Timber iQ August - September 2020 // Issue: 50 August - September 2020 | Page 24

LOCAL PROJECT
The installation of the ceiling and façade sections.
The findings of our test led us back to the drawing board and we
redesigned the jointing system of the puzzle pieces. The interlocking
joints were redesigned, and blind nut clamp connectors integrated
into the connections. We then retested the structure and complied
with the standards.
When we start the manufacturing process, the primary portal structure
took 90 days of cutting (two days per portal), a total of 820 puzzle
pieces and 45 days of assembly (one completely laminated portal per
day), using approximately 1 920 blind nut fasteners to clamp the
portals together.
The systems of assembly were also designed for elements to be
easily manoeuvred and installed on site. Based on the these ‘small
building components’ principles, this allowed us to use vehicles with
trailers or a small flatbed truck for transporting.
When installation started, it merely came down to the correct
sequencing. First the baseplate brackets, our main connections
between structures. Secondly, we started erecting pieces into place,
again making use of smaller equipment such as telehandlers and
cherry pickers to place the portals correctly.
The portal had to be erected in two stages, first the short portals and
then the larger portals followed, lifted into place and connected with
steel brackets. The process of erecting the entire structure took
approximately a month to complete.
When the primary structure was installed, we moved to the secondary
structure. The roof, façade and ceiling structure. The roof structure
was constructed using pre-cut and ready to fit on-site Laminated
Veneer Lumber (LVL) beams with steel connector brackets. Façade
elements being installed parallel to the roof structure installation, all
elements contributed to the structural integrity of the building.
Once the primary and first stage secondary structures were complete,
we proceeded to final testing. The test conducted by the engineers
consisted of suspending 950kg from the ridge, and 2 x 650kg from
central points in the largest span area. The structure had to support
the weight for three hours, without a deflection of more than 45mm.
The structure only deflected by 5mm, and subsequently passed.
From testing we carried on with further installation of the secondary
structure. These ceiling panels and façade structure were designed as
clip-on elements to the primary structure (also being manufactured
off-site and assembled on-site).
The finished product of the Hub – Internal and external views.
After the secondary structure was complete, and the building
enclosed, we moved to the tertiary structure. This consisted of the
fixed furniture and joinery elements in the building, also all
manufactured off-site in six weeks and assembled on-site in a week.
HOUSING UNITS
The design of the elements in the housing units was developed to be
pre-manufactured off-site during the construction of the primary
concrete and brick structure, transported to site when the units were
completed and installed on-site within a matter of hours. Elements
that could be handled by hand, positioned in place and fixed.
22 AUGUST / SEPTEMBER 2020 // www.timberiq.co.za