Medindie Project
Commercial
Taylors Rd, Aberfoyle Park SA 5159
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Architectural Aluminium Screens and Structural Steel Framework – Commercial Installation
This project involved the design, fabrication, and installation of a high-performance perforated aluminium screen system, supported by a custom-engineered structural steel framework. Spanning 180 square metres, the perforated aluminium screens serve both as a striking architectural feature and a functional element, providing solar shading, privacy, and improved airflow across the building’s façade.
The structural framework was fabricated from 100 x 50 x 4.0 mm RHS mild steel, providing the necessary strength and stability for the screens. These framework members were attached to the existing concrete structure using M12 grade 8.8 structural bolts through 10 mm laser-cut cleat plates, ensuring a secure and durable connection. With the structural steelwork weighing 16.6 tonnes, the installation was engineered for efficiency, utilising a bolted connection system that required no welding on-site.
To ensure long-term performance in an external environment, all structural elements were finished with a 3-part paint system in Surfmist, which provides excellent weather resistance and durability. The paint system included a primer, a mid-coat for additional protection, and a topcoat that provides UV and corrosion resistance, ensuring the steelwork maintains its integrity and appearance over time.
The aluminium perforated screens were powder-coated in Surfmist, matching the structural elements to achieve a cohesive aesthetic. The powder coating offers superior finish quality, durability, and resistance to the elements, ensuring the screens remain functional and visually appealing for years to come. The perforation pattern was specified to meet both design and performance needs, balancing light transmission, ventilation, and privacy.
The final system was assembled and installed using mechanical fixings, ensuring both precise alignment and structural safety. The perforated screens were fixed to the steel framework with concealed fasteners, providing a clean and seamless exterior look while ensuring easy maintenance.
This project highlights our expertise in delivering highly technical architectural and structural solutions, with a clear focus on design cohesion, material selection, and durability. By combining precision fabrication with performance-driven finishes, we achieved a successful, long-lasting installation tailored to the client’s needs.
This project presented several complexities during both the fabrication and installation phases. One of the primary challenges was the fabrication of multiple large structural frames, each measuring 8 metres by 3 metres. These frames were crucial to support the perforated aluminium screens and required precise engineering and careful handling due to their substantial size and weight.
On-site, limited access posed a significant hurdle, as the terrain around the building was undulating, and dense foliage obstructed conventional machinery access. With access only available from one side of each building, it was necessary to use a 16-tonne city crane to lift the large frames over the building. This added complexity to the installation, requiring careful coordination between the crane and installation teams to ensure safe, precise placement of each panel.
The installation also took place during the winter months, which introduced additional weather-related challenges. The team had to contend with cold temperatures, rain, and wind, all of which could impact both safety and the integrity of the materials during installation. Despite these obstacles, the team successfully executed the project with minimal disruption, ensuring all frames and screens were installed safely, securely, and on schedule.
1. 100 x 50 x 4.0 mm RHS Mild Steel (Structural Steel Framework)
The primary material used for the structural framework supporting the perforated aluminium screens. This Rectangular Hollow Section (RHS) mild steel was chosen for its strength, versatility, and ability to support the large frames. The 4.0 mm wall thickness ensured robust load-bearing capacity, while the 100 x 50 mm dimensions provided the required structural stiffness.
2. 12 mm Mild Steel (Cleat Plates)
Used for the laser-cut cleat plates that connected the RHS framework to the existing building structure. These cleat plates were 10 mm thick and were bolted to the structural steel frame with M12 structural bolts for secure attachment to the columns and concrete slab.
3. 180 m² Perforated Aluminium Sheets (Screens)
The perforated panels were made from aluminium sheets designed to provide both aesthetic appeal and functional benefits, such as solar shading and ventilation. These panels were fabricated with a perforation pattern to match the architectural specifications, providing the required visual and environmental benefits.
4. Powder Coating (Surfmist)
Both the aluminium screens and structural steel framework were finished with Surfmist — a light grey colour from the Dulux powder coating range. The powder-coated aluminium screens offer high durability and UV resistance, while the structural steel was treated with a 3-part paint system to ensure long-term weather resistance and match the aesthetic requirements.
5. M12 Grade 8.8 Structural Bolts
These bolts were used throughout the project to mechanically fix the structural steel framework to the building’s existing columns and slab. The M12 grade 8.8 bolts provided high tensile strength and were selected to meet the project’s load requirements and ensure structural integrity.
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