Another award for Macsteel’s World Record holders

The South African Institute for Steel Construction describes the Weelee Centurion Project as a shining example of the innovative and sophisticated use of steel in modern building construction. This prestigious development, completed in June 2023, showcases the exceptional capabilities of steel as a building material, as well as the expertise of the construction team in leveraging its unique properties.

At the heart of the project is the extensive use of high-quality steel cladding and roofing. The roof cladding utilised the Novotexi 440™ profile with a thickness of 0.53mm, covering an impressive area of 22 000m2. For the side cladding, the team opted for a clean Colorbond widespread profile, covering 9 000m2 and totalling approximately 200 tonnes of cladding material.

“The achievement of the Novotexi/Roofing team stood out again at this year’s Steel Awards,” says Mike Benfield, Macsteel CEO. “The innovation of forming the roofing in the sky is what sets this product offering apart and enables other contractors to work in tandem with the roofing team. It saves time, money and effort. We couldn’t be prouder.”

The attention to detail and precision in the use of these steel components is what truly sets this project apart, according to the SAISC. The roof design features a complex curved shape, requiring the roofing contractor to navigate a series of challenges to ensure a seamless and water-tight finish. One such challenge was the installation of the bull noses which needed to be carefully crafted to integrate the Novotexi roof cladding. The team created ten different bull noses, each with a unique run-out at the top end and conducted 100 tests to ensure the perfect fit and water-tightness.

The integration of the steel cladding and roofing components was further enhanced using custom-designed flashings. To accommodate the 160mm difference between the roof and bull nose, the team developed a series of flashings that would create a bold, yet visually seamless, transition. This involved tapering the flashings from 380 to 280 mm ensuring that no unsightly steps or joints were visible form the exterior.

The team’s commitment to quality and attention to detail is further exemplified in the incorporation of poly carbonate elements. The project utilised 1,2mm widespread satin grey poly carbonate with 20% light transmission, which not only enhanced the functionality of the structure but also contributed to its overall aesthetic appeal.

One of the most impressive feats of engineering on this project was the installation of the Novotexi-sky formed roof. This operation required the use of a 50-tonne crane and meticulous planning to ensure the safe and precise placement of the large steel components. The team’s logistical expertise and safety-conscious approach were crucial in overcoming this challenge, demonstrating the level of coordination and skill required to execute such a complex project.