Alternative Building Methodology

Presented by Andre Schlunz

 Why Alternative Building Methodology
• Energy Efficiency Code SANS 204 and NBR 10400 XA
Compliance
• Acceptance of Light Weight Steel Frame Construction
SANS 517
• Change in steel frame manufacturing technology and
software evolution
• Change in plastering systems projection/ spray plaster
technology
• Pre assembled building systems
• Business Opportunity
• Value Re - engineering of building s
• Saving on loadings 84% lighter
• FACTS –Fire , Acoustics, Composite Thermal Systems
• Architects now have the ability to manipulate the
building performances at cost effective prices
• High Performance Building Solutions
• Fast Track , Safe and Efficient Building Site
Concept Design Consultation Integration Reality
• Light Weight Steel Frame Builders

• Trained and endorsed by The South African

Steel Frame Association SASFA

• NHBRC approved building system

• Green Building Council Members

• Bonds approved by most banks

• Offering value `` Re Engineering ``

• Fast Track Turn Key Projects

• Specialised Systems Applications

• Involved with many prestigious projects from

Concept to Reality
 40% of SA total energy currently used in buildings

≈ 25% Summ
Roof er

≈ 15%
Air Principle of
renewal
insulation
≈ 30% Wall Glazing ≈ 10%
s
Thermal
Winter
bridges Floor

≈ 10%
≈ 10%
Ground

Improving the insulating envelope can reduce energy losses and shrink energy consumption by
up to 90%
 SANS 204 - Key Aspects
• General requirements
– Climatic zones
– Max energy consumption per
annum
– Max demand
• Factors incorporated in building
design
– Orientation & shading,
– Fenestration
– Floor insulation
– Wall requirements
– Roof & Ceiling
– Service( including water
heating )
– Sealing
• R-values (thermal resistance)
 Thermal Performances
• Ideally the design should be that of passive heating and cooling in
order to save electricity and water

To create a comfortable internal temperature 18-23 deg C

Design an appropriate thermally l insulated building using
intervention/ by building methodology in each climate zone to
meet or surpass the energy efficient code

• To meet or surpass energy efficiency code Cold Interior Region

• The envelope wall System R value =2.20- composite wall system
• The Roof System R value =3.35
• Foundation R value =1
• Heating of geyser 50 % by other means solar panel system .
heat pump , geyser blanket ,geothermal

• Frame building gives the ability to create Thermal Intervention

Systems whilst building -
• The building can be manipulated -depending on price FACT
performances required
 Energy Efficiency in New Buildings achieved by :
● Option 1: Compliance to SANS 10400XA
➢ Otherwise described as “Deemed to Satisfy”
➢ Requirements partially aligned with SANS 204

● Option 2: Rational design

➢ This alternative requires input of a professional “competent” person
➢ Thermal performance of building needs to be calculated
➢ Performance should be equal or better than specified in SANS 10400 XA

● Option 3: Comparison with a compliant theoretical building

➢ Allows comparison with the building design performance with that of a
“national” building
➢ National building should be designed to “Deemed to Satisfy” standards
➢ Thermal performance calculations software must be approved by Agrement
SA
The only thing you need to know!

• R-value = The ability of a product to resist the transfer of heat.

• The higher the R-value the more effective the insulation
• R-value = Thickness of the Insulation / Thermal conductivity (k)
 Traditional Wall vs New Systems
Thermal Intervention
Solid Wall System Steel
Traditional wall Frame
R = 0.26 Cavity wall, insulation
R = 1.00
R value = 1.69

[Single: R = 0.13]
ETICS on steel frame
Lightweight steel ETICS on single brick wall;
R = 3.76
frame wall R = 2.21
R = 2.50

R-value required for Zone 1 = 2.20

Light Weight Steel Frame Building Systems and Solutions
Geo Slab System
• Saving material requirements
• Monolithic pour
• Ventilation convection flow
• Prevention moisture
• Higher load bearing capability
• Ability to handle unstable ground and seismic
activity
• Excellent thermal performance R value =1.2
Framecad External Thermal Insulation Composite System (ETICS) on
masonry or Steel Frame

Base Coat Plaster Extreme

Fischer Fixings

EPS 60mm @20Kgm3

Embedded Mesh in Base

Coat Plaster

Decorative Render
(mineral, organic or
cement )
 APPLICATION for the evaluation of a material,

Agre`ment Board Certification- BBA Standard

product, component or system (other than building system)

Name of subject to be evaluated ………Weber .Therm ETICS on Steel Sub Frame or Timber Sub Frame as a
Ventilated Facade System ………………………………………………………………………………….
Name of company / individual making application ……Saint –Gobain Construction Products (Pty ) Ltd
Signed Andre Schlunz Date : 07.12.2010
Name (print) Andre Schlunz Position in company: National Sales and Marketing Manger Gyproc

Document no(s)
Refer To Document 2
DOCUMENTS SUBMITTED IN SUPPORT OF THIS APPLICATION Weber .Therm- ETICS
Ventilated Façade System
(Please refer to the third page when completing this section)
……………………………
……………………………
A. Description of subject
……………………………
B. Technical specification of materials
……………………………
C. Description of manufacturing process
……………………………
D. Description of erection / installation process
……………………………
E. Technical drawings (please ensure that each drawing is numbered and dated)
……………………………
F. Outline of the quality system applied to the subject
……………………………
G. Test reports and / or approvals from other organisations
……………………………
H. Other (please specify)
……………………………
………………………………………………………………...
………………………………………………………………...
……………………………
……………………………
 Projected Plaster
Base Coat Extreme
Polymeric Top Coat
 Projects External Façade and Internal Building Methodology

• The Zambezi Shopping Mall

• The Villa Shopping Mall
• SANRAL Office Samrand
• Yamaha
• Riverwalk –Deliotts
• All Africa Games –Maputo Mozambique
The Villa Mall Shopping Centre
 The Villa Mall Shopping Centre

Envelope 23,000m2 Internal Walls 270,000m2

• External Thermal Insulation
System (ETICS)
• System R Value= 4
• Light Weight Steel Frame
System
• Composite EPS and External
Pigmented Render System
• Height 6.55m
• Light Weight Steel Frame
System
• 15m Fire stop Gypsum
Board on each side =60 min
fire rating
• Full skim plaster with
Projection/Spray Plaster
Machine
 Weight Reduction

• Traditional Full brick and plaster

weight = 400kgm2

• Light weight steel frame system

ETICS System
15mm Gypsum Board
x 2 layers
= 53 kgm2
7.5 times lighter
4x faster
Thermal efficiency is
improved by 11.7 times
 The Villa Mall Project

• Light weight steel frame is pre -

assembled on the floor then tilted
into position to form the outer
exoskeleton frame of this building

• Note that there is no scaffolding on

the outer part of the building –
savings to be made
• Savings –crane time , leasing of
scaffolding
• Safe site –enclosed steel frame
system
• Shortened Project Management
Time
 The Evolution
Load Bearing Extra High Systems

Cold Rolled Steel Frame

1.4kg perl/m
60m2 wall
Steel Frame =171kg
Gypsum Board =1,742kg
Total Wall = 1,913kg m2

Traditional ½ Brick
60m2 x 200kg m2
Total Wall = 12,000kgm2

6 Times lighter
Inner atrium area
The Villa Mall
The Villa Mall
 Scope of works at high levels- Application and preparation of
fibre glass mesh immersion and Base Coat Plaster application
 The Villa Mall E
External wall insulation
 The Villa Mall
Acceptance of Mock Up and Roll out
 The Villa Mall Shopping Centre
90,000m2 Floor area
23,000m2 Wall envelope ETICS EPS On Steel Frame
 Hot Rolled H Beam

• Integration of H beam system

and cold rolled extra high load
bearing stud and track creates
the separation between shops .

• High performance Fire and

Acoustical requirements
 Toilet System

• Typical example of a toilet bowl

load bearing system
• Ability for plumbers to pressure
test and pre -commission works
before cladding
• The section behind the toilet
frame leaves an area where
inspections and repair can be
carried out
 Integration of H Beam and Light Weight Steel Frame –Interior
The Villa Shopping Mall Pretoria

42
Typical retail outlet ``mock up``
The Villa Mall
 Steel Sub Grid Pre Assembly
Pre formed gypsum bulk head detail –speeds up erection –
saves skimming time –saves steel
Preassembled Floating Ceiling Systems
Preformed bulk head detail
 Zambezi Mall
• Shopping after market research –required 8
cinemas , action cricket , 4x restaurants
• Car park used in order to achieve this –all light
weight steel frame construction
• External Envelope Steel Frame EPS / EWI
render system
• Internal Steel Frame 15mm Gypsum Boards
80kgm3 insulation
 The Zambezi Shopping Mall
Light weight steel envelope wall system
Extra High interior wall system

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Example of extra high 12m light weight steel wall system
integrated with H beam system
Isover vapor breathable membrane
Zambezi Mall
 Zambezi Mall
External ETICS Walls in build up stage
External Projection Base Coat Plaster on Polystyrene Wall Labour Efficiency
300m2 per day
 Zambezi Mall
Internal Wall Cinema areas
Extra high steel frame walls to a Cinema area
Fire ratings and acoustical performance
critical tested on site 75dB
Yamaha Facade
 The Yamaha Project
External Thermal Façade System( ETICS )
 The Yamaha Project
Off site manufacture in
modular form

Brought to site in panels

Erected on site with crane

positioning

Final Plaster jointing and final

render applied
 Riverwalk Project –Pretoria 2011
aesthetics , cost effective , energy efficient façade system , speed of
erection
 All Africa Games Project Aug 2011

• 90,000m2 floor area

• 320,000m2 internal linings insulation and plaster walls and
ceiling detail
• 980 apartments 3 bedroomed / 4 floors in height
• Contract period start to completion 9 months
• Achieved and winner of the`` light weight steel frame`` award
2011 by the South African Steel Institute
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 Projection/Spray Plaster
M100 Projection Machine 450m2 per day
Projected Self Leveling Screeds Preparation for floor coverings
acoustical and fire performances
Typical example of light weight steel frame integrated with H Beam
Eastgate shopping mall entrance 9 Food Court

102
Fibre Cement Flat Boards Composite System on Steel Frame
Steel Frame (Durban Airport), Commercial
Cold Roll Forming Machines- On Site
Roofing and Gutter Systems
 Approach to Market
Pull Strategy
• Developers • Existing Framecad Roll Former
• Architects • Roll Formers Existing Builders
• Engineers • Projects by Region
• Quantity Surveyors
• Professional Specifier
• Create new roll formers
• Create new builders
• Paradigm Shift • Create potential new warehouse
• Concept Sales Facilities Distribution Channel by
• Feasibility LSF vs Masonry Region

• Sales of Framecad Building

Products / Systems / Solutions
• Sales of Roll Forming Machines
• Other technical equipment
• Framecad `` Own The Project`` • Sales of services
Andre Schlunz
Cell : +27 726472533 e mail : andres@framecad.com
Sales Manager Africa Region
 Residential Market
• Single dwelling
• Multi storey dwelling
• Townhouse development
• Single hold cluster development
• Residential multi storey developments
Fulcrum Light Weight Steel Frame Building Systems and Components
 Residential
Steel rolled sub frame clad with Weber ETICS system
Cantilevered structure with off site manufactured fenestration
hoods
Light Steel Construction
UNIT TYPE: APARTMENTS / DUPLEX
UNIT SIZE: 4 x 45-75 each sqm
MARKET: Residential 3 Apartment
LOCATION: ZAMBEZI, PTA
 Differences in thermal surface temperatures
Fibre Cement vs Weber Therm
Cool In Summer – Warm In Winter – Cooler Box - Passive Heating and Cooling
Light Steel Construction
UNIT TYPE: Luxury 3 Storey house
UNIT SIZE: 320 sqm
MARKET: Cluster R2.2M
LOCATION: ARLINGTON, JHB
Bela Bela House limestone rivens wall cladding weight load
calculations on steel frame
Steel Frame Housing In Upmarket Estates -Accepted by Homes Owners

Association
Steel Frame Housing In Up market Residential Estates –Acceptance by

Homes Owners Association

 Facts
• Masonry envelope wall 400kg m2
• Envelope thermal performance
R value =.26 or .35 with cavity
• Internal wall weight 200kgm2
• Sound air bourn internal wall 43dB
• Fire rating compromised when
anchoring services –extra work with
re plaster
• Drying period for paint
• Heavy construction –safety issues
dust and crane time
• I Ton of masonry =5m2 wall area
• Mechanical heating and cooling
required
• Steel Frame and EWI system65kgm2
• Envelope thermal performance
R value = 3.75
• Internal wall weight 35kgm2
• Acoustical internal wall 45dB with
cavity batt insulation 52 dB
• Services are integrated with building
process
• Painting can start immediately
• Fast track building system no crane
required
• I Ton steel frame and board =35m2
wall area seven less truck loads
• Considered passive design –thermal
tool box performances
Framecad Approach to Market
 Fulcrum Projects
Lightweight Steel Frame Construction

Interior Construction

Flooring Systems

Andre Schlunz Cell :072 647 2533 e mail : andre@fulcrumsa.co.za

 Commercial Market
• Rejuvenation of old commercial buildings to apartment blocks and or
mixed development – shops ground floor –hotel –offices –apartments
• Hospitality Industry
 Commercial Building Rejuvenation
Change from Commercial Building to an Apartment Block-
• Loading -weight capabilities
• Cost effective
• Energy efficient
• Aesthetics
• Return on investment
• Limited space material handling
• Turn around time
• Pedestrian safety issues
• Loading of material masonry
0ne ton = 5m2
Dry Wall = 35 m2
7 times more efficient
No cranes required
7 less truck loads
Reduced site congestion
Innovative building solutions for
dedicated market segments
Wall Mount Toilet Frame System
Feeding Soil Pipe Duct
Moisture Resistant Rhino walling with steel sub frame
Gyproc Moisture Resistant Rhino Board with steel sub frame and Weber
waterproof compounds and ceramic tiling adhesive
 Hospitality
• Critical success factors • High loading of interior
• Challenges walls
• Acoustics walls /doors
• Fire rating
• Plumbing
• Electrical
• Services Integration
• Speed of erection
• Total comfort
• Aesthetics
 Projects Completed
Period of 36months

Hotels
• Taj Palace Hotel
• 15 On Orange
• Crystal Towers
• Protea Hotel Group x 3
• City Lodge Hotel Group x 3
• Radison Hotel Group x 4
• Southern Sun Hotel Group x3
• Legacy Hotel Group
• Park Inn Hotel
• Fairways Hotel Natal
Residential Apartments
• The Pearls
• Cape Royal
• Newtown Rejuvenation Project
• Raphael Sandton
• 88 Point Road
• Old Mill Way Natal

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• Holiday Inns –
Rivonia Road
• 350 Bedrooms
• 7months

• Radison Hotel
• 368 Bedrooms
• 7months with
Pod Building
System
Start with a shell
Skim Soffit and preparation for services installation – ease
of movement on site
 Installation of 102mm
Stud and Track System
Design of Acoustical Performances Critical
 Ist Layer of Gypsum Board Cladding –
Plumbing and Electrical Services Installation
Work in progress - Work Complete
Internal finish no compromise
 Fulcrum Projects
Lightweight Steel Frame Construction

Interior Construction

Flooring Systems

Andre Schlunz Cell :072 647 2533 e mail : andre@fulcrumsa.co.za

 Pre Assembled Building Solutions

• Bathroom Pods
• Entrepreneur Retail Pods
• Living Pods
• Studio Pods
• General
 Start With a new Frame In mind

Fulcrum Projects ________________

 Change in Technology and Legislation

• Business Opportunity
• Energy efficiency code SANS 204
• National Building Regulations 10400 XA
• Light Weight Steel Frame Construction

• Pre Assembled Construction Solutions

• Concept
• Opportunity
• Sustainability
• Market Requirements

Fulcrum Projects ________________

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 Concept Design –Product System Performance
Branding – Dedicated Service –Positioning

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 Internet Electronic or Hard Copy Library

164
 Retail Facility – Cell Phone –Internet –Banking

165
 Building Facility ``Creates Opportunity``
Form Of Reference and Sustainability

166
 Pod -Building System

• A Vanilla Box –You Create

• Aesthetics
• Theme
• Internal requirements
• External requirements
• Power Up
• Choose gas or electricity, photovoltaic cell
• Plumbing –solar, gas heating
• Secure glass and folding door
• Roller door system
• Floor covering

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 Pod -Building Concept

• Retail Outlet and or Brand Positioning in

environment where you need immediate brand
attention and a retail facility –
• Corporate Involvement

• Ability to design to specification and place corporate

signature integrated in and on the exterior of the Pod
``The building becomes the brand ``

• Power Brand

• Ability to move the POD building in and off site

position when required –multiple lift and drop

Secure and Energy Efficient-Passive building

• Ability to manipulate the performance of Pod

Building depending on what your requirements
FACTS –Fire, Acoustics , Composite ,Thermal
Systems
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 Pod
Building Solutions

• Design and Build with A New

• Frame of Mind
• Retail
• Classroom
• Micro Clinic, Library , Internet , Food
• Office
• Sport
• Studio
• Living POD

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 Pre Assembled House Delivery

171
 Preparation of earthworks –delivery of house pod and connection of
services

172
 Fulcrum Projects
Lightweight Steel Frame Construction

Interior Construction

Flooring Systems

Andre Schlunz Cell :072 647 2533 e mail : andre@fulcrumsa.co.za