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Sustainable Alternative Building Solutions Presented By

Andre Schlunz Representing Framecad in

Sub -Sahara Africa

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Agenda

• Current situation

• Energy efficient code NBR 10400 XA

• Who is Framecad what do we do

• Change in building methodology

• Skills change |Training and Creating Of Sustainability

• Ability for market to change – Framecad Roll Framers in position

• Building solutions for specific markets

• Cost | Production efficiencies

• Gallery Projects

• Sustainability

• Conclusion

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• FRAMECAD® renowned Steel Frame Business Solutions -that empowers clients to profitably achieve fast, reliable, and automated production & construction capabilities without the need for skilled labour, resulting in fast project completion, improved product quality and delivery

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• We have building system researchers, software developers, CAD designers, engineers, machine control experts, technicians and on-site construction experts. We also have people who are good at listening to customers – we’ve always been driven by market needs,

`` because a solution is only worthwhile if it delivers better productivity and quality to our customers.”

Mark Taylor CEO/Chairman

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Customer FRAMECAD® offices Manufacturing Plants

Currently export to over 60 countries

Over 460 construction |Roll Forming Factory sites

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• Design & Planning

• Manufacturing Solutions

• Construction Methodologies

• Building material

• Global supply chain

• Care

- Support

- Training

- Consultancy

Complete Design and Build Solution

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Developed from experience FRAMECAD® can offer a range of designs that can quickly constructed these include: • Low cost residential • Villas • School and Community centers • Labour Accommodation • Hotels & Hostels • Hospitals • Military

Process Design

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Efficiency = Housing people faster Time = Money

Low Cost Housing Solution – 40sqm 1.35 hours production for framing

Speed | Cost Efficiencies

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Increased Productivity & Building efficiencies FRAMECAD® Rapid Construction 30% faster than timber and 50% faster than masonry

1 Shift = 8 Hours

1 Week = 5 Days x 2 Shifts = 80 Hours

1 Year 48 Weeks 3,840 Hours

11 houses per shift |day 40hrs.

110 houses per week

5,280 houses per year

Rapid Production

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Skills Training Process

• Steel Framer

• External Cladding

• Internal Cladding

• Foamed Cement Infill Systems

• Ceiling |Cornicing

• Roofing Systems

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• Empowering and training local communities • Working close to our markets • Rapid delivery of quality housing and community

centers

Rapid Repetitive Production Simplify Skills Training

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The World’s Most Approved and Certified Steel Profiles and System

ICC ES Certification in the US (ESR-2361)

ATI Certification in the US (CCRR-1030)

CE Certification in Europe (1224-CPD-0200)

Certification in Poland (AT-15-8394/2010)

SASFA Accreditation in S. Africa

NZ and AUS Certification

Advantage in the Market

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• 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 |Pre Engineered Buildings

• Change in plastering projection/ spray plaster technology

• Pre assembled building systems

• Business Opportunity

• Value Re - engineering of building 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 System

Alternative Building Methodology

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Innovative, Compact, Fast, Reliable

& Versatile Manufacturing Solution

Specifications - Profile: 63mm – 150mm (89mm typical)

- Gauge: 0.6 - 1.2mm (TCT)

- Output 300 to 750m/hour

- 11 tooling punches

Applications - Social Housing

- Military

- Transportable & Modular

- Light Commercial & Partitioning

- Roof Truss Systems

- Remote Locations

Construction Scope - 1 to 3 level Construction - Wall Stud Heights to 3.5m - Roof Truss Clear Spans to 15m - Floor Joist Clear Spans to 6m

These are guidelines NOT Limitations

Machines

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The Product

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Benefits to the Builder/ Developer

Speed – Faster erection and delivery time

Up to 25% faster than wood

Up to 50% faster than concrete

Weight – Lighter than other framing materials

Up to 30% lighter than wood

Up to 60% lighter than concrete

Scrap – Less scrap and waste

Quality – Higher quality offering to the consumer

Green - Steel framing is “Green” because it is recycled and recyclable

Safer Construction – Lighter material & controlled operations

Call-Backs – Straight walls, square corners, fewer call-backs

Why Cold Rolled Steel ?

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Benefits to the Customer

Mold – Will not host mold

Insects – Insect-Proof

Indoor Air Quality – Healthy House , no chemical treatments

Safety – Fire safety, non-combustible

Speed – Faster construction (move in, sell, rent sooner!)

Strength – Stronger Lighter Structure

Design Life – Galvanized Steel Protection (50 years +)

Maintenance – Less maintenance = Less cost!

Why Cold Rolled Steel ?

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Strong – highest strength to weight ratio of any building material. Meets very tough performance standards

Inorganic – will not rot, warp, split, crack, creep, support mold growth, or be eaten by termites and other insects

Dimensionally stable – does not expand or contract with moisture content

Consistent Material Quality – No regional variance in composition performance. International standards, global requirements.

Noncombustible – does not burn and will not contribute fuel to the spread of a fire

Earthquake Resistance - Superior seismic performance due to steel’s ductility

Basic Material Attributes

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Steel can

be 100%

recycled

Benefits to the Planet

Sustainability

6 Old Cars = 1 x 140 Sqm

House

Cold Rolled Steel

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.

FRAMECAD® Building products provide Sub Assemblies from simply claddings through

to fully insulated wall and composite floors .

Building Systems

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Purlins / Battens

Floor Panels

Building Systems

• Deep Roof Truss

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40% of SA total energy currently used in

buildings

≈ 25%

Roof

Wall

s ≈ 30% Glazing

Thermal

bridges

≈ 10%

Ground

Floo

r

≈ 10%

≈ 10%

≈ 15% Air

renewal

Summ

er

Winter

Principle of

insulation

Improving the insulating envelope can reduce energy losses and shrink energy consumption by up to 90%

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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)

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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

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• 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

• Specialised System Applications

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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

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Traditional Mass Construction | LGS System

Solid Wall

Steel

Frame System

Cement +Poly

R value = 1.69

Foamed Cement

R value =2.60

Cavity wall, insulation

R = 1.00

Insulated Facade on steel

frame

R = 3.76

Insulated Façade on single

brick wall; R = 2.21

Lightweight steel

frame wall

R = 2.50

[Single: R = 0.13]

R-value required for Zone 1 = 2.20

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Energy Efficient Roof System Code

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Light Weight Steel Frame Residential Market

Choices Of Building Systems

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Greenbuild | Foamed Cement Infill System Solid Wall Building Solution

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Greenbuild Solid Wall In Fill System Foamed Cement Mix

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Greenbuild Steel Frame Solid Wall System

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Greenbuild Solid Wall Foamed Cement Mix Projected Infill

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UFCC Solid

Wall Polystyrene and Cement Infill System

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UFCC Solid Wall Polystyrene and Cement Mix Core In Fill

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All Africa Games Maputo Mozambique

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All Africa Games Stats.

• Slabs down Jan 2011 –started Steel Framing Jan 2011

• 840 Apartments | 27 Buildings | G + 3

• 90,000m2 floor area

• 320,000m2 Internal Insulation , Gypsum Cladding , Gypsum full Skim

Plaster

• 360 Interlinks of material |3 per day (120 days )

• On average 2,000 workforce on site per day

• Would have gone faster if water and diesel was delivered faster !

• Completed End August 2011 - 8 Months

• Cost Effective , Energy Efficient , Aesthetic Appeal

Technology + Rapid Build

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Cold Rolled Steel

G + 3 Multi Storey

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Projection/Spray Plaster

M100 Projection Machine 450m2 per day

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Projected Self Leveling Screeds

Preparation for floor coverings

Acoustical and Fire performances

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Multi Story Apartments 840 apartments |9 month Build | 2,000 man workforce stages

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Unit Type Apartments / Duplex

Unit Size 4 x 45-75 each m2

Market Residential 3 Apartment

Location Zambezi , Pretoria

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Residential

Steel rolled sub frame clad with Framecad Insulated Façade System

Cantilevered structure with off site manufactured fenestration hoods

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Modular Homes The Next Evolution Pre Assembled Units

Portables

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Mobile Factory Solutions

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Framecad Roll Formers

South Africa

• Clotan Steel

• Tru Mod

• Clyde Steel

• SA Steel Frame

• KUSASA

• Container Leasing

• Steel World Roofing

Systems

• Kwik Space

• Mitek

• Matgotamishi

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Steel Frame Builders SA

South African Steel Frame Association

www.sasfa.co.za

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Framecad Relationships |Channel Marketing

• Warehousing

• Distribution

• 12 Outlets In South Africa

• Distribution of Framecad

Branded Building Products

• Builder Training

• Framecad Roll Formers

• Design

• Detailing

• Engineering |Sign Off

• Rolling Steel Profiles

• Builder Training

• Warehouse and Distribution of

Framecad Branded Building

Products

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Wall Panels Roof Truss

Applications

Floor Joists Lattice Beams

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Applications

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Multi Storey Hospital

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Mass Accommodation

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AREA : Ground floor = 1339 m2 First floor = 1381 m2 Second floor = 1381 m2 PLANNED PROVISIONS PER UNIT : 1. CLASS ROOM : 15 NOS. 2. PRINCIPAL ROOM : 1 NO. 3. OFFICE ROOM : 1 NO. 4. LAB ROOM : 2 NO. 5. COMPUTER ROOM : 1 NO. 6. TEACHER'S COMMON ROOM : 1 NO. 7. ENTERTAINMENT HALL : 1 NO. 8. SICK ROOM : 1 NO. 9. TOILET : 3 NOS. 10. GENTS TOILET : 3 NOS. 11. LADIES TOILET : 1 NO.

PLAN & DETAIL FOR SCHOOL BUILDING

D 2D 2

W 1

D 2

D 2D 2D 2D 2D 2D 2

OPEN COURT

2900 X 22600

W 1

V 1

V 1

V 1

V 1

D 3

D 4

TO

ILET

L.TOI G.TOI

W 2

W 1

W 1

W 1

W 1 W 1 W 1 W 1 W 1 W 1 W 1 W 1

W 1 W 1 W 1 W 1 W 1 W 1 W 1 W 1

W 1

W 1

V 1

V 1

V 1

V 1D 3

W 1

W 1

W 1

W 2

V 1 V 1 V 1 V 1

FIRST FLOOR PLAN

14097.34

10

20

9.0

8

14097.34

26

65

.21

48

78

.65

26

65

.21

2310.00

2310.00

D 2 D 2

CLASS ROOM - 5D 3

CLASS ROOM - 3 CLASS ROOM - 2 CLASS ROOM - 1

CLASS ROOM - 6 CLASS ROOM - 7 CLASS ROOM - 8

CLASS ROOM - 4

ENTERTAINMENT HALL

TEACHERSCOMMON ROOM

LIBRARY

LIBRARY

TO

ILET

SICK ROOM

GEN

TS

TO

ILET

LA

DIE

S T

OIL

ET

C O R R I D O R 1500 W I D E

C O R R I D O R 1500 W I D E

UP

D 2D 2D 2D 2 D 2D

NC

O

R

R

I

D

O

R

15

00

W

I

D

E

D 2

D 1

D 3

W 1

W 1

D 2

D 2

D 2D 2

W 1

D 2

D 2D 2D 2D 2D 2D 2

OPEN COURT

2900 X 22600

W 1

V 1

V 1

V 1

V 1

D 3

D 4

TO

ILET

L.TOI G.TOI

W 2

W 1

W 1

W 1

W 1 W 1 W 1 W 1 W 1 W 1 W 1 W 1

W 1 W 1 W 1 W 1 W 1 W 1 W 1 W 1

W 1

W 1

V 1

V 1

V 1

V 1D 3

W 1

W 1

W 1

W 2

V 1 V 1 V 1 V 1

FIRST FLOOR PLAN

14097.34

10

20

9.0

8

14097.34

26

65

.21

48

78

.65

26

65

.21

2310.00

2310.00

D 2 D 2

CLASS ROOM - 5D 3

CLASS ROOM - 3 CLASS ROOM - 2 CLASS ROOM - 1

CLASS ROOM - 6 CLASS ROOM - 7 CLASS ROOM - 8

CLASS ROOM - 4

ENTERTAINMENT HALL

TEACHERSCOMMON ROOM

LIBRARY

LIBRARY

TO

ILET

SICK ROOM

GEN

TS

TO

ILET

LA

DIE

S T

OIL

ET

C O R R I D O R 1500 W I D E

C O R R I D O R 1500 W I D E

UP

D 2D 2D 2D 2 D 2

DN

C

O

R

R

I

D

O

R

1

50

0

W

I

D

E

D 2

D 1

D 3

W 1

W 1

D 2

D 2

Case Study Multi Level School

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Schools

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Schools Concept | Plan | Reality

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School Projects Concept to Reality

Olievenhoutbosch School Pretoria

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Olievenhoutbosch School Pretoria

Solid Wall System

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Schools Isolated areas

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Affordable and Social Housing

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Conclusion

• Technology Change

Framecad Roll Formers

• Software –Evolution

• Projection Machines

• Foaming Agents and Machines

• Process Calculations Speed

• Re Engineered Buildings

• Distribution Channel

• Training –SASFA

• Speed Of Process Rapid Build

Systems

• Pre Engineered Buildings

• Plaster |Projection Floors

• Solid Wall Systems

• Effective Efficiencies Rapid

Build Systems

• Safe , Consistent Quality

• Availability Of Materials

• Skills Training | Sustainable

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Technology Availability = Rapid Build Solutions

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Thank You

Andre Schlunz

Cell : 0726472533

andres@framcad.com