exceeds AS3566 Class 4
COMPATIBILITY
Zinc/Aluminium, ZINCALUME®, COLORBOND® ULTRA® Steel, COLORSTEEL® Maxx, Galvanised & Zinc Coatings
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h ot d i p Ga lva n i z i n g
Corrosion of zinc
Corrosivity of atmospheres Used by the HDGASA to determine service life of hot dip galvanized steel exposed to various atmospheric environments Reference source: ISO 9223:2012 Summary of ISO 9223 specification The ISO 9223 specification considers key factors in determining the atmospheric corrosion rate of carbon steel, zinc, copper and aluminium. These factors are: 1. Time of wetness, Table B.1 – Classification of time of wetness (τ) being the period that the zinc surface is covered by liquid containing the corrosive elements (electrolyte). 2. Outdoor concentration, Table B.2 – Some of the most important range of pollutants. 3. Pollution by sulphur containing substances represented by SO2 , Table B.3 4. Airborne pollution containing salinity, Table B.4 – represented by chloride usually in the form of chlorides carried in the prevailing winds from off the sea. NB: This information will only consider the corrosion rates of zinc. Classification of atmospheric corrosivity include three additional ISO specifications, these are: 1. Guiding corrosion values of each category for specific metals ISO 9224. 2. Measurement of environmental parameters affecting atmospheric corrosivity ISO 9225. 3. Determination of corrosion loss on standard specimens ISO 9226.
Category
Various tables are published within the ISO 9223:2012 specifications and are listed here for reference purposes. Detailed data pertaining to each of these tables are contained within the ISO 9223:2012 specification. Table B.1 – Time of wetness in different exposure conditions (τ). Table B.2 – Outdoor concentration of some of the most important pollutants in different types of environments (a range of pollutants). Table B.3 – Grouping of pollution by sulphur containing substances represented by SO2 . Table B.4 – Grouping of pollution by airborne salinity represented by chloride. Table C.1 – Description of typical atmospheric environments related to the estimation of corrosivity categories.
Table 1 – Description of typical atmospheric environments related to the estimation of corrosivity categories:
Typical environments - Examples
Corrosivity
Indoor
Outdoor
C1
Very Low
Dry, air-conditioned with low relative humidity and insignificant pollution, e.g. offices, schools, museums.
Dry zone very low pollution and time of wetness, e.g. certain deserts, central Arctic/Antarctica.
C2
Low
Unheated, no air-conditioning with restricted variation in temperature, humidity and minimum condensation and pollutions, e.g. storerooms, sports halls.
Temperate zone (dry or cool) with minimum pollution (SO2 < 5μg/m3), short time of wetness, e.g. rural areas, subarctic areas, some arid and desert areas, small villages or towns.
C3
Medium
Moderate frequency of condensation, pollution from process plant, e.g. foodprocessing, laundries, breweries, dairies.
Temperate zone with medium (SO2 5 to ≤ 30μg/m3) or some effect of chlorides, e.g. urban areas, between one to thirty kilometres (depending on prevailing winds, buildings, vegetation and topography) from the ocean, or within one hundred metres of sheltered coastal areas with low chloride deposits.
C4
High
High frequency of condensation, time of wetness, high pollution from production process, e.g. industrial plants, swimming pools.
Temperate, subtropical to tropical low to high pollution (SO2 30 to ≤ 90μg/m3) or substantial chloride effect, e.g. < than one kilometre of the ocean or within one hundred metres of sheltered coastal areas and outside the splash zone of salt water.
Very High
High frequency of condensation, periods of time of wetness, and/or high pollution from production process, e.g. certain mines, caverns for industrial purposes, unventilated sheds in subtropical and tropical zones.
Subtropical to tropical, periods of time of wetness, very high industrial pollution (SO2 90 to ≤ 250μg/m3) or significant chloride effect/deposits, e.g. industrial polluted areas, jetties and offshore structures, within a few hundred metres of the ocean and certain exposed areas along the coastline.
Extreme
Almost permanent condensation or extended periods of exposure to extreme humidity and/or high pollution from production process, e.g. unventilated sheds in humid tropical zones with penetration of outdoor pollution including airborne chlorides and other pollutants and particulate matter.
Subtropical to tropical, extended time of wetness, very high industrial pollution (SO2 > 250μg/m3) or significant and extended chloride effect/deposits, e.g. highly industrialised and polluted areas, jetties and offshore structures, within a few hundred metres of the ocean with extended periods of on-shore prevailing winds and certain exposed areas along the coastline and within the splash zone of salt water.
C5
CX
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Tables used in the development of the atmospheric classifications (reference source ISO 9223:2012)
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h ot d i p Ga lva n i z i n g
The typical descriptions detailed in Table 1 are intended as a general guide only and it is recommended that a review of actual site conditions should be undertaken before finalising the applicable corrosive category. A general review of existing hot dip galvanized structures is an ideal method used to establish the corrosive conditions in the general area of a particular site.
Corrosivity Category
Table 2 – Estimated service life for hot dip galvanized steel (zinc) complying with SANS 121 (ISO 1461:2009) and subjected to atmospheric environments classified in terms of ISO 9223:2012
Corrosion Rates (rcorr) and Service Life in Years for Hot Dip Galvanized Coated Steel (Ref ISO 1461:2009 and ISO 9223:2012)
Units
Zinc
55μm mean coating thickness for steel ≥ 1.5 mm to ≤ 3mm (years)
70μm mean coating thickness for steel > 3mm to ≤ 6 mm (years)
85μm *** mean coating thickness for steel > 6 mm (years)
C1
μm/a
rcorr ≤ 0.1
> 80
> 80
> 80
C2
μm/a
0.1 < rcorr ≤ 0.7
< 78
> 80
> 80
C3
μm/a
0.7 < rcorr ≤ 2.1
26 to ≤ 78
33 to < 80
40 to > 80
C4
μm/a
2.1 < rcorr ≤ 4.2
13 to ≤ 26
16 to ≤ 33
20 to ≤ 40
C5
μm/a
4.2 < rcorr ≤ 8.4
6.5 to ≤ 13
8.3 to ≤ 16
10 to ≤ 20
CX
μm/a
8.4 < rcorr ≤ 25
2.2 to 6.5
2.8 to 8.3
3.4 to ≤ 10
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13
h ot d i p Ga lva n i z i n g The conservative and wide range of service life estimates shown in Table 2 are only intended as a general guide. It is a recommended requirement that a more detailed assessment of the actual site environmental conditions should be investigated in order to refine longevity expectations for hot dip galvanized carbon steel.
The synergy factors vary from 1.5 to the extreme corrosive environments to 2.7 in less aggressive environments. In a highly aggressive environment (ISO 9223:2012 C4, C5 and CX corrosivity categrories) hot dip galvanizing on its own tends to become marginal in terms of service life extension. On the basis of the synergistic effect increase factor of 1.5, Table 4 has been developed.
Duplex Systems Duplex systems (hot dip galvanizing plus suitable paint system) provide synergy by virtue of the fact that the durability of the combined hot dip galvanized substrate and top organic coating system is greater than the sum of the separate durabilities of the two forms of corrosion control. Synergistic effect can be estimated mathematically as follows: Duplex Life = factor x (zinc life + paint life)
Table 3 â&#x20AC;&#x201C; Synergistic protection provided by the combined use of a zinc coating and a paint coating (Refer Jan van Eijnsbergen and Porter) Environment
Synergistic Effect Increase Factor
Industrial and Marine
1,8 to 2,0
Seawater (immersion)
1,5 to 1,6
Non-aggressive climate 2,0 to 2,7
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Corrosivity Category
Service life in years for Duplex Coated Steel Units
Hot Dip Galvanizing rcorr
85μm*** mean coating thickness for steel > 6 mm (years) **
Estimated service life of a 2 coat paint system 270 to 300 μm (years)
Estimated service life of a Duplex system 355 to 385 μm (years)**
C1
μm/a
rcorr ≤ 0.1
> 80
15
Not required
C2
μm/a
0.1 < rcorr ≤ 0.7
> 80
15
Not required
C3
μm/a
0.7 < rcorr ≤ 2.1
40 to > 80
12
Not required
C4
μm/a
2.1 < rcorr ≤ 4.2
20 to ≤ 40
10
(20 + 10) x 1.5 = 45
C5
μm/a
4.2 < rcorr ≤ 8.4
10 to ≤ 20
8
(10 + 8) x 1.5 = 27
CX
μm/a
8.4 < rcorr ≤ 25
3.4 to ≤ 10
6
(3.4 + 6) x 1.5 = 14
h ot d i p Ga lva n i z i n g
Table 4 – Estimated service life for Duplex system (zinc plus paint) complying with SANs 121 (ISO 1461:2009) and subjected to atmospheric environment classified in terms of ISO 9223:2012 ** Assumes the worst case in terms of hot dip galvanizing figures used in calculating Duplex service life. The document ‘Duplex Coating – An overview,’ is available from the Association. *** In most structural steel applications the mean coating thickness of 85μm is generally exceeded by upwards of 100% due to reactive steels. The service life in this instance is therefore quite conservative.
The images in this article indicate the residual hot dip galvanized coating thickness taken on applications which have been exposed for a number of years and still provide coating durability according to customers' requirements.
For more information, contact: Hot Dip Galvanizers Association Southern Africa Johannesburg – Bob Wilmot (t) 011 456 7960 (c) 082 325 8840 (e) bob@hdgasa.org.za
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Cape Town – Terry Smith (t) 021 797 4735 (c) 082 893 3911 (e) terry@hdgasa.org.za www.hdgasa.org.za
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A rc h ite ctu r e
Bridge Park
The new focal point in Century City, Cape Town The new Bridge Park development is the epitome of contemporary architecture and will be located in the heart of the new Bridgeways Precinct. It will offer 18 700m² of prime office space in its striking Century City location.
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esigned by dhk Architects for developers, Rabie Property Group and Growthpoint Properties, the site will be a new focal point for the area. Construction on the new office buildings is due to commence at the end of 2013 and the completion thereof scheduled for early 2015. The four-storey buildings, located on an attractive green podium, will dominate the view from both Ratanga Road and Bridgeway with their striking glazed and aluminium panelled façades, large balconies and enclosed private forest spaces. The focus has been on both aesthetic and functional aspects of the space so that it truly is a wonderful place to work.
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“The design seeks to leverage the position of the site so that the views are unparalleled. Design ethos is carried throughout, with each building receiving generous lobbies, a full height central glazed atrium and a private enclosed forest, creating a powerful design statement. The communal spaces within the buildings provide meeting points and spaces for collaboration, while, the tranquillity of the forest areas, provide places for contemplation,” says Derick Henstra, Executive Chairman of dhk Architects. The design of the façades and of the glazed atriums ensures optimum light penetration throughout the office spaces, while carefully controlling both glare and heat gain, ensuring the comfort of the occupier.
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A rc h ite ctu r e
The large floor plates promote efficiency, flexibility and connectivity for prospective tenants. Secure basements provide parking at a ratio of 3,5 bays per 100 m² of GLA, while visitors parking and cyclist facilities are provided on the green podium.
“The project is registered for a Green Star SA Office Design v1 rating. We recognise the importance of sustainability and ecological responsibility within our designs and have worked hard to ensure that our buildings achieve these ratings,” says Henstra.
Bridge Park East and West are designed to provide a healthy and productive working environment for occupants.
Reg No: CoR18.3 2013/068719/07
VAT No: 4930188372
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Solar
New legislation and rising electricity costs force increase in solar power usage across South Africa The South African economy is very sensitive towards the topic of energy, mostly owing to the price of electricity, the scarcity of electricity, climate change and a focus on sustainable living.
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n a bid to not only combat the electricity shortage issue, but to force a movement towards an increase in sustainable living, late last year a new legislation was passed whereby at least half of all hot water supply in all new buildings, residential or commercial, are to be produced by means other than electrical resistance heating (i.e. Eskom). According to the new legislation ('SANS10400XA'), “A minimum of 50% by volume of the annual average hot water heating requirement shall be provided by means other than electrical resistance heating including but not limited to solar heating, heat pump, heat recovery from other systems or processes.” The result is that builders, contractors and even architects must change the way in which they plan and construct all new buildings to ensure that the new laws are met. Statistics identify the support of the new legislation, showing that the use of solar power in both residential and commercial buildings is now climbing swiftly, and has been doing so since the new legislation was passed. According to Ori Saban of leading solar water heating product supplier and installation company, AGS Solar, ''As a result of the new building regulations, homeowners and companies are becoming more aware of the need to invest in solar energy and more predominantly solar water heating (SWH). The bottom line is that this new legislation has now remoulded the way in which properties are built, as architects/designers now need to implement the new standards and requirements to ensure they meet the new legislation. The building industry has become even stricter, and if the regulations are not adhered to, it will result in plans not being passed.”
to a large decline in consumers and trade installing solar water heating units. This affects the entire industry and consumers became less confident in solar power. These poor quality products are being filtered out, but again it is important that consumers do their research when making such solar power decisions. Poor management of the rebate programme in the past was a factor that also attributed to its uncertainty, which is why we take over and manage this procedure on behalf of our customers.” AGS uses a product called Chromagen, the current market leader in Israel with over 50 years of experience in specialised designs to ensure top of the line manufacturing and long-life warranties (Israel is currently the global leader in terms of solar heating installations per capita). Israel has had a SWH building regulation in place since 1980, and 95% of households in Israel now use SWHs.
ADDENDUM C Energy usage in a typical household.
“Due to South Africa’s historic electricity supply issues, resulting in unannounced load shedding, the market has been forced to become more educated and reliant on solar power and its benefits,” continues Ori. In 2008, the South African government introduced the solar water heating programme to the market to facilitate the transfer to solar water heating. Nersa provided Eskom with R1.068bn to fund the rebate programme, and in 2008 less than 200 solar water heating systems were installed per month. This figure has recently increased to an average of over 6000 per month showing a huge increase in demand. According to Saban, SA saw a drop in sales over the last year, primarily as a result of inferior quality of product being imported and introduced into the market.
“The new legislation is in fact doing homeowners a big favour. We continue to receive an increasing number of queries from homeowners and those in the trade alike as they realise the new laws which need be adhered to, not to mention the financial benefits of moving to solar.''
''The inferior products, as well as uneducated and illexperienced companies installing the incorrect or poor quality systems for specific homes or environments, have attributed
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Educating consumers is the key to ensuring the new legislation is adhered to and the numerous benefits of solar heating are realised. ''Due to our (South Africa's) geographic location, we have an abundance of sunshine with some provinces receiving over 300 days of sunshine per annum. This high level of solar radiation allows solar water heating to be the most beneficial and cost-efficient form of energy and ensures that even during
Solar
ADDENDUM A
winter there is ample supply of electricity for heating a household geyser. By South Africa having amongst the highest winter solar radiation, the solar geyser will still operate even if there are fewer sunlight hours. Even without sunshine, a solar geyser is more efficient in terms of electricity usage than a regular geyser. This is due to its insulation qualities as it retains heat more effectively.
ADDENDUM B
''At the end of the day, such units reduce electricity costs drastically via the lower power usage and rebate programme, and at the same time lower the environmental impact of a
building or home. By installing a SWH one can save up to 40%60% on electricity from day one.â&#x20AC;?
ADDENDUM D Average electricity account for a standard home vs. savings on electricity cost if a solar water heater is present.
For more information please contact AGS Solar on 021 - 556 2015 or email info@agssolar.co.za, alternatively visit our website on www.agssloar.co.za
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A rc h ite ctu r e
Portside the first high rise office development in South Africa to achieve a 5 Star ‘Design’ rating Portside (Buitengracht St, Cape Town), designed by dhk Architects in a joint venture with Louis Karol Architects, was awarded a five star ‘Design’ rating under the Green Building Council of South Africa’s (GBCSA) Green Star rating system for offices. The rating system recognises achievements in sustainable architecture. This acknowledgement makes Portside the first 5 Star Green Star SA certified high rise office development in South Africa.
Artistic impression by dhk Architects.
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pmsa 1-3 vert advert SA ROOFING ADVERT.pdf
Construction of Portside – photographer Raphael Helman.
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he five star rating recognises South African excellence in terms of green design. According to the GBCSA, the ‘Design’ rating is based on design documentation.
“We are proud that Portside has achieved this rating for the ‘Design’ category,” says Derick Henstra, Executive Chairman of dhk Architects. “The design was sensitive to both the environmental and aesthetic requirements of the building. We believe that we have successfully balanced the two imperatives; this rating is evidence of this.” C
Steve Peters, the dhk Director responsible for Portside, says “A particular challenge was the balancing of a vast double glazed curtain wall façade with the mechanical and electrical services necessary to maintain high occupant comfort. This is great example of our commitment to sustainable architecture and green design.”
M
Y
CM
MY
CY
CMY
K
Construction of Portside – photographer Raphael Helman.
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Wate r proo fi n g
Guttering given durable waterproofing by Sika Maize seed developers, Pioneer Hi-Bred, recently contacted Sika to assess the state of box guttering at its manufacturing plants in Rosslyn, Pretoria North.
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t a meeting with Marchant Wolfaardt of Sika, Pioneer HiBred explained that since they manufacture dry products, it is vitally important that these products are not contaminated with moisture, which would render them useless and lead to costly disposal for the company. Every few years, to help combat any threat of moisture contamination, the company has replaced the box gutters, a pricey undertaking which can only be carried out during plant shut-down times.
During application of the base coat, SikaReemat Premium (eight rolls), a glass fibre mat reinforcement, was placed in the gutters. This reinforcement, specifically designed for use with the liquid-applied waterproofing membranes from the Sikalastic 600 series, is easy and quick to apply and adapts to different shapes and profiles on the substrate surface. It ensures correct thickness of the base coat as well as enhancing the crack-bridging properties of the base coat.
Pioneer Hi-Bred therefore required a durable solution that would increase the life cycle of its gutters and Sika recommended a basecoat and a topcoat from the renowned Sikalastic 600 series as suitable for this application. The highly experienced SA Rope Access Company was awarded the contract to apply the specified Sika products.
Sikalastic-601 BC (35 tins, oxide red) was applied as a base coat in conjuction with the glass fiber reinforcing layer. This was followed by a topcoat of Sikalastic-621 TC (25 tins, slate grey). Both coats are one-component, polyurethane products, whose proven technology boasts a track record of over twenty years; they are cold-applied, seamless, highly elastic and moisture-triggered curing. Easy and quick to apply while emitting low odour, they are fast-curing with resistance to rain damage during the wet application.
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All three Sika products used in this project are suitable for new or refurbishment roofing projects and can be applied to roofs displaying many details and complex geometry, even when accessibility is limited. They provide a cost-efficient life cycle extension of failing roofs and, as in this case, guttering. Ponding water and sudden rainstorms during the Pioneer HiBred project caused logistical and application challenges, but, owing to the fact that Sikalastic products are moisture-
triggered curing, water could simply be swept away, allowing contractors to quickly proceed. The project, which commenced in January 2013, was completed by April 2013. Due to the efficacy of its high performance products, Sika was able to offer an extensive guarantee to Pioneer Hi-Bred in conjunction with a maintenance plan. Certainly Sika is confident that this project will prove a worthwhile undertaking and will save Pioneer Hi-Bred a large expenditure over the coming years. For more information on Sika products and systems, visit zaf.sika.com.
Wate r proo fi n g
When used with approved primers, they will fully bond to most substrates, preventing the migration of water. Both are vapour permeable and provide strong resistance to common atmospheric chemicals. The topcoat, Sikalastic-621 TC is UV colourstable.
YOU CAN HUFF AND PUFF BUT YOU WON’T BLOW OUR ROOFS DOWN! KLIP-TITE - ONLY FROM GRS Developed through continuous in-house testing of existing products, where it was realised that failure is normally caused by the sheet unclipping from the fixing clip, during high wind uplift pressure. • Transverse stiffeners introduced in the trough of the sheet to achieve a balanced system design and even higher wind uplift resistance. • The deflection of the pan is reduced, increasing the wind uplift resistance of the sheet. • Transverse stiffeners are a first in the South African sheeting market. • Offers improved wind uplift resistance results compared to other traditional clipping systems and more difficult to remove • The ultimate wind uplift resistance of Klip-Tite exceeded expectations Talk to us, THE SMART ROOF PEOPLE on 011 898 2900 or visit www.globalroofs.co.za or email info@globalroofs.co.za
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C a s e stu dy
Datlink Case Study
Norman Henshilwood School – ThermocousTex exposed ceilings Norman Henshilwood School’s motto is ‘Scientiae et Integritate’ – Knowledge and integrity serve as our guide. We strive to gain knowledge within a climate which provides a sound value system.
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art of this commitment is to create an improved, positive learning environment that is ‘quietly calm’ and suitable for both students and teachers alike. Noisy classrooms (with traditional design) have proven to inhibit learning, as well as hinder the development of social skills where teachers, students and noise are competing against each other at all times within the classroom. Thermal fluctuations from poor insulation can also negatively impact the learning process due to discomfort. These were the concerns when Norman Henshilwood constructed their new West Campus over three years ago. Acoustic and thermal comfort within the classroom environment was paramount to the success of the project. The architects chose Datlink’s ThermocousTex Plaster Boards as an exposed ceiling, which were specifically developed to improve both the acoustic and thermal properties within occupied spaces where noise pollution and poor thermal controls have negative effects on the inhabitants.
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Datlink visited Norman Henshilwood School recently (three years after completion) to find out if the improved design of the new West Campus was successful with particular reference to any noticeable improvement in both teacher and student behaviour within the classrooms. Ms. Shandre Otto, the school’s Deputy Principal, stated that the success of the West Campus is due to the fact that the classroom environment is quieter, less prone to seasonal temperature fluctuations, providing optimal learning conditions and making teaching easier. Ms. Otto also added that students show improved concentration and social behaviour within the new classrooms where the exposed ThermocousTex ceiling finish has been installed and have voiced an interest in trying to create a similar environment in the existing main campus that does not yet have the improved design.
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C a s e stu dy
Mr. Van Wyk, who teaches Commerce in the new West Campus, also confirmed that he has seen both social and academic improvements in his classes since teaching in the quieter and better thermally controlled classrooms. What is also interesting to note is that these boards were chosen well in advance of the new SANS legislation where improved insulation is required in all new buildings. Academic studies have shown that improvement in teaching environments benefits both teachers and students, including academic results, social development and fundamental daily enjoyment. Improving acoustic and thermal environments, such as schools, public meeting places and offices is easily achieved with good upfront rational design by the architects and specifiers. Datlinkâ&#x20AC;&#x2122;s team of insulation and acoustic specialists offers upfront service and assistance in creating the perfect environment through use of a range of their products to establish the most suitable fit-for-purpose solution. Installation of the solution is both commercially competitive and easily executed by industry specialists, such as Sekramo Roofing, who fitted the ThermocousTex boards as part of their installation. Brett Woolridge, of Sekramo Roofing, confirmed that this installation was as easy as any conventional product, the proof of which is obvious today, as the finish within each classroom is still as good as it was when installed over three years ago. Norman Henshilwood students and teachers are enjoying the benefits of good rational design in the new West Campus, including the use of ThermocousTex boards as an aesthetically pleasing exposed ceiling.
For further queries, please contact Datlink Insulation & Acoustics on 0861 328 546, info@datlink.co.za, or visit www.datlink.co.za.
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e n e rgy e ffi c i e n cy
6 Green Stars to shine at
Environmental Affairs Head Office The new Department of Environmental Affairs (DEA) head office in Pretoria has received a 6 Star Green Star SA Office Design v1 certification from the Green Building Council South Africa (GBCSA).
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his is the first government building in South Africa to achieve a 6 Star Green Star SA rating, as well as being the first 6 Star rated green building in the City of Tshwane. A further stellar accomplishment was that the project achieved the highest score for a large commercial office space of this magnitude awarded by the GBCSA to date. “The DEA has taken the lead, and is demonstrating commitment to market transformation in the built environment in South Africa. This is an exceptional illustration of the public and the private sector working together to deliver an outstanding example of green building,” said GBCSA, CEO Brian Wilkinson. Achievement of this 6 Star Green Star SA rating signifies world leadership in green building and shows dedication to sustainable design by all stakeholders in this sizeable public-private partnership (PPP) project. ‘’This is not just another good looking block of offices in town, but a performing green building with specific targets on energy efficiency, water efficiency, an industry-first sophisticated energy consumption mechanism never implemented in any other project in the construction sector, the use of renewable source of energy and a unique first facilities management system that encapsulate a rigorous penalty regime (with no precedent in the construction sector) to reward operational efficiency and penalise poor performance,” says Minister Edna Molewa. The entire project team has worked together to express the core values of the DEA through sustainable design, resource efficiency, and excellent project execution, added Wilkinson. A significant benefit of this PPP structure is that contractual obligations for all participants ensured that all cost, timeline, and green specifications were clearly outlined, and successfully met during design and construction.
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It will also ensure that the building is operated optimally over the next 25 years to ensure that it stays green throughout its lifespan, and achieves the environmental and resource savings envisaged at the outset. ‘’Through this Green Building we will propel the department above the construction industry players, setting a good example for other organisations, of course for the benefit of the environment and future generations,’’ concluded Minister Edna Molewa.
Going Green The Green Star SA ‘design’ rating objectively assesses how ‘green’ the building plan is, with all the green initiatives included. It considers categories including management, indoor environmental quality (IEQ), energy, transport, water, materials, land use and ecology, emissions, and innovation. The DEA specified that the building should achieve a minimum 4 Star Green Star SA rating; however, the professional team surpassed this goal by scoring full points in the energy category, as well as being only the second project to achieve five points in the innovation category. Once construction is complete and the building is occupied, the DEA head office will also submit documentation towards receiving an ‘As-built’ Green Star SA rating, which ensures that the original intentions in the design phase were adhered to.
Green team A major benefit of green building is that it breaks down the traditional silos of work, and encourages teamwork between disciplines to ensure the best outcome.
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Aveng Grinaker-LTA project manager Derek Andresen chaired weekly multi-disciplinary design review meetings throughout the design phase of the project, while daily meetings were held on site during construction.
Extreme Green Aldous explains that the project made extensive use of 3D building modelling upfront, allowing the professional team to identify, and resolve potential issues before they emerged, and improve integration and co-ordination. Every discipline created 3D Building Integrated Models of their work to ensure that the building was fully coordinated from a services and structural point of view, explains Boogertman & Partners architect, Lood Welgemoed. This reduced on-site issues, which could cost time and money. The project brief specified that energy consumption in the building should not exceed 115kWh/m²/annum – a lofty goal, which required optimal building orientation from the start, and intense modelling and efficiencies to be met. The roof of the building is almost entirely covered with solar photovoltaic panels, which exceeded a 10% target, and will supply almost 20% of the building’s energy needs. The northern parking area hosts a large concentrated photovoltaic panel (CPV), which tracks the sun during the day, and supplies power to the electric vehicle (EV) charging station for the DEA’s EV pilot project. Water efficiency is also a major characteristic of the building, which is expected to consume 30% less water than a comparable conventional building. This is thanks to numerous water saving devices installed in the building, including a rainwater harvesting system, and use of water-wise indigenous plants for landscaping, with efficient irrigation systems. Uys & White Landscape Architects’ Tiaan Laker explains that the landscape design was seen as an extension of the building design. The landscaped entrance includes a custom designed vertical green wall, roof gardens and a wetland component facilitating storm water run-off. A natural veld component surrounds the parking and building areas.
Long-term Green The Facilities Management (FM) team has been involved with the project from the very start – including decisions on designs, suppliers, materials, and sub-contractors. FM plays a role in the commissioning of the building, ensuring that accurate data is collected, and used as a benchmark to evaluate the ongoing building performance. “Operating the Building Management System will require specialised training, as will the Facilities Management System. Facility managers will attend the GBCSA Accredited Professional course to gain insight into green building and what they are required to do to keep this building green,” explains Dijalo Property Group director, Peter Gray. Green buildings represent responsible investment and reduced liability, and financial benefits of green buildings are realised through savings on energy and water over the long-term. Importantly, green buildings can also play a role in increasing productivity in the workplace, and greater attraction and retention of valuable skills. The new DEA head office is likely to be a catalyst in the South African built environment, spurring momentum of the adoption of sustainable building practices.
Fast Facts: Project size: 30 654m² (Green Star SA certified area) Project cost: R653-million Project start: July 2012 Project completion: May 2014 Green Star SA Certification: 6Star (82 points), May 2013 Building Owner: Department of Environmental Affairs Project developer: Imvelo Concession Company (Private sector participant - comprising Old Mutual, KagisoTiso Group, Wiphold and Aveng Grinaker- LTA Design & Construction: Aveng Grinaker-LTA & Keren Kula JV Architect: Boogertman & Partners Quantity Surveyor: Pentad and PDNA Consulting Engineers Facilities Manager: Imvelo Facilities Management (An Old Mutual Property & Dijalo Property Group JV) Green Star SA Accredited Professional: PD Naidoo & Associates
e n e rgy e ffi c i e n cy
PDNA Consulting Engineers' Green Building & Sustainability Services head, Mike Aldous has been responsible for the Green Star SA submissions, and ensuring that the project remained on track to achieve accreditation.
pa i nt s & coati n g s
Industry should make sustainability demands work in its favour
The coatings industry should use the global demand for increased sustainability to its advantage instead of regarding it as an obstacle to future profitability, Howard Harris, an independent Energy Consultant, told the recent Coatings for Africa 2013 symposium.
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ointly presented by the SA Paint Manufacturing Association (SAPMA) and the Oil and Colour Chemists’ Association (OCCA), the symposium, backed by the Department of Industry, was held at Gallagher Estate in Midrand. Delivering one of the symposium’s keynote addresses, Harris said South African industry, including the coatings sector, faced many challenges to improve its sustainability. Included were: • Eco-design: the integration of environmental aspects into product design; • Life-cycle assessment: the evaluation of all environmental aspects of production; • Green Building design: utilising design and construction practices that eliminate the negative aspects of product environmental impact; and • Volatile Organic Compounds (VOC): the increasing need for low VOC content in paint products. “If the South African paint industry cannot comply with future demands for lowering VOC content in paints, an increasing number of buildings will remain unpainted,” he warned. Energy management is another challenge facing the coatings industry. “With energy likely to be in short supply in South Africa until 2017 at least – and also increasingly costly – energy efficiency should be a top priority for industry. Overseas, Johnson & Johnson is now allocating US $40 million a year on greenhouse gas reduction projects, and the costs of environmental impacts of raw materials purchased now form part of Natura’s supplier selection process.” Harris said business had the responsibility of providing products and services in a way that would enrich the lives of employees and customers, and ensure that the environment is managed at all levels. “Sustainable growth should meet the needs of the present without compromising the ability of future generations to meet their own needs. If the coatings sector and industry in general can synchronise the 3Ps – prosperity, people and planet – and embed these into its everyday business processes, sustainability can be achieved,” he added.
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Independent energy consultant, Howard Harris.
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Connect with global property sustainability experts who have chosen to design and build green. The Green Building Council South Africa and the World Green Building Council are collectively powering The Global Green Building Convention 2013 in Cape Town. This premier event gathers the largest network of influencers and key decision makers in the global green building industry.
Reserve your place now.
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Contact us on 0861 042 272 or visit www.gbcsa-convention.org.za
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fa ste n i n g s yste m s
Exceptional performance from Mapei chemical anchor With their strongly customer orientated focus and emphasis on technical service, Mapei South Africa, local subsidiary of the international Mapei Group, is rapidly setting new performance benchmarks for speciality building chemicals in the construction industry, not only in South Africa but also in nearby territories.
Mapefix PE SF
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he recently introduced Mapefix chemical anchors are styrene-free, two component mixtures of synthetic resins, specifically developed for chemically anchoring steel and zinc-plated steel deformed bar in a variety of solid and porous substrates. The versatile products – VE SF for heavy loads and PE SF for light loads – can provide anchoring in noncracked concrete, lightweight concrete, stone, wood, bricks and mixed masonry, and can even be applied to substrates which are wet. Mapefix VE SF is recommended as the solution for immersed anchors in marine and industrial environments. Since the chemical anchor does not generate the lateral stress associated with conventional mechanical expansion fasteners, it also provides the solution for anchoring close to edges or when there is limited pitch between the bolt holes.
“There is no waiting as Mapefix begins curing straight away and there is no need to rod from top to bottom of the holes,” Lunda says. “To locate the sieves, we were anchoring 96 anchor bolts, 30ml in diameter and 1,3m long into heavily reinforced concrete and the time saving with Mapefix was a huge benefit.” Mapei’s range of 1400 advanced building technology additives, sealants, adhesives and concrete performance chemical are recognised throughout Europe, America and the Far East for their performance standards and environmentally-friendly formulations.
In Botswana, Mapei South Africa has recently supplied Mapefix VE SF to specialist civil works contractor, RCL Holdings, for three anchoring contracts on mines in that country, including anchoring the giant sieves for a diamond mine. “We have extensive experience in this type of work and have tried a wide range of anchoring products,” comments the company’s MD, Robert Lunda, “but Mapefix stands out with its exceptional performance.” Using the convenient twin cartridge pack with the supplied static mixing attachment, the resin mixture is injected bottom up into the holes.
Mapefix VE SF
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ROOFCO STEEL GAUTENG After much anticipation, we are pleased to announce the opening of an inland leg of Roofco which will operate from the Boksburg area from early July. The motivation behind opening this branch was to provide more personalized service to businesses in the area and to introduce our carports that are taking the coast by storm!
INDUSTRIAL ROOFING Roofco has made a name for itself in the industrial and commercial property arena with the capacity to supply large quantities of material,of an extremely high quality at a reasonable price. We also have a large range of roofing supplies and accessories. Call Roofco Gauteng on 082 893 7864 or email: jhb@roofco.co.za for a quote today â&#x20AC;&#x201C; or visit our website www.roofco.co.za
CARPORT DIVISION Dedicated to supplying material specifically designed for carport and awning installations. Get all the material you need to install carports at one location. We cater for contractors and DIY enthusiasts. Watch out for our beautifully designed fascia gutter (single length spans with no joints, looks better - avoid leakage and corrosion) Our carport supply centre is based on the corner of All Black Road and Hamba Gahle Street in Anderbolt, Boksburg.
n e ws
New president of KZN Institute for Architecture is inducted Kevin Bingham of FGG Architects in Durban was inducted as president of the KwaZulu-Natal Institute for Architecture (KZNIA) at the KZNSA Gallery in Glenwood on May 16, 2013.
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e was congratulated by outgoing president, Durban City Architect, Nina Saunders, who said that she was comforted to be leaving the organisation in good hands and was assured that it would continue to grow and flourish under his leadership.
The inauguration ceremony, sponsored by Corobrik, was combined with the official opening of the KZNIA publiCITY Exhibition in honour of the new president, which offered members the opportunity to present a favourite project of theirs for the public to view at the KZNSA Gallery until May 19. “Members were given a free rein to feature models, travel sketch diaries, 3D presentations, posters or any material they felt was relevant, resulting in a diverse exhibition which expresses all the versatility and creativity one would expect of this dynamic profession,” said Dirk Meyer of sponsor, Corobrik. “We value our longstanding association with the KZNIA and wish it continued success under its new president.” The publiCITY exhibition will run concurrently with an exhibition of the work undertaken in Haiti by ARCHIVE Global, an international non-profit organisation using housing and environmental design to combat disease among the most disadvantaged. Peter Williams, the founder and executive director of Archive Global, was the guest speaker at the presidential inauguration ceremony. The KZNIA, founded in 1901, is one of the oldest architectural institutes in South Africa. Its aim is to connect and enrich the local architectural community, to foster a working environment in which they can pursue excellence and to provide a professional support system.
Nina Saunders, outgoing President of the KZN Institute for Architecture inducts Kevin Bingham as incoming President of the KZNIA.
The KZNIA presidency is ordinarily a two-year term of office and Bingham was elected to the position in October last year after many years of involvement with the organisation.
The UIA has a membership of 1.3 million architects globally and holds the largest architectural congress tri-annually. The theme for the Durban event is ‘architecture otherwhere.’
He began serving on the Natal Institute of Architects (NIA) committee in 1992 and over the years has chaired or served on the institute’s youth, education and marketing committees before becoming a member of the KZNIA Executive Committee last year.
Commenting on other key projects he will be driving during his presidential term, Bingham said, “The KZNIA is also spearheading the development of an office-based on-line education unit aimed at enabling architectural professionals to continue their advanced architectural studies while in employment. This will assist the existing resource-strapped universities and promote the positive transformation of our profession.”
“Our current focus is the International Union of Architects (UIA) 2014 conference which is being hosted by South Africa in Durban in August next year,” Bingham said. “This event will see thousands of architects from across the globe visiting our region and is an opportunity for architects from KZN and the whole of South Africa to showcase their work and to learn from others.”
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“We also have a number of task teams striving for excellence in matters of professional practice, heritage, habitat and education.”
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Bingham, a Northlands Old Boy, completed his Bachelor of Architecture degree at Natal University and his Master of Architecture degree at UKZN. His career has spanned the academic and private sector, taking him to many different countries and involving him in a variety of architectural projects. The relationship between AIDS and architecture, designing medical facilities and building for rural communities are strong interests of his and he has presented numerous papers and published articles on these subjects. Bingham has worked for a number of architectural firms in Durban and established his own practice in 1997. His current position is as director of FGG Architects. In the academic world he has been a lecturer at Durbanâ&#x20AC;&#x2122;s two universities in subjects ranging from design, architectural acoustics, to building technology and was external examiner at the University of the Free State. On the international front he has taught architecture and interior design at Liverpool University in the UK and Queensland University of Technology in Australia. Married with two university-going sons, Bingham is a dedicated family man. Out of office hours he can be found at Durbanâ&#x20AC;&#x2122;s Point Yacht Club where he is the Vice-Commodore or on the treadmill wondering how he can build on his tally of five Comrades marathon medals.
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Select PPE celebrates 15 years of uninterrupted growth in Africa Select PPE, a multi-brand service provider of customised on-site personal protective equipment managed solutions in Sub-Saharan Africa, celebrates its 15th anniversary in the local market with plans for measurable growth and expansion.
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rom humble beginnings issuing personal protective equipment to a handful of clients through a paper-based system, Select PPE today boasts a state-of-the-art electronic system and more than 200 on-site stores, with a stockholding of R100-million and an annual turnover of more than R400-million. Select PPE sales director, Dries van Tonder points out that the company serves as a partner that provides timeous and costeffective outsourced management processes that leverage application specific expertise to clients operating in the mining, oil, gas and petroleum and steel industries. "Select PPE procures, disburses, controls and tracks on-site usage of customer specified personal safety products that protect workers by ensuring product compliance with regulations and supporting documentation by individual user, thereby reducing claims," he explains. Together with its customers, Select PPE determines an Issuing Protocol (IP), which stipulates the rules under which it will supply PPE. The IP allows the customer to determine the specific PPE needs and frequency of issue for each employee in line with their specific job requirements. Van Tonder notes that the IP is supported by a sophisticated IT system that provides real time information on all PPE issues
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and usage, and is able to store historical data in various formats, depending on customer requirements. "This system enables customers to exercise complete control and effectively manage their budgets," he continues. As part of the company's plans for continued growth, van Tonder indicates that Select PPE recently launched its newlyestablished online store - www.selectppe.co.za - in February 2013. He adds, "The online service adds further value to our niche market base, by ensuring that the provision of partnership-based management solutions for the procurement and individually recorded issue of personal protective equipment is now only a click away."
A timeline of success achieved through technological innovation and advancement Select PPE was conceptualised in 1998, and stores were run on a paper-based record-keeping system. Stock taking was done manually out of books, and invoicing was completed by recapturing all sales into spreadsheets for the following three years.
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By 2003, Select PPE had expanded to 80 stores, and the company had created a built-in stock order system that produced its own stock orders based on historical sales data and sales trend analyses. Van Tonder reveals that the company also started delivering management reports to clients, whereby it would inform clients of the over or under utilisation of individual PPE. "A major benefit of the management reports for the mines is that it allowed them to notify an employee who was not using their PPE correctly in advance, before an injury occurred. An example of this would be proactively preventing hearing loss from the under-utilisation of ear plugs," he says. During the 2004/2005 period, Select PPE refined its management reports, with more features being added to the system that enabled the client to measure and interpret various aspects of cost, such as cost-per-company, cost-perperson and cost-per-site.
Select PPE Sales Director, Dries van Tonder.
This was the same time that Select PPE entered into a joint venture with NYSE-listed global safety leader MSA, to open 13 stores in Zambia. "This was a major milestone in the company’s history, and the joint venture brought our overall tally of stores to 120," notes van Tonder.
In 2001, the company computerised its sales processes at its five stores located on-site at Impala Platinum and at an additional five stores at Union Mine. Stock taking, personal deductions and stock orders remained manual, with reporting remaining largely unavailable.
In 2006, Select PPE achieved R10-million turnover per month for the first time, and officially became a division of MSA Africa, which purchased a majority stake in Select PPE. Van Tonder continues: "By the end of 2006, we had 135 stores, and have continued our sustained success where today we employ more than 400 people across 200 stores."
Van Tonder highlights the fact that Select PPE further developed its computerised sales system in 2002, by making personal items more easily accessible to employees. "These were items above and beyond what was issued to workers by the mine, and included essential PPE such as boots or winter coats that the mine workers purchased for themselves or their family members." According to van Tonder, 2002 also saw Select PPE computerising its stock taking procedures, which made the business more efficient by significantly reducing stock redundancies and stock losses. "This continued advancement resulted in the company expanding to 35 stores nationwide," he adds.
Despite its measurable success over the past 15 years, van Tonder does admit that Select PPE faces a number of challenges, with the continued global economic downturn and labour unrest in the South African mining industry being the major causes for concern. "Our main focus in overcoming these challenges will be to assist our clients in cost saving initiatives and to ensure that we support them during the difficult times ahead. What's more, we are also planning on diversifying into the manufacturing, engineering and automotive industries, through the continued promotion of our online sales offering," he concludes.
STOCKISTS OF:
Unit 8/9 Lansdowne Junction Cnr Jan Smuts Drive & Bloemvlei Road Lansdowne, Cape Town, R.S.A Tel: 021 – 691 0084 Fax: 021 – 691 2204 Unit 6, Koorzen Street, Behind Gantz Plaza Strand, Cape Town, R.S.A. Tel: 021 – 854 8550 Fax: 021 – 854 8524
ALL BOARDS S.A.B.S APPROVED & LOCALLY MANUFACTURED
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sales@cityceilingsupplies.co.za www.cityceilingsupplies.co.za
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Long-awaited coatings sector
training centre opened in Springs The new SAPMA/SAPITI Centre of Excellence training facility for the coatings industry is the first industry-dedicated training centre, established through prolonged co-operative efforts between a specific industry and the government, initiated by the coatings sector.
An exterior view of the new Centre of Excellence.
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he long-awaited Centre of Excellence at 33 Argon Road, Fulcrum, Springs, was officially opened on June 14. It is based at the revamped old Building Industries Federation of SA (BIFSA) premises, now owned by PC Training & Business College with which SAPMA/SAPITI has entered into a partnership to establish the facility.
The Centre – which has access to the internationally-respected British Coatings Federation (BCF) training modules – will offer technical tuition at advanced levels, as well as for non-technical industry staff to improve their knowledge of coatings. BCF training is recognised by the City & Guilds Institute of London Institute, which is accepted and respected worldwide.
The Centre will offer training programmes accredited by the Chemical Industries Education and Training Authority (CHIETA) and endorsed by the Department of Labour, as well as the Department of Higher Education and Training. The Centre will be operated by the SA Paint Manufacturing Association (SAPMA) and its training arm, the SA Paint Industry Training Institute (SAPITI), and contains extensive facilities for both theoretical and practical training.
Deryck Spence, executive director of SAPMA, says the new facility will, for example, offer a first for South Africa: the fully accredited Practical Applications Qualifications course, consisting of 25 days’ training, split into five five-day modules. It will also offer:
SAPITI has revised its paint technology modules to bring the training offered at the Centre in line with international standards and encourage the training of a wider spectrum of students to meet the government’s calls for the expansion of skills and job creation.
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• Accredited training for the retail industry, where the level of training among store personnel urgently needs improvement; • Short, non-accredited training for smaller retailers; and • Short, non-accredited training for paint applicators from smaller painting contractors who are unable to afford the time to send staff on longer, accredited courses.
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The Centre of Excellence facility, which includes miniature houses installed for practical painting lessons for the students.
Spence says the opening of the new Centre is the result of the “excellent working relationship” that had eventually been established with CHIETA. “Obtaining CHIETA accreditation for the courses was crucial and we cannot commend CHIETA highly enough for its industry empowering support and its funding, which means that employers who send students for training can claim back on training levies paid to the government and also access training that will add to the BBBEE points. “SAPMA had for many years tried to obtain CHIETA accreditation for our training. A significant amount of money was spent in this quest but we were regularly thwarted by repositioning of the goal posts and suspension of CHIETA management for one reason or the other.”
Mollie Ramnundlall (left), a director of the SA Paint Industry Training Institute (SAPITI), officially ‘cuts the ribbon’ to formally open the new Centre of Excellence in Springs. Jay Ramnundlall, also a director of SAPITI, and Terry Ashmore (right), chairman of SAPMA, look on. “Further down the line, we intend expanding training programmes in business sectors, such as spray painting, waterproofing, colour tinting, independent paint laboratory services, paint application training for the Department of Correctional Services, and training of candidates from the Department of Social Development and Department of Public Works,” Spence stated. “The Centre of Excellence will offer the coatings industry the opportunity of staff training, subsidised by the government. This will result in improved skills within the companies themselves, as well as the industry, and will include increased productivity, the manufacture of higher quality products, increased profits, and ultimately more job opportunities and higher BBBEE score sheets.”
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“Training is vitally needed in the coatings sector – not only from a technical and production point of view but also from an application standpoint as well. About 80% of all painting problems arise from inferior surface preparation and the Consumer Protection regulations hold a minefield of potential problems for companies using untrained staff,” he adds. As student accommodation and kitchen amenities are available at the new Centre, SAPMA/SAPITI will also be able to recruit candidates from anywhere in southern Africa and the Indian Ocean islands. Despite the lack of government accreditation, SAPMA/SAPITI managed to train over 7 000 employees of the coatings industry since 1987.
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Coega delivering on jobs promise and investments Construction boom at Coega as projects under production amount to R1.2-billion, over 2500 jobs created
Sealing the deal: A worker on site at Chinese car and truck manufacturer, First Automobile Works’ (FAW) new plant in Zone 2 of the Coega Industrial Development Zone (IDZ).
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uilding projects in the Coega Industrial Development Zone (IDZ) have injected over R1.2-billion into the Nelson Mandela Bay construction industry over the past two quarters. Six major construction projects are currently under way in the Coega IDZ including erection of: • Chinese car and truck manufacturer, First Automobile Works’ (FAW) plant; • Famous Brands’ cold storage plant; • DCD Group’s wind tower manufacturing plant; • the addition of Coega Cheese onto the Coega Dairy outfit; • Agni Steels’ R400-million smelter facility; and • Rehau’s extension in the Nelson Mandela Bay Logistics Park (NMBLP). Industrial gas company, Air Products South Africa, is also about to begin construction of its R300-million state-of-theart air separation unit in Zone 3 in July, bringing the total number of projects being built to seven. “The global economic climate is still not stable, yet investment continues to flow into the Coega IDZ and is literally taking root in the construction projects under way,” said Ayanda Vilakazi, Coega Development Corporation (CDC) head of marketing and communications. “We currently have 20 operational investors, and once these seven construction projects are complete, we will be up to 27 operational investors by mid-2014.” Vilakazi said the activity meant major spinoffs not only for lead contractors, but also sub-contractors, suppliers and the whole built environment supply chain: “At a time when there is industry malaise at a national level, the Coega IDZ is experiencing a construction boom to the value of R1.2-billion.”
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Solid foundations: The Famous Brands cold storage unit in Zone 1 of the Coega Industrial Development Zone is almost complete with the company scheduled to take occupation of the building next week. “The unaudited results of the 2012/13 financial year also show that construction jobs in the Coega, IDZ and the NMBLP for April 2012 to March 2013 amount to 1722 and investor jobs created are at about 856 – so just over 2500 jobs created directly through activity in the Coega IDZ,” said Vilakazi, adding that it was through these major investments that the CDC was delivering on its mandate to create jobs.
Famous Brands The Famous Brands project is nearest completion and the company was given access to the warehouse portion in the first week of May allowing its service provider to start with racking on the warehouse floor. The warehouse is operational and Famous Brands moved its stock into the cold storage unit on June 10. “Everything is on track, with time frames tight but on target to be met. The project is still well within original time, cost and quality parameters set – despite loss of a number of days due to inclement weather, mainly wind and rain,” said Bruno Ponzi, CDC senior project manager for infrastructure development. The company, which owns the likes of Steers and Debonairs, was also given access to the ground floor of the office block portion, with the balance of the building due for hand over on June 21. Once delivered Famous Brands would become the newest operational tenant in the Coega IDZ. Vilakazi said Famous Brands was a prime example of the short conversion times investors experience from the point of signing a lease with the CDC to full operation.
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Insider's view: A snapshot of the inside of the Agni Steels plant in Zone 11 of the Coega Industrial Development Zone. “The turnaround times are much quicker now than they were a couple of years ago and we are able to construct buildings for investors relatively quickly, meaning that they move to operational phase within about a year of signing, depending on this size of the project,” said Vilakazi. “This has implications for investors’ bottom line as they are able to start production relatively quickly.” A partnership between Famous Brands and Coega Dairy has also seen the dairy expanding its operations to supply cheese products to the group in a project dubbed ‘Coega Cheese’ with a joint valued investment of R45-million pouring into the Coega IDZ as a result.
FAW In addition, says Vilakazi, the construction activity is creating needed jobs on the city, particularly on the FAW site, with the R200-million FAW construction project well under way. To date about 304 construction jobs have been created on its site, a number that grows from week to week. In total the construction phase will see about 2000 jobs generated over the year-long duration. In the operation phase of the truck assembling plant a further 280 jobs will also be created.
design on the office and reception area – particularly the exceptional use of concrete, so that’s set to be the highlight of the building,” said van Jaarsveldt. “Otherwise, we are working hard to keep to a strict timetable, and you will see the columns almost completed and some initial top structures going up over the factory portion. With a long way to go, the skeleton is definitely taking shape.” Van Jaarsveldt said construction is on-track for completion end December 2013, adding that there was significant collaboration between the Chinese engineers and their South African counterparts – a coup for skills development and mentorship.
AGNI STEELS Agni Steels is also wrapping construction of its R400-million steel plant in Zone 6 of the 11500Ha IDZ. Agni Steels will operate in a high-tech smelting facility to produce mild steel billets from scrap metal. The plant at Coega will use 10 000 tons of scrap metal in phase 1 and 20 000 tons in phase 2.
DCD GROUP
According to Arnie van Jaarsveldt, WBHO Construction Eastern Cape managing director and lead contractor on the FAW project, the highlight of the construction will be its architectural finesse.
DCD Group is also in the early phases of its R300-million wind tower manufacture factory which when completed, is expected to employ 168 workers, and produce between 110 and 120 wind towers annually.
Van Jaarsveldt said Eastern Cape Architects Studio d’Arc wanted to make a statement with the Chinese automotive giants’ building in Zone 2 of the IDZ.
“Coega is boldly delivering on our jobs promise through the attraction of investments,” said Vilakazi. “The construction boom is just a taste of things to come. Never before has it been so important to say: watch this space.”
“Its prime position on the N2 means it will get heightened attention. FAW management loved Studio d’Arc’s unique
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a dv e rto r i a l
Sunny skies shine hope
for a sustainable SA
As we are all very well aware, South African electricity rates have continued to rise at an unprecedented rate of +26% for the last three consecutive years, year on year (YOY).
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ith extraordinary electricity price hikes from City Power, and Eskom requesting another 16% YOY price increase over the next five years, we ask you if you are:
• Feeling the pressure of escalating electricity charges? • Concerned about the latest Nersa price application from Eskom? • Considering implementing your own renewable energy solutions? As a national ICT distributor, Mustek currently import and distribute Solar Photovoltaic products to the market, and in partnership with Green Habitat, provide end-to-end turnkey solutions too. Mustek have implemented a number of energy saving projects over the past three years, resulting in significant reductions in energy consumption. These projects have also provided the considerable power cost reductions offered by renewable energy – taking advantage of the new grants/ subsidies to assist with the implementation of these energy saving projects. One such project that stands out is the R15.5-million refurbishment and transformation of the National Union of Metalworkers of South Africa’s (Numsa’s) regional office, in central Johannesburg, into the first eco-friendly union office in Gauteng.
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This project, due for completion in the next few months, involves a nine-storey building, housing Numsa’s regional office for the Greater Johannesburg and West Rand area. The refurbishment, which kicked off in March last year, formed part of Numsa’s undertaking to reduce the carbon footprint of its buildings – a process that started at the union’s head office, in Newtown, in 2007. It was also in line with the Congress of South African Trade Unions’ resolution for affiliate unions to reduce their carbon footprints. The programme will eventually see about 30 buildings being revamped, and is estimated to continue for the next ten years.
The solar energy solution for Numsa In order to provide additional power to service the requirements of the refurbished building, a 30 KWp solar photovoltaic (PV) panel solution was installed on the roof, which was designed to provide about 30% of the building’s daily peak electricity requirements. Green Habitat CEO, Maurits Perold, who was tasked with the provision and installation of the PV system, says that the installation “is the highest of its kind in the country.”
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a dv e rto r i a l To further enable energy savings, inverters that modulate compressor speed and that have soft-start features were installed. These devices enable a 50% reduction in power consumption.
Mustek ‘walks the walk’ and provides for the future As a company committed to the future success of South Africa, we understand that ensuring sustainability for generations to come is at the heart of this mission. For this reason, we believe that starting at ‘home’ is essential if we are to make this a reality. We are proud to share that Mustek’s very own 220kWh roof installation will be completed in the course of the next month.
The solar panels feed into a 30 kW uninterruptible power supply that powers all the main functions of the building, such as security, computers, emergency lighting and some airconditioners. The system had also been synchronised with the municipal supply to reduce consumption and costs.
We look forward to showcasing our own implementation and discussing the considerable return on investment opportunities of these end-to-end turnkey solutions and welcome you to get in touch if you wish to discuss your solar energy requirements and options with us. Contact Mike Cassidy on 011 237 1000 or e-mail MikeC@mustek.co.za.
In addition to this solar energy saving solution, the building was also equipped with low-energy fluorescent lighting and lightemitting diode lights, while floors occupied by Numsa were fitted with motion and ultrasonic sensors that switch lighting on and off depending on occupancy.
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Pro d u ct Pro fi le
Vital components for a ‘grate’ project Industrial and mining environments are often harsh on products. Designing and engineering products with this in mind is a key factor in the longevity and reliability of a product. Experience, knowledge, and expertise regarding these industries and their specific requirements, are critical in developing hard-wearing and durable products and equipment.
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odds Pringle, Managing Director of Vital Engineering and Angus McLeod, says that manufacturers should never rest on their laurels when it comes to the manufacturing of high-quality products. “Meeting the fluctuating demands of industry requires ingenuity and constant effort to improve on current offerings.Vital Engineering’s range of Vitagrid fully serrated gratings, stair treads, and Vitex expanded metals patented and trademarked systems have been developed and refined over many years.
“Acceptance in the local and international markets does not happen overnight. Our technical team has expended time and energy to gain recognition for the brands. Our goal is to lead the market by example in the manufacture of safe, high-quality, acceptable gratings and product systems that conform to the ever-changing needs of the market and clients’ safety demands,” says Pringle.
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Vital Engineering uses 350WA mill drawn material in the production of its Vitagrid products. “This ensures a sound, economical and definable design base for all our clients’ loading requirements. It also guarantees a high galvanising quality with a lower maintenance cycle than commercial-quality mild steels,” says Pringle. Pringle points out that all Vitagrid and Maclock products are suited to hot dip galvanising. “An advantage with Vitagrid products is that all the material used is mill dressed, giving a rounded edge on the bearer bars. This allows hot dip galvanised coating to adhere without chipping or corner damage.
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Pro d u ct Pro fi le
Pringle explains that the high level of welding employed to AWS D1.1 standards ensures that porosity is kept to the minimum on fully banded products. “This ensures that critical items, such as stanchions, are welded to provide conformance to safety regulations.” As an alternative to tubular handrails, Vital Engineering developed the Maclock solid forged stanchions in 1940 in South Africa. These high-quality ball-type stanchion units are a single forged unit and are not welded together at the ball joints. Many of these units are still in existence today in older buildings. “The copyrighted slotted base plate makes fitment and replacement of any existing type of stanchion holing simple when clients wish to change existing, non-conforming products for either the tubular or solid forged systems,” says Pringle. “The patented Maclock angle section ball stanchion now allows clients to replace all their current site-fabricated angle stanchions with a new, safer alternative that allows a free hand passage along the handrail. This was not possible with the older systems,” says Pringle. Pringle points out that the older systems required ‘hot work’ on site for their installation. “This resulted in plants being shut down to make sensitive areas safe. The Maclock angle ball stanchion can now be installed and erected without welding on site and it will maintain its corrosion integrity. This saves endusers considerable production shutdown and maintenance costs, and allows them to maintain a high level of safety in these replacement plant areas.
Dodds Pringle, Managing Director of Vital Engineering. Vital Engineering’s range of Vitagrid fully serrated gratings have been developed and refined over many years.
Slit material that is not properly de-burred or dressed will result in chipping at the sharp edges and have less coating adherence in these areas. This causes transportation and erection damage in addition to earlier corrosion and wear. The net result is high-maintenance cost. Vitagrid’s specialised Maclock handrail tubular system design allows full hot dip galvanising both on the inside and outside of the stanchions and their accessories, giving the client peace of mind that no uncoated areas will be exposed to corrosion. The release of Vital Engineering’s latest version of its interactive product, design and detailing Vitagrid CD makes specifying, using and managing the product range very easy. There is a specific emphasis in the CD on ensuring that the special coating integrity is maintained during manufacture and after the construction phase has been completed. “Easy to understand design, interactive visual suggestions, erection recommendations and training areas on the CD ensure that any site rectifications or changes are kept to the absolute minimum,” says Pringle.
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“Vital Engineering is the only South African grating, handrail and expanded metal manufacturer to hold an internationally recognised design rated ISO 9001 certification for its design and manufacture. Quality certification of this level involves many years of hard work and effort by a team that aims for a common goal: durable and long lasting products that address specific client needs in the workplace,” says Pringle."
About Vital Engineering Since 1939 Angus McLeod and Vital Engineering have established a reputation for quality and service in the manufacture of all types of gratings, stair treads, pressed floors and safety handrails. Its brand names of Vitagrid and Maclock have become synonymous with versatility, quality and service. The Group offers a wealth of product expertise and has been involved in the supply to power plants, petrochemical plants, materials handling projects, mining, process plants, food, beverage as well as most facets of the civil and structural engineering industries, both domestically and internationally. A variety of products and materials for numerous applications are readily available, when either costs or corrosion are factors. The range includes bitumen dipped, galvanised (610g/m²) and mild steel. Other grades of materials such as SS304, SS316, structural grade aluminium and 3CR12 can also be manufactured.
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Wide range of Chryso products to
enhance pigmented colouring of concrete Chryso Southern Africa produces a wide range of products to affect and enhance concrete colouring.
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he company is the sole distributor of Lanxess inorganic iron oxide Bayferrox pigments for the Southern African construction industry. Germany’s Lanxess is a global leader in the production of pigments for coloured concrete. Hannes Engelbrecht, Chryso S.A. Business Manager: Concrete Aesthetics, says in addition to the wide range of Bayferrox pigments available from Chryso S.A., the company can also provide several products that play an important ancillary role in the colouring of concrete. Included are: • Chryso Pareflo 20 – an efflorescence-reducing water repellent that reacts with the cement matrix, creating a polymer network that fills the capillary holes in the concrete thereby preventing efflorescence because the soluble salts cannot travel through the capillaries and crystalise as they would have once in contact with air. Chryso Pareflo 20 also limits colour variations of concrete and assists in producing a richer colour in the concrete. • Chryso Colour Flash D – a chloride-free admixture used in dry concrete to provide colour stability and improvement of mould filling, with higher compressive strengths and impermeability.
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• Chryso Fibre Plus – microfibres that control and reduce plastic shrinkage and plastic settlement cracks. It also greatly improves the concrete surface quality by reducing the amount of bleed. “Excessive bleeding on the surface can cause colour to fade and make the concrete porous,” Engelbrecht explains. “Chryso Fibre Plus also boosts the hydration of cement and improves the bonding of the cement matrix to achieve a more durable concrete surface that is resistant to abrasion that would expose aggregate that is not the same colour of the pigmented concrete.” • Chryso Superplasticisers, such as the ChrysoFluid Optima (for readymix) and Premia (for precast) ranges assist in the homogenous dispersion of pigments throughout the concrete mix. • Chryso Dem Aqua 100 – an essential mould release agent for concrete producers with stringent quality requirements. The release agent creates a consistent, smooth and blemish-free concrete surface with minimum blow holes and reduced dusting of mould surfaces. Chryso Dem Aqua 100 does not leave stains on the concrete and is particularly suited to the production of architectural and decorative concrete.
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Guidelines on coloured concrete from Chryso S.A. There are seven important factors that influence the quality of coloured concrete, says Engelbrecht. The vital factors to consider when producing pigmented concrete are: • Cement: Portland cement can vary significantly in colour – from light to dark grey. This change in colour can influence the final colour of pigmented concrete. “That is why it is important to use the same cement throughout the production of coloured concrete. White cement should be used when producing pigmented concrete with great colour clarity, particularly for bright colours. The higher the cement content, the more intense the colour,” Engelbrecht explains. • Aggregates: The colour of aggregates also influences the ultimate colour, so it is important to ensure that the entire surface area of the aggregate is coated with the pigmented cement paste so that the final product is not a mixture of the colour of the pigment and the colour of the aggregate. • Mixing water: Water dilutes the colour of the pigments in the mix and excess water evaporates from concrete, leaving behind pores that scatter incidental light and lighten the colour of the pigment. “Excess water also causes excessive bleeding and a non-uniform colour,” Engelbrecht states. • Formwork: The type, colour and condition of formwork can influence surface colour. Formwork with different rates of absorption will create surfaces with different colour shades. Absorption discolouration also occurs when release agents are not applied uniformly. Formwork that pulls away from the concrete surface, or has leaky joints, can cause uneven water loss from the concrete and cause a streaky surface. • Dispersion: It is important to mix the pigment with the aggregate before the cement is added. From then on, the mixing process is the same as for un-pigmented concrete.
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C e m e nt & Co n c r e te
Chryso Pareflo 20 water repellent plays a major role in preventing efflorescence (such as pictured on left) in pigmented concrete.
Hannes Engelbrecht of Chryso says there are seven important factors to consider when producing coloured concrete. • Temperature during drying: In higher temperatures, fine crystals develop in the cement matrix. These crystals determine how the light that falls on the concrete is scattered. The smaller the crystals, the lighter the pigment in the concrete. • Efflorescence: “This is the result of free lime formed when the cement sets that, dissolved in the mixing water or in external water such as rain or dew, migrates through capillaries in the concrete matrix to the surface. There it reacts with carbon dioxide in the air to form insoluble and unsightly calcium carbonate deposits particularly noticeable on the surface of pigmented concrete,” Engelbrecht says. “Care should be taken when using admixtures with high levels of calcium chloride as this can cause primary efflorescence. The more impermeable the concrete, the less likely that efflorescence will appear.” All Bayferrox pigments are UV-stable and comply with quality standards EN 878 (the use of pigments for colouring building materials), and ASTM C979 (pigments for integrally coloured concrete), and carry the CE mark on their packaging. The CE mark is a mandatory conformity marking for products sold in the European Economic Area (EEA). Chryso S.A. has a colour laboratory in Jet Park that houses sophisticated equipment such as a Colourimeter that can measure the colour strength of pigmentation. The laboratory can provide customers with specifications to colour-match available concrete masonry production lines at competitive rates. Chryso SA has recently produced an informative free leaflet ‘Pigmented Concrete,’ containing essential advice for members of the construction industry involved in the pigmented colouring of concrete. Copies of the leaflet can be obtained by phoning Hannes Engelbrecht on 011 395 9700, or sending an email to hannes@chrysosa.co.za. Also visit the Chryso SA website, www.chryso.com for more information about coloured concrete.
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School of Concrete Technology to start next Advanced Concrete Technology course this year The Concrete Institute will exclusively offer the internationally-respected Advanced Concrete Technology (ACT/SCT50) diploma course from September this year.
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ryan Perrie, managing director of The Concrete Institute, says the Institute’s School of Concrete Technology in Midrand has been presenting the course every two years under the auspices of the Institute of Concrete Technology (ICT) in the UK.
“News that the course will again be presented this year by the SCT has been widely welcomed. Training at this level is vitally needed as one of the biggest threats to the future economic growth of South Africa is the shortage of technical skills in engineering and technology,” Perrie stated. “The ACT course will expose students to a wide range of concrete disciplines and insights that could provide a competitive advantage to both the delegates themselves and their companies.” Students for ACT courses are drawn from qualified civil engineers, cement chemists, concrete technologists and technicians involved in the building, construction, precast concrete, mining and also the cement, aggregate, admixture, and ready-mixed concrete industries.
The ACT diploma offers successful candidates the following: • International acceptance as the holder of the world’s leading qualification in concrete technology; • International qualification that is examined by the ICT in London; • The highest concrete technology qualification available in Africa; • Membership of the ICT and the right to use the letters ‘MICT’ behind his or her name; • Extensive networking opportunities to meet many industry experts and leaders in different fields of concrete technology; and • Detailed knowledge of all facets of concrete technology with good problem solving abilities. Applications to enrol for the two-year course close on 31 July 2013.
For further information, phone John Roxburgh or Gary Theodosiou on 011 315 0300 or visit the website www.theconcreteinstitute.org.za
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