www.trademax.co.za
OUR ROOFING DEALS ARE A STEEL
APRIL 2013 Issue: 48
SA R36 each incl. / R360 per annum incl.
APRIL 2013
ISSUE: 48
Trademax Publications SA Roofing Tel: 0861 SA ROOF Tel: 0861 727 663
EDITOR’S COMMENT......................................................................................................... 2
Cell: 082 266 6976
waterproofing...........................................................................................................4-9
www.trademax.co.za
Fax: 0866 991 346
cover story.............................................................................................................. 10-11
P.O. Box 37053 Chempet,
fasteners..................................................................................................................... 12-15
7442
paints & coatings................................................................................................. 16-18 architecture........................................................................................................... 20-26
Publisher:
news............................................................................................................................... 28-29
Billy Perrin
Photovoltaics........................................................................................................ 30-31
0861 727 663
billy@trademax.co.za
Company Profile.................................................................................................... 32-33
Editor:
insulation................................................................................................................. 34-35
Jennifer Rees editor@trademax.co.za
cement & concrete............................................................................................. 36-38
0861 727 663
architecture........................................................................................................... 40-43 Editorial assistant:
health & safety....................................................................................................... 44-45
Alex Struck alex@trademax.co.za
height SAFETY........................................................................................................... 46-48
0861 727 663
10
Advertising: Jacqui Marsh jacqui@trademax.co.za 0861 727 663 Bradley Williams bradley@trademax.co.za 0861 727 663
Layout & design: Craig Patterson craig@trademax.co.za
SUBSCRIPTIONS & DATA: Celeste Perrin celeste@trademax.co.za 0861 727 663
12
20
32
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 this issue.
april 2013
1
EDITOR’S commentS
Home and away The April issue of the SA Roofing magazine boasts a variety of roofing and related stories from South Africa with a dash of international flavour.
W
e feature Sika Sarnafil, worldwide market leader in thermoplastic roofing and waterproofing membranes, who won the 2012 RoofPoint™ Excellence in Design Award in recognition of their supply of sustainable roofing products to the General Motors (GM) Customer Care & Aftersales Warehouse at GM’s Distribution Centre in Lansing, Michigan, USA. We also feature the largest photovoltaic installation in the Nordic region, completed in 2012, which is connected to the grid. Commissioned by insurance company, Topdanmark, the installation’s 3042 panels and 45 Danfoss TLX Pro 15 inverters reduce the company’s CO2 emissions by 600 tons per annum.
With that, I welcome you to the April issue of the SA Roofing magazine. Enjoy the read! Jen PS: Your thoughts, comments and suggestions are always welcome. If you have anything you’d like to share with me, please don’t hesitate to email me at editor@trademax.co.za.
From an architectural perspective, we feature two noteworthy local roofs. One of these is that of the new R100 million SAPS 10111 Radio Control Centre in Korsten, Port Elizabeth, a topclass facility designed to better police service response times and call-out efficiency. We also feature the beautiful Lucas Quality Thatchers thatch roof of Silver Bay House, designed by SAOTA – Stefan Antoni Olmesdahl Truen Architects. Last, but not least, on the cover this month is Roofco Steel, a company that, by virtue of its attention to quality, customer care and good, honest business principles, has grown into one of the most comprehensive steel roofing suppliers in the country.
2
Topdanmark photovoltaic installation.
april 2013
We design & manufacture all precision roof trusses
At our Builders truss division we offer the following services: • Free roof truss quotations • Professional advice and friendly service • Supplier of all roof coverings at competitive prices • Member of the ITC (Institute for Timber Construction) • ITC certificate offered with all quotes (Roof inspection A19 certificate) • Precision truss manufacturing • Installation of trusses and coverings • 5-7 day turn-around from order to delivery*
TWNA18_Week 2_2012_X
* (order means that money has been deposited and reflects in the Builders account)
FOR YOUR NEAREST STORE CALL OUR CALL CENTRE
0860 builders/0860 284 533 or visit us at www.builders.co.za like
follow
share
check
wate rproo fi n g
Waterproofing Concrete Roofs Article courtesy of Derbigum Reinforced Waterproofing Systems
T
his article refers to general low-slope (less than 5ยบ pitch) concrete roofs screeded to falls and crossfalls to outlets where the roofing membrane is exposed to the elements and temperature fluctuations. The waterproofing membrane, correctly selected, installed and properly maintained is now considered as a permanent structural element with a life expectancy equal to that of the building it is protecting.
Substrates and Surface Preparation Design and detail, together with proper preparation of the substrate, are key elements to successful roofing. Too often waterproofing contractors are compelled to install the waterproofing system on inadequate or poorly prepared surfaces. It is good practice to ensure that ponding of water does not occur. Whilst the Derbigum membranes are unaffected by standing water, it should be noted that ponding, besides being unsightly, could result in deterioration of the final painted finish if painted finish was specified. The substrate shall be to falls and cross falls of 1:80 to outlets. If no falls and cross falls exist (not recommended) a dual layer system must be used. The substrate shall be surface dry, clean and smooth; free of voids, protrusions and contaminants. The area is then to be primed using a bituminous primer. Internal corners shall be filleted and external corners rounded. Most waterproofing materials are bonded or applied to surfaces that are installed by other trades. It is essential to the performance of the waterproofing system that these substrates be structurally sound and free from excessive cracks, holes or projections. Certain curing compounds and finishes may affect or interfere with the performance of the waterproofing material. The use of oils, waxes and other surface contaminants should be avoided or the contaminants must be removed prior to waterproofing. The waterproofing contractor should visually inspect the substrate surfaces before the application of waterproofing materials and report any deficiencies so that they may be corrected by the responsible trade.
Honeycombs, tie-wire holes and other voids in the concrete substrate must be cut out and re-pointed with a non-shrinking concrete patching compound. Concrete fins or other projections should be removed to provide a smooth surface. Horizontal concrete slabs should be free from cracks, voids, depressions, ridges and concrete droppings.
Sand and Cement Screeds A sand/cement screed is the most widely used and acceptable substrate. It provides a firm and even surface to which the waterproofing membrane can be properly sealed. It should be free of voids and protrusions, dry and clean, free of contaminants. The substrate should be stable and inert. Falls to outlets, etc. should be formed in the substrate and not in the loading layer.
Lightweight Screeds Foamed or expanded cement, polystyrene bead screeds, etc. used to create falls and crossfalls are to receive a sand/cement topping and are to be properly cured and thoroughly dry prior to installation of the waterproofing membrane. It should be smooth, free of voids and protrusions, contaminants and undulations. Ash breeze and vermiculite are not conducive to stability and should be avoided wherever possible, as they may severely impact on the long-term effectiveness of any waterproofing system.
Priming Generally, all surfaces to receive Derbigum modified-bitumen membranes are to be primed with a bitumen primer. Allow solvents in the primer to flash off prior to application. Surfaces primed too far in advance which have gathered dirt and dust must be lightly re-primed prior to application of the membrane.
Concrete Floated concrete surfaces are to be finished smooth without voids and/or protrusions. It is recommended that horizontal concrete decks cure a minimum of 28 days, or as specified by the material manufacturer, to allow moisture to dissipate from the top surface (forming systems typically prevent dissipation of moisture from the underside of horizontal decks) prior to applying waterproofing materials. Form release agents and concrete curing compounds must be compatible with the waterproofing materials being used or must be removed from the concrete surface by the responsible trade.
4
april 2013
Bituminous Aluminium Paint It is the most widely used protective coating, with the particular advantage of excellent solar reflective properties.
Crushed Stone A layer of light coloured stone chips laid loose over the Derbigum waterproofing provides a number of advantages: • Insulation – the stone layer reduces diurnal temperature fluctuations. • Provides an aesthetically attractive finish. • Acts as ballast – in high wind areas and for loose laid systems especially over insulation boards. • Ensures low maintenance costs. • Provides ultra violet protection • Additional protection from hail damage.
wate rproo fi n g
Specification Specification One layer Derbigum SP4 waterproofing membrane, with 75mm side laps and 100mm end laps, sealed to primed surface to falls and crossfalls by 'torch-fusion' finished with two coats bituminous aluminium paint. Waterproofing to be installed by an Approved Derbigum Contractor under a ten year guarantee.
Specification One layer Derbigum SP4 waterproofing membrane, with 75mm side laps and 100mm end laps, sealed to primed surface to falls and crossfalls by ‘torch-fusion’ including protection of 50mm thick layer clean 19-25mm crushed stone on Interdek separation layer. Waterproofing to be installed by an Approved Derbigum Contractor under a ten-year guarantee.
A stone-guard or band of larger stones should be positioned around the outlets so as to ensure that the smaller stone is not 'washed' down the outlets.
APRIL 2 0 1 3
5
wate rproo fi n g
Outlets The waterproofing is to be fully dressed into the drainage outlets so as to ensure a watertight seal. Outlets are to be positioned so that they are easily accessible both for the waterproofing contractor at the time of installation and maintenance purposes at some future date. Ensure that the level of the flange is kept below the screed level to prevent ponding around the outlet.
Derbigum provides a flanged water outlet that is sandwiched between two layers of Derbigum thus forming an integral part of the system ensures complete drainage and is simple in its installation.
The basic principles to be followed: • A sand/cement cove with a 35mm radius is to be formed at all internal angles. • The surface to receive the Derbigum is to be fully primed with a bitumen primer.
Derbigum is sealed by 'torch-on' fusion over the cove and to the vertical surface to a minimum height of 100mm. (Sketch 1)
• The screed around the outlet is preferably recessed to accommodate the additional membrane layer and assists in achieving complete and effective drainage. • The number and size of outlets to be determined by the design team. • The inclusion of emergency overflow pipes is to be considered.
Coves and Rounded Edges All angles, internal and external, should be rounded. Provide a min. of 35 mm radius rounded cove at all internal angles. Horizontal and vertical surfaces are usually of different materials and are subject to different heat transference rates and thus differential movement. The waterproofing membrane is subject to unnecessary stresses and practical installation problems if it is sealed into or over a 90º angle. Sharp edges and angles are to be avoided. The cove will greatly reduce these stresses and provide a neat finish.
6
Turn-ups greater than 200mm high should be treated as turnup and capping. (Sketch 2) It is good waterproofing practice that all exposed terminations on vertical surfaces are either flashed or counterflashed. A variety of flashing methods and systems are available. The nature of vertical surface and aesthetic requirements will determine the flashing type.
april 2013
(Pty) Ltd
Sketch 5450/13
LIVING GREEN AND HELPING YOU LIVE GREEN.
RIGIFOAM, manufacturers of (discontinuous) Polyurethane and Polyisocyanurate Block Foam. We offer a range of densities from 32 kg/m3 to 80 kg/ m3. With the aid of computerised profile cutters material can be supplied in any 2-dimensional shape, from flat sheet to pipe insulation.
TM
TM
(Pty) Ltd
Polyurethane foam systems are extremely versatile materials. Consisting of a formulated Polyoland Diisocynate that is mixed together, the reaction producing a foam that flows and fills the cavity. Two basic types of foam are produced - Rigid foams and flexible foams.
LAMBDABOARDTM is a flexible faced Polyiso-cyanurate (PIR) insulation board made on a continuous laminator. Installations include; over purlin, ceilings, side cladding and cavity walls. The core material (PIR) a thermosetting closed cell foam plastic, offering the highest levels of insulation properties.
ECOSPRAYTM is an affordable non-ODP, non-GWP, and VOC exempt polyurethane foam that helps protect the environment - while providing excellent insulation and safety properties to products for a variety of industries.
cape Town: Tel: +27 (0)21 981 8814 • Fax: +27 (0)21 981 6322 • E-mail: robin@lambdaboard.co.za • Units B18/19 Kruis Road, Brackenrite Business Park, Brackenfell. poRT eLIZaBeTH: Tel: +27 (0)41 453 0277 • Fax: 086 532 5702 • E-mail: ronnie@rigifoam.com • 4 Bedford Road, Neave Industrial. Kwa-ZULU naTaL: Tel: +27 (0)31 700 5250 • Fax: +27 (0)31 700 4924 • E-mail: lloyd@rigifoam.com • Unit G Pine Mead Industrial Park, 47 Gillitts Road, Westmead. joHannesBURg: Tel: +27 (0)11 421 0313 • Fax: +27 (0)11 421 0410 • E-mail: duncan@rigifoam.com • 3 Detroit Street, Apex, Benoni.
H O M E
•
B U I L D I N G
•
R E F R I G E R A T I O N
www.rigifoam.co.za
•
I N D U S T R I A L
wate rproo fi n g
Parapets and Kerbs Attention to detail is important. The general principles involved are noted in the example sketches. It is recommended that brick parapets be rendered and protected with one layer of Derbigum SP3 or SP4.
Specification One layer Derbigum SP3 or SP4 waterproofing membrane, with 75mm side laps, sealed by 'torch-fusion' to side and top of parapet wall to receive paint (elsewhere).
Alternative Acrylic waterproofing system to parapet dressed down over counter flashed Derbigum turn-up.
The top of the parapet is plastered with an inward slope and rounded edges. A counterflashing of fibre-reinforced bitumen, metal flashing or similar over the Derbigum turn-up is recommended.
Inverted Beams Inverted beams should be capped in Derbigum similar to any kerb. Water should not be drained through an inverted beam. Where this is unavoidable, the opening is to be sufficiently large as to enable proper dressing of the membrane. Alternatively, a flanged outlet pipe is to be inserted through the beam from the 'higher' side ensuring that the screed level on the 'lower' side is sufficiently below the base of the pipe as to be able to achieve a proper seal at that point.
8
Plinths Ensure that double or multiple concrete supports are constructed to such a height to allow adequate access both for the waterproofing contractor at the time of installation and for cleaning and maintenance at some future date. Plinths or bases built on the waterproofing membrane are to be placed on an additional layer of SP4 and not directly to the waterproofing membrane.
Specification One layer Derbigum SP4 fully sealed (as described for roof areas), up and over plinths with a sheet metal capping detail over the plinths to serve as protection to the membrane. Allow sufficient height for maintenance purposes (600mm).
april 2013
wate rproo fi n g
Derbigum Manufacturing (Pty) Ltd is a fully South African owned company specialising in the manufacturing of reinforced waterproofing systems. During the last thirty years of its existence a broad knowledge base has been established specifically with regards to South African climate conditions. Derbigum and its staff have and will continue to play a pivotal role in the South African construction industry.
For more information, contact: (t) 011 608 0317 (e) info@derbigum.co.za (w) www.derbigum.co.za
APRIL 2 0 1 3
9
cov e r sto ry
Roofco Steel Established in 2001, Roofco has evolved itself into one of the most comprehensive steel roofing suppliers in the country. Product quality, customer service and good, honest business principles are the foundation of the business that have seen the family-run enterprise grow from strength to strength. Industrial Starting out as a supplier predominantly active in the low-cost sector of the roofing market, Roofco has slowly built the product range to include higher-end steel roofing products. Product development included acquisitions of new machinery for IBR, SureLok (concealed fix profile) and lipped channel/purlin lines. Using in-house slitting, the lipped channel lines have continuous material supply with the shortest possible turnaround time. A dedicated flashings department allows fluent supply of accessories and trimmings for tailor-made requirements.
Accessories In order to achieve a truly ‘one stop’ experience, accessories have been sourced in bulk to ensure the most competitive supply. Products such as polycarbonate sheeting, insulation products, ventilation products and fixings are carried in stock. All these items are sourced in bulk by Roofco either through direct import, manufacturing or assembly at the facility. By accessing materials at their source and purchasing in bulk, Roofco are able to competitively supply all products with the savings being passed on to the customer. It is the idea to incorporate a range of industries through keen product sourcing to ensure the competitiveness of each item, whether sold individually or as a package of material.
Carports A dedicated retail carport division supplies materials to professionals and individuals specifically designed for carports and small roofing requirements. The carport division, dubbed STEELMART, carries products in various grades and qualities to cater for individual needs. Tailor-made fascia gutters, powder coated white beams and poles and polycarbonate sheeting are available for aesthetically pleasing carports. The fascia gutter is rollformed to ensure single length spans with no joins to prevent leaking and corrosion.
10
april 2013
cov e r sto ry
Products & Services:
• Low-cost and thin gauge roofing • Galvanised IBR and corrugated ridges • Industrial Roofing • Accessories • Aluminium gutter coil • Roofing materials • Zincalume • Galvanised steel • Purlins/lipped channel • Flashings and ridges • Whirlybirds and turbines • SureLok • Widespan • Screws and fixings • Polycarb sheeting • Insulation: Bubble foil and Sisalation • PVC straining wire • Chromadek • Carport supplies • Colorbond • Louvers and vents
For more information, contact: (t) 031 577 8885 (e) info@roofco.co.za (w) www.roofcosteel.co.za
OUR ROOFING DEALS ARE A STEEL
APRIL 2 0 1 3
11
fa ste n e r s
Fastener testing – is it for real? Traditionally, roofing fasteners have been tested by means of various types of laboratory tests. The most popular of these tests are salt fog and sulphur dioxide (Kesternich) tests. Salt spray tests try to simulate a marine environment and to test the effect of salt laden air on fasteners. Sulphur dioxide tests try to simulate an industrial environment and to test the effect of industrial fall-out on fasteners.
Laboratory test cabinet.
W
hile laboratory tests can be useful to get comparative tests done between different fasteners, there are some inherent flaws in this type of testing.
Firstly, the tests only test performance in one specific type of environment, i.e. marine or industrial. Often fasteners are used in industrial areas in close proximity to the coast. Areas like Richard’s Bay, Durban, Cape Town and other coastal cities are examples of this. In Gauteng and large areas of Mpumalanga a combination of ultra violet radiation, condensation and industrial pollution contributes to high corrosion rates. These environments cannot be duplicated in laboratory tests and therefore the results of lab tests are not a true reflection of how fasteners will perform in reality. Secondly, laboratory tests are conducted at a temperature of 35°C, but in the real world, temperatures on a roof will reach 80°C. As corrosion rates increase at higher temperatures, the actual corrosion rate will often be much higher than the results obtained in lab tests.
Fasteners sold in South Africa as class 4 tested by SABS failed dismally in salt spray test.
The lab tests cannot provide these answers so are actually meaningless and best limited to comparative testing only. Since the publication of the revised standard on roofing fasteners (SANS1273 – 2009) the ‘Deemed to comply’ method of testing fasteners was introduced. Based on this method, fastener coatings have to conform to three criteria: • Coating thickness • Coating composition • Coating porosity The reasoning behind this method is that if a coating contains a specified percentage of zinc or zinc/tin alloy and the coating has a specified thickness and a porosity rating of at least 8 on the scale given in the standard, then the screws will be suitable for use in specific environments.
Thirdly, when fasteners are tested in a laboratory they are tested in isolation – in other words they are not in contact with a roofing washer, roof sheeting or clip, insulation or the purlin. All these dissimilar materials that make up the complete roof structure lead to galvanic cell corrosion in the real world and will affect the service life of roofing fasteners. Again, laboratory test cannot provide reliable results on which to determine the expected life span of a fastener. Another drawback of lab tests is how to interpret the results from lab tests. If a fastener passes a 1000 hour salt spray test, what does it really mean? How long will that fastener last if it is used on a shopping mall in Umhlanga Rocks? If a fastener passes 15 cycles in a Kesternich test how long will it last when used on the roof of a chemical factory in Vanderbylpark?
Coating thickness.
12
april 2013
ITW BUILDEX THE INNOVATORS ®
Can you trust roof fasteners imported into the South African market? ITW have been in business over 90 years & invented the self drilling Tek’s point used Worldwide. We were the first to develop ISO Class 3, 4 and now the new Class 5 coating to combat corrosive environments . First to test in Outdoor “ Real World ” corrosive environments. First with Shank Guard® & Hi Grip® features . First to use Non Conductive EPDM seals & First to give Warranties to roof owners.
Buildex® as the market innovator have been “ Real World ” testing since 1994 as part of AS3566-2002 section B not lab testing as that does not replicate the combined corrosive elements a steel building is subjected to such as UltraViolet light, Humidity, Salt spray, Chemicals, Galvanic cell corrosion from dis-similar metals in contact and the accelerating effect of high temperatures. Buildex screws often last over 4000 hours in lab salt spray tests but our outdoor tests prove that other brands may not pass the realistic more harsh outdoor test as the samples of Asian made screws, (left) show after just 16 months of exposure.
Using proven Buildex® screws is cheap insurance against failure. Can you trust the others? The cost difference between cheap and Buildex® fasteners for an average house can be just R700. Compared to the total cost of an installed roof this is very cheap insurance and assurance for the roof owner and installer alike.
fa ste n e r s The shortfall of the ‘Deemed to comply’ method is that there is no government institution or independent authority that monitors the true quality of coatings that is sold to the South African market. Virtually no fastener manufacturers/importers in South Africa provide reputable and independent test results that confirm compliance to the ‘Deemed to comply’ table of the standard. Many fastener distributors have no test results at all while others present dubious and misleading reports.
2
The three tests of table 2 all have to be done in a laboratory with relatively expensive equipment which makes the continuous testing of fasteners an expensive exercise. Irregular testing defeats the purpose of testing, as porosity and tin content in fasteners tends to be very inconsistent.
8
What then is the testing solution? The logical solution is to test fasteners where they will be used – outdoors in the real world, where they are exposed to harsh conditions, in contact with other roofing materials and in varying temperatures. This same logic is used by many quality companies like BlueScope and paint companies, for example.
The way Real World Testing works is as follows: Fasteners are fixed through roof sheeting panels onto steel or timber purlins in a highly corrosive environment. (See above)
14
Microscopic images of metal coatings show rating 2 (Poor) and porosity rating 8 (Required).
Zinc coupons are placed on the test panel and zinc loss on the coupons is measured at regular intervals. If red rusts appears on 5% of the head and/or shank of the fastener by the time the zinc coupon has lost 21 micron of zinc (for Class 3 fasteners) the fastener has failed. For Class 4 fasteners the zinc loss on the coupons is 42 microns.
april 2013
The test racks comprise exposed and sheltered panels to simulate the effect of rain washing the fasteners and roof sheeting which has a big influence on corrosion, sheltered being worse. The photos of the real world test site above are at King Island, Australia. This test site is run by ITW Buildex and corrosion results are independently monitored by the Australian CSIRO. ITW Buildex Australia will be launching their first Real World Test Site in South Africa shortly. The site will be monitored by an independent company to ensure that all results are authentic and reliable. Only two or three fastener companies run outdoor tests sites, which raises many questions as to why more companies do not, and even those that do may not always publish full results. The main aim of the new test site will be to provide the South African roofing market and its customers a report on the real quality of fasteners that are currently being sold as Class 3, Class 4 and now lately as Class 5. Many fasteners will then show their true colours – red rust! Article provided by Reitze Hylkema of Kare Industrial Suppliers.
For more information, contact: (t) 011 334 0922 (e) reitze@kare.co.za
april 2013
pai nt s & coati n g s
Ceratech CeraShield Keeping it Cool Living in Africa, sunshine is more often than not the order of the day and there are few places where an effective, affordable solution to extreme heat is more applicable.
T
he table shows typical roof cladding temperatures measured during the hottest part of the day on an average day between October and March in Johannesburg, with a maximum temperature of 24.8°C and no clouds. This table illustrates the fact that different colours and types of roofing material result in vastly different roof temperatures. The more heat that is reflected or radiated away from the roof, as opposed to being absorbed by the roof sheets, the less heat there is available to be transferred into the building. How the temperature of the roof material relates to the ambient air temperature inside the building is subject to multiple parameters, such as ventilation, insulation, heat generated by processes inside the building, the number of people occupying the building and their activity level and the list goes on. But the bottom line is that a cooler roof will mean a cooler building, whether it is a 12°C drop in maximum ambient air temperature in a galvanized iron structure with no insulation or a 2°C drop in a building with reflective foil under the roof sheeting and a well insulated ceiling. As a matter of interest the hottest roof material temperature measured thus far during testing this year was 72.2°C on the 25th of January when the maximum daily temperature was 34°C. The graph below shows a temperature trace taken on this day which directly compares the temperature of an uncoated galvanized iron sheet to that of a sheet coated with CeraShield.
16
Dark green acrylic roof paint
69°C
Dark grey acrylic roof paint
56°C
Uncoated galvanised iron
55°C
Uncoated fibre cement
52°C
Light grey acrylic roof paint
50°C
Dark blue acrylic roof paint
47°C
New Kraft paper based reflective foil insulation under plain galvanised iron
45°C
New bubble plastic based reflective foil insulation under plain galvanised iron
42°C
High reflectivity silver paint
42°C
Light green acrylic roof paint
42°C
Light blue acrylic roof paint
41°C
White pre-coated sheet
40°C
White acrylic roof paint
38°C
Cheapest RHBC coating
34°C
Most expensive RHBC coating
31°C
CeraShield RHBC coating
30°C
april 2013
Shield roofs from
solar heat penetration CeraShield is an innovative, environmentally friendly heat barrier product from Ceratech that offers a tried and tested method for reducing temperatures inside buildings by reflecting solar heat and preventing heat penetration.
SPRAY IT ON! This highly reflective coating, spray-painted onto roofs and walls, creates a cost-effective, energy-efficient, heat-reduction solution with a smooth, easy to clean finish. In addition to making a significant difference to building temperatures, CeraShield also guarantees an extended roof life and reduces the amount of electricity used for air conditioning, diminishing your negative environmental impact – and reducing costs.
APPLICATION ADVANTAGES
OUTSTANDING FEATURES • Reduces building temperature by up to 45% • Reduces HVAC costs instantly
For more information and technical specifications, call Ceratech today.
• Environmentally green • Non-toxic
• Reduces HVAC costs instantly
• Mildew-resistant
• Environmentally green
Choose White to go Green – join the Ceratech White Roofs Project and help reduce global warming, electricity and roof maintenance costs.
• Reduces roof degradation by up to 80%
• Reduces building temperature by up to 45%
• Reduces roof degradation by up to 80%
REDUCE GLOBAL WARMING
• Abrasion-resistant • Non-yellowing • Cleaned with soap and water • Water borne • Flexible
Tel: 086 000 0703 MeeA: 079 890 9488 info@ceratech.co.za www.ceratech.co.za
pai nt s & coati n g s The cost of cooling a building in terms of both direct air conditioning costs and the loss of production due to heat stress can be reduced by adopting a cool roof option. Numerous studies and actual tests have shown that the cost of applying Ceratech CeraShield is recovered in a relatively short period of time, after which the savings add to your bottom line. Apart from helping to cool the inside of your building, a cool roof presents another significant benefit in reducing future roof maintenance costs. Foremost, the roof is directly exposed to the elements and experiences continual cyclic thermal movement as the roofing material heats up and cools down during the course of a day. Not only does this movement occur between night and day cycles, but also as a result of passing clouds, wind, rain and condensation. The average temperature differential a galvanized roof sheet experiences in Johannesburg between October and March is 42°C. Given the linear thermal coefficient of expansion of steel, such a temperature differential would result in 10mm movement along the length of a 20m long roof sheet daily. This movement not only places stress on the roof fastening system, but also results in abrasion between various roof sheet and flashing interfaces. With a CeraShield coating, the average temperature differential drops to 17°C, resulting in less than half the movement at 4mm along the length of a 20m sheet. The less movement, the less stress there is on the roof and its related components and structure.
By keeping temperatures in the ceiling space down, CeraShield helps to prolong the life of various types of insulation materials, as well as helping them to perform better, since insulation is less effective at retarding heat flow the hotter it gets. Furthermore, other components, such as alarm system control boxes, plumbing, electrical conduit and connections, etc. are all exposed to less thermal stress beneath a cooler roof. Radiant heat barrier coatings are often maligned as poor insulation material. The truth is that such coatings are not insulation and should not be construed as such. Insulation has its rightful place and is not an either/or option. Radiant heat barrier coatings (RHBCs) keep radiant heat away from a building while insulation prevents heat flow through the building envelope – be it heat flow into or out of the building. During winter, an RHBC can not be expected to keep a building warm, but tests have shown that they at least do not make the building significantly colder than it would be otherwise. At a time when energy is at a premium and the world is clamouring for effective, environmentally friendly cooling systems, Ceratech CeraShield offers a host of benefits in one fast, affordable solution.
For more information, contact: (c) 0860 000 703 (e) info@ceratech.co.za (w) www.ceratech.co.za
In addition to the significant decrease in wear caused by thermal expansion and contraction of the roof sheets, CeraShield also blocks 100% of harmful UV radiation, preventing degradation of previous roof coatings, washer seals, waterproofing material, and linings.
18
april 2013
IS PROUD TO INTRODUCE
MULTIFIX AND BREMICK ARE PROUD TO INTRODUCE THE REVOLUTION B8 COATING SYSTEM TO THE SOUTH AFRICAN MARKET. Revolution B8 Coating provides more than four times the corrosion protection of traditional galvanised fasteners* Independently tested by a world-leading corrosion scientist at severe marine “Outdoor Exposure Test” sites (AS 3566.2), Bremick’s Revolutionary B8 coating system provides more than four times the corrosion protection of traditional Class 3 galvanised coatings (AS3566.2) and more than double the corrosion protection of traditional Class 4 galvanised coatings (AS3566.2).
The Revolution B8 Screws are engineered to drill 28% faster than conventional galvanised screws** • The drill point design employs unique geometry to optimise the starting performance. • The extended cutting flutes minimise swarf during drilling. • The thread geometry has been designed to form threads quickly to provide fast installation, while maximising the holding strength. • The B8 coating is up to eight times harder than traditional coatings, meaning that the point and threads remain sharp through the entire drilling process, avoiding the points and threads being rounded by thick galvanised coatings.
Initially developed for the US Navy, the Revolution B8 coating technology is now widely employed by all major automotive, aerospace and marine engineering organisations worldwide, including Boeing, Rolls Royce, BMW, Honda, US Army and NATO. Revolution B8 coating has excellent adhesion properties and remains intact after installation, protecting the entire fastener, even when drilled through high tensile steel.
CORROSION PROTECTION
Double Conventional Class 4 Suitable for use in Very Severe Marine environments (ISO 9223 Category 5)
WARRANTY
Double Conventional Class 4
DURABILITY
8 Times Conventional Class 4
DRILL DRIVE PERFORMANCE
28% Faster than Conventional Class 4
APPEARANCE
Smoother, finer & matched to ZINCALUME®
CONFORMANCE
Exceeds AS3566 Class 4
COMPATIBILITY
Zinc/Aluminium, ZINCALUME®, COLORBOND® ULTRA® Steel, COLORSTEEL® Maxx, Galvanised & Zinc Coatings
ASK FOR YOUR FREE SAMPLES TO TEST TODAY! DISTRIBUTED IN SOUTH AFRICA BY: GAUTENG: (011) 791-1851
MARCONI BEAM: (021) 552-0383
www.multifix.co.za
GOODWOOD: (021) 591-9129
arc h ite ctu r e
Corobrik adds to efficiency of new SAPS 10111 Radio Control Centre The new R100 million South African Police Service (SAPS) 10111 Radio Control Centre in Korsten, Port Elizabeth, designed by The Matrix… Urban Designers and Architects for the National Department of Public Works (NDPW), is a world-class facility built primarily to improve on SAPS response times and provide a significantly improved and more efficient call out rate to the country.
The main entrance of the SAPS 10111 call centre building which has been built in Korsten, Port Elizabeth. “The brief was in no way open ended and set out, within strict criteria, specific areas and sized accommodation to suit the particular needs of the end user,” says project architect, Neal Fisher. The brief was developed through numerous workshops held between the design team and end user, facilitated by the client, and finalised through stringent design reports and sketch plan committee approvals. “The need for design workshops was crucial in planning the relationship between the two key divisions to be housed within the building, that being 10111 and Radio Technical, and the core functioning between them,” he explains. The need for the new building was evident due to the fact that the existing facilities at Mount Road were inadequate in terms of size. The new facility was necessary to deal with large, sensitive electronic equipment, the value of which exceeded the building threefold, and all its related supporting functions and requirements to be housed within a single, dedicated ‘high tech’ building to expand SAPS operations to provide a significantly improved and more efficient call out rate to the Eastern Cape, and in turn, set a precedent for future development nationally.
20
The new building is positioned on a generous 2.4ha site surrounded by secondary arterial roads to the South and open space to the North. The site, being one of the highest points in the area, provides great opportunities with respect to panoramic views across the bay. It can be viewed from the N2, a high traffic route that links William Moffet express way with North End and adjacent suburbs. The 50m communications mast has also become a landmark in the area and a beacon for the site. The project’s core function is to communicate, nationally, between different key high sites as part of the South African Police Service’s (SAPS) drive to eliminate crime. The Eastern Cape is the first region to receive a facility of this kind with prime emphasis placed on systems management. “The project is high profile and considered ‘mission critical’ with every electronic and mechanical system having to be 100% redundant in terms of failures to provide a self sufficient uninterrupted service. The facility also houses a Radio Technical Workshop to repair and improve on electronic equipment within squad vehicles which forms an integral part of communication between the 10111 Call Centre and public at large,” explains Fisher.
april 2013
arc h ite ctu r e
The building’s footprint is orientated along an East West axis aligning itself to the North as opposed to the sites North East boundaries. According to Fisher, this juxtaposition intentionally reinforces the building’s form as a pavilion with its massing defined by the levels of the site. Access is from the North East directly along the buildings central axis, allowing views though the building to the West. The central Call Centre/Radio Control is perceived as the hub of the facility and designed as an independent entity inside the space of the building’s structure, defined by a single mono-pitched roof. All supporting accommodation feeds off this central space, taking advantage of the views and promoting transparency throughout the facility.
Although conceptually there was a need for transparency, it was also fundamental to ground the building to provide a firm base to work from. This was achieved by detailing the four outer corners of the building's structure in face brick. These corners wrap around textured plaster and seemingly elevate just off the surface of the surrounding finishes through a recessed shadow line of raw terelyne to help soften its connection. “The bottom two courses of face brick above the recessed plinth is in essence a result of the need for a composite beam to form the cantilever in the brickwork,” notes Fisher. The brick-on-edge and soldier course in the brick work rests on a continuous length of 5mm galvanised steel plate – over the full width of the wall – and a concrete cavity filled to the height of the soldier course.
Choice of materials
“The differing course configuration also facilitated the need to tie back into the required brick courses of the inner skins,” he says. The choice in using brickwork was also taken a step further through the use of carefully detailed reveals and the combination of travertine and satin faced bricks. Light naturally reflects off smooth surfaces which intentionally created a ‘mosaic’ effect across the face brick facades. Corobrik’s Terracotta Travertine and Satin mix, batched 50/50 was specified for the exterior brickwork, while internally, Corobrik’s Firelight Satin was used.
The underlying design intension was to create awareness through detail of materials across a limited palette. All materials of which were detailed to be exposed and taken back to their most basic form, brought together to produce a sense of proportion and space that could blur the boundaries of the envelope both externally and internally. The client’s brief to provide an uninterrupted space for call takers required an intricate steel structure to both span and support a service platform above over an area of 800m². Within the Call Centre space two primary steel girder beams are visible with supporting steel bearers being concealed within the ceiling void. The concrete framed structures that flank this central entity delicately interface with this core using carefully detailed steel walkways.
APRIL 2 0 1 3
Internalised purpose-made galvanised steel brick shelves, fixed to concrete ring beams, allowed for full height brick work with horizontal expansion joints at roughly 3,5m centres. These shelves also allowed the face brick work to continue across cantilevering slabs to allow the brick to wrap around the scratch plastered recesses.
21
arc h ite ctu r e
The impressive entrance to the SAPS 10111 Call Centre building in Korsten, Port Elizabeth. Furthermore, all openings are finished with header courses forming the side reveals and brick-on-edge courses to the lintel and sill of openings. Lintel and sill brick work intentionally project past the face of the facades as capping pieces. “These face brick lintels and sills are taken through into plastered sections as well,� he points out. Slit windows are expressed using a centrally recessed panel of scratched plaster to highlight window bays across the facades. Openings within deep 640mm thick walls were bridged using purpose designed voluted precast concrete lintels, the bases of which are detailed using header bond. The versatility of face brick was significant in allowing the architects to utilise the material successfully in many guises in the Radio Control Centre.
The central, outer and inner zones of the building were left plastered and simplified in terms of detail to highlight the underlying central steel roof structure and space that is allowed to flow beneath.
22
april 2013
Timber Nail Plated Trusses Light Gauge Steel Trusses Steel Wall Framing Full engineering service & guarantee on all products Unmatched Quality provided in over 200 countries
MiTek Industries South Africa (Pty) Ltd Midrand: 011 237 8700 Durban: 031 700 6332 P.E: 041 581 7525 Cape Town: 021 905 0244 E-mail : marketing@mitek.co.za
arc h ite ctu r e The canopy is elevated to seamlessly connect the two masses of the buildings form. Although the steel roof structure interfaces with standard materials and finishes, very little conventional engineering was followed. In most cases, aesthetic preferences manipulated the structural designs resulting in many elements, particularly steel, having to be considered in a different light. “Due to budgetary constraints, the choice to adopt an industrial aesthetic/ideal was considered to enable the use of a limited palette of materials, as well as colours,” says Fisher. Extravagant finishes were rejected and rather made allowance for the detail between element and surrounding space to speak for itself. This ‘industrial’ aesthetic was followed through into the design of supporting walkways, composite beam structures and staircases. All steel was left galvanized as its finishing coat to re-enforce the mechanical beauty of the steel and to increase the maintenance cycle of the lattice structures. Walkways that surround the central space, although elaborate, were economized by utilizing the surrounding moment connections between connecting pipe sections and concrete reception zones of the two blocks. Below the central connecting roof structure lays the heart of the building in the form of the Radio Control/Call Centre and was designed as such. The Control Centre is housed within a face brick box detailed to be transparent from all sides. To highlight the ‘box’ as a further layer to the inner space of the building, the face brick in this case was changed to a lighter shade and all faces being of a satin finish. Curtain walls were also changed from the surrounding grey to black.
24
april 2013
arc h ite ctu r e Green rating “The building has been registered with the Green Building Council of South Africa (GBCSA) with the intention of achieving a four star Green Star SA – Office ‘as built’ accreditation that would recognise the building as being Best Practice,” says Fisher. As the project is high profile and considered mission critical, a core feature of the building is systems management. It was therefore important to manage these systems and the building’s green initiatives he says. “A central Building Management System (BMS) was incorporated to drive, monitor and record all operational data of the building, which includes electrical/mechanical services and water consumption to ensure their optimal performance and use. Other noticeable features would be rain water harvesting for 100% irrigation requirements, double glazing, solar glare control, acoustics, steel disassembly and intrinsic design features, such as orientation and daylight views,” he notes. “The project was backed by a client whose standard specification for building works goes way beyond that of commercial development. The use of an emerging building contractor and the use of EPWP initiatives were important to the success of the project. We believe that our project should be considered a great achievement considering the use of these initiatives and the government’s objective in taking a further step to ensuring the safety of our country. Further to this, the building reflects this objective with the intention to create awareness through detail that has been paid between all materials resulting in an overall well-proportioned form,” concludes Fisher. The building aims to improve on standard preconceived ideas of what we know as a Call Centre. In the past, they have often been regarded as being introverted, where in this case the project team have aimed to expose this function as the heart of the facility visually connected to all corners of the building and public realm which it serves.
26
april 2013
n e ws
Sika Sarnafil Wins Excellence in Design Award For Largest Vinyl Roof Recycling Project in North America Sika Sarnafil, the worldwide market leader in thermoplastic roofing and waterproofing membranes, has been awarded the 2012 RoofPoint™ Excellence in Design Award. The accolade was in recognition of their supply of sustainable roofing products to the General Motors (GM) Customer Care & Aftersales Warehouse at GM’s Distribution Center in Lansing, Michigan, USA.
T
he RoofPoint™ Excellence in Design Award, developed by the Center for Environmental Innovation in Roofing, recognises the best in design and installation of long lasting, energy efficient, and environmentally friendly roof systems. The Sika Sarnafil-GM project was one of 100 entries received for the 2012 awards and was selected for demonstrating ‘Excellence in Materials Management,’ including material recycling, project waste management and the use of environmentally preferable construction materials. This General Motors (GM) project involved reroofing 44 130m2 with Sika Sarnafil’s reflective, energy-efficient Sikaplan vinyl membrane. Two layers of vinyl roof were removed from the building and as a result, nearly one million square feet of membrane, equaling 140 tons, was recycled – making it the largest vinyl roof-recycling project in North America. The material has been recycled into Sika Sarnafil roofing membrane products. “Sika Sarnafil is committed to helping contractors, building owners and government to reduce their environmental footprint and achieve their sustainability goals,” said Brian J. Whelan, Senior Vice President of Sika Sarnafil. “The Sika Sarnafil Roof Recycling program helps reduce waste and allows us to be more efficient with our products and resources. We are honoured to be recognized for this project by the Center for Environmental Innovation in Roofing.”
28
Why Choose Sika Sarnafil? Performance over time is the only true test of a waterproofing system’s quality. Sika Sarnafil has been waterproofing green roofs and other landscaped areas across Europe for over 40 years, in the United States for over 25 years, and in South Africa since 2008. With close to four hundred million square metres of roofing and waterproofing membrane installed worldwide, architects, specifiers and building owners depend on Sika Sarnafil for proven products and system performance. When you specify a Sika Sarnafil Green Roof, you get watertight security and peace of mind. The Sika Sarnafil G476 membrane is specially designed for sub-grade environments, compounded to remain watertight in extreme conditions including constant dampness, ponding water, high and low alkaline conditions and exposure to plant roots, fungi and bacterial organisms.
Benefits: As you can imagine, the addition of a green roof to an otherwise unused area on a building, is beneficial for the surrounding environment. Initial loss of ‘green’ space and its inherent natural processes like photosynthesis are restored - albeit just a few storeys higher. But green roofs also have other benefits that you might not be aware of.
april 2013
Reducing Energy Consumption: Green roofs are great insulators. They can reduce peak energy demand by lowering a building’s cooling costs in the summer months and heating costs in the winter months. Reducing the Urban Heat Island Effect: More green roofs and fewer dark coloured roofs equal a cooler city. Dark roofs retain heat while plants naturally cool their surrounding environments through evapotranspiration cycles. In cities where the ambient temperature can be up to 10 degrees hotter than the surrounding areas, green roofs can help bring the overall temperature down. Waterproofing Membrane Protection: A green roof protects the waterproofing membrane from damaging UV rays, freeze-thaw cycling and repeated foot traffic, extending its lifespan. Some green roofs in Europe have lasted more than 40 years without being replaced. Improved Air Quality: Green roofs filter air by absorbing and converting carbon dioxide to oxygen. Sound Insulation: Soil and plants are effective sound insulators.
Aesthetics: Green roofs are visually stimulating and can make great areas for recreation and pleasure. Increased Property Value: Installing a green roof can increase property value by providing a valuable building asset. Root Resistance: Many waterproofing membranes are not resistant to root penetration. They fail, often in five years or less, due to root infiltration into the field seams and flashings. Sika Sarnafil membranes are inherently root and algae resistant and require no additional barriers to be added to the system. Sika Sarnafil membranes have passed the most stringent European tests (German FLL Standards) for root resistance. The FLL standard test exposes the waterproofing membrane to four years of accelerated root growth. Heat Welded Seams and Flashings: Faulty seams and details are a common source of leaks in green roofs. Some waterproofing membranes use sealants, adhesives or tapes to secure the seams, but because Sika Sarnafil’s membrane is thermoplastic, seams and flashings are welded together using Sika Sarnafil’s automatic hot-air welder, the Sarnamatic. When welded together, the sheets become one monolithic layer of material impervious to moisture infiltration.
For more information on Sika products and systems, visit zaf.sika.com.
n e ws
Storm-Water Retention: During heavy rainfalls, runoff from surfaces such as pavements and rooftops can cause serious problems such as sewer overflow and water pollution. Green roofs slow down the water flow by retaining up to 75% of the rainwater, thus alleviating the pressure on storm-water infrastructures.
Ph otovo ltai c s
Largest Nordic PV installation Topdanmark uses TLX inverters Article courtesy of Danfoss Solar Inverters A/S.
Image courtesy: LiorZ.
I
n August 2012, the largest PV installation in the Nordic region, commissioned by insurance company, Topdanmark was connected to the grid. Its 3,042 panels and 45 Danfoss TLX Pro 15 inverters reduce the company’s CO2 emissions by 600 tons annually. The installation has become a major case for the economical and environmental benefits of solar energy. A great challenge faced Topdanmark as they started to look into the energy consumption of their premises in Ballerup. In addition to changing the roof they wanted to upgrade the older building to modern standards of energy efficiency and sustainability – as quickly and economically as possible. In-depth studies indicated that a large, efficient PV installation would be the most environmentally and economically effective energy solution for the property. The resulting PV system utilises 5,000m2 of flat roof for 3,042 solar panels and 45 Danfoss TLX Pro inverters, making it the largest PV system in the North.
When efficiency counts The choice of Danfoss TLX Pro inverters for the project was made by the Danish sustainability-driven company, DrivhusEffekten. “It’s our job to give every customer the opportunity to contribute to a cleaner environment – without a negative impact on their economy or daily business.
30
With years of experience in building solar/PV installations, we understand the importance of efficiency and the bottom line result for our customers,” said Bjarne Rasmussen, CEO of DrivhusEffekten. By using the TLX Pro in a multi-string layout, where each row of modules is connected directly to the inverter inputs, the output is optimized. With the TLX Pro’s 1000 V input and 250-800 V MPP range, a layout design is possible where the system is able to carry power longer at higher levels of voltage, keeping power losses to a minimum. With such an economically driven sustainability project, efficiency is crucial – especially given the fluctuating environmental conditions experienced in Denmark. The TLX Pro inverter’s precise MPP tracking – which gives 99.7% efficiency in dynamic conditions – made it the ideal choice of inverter to harvest all the available energy from the roof mounted PV modules. “On an annual basis the system is expected to supply around 15% of the total power consumption of Topdanmark’s head office. The largest electricity production will be generated in the period from March to September, with less power available during the darker winter months,” said Pernille Fogh Christensen, CSR Manager, Topdanmark. “In the first month of the system’s life, it produced 82,173 Kwh of electricity corresponding to 13% of the power consumption of our head office. Since the system went online in August 2012, it has worked excellently,” she added.
april 2013
Additionally data including real-time CO2 savings is also an option for display viewing on daily, monthly or yearly basis. This means the targets set for the system can be tracked and monitored, centrally. The online web interface makes it easy to make comparisons and overview data of each individual inverter, as well as the system as a whole. This data is collected in quarterly reports and shared.
Raising the profile of solar solutions
Topdanmark’s solar installation was inaugurated in August 2012 by Lars Lokke Rasmussen, Chairman of Global Green Growth Institute and Connie Hedegaard, the EU Climate Commissioner. “Environment and economy must go hand in hand in the 21st century and that’s why I am glad that Topdanmark is telling the world about this investment. It is important to have a long-term perspective and that is why good examples are so important,” said Connie Hedegaard, who continued: “From a European point of view it is also important to learn from Topdanmark’s investment in sustainable energy. I’ll take your example into the world and tell people about it.”
As supporters of the UN Global Compact, Topdanmark continually works to reduce the adverse impact on the environment of their business operations. Their environmental initiatives include the goal of reducing their CO2 emission by 10% in 2014 compared to 2011. The new PV system is expected to play a key role in reaching this target. “In addition to reaching our energy goals, we see it as our responsibility to share our knowledge and experiences with others to inspire and promote green solutions – in this case, solar cell systems,” said Pernille Fogh Christensen. Key production and performance data are provided by the TLX Pro’s built-in web server.
A compelling case for solar energy
For more information, contact Norbert Apfel from Danfoss Solar Inverters at apfel@danfoss.com or visit www.danfoss.com/solar
Ph otovo ltai c s
In addition to reaching our energy goals, we see it as our responsibility to share our knowledge and experiences with others to inspire and promote green solutions – in this case, solar cell systems. - Pernille Fogh Christensen
Co m pa n y Pro file
Add Light, Add Life Four Seasons Roof Windows is a Cape Town based company started by Four Seasons Aluminium Products in 1991 in order to create ventilation in their conservatories. We saw a gap in the market for Aluminium Roof Windows and began to develop these to be suitable for all other roof applications.
A
ll products used have been tried and tested, affording the customer the best possible solution to adding ‘light and life’ to their homes.
A Leader in all Skylight Solutions Installing a Four Seasons Roof Window is a unique, affordable way to brighten up your home or workplace. Four Seasons Roof Windows are locally manufactured in our factory in Montague Gardens from high quality, purpose-designed aluminium extrusions and all parts are welded to ensure a 100% weather-tight base and element making us the leaders in Aluminium Skylights in the Cape. All dies are designed and owned by Four Seasons Roof Windows. Four Seasons glass is bevelled on all four sides. Our Skylights are glazed to required specifications and are available in any kind of glass from 4mm toughened, 6.38 laminated Solarvue glass, tinted or sandblasted glass and double glazing.
32
All Four Seasons Roof Windows are powder coated by an SABS approved applicator to guarantee a durable and maintenance-free product. The use of aluminium frames ensures no warping, no maintenance and a long lasting amazing looking feature in your home. As a manufacturer, Four Seasons Roof Windows can offer you the lowest prices, solutions to suit your specifications and a five year factory guarantee. A large variety of colours are available on request. We custom manufacture roof windows, access hatches and glass pyramids to any size. The roof windows are available in fixed and various opening options and are suitable for all types of roofs. We will always have stock available in our two standard sizes in 600 x 600 and 600 x 900 in both fixed and opening options. These sizes are also available at Builders Warehouse, Penny Pinchers and Brights Hardware.
april 2013
Co m pa n y Pro file
New Division: Four Seasons Tubular Skylights Our Tubular Skylights are the most cost-effective and affordable way of bringing light and life into a dark roof and are quick and easy to install. Four Seasons tubular skylights are created with original fibreglass roof flashings and the high quality dome, diffuser and ring profile is specially designed to allow in maximum light. Installing Four Seasons Tubular Skylights will reduce electricity consumption, therefore making them a more eco-friendly alternative to electric lighting
Installations All our Cape Town installations are done by our own approved professional in-house installation team. This installation team is run and supervised by the owner's son. We also have approved installers in the Garden Route and Nelspruit areas.
For more information, contact: (t) 021 551 7533 (e) joyce@fsroofwindows.co.za (w) www.fsroofwindows.co.za
APRIL 2 0 1 3
33
i n s u lati o n
Spray Foam Insulation Polyfoam Spray Foam insulation or SPF, as it is commonly known, is a polyurethane foam that is sprayed on to the surfaces of walls and ceilings, where it sticks, expands and hardens.
W
hile it has a higher initial cost than other insulating materials, it has a number of side benefits that more than justify the cost for a product that has proved to be the most efficient and effective insulator one would find on the market today. Only trained and reputable contractors should be used to install the SPF, as it is a specialised service.
Blowing away competition Without question, spray foam insulation is the best insulator available to home and property owners. Because it expands to fill cracks that other insulating materials simply cannot reach, it creates a lock-tight seal for one's home. As a result, it can lower heating and cooling bills by up to 40 per cent year round. And since it sticks to just about any material or surface, it is easily installed on ceilings and in hard to reach places, such as crawl spaces, where other materials are tough to apply and provide less protection. Its ability to harden and hold in place allows it to last longer than traditional materials that often sag or come loose over time.
34
Safe to use Besides its excellent insulating properties, spray-on insulation is not a danger to one’s health. Because it is polyurethane foam, there are no fibreglass or other loose fibre particles floating around after it is installed. Because it is a closed cell system, it is also water resistant, reducing the instances of mold and mildew accumulation that can be a problem in other insulation products. And as an added bonus, it does not cause itching and rashes like fibreglass can; something any homeowner who has had to crawl through a fiberglass insulated attic can appreciate.
Fire and insect resistant As if all these distinguishing features are not enough, spray foam insulation is insect and fire repulsive and an excellent insulator against noise too. When one takes into account all of these considerations, it is easy to understand why this product is leading the way when it comes to insulating anyone's home or business structures.
april 2013
i n s u lati o n
Invest in spray foam Polyurethane foam can help save money on equipment costs too. With polyurethane foam insulation, one can downsize one’s investment on the mechanical heating and cooling equipment needed. For instance, in the polyurethane foam house, a 60,000 BTU furnace could provide the same indoor comfort level as a more costly 80, 000 BTU unit, thus making polyurethane foam a smart investment from the onset. It goes without saying, that an investment in polyurethane foam would reap long term returns in saved energy, Rands, comfort, control of indoor air quality, health and safety for the life of one’s home. Owing to the fact that polyurethane is a closed cell insulation material delivering the highest R-value per inch, heating and cooling equipment works more efficiently, uses less fuel and maintains consistent and uniform temperature.
Looking forward The age of insulating homes with traditional thermal protection technologies is fast coming to an end. With the escalating energy and building costs, and health concerns, plus the potential for added personal comfort, there is consensus among architects, engineers and contractors to use innovative methods such as polyurethane spray foam to insulate residential and commercial structures.
Wait, you mean there’s more? When it comes to protection against natural disasters, which tend to violently test the structural integrity of a building, wall and roof spray foam systems have displayed tremendous resistance to high wind pressure and blow-off as a result of the product's strong adhesion qualities and the absence of joints and or edges.
The wave of the future is sprayed-in-place polyurethane, whose effective use offers the potential to enhance the thermal efficiency of residential structures, important structural benefits and the potential for significant improvements in the quality of residents' lives.
For more information on this product contact: Willie Swiegelaar at Polyfoam (t) 011 264 0331 (e) willie@poly-foam.biz (w) www.polyfoam.co.za
Roofing spray foams, supplied by Polyfoam have a favourable comprehensive strength which literally forms an integral part of the structural elements of a building.
APRIL 2 0 1 3
35
c e m e nt & co n c r e te
AfriSam Thermal Concrete lightens the concrete load AfriSam Thermal Concrete combines the lightness of EPS beads with the strength of concrete to create a lightweight insulating concrete overlay.
A
s a light but strong building component, expanded polystyrene (EPS) concrete has high insulating properties and can create a stone-like surface for creative projects. Garden statues, curved projects, panels for energy-efficient homes, or unusual items such as concrete counter tops, can be created using EPS concrete. AfriSam Thermal Concrete, developed, produced and marketed by Concreate and cement and concrete giant, AfriSam, is a lightweight concrete that uses selective grades of EPS beads (in conjunction with special admixtures), which act as a thermal insulating aggregate to increase the thermal capacity of a structure. Decorative concrete company, Concreate’s director, Peter Norton explains, “Thermal Concrete is supplied by a readymix truck to your site. The mix contains cement and EPS beads to create a product that combines the construction ease of concrete with the thermal insulation properties of EPS. Thermal Concrete can be used for a wide range of applications where light loads and thermal insulation are both required.”
36
Norton explains that insulation and thermal capacity are both closely linked to air, so the more air a product incorporates, the more insulating it becomes — and this is where the EPS beads come into play. Because Thermal Concrete is 10 times lighter than normal concrete, pumpable to 60 metres and easy to apply, the product can be used on flat reinforced concrete roofs without adding the extra weight of concrete. It can also be used on flat metal decks, green roofs, balconies and terraces and as a protection screed over waterproofing membranes. It is easy to cast to falls and is often used for a base screed to receive torch on waterproofing systems, at the same time providing thermal capacity to the structure. “AfriSam Thermal Concrete is mainly used to increase the thermal capacity of a structure and, because it can be moulded into any shape and slope, it can also be used on basement and cavity walls, as well as in decorative concrete finishes and furniture. The product is quick setting, durable and will last as long as any concrete finish. The insulating properties of the EPS also render it environmental friendly,” says Norton.
april 2013
COOL ROOF: YOUR HOME’S ANSWER TO GLOBAL WARMING.
Coverland Cool Roof is a sustainable roofing solution that saves energy, reduces electricity costs and is a scientifically proven system to keep your home cool in summer and warm in winter. The Cool Roof system creates a natural airflow and heat barrier that limits the transfer of heat through your roof, providing a consistently cool and comfortable interior.
CoolRoof System
The Cool Roof system comprises: Hot Ai r
Compactroll® Ridge Tree Roof System RadenShield® Counter Battens Eaves Filler Comb
Ventilation
Retains warmth in winter
purpleberry 0212/6684
Up to 10° cooler in summer
• Compact Roll – a highly durable and easy-to-install sealing solution for the ridge. Its integrated ventilation capability allows heat to escape. In combination with the Compact Roll, the Ridge Tree aligns the ridge battens for optimum air flow. • RadenShield – a single or double-sided reflective aluminium membrane that reflects radiant heat and provides further protection from wind driven rain or dust. • Eaves Filler Comb that promotes natural ventilation flow while deterring nesting. • Counter battens that create a natural ventilation stream.
For more information, visit www.coverland.co.za or email info.sa@monier.com
ROOFING SOLUTIONS
c e m e nt & co n c r e te To date, AfriSam Thermal Concrete has been used on the MTN switchgear project in Centurion, where specialist flooring contractor Concrete Laser Flooring (CLF) used the product on a 2000m2 flat roof, without adding weight to the structure. It was also used at the Melrose Arch apartment complex as a sloped screed to receive torch on waterproofing and at the BMW facility in Roslyn, where it provides a levelling and thermal insulting layer underneath the post-tension floor.
About Concreate
About AfriSam AfriSam is one of the most widely spread Cement, Readymix and Aggregate groups in the southern African region, with operations in South Africa, Botswana, Lesotho and Swaziland. Founded in 1934, the company employs nearly 2000 staff members and about 1000 contractors. AfriSam has an annual cement production capacity of 4.6 million tons, produced from six production facilities and distributed to customers through nine strategically-located cement depots.
Concreate is an interactive hub where anyone can experience the world of concrete. Architects and interior designers can be inspired through the showroom and create their unique designs using the products, while builders and contractors have the opportunity to offer their clients attractive and decorative finishes that are time saving, cost saving and energy efficient.
38
april 2013
Africa’s only event where the cement, concrete, and construction industries come together Africa’s only all things cement and concrete event is a one-stop shop to discover new applications for the entire spectrum of concrete, masonry, construction, project delivery and management.
SPECIAL OFFER TO SA ROOFING READERS
FREE ACCESS to the expo if you register before 30 April 2013. Visit www.totallyconcrete.co.za and quote code: VP003 to save R495!
Meet all your equipment, solution and service suppliers and partners to conclude months of interaction in just two just days
Platinum sponsor
Free and accredited training, workshops and demonstrations on the exhibition floor
Silver sponsor
Learn to apply the latest trends in concrete innovation to your projects for improved structural integrity
Bronze sponsors
Endorsing Associations
Conference and exhibition
4 – 5 June 2013 As part of
Media partners
Organised by
Sandton Convention Centre, Johannesburg, South Africa • Pre-conference seminars: 3 June 2013 • Site visits: 6 – 7 June 2013
Visit www.concrete.TV for the latest news and information about cement and concrete.
www.facebook.com/TotallyConcrete
@totallyconcrete
http://linkd.in/XnbnNB
http://bit.ly/XFjmqz
www.totallyconcrete.co.za
A rc h ite ctu r e
A win for thatch and steel Silver Bay House, Shelley Point
Images: SAOTA – Stefan Antoni Olmesdahl Truen Architects
T
he site is positioned at Shelley Point on the West Coast Peninsula which runs from Saldanha Bay in the South, to St Helena Bay in the North. Shelley Point sits on the Northern tip of the Peninsula and is a small spur of land that juts into the Atlantic with West, North and East facing beaches. St Helena Bay itself is made up of a number of bays and the site faces into one of the first of these, Stompneus Baai. Uniquely for the West Coast, the site faces East over the bay looking towards the mountains behind the small Swartland town of Aurora. “The brief was to create a holiday home for a young family that could be enjoyed by an extended circle of friends and family. The house needed to create an internal environment that maximised the connection with the view, minimised views on neighbouring buildings and created sunny wind-free outdoor living spaces,” says Greg Truen, Project Partner.
40
The design is largely formed by three contextual conditions. The first is the elevated entrance which placed the living spaces on the upper level and the bedrooms and playroom on the lower level. This decision allowed the living spaces to maximise the views of the bay and to see the water’s edge. The second issue is the prevailing South-Easterly wind. The challenge here is that the views are in this direction and a large set of glazed sliding doors allows the maximum view. The third major issue is the sun on the North side. The response to this and to the South-Easterly wind was to position the pool in a courtyard on the Northern face that captures sun for the house and also creates a wind free outdoor space that can be enjoyed year round regardless of the wind.
april 2013
A rc h ite ctu r e
The upper floor has been conceptualised as a single space holding the pool courtyard, an elevated entrance hall, a kitchen with a large table and a dining and living space on the East edge. The L-shaped space is broken up by level changes which create distinctly different spaces. A conical flue made from Corten steel forms a visual element around which the spaces pivot, the rusted surface reflecting the coastal environment.
Gabi Wuister, Marketing Manager for Lucas Quality Thatchers, the thatching contractors responsible for the design and construction of the thatch roof, says, “One of the challenges of the design was the weight implication when working with thatch, as well as the idea of blending a modern ‘open’ feel with a traditional thatch roof construction, which is often something many people think might not be possible.
A curved Corten ‘hat’ sits over the braai flue and watches over the pool courtyard, a playful companion for the Corten cone that sits on the other side of the courtyard. The North face of the courtyard is formed by a timber wall. On the lower level, the off-shutter concrete slabs form the ceiling. The slabs retain rust marks from the steel that was laid in the slab and the chalk markings of the contractor.
In the end, the blend of old and new, combined with the feelgood factor of having an eco-friendly roof covering, has yet again proven that thatch is a material here to stay.”
The simple cellular bedrooms have a serrated façade that allows for corner glazing to maximise views. The curtain track was cast into the slab with a radiused corner that creates a cave-like space at night when the curtains are closed. Simple glass walls separate the en-suites from the bedrooms, allowing the two spaces to share a larger volume. The stair connecting the two levels is also made from I-beams with 75mm thick Eucalyptus planks forming the treads. The thatched roof is supported on a perimeter I-beam. The timber tie beams of the thatched roof are replaced by steel tie rods that allow the open volume of the roof to form the top of the space, the woven thatching grass and the latter forming a counterpoint to the granite floors.
APRIL 2 0 1 3
“Now more than ever, as roof structure options become more and more varied, a client’s choice, especially with regards to ‘flows and views’ can be met. Steel I-beams where used to create a completely open feel, allowing the owner unobstructed views in all directions. The clean interior lines combined with the use of a natural light SA pine pole for the structure complement the interior beautifully,” she adds. “Only the best Albertina Winter reed is used in our projects. It is harvested in the winter months, when the plant is dormant and therefore stronger. The thatch is cured for approximately three months before it can be used. The thatch should have a moisture content of between 14 – 16% to ensure it still has some flexibility.”
41
42
april 2013
A rc h ite ctu r e
Project details
Premium roofing from Europe
Location: Shelley Point, West Coast, South Africa Architects: SAOTA – Stefan Antoni Olmesdahl Truen Architects Project Team: Greg Truen & Yusuf Vahed Interior Design: ANTONI ASSOCIATES Project Team: Mark Rielly, Ashleigh Gilmour & Silvia Eigelaar
Hassle-free Thatch
Main Furniture Supplier: OKHA Interiors Completion Date: 2010 Web Contacts:
Metrotile Woodshake
www.saota.com www.aainteriors.co.za www.okha.com www.lucasqualitythatchers.co.za
Green style defined
Metrotile Bond & Lightpower* About thatch [LQT]: The SANS specification for the thickness of thatch is 180mm and a thatch roof should aim at being 45 degrees in pitch or more. Any less and the roof would have a slower water run-off and therefore absorb more water, decreasing its life span. As far as fire prevention goes we are firm believers that a fire blanket is the best fire retardant available. It works hand in hand with a galvanized or stainless steel binding material, is the only permanent fire protection method available and remains in the roof throughout its lifespan.
NE
Aquapan W Tile sheet
Easy DIY solutions
T: 082 451 8711 F: 086 648 3231 E: info@metrotile.co.za
APRIL 2 0 1 3
www.metrotile.co.za
your dreamhome in eco-friendly Metrotile
h e alth & SA F ETY
Keep your head when selecting the correct protective equipment Although safety helmets and hardhats are often wrongly regarded as being basic and unsophisticated pieces of personal protective equipment (PPE), MSA Africa warns that it is important to bear in mind that they protect the most important part of the body, and careful consideration should therefore be taken during the selection process.
M
SA is a global leader in the development, manufacture and supply of sophisticated products that protect people's health and safety, and MSA Africa HEFHC senior product manager Loren Pearson stresses the importance of making the correct choice in what could ultimately be a lifeand-death decision when selecting head protection equipment. With almost 100 years of safety equipment manufacturing experience, Pearson points out that MSA is able to offer some practical advice to ensure the most effective head protection. She notes that there are six criteria that determine the choice of a certain hardhat, and all of these have to be taken into account to ensure that the best possible product is selected for a specific application. They are: performance, durability, comfort, extra features, style and price.
Performance This should never be compromised as the consequences are severe. Ensure that you select a certified product that has been tested to minimum safety specifications such as SANS 1397:2003, EN 397:2000 and have approvals from recognised bodies such as the Department of Mineral Resources (DMR). A high quality, strong and durable product made by a reputable safety equipment manufacturer will ensure good protection with minimal replacements.
44
The MSA range of V-Gard® caps and hats and V-Gard® 500 vented caps are DMR-approved and exceed SANS 1397:2003 and EN 397:2000 specifications. The V-Gard shell is made from 100 percent virgin HDPE, while the V-Gard® 500 and 520 range are manufactured from high quality ABS. The MSA HeatGard cap is made from special heat tolerant material that makes it suitable for high heat applications such as furnaces.
Comfort Uncomfortable hardhats are often not worn and, without proper fit, do not offer adequate head protection. The MSA V-Gard® caps and hats offer a choice of two four-point suspensions - either the economy Snugfit or the premium FasTrac (ratchet-type). The V-Gard® 520 linesman cap, V-Gard® 500 vented cap and HeatGard cap all come fitted with a four-point FasTrac premium liner. All caps and hats in the V-Gard® range feature a patented Glaregard surface underbrim to reduce reflective glare. What's more, they also have a slot above the ear for compatibility with hearing protection and face protection products also offered by MSA.
april 2013
h e alth & SA F ETY
Price Hardhats are considered basic PPE despite the fact that they are required to protect the most important part of the body. Consider price carefully, as extra features and outstanding safety performance of approved products ultimately add to the final price.
Other factors that are worth consideration include: • How often will the head protection equipment be worn? • What is the working environment? • Are different styles or colours needed to identify different workers onsite? • What is the most appropriate shell material and shape? • Should it be vented or non-vented? • What type of suspension/liner - plastic or textile? • Should it have ratchet or quick adjustment system? • Are any extra features needed? • Should it be customised with a logo or brand name? • Should it accommodate accessories?
MSA Africa HEFHC senior product manager, Loren Pearson.
Extra features It is important from the outset to determine whether options such as a chinstrap, reflective tape (for visibility) and face, hearing or neck protection is required, and how these will impact on the safety and fit of the hardhat. Only use accessories that have been developed to be used with a particular brand hardhat. MSA's entire hardhat range easily accommodates accessories such as mining lamps. The V-Gard® range of caps and hats feature 440 VAC dielectric approval for use in electrical environments. The V-Gard® 520 linesman cap, is specifically designed for high performance protection while working at heights and in confined spaces, features a cutaway peak for undisturbed upward vision and unrestricted movement, and comes standard with a 3 point chinstrap.
Style A good looking hardhat will in all likelihood have a better chance of being worn. MSA V-Gard® is available in a wide range of colours and in cap (peak) or hat (brim) styles. The V-Gard 500 vented cap is available in six colours, although the V-Gard 520 linesman cap is only available in white. Extra features such as MSA's Logo Express allows for customisation and branding.
APRIL 2 0 1 3
MSA offers the ideal solution to these criteria with stylish and patented V-Gard ® hardhats that provide high comfort and performance levels for protection against various hazards in industrial environments. The V-Gard® range has become a well recognised product worldwide and has a proven track record for saving people's lives, and is characterised and easily identified by the trademark 'V' on top. It has been adapted to the needs of different user profiles in order to offer the safest and most comfortable protection in the industry. Due to the overwhelming international success of the MSA range of head protection systems, the company is proud to sponsor the MSA Golden Helmet Award - which acknowledges companies that believe in protecting their staff by selecting and purchasing high quality head protection products that have directly saved a worker's life.
To find out more about the comprehensive range of MSA head protection systems visit www.MSAsafety.com
45
h e i g ht SA F ETY
Height Wise hosts Career Day
with Johannesburg Central College In an effort to create awareness about the career opportunities available in the work at height sector, leading height safety consulting and training provider Height Wise Training Academy recently hosted its first work at height Careers Day at its training venue in Halfway House, Midrand.
Students testing out the work at heights gear.
T
he Careers Day, which was facilitated by work at heights specialist consultant Louis Roodt and Height Wise senior project manager, Jansen Madike, was aimed at a group of final year Mechanical Engineering students from the Central Johannesburg College – a public Further Education and Training College with six campuses across Johannesburg.
46
Height Wise Academy director Penny Fabricius says that creating enthusiasm and interest through the launch of the Height Wise Careers Days is paramount to securing skills development and an able pool of professionals for the future growth of working at heights in South Africa.
april 2013
h e i g ht SA F ETY
Johannesburg Central College students with work at heights specialist consultant Louis Roodt. Roodt and Madike pointed out to the students that obtaining a work at heights qualification, coupled with another technical qualification, such as mechanical engineering, provides the scope to develop a career in a variety of industries across the world. By obtaining a work at heights qualification, the group of students from the Central Johannesburg College would have the ability to work on a number of applications in a variety of industries from a design, manufacture and maintenance point of view. Students from the college were presented to on the various work at heights courses available through Height Wise Training Academy, which includes fall arrest technician, basic fall arrest technician, fall protection planning and rope access technician, practitioner and supervisor. Speaking on skills development within the work at height industry, Fabricius says : “The challenges in the work at height sector mirror the employment challenges for industry at large. We support the spirit and intent of the Skills Development Act to improve employability of work seekers and plan to host more career days. The aim is to encourage young people with technical skills to also become professionally qualified rope access technicians.�
About Height Wise
Work at heights specialist consultant Louis Roodt giving the students a work at heights demonstration.
48
Height Wise provides training either at our new state-of-the-art, in-house training venue in Midrand or on site (at clients’ premises), to give learners the full benefit of applying height safety practices.
april 2013
Following the great success of the 2012 Knysna Woodworkers Festival, bookings for exhibition space at the 2013 Knysna Woodworkers Festival are now open! Calling on local and national timber and timber-related industries, as well as associations to exhibit at this specialised event! Maximum exposure for all sponsors and exhibitors via extensive media coverage and premium on-site advertising!
Exhibitors to include: • • • • • • • • • • • • •
Arts & Crafts Furniture Manufacturing Timber Frame Building Timber Treatment & Preservation Paints, Coatings & Protective Sealants Forestry & Sawmilling Woodworking Machinery (Industrial & DIY) Power Tools Fastening Systems Handles, Hinges & Accessories DIY Training & Education And much more!
For more information about exhibiting at the Festival or for our premium sponsorship packages, please contact Johan Nel: (c) 073 394 0057 (e) info@knysnawoodworkers.co.za
www.knysnawoodworkers.co.za
速