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Historic KZN warehouse revamp wins SAISC Steel Award 2017

The historic Dunlop Factory in Cato Manor, KwaZulu-Natal, opened its new 12 5000m2 warehouse and distribution facility in 2016. The project was recently announced as the Winner of the Factory and Warehouse Category at the 36th edition of the Southern African Institute of Steel Construction (SAISC), which was held in September 2017. Global Roofing Solutions supplied over 49 000m2 of Klip Tite and 6086m2 of IBR for this iconic project.

49 000 square metres of Global Roofing Klip Tite roof sheeting used in upgrade and extension of Dunlop factoryThe previously-occupied property in Sydney Road was used for 80 years, from 1934 to 2014. The need for a new facility was spurred by the increasing demand for tyres into the rest of Africa and to meet growth projections that are anticipated for the supply of tyres in the automotive industry. The brief to the project team was to redevelop the site into a modern, user-friendly facility that would lend itself to high, large span warehouses, as well as preserve the original Dunlop house as a heritage building.

Large span, 120m warehouses were proposed. The structural framing for the warehouses included lattice trusses with spine girders and internal columns to optimise clear areas and spans for tenant usage.

Two major challenges were experienced on the project, namely finding a solution that would seamlessly blend the new facilities with the older structures; and lifting roof sheets on site because the sheets had to be lifted and installed 160m across the roof in adverse weather conditions.

While the original design included over 70 columns and an eaves height of 4.5m, the project team were able to optimise the solution provided to the client by installing only 18 columns and achieving a clear 12m eaves height without significant changes to the budget. The result is a modern warehouse that will serve the client well for years to come.

The historic Dunlop factory prior to being revamped using Klip Tite and IBR from Global Roofing SolutionsRoof cladding for the modern Dunlop warehouse

The roof cladding solutions from Global Roofing Solutions proved ideal for the project specifications. Klip Tite is a new generation concealed fix roof sheeting offering superior wind uplift capabilities to that of any other concealed fix sheeting currently available on the market.

“Klip Tite incorporates transverse stiffener ribs in the pan, which is the latest technology in the roofing industry. It’s manufactured in continuous lengths with on-site rolling for sheet lengths in excess of transportable limits, making it ideal for industrial projects such as the Dunlop Factory in Sydney Road. Additionally, the trapezoidal flute design of our IBR system offers the optimum strength, mass and load-span characteristics compared to alternative products,” says Martin Smith, Managing Director of Global Roofing Solutions.

Over 200 temporary jobs were created during the construction phase of the project. The local ward councillor in the region helped to coordinate the employment of local residents during the warehouse construction.

“Global Roofing Solutions is proud to have been involved in this award-winning project. The historic significance, combined with the innovations used to create an innovative, modern space, makes this a prime example of what can be achieved when great minds use great steel solutions,” concludes Smith.

Watch the video of the winning 265 Sydney Road project here:  https://www.youtube.com/watch?v=9A9Udzm5Zvw

Global Roofing Solutions
Previously Brownbuilt Metal Sections and HH Robertson

Cnr Quality and Barlow Road
South Africa

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