Massmart Distribution Centre

Project Details:

Value: R239.2m
Date: 2020
Client: Redefine Properties & Van der Merwe Venter 11
Architect: Francois du Toit Architects

The Isipani Construction team completed a new centralised distribution centre for Massmart in December 2020. The project included a large warehouse, a CDS office and two pilot offices for a total covered area of 67,000 m². The Massmart development is in the Brackengate 2 Business Park on the corner of Bottelary Road and Cecil Morgan Drive in Brackenfell, a prime 160 ha industrial precinct with easy access to the N1, N2, the Stellenbosch Arterial Road and the R102.

The massive warehouse structure is the most striking feature of this development. It has an under-roof space of 52,000 m², which is equivalent to seven rugby fields. The structure required 80,000 m² of roof sheeting and 1,140 t of steel. The warehouse’s continuous roof sheeting system was designed to minimise weaknesses in the roof area and prevent leaks that could damage the goods stored inside the warehouse. It is one of the largest single-roof surfaces in Cape Town and the largest under-roof warehouse undertaken by Isipani Construction. At its centre, the vaulted roof has a maximum height of 15.5 m.

The structure consists mostly of steel elements, not traditional brick and mortar. Rheinzink cladding, a material made of a titanium zinc alloy, was used to give the building a modern finish. The warehouse does not a conventional concrete floor, but a floor of reinforced steel fibre to create a surface with fewer joints to decrease maintenance and a smoother surface for forklift operators.

The project started on 10 October 2019. The concrete infrastructure was installed by the end of December 2019 and included over 350 concrete bases and pre-cast columns. Tilt-up panels and columns were used to increase the speed of construction. The slabs were first cast on the building’s floor slab and then lifted upright onto their foundations to construct the exterior walls and columns.

The project came to an abrupt stop in March 2020 when a national lockdown was declared due to the Covid-19 pandemic. With 50% of the project completed, 400 workers had to be sent home. The original completion date set for 14 September 2020, had to be extended to 8 December 2020, the date the tenant required full occupation. Once the lockdown was lifted, amid strict Covid-19 prevention measures, the project required round-the-clock teamwork to meet the new deadline.

The distribution centre has a number of green design elements. The building itself is orientated to minimise temperature fluctuations and improve overall thermal comfort. Water-saving designs include air-cooled air conditioning with inverter-type technology to save 25% on electricity. Energy-efficient LED light fittings and motion sensors were also installed throughout the building.