SASFA IS A DIVISION

OF

November 2013
Light Steel Frame Building in SA
Taking LSFB to the next level

John Barnard, SASFA


2
Steel Workshop, November 2013
Introduction to LSFB
Manufacturing and Building Process
Pros and cons of LSFB
Approvals by authorities
SASFA & the RSA industry
Multi-storey building projects
Eastgate
Novo Warehouse, Paarl
Zambezi Mall
Villa Mall
Riverwalk Office Park
Pan African Games Village, Maputo
Questions?
A
g
e
n
d
a

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The Manufacturing and Building Process
What is LSFB, and what does it offer?

Light steel frame building systems consist of
cold formed sections
manufactured using high strength, thin gauge galvanised steel sheet
integrated design and manufacturing facilities
optimally designed to provide required structural strength
used for roof trusses, walls and
suspended floors

LSFB has been used for decades and is
growing in popularity worldwide,
especially in the US, UK and Australia.
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1. Introduction
LSF used for wall
panels, floor joists
and roof trusses
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The Manufacturing and Building Process
1. Architects building plans are copied into
CAD/CAM building system design facility.
Structural design automatically carried
out.
Bill of quantities and costing.
2. Design facility is linked to roll profiling
machine. Sections are produced to the
exact required lengths, holes punched,
and each section marked. In the correct
sequence for assembly.
No wastage.
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The Manufacturing and Building Process
3. Trusses and wall panels are assembled in the
factory, using steel rivets or screws in pre-
punched holes.
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The Manufacturing and Building Process
Frames are strapped together
for each building project. Note
the pre-punched holes in the
sections for services, and the
cross-bracing.
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The Manufacturing and Building Process
4. Frames and trusses are delivered to
site, where the floor slab has been cast,
and power floated.
Erection of the wall frames and roof
trusses takes place within 2 to 3 days.
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The Manufacturing and Building Process
5. Services (electricity and
water) are installed using pre-
punched holes in the studs.
Note no cutting and chasing of
brick walls!
6. A vapour permeable
membrane is fixed to frames of
all exterior walls.

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The Manufacturing and Building Process
7. Exterior panels erected, and
fastened to steel frame.
Also used for multi-storey
buildings. Note shear panels.
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The Manufacturing and Building Process
Fibre blanket
insulation is
installed in the
wall cavity
created by the
light steel
frame.
Insulation
requirements
are designed to
suit the
geographic
climate zone of
the building.
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The Manufacturing and Building Process
6. After installation of insulation in the wall
cavity, interior dry wall panels and ceilings are
fixed to steel frames using self-drilling screws.
Joints are rendered using tape and filler to
obtain a perfect finish.
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1.2 The Manufacturing and Building Process
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1.2 The Manufacturing and Building Process
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The Manufacturing and Building Process

Advantages Quality, cost-efficiency & sustainability

Quality:

Tried & tested US, Europe, Australia
Complies with the rational design requirements of the SA NBR.
Structurally sound - each structure is signed off by an engineer.
Only quality certified materials are to be used.
Can accommodate imperfect foundation conditions, sloping sites.
Frames are normally assembled under controlled factory conditions
Thermal insulation superior to double skin brick walls.
Industry association (SASFA) quality and code compliance monitor.

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The Manufacturing and Building Process

Advantages Quality, cost-efficiency & sustainability

Cost-efficiency:

Fast
Dimensionally accurate everything fits
Minimal wastage and rework
Durable steel inside building envelope has a predicted life of > 100
years
Light weight logistical and handling costs reduced
Energy efficient range of insulation options
Flexibility can be built in stages, alterations
Additional (~ 4%) floor space
Installation of services
Predictable - accurate costing
Earlier occupation

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Minimal scrap / waste
Logistical cost advantage
Energy efficient - insulation
Embodied energy (MJ/m)
Operational energy CSIR research
Materials recycled / recyclable
Site water use



The Manufacturing and Building Process
Sustainability
Advantages Quality, cost-efficiency & sustainability
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The Manufacturing and Building Process

Challenges

Mindset of home-owners
Walls bullet-proof?
Break in through walls?
Numbers of competent LSF builders
Current tough market conditions
Supply chain is developing

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Approvals by authorities

All buildings must comply with the National Building Regulations
Three alternative routes:
Prescriptive requirements (conventional building),
Agrment certification, or
Rational design
Engineer (competent person) takes responsibility
Submits his rational design
Ensures building is erected to specification
Signs off
Plan approvals
NHBRC, enrolment
Local authorities



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SASFA

Southern African Light Steel Frame Building Association
Why an Association?
Interested parties, early 2006
Needed a forum for industry to
develop and set standards
monitor quality
coordinate industry development
Funding: major material suppliers
Steel
Fibre cement board
Gypsum board
Insulation
Formed as division of SA Institute of Steel Construction
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SASFA

Mission : To develop and grow the Southern African and export
markets for Light Steel Frame Building.

Vision : SASFA strives to realise the following
LSFB is established as a high quality, energy efficient, cost
effective and preferred method of building in Southern Africa, for
low rise residential and non-residential buildings.
Light steel frames constitute a significant export industry.

Goal : To capture 10% of all new low rise building projects in South
Africa, including additions and alterations.
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SASFA

Milestones achieved
SASFA established as the industry representative association. Major
material suppliers as founder members.
Website established. More than 1000 visits / month.
SASFA Code for low rise Light Steel Frame Building published, replaced
by SANS 517.
Training course for LSFB erection established. Australian input.
Code training courses presented, major centres. Overseas speakers.
Course for building inspectors.
Obtained support from the NHBRC and the major banks bonds.
Publicity: 3 - 4 media articles per month. Building exhibitions.
Quality checklist compiled.
Accreditation Scheme drafted, being implemented.
Accepted as Associate Member of NASH, LSK (Europe) and SFA (USA).


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SASFA
SASFA Company Membership
Member category Oct-13
Major material supplier 6
Other material, component and equipment suppliers 6
Manufacturers of Light Steel Frame Building Systems
Large (>1000t / yr) 14
Other (<1000t/yr) 4
Merchants, service centres and distributors 7
Building Industry member
Large 5
Small 17
Design Consultants 7
Associate member 14
Total 80
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Industry capacity
Current profiling capacity in m floor area / yr :
trusses => 1.8 million m
systems => 2.7 million m
LSF Manufacturing facilities RSA
Jun-13
Profilers Number 35
Profiling machines Number 67
Profiling capacity
10
6
lin m/yr
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10
3
t ons/yr
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Products manufactured
trusses only % of t ot al 25%
full LSFB systems % of t ot al 75%
Capacity of SASFA members % of total 80%
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Whats happening?
Hazy Crest, Pta North
5 Sept 06
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Whats happening?
Double storey house, Johannesburg
Office building, Durban airport
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Whats happening?
Offices inside
industrial building,
Durban
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Whats happening?
College building, Durban
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Whats happening?
Trusses, school
buildings for GDE
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Whats happening?
Vaal Dam
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Whats happening?
Action cricket hall, Pretoria
2300 sq m, 7kg/sq m
Tiled roof, 12,5m span
Industrial building,
26m span
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Whats happening?
Antigua Estate,
Amanzimtoti
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Whats happening?
House in Macaneta, Mozambique.
MB Construction.
Zivania Village, GDS
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Whats happening?
Bela Bela house
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Whats happening?
Xanadu Eco Village, Hartebeespoort Dam
Multi-storey applications

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Eastgate extensions, Bedfordview
Novo Packhouse, Paarl
Zambezi Mall, Pretoria
Villa Mall, Irene
Riverwalk Office Park
Athletes Village, Maputo


Multi-storey applications : Eastgate extensions

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Multi-storey applications : Eastgate extensions

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Built on top of parking area mass saving essential
4000 sq m of walls, up to 10m high

MDS Architects
Grinaker LTA
Vela SBS / Browndeck
Multi-storey applications : Novo Packhouse, Paarl

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Multi-storey applications : Novo Packhouse, Paarl

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Multi-storey applications : Novo Packhouse, Paarl

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Johan Wessels Architect
Main contractor: Murray & Roberts Construction Western Cape
LSF supplier and erector: Light Frame Homes
Multi-storey applications : Zambezi Mall, Pretoria

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Osglo Architects
Steel supplier: MiTek / Razorbill
Multi-storey applications : Zambezi Mall, Pretoria

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Multi-storey applications : Zambezi Mall, Pretoria

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Multi-storey applications : Zambezi Mall, Pretoria

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Multi-storey applications : Villa Mall

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Osglo Pretoria, Architects
Light steel frame supplier and erector: GDS

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External walls
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External wall detail
15mm FS gypsum board
Light steel track
EPS fastener
90mm thick 20kg/m EPS board
1.0mm G550 Z275 stud
2 x 4mm layers of proprietary
render with embedded fibre
mesh
EIFS
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Internal wall detail
15 mm FS gypsum board
0.8 mm G550 Z275 stud

Staggered joint finished with 2 layers
of proprietary render with embedded
mesh
15 mm FS gypsum board
0.8 mm G550
Z275 stud

Steel door frame
Bottom track
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Alternative building methods ...
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Internal and external finishes
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Advantages of LSF walling
Reduced dead loads on structure
Savings in structural concrete
Logistics
Speed of construction
Water consumption
Time & cost savings
Energy savings
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Reduced dead loads:

Mass of a double leaf masonry wall, plastered both sides: 450 kg / m
LSF internal wall 30
LSF external wall 35

Area external walls 23 000 m
Area internal walls 50 000 m


Mass saving (load reduction) : 31 000t


Advantages of LSF walling
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Reduced dead loads:

The lower mass of the walls, made the use of coffer slabs, spanning 8.5m,
possible. Used less concrete than 350mm solid slabs, saved time.

mass saving 48 000 tons

The lower mass of the walls & slabs resulted in reduced section columns,
using less concrete.

mass saving 23 000 tons

All the above savings made the use of 1.2m diameter piles possible, in lieu
of 1.5m piles.

mass saving 13 000 tons





Advantages of LSF walling
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Logistics

Walls: transport of 31 000t less materials than for masonry
construction, at 20t / load 1550 fewer truck loads

Rubble removal:
Inherent in wet trades : 10% breakages and wastage using LSF
walling reduces rubble removal by 3 900t
195 fewer truck loads.

Concrete:
Saving of 114 000t (49 500 m) of concrete
8 260 fewer concrete trucks

Total reduction of 10 000 truck loads
Advantages of LSF walling
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Site water consumption

i) Water requirement for mortar and plaster : 24 l / m wall area

=> Water saving = 73 000 m x 24 l
= 1,75 million litres


ii) Water requirement for concrete: 180 / m

=> Water saving = 114 000 m x 180 l / m
= 6.53 million litres

Total water saving : 8.28 million litres
Advantages of LSF walling
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Time and cost savings

Erection of internal & external walls : saving 60% on time for
masonry construction

Mass reduction of LSF => use of special coffer slab
=> 25% saving in RC construction
time period




Advantages of LSF walling
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Professional team comments:

Structural engineer we will definitely use LSF
walling again in the future

Architect a huge success! It is faster, more energy
efficient, cleaner, and it facilitates hassle free
changes to the floor plan at a later refurbishment
stage a real advantage in the retail space market.
Advantages of LSF walling
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Riverwalk Office Park, Pretoria
EIFS
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Office building, Pretoria
Architect: Boogertmann
LSF erection: GDS
LSF supply: Vela SBS
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Athletes Village, Maputo
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Athletes Village, Maputo
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Athletes Village, Maputo
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Athletes Village, Maputo
Progress Photograph
Moambique: December 3, 2010

Progress Photograph
Moambique: May 11, 2011
Progress Photograph
Moambique: May 11, 2011
Progress Photograph
Moambique: August 10, 2011
Progress Photograph
Moambique: August 25, 2011
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Questions?
John Barnard

john.barnard@saol.com

083 468 1410

www.sasfa.co.za
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VSE
C
P.M
. -
Heritage Walk
Baltimore, Maryland
5-story loadbearing CFS with
Hollowcore Planks
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Hotel, Carlsbad, California
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Dormitories at Cal Poly
San Luis Obispo, California
Condominiums in Mercer Island, Washington

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114 Senior residences, 1000 2000 s.f. each: 5 stories CFS on concrete
podium.
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Hotel in Central Ohio
Podium: All structural steel
Walls: CFS
Floors: CFS joists
Roof: CFS trusses
Lateral Mixed: Tilt-up concrete stair and elevator towers; CFS shearwalls
sheathed with sheet steel
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Ohio Hotel
February 20, 2007
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Ohio Hotel
February 23, 2007
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Ohio Hotel
February 26, 2007
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Ohio Hotel
March 16, 2007
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Ohio Hotel
March 30, 2007
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Ohio Hotel
April 13, 2007
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Ohio Hotel
April 26, 2007
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Ohio Hotel
May 11, 2007
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Ohio Hotel
May 18, 2007
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Ohio Hotel
June 1, 2007
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Ohio Hotel
June 15, 2007
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Ohio Hotel
June 29, 2007
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Ohio Hotel
July 20, 2007
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Ohio Hotel
August 3, 2007
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Ohio Hotel
August 17, 2007
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Ohio Hotel
September 12, 2007
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Ohio Hotel
March 30, 2007
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Ohio Hotel
June 15, 2007
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Ohio Hotel
July 20, 2007
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Ohio Hotel
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Ohio Hotel
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Ohio Hotel
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Ohio Hotel
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Ohio Hotel
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Ohio Hotel
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Ohio Hotel
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Ohio Hotel