Fulton Awards

FULTON AWARDS

2013

Concrete Beton

A celebration of excellence and innovation in the use of concrete

CONTENTS

Introduction 2 President’s Message 4 Adjudication Panel 6 The Fulton Awards History Civil Engineering Projects 8 Winner De Hoop Dam 11 Commendation Chota Motala 13 Commendation UTCRCP Pavements Building Structure 16 Winner SANRAL Head Office 20 Commendation 115 West – Alexander Forbes Architectural Concrete 20 Winner 115 West – Alexander Forbes 16 Commendation SANRAL Head Office 30 Commendation The Podium at Menlyn Sustainable Concrete 8 Winner De Hoop Dam 24 Commendation Gauteng Freeway Improvement Project- Package E1 & E2 28 Commendation Koeberg Interchange Innovative Construction 30 Winner The Podium 32 Commendation Mahatma Ghandi Road Sewer Gravity Extension Tunnel 13 Commendation CRCP & UTCRCP Pavements Nominated Projects 34 22 Wellington 35 Allandale N1 Interchange bridges and Le Roux Overpass 37 D F Malan High School – Multi Purpose Activity Centre 38 KwaMsane Community – Access Roads and Pedestrian Facilities Phase 2 39 Mangaung Intermodal Public Transport Facility 40 Moss Kolnik Interchange 41 N3 Elands Interchange 42 New Offices for Buhrmann & Partners 43 Newclare Road-Under-Rail Underpass 44 Protea House 45 Reading Interchange 46 Sephaku Cement – Aganang Plant 48 The Quarter 49 UNISA – Florida Campus 50 University of Pretoria – Aula Foyer Project 51 Wits Science Stadium 52 Worcester Interchange 1 President’s Message It is my honour as President of the Concrete Society of Southern Africa NPC (CSSA) to present this Fulton Awards edition of the Concrete Beton. In this special issue we detail descriptions of all the entrants in the 2013 Fulton Awards and, of course, the winners!

he biennial Fulton Awards is one of the 26 entrants.The quality was I would like to thank the administration arguably the most prestigious exceptionally good and it is once again staff of the Society - the team ‘behind Taward that a project team can an indication of the high standard of the scenes’. A large event such as the receive in the built environment sector our local industry. We can really say that Fulton Awards requires an extremely of southern Africa. The Awards are held the innovation and excellence of these diligent team to ensure a successful in honour of the late Dr Sandy Fulton projects can be compared to any project event. Thank you, Natasja and Jeanine who made a significant contribution to worldwide. for everything that you have contributed the concrete industry. The first Fulton The judges had a very difficult task to to this prestigious event and also to the Awards was held in 1979 and has select the winners amongst the many Society in general. grown to be one of the highlights on entries. The adjudication team included Lastly, I wish to express my gratitude to the industry’s calendar. The mission of John Sheath, CEO of the Concrete the sponsors of this event, particularly the CSSA is to promote excellence and Society of Southern Africa NPC; Peter AfriSam, Lafarge, NPC-Cimpor and innovation in the use of concrete and Kleynhans, President of the South PPC who collectively are our Anchor these awards reflect the very best use of African Institution of Civil Engineering Sponsors. The event, would of course this material in the country. and Sindile Ngonyama, President of not have been possible without our My heartiest congratulations to the the South African Institute of Architects sponsors and their generous donations. winners of the iconic 2013 Fulton - they spent nearly three weeks visiting Thank you for being part of the Awards. This is truly a great achievement every project in the country and one development of our industry. and reward for the vision, hard work in Namibia. Their contribution was and effort put into your project. It was essential to the success of the event and unfortunately not possible to make an they were not only impressed by the award to a project in the Community projects, but also by the professional Structure category. manner in which the project teams Yours sincerely, I also wish to commend each and every hosted them. Billy Boshoff

VISION: To be the most relevant forum for those who have an interest in concrete and to promote the related services of the CSSA members. MISSION STATEMENT: To promote excellence and innovation in the use of concrete and to provide a forum for networking and for the sharing of knowledge and information on concrete. Office Bearers: President: WP Boshoff (Prof), Vice President: R Maliehe, Past President: NP van den Berg, Branch Chairs: R McSporran, H Turner, T du Plessis, J Fortune. Directors: PRA Flower, BD Perrie and CD Kalis, Chief Executive Officer: PJ Sheath, Administrator: NL Pols, Honorary Members: WM Johns, DP Samson, CJ Thompson, AR Dutton, GF Loedolff (Prof), MO de Kock (Prof), MG Alexander (Prof), the late GS Gamble, Editorial Committee: Chairman: WP Boshoff (Prof), GC Fanourakis (Prof), GPAG van Zijl (Prof), EP Kearsley (Prof), HD Beushausen (Prof), Editor: C Dalglish, Production: Kris Srsa, Crown Publications, PO Box 140 Bedfordview, 2008. Printed by Tandym Print. OFFICIAL PUBLICATION OF: The Concrete Society of Southern Africa NPC; Physical address: Suite 301, The Hillside, 318 The Hillside Street, Lynnwood, 0081; Postal address: PO Box 75364, Lynnwood Ridge, 0040. Telephone: 012 348 5305 Fax: 012 348 6944 Email: [email protected] Website: www.concretesociety.co.za The Concrete Society of Southern Africa NPC, (CSSA), its directors, officers, employees, representatives and agents are not liable for any death, harm or injury caused to any person or any loss, destruction or damage caused to any person’s property or possessions arising from goods supplied by or services rendered by the CSSA. © COPYRIGHT All editorial material published in the Fulton Awards is reserved to the Concrete Society. Requests for permission to use any of the material, in part or in full, should be addressed to the President of the CSSA. Although the CSSA does its best to ensure that information is accurate, no liabilities for negligence are accepted by the CSSA, its offices, its members, publishers or agents. 2

INNOVATIVE CONSTRUCTION COMMENDATION The Adjudication Panel The biennial prestigious Fulton Awards adjudication panel includes: Sindile Ngo- nyama, who was appointed by the National Department of Public Works to run the Contractor Development Programme and is currently a member of the Program Man- agement Team for the Department of Public Works in the Eastern Cape; Chartered Marketer and CEO of the Concrete Society of Southern Africa NPC John Sheath has spent most of his career with a South African non-profit Institute and two multi-national companies. Industry stalwart Peter Kleynhans has chaired and held a number of posts on the Executive Board of the South African Institution of Civil Engineering. Sindile Ngonyama Sindile Ngonyama’s career started in the initiatives, from setting up community devel- Drawing Office, as a draughtsman for the opment structures at no cost to establishing Ciskei Government. In 1980 he received a the Mdantsane Development Trust. bursary to study Architecture at the University He was appointed by the National Depart- of Cape Town. ment of Public Works to run the Contractor In 1997 he formed an architectural com- Development Programme. This Programme pany, Ngonyama Okpanum & Associates afforded Previously Disadvantaged Individual with Dr Okpanum, in East London. Within a contractors to undertake contracts worth R5 very short period the practice expanded and million with great success. Ngonyama became had offices in Port Elizabeth, Cape Town and part of the National Programme Management Johannesburg. Team for Community Based Public Works Programme Management Team appointed With the new democratic government in Programme (CBPWP. This programme saw by the Department of Public Works, to co- 1994, it became apparent that there was a the roll out of projects, during this period, ordinate and manage the School Building growing need for development programmes. totaling R1 billion. Programme in the province, which has been Ngonyama became involved with a number of Ngonyama is part of the Eastern Cape’s running since 2002.

Peter Kleynhans Over the past 30 years, Peter Kleynhans has served As a registered Professional Engineer, Professional on several of the South African Institution of Civil Planner, and Professional Construction Project Engineering’s divisional committees as well as being Manager as well as being a Chartered Engineer he Chairman of the SAICE’s Finance and Administration has a broad range of experience, spanning more Committee. Kleynhans also assisted the national of- than 40 years. Kleynhans is a Fellow of the South fice to put the Institution’s management on a sound African Institution of Civil Engineering (SAICE) as financial and business footing. well as being a Fellow, or Corporate Member, of five He was awarded the SAICE President’s Award other professional institutions in South Africa and the in 2002 for ‘Meritorious Service’ for his significant United Kingdom. ongoing contribution towards the profession. In He owns and operates Mogwariepa Consulting, 2010 he was received the SAICE President’s Award one of the independent businesses, providing con- for ‘Exceptional Voluntary Service’. sulting services to government departments.

John Sheath John Sheath is a Chartered Marketer who has spent most As Marketing Manager of the Cement & Concrete Institute of his career with a South African non-profit Institute and from 1996 he drove the transformation of the company two multi-national companies. over a period of 13 years into a technical marketing As Marketing Director of Expandite, at that time part organisation. The Institute focused on growing the of the Burmah-Castrol Group, he was able to expand its market for concrete for its members within the building industrial adhesives business through acquisition and materials sector of the construction industry. by gaining several large contracts. Later as Marketing Since January 2011 he has been the Chief Executive Director of the Burmah-Castrol Group company (Fosroc) Officer of the Concrete Society of Southern Africa NPC, he successfully merged two culturally-diverse organisa- whose mission is to promote excellence and innovation tions to form a strong, unified sales and marketing team. in the use of concrete.

4 CIVIL ENGINEERING COMMENDATION FULTON AWARDS HISTORY The Fulton Awards andy Fulton was unquestionably Concrete Society of Southern Africa NPC’s most prestigious one of the doyens of the inter- Snational concrete industry with concrete awards began as a tribute to the late Dr Sandy Fulton for impressive achievements in research his outstanding contribution to the understanding of concrete, its contained in 35 published papers. He left a legacy of scientific and tech- development, and improvement. nological advances in the construction cally to the structure and is presented tive Construction; and Community industry. The Fulton Awards continue as a celebration of the life and achieve- to the entire team responsible for its Structure. This year the Fulton Awards ments of this remarkable South Af- construction, including the owner/ attracted 26 entries, representing the rican. Through the Fulton Awards, developer, all professionals, and the most innovative, exciting and iconic the Concrete Society of Southern contractors. The six award categories projects from around the country. The Africa NPC recognises and rewards include: Civil Engineering Projects; team of judges travelled throughout excellence and innovation in the use of Building Structure; Architectural Con- South Africa to inspect the projects concrete. The Award is made symboli- crete; Sustainable Concrete; Innova- and determine the winners.

Company Members

Event Sponsors Platinum Gold Silver Bronze

6 COMMENDATION CIVIL ENGINEERING WINNER

DE HOOP DAM – Immersion-Vibrated Roller-Compacted Concrete onstruction of the dam com- De Hoop Dam will be one of the biggest dams in South Africa with menced in June 2007 and the Cproject is currently nearing com- a total concrete volume of more than 1,1 million m³ of concrete pletion. Significant improvements in including Immersion-Vibrated Roller-Compacted Concrete as the Roller-Compacted Concrete (RCC) mix design were implemented at the well as Conventional Vibrated Concrete. beginning of the dam construction. The impressive project is a worthy winner of two prestigious 2013 These led to a vast simplification of the construction process and allowed the Fulton Awards categories, ‘Civil Engineering Structure’ as well as highest construction rates ever achieved in South Africa, with a peak of more than ‘Sustainable Concrete’. 130 000m³ of RCC placed in one month. extremely successful and made it one was proven that the new RCC mix did This resulted in the Department of Water of the most significant contributions not require any additional grout at Affairs becoming a world leader in RCC of the last years to the RCC dam con- the point of placement and it could Construction Technology and effectively struction technology. A very workable be directly consolidated by immersion developing Immersion-Vibrated Roller- RCC mix was designed that allowed vibration. IVRCC has been used against Compacted Concrete (IVRCC). placement with both roller compaction the formwork and rock abutment as The first international experience and with immersion vibration. During interface concrete in the main dam with IVRCC at De Hoop dam proved the preliminary trials in April 2009, it achieving an excellent finish and an 8 DE HOOP DAM

extraordinary in-situ quality. Following allowance for the fine content of the with 70% pulverized fly-ash. The water/ this first experience, IVRCC has been sand was increased up to 10% pass- cementitious ratio was 0,62. further implemented in other projects. ing 0,075mm sieve. Coarse aggregate Investigation of the initial mix at The experience at De Hoop dam following the SANS standard and with the laboratory and on several test sec- has been extremely useful in develop- a maximum size of 53mm was used tions concluded that there was still a ing a new approach to RCC materials need for improvement. Although the and mixes in South Africa. Former RCC mix behaved well at the laboratory dams built in the past by the Water Af- Team (compaction and strength), the cores fairs Authority followed the low paste • Client: Department of Water extracted from the test slabs showed approach. RCC mixes were formerly Affairs; Capital Projects some spots with segregation and, in placed at a water to cement ratio of some cases, lack of bonding between about 0,9. Despite the relatively high • Principal Agent: De Hoop Dam layers. During placement, the fresh water content, these mixes tended Consultants RCC mix did not look like a typical to segregate and the concrete was • Main Contractor: Department high-pozzolanic workable mix. When generally of a poorer quality than the of Water Affairs: Construction dumped on the field there were still traditional conventional concrete. As West some signs of segregation at the bot- a result of this, the design team at De tom of the heap and the mix looked • Submitted by: Department Hoop decided, from the beginning to too dry. During compaction it was of Water Affairs: Construction follow a mix approach with a higher not possible to get much paste on the West paste content that would also be easier surface and there was no movement to consolidate by roller compaction. when walking on top of this concrete. Crushed coarse and fine aggregate during the preliminary trials. In the These were all signs of a less workable have been used from a quarry produc- original specified mix, the sand/total and drier mix than desired. tion installed in the future reservoir aggregate ratio was 41% and work- The replacement of the conven- area. In the initial stages of the mix ability between 15 and 25 seconds. tional facing concrete by grout- design, the envelopes of the aggre- The total cementitious materials con- enriched RCC was also tested in the gate grading curves were revised and tent ranged between 180 and 190kg/m³ early trials. Despite the fact that the 9 CIVIL ENGINEERING WINNER

surface finish was adequate, the vibration effort was high, even when adding a grout that had a water/cement ratio as high as 1,0. Some difficulties were experienced in achieving a good consolidation and bonding with the adjacent roller-compacted concrete. In order to overcome these problems a more workable mix was suggested during an external review of the construction methodology and the placement procedures in 2009. The modifications suggested included: Maximum size of aggregate 38mm (instead of 53mm); slight modification of the overall gradation curve; fine aggregate 38% of the total aggregate (instead of 41%); cement (OPC) 60kg/m³ (instead of 56kg/m³); fly-ash 140kg/m³ (instead of 130 kg/ m³); mix consistency between 8 to 10 seconds VeBe; a water content was increased from 114 to 125kg/m³ (water /cementitious ratio kept at similar value as before) and use of a retarder admixture to achieve an initial set of the RCC of approximately 20 hours, to improve bonding between layers. The main features of the dam are as follows: gross storage capacity 347,4million m³; catchment area 2 865km²; approximate length 1 017m; approximate height 88m; total excavation – dam footprint 415 000m³; total excavation – quarry 1,3 million m³; total estimated concrete volume of the dam 1,1 million m³. The De Hoop Dam Project is a flagship project for the Department of Waters Affairs of South Africa and possibly one of the largest projects for the forseeable future. Water needs will be met in the Lim- popo Province. Lessons learned and technological innovations will change how future projects will be addressed.

Judges’ Citation De Hoop Dam will be one of the biggest industry, was a first in roller-compacted 130 000 m³ of RCC placed in one Roller-Compacted Concrete (RCC) dams concrete dam construction. IVRCC was month. The De Hoop Dam Project is in South Africa, with a total concrete used against the formwork and rock a flagship project for the Department volume of more than 1 million m³. abutment as interface concrete in the of Waters Affairs and will address a The judges were highly impressed main dam, achieving an excellent finish significant portion of future water with the attention paid to reaching the and a high in-situ quality. needs in Limpopo Province. optimum mix design that yielded vast This also led to significant The judges had no hesitation in improvement in the Roller-Compacted simplification of the construction proclaiming this project the winner Concrete. The work led to the use of process and allowed one of the highest of two of the 2013 Fulton Awards immersion-vibration of the RCC, which, construction rates achieved in South categories – ‘Civil Engineering Structure’ whilst not new to the construction Africa, with a peak of more than and ‘Sustainable Concrete’.

10 CIVIL ENGINEERING COMMENDATION CHOTA MOTALA – Incrementally Launched Bridge Chota Motala Interchange has been operating at more than median and rehabilitating the existing concrete pavement and widening the capacity for some time; and this has resulted in long traffic existing Sanctuary Road off ramp on delays between Chota Motala Road and the N3 national highway. the eastern side. Structural work on this project To improve capacity, SANRAL implemented the Chota Motala comprised demolishing two bridges Incrementally Launched Bridge. and constructing two; widening one bridge; new and lengthened culverts; The new interchange received a commendation in the 2013 and a number of retaining walls and Fulton Awards ‘Civil Engineering Structure’ median traffic barriers. Once the decision was made to he South African National Roads Ramp E of the interchange, carries provide an incrementally launched Agency Limited (SANRAL) and traffic travelling on the Chota Motala bridge, it was logical to propose pre- TMzunduzi Municipality inves- Road towards Pietermaritzburg over stressed concrete as the construction tigated options as the N3 national the N3, and Chota Motala Road merg- material. The only alternative was a highway traffic was confronted with ing with the N3 national road towards launched composite deck, consisting slow moving or stationary traffic at Johannesburg. of an open steel box-girder with a con- Chota Motala. This stretch of road Roadworks on the project in- crete slab on top. An open box-girder could be hazardous for road users. cluded: upgrading Chota Motala could have been launched over the The Incrementally Launched Bridge Road from a four- to a six-lane urban whole length of the bridge and later proved ideal as there was very little arterial; widening and minor realign- a concrete slab could have been cast disruption of traffic during construc- ments to ramps and construction of above it. This option was not consid- tion and at the same time, the cli- a new directional ramp over the N3; ered further for the following reasons: ent’s requirements were fulfilled in upgrading the N3 national road by • A composite steel bridge deck is every respect. The bridge, situated on adding an additional fast lane in the generally more expensive than a

11 CIVIL ENGINEERING COMMENDATION

Team • Client: South African National Roads Agency SOC Limited • Principal Agent: Illiso/ Aurecon JV • Main Contractor: Group Five • Subcontractors: Structural Systems Africa; Metier Mixed Concrete • Submitted by: Aurecon

Judges’ Citation This aesthetically pleasing, incrementally launched concrete bridge fully deserves a judges’ Commendation in the 2013 Fulton Awards category ‘Civil Engineering Structure’. Concrete was chosen for this bridge for its lower costs, the need for ultimate safety during construction, low maintenance costs and its long life-span. Of special note was that the engineers, in the absence of an concrete bridge deck. The con- shape is reminiscent of a champagne architect, paid particular attention struction of the concrete top slabs flute and provides two support points to the aesthetics of the bridge and would have posed a safety risk to to give torsional rigidity to the deck. considered many aspects such as traffic below, negating the main The shape, height and location slenderness, span lengths, pier advantage of the launch bridge. of the piers make access for main- diameter, shapes of members, • A composite deck has much higher tenance or replacement of bearings shadow and lighting. maintenance costs than a concrete difficult. Access was therefore pro- The result is an elegant bridge, vided through the deck. Recesses and aesthetically pleasing civil • The required maintenance is dif- are provided in the deck diaphragm engineering structure that showcases ficult to undertake in the presence beams, soffit and top of piers for this concrete in an excellent manner. of heavy traffic above and below. purpose. The horizontal alignment • Reinforced concrete is the most is a 175m diameter circle, with a popular choice of construction straight vertical alignment of 0,5%. making use of friction between the material for bridges in South Africa This results in a bridge geometry bearing plates and the deck soffit, because it offers the lowest initial that is a three-dimensional circle in negating the requirement for pulling costs, it provides the lowest main- space - making the launching process sticks or other temporary works. tenance cost, it has a long lifespan extremely complicated. The Formwork used for the Ramp if maintained properly and it can Two methods were used to check E Incrementally Launched Bridge was be cast to any shape provided by and cross-check the bridge levels. designed by Formscaff and was made the formwork. The designers used an in-house de- out of steel, to obtain a smooth F3 off- The 220m long deck consists of a veloped computer program, whereas shutter finish. The formwork was sup- pre stressed concrete box girder with the contractor’s temporary works ported on a jacking system, allowing it seven spans varying between 25,15m designer used three dimensional to be raised into position for concreting and 36,05m long, arranged symmetri- drafting. Close correlation was found and then lowered for launching. cally around the centre. between the methods, resulting in Extreme care taken with details The piers vary in height from high confidence in the calculated and concrete finishes resulted in an 6,245m to 15,913m, start off with a 2m levels. The Eberspächer AH124 system aesthetically pleasing structure that circular section and flares out over the was used for launching the deck. The will be a landmark on the Pieter- top 6m to a 3,6m diameter. The pier jacks operate on a lift and slide cycle maritzburg horizon for years to come. 12 CIVIL ENGINEERING COMMENDATION CRCP & UTCRCP Pavements The N12 Highway road system in Gauteng is often referred to as ‘the veins and arteries’ of South Africa’s economy. Since this highway cannot be congested and must be kept open in order to allow unimpeded growth, the South African National Roads Agency Limited (SANRAL) decided it should receive bypass surgery. As part of the Gauteng Freeway Improvement Project 560km of highway was upgraded. The mammoth project received a ‘Civil Engineering Structure’ commendation in the 2013 Fulton Awards as well as in ‘Innovative Construction’.

asil Read undertook design, planning and construction of Work BPackage K, which covers 9,7km of road on the N12 Highway between the Rietfontein Interchange and the Tom Jones Interchange in the East Rand. The task was to plan, design and use innovative techniques for the successful implementation of Continu- ously Reinforced Concrete Pavements (CRCP) and Ultra-Thin Continuously Reinforced Concrete Pavements (UT- CRCP) that were constructed with an asphalt overlay. first rolled out by the national roads not least of which was little scope for Concrete pavements were chosen agency, introducing UTCRCP at a high error. Conventional concrete pave- primarily for their 30-year life cycle volume. While many hours of research ments are rigid, usually 200mm thick, and lower maintenance costs. As this may have gone into fibre-reinforced with large amounts of reinforcing (50t is one of South Africa’s most densely concrete, applying it in this environ- per km per lane) and are constructed trafficked roadways, it seemed the ment bordered on ground-breaking either in panels with movement logical infrastructure to implement. experiences. joints at set intervals or continuously The skills learned in concreting in UTCRCP is a new technology to reinforced throughout. Rigid concrete roads can easily be transferred to the South Africa and a high quality fin- pavements are brittle and may be civil engineering and building sectors. ished product was achieved despite found to crack over time, given heavy This particular project was one of the difficult challenges and conditions, loading conditions. While these cracks 13 CIVIL ENGINEERING COMMENDATION

may not result in failure of the pave- concrete mix designs for the project, driven Terramite, however, made ment, they could give rise to water and it was the 33rd mix design that was light work of driving forward. This ingress. This scenario is accentuated eventually suitable for use on site. meant that it took a significantly less in flexible bitumen- or gravel-based This mix design was used for UTCRCP amount of effort to manoeuvre the pavements over a similar time pe- throughout the entire Work Package roller screed in the required direc- riod. Movement of these cracks due K contract. UTCRCP was applied at tion, and consequentially allowed for to heavy wheel loads may create a the Mvoti Toll Plaza in Natal, on the much higher daily production rates pumping action, ejecting the water N1 Freeway near the Huguenot Tun- and volumes. and fines dissolved in the solution and nel in the Western Cape between the It was in the implementation of ultimately create potholes. Gilloolys and R21 Interchanges on the Work Package K of the GFIP that fibre- The idea behind constructing N12, adjacent to Basil Read’s project reinforced concrete (reaching 90MPa Ultra-Thin Continuously Reinforced in Johannesburg. and placed to 50mm levels over large Concrete Pavements was to create a surface areas) was for the first time pavement that was semiflexible. In successfully batched in vast quanti- other words, neither rigid nor flexible, Team ties at a readymix plant. a concrete pavement strong enough • Client: South African National While previous UTCRCP jobs used to with stand the loads that a conven- Roads Agency Limited pan mixers on site, Basil Read elected tional concrete pavement would, but (SANRAL) Northern Region to use a fixed pan mixer readymix flexible enough to handle the effects • Principal Agent: Aurecon/Vela batch plant, due to the growing num- of shrinkage, dynamic traffic loads VKE ber of variables. The group partnered and temperature fluctuations through with privately-owned Skyline Ready- the seasons. • Main Contractor: Basil Read mix who dedicated an entire batch The result was a high strength • Subcontractors: University of plant and a fleet of readymix trucks (90MPa+) concrete pavement, 50mm Pretoria; Lafarge Cement; to Work Package K. thick, high yield mesh-reinforced, Chryso SA This plant supplied up to 40m³/day with steel fibre reinforcement in the of UTCRCP. The plant was outfitted • Submitted by: Basil Read region of 100kg/m³. The main prin- with four admixture units and a con- ciple around UTCRCP was to elimi- veyor system, which was used to add nate the number of movement joints Potential problems and solutions steel fibres to the mix at a required (where most concrete pavements as regards UTCRCP were shared on rate to prevent balling of fibres in the fail), and to make the concrete less site. This information assisted Basil mixture. As the lanes (3.75m wide x brittle by using steel fibres and mesh Read to decide on the best approach 50mm thick) required 0.19m³/m on reinforcement, which would provide to take for the project. It was clear that each lane it was only possible to prog- a better spreading of loads. the methods implemented in the con- ress 210m per day, per lane. Basil Read partnered with the Uni- struction of the UTCRCP needed to be It was imperative that every batch versity of Pretoria, Chryso and the Ce- streamlined in order to make it a suc- of concrete used cement with the ment and Concrete Institute amongst cess, especially on such a large scale. identical chemical composition - as a others, with regard to research work One such implementation was slight difference in the clinker could done on fibre-reinforced concrete and the Terramite oscillating triple roller impact concrete properties, such as its application in UTCRCP pavements. screed. After the concrete was com- air entrainment, that would affect The University of Pretoria was heavily pacted, it was rolled onto the surface the ultimate strength of the concrete. involved in developing the correct with this screed. The hydraulically Samples were randomly analysed 14 CRCP & UTCRCP PAVEMENTS to ensure quality. Initially, a CEM I cement was specified but this was later changed to a CEM II – the La- farge Rapidcem (52.5N), a high early strength cement with a fixed percent- age of fly ash. Comprising high quality raw materials to minimise product variability, Rapidcem offers high early and ultimate strengths and while fly ash is incorporated into the formula- tion, it can be further blended with fly ash due to the inclusion of a special strength enhancer. Lafarge guaranteed a steady supply of consistent cement. With blended cement, it is imperative that the ratios of extender are kept to a uniform quality. Verification of outgoing product is undertaken on each tanker leaving the factory, a procedure that includes the deter- mination of fly ash content using an XRF testing method. When making the mix, it was essential to achieve the correct ratio between cement, sand, fly ash and silica fume. Particle size distribution of all materials and their impact on the mix flow characteristics had to be considered and as the sand had to have a specific grading, strict controls were implemented in order to ensure that the same sand was used in every UTCRCP batch. SANRAL wanted both concrete pavements to have asphalt overlays in order to guarantee the Interna- tional Rideability Index (IRI) of the roads. SANRAL required International Roughness Index readings for all roads at a maximum of 1,4. Concrete pavements normally achieve a reading of between 1,6 and 2, before the asphalt surface is applied to improve the riding quality. Basil Read was achieving readings of between 0,9 and 1,1 but although there was no need for the asphalt overlay, the roads agency insisted on uniformity throughout all GFIP projects. Judges’ Citation Basil Read’s team, assisted by some of the industry’s most recog- The judges commend this project for reduced number of movement joints, nised specialists in their fields, has its innovative and unique approach to less brittleness through use of steel done much to illustrate the potential the design of, and research into, the fibres, and better spreading of load that this technology holds. With over concrete designs for construction of owing to the mesh reinforcement. 5 500m³ of UTCRCP and almost 30 the concrete pavements. Concrete was This project’s Commendations 000m³ of CRCP paved, this project has chosen for its relatively lower life-cycle in ‘Civil Engineering Structure’ and shown the scale of success that can cost, often underestimated or ignored ‘Innovative Construction’ 2013 Fulton be achieved through integration of by owners and constructors of roads. Awards have shown how the integration research, design, skills, science, tech- The resultant ultra-thin concrete proved of research, design, skills and science to be of high strength (90MPa +), with a nical and adaptive methodologies. contributes to success.

15 BUILDING STRUCTURE WINNER

SANRAL HEAD OFFICE he innovative use of concrete The South African National Roads Agency SOC Limited (SANRAL) along with the use of sun screen- Ting and high-tech building sys- corporate head office in Vale De Grace, Pretoria, presented an tems contributed significantly to the opportunity to design a building that expresses the role the energy efficiency of the building, which has been awarded the Green Building organisation plays in connecting networks of national roads and Council of South Africa (GBCSA) 4 Star bridges to cities and towns nationwide. Office V1 Design rating. The client had a number of objec- The building design makes use of concrete to pay visual reference tives for its new corporate head office to flowing roadways and spanning bridges and is a worthy winner development. These included: accommodation for 100 personnel; premium of the 2013 Fulton Awards ‘Building Structure’. The building grade office space; energy efficiency and environmental specifications. also received a Commendation in the ‘Architectural Concrete’ The project was conceptualised as a category. ‘connector building’ accommodating three key divisions; Corporate Servic- provides staff parking and building such pride in designing, constructing es, Engineering Services and Financial services. The building design maxi- and maintaining. Another reason Services, each in its own wing of the mises natural daylight at work sta- for using concrete was that the con- building. The design included a large tions. The courtyards, or green lungs, crete roof presented an opportu- flowing lobby, much like a highway in- between the buildings have natural nity to design a green planted roof to tersection, public space in the ground cooling and shading benefits. take advantage of the thermal mass floor under the three office wings. The use of a concrete was a very properties and optimise the energy The ground floor connects to exciting choice – the visual and struc- requirements for the indoor climate outdoor planted areas, canteen, and tural properties of concrete enabled control of the building. The building boardrooms that open onto land- a reference to the flowing roads and makes use of a concrete frame struc- scaped terraces. The basement level spanning bridges that SANRAL takes ture supporting the concrete roof and 16 sanral head office

Team • Client: The South African Roads Agency SOC Limited (SANRAL) • Principal Agent: Rouillard Consulting Engineers • Main Contractor: GD Irons Construction • Subcontractors: Pre-Form; Civil Concepts; Plantech Consulting Engineers • Submitted by: Activate Architecture

suspended floors, which were de- line with the parameters set by the sion loads. This reduces the overall signed using a beam and light weight GBCSA. All the steel reinforcing used cooling load demand of the HVAC hollow block system. The structural in the construction of the building was system by 35%. The planted surface grid required to accommodate an manufactured using 92% recycled area of the site is increased by 1700m² optimal basement parking layout as ferrous content, thereby reducing using the concrete green roof design, well as the client’s preference with the negative environmental impact compared with a conventional roof. regard to office layout, resulted in of the construction by a significant The indigenous vegetation becomes a larger structural spans. A typical reduction in the use of raw natural private entrainment and break-away structural bay built using an onsite flat resources. area for the occupants of the build- suspended slab design would have The Xeroscape roof garden has ing. The biodiversity of the site is also needed to be approximately 360mm 350mm of soil and indigenous plants. enhanced as the roof has become a thick with approximately 30kg/m² of The thermal insulation of the compo- nesting home for a number of indig- steel reinforcing. Using lightweight sition of the roof protects the space enous birds; physically, environmen- precast hollow blocks supported by from outdoor thermal conditions, but tally and symbolically connecting the a concrete beam system, the sus- more importantly; the depth/ thick- building to the landscape. The project pended floor and roof slabs resulted ness of the roof system vegetation, required a high quality concrete finish. in a 57% reduction in reinforcing steel soil and structure results in an eight This, coupled with a tight construction (14kg/m²) and a 20,5% reduction in hour time lag on heat gain and loss via timeframe, meant there was no margin the volume of concrete compared the roof, which flattens out the peaks for errors, necessitating careful design with the onsite flat slab option. The and troughs in the heating and cool- collaboration between the profession- significant reduction in material used ing cycles of the indoor environment. als and the contractor teams to ensure reduces the environmental impact of ‘Evapo-transpiration’ also takes the successful outcome of the building. the building. place and this helps to cool the build- The professional team was sourced The building was constructed using interior; the process occurs in the by the client in an open tender in mid ing concrete and a fly ash substitute hot summer months when rain water 2009 - the design and documentation (Ulula Fly Ash) a waste product from that is attenuated in the soil results process was undertaken in a five coal at Kriel Power Station and a in a cooling effect on the concrete month period. The tender for the water reducing BASF admixture. This roof structure. The concrete green main contractor was an open public reduced the quantity of Portland ce- roof system significantly contributes tender which took seven weeks. ment required for the project by over to the indoor environment thermal Construction started in mid-March 30%, thereby further reducing the control and is, in general, responsible 2010 and the client took occupation embodied energy of the concrete in for a 50% reduction in roof transmis- on April 1st 2011. 17 BUILDING STRUCTURE WINNER

Judges’ Citation This fascinating Green Building Council was particularly commendable as it thereby reducing the ‘carbon footprint’ of South Africa 4-star rated building is conceptualised a ‘connector building’ of the concrete in line with parameters a worthy winner of the 2013 Fulton linking the three main departments of the set by the Green Building Council of Awards ‘Building Structure’ and also company via a large, flowing lobby, much South Africa. received a Commendation in the like a freeway intersection. Great thought Special attention was paid to shaping ‘Architectural Concrete’ category. The went into the positioning of the building and proportioning the edges and corners use of concrete, apart from the accepted vis-à-vis the natural slope of the land, its of the concrete overhangs to give the roof reasons of cost effectiveness and low relationship to the main road, the views a bridge-like feel and, at the same time, a maintenance, was chosen as it provided a and visibility to nearby private homes. high quality, flowing, elegant shape. The visual and structural reference to flowing The building achieved a certain final finish provided a straight, smooth roads and spanning bridges. The style playfulness through the use of concrete and uniform quality, as well as consistent typifies the projects that South African in the creation of interesting shapes, colour and texture. National Roads Agency SOC Limited has with finishes that were excellent and The courtyard of the building was undertaken. innovative and showcased the versatility designed to house an urban garden above Concrete was used to produce a of this unique building material. the basement and the concrete planters, ‘green roof structure’ and planted roof The concrete for this building was of flowing shapes, were particularly garden. This takes advantage of the designed and constructed using a fly aesthetically-pleasing. Concrete fire- thermal mass properties of concrete and ash substitute and a water-reducing escapes featured high walls where the connects the building to its tree-lined admixture. This resulted in a reduction of concrete has been softened and textured suburban context. The design approach 30% in the quantity of cement required, with a bush-hammered technique.

ARCHITECTUAL CONCRETE WINNER

115 WEST – Alexander Forbes The new landmark headquarters for Alexander Forbes he 100 000m² Four Star Green Star Design V1 rated building is one of the largest and most innovative buildings to be Tsymbolises more than simply a completed in South Africa in the past two years. The eight storey new work space from where clients are served – it also symbolises a new building can accommodate 2 500 people within a combined beginning. The architecture features 35 000m² office space, six levels of parking and three entrances on a continuous design of fluid curves. Sections of the façade incorporate different levels, to increase traffic flow in and around the building. S-shaped ‘scallop’ walls and wavy flowing lines are further incorpo- The prestigious project is the winner of the 2013 Fulton Awards rated throughout the interior of the ‘Architectural Concrete’ category and also earned a Commendation building. The role of concrete in the con- in ‘Building Structure’ category. struction of this building was critical, not only in its obvious structural application, but also for specialist architectural elements. It is the expression of concrete that sets the building apart. Off-shutter concrete columns are an architectural feature of the project. Raked and vertical columns on the ground floor are 8,5m tall and moulded in a single cast. Self-compacting concrete was used due to the amount of reinforcement within the column and to obtain a quality finish. Textured off-shutter concrete walls and S-shaped ‘scallop’ walls clad with Rheinzink form part of the office façades. Randomly placed pre-cast panels of varying sizes, combined with steel wire mesh, were used in 20 115 WEST - ALEXANDER FORBES

the construction of the basement by polished concrete walkways. In cialised formwork was generated in façades. Creepers in planters behind total, 45 750m³ of concrete and Revit Design and Revit Structure; and the mesh, will in due time, create a 4 974 tons of reinforcement were exported to AutoCAD in DWG format green wall that will soften the look of used. At 100 000m² under construc- to the sub-contractor for construc- the exposed basement. tion, concrete was always going to be tion. Minimum sizes were specified Link bridges span the north and an integral part of the project. by the engineer and then sculpted south atriums to link the large office From the complex raked columns by the architects, who pinched the plates for easy access between work to the in-situwalls, both smooth and noses of the columns to create a more spaces. The long spans of these bridg- textured, concrete was widely used elegant and sculptural form. There es, along with the architect’s request in elements from floors to walls, roof, are two types: a Y-shaped branch that to keep the bridges as thin as pos- columns and landscaping. supports the cantilevered walkway, sible, meant suspending them from The building programme took 19 and a simple style that supports the the roof. Seven levels of suspended months, so documentation and con- building structure. Self-compacting bridges meant that they had to be struction often ran concurrently and concrete was used to support the lightweight and constructed of steel clear and consistent communications amount of reinforcement within the and concrete. Construction took place was vital. Given the extent of the proj- column and to handle the difficulty as each plate was being constructed ect and the timeline for completion, of vibrating the concrete for 8,5m tall and all seven levels of bridges were the mammoth task was contracted raked columns. supported temporarily on the lower to the WBHO/Tiber joint venture. It SA Pine shutter board cut into vari- level floor slab by means of a tempo- also meant that clear and consistent ous thicknesses and widths was used rary supporting steel frame. communication was critical. as a lining in the shutters to create Smooth off-shutter concrete Raked and vertical columns on timber-grained, textured off-shutter planter walls to create break-away ground floor stand 8,5m tall and are walls for the north gable and south meeting areas, which are linked moulded in a single cast. The spe- concrete walls. The textured finish

21 ARCHITECTUAL CONCRETE WINNER

also accommodated the varying quality of concrete finish, and construction joints could easily be hidden at the board edges. These walls were cast past the floor slabs to minimise horizontal construction joints, which meant that all floors slabs had to be tied to the concrete walls with either pull-out or dowel bars. To guarantee a quality finish, self-compacting concrete was also used for these off- shutter walls. A further architectural feature was the S-shaped or ‘scallop walls’, on the east and west façades. The accuracy and finish required would normally have called for highly specialised formwork, at a high cost. Peri used its girder wall formwork system, made up in 10m long units with special radius whalers to construct these curved walls with the same quality and tolerance, but at a much lower cost. A different texture was required by the architect for these walls, which were cladded with Rheinzink. Planter walls, constructed from smooth off-shutter concrete, create various meeting areas in the planted and xeriscaped areas to the north and south of the building. Polished concrete walkways with exposed aggregates link the different meeting and break-away zones. Concrete

22 115 WEST - ALEXANDER FORBES was chosen for its durability, texture and reduced maintenance costs. Complexity of design, coupled with intense programme constraints and Judges’ Citation the sheer scale of the project, made This new Alexander Forbes head office concrete double-storey raked columns it a health and safety challenge for is an architecturally ground-breaking and curved scallop walls. The off- the contractor. space with environmental sustainability shutter, raked and vertical columns, The WBHO/Tiber JV rose to the being crucial to the design as the each cast in a single pour, are an challenge and won the Gauteng building is accredited by the GBCSA as impressive architectural feature of the Master Builders Association’s top 4-Star Green Star rated. structure, which creates elegant and award in the GMBA annual Regional The judges were impressed with sculptural forms, and also helps to Safety awards as well as the FEM Su- the use of concrete in this landmark reflect light inside the building. per League Trophy for its health and office block within the Sandton Other special architectural concrete safety achievements on the project. economic node, and are pleased to elements utilised were: smooth off- declare this project the winner in the shutter roof soffits and overhangs; 2013 Fulton Awards ‘Architectural textured off-shutter concrete walls; Team Concrete’ category. The project also precast panels on the basement receives a Fulton’s ‘Building Structure’ façade; precast stair treads to the main • Client: Zenprop Property Commendation. entrance, smooth off-shutter curved Holdings This iconic building utilised walls integrated with landscaping and polished concrete walkways in the • Principal Agent: Capex concrete in structural, architectural landscaped areas. Projects and artistic ways. The timeline for the superstructure was eight months, Due to its advantages, self- • Main Contractor: WBHO/TIBER during which a horizontal concrete area compacting concrete was used on all BONVEC JV of 101 000m² and a total amount of 43 the vertical walls. This raised concerns • Subcontractors: Paragon 000m³ of concrete was poured. due to high pressure on the formwork, Architects The complex architecture is so special high-tolerance box-outs were technically difficult and iconic, designed and manufactured for the • Submitted by: Sotiralis incorporating elements such as entire project. Consulting Engineers

23 SUSTAINABLE CONCRETE COMMENDATION GAUTENG FREEWAY The launch of the Gauteng Freeway Improvement Project (GFIP) signalled an exciting multi-billion rand commitment to upgrading and developing more than 500km of freeway within the province. The joint venture between the Gauteng Province, Ekurhuleni, Tshwane and Johannesburg Metros, under the guidance of the South African Roads Agency (SANRAL), was geared to provide an effective transport network. The project received the 2013 Fulton Awards Commendation in the ‘Sustainable Concrete’ category.

auteng, the economic heartland Soccer World Cup event. Package E Joint Venture to producing fine qual- of South Africa, generates nearly comprised a substantial upgrade to ity off-shutter concrete throughout G38% of the total value of South three interchanges, upgrading two the project. Package E1 comprised a Africa’s economic activities. By the turn busy intersections, widening the high- 12km section of the N3 to the south- of the century, it was evident that provi- way to five lanes and the construction east of Gauteng, between the Old Barn sion of road infrastructure had not kept of three bridges using the incremental (Heidelberg) and Geldenhuys (M2) pace with increased traffic demand, launching method, a 70m long new Interchanges, and included widening resulting in a road and freeway network bridge over the Natalspruit River at the N3 on both sides and upgrading that was over capacity. the N12/N17 intersection and a cut the Elands interchange, including the Its aims included the promotion and cover tunnel. The longest of the construction of the switch ramp con- of social development, a reduction incrementally launched bridges was necting the N3 to the N12. in the cost of doing business and a 420m long switch ramp. The incre- Package E2 comprised a 4km sec- sustainable economic growth. It also mental launching method has been tion of the N12 between the Reading aimed to greatly improve accessibility successfully used by Group Five on (R59) and Elands (N3) Interchanges. to Gauteng’s roads, while managing long spanned bridges and in this case This section included the construc- and reducing congestion issues. The minimised traffic interruptions on the tion of two bridges over the N17 first phase, comprising the upgrade adjacent freeways. The new bridge and Natalspruit River and another of 185km of the most congested free- was constructed using a conventional comprising a cut and cover tunnel at ways in the region, was divided into precast concrete I-beam construction the Reading Interchange. The entire total of 15 work packages. method. Structural Systems Africa, project involved the construction Group Five, as lead contractor for which is 50% owned by Group Five, of 37 concrete structures which, as the Siyavaya Joint Venture, with con- supplied the launching equipment, well as the above, included moving sulting engineers UWP/Nyeleti Joint including the launching girder, manu- a 2,2m diameter Rand Water pipeline Venture and KAS Joint Venture, was factured by Group Five Steel. to accommodate the new ramp at the awarded Package E which, in turn, was SANRAL’s requirement was that all Elands Interchange and the construc- divided into two sections, Packages E1 structures should be functional yet tion of two new loops at Grey Avenue, and E2. The 36 month project started aesthetically pleasing. In view of this, Alberton, to eliminate a right-turn in July 2008 and was substantially particular attention was paid by the against oncoming traffic. complete by July 2011, including a consulting engineers to the design Whilst the majority of the freeways one month delay in mid-2010 for the and by Group Five and the Siyavaya in the GFIP were widened along the 24 gauteng freeway improvement project IMPROVEMENT PROJECT – Package E Judges’ Citation Concrete’s quality and strength were recognised by this joint venture team as being of paramount importance given the durability requirements for the several bridge and ramp structures and the tunnel on this project. The quality of the concrete was under tight control, with the testing regime including durability tests such as oxygen permeability and water sorbtivity. The team opted for a 60MPa concrete for the permanent structures. This significant project is worthy of the judges’ Commendation in the 2013 Fulton Awards ‘Sustainable Concrete’ category.

Team median, the entire length of Package able shutter system. Moving along • Client: South African National E was also widened along the outside the base of the tunnel, the foundation Roads Agency SOC Limited lanes, resulting in major earthworks of the shutter was forced to contort (SANRAL) either side of the busy freeways. slightly to follow the vertical profile of • Principal Agent: KAS JV/ One of the major challenges was the road, taking the super elevation UWP-Nyeleti JV the safety of the public and workforce, into account, and thereby creating whose protection was a priority. Traffic the symmetry required for the tunnel. • Main Contractor: Group Five accommodation was planned to the Each joint was sealed with a water- Civil Engineering last detail and supported by the Metro proof bandage, while expansion joints • Subcontractors: Afrimix police, whilst the site personnel were were installed at every third joint. trained to comply with strict safety The portal faces, which slope back • Submitted by: Group Five Civil Engineering regulations. The bridge at the Reading at a gentle angle, are completed with Interchange comprises an aestheti- precast concrete tiles, each one spe- cally designed and constructed cut cifically designed and cast to fit the post-tensioned 3,5m deep, concrete and cover tunnel approximately 345m curve of the portal. hollow box girder, located on a 378m long, divided into two sections mea- Widening the existing bridges at radius horizontal-curve and constant suring 162m and 63m respectively, and the Reading interchange by a lane’s longitudinal grade of approximately separated by an opening of approxi- width of 2,6m was done in sections 0,37% falling from north to south. mately 38m. The tunnel, which diverts to reduce lane blockages caused by The final span lengths varied from traffic from the R59 north directly onto the scaffolding. Of the three launched 29m (span 1) to 70m (span 7). Two the N12, passes under the widened bridges, the switch ramp – connecting temporary piers were used to reduce section of the R59 south. To counter the Elands Interchange over the N12 the maximum launching span to 45m. poor soil conditions, the structure is from the N3 East onto the N12 North - The Siyavaya Joint Venture contracted founded on heavily reinforced con- was the most challenging. Its purpose with Afrimix to design and supply crete foundations up to 16,5m deep. was the elimination of what had pre- suitable concrete. The specification Due to the extreme contours of the site, viously been a potentially dangerous for the permanent structure called for the tunnel is on a sharp horizontal and transection between traffic from the 40MPa at 28 days, W-type concrete, vertical curve. To accommodate the N3 and N12 joining the M2 systems but this would not have suited the curves, the tunnel was constructed in interchange. The bridge comprises production schedule and the joint 10m straight segments using a mov- a nine-span, single cell, internally venture team opted for a 60MPa mix. 25

INNOVATIVE CONSTRUCTION COMMENDATION

KOEBERG INTERCHANGE he contract required innovative The Western Cape Provincial government identified the N1 design and close cooperation Tbetween the consultants HHO Corridor and the Koeberg Interchange, which serves as a primary Africa and the contractors, Group Five freight route between Cape Town and Bellville central business and Power Construction’s joint venture (PaardenEiland JV). district, as one of several in need of an extensive upgrade. The The project included: construct- R690 million project received a commendation in the 2013 Fulton ing directional ramps connecting the M5 with the N1; Ramp A: 640m long Awards ‘Sustainable Concrete’ category. x 110,7m wide, which connected the M5 and N1 in a southerly direction; first built in the 1950s, since then the 3 500 reinforced-earth panels for the Ramp B: 690m long x 10,7m wide, in volume of traffic increased and there ramp entrance and exit points and a a northerly direction, which spanned was severe traffic congestion with number of manhole lids. the operational railway link between 200 000 vehicles using the route daily. To achieve the connection between Cape Town CBD and Bellville. In order to cope with the influx of traf- the two arterials, which crossed the An extra traffic lane was con- fic associated with the 2010 Soccer multi-track railway line between structed on the N1 southbound and World Cup the bridges were construct- Bellville and Cape Town, this section the northbound access was widened ed using precast concrete elements, was constructed in-situ. Safety regula- through the Koeberg Interchange to to maximise off-site production and tions dictated that construction over three lanes. From the Koeberg Inter- minimise traffic disruptions during the railway lines could only take place change two additional traffic lanes construction. at night. were constructed to Sable Road. At The precast concrete elements With much of the heavy lifting Berkley Road the M5 was widened to comprised:135 U-beams measuring taking place at night, the use of pre- create two additional lanes in each 25m x 40m weighing 84 tons each; cast concrete elements kept traffic direction. The Salt River Canal was 130 T-beams used to widen the M5, disruption to a minimum without relocated 15m. The Koeberg Inter- each one of a different length to al- compromising the safety of road change was designed to handle up low for the curve of the M5 ramp; users or contractors. There were to 500 vehicles per day when it was 5 700m of designed balustrades; also a number of other challenges 28 KOEBERG INTERCHANGE

Judges’ Citation

The judges commend this project for the attention paid to the high performance concrete mix and the sustainability requirements. A minimum of 400kg cementitious content was maintained, the use of extenders was paramount due to the possibility of alkali- silica reaction, and when slag became unavailable, new mix designs utilising fly ash had to be developed. The density of the concrete was including precasting and transporting and post tensioning cable sleeves increased further through the use the largest U-beams to date in South of the U-beams, a special concrete of a special blend of natural sand Africa without lane closures during mix, comprising a new generation and processed crusher sand, giving peak hours as well as the construc- super plasticiser from Chryso, was the final product the durability and tion of the longest road-over-railway conceived. This reduced the required longevity that is vital to this type of bridge in southern Africa. mix water from a 160ℓ/m³ to 140ℓ/m³. structure. The Koeberg Interchange received a The team had to relocate cables With the low water demand and the Commendation in the 2013 Fulton Awards ‘Sustainable and services of a major Telkom ex- super plasticiser a consistent work- Concrete’ category. change as well as a City of Cape Town ability of 175mm was achieved. sub-station before they could start The innovation included an equal excavations for the piers that support blend of 19mm and 9mm aggregate. to 100% by which time the concrete the ramp structures.To accommodate had reached about 80% of its 28 day the alignment of the new ramps – Salt target strength. River Canal was relocated 15m to the Team west of the M5 for a distance of 600m. However, due to their additional • Client: Provincial Road An abandoned and undocumented weight the longer beams were stressed Network Management; World War II oil pipeline, used by to 50%, de-moulded and lifted into po- Transport & Public Works sition before being stressed to 100%. the Royal Navy was discovered to be Western Cape filled with oil. This had to be decom- In total the project used 550km of missioned and the oil drained before • Main Contractor: Group Five stressing cable and approximately some 200m of the pipeline could be Civil Engineering/Power 24 000m³ of concrete. removed. Construction JV The project claims to be South As with all road upgrade projects, • Subcontractors: HHO Africa Africa’s largest U-beam construction traffic management was one of the contract and to have the longest un- • Submitted by: Group Five Civil major challenges that ran for the supported railway crossings amongst Engineering duration of the project. The safety its many technical achievements. of motorists, pedestrians and the Since the completion of the project workforce was paramount so all road The fine aggregate ratios stayed the traffic moves smoothly over the inter- closures and diversions were planned same as for the other mixes, but change and not through it, thereby down to the last detail at the design the minimum cementitious content reducing the congestion in what stage to ensure constructability and increased to 480kg/m³ in order to was previously a bottleneck prone at the same time, accommodate the achieve a 55MPa minimum strength. interchange. major daily traffic flows. The high workability mix proved to be Innovative design and construc- Due to the position of the precast a success with strengths of between tion was integrated to achieve a yards the heavy U-beams had to be 70MPa and 80MPa achieved. remarkable result, which benefits the transported across both inbound and The strength achieved at three lives of many road users and contrib- outbound traffic. Exacting penalties days was more than the required utes to the success of Cape Town as a for every 15 minutes of unapproved minimum, and therefore the shorter winning South African city. lane closures during working hours of the large U-section beams could This project has been deemed as resulted in extensive night work. be de-moulded, stressed to 50% one of the largest and most difficult To accommodate the design and and placed in the yard to cure. After infrastructure projects ever under- the large quantity of reinforcing steel seven days the beams were stressed taken in the Western Cape. 29 INNOVATIVE CONSTRUCTION WINNER PODIUM AT MENLYN The Podium at Menlyn was designed to create an iconic, flagship, chromatic triangular façade consists of a three-shaded curtain wall of grey low maintenance building for the Emira Property Fund’s new office glass, which spans the soft curve of development. This spectacular building has been a talking point the building on the corner of Atterbury Road and Lois Avenue. This striking ever since the first off-shutter concrete façade was revealed and is feature takes full advantage of its a worthy winner of the prestigious 2013 Fulton Awards ‘Innovative prime location directly opposite the Menlyn Park Shopping Centre. The Construction’ award and the recipient of Commendation in the curtain wall acts as a mirror, evolv- ing in colour and intensity as the sun ‘Architectural Concrete’ category. moves across the African sky. In some odium at Menlyn aspired to in- gram dissection puzzle. This puzzle, instances, the mottled façade appears corporate a triangular geometry. consisting of seven flat shapes called as a single, uniform colour. Breaking The use of triangular geometry in tans, is put together to form shapes. the length of the southern façade, P and anchoring the building on the the design of the curtain wall was one The design team met the client’s brief that was simplistic and remained only by transforming this ancient game northern side, the off-shutter concrete 2-Dimensional. The design team was into a magnificent triangular grid feature walls amplify the triangular looking for a material that would be which features on the eastern and module of the façades. able to incorporate a third dimension southern façades of the building in The triangular forms of the façade to the triangular forms of the façade. Phase 1. are now seen as a 3-Dimensional What better material than raw concrete The abstract design is produced shape as opposed to the 2-Dimen- to achieve this. The raw concrete is jux- as a modular unit that can be config- sional form of the curtain wall trian- taposed with the smooth curtain wall ured into a geometric grid, making gles. The creation of a 3-Dimensional to create a harmonious balance in the the implementation of the design triangle was a construction feat in design, leaving passers-by with a sense an exact science and representing a itself. The triangular forms in the con- of curiosity as to how the building’s synthesis of mathematics, symbolic crete façade were created by 35mm concrete forms were created. systems and art. Even the basement deep recesses. A further resolution The seamless triangular union of and lift lobby artworks make use of for triangular windows was to allow glass and off-shutter concrete was in- the tans to create a ‘geometrical gar- natural light to filter into the internal spired by ancient engraved artworks den’ within an urban space, giving the office space. found in the Blombos Caves on the feeling of being in a digital landscape. The beauty of off-shutter concrete southern Cape coast of South Africa. The artwork transforms a once dull lies in its seamless and sculptural They symbolise a bridge between a 77 basement into an exciting space. The appearance and texture. During con- 000 year old culture and a futuristic design suggests the archaic nature of struction of the sample panel, differ- South Africa. Inspiration was also its origins and the sophistication of ent methods were explored in order drawn from the ancient Chinese Tan- 21st century technology. The mono- to obtain the required effect. These

30 PODIUM AT MENLYN included: using fibre reinforced concrete and self compacting concrete and the use of pre-mixed concrete with a smaller aggregate. The structur- Team al engineer required that the concrete • Client: Emira Property Fund feature walls be part of the structural • Principal Agent: PPM, Project framework of the building – the con- Managers tractor cast the feature wall simultaneously with the main frame building. • Main Contractor: WBHO What makes this methodology Construction unique is the fact that the building’s • Subcontractors: Peri South entire façade was set out using the Africa; Lafarge South Africa geometrical grid of the concrete fea- Holdings – Concrete; DG ture walls. The construction joints in Consulting Engineers the concrete walls were required at • Submitted by: Boogertman & specific heights in order not to impact Partners the contractor’s programme. Numer- ous consultations were held between the structural engineer, the off-shutter concrete specialist, the contractor and the architect. Two sets of shutters were used for the construction of the three feature walls: a set of shutters was used for the feature walls in the eastern and western façades. While the second set was used for the fire escape stairwell on the southern façade. Utilising the same shutter for the construction of sunlight throughout the day. To avoid double curtain wall façade, 765mm the two walls meant a saving of 40%. excessive heat build-up, a double bulkheads and passive sun shading WBHO used 360m3 of Lafarge’s Agil- curtain wall system was designed. The on the northern façade, and perfor- ia Vertical self-compacting concrete top and bottom of the curtain wall are mance glazing to reduce heat loads and a total of 11 500m3 of concrete. open to assist the stack effect of heat substantially. The building's northern façade is dissipation within this void. The Podium at Menlyn has become divided into two main sections. The The main entrance is a celebra- the gateway to the Menlyn economic first section, affectionately known as tion of space with the bold concrete node, which will provide an A-Grade the ‘egg-crates’, has off-shutter con- entrance towering the full height of business hub – 300 000m² of mixed crete sun-shading devices, created by the five-storey building, to welcome use including retail, offices, hotels a combination of concrete overhangs, each visitor to the ‘jewel’ of Pretoria. and residential units. The success of which protect the office space from The geometric grid continues the project can be attributed to the the midday sun throughout the year. throughout the interior of the build- unbeatable combination of limitless The combination of walls and over- ing. Spontaneous triangular mono- creative talent, project management hangs creates the ‘egg-crates’, which chrome floor tiles on the floor of the expertise and a client who had com- has a multi-functional patio overlook- lobby contrast playfully with the pure plete faith in both of them. ing the main intersection of Lois Av- white glass wall cladding.A number There is a saying: ‘Be so good they enue and Ingersol Road in Menlyn.The of green principles include T5 light can't ignore you’; Podium at Menlyn northern façade is exposed to direct fittings, a VRV HVAC system, the has made this saying its own.

Judges’ Citation

The Podium at Menlyn is the winner of building façade, thereby placing raw Particularly impressive was the grid of the prestigious 2013 Fulton Awards concrete side-by-side with a smooth triangles on the feature walls reproduced ‘Innovative Construction’ category glass curtain wall to create a harmonious both externally and internally. and receives a Commendation in the balance and design. The beauty of off-shutter concrete ‘Architectural Concrete’ category. The liberal use of self-compacting is clearly displayed in this structure The judges were impressed by the concrete in the construction of the by a sculptural, textural and seamless use of concrete to incorporate a third building demonstrates an innovative appearance. dimension to the triangular forms of the approach to placing concrete.

31 INNOVATIVE CONSTRUCTION COMMENDATION MAHATMA GANDHI ROAD Sewer Ext Micro tunnel The Mahatma Gandhi Road S e w a ge P u m p S ta t i o n occupies a prime site within the Durban Point Development Corporation’s up-market zone. This required extending an existing 1 350mm diameter concrete gravity sewer line, a distance of 230m from the existing pipe station to the new location.

he Mathatma Ghandi Road gravity sewer and pump station services Tthe greater Durban catchment area, including the central business district and Berea areas, from Umgeni River in the north and Umbilo River in the south. The alignment of the new pipeline was required to run in the centre of the double lane main feeder road for Harbour mouth; numerous under- Intermediate jacks were installed at the Point Precinct. Furthermore, there ground services; and launching the 33m and 133m behind the machine. exists an historically protected build- incoming sewer connection in the Laser Guidance System was fixed in ing between the starting and finishing middle of the busy Mahatma Gandhi the jacking pit, to the set reference point, which meant a straight line Road. alignment and grade to monitor the design was impossible. The micro-tunnelling machine relative position of the TBM cutting The site is located at the mouth manufactured by Herrenknecht was head. The laser target position was of the Durban harbour in an area operated by Coleman Tunnelling then relayed to the control cabin to previously occupied by the mouth Africa. The Micro TBM was an AVN allow the operator to effect steering of the natural estuary of the rivers 1200TC with a ‘Mixed Ground’ cutting adjustments as necessary. When draining into the south Durban basin wheel for 1200mm internal diameter the tunnel reached the curve, a Gyro and, prior to that, by the mouth of the jacking pipes. Scope Guidance System was used to Umgeni River. A total of five boreholes The 221m tunnel consisted of a control the line and level. were drilled along the sewer exten- 113m straight section from the jack- The systems were checked manu- sion alignment. The team evaluated ing pit; a 102m length arc with a 350m ally using standard surveying equip- installation options within the site radius curved section – to bypass the ment every 40m to ensure that the and the alignment constraints to be protected historical Harbour Master positioning systems remained accu- able to provide the client with recom- Building; and a 6m straight section rate. The TBM reached the end point mendations. breaking into the existing harbour within a deviation of less than 20mm, The most favourable sewer pipe tunnel north shaft. testament to the accuracy of the guid- extension method was pipe-jacking Due to the length of the tunnel ance system. using a micro-tunnel boring machine. and curved section, two interme- The client’s requirements included Some of the challenges that had to be diate jacking stations, with eight gaining access to the sewer line in the overcome included disruption to traf- 646kN and 700mm stroke hydraulic area – the 1 200mm internal diameter fic on Mahatma Gandhi Road, a major cylinders were installed to reduce the reinforced concrete pipe, designed for urban road servicing the Durban jacking pressures on the front pipes. a 100-year life span, was used. The 32 MAHATMA GANDHI ROAD

reinforced, 145mm thick wall concrete the first choice. The combination of pipes with characteristic strength concrete for strength, HDPE liner for of 40MPa were designed taking into corrosion and duplex stainless steel Team consideration the known fact that collars resulted in a final design of the • Client: eThekwini Municipality the Durban marine environment is pipes that achieved all the objectives - Water & Sanitation highly corrosive. This, combined with of the brief. The design of the jointing • Principal Agent: Goba the fact that the concrete sewer pipe system also gave the flexibility for the would be below the saline ground- pipe jack to negotiate the 350m radius • Main Contractor: Group Five water table, required high durability without having to construct addi- • Subcontractors: Coleman concrete. tional reception shafts. These protec- Tunnelling Although the extrados of the pipe tion measures will enhance material • Submitted by: Goba will be permanently submerged, durability to achieve the intended 100 measures had to be put in place to year design life and beyond. minimise material attack by salt water. These materials included stainless steel collars and rubber seals for pipe joints. A special grade (AISI 32507) Judges’ Citation duplex stainless steel was used for The judges awarded the Mahatma boring machine. Concrete was the its resistance to pitting corrosion. To Ghandi Road Sewer Gravity Extension chosen material for the pipe, owing to eliminate chemical (sewage gases Tunnel, in Durban, a Commendation in its strength for jacking and corrosion and hydrogen sulphide) attack to the the category ‘Innovative Construction’ resistance. Due to the difficulty in concrete, the pipe intrados was lined 2013 Fulton Awards. gaining access in the area, the reinforced with ‘cast-in’, continuously welded Innovative construction techniques concrete pipe was designed for a 100- thin sheet of HDPE. were used on this project, which year life span. The selection of the pipe material involved the extension of a gravity The entire pipeline extension was in this application was based on con- sewer by approximately 221m. jacked forward from the rear end of the structability and corrosion ‘resistivity’. Given the constraints of the site, pipeline and the judges commend the Although concrete may not be as good which were numerous, the team team for overcoming challenging design as HDPE in terms of corrosion resis- selected the pipe-jacking method of constraints and the innovative way that tance, the strength requirement for construction using a micro-tunnel the final construction was approached. the jacking operation made concrete 33 NOMINATED

DO decided to demolish the existing building and construct Ban entirely new one to accommo- 22 WELLINGTON date its specialist divisions that were previously located in Houghton and BDO South Africa’s striking new R90 million Johannesburg Parktown. The civil work started during March and April 2011, with construc- headquarters at 22 Wellington Road, in Parktown, was tion following immediately afterwards. constructed within an extremely tight 12 month construction The new building will house more than 1 000 members of staff, con- programme.The development is a joint venture between BDO structed on a 4 085m² stand, the 8 South Africa, the world's fifth largest accountancy network and 500m² five-storey multi-tenanted office complex has four levels of parking, Alchemy Property Investments. providing a total of 11 000m² of parking across 367 bays. BDO occupies work through, owing to a cantilever reinforcing. A total of 413 000 face and three floors with tenants taking up on the fourth floor. Labour intensive stock bricks were used and 14 850m² the remaining two floors. methods were used to hoist formwork of walls were plastered. Formwork to In total, the main contractor Mur- to and from the fourth floor and to decks totalled 19 000m², with 1 970m² ray & Roberts Building cast 9 700m³ cast concrete through to that level. of wall formwork for the external fa- of concrete. A natural, off-shutter The most challenging section was çades. A total of 475 people, including wood-grain finish for the castings was the construction of part of the north- sub-contractors, worked on site at the accomplished by nailing marine ply east sloping picture frame wall where peak of the project. with a 3mm and 6mm pattern onto the team had to construct 120m² of sof- the formwork. fit a vertical shutter for the supporting Each set of formwork lasted be- sloping wall. The panels were built on Team tween four and six casts before the the ground and lifted into place. Each • Client: Alchemy Property Asset marine ply had to be replaced.Walls panel weighed about three tons and Management on the northern façade and similarly the work was undertaken at a height of the southern façade, had to be cast over eight metres. The formwork pan- • Principal Agent: Baseline Project without horizontal casting joints. els were lowered into position by crane. Management The walls form part of the structure The new office block has been de- • Main Contractor: Murray & Roberts and, because of the angles involved, scribed by observers as a vibrant new the corners had to rebuilt each time, landmark in Parktown. The face brick • Subcontractors: Paragon and the mould had to be redone as work required a more complex ap- Architects; Form Scaff/Fix Form; the forms moved up to the next slab. proach than unusual to meet the heri- Macsteel Reinforcing; Lafarge The western façade also presented tage requirements of the Parktown South Africa a challenge to the team. Although the Residents Association. In total, Murray • Submitted by: Sotiralis Consulting casting principle remained, holes had & Roberts Buildings cast 9 700m³ of Engineers to be left in the fourth floor slab to concrete and used 960 tons of steel 34 NOMINATED Allandale Road/N1 Interchange bridges and Le Roux Overpass he R1,654 billion project took South African National Roads Agency Limited (SANRAL) as part 40 months to complete and in- Tcreased the number of lanes from of the Gauteng Freeway Improvement Project constructed five eight to 12. The mammoth task was un- new bridges on the 21km stretch of road between the Buccleuch dertaken by consulting engineer, BKS, and a tri-party joint venture between Interchange in the south and the Brakfontein Interchange in Grinaker-LTA Roads & Eathworks; the north. Moseme Road Construction and Boit- shoko Road Surfacing and Civil Works. The original Ben Schoeman High- the Jukskei River and Maxwell Drive. The main purpose of the continuous way was constructed as a four-lane Additional road reserve was needed auxiliary lanes is to reduce the friction dual carriageway and, at that time, to accommodate the wider road. caused by merge and diverge move- provision was made for the design to Between the Allandale and New ments at on- and-off ramps and to mi- increase to a six lane dual carriage- Road Interchanges, the freeway was nimise the choking congestion effect. way. This meant that all overpass widened to five lanes per direction To fit four lanes, per carriageway, bridges were designed with horizontal with short auxiliary lanes at the Allan- underneath the existing bridges clearances to accommodate three dale interchange northbound on-and designed to accommodate 3 x 3,7m lanes per direction. southbound off-ramps. lanes per carriageway, the lane widths Between the Allandale and Buc- The 40-year-old Allandale Road had to be reduced to 3,4m and the cleuch interchange the annual daily and Le Roux Avenue Bridges did not outside shoulders to 1,5m. The effec- traffic exceeds 159 000 vehicles and have sufficient horizontal clearance to tive width of the median shoulder is between the Old Johannesburg Road accommodate five lanes and six lanes 1,7m. These lane and median shoul- and Brakfontein interchange, over 110 per carriageway, respectively, and had der widths were adopted over the 000 vehicles. The project aimed to to be demolished and replaced. The entire length of the freeway. improve capacity and reduce traffic freeway bridge over Alexandra Road Between the Old Johannesburg congestion and the friction caused also had to be widened and retaining Road (Rooihuiskraal) and Brakfon- by high traffic volumes and choking walls constructed to keep the toes of tein Interchanges, the freeway was at on-ramps. cut and fill within the road reserve. widened to five lanes per carriage- Between the Buccleuch and Al- Between New Road and Old Johan- way, which increases to six when landale interchanges, the freeway nesburg Road (Rooihuiskraal) Inter- approaching the Brakfontein Inter- was widened from three to six lanes changes, four lanes in each direction change. The Nellmapius Road Bridge, per direction. This is the first 12-lane were provided with continuous aux- over the Ben Schoeman Freeway, freeway section in South Africa and iliary lanes between the on-and-off did not have sufficient horizontal required widening of the bridges over ramps of consecutive interchanges. clearance to accommodate five lanes

35 NOMINATED

per carriageway and had to be demolished and replaced. The Allandale Interchange was a major part of the project - almost half of the earthworks and structure quan- tities were allocated to upgrading it. Traffic had increased to such extent that it was not possible to upgrade the old diamond interchange sufficiently to acceptable levels of service. The interchange had to be replaced and the new interchange now provides a free flow interchange system with an additional carriageway overpass and new directional ramps and loops. Five new bridges were constructed at the Allandale Interchange. The deck width of the two bridges carry- ing Allandale Road Westbound and Allandale Road Eastbound over the Ben Schoeman Freeway is 16,1m and 28,48m respectively. Both bridges have four-span continuous decks with main spans of 22,2m and end spans of 13,34m. The main spans consist of precast, prestressed, M-beams in a pseudo box girder configuration. The end spans are in-situ reinforced concrete voided slab decks. Elevation of the bridge decks is enhanced by the use of precast concrete panels. The end span elevations are grooved to simulate the main span panels. The substructure for these bridges comprises multiple column type piers and wall type abutments with return walls. The columns and abutment walls are provided with fluting to form an aesthetic finish. Due to the very high abutments, buttress walls instead of tapered walls were used for structural and economic reasons. Concrete provides a cost effective way for a bridge designer to shape structures in order to project a specific aesthetic idea. In the case of these bridges, reinforced concrete, pre-tensioned prestressed concrete, post-tensioned pre-stressed concrete, precast reinforced concrete and in-situ cast Team concrete were all used effectively to • Client: South African National Roads Agency Limited SOC (SANRAL) Northern design and construct. Region Using the design principles of durable concrete, coupled with good • Principal Agent: BKS construction quality assurance on • Main Contractor: Aveng Grinaker – LTA/Moseme/Boitshoko JV concrete cover, placing, compacting and curing, ensures that these bridges • Subcontractors: Civilcon will be maintenance friendly and live • Submitted by: BKS up to their 100 year design life. 36 NOMINATED

horizontal modular banding, both inside and on the exterior of the build- DF MALAN HIGH SCHOOL ing. The structure was held together – Multi-purpose activity centre by exposed steel roof trusses. The panels were cast and erected within four days and all 375 linear DF Malan High School in Bellville has gained an international metre panels were placed in position reputation for academic excellence. The governing body took within 10 days after casting com- menced. These panels are robust the decision to build a new multi-purpose activity centre for enough to withstand the site instal- concerts, dances, dinners, exhibitions, assembly, examinations lation process and future occupancy wear and tear. This construction and sports training. method reduced construction time and costs. ith 1 040 learners attending ventional robust materials. A 50MPa the tertiary facility, the big- strength was specified, 40% less The architectural concrete ele- gest challenge was to effect weight and a high thermal quotient. ments perfectly complement the W design of the school. quick, efficient construction of a robust, A vertical H-shaped off-shutter cast elegant space. Apart from noise, access, concrete column system, between time and budget constraints, the design 7,6m and 8m high, was designed and materials had to complement the into which the precast panels could Team existing visual landscape and school be slotted first to form the founda- • Client: D F Malan High School, complex. tion beams and then the walls. The Bellville Van Biljon Barnardo Architects and panels were hoisted individually Isipani Construction collaborated and carefully manoeuvred into place • Principal Agent: Van Biljon with KLS Consulting Engineers and with the panel ends sliding into the Barnardo Archiects the Portland Group to provide an in- column slots. • Main Contractor: Isipani novative solution using precast and No strip foundation was required Construction in-situconcrete. as the columns were designed to • Subcontractors: KLS Large scale hollow core precast withstand major lateral force and at Consulting Engineers concrete panels, 160mm x 1200mm foundation level the panels rest on the x 4700mm long, manufactured by column footings. The precast panels • Submitted by: Van Biljon means of the extrusion method, could stacked between the columns created Barnardo Archiects be installed faster than other con- a high, open space with pertinent 37 NOMINATED KWAMSANE COMMUNITY – Access Roads and Pedestrian Facilities Phase 2 The South African National Roads Agency SOC Limited (SANRAL) recognised the need to reduce the potential for accidents on a section of the N2 national road near Mtubatuba, which passes through the township of KwaMsane.

oba was appointed by SANRAL as the consulting engineer for the Gdesign and construction super- vision of the KwaMsane Community Access Roads and Pedestrian Facilities, Phase 2. This community project included upgrading three interlinked access roads, the Western Collector, the East- ern Collector and the N2 underpass, using Continuously Reinforced Concrete on site by means of hand labour and to optimise the steel diameter and Pavement (CRCP). mechanical mixers. steel spacing required. Load transfer across the centre line of the half-width The existing potholed roads re- In order to minimise future main- constructed pavement was by means sulted in pedestrians and taxis using tenance of the road, the concept of a of tie bars and a cast in-situ keyway. a portion of the N2 as a collection and perpetual pavement was introduced The side drains were tied to the con- drop off point, as the other roads were and a 150mm thick CRC pavement crete pavement to eliminate the need almost impassable, particularly in the with an unsealed tied and keyed for a sealed joint, further reducing the wet season. longitudinal centre line joint was designed and constructed. This pave- maintenance liability. The Mtubatuba local municipality ment structure would also provide was unable to effectively maintain the a sustainable solution for the local roads, which was caused by a weak Mtubatuba Municipality. The CRC pavement and sub-grade structure. In pavement thickness was modelled addition to the 2,8km road upgrade, using the design traffic loading ob- additional pedestrian sidewalks were tained from data from the UCOSP constructed along the Eastern Collec- Quarry located on the eastern side tor and N2 Underpass to ensure the of the N2. The Cement and Concrete safety of learners at the two nearby Institute’s cncPave software was used local schools. SANRAL and Goba identified the need for a road system that was safe, provided pedestrian access and re- Team quired minimal future maintenance. • Client: South African National A number of options were considered Roads Agency SOC Limited but the CRC pavement was selected as (SANRAL) it was an ideal choice of material for a • Principal Agent: Goba labour intensive project. The project was undertaken as a • Main Contractor: Mazcon Civil and Building Contractors community upliftment project with stipulated community participation • Subcontractors: Amajika goals. In order to maximise benefits General Trading 2 to the community on this project it re- • Submitted by: Goba quired that the concrete was batched 38 NOMINATED MANGAUNG INTERMODAL Situated in the heart of the – Public Transport Facility Free State in Bloemfontein’s second and third levels. There were a The team constructed CFA pile foun- Central Business District is one number of infrastructure challenges dations, post-tension floors, off- of the biggest public transport including accommodating sewerage shutter concrete columns and walls, pipelines. perimeter walls and framework, sew- facilities in Africa. Vela VKE performed the geotechni- erage inlet and outlet infrastructure. The Mangaung Metropolitan cal investigations and assessment. The in-situ and post-tension con- The natural stormwater canal site crete slabs were used to optimise the Municipality appointed Vela required a piling system 8m below design of the floor, with considerable VKE Consulting Engineers natural ground level. The ground vertical in-situ off-shutter concrete water and collapsible sides called panels to achieve the architect’s in conjunction with their for continuous flight auger piles to aesthetical requirements. A total of Joint Venture partner, Incline be installed. With the canal being ap- 23 500m³ of concrete was used, 1 600 proximately 6m deep, the columns tons of reinforcement and 160km of Architects, as principle agents (piers) situated inside the canal re- post tension cabling. and designers of this flagship quired pad foundations at a depth of The project also included 223 tons approximately 1,5m to 2m. of structural steel for steel canopies project. Three large diameter sewer lines and staircases and a further 74 tons of 900mm, 600mm and 375mm as well steel for the Hanger Street Pedestrian he municipality required a public as a 160mm diameter main water Bridge linking the existing bus rank transport node to accommodate line had to be either accommodated, with the new facility. Tthe existing taxi rank, bus services or relocated, in order to minimise A unique feature of the building is such as Greyhound and Translux, a rail the changes to column layout during the complex off-shutter concrete lines link and retail services. construction. Innovative transverse that the architect achieved by means Structural off-shutter concrete ground beams with additional col- of wall formations, recesses and can- was chosen due to its durability and umns were designed to distribute tilevers. The building was designed to low maintenance as well as being forces around these sensitive and be sustainable with natural light and vandal-proof. brittle pipes. Special measures also ventilation. The innovative project The multi-storey reinforced con- had to be taken while piling to prevent met all the client’s requirements and crete building was designed to include the pile from damaging the existing was completed within the budget and informal trading facilities on the first, sewerage infrastructure. timeframe allocated.

Team • Client: Mangaung Metropolitan Municipality • Principal Agent: Vela VKE/Incline JV • Main Contractor: RSI Intermodal Construction • Subcontractors: Penetron • Submitted by: Vela VKE Consulting Engineers (Part of the SMEC Group) 39 NOMINATED

MOSS KOLNIK INTERCHANGE – Overpass Bridge Rapid urbanisation around Arbor Town and increased traffic volumes on the N2 national road required an upgrade of the Moss xisting traffic patterns show that 25 000 vehicles commute in each di- Kolnik Interchange. The South African National Roads Agency Erection daily. The large Arbor Town SOC Limited appointed Royal HaskoningDHV (RHDHV) as the regional shopping centre is situated adjacent to the N2 northbound route, principal agent for the Moss Kolnik Interchange Overpass Bridge. and occupies a strip of land previously used by the Umbogintwini Golf Club. geometric requirements and aes- sand. The combination of pre-stressed It was impractical to incorporate thetic styling. Structural steel was and reinforced concrete components any part of the existing Moss Kolnik found to be uneconomical because has proved to be technically suitable Interchange Bridge in the upgrade, of the particular geometric require- and economical for a number of inter- mainly owing to geometric incompati- ments and its unsuitability for site, change bridges in the past and was the bility. The interchange layout required 300m from KwaZulu-Natal coastline. most realistic solution in this instance. widening Moss Kolnik Drive, on the The superstructure of the new Materials include the use of fly ash, south side of the existing road, which bridge comprises a continuous in- slag and silica fume constituents, all provided an opportunity to construct situpre-stressed concrete box girder waste by-products from power plants the new bridge in two stages. Traffic deck, constructed in stages with a installations. had to be accommodated on the ex- 38m span over the north-bound car- isting deck and also on the existing riageway; a 42m span over the south- off-and-on ramps. bound carriageway and adjacent Team The existing bridge had to be ramps; and a 21m east end span. The • Client: South African National replaced with a new structure, with architect has visually ‘softened’ the Roads Agency SOC Limited substantially longer spans over the deck by curving the pier faces and (SANRAL) N2 carriageways, a wider deck to the intersection of the deck soffit and accommodate six traffic lanes and a sides to improve the aesthetic appear- • Principal Agent: Royal pedestrian walk-way. ance of the structure. HaskoningDHV At the conceptual design stage, The piers comprise partial V- • Main Contractor: Steffanutti consideration was given to: the pri- shaped reinforced concrete columns. Stocks Civils KZN mary structural form; configuration The abutments consist of reinforced of components; method of con- concrete bank seats with ear-wings • Subcontractors: Jeffares & Green struction, and bridge construction. to support the parapet end blocks. Concrete was strongly favoured The abutments are also supported • Submitted by: Royal for its economy and durability and by precast concrete piles driven to HaskoningDHV also for its amenability to meeting a predetermined set in very dense 40 NOMINATED N3 –12 ELANDS INTERCHANGE KAS JV, a joint venture between consulting engineering – Switch Ramp Bridge firms Knight Piesold as lead consultant, Gibb and PD Naidoo & Associates, was appointed by the South African National Roads Agency SOC Limited (SANRAL) to design and construct Package E1 of the Gauteng Freeway Improvement Project.

he project required creating ad- In-situ concrete, both reinforced and three separate casts from bottom ditional lanes on a 12km stretch post-tensioned, was used for the slab, webs to top slabs. To reduce Tof road along the N3-12 dual- construction of all foundation, sub- differential shrinkage and any result- carriageway between Heidelberg Road structure and superstructure elements ing potential crack development, and the Geldenhuis Interchange. of the bridge, with precast reinforced the time between casts had to be This complex interchange system concrete being used for bridge deck kept to a minimum, requiring early connects the N12 and N3 freeways, parapets. All in-situ concrete was stripping of any interfering internal and crosses over and provides access sourced from a commercial ready- side formwork for subsequent casts. to Rand Airport Road. The interchange mix plant, using dolomite coarse and Also, in order to satisfy the very tight experienced severe congestion in blended fine aggregates throughout. programme for construction of the peak periods as N3 north-bound Conventional placing methods were deck segments, stressing was re- traffic joined the M2 east/west mo- used for accessible locations and quired to be undertaken within three torway at the adjacent Geldenhuis heights, with pumping methods for days of completion of the final cast, Interchange. elevated substructure pours and for followed immediately thereafter by The purpose of the new Switch all deck segment construction. All con- launching. All these time and strength Ramp was to minimise congestion crete compaction was undertaken with constraints were successfully met by from weaving and switching, N3 conventional poker vibration methods. the purposely designed concrete mix. northbound traffic destined for the Specially designed early high Off-shutter concrete with conven- M2 onto a dedicated elevated ramp strength, high slump pumped con- tional finishing methods was used through the Interchange leading di- crete was used for the heavily rein- throughout the bridge on all exposed rectly to the M2 off-ramps. forced and congested deck segments, surfaces, with resulting good and aes- The Elands Interchange Switch which were constructed in two or thetically pleasing concrete finishes Ramp Bridge is an impressive 400m being achieved. long, horizontally-curved concrete The 400m long horizontally-curved feature bridge designed for and con- Team bridge consists of a permanent nine structed by the incremental launching • Client: The South African span, continuous 3,5m deep, post- method of construction, to satisfy National Roads Agency SOC tensioned concrete box girder deck, SANRAL requirements that the bridge Limited(SANRAL) supported on reinforced concrete be constructed under uninterrupted piers and spill through type abut- • Principal Agent: KAS JV traffic flow through the Interchange. ments on spread footing foundations (Knight Piesold, Gibb, The incremental launching method on rock at relatively shallow depth. PD Naidoo & Associates) of construction of the bridge deck The pier immediately adjacent to the was adopted for design, thereby • Main Contractor: Siyavaya N12 northbound carriageway is the completely eliminating any otherwise Highway Construction JV; exception, being founded on large restrictive deck staging formwork. (Group Five Construction – diameter bored piles taken through Concrete as the construction mate- Lead contractor) the road embankment fill and sock- eted into the underlying rock, so as rial was undoubtedly the only choice • Subcontractors: Structural for this bridge, in terms of cost, con- Systems Africa to eliminate an otherwise deep and structability, long term durability and costly laterally supported excavation • Submitted by: Gibb minimised maintenance requirements. alongside the roadway. 41 NOMINATED NEW OFFICE FOR BUHRMANN & PARTNERS part from the nearby Aigams The new office for Buhrmann & Partners is located on a narrow Shopping Centre and the UN ABuilding, single and double sto- 1 500m² cul-de-sac low-density office development in Klein rey structures prevail. The client, an Windhoek. The area is gradually being transformed without engineering company that provides civil, structural and project manage- sacrificing its distinct residential scale. ment services, proposed demolishing the existing structures but retaining and single architectural structure. Per- building are clearly defined. A brightly integrating the garden in the design. haps the most striking visual feature, coloured curved wall element shields The company’s three partners had however, is a broad butterfly roof the clustered service elements from to be accommodated in separate of- that stretches almost the entire width the fierce west sun. A minimalist and fices with views over the garden. Oth- of the site. A metaphor for a wide- robust approach was followed in the er requirements included maximising spreading acacia, it defines the gener- choice and application of materials, available bulk, the introduction of a ous main working space. Conceived details and finishes: mindful of low water element and, more importantly, as a double volume container, the maintenance, exposed structural ele- the use of off-shutter concrete. large draughting office has a winged ments are used alongside unadorned The client’s distinct preference for and centrally cantilevered concrete concrete, steel and aluminium, timber concrete as the material of choice roof with clearstory windows to the and glass. presented a creative opportunity south and north to ensure sufficient An integral component of the to design a building of restrained daylight. Individual offices and dis- Bührmann & Partners building, sus- simplicity where not only structure cussion nodes in the north and south tainability was approached from a but also detailing and finishes would are attached to the glazed façades pragmatic point of view by complying serve as a mute advertisement of the as cubed pods framing views of the with basics such as correct orienta- owners’ engineering profession. garden from within. A generous roof tion, prevailing sun angles, shading Simplicity and transparency were overhang shades the glazed façades and effective shading devices, cli- the overriding design aspirations. A of the main space to the north whilst matically appropriate fenestration long concrete beam with impressive horizontal louvres provide shading for and effective lighting, evaporative clear spans was designed as a promi- the three office pods. cooling, rain-water harvesting, and nent circulation axis, demarcating Forming a building threshold the appropriate use of materials and a clear approach to the building for from public to private and physically finishes. It is steeped in the belief that both visitors and staff, and separating separating building from garden is a those decisions that shape an indi- the production from the support ser- linear water element. The office pods vidual project have implications not vice zones. It also serves as a unifying are recessed below the floor line and only for its inhabitants, but also for element that ties the various building appear to be floating. Public, semi-pri- the shaping of the surroundings and components and staff parking into a vate and private domains within the for the use of the available resources.

Team • Client: Buhrmann & Partners Consulting Engineers • Principal Agent: Wasserfall Munting Architects Inc • Main Contractor: M A T T Construction • Submitted by: Wasserfall Munting Architects Inc 42 NOMINATED NEWCLARE ROAD-UNDER- The Johannesburg Devlopment Agency’s Rea Vaya Bus RAIL UNDERPASS Rapid Transit route through Coronationville and Newclare has necessitated a new road- under-rail crossing. This links Price and Hoy Streets. Concor Civils, a Murray & Roberts construction company, was tasked with designing and constructing the road-under-rail underpass project in Newclare.

uring the 18-month project, Newclare to Westbury rail traffic Dremained operational and it is believed that this is the first structure of this size to be jacked into an operational railway line embankment, without interruption to railway traffic. The 52,5m long underpass is 12m by the lateral support, utilising a steel walls and constructing a steel cross- wide, allowing for two road lanes of sliding surface and steel guides on the head over the top of each wall. Double 3,7m each and two sidewalks of 2,3m. sides to keep the structure on track steel sliding plates were built into the The structure was constructed in two throughout the jacking operation. top of each wing wall, with Teflon pads halves, one 28m long, the other 24,5m The top surface of the steel sliding placed below the steel cross-heads. long, with the structures meeting on surfaces was placed within 0.5 mm, As the structures were jacked the centre line of the railway. using a specially designed adjustable forward, the initially vertical tendons The project team comprised con- support and grouting system. simply displaced to an angle of 2.3° sulting engineers Vela VKE with struc- degrees, representing the friction tural design provided by Concor Civils angle of Teflon to steel. and lateral support design by Jones This proved a pleasant surprise to & Wagener. Esorfranki Geotechnical Team the site teams, who had anticipated constructed the lateral support and • Client: Johannesburg jacking the cross-head backwards as conducted the jacking, with Concor Development Agency the structures moved forward. Civils undertaking the concrete con- • Principal Agent: Vela VKE The Hoy Street structure weighed 1 struction. AfriSam supplied all the con- 100 tons and required a jacking force crete and provided technical advice. • Main Contractor: Concor Civils of 1 200 tons, while the Price Street This unusual and challenging • Subcontactors: Esorfranki side weighed 1 140 tons, needing a project began with the construction Geotechnical; AfriSam jacking force of more than 1 000 tons. of the lateral support, by creating two The individual walls on each structure semi-complete box cuts, one on either • Submitted by: Coralynne & were sometimes jacked with differ- side of the embankment, close to the Associates ent forces in order to provide limited railway platforms to reduce the jack- steering of the structures. ing length. Originally it was intended The two structures met exactly as ex- that both structures would be jacked About 5m from the final jacked po- pected on the centre line of the project, simultaneously to maintain a stable sition, both structures were unstable with the final gap of 150 mm partially embankment. The team placed verti- due to the large soil and rail loading. sealed using gunnite. The construction cal micropiles on the line of the exca- Therefore, to maintain stability over this of road works, a pedestrian bridge over vation to keep vertical displacement crucial construction stage, it was neces- the railway lines, sidewalks and drain- of the railway lines to a minimum. sary to anchor the back of the structures age concluded the project, with a final Reinforced concrete strip foundations during the last 5m of jacking by placing completion value of R29,5 million. were cast within the box cut formed rock anchors on either side of all four 43 NOMINATED

Team PROTEA HOUSE • Client: Richard Goldstein • Principal Agent: Studio Mas • Main Contractor: Bos & Punt • Submitted by: Hulme & Associates

he decision to use exposed concrete was to show that concrete Protea House is a striking residential structure, located at the Tneed not be considered only as foot of Lion’s Head, in Fresnaye, Cape Town. The client’s brief a structural material. Inspired by the cliffs of Table Mountain, the façade is was to create a unique residence, connecting two homes for an an abstracted cliff-face built out of off- extended family. shutter concrete. The concrete recesses and ridges are designed to support for the textured areas, the final shut- maximum size of the concrete pour; the growth of endemic air-plants and tering choice consisted of horizon- sequence of casting to control shrink- succulents to ultimately mimic nature. tally placed timber boards. Additional age; and the positions of cold joints. The textured finishes and relief shuttering to create the recesses were The concrete used was 30MPa, with work set against the landscaping are fixed to this. The timber boards were a Penetron waterproofing additive in good examples of how the beauty fixed to conventional proprietary steel all external concrete elements. The of concrete can be used to greatly shuttering, which offered the robust- concrete was provided by Lafarge with enhance the end product. ness to the system to allow it to be a slump of between 90 and 120mm. The urban nature of the site, the lifted as a unit. The wall thickness was increased to parameters of the local authority’s The problem of successfully releas- allow the pouring of the concrete to be zoning scheme and the client’s desire ing the shutter without damage to the via a 110 diameter pipe, extended to the for a large garden resulted in a perim- vulnerable recesses was identified at lower sections of the wall shuttering to eter block typology. an early stage. reduce the risk of honeycombing. Cur- The choice to conceive the struc- While several ideas were working was done with a proprietary spray- ture as a series of flat slabs supported shopped, in the final choice, polysty- on curing compound. by concrete columns and load-bear- rene was faced with timber plywood Extensive use was made of wide ing masonry was made on sound en- to provide enough flexibility in the concrete brows above the door open- gineering rationale. No other material recesses for successful release. Off- ings. These brows allowed the door could combine as many qualities to shutter concrete work is always going heights to be limited and, at the same achieve the same result. to present challenges and this project time, form a wide shading element. Almost from the outset, the cli- was no exception. The brow concrete was partly sus- ent had expressed a desire to see Meticulous detail was paid to the pended from the reinforced concrete off-shutter concrete as the final aes- shuttering design as nearly every shut- slabs with thin steel plates. thetic finish and this substantially ter was unique. The design of the shut- The success of this project relied on guided the design process. While ters had to be cognisant of: the maxi- acknowledging input from everyone several alternatives were considered mum size the crane could hoist; the on the team. 44 NOMINATED THE READING INTERCHANGE he UPW Consulting/Nyeleti Con- sulting Joint Venture was award- – Cut and cover tunnel structure Ted the Reading Interchange Cut and Cover Tunnel Structure Package E2, The Reading Interchange was selected by the South African of the GFIP project. Nyeleti Consulting was responsible for the structural de- National Roads Agency SOC Limited (SANRAL) as one of the sign, while UWP Consulting was tasked Gauteng Freeway Improvement Project (GPIF) focus points. The with the geometric alignment and road design. Siyavaya Joint Venture was ap- design team was requested to incorporate artistic and aesthetic pointed the main contractor. elements in the design in order to create a visual experience The design team proposed a cut and cover tunnel structure that would for the road user over and above the functional solution to the divert traffic from the R59 north di- traffic issues. rectly onto the N12 east ramp, under the R59 south. Besides its many other ferred to what can practically be installed at the start and end of the practicalities, this solution could be constructed. To enable the designers tunnel. WMS Architects was involved constructed without any disruption to strike this balance it was decided from the start of the detail design to traffic. to model the complete tunnel struc- phase and provided architectural The total length of the structure ture in a three dimensional AutoCAD input which was incorporated into the is approximately 345m long, divided model. A straight segment length of design. Several details were slightly into two tunnel sections measuring 10m long provided the best combi- modified and adjusted to provide 162m and 63m respectively, sepa- nation of visual effect and ease of a more pleasing and aesthetic end rated by an open gap of 38m and re- construction. result. taining walls measuring 120m in total. The tunnel structure is ideally The Reading Interchange cut and The gap is essentially a safety element suited to be constructed using cast in- cover tunnel structure is not a compli- providing natural light in the event situ reinforced concrete. The segment cated ‘world first’ type structure, but of power failures and assisting in the length and formwork was designed rather a combination of fundamental, expulsion of carbon monoxide fumes to enable each segment to be cast tried and tested engineering elements from the tunnels. continuously in one pour. that were put together with care and The tunnel alignment is on a LED lighting was used to project attention to detail. slight vertical curve with a 276,4m green light on the ceiling of the tun- This project is testament to the fact horizontal radius and varying super nel and thereby creating a special that a functional and aesthetically elevation. With a complex geometric and distinctive atmosphere when pleasing structure can be achieved layout, a balance had to be found driving through the tunnel. Special without spending large amounts of between what is aesthetically pre- light masts were also designed and additional funds.

Team • Client: The South African National Roads Agency SOC Limited(SANRAL) • Main Contractor: Siyavaya Highway Construction JV • Subcontractors: UPW Consulting; WMS Architects • Submitted by: Nyeleti Consulting 45 NOMINATED

22 000 tons of finished cement product. Construction began in September SEPHAKU CEMENT 2011 and old and new techniques and methodologies were merged to create – Aganang Plant the gigantic plant. The overall quality of plant de- From design and fabrication to construction delivery, Aganang, sign reflects intelligent solutions, Sephaku Cement’s R2,8 billion flagship integrated clinker and specifically pertaining to the way in which rebar was delivered, as well cement production plant is a concrete superstructure. It showcases as construction of supporting steel the use of concrete as a material of choice in the production of structures. The result was delivery of epic efficiencies and excellent project cement and in the design flexibility and durability of concrete. management. For example, some 13 000 tons of ephaku’s plant, Aganang, a Setswa- only 80 000m³ of concrete and 8 000 rebar was processed through on site na name which means ‘empower- tons of structural steel. The Aganang bending yards, with a team of just sev- Sing each other’, aims to live up to plant has an operational capacity of en rebar workers typically bending six its name and marks the beginning of producing 6 000 tons of clinker per tons and placing four tons of rebar per the cement manufacturer’s role as a day and 1,2 million tons of cement day. Through stringent quality control key industry player, in the South African per annum, with storage volumes of holding points, the project owner cement industry. 56 000 tons. For the clinker silo beam managed the high speed delivery. The project is also an example of alone, a civil structure that started 7m Aganang is the first South African the sheer scale of construction and below ground level, concrete sliding based clinker and cement producer productivity that is possible through required two 38m boom pumps and in the market in over 70 years. With concrete usage. It is an exhibition of two stationary concrete pumps. Sephaku Cement being the recipient massive civil engineering construc- Its clinker silo is one of the largest of the largest African investment into tion scale, impressive efficiencies and single storage bunkers in South Africa. South Africa. intricate precision, combined with a The kiln is also the longest burning Not only will Aganang generate sus- dimension of pragmatic innovation. and biggest single kiln in the country. tainable employment opportunities As one of the largest privately fund- Raw meal silo storage capacity ac- for South Africans but it will contribute ed capital projects in the country, a to- commodates 20 000 tons, along with to economic growth through its par- tal of 120 000m³ of concrete was used pre-blended stockpiles that extend ticipation in the country’s value chain; and 17 600 tons of structural steel. To the length and breadth of four rugby consistently contributing through put it into perspective, Johannesburg’s fields. The cement silos also have revenue generation and related tax world class Soccer City stadium used the capacity to store approximately contributions.

Team • Client: Sephaku Cement • Principal Agent: Sephaku Cement • Main Contractor: Sinoma Construction International • Submitted by: Sephaku Cement

NOMINATED

THE QUARTER he project developed by the The Quarter, a small 2 400m² shopping centre with parking for 112 owner/contractor, JNM Construc- Ttion, designed the retail shopping vehicles, is the newest development in Ballito’s suburban paradise, centre to include offices, a showroom on KwaZulu-Natal’s north coast within 10 minutes drive from King and food quarter. The simple uncluttered concrete Shaka International Airport. architectural lifestyle complex aims to offer a pleasant local shopping of South Africa, Head of JNM Construc- 150 panels were lifted over two stages experience. JNM Construction have tion, Brent Youens sought to improve spanning five days. The entire project developed a number of buildings in the quality and finishes in this spe- was completed within six months. the area ranging from commercial, cialised area of concrete construction. The shopping centre was an ideal light industrial to a church. Planning was extremely important property for this type of construction The contractor has worked with tilt- as there was no available space off- given the relatively flat open site and up construction for a number of years, site to prepare the concrete panels. design considerations. By utilising as a highly efficient and cost effective An intricate plan was developed with tilt-up construction the project was methodology compared to standard the engineer to cast the walls panels completed timeously and achieved construction methods in South Africa. on the ground and then hoist them substantial savings in operational As a member of the Engineering Council into place with cranes. Approximately costs.

Team • Client: JNM Construction • Principal Agent: Hugh Fraser Architect • Main Contractor: JNM Construction • Subcontractors: Slabbert & Associates

48 nominated UNISA - Florida campus The existing UNISA Florida Campus on the West Rand needed to increase its capacity and the R427 million project included three additional buildings – a four-storey main building, a three-storey engineering block as well as a single-storey agricultural facility.

SI Engineers and Environmental The engineering structures consist cast. Where the depth was insufficient Consultants (trading as Royal of five buildings namely mining, to cast the piles, large pad footings SHaskoningDHV) provided the electrical, industrial, mechanical and where designed to transfer the load to structural, civil, electrical and mechani- civil. These structures are three storey, the ground layers. One area required cal services, while HMZ Architect’s were framed, reinforced concrete struc- shotcrete to avoid subsidence around responsible for the design and WBHO, as tures founded on pad and strip foot- existing footings. Retaining structures the main contractor. ings. The building frames are divided were used to create the basement The client stipulated that all the in average 6m grids with 255mm thick and a central tunnel, nicknamed the existing university facilities had to be suspended floor slabs supported on ‘Gautrain Tunnel’ designed to accom- operational during the construction reinforced concrete beams of varying modate the building’s centralised of the new buildings. This included sizes. The engineering buildings also services. continuous connectivity for learners, have 6 ton cranes operating in the The buildings were made up of which required the contractor to be mining, industrial, mechanical and concrete columns with concrete plant particularly careful not to damage civil buildings. Due to the high engi- rooms and a steel roof structure. Two services to the existing buildings. neering equipment high live loads of other buildings used a structural steel 10kN/m² were adopted in the design. portal structure with brickwork infill. All roof coverings were structural steel The most exciting and challenging Team frames with metal sheeting. structural elements were the archi- The engineering building was de- tectural ‘steel trees’ feature that was • Client: University of South signed with two sections, the upper used as a covering canopy structure. Africa (UNISA) part consisting of civil, mechanical RHDHV coordinated all services • Principal Agent: HMZ and industrial engineering and the in the main building basement area Architects lower part comprising mining and through the use of the computer pro- electrical engineering, with a connect- gram Revit. The exercise was used to • Main Contractor: WBHO ing walkway. minimise clashes of services during • Subcontractors: HMZ This concrete structure consists the installation. Architects; SSI Engineers & of columns, beams and slabs up to Environmental Consultants; roof level. At roof level, a ring beam (Trading as Royal Haskoning- supports the steel roof structure. It DHV) was designed to accommodate the • Submitted by: SSI Engineers gantry cranes in each building, which & Environmental Consultants; necessitated the inclusion of large (Trading as Royal Haskoning- roll-up doors to provide sufficient DHV) access to the various engineering areas. These floors were designed as a composite structure and due to the Concrete was the most appropriate steel being exposed in a high risk fire material, offering flexibility of de- area, the beams were treated with sign, longevity, corrosion resistance, fire-retarding coatings. strength and overall performance Due to the poor soil conditions, to meet the building’s operational high loads and proximity of existing requirements. buildings and services, 68 piles were 49 NOMINATED UNIVERSITY OF PRETORIA fter prolonged consultation with the national heritage authorities, - Aula Foyer Project Ait was agreed that the new foyer would be constructed on the side of the existing building. The Aula Theatre has been classed as a Heritage Building and The creation of large access open- located at the University of Pretoria, the venue is commonly used ings would link the existing concrete side wall to the new foyer. After a for the university’s graduation ceremonies and events. As the careful analysis of the existing struc- oldest operational theatre, the 550m² building required upgrading tural frame and detailed modelling, new access openings were created, to improve its usability during inclement weather. which mirror the style of the heritage building. being cost efficient and lower in maintenance costs. Concrete also offers the The space within the new build- Team ability to construct complex structural ing has been optimised through the • Client: University of Pretoria shapes to comply with architectural construction of a structural six-sided • Principal Agent: ARC Architects design requirements. column, which functions as a vertical The new foyer had to match the service shaft. • Main Contractor: Stefanutti original concrete foyer and provide This stylish, tree-like structure also Stocks a functional and aesthetically pleas- inconspicuously houses the Heating, • Submitted by: Aurecon SA ing space, which will cater for the Ventilation and Air-Conditioning university’s ever increasing number (HVAC) plant room recessed within of under-and-post graduate students. the splayed space below the roof Concrete has proved the most popu- slab of the new foyer, ensuring that lar choice for the construction of com- The project team is extremely air-conditioning equipment is not mercial and institutional buildings proud to be associated with the com- visible in elevation. in South Africa. This is partly due to pleted project.

50 NOMINATED

WITS SCIENCE STADIUM ocated on the relatively under- The new Wits Science Stadium combines the conversion of developed west side of the Braam- Lfontein Campus the decision was an existing sports stadium into five large scale auditoria, to taken to utilise reinforced concrete as accommodate 1 570 students, twenty tutorial rooms, which seat the primary structural material. The existing stadium comprised 830, the construction of three double volume laboratory space of reinforced concrete frames, with with bench seating for 1 100 students. precast seating spanning between frames. The main design challenge entailed rebuilding the raked seating The troughs have aesthetic appeal, the aesthetic beauty of off-shutter at an optimal angle. The continued and relatively large surface areas, re- concrete, durability and robustness durability of the existing stadium sulting in efficient heating and cooling of off-shutter concrete resonates concrete structure was a major factor via piped water (TABS) system. with the existing concrete buildings in the viability of the overall project, The NEC Target Cost form of con- on campus. given the prohibitive costs associated tract provided a significant advantage The end result is a world class with demolishing and rebuilding a to the project, by forcing the design facility that entices the visitor into new structure. and construction teams to work the world of science. The imposing The front part of the auditoria together to come up with efficient yet engaging concrete structure was formed by a new three-storey solutions. This had a major impact epitomises the vital support role that reinforced concrete coffered slab in bringing the project in on time, science has today and tomorrow. The structure. On the second floor, large within budget and at the required durability of concrete will ensure that upstand beams were used to span the quality level. this complex stands the test of time, plant areas over the auditoria, with as the backdrop to the focal public The feature staircases and plat- spans of up to 20m. space on the West Campus of the forms that rise inside the colonnade One of the primary design concepts University of Witwatersrand. posed challenges. The requirement of the laboratory section of the build- to minimise column pours, to en- ing is the emphasis on making science accessible. Hence, all three labora- sure straight and uniform columns, tories have extensive glass window required the use of threaded connec- Team tors, to construct the corbel beams areas, framed in a visible concrete • Client: University of Pretoria structure. The laboratory building was that support the staircases. From a conceived as open space, to provide technical concrete point of view, many • Principal Agent: ARC Architects of the visible vertical elements are tall large teaching spaces and clear lines • Main Contractor: Stefanutti of sight. This 17m clear span was and slender, requiring the use of self- Stocks achieved using shaped reinforced compacting concrete. concrete ‘fin’ frames, with trough Concrete’s versatility and ability • Submitted by: Aurecon SA slabs spanning between the frames. to be formed in geometric shapes, 51 NOMINATED

WORCESTER INTERCHANGE he Worcester Interchange project The South African National Roads Agency SOC Limited was a successful Public/Private TPartnership (PPP) financed by (SANRAL) required an interchange at Worcester to cope the Golden Valley Casino, Breede Valley with the increase in traffic along and across the N1 at Municipality, SANRAL, Worcester Land Trust and Altona Development. the town. The interchange forms part of the long term The Worcester Interchange bridge, planning for the N1/N2 Winelands Toll Highway Project. is an eye-catching and unique structure which symbolises the vision of structural engineers to meet the funda- where the panels were made solid and cast in-situin order to accommodate mental requirements. The bridge was cast in situ. The design concept was the top steel over these supports. After completed within 18 months at a cost based on the requirement that the deck finishing the in-situcast part of the top of R17,19 million. The overall project, construction method would not need slab, the precast slabs were installed including the interchange and road any staging over the N1 carriageways. and finally the top slab was completed upgrades, cost R105,8 million. This was achieved by using a beam and by filling in the 600mm wide casting slab type deck, consisting of precast in- gaps between the slabs. The bridge consists of four spans verted T-beams and in-situcast top and New construction technologies and which cross the N1 at right angles. The bottom slabs. The main span beams techniques have led to the ease in cre- substructure consists of Y-shaped piers were prestressed with post tensioned ating unique aesthetical features using with capping beams supported on spill cables, but the shorter end span beams concrete as a construction material. through abutments and is supported have conventional reinforcement. The The durability and strength of concrete on 1 080mm diameter oscillator piles `cantilever’ parts of the deck top slab, has made it a logical choice for bridges founded on rock. The main spans and which carry the sidewalks, were con- for many years and still remains one of end spans are 21m and 13m in length structed using precast slabs of average the most used construction material respectively. The beam and slab type length of 2,62m, which were supported worldwide. deck has an overall width of 16,66m, on structural steel ribs attached to the which includes a carriageway width of edge beams. Team 11,9m and two 1,8m wide sidewalks. The steel ribs were hot-dip galva- The roadway and sidewalks are nised and painted and bolted to the • Client: South African National separated by means of 800mm high edge beams before being lifted into Roads Agency SOC Limited F-shape barriers. At the outer piers, position. Anchoring of the ribs to the • Principal Agent: South African the deck was made continuous for live in-situcast part of the top slab was National Roads Agency SOC loading. The deck expansion joints at achieved by means of steel ties, which Limited the abutments are buried below the formed part of the rib fabrication. • Main Contractor: Martin & East surfacing and at the centre pier a claw After placing all the precast beams type joint is present. using a 220t crane, the bottom slab of • Subcontractors: Darson Con- The precast beams are supported on the deck was formed by filling in be- struction rubber pads. The balustrades consist of tween the beams. At the outer piers, the • Submitted by: Nadeson Con- precast concrete frames with structural deck was made a continuous part of the sulting Services steel infill, except at the bridge supports cantilever slab, each side of the pier was 52 A RECORD OF THE FULTON AWARDS AT A GLANCE

Fulton CSSA Fulton Total Fulton Award Winners in Categories: Awards President Memorial No of Awarded Speaker Entries Civil Engineering Structures Building Structures Sculptures Aesthetic Appeal Design Concepts Construction in Techniques

1980 MA - 13 Public Library, Sasolburg - - - - Vasarhelyi

1981 GD Bendall - 15 Preheater Tower, CSSA & School of Concrete - - - - De Hoek Technology, Halfway House

1982 CJ Thomp- Dr D Davis 9 Glenwood Tunnel, Durban SATS Container Workshops, - - - - son (RSA) Cape Town

1983 KC Tucker SC Watson 12 Bloukrantz Bridge, Cape Port Control Building, Port - - - - (USA) Elizabeth

1984 EPJ van Prof D 26 Tutuka Power Station No 2 Cape Provincial Administra- - - - - Vuuren Billington Chimney, near Standerton tion Head Office, Cape Town (USA)

1985 A Dutton F La Due 18 Main Dam, Otjivero-Gobabis No winner. - - - - (USA) Regional State Water Scheme

1986 DP Samson Prof W 23 Stellenberg Interchange Precast Acoustic Drapes - - - - Hestor Bridges, Cape Town - Natal Provincial Theatre (USA) Complex

1987 JE Hodgkiss Mrs A 21 Lethabo Boiler House Human Sciences Research - - - - Smithson Structure, near Vereeniging Council Building, Pretoria (UK)

1988 JE Hodgkiss R Lacroix 16 FW de Klerk Bridge, No winner - - - - (France) Vereeniging

1989 RJ Snowden Dr J Davi- 22 John Ross Bridge over the NG Kerkkompleks, - - - - dovitz Tugela River Somerstrand

1990 PC Graham D Lee (UK) 21 Swartklip Interchange South African Trade Mission, - - - - Bridges, Cape Town Maputo

1991 CJ Lloyd TW 29 Malibamatso River Bridge, Klein Constantia New Matu- Untitled Relief Panels - - - Kirkbridge Lesotho Highlands Scheme ration Cellars, Cape Town (UK)

1992 VE Black- EC Chaplin 41 KSM Mill Complex, Pieter- Bophuthatswana Parlia- Untitled Concrete - - - beard (UK) maritzburg ment Building, Mmabatho Sculptures, Medfem Clinic, Sandton

1993 D Peters R Choy 30 No winner The Oaks Pavilion,& North Cape of G H Nature - - - (Australia) Stand, Newlands, Cape Res Gateway. Mould Town for Panoptic Gaze

1994* MG Latimer P Matt 21 Tugela River bridge, No B351, Shanti Nikatan – House of Woman Dancing, - - - (Switzer- N2, Durban – Richards Bay Peace, Westville, Natal Princess Daisy Boat, land) Soma Tree

1995* Prof M Dr AK 18 Main Concrete Structures, BMW Pavilion, V & A Water- - - - - Alexander Mullick Alusaf Hillside Smelter front, Cape Town (India)

1996 CH Waterson J Pierce 17 Johannesburg Stadium, Standard Bank Centre, - - - - (USA) Johannesburg Johannesburg

1997 BA Raath Sir Michael 13 Harper Road Bridge, Eastgate Centre, Conch Structure, - - - Fowler Johannesburg Harare Lalucia Ridge Office (UK) Estate, Umhlanga

1998 PRA Flower Dr G 12 Katze Dam, Lesotho High- Administration & Academic - - - - Rosenthal lands Scheme Building, University of PE (RSA)

1999 DP Samson L Mills 16 New Black River Bridge, No winner - Driekoppies Dam, Post-tensioned Precast Cooling Tower Shells, (RSA) Cape Town Mpumalanga Concrete Reservoirs, Majuba Power Station Mpumalanga

2001 G Maritz - 34 Mozal Aluminium Smelter, Tokara Winery, Stellenbosch, - SA Jewish Museum, Sandton Convention Finger Jetty, port of Mozambique Cape Town Centre, Sandton Richards Bay

2003 PRA Flower - 23 Maguga Dam, Komati River, Apartheid Museum, Johan- - No award Westcliff Estate, Morland Millenium Swaziland nesburg Johannesburg Bridge, Umhlanga Ridge

2005 VA da Silva - 29 Mohale Dam, Lesotho Constitutional Court, - Nelson Mandela Chapman’s Peak, Cape Mohale Dam, Highlands Hillbrow, Johannesburg Bridge, Johannesburg Town Lesotho Highlands

2007 DC Miles - 29 Impala Platinum Mine, No 16 Athlone Soccer Stadium, - Bosmansdam Road Mkomaas River Pedes- Durban Harbour Shaft, Rustenberg East Stand, Cape Town Pedestrian Bridge, CT trian Bridge, KZN Services Tunnel

Fulton CSSA Fulton Total Fulton Award Winners in Categories: Awards President Memorial No of Awarded Speaker Entries Civil Engineering Project Building Project Unique Design Concrete in Construction Special Category: Aspects Architecture Techniques Repair and Maintenance in Project

2009* FB Bain - 28 Berg Water Project, Soccer City Stadium, Moses Mabhida Soccer City Stadium, Cold Weather Concret- Concrete Retrofitment Franschhoek Soweto Stadium, Durban Soweto ing on the Letseng Solutions Utilised At Diamond Mine Project, The Van Der Kloof Dam Lesotho Highlands Spillway Bridge, Van Der Kloof Dam

Fulton CSSA Fulton Total Fulton Award Winners in Categories: Awards President Memorial No of Awarded Speaker Entries Civil Engineering Project Building Project Unique Design Concrete in Construction Innovative Technologies in Aspects Architecture Techniques

2011* NP van den - 31 Blackburn Pedestrian Bridge, Ubuntu Education Centre, Mountain House Ubuntu Education Hospital Bend Pre- 15 Alice Lane Towers, Berg Umhlanga Port Elizabeth Roofs, Cape Town Centre, Port Elizabeth selection Scheme: New Johannesburg Overpass Bridges, Cape Town

Notes: Up until 1994 the Fulton Awards were named in terms of the preceding year (the year in which the projects were substantially completed). From 1995 onwards they were named in terms of the year the Awards were made. In 2009 the names of the Fulton Awards Categories underwent a slight change. In 2011 the names of the Fulton Awards Categories underwent a slight change.