Medindie Project

Project Details

Client:

Ronald Richardson

Tags:

Residential

Location:

Medindie, SA 5081

Hey guys, Riley here from ProFab Engineering.

We’re onsite in Medindie, checking out a residential extension we’ve been working on.
This job involved 7 tonnes of structural steel, including crank beams over the garage and exposed fascia beams — one of which is a 15 metre span.
If you’re looking for high-quality structural steel for your project, reach out to the team at ProFab Engineering.

Project overview

This project involved the fabrication, supply, and installation of 7 tonnes of structural steel for the residential expansion of a garage, kitchen, and outdoor entertaining area. The project required precision fabrication and on-site welding to meet both structural and aesthetic requirements.

A key feature of the project was the garage expansion, which included the fabrication of cranked garage beams. These beams were carefully designed and fabricated to ensure the correct offset for proper alignment within the structure. The 9-meter kitchen header beam, weighing 1.4 tonnes, was another focal point of the project. This large beam spanned the kitchen space, supporting the weight of the upper structure and ensuring a seamless, open design for the expanded area.

The installation also included a 15-meter fascia beam, which presented additional logistical challenges due to its size and the need to maneuver it through the narrow residential access. To address this, careful planning was required to manage the installation process, which included utilizing cranes and rigging equipment to safely position the large steel components.

In addition to these structural elements, four exposed fascia beams required on-site welding to create a flawless, seamless finish. This welding process ensured that there were no visible joins or welds, maintaining the high aesthetic standards for the exposed steel elements of the project.

For the coating, red oxide primer was applied to all internal steelwork, offering corrosion protection. The exposed steelwork was coated with Zinc Anode 402 primer to ensure a durable, long-lasting finish capable of withstanding external elements.
Throughout this project, we adhered to the relevant industry standards such as AS 4100 for structural steel and AS/NZS 4680 for galvanisation, ensuring the steel components were robust, secure, and protected for long-term use.

Complexities:

The complexity of this project stemmed from several factors, particularly the logistics of delivering and installing large-scale structural steel components in a residential setting. Key challenges included:

Large Steel Components and Tight Access: The project required the delivery of significant structural steel elements, including the 9-meter kitchen header beam, 15-meter fascia beam, and cranked garage beams, all of which were delivered on a semi-trailer. The site had limited access, with the steel needing to be moved down a single driveway, which presented logistical challenges for both delivery and unloading.
Managing Existing Utilities and Site Constraints: With the site located in a residential backyard, there were existing utilities and obstructions that had to be carefully managed. This required coordination with utility providers and meticulous planning to avoid any disruptions to services during installation.
On-Site Welding and Finishing: The four exposed fascia beams required on-site welding to ensure seamless connections and no visible welds or joints, which was a time-consuming process. The welding had to be performed with precision, followed by a thorough finishing process to match the aesthetic quality expected for exposed steel elements.
Handling of Heavy Components: The kitchen header beam (weighing 1.4 tonnes) and the fascia beams required precise handling and positioning, adding further complexity to the installation. Due to their weight and size, the team used cranes and rigging equipment to position these elements accurately during installation.
Coating Requirements: In addition to fabrication, we had to apply the appropriate coatings. Red oxide primer was used for the internal steelwork, while all exposed steel components were coated with Zinc Anode 402 primer to ensure long-term protection from the elements. This coating process required careful planning to ensure the steel was adequately protected while achieving the desired finish.

Materials:

Structural Steel (Various Beams and Supports):
The project used 7 tonnes of structural steel, including cranked garage beams, the 9-meter kitchen header beam, and 15-meter fascia beams. These beams were fabricated from mild steel for strength, with precise dimensions for load-bearing. The cranked garage beams were offset for alignment, while the kitchen header beam spanned 9 meters. The fascia beams covered a 15-meter length and required careful planning for fabrication and installation.

Red Oxide Primer:
Red oxide primer was applied to internal steel components like beams housed within the structure. This primer provides corrosion resistance and ensures strong adhesion for subsequent finishes. It is ideal for interior applications, protecting steel from moisture and environmental factors.

Zinc Anode 402 Primer:
Zinc Anode 402 primer was used on exposed steelwork, including fascia beams. It provides superior corrosion protection for external steel, shielding it from weathering and environmental corrosion over time, ensuring durability and longevity.

Welding Consumables:
Welding consumables like electrodes and welding rods matched the mild steel used in the beams. These were critical for on-site welding, especially for the fascia beams, ensuring seamless connections without visible joints.

Structural Bolts and Fixings:
Structural bolts and fixings were used to secure beams during installation. These fasteners ensured that the large beams were anchored firmly to the surrounding structure.