Tag Archives: Design Engineering

Glazing 918 Darwin Apartments in a Single LEAP

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G.James Glass and Aluminium - Transport DivisionStage 2 of the Australian Defence Force’s accommodation upgrade to their Single Living Environment and Accommodation Precinct (LEAP) in Darwin saw the construction of 918 new apartments. It was a highly organised development that had strict protocols and required innovative task management to accomplish the project.

This upgrade will improve and better integrate the living standards and communities where single defence personnel reside. The project is being managed by the Plenary Group, recognised as international specialists in providing whole community concepts, with Woods Bagot as the architect.

G.James Role

G.James Glass and Aluminium’s Darwin office successfully negotiated the contract to supply and fit glazed windows, door frames, security doors and louvres to the various planned concepts in two locations – Larrakeyah (in the city) and Robertson (rural). Each site had individual acoustic, thermal (energy efficiency), wind loading, water penetration and bushfire requirements which formed part of the specification. To ensure compliance, G.James undertook  product modifications, the development of new systems and conducted testing for the intended suites. The contract is to be achieved in two phases of supply and installation that span over 1 ½ years.

G.James is organised to take on projects of this scope. Divisions including business support services and transport are combined with a large workforce and the latest technology to fulfil the resource requirements of larger ventures. For the Darwin project, initial discussions internally located potential branches with facilities and personnel available. Once the project was awarded, managers designated the resources available to meet the commitments.

Design

Darwin comes with stringent water and wind pressure requirements.  Product testing was needed for the new 472 Series door framing system and the 246 Series sliding door for Darwin’s conditions.

Testing for all products can be done in house with the G.James rig and amenities.
The glazing line that provides all of G.James insulated glazing units.

Energy efficiency was addressed using IGU’s.  This also helped resolve the acoustics issue at the Robertson location, as there was a flight path located overhead.

BAL Rating

Bushfire ratings are addressed at the Robertson location due to the proximity to bushland in its rural setting.  A Bushfire Attack Level (BAL) rating is given to an area or facade to determine the requirements of the materials used.  Glass and gaskets are selected that comply with these conditions from the G.James BAL Manual.

The BAL ratings applied to G.James materials have been determined from AS3959 as “Deemed to satisfy” or the prescriptive method.  The prerequisite for the physical properties of glazing materials in bushfire prone areas is to resist ember attack and radiant heat transfer.  Your local branch or G.James representative can give you further information on BAL compliant products available.

G.James Bushfire Attack Level manual stating the G.James products that are deemed to satisfy, and the Australian Standard.
Kingsford Smith Drive, Eagle farm is flanked with G.James departments and offices.

Implementation

The work was divided up in accordance with the capabilities and current workloads of various branches. Some were accustomed to this volume of work, and others were introduced to it.  The branches involved are outlined as follows, with a brief summary of the who they are, and a quote about what this project entailed for them:

Head Office

Initially, the Business Support Service division at G.James’ Head Office assisted the Darwin branch with project specific engineering, product design, contract administration and material / production coordination.

G.James Head office – 1084 Kingsford Smith Drive, Eagle Farm, Queensland
G.James has been publicly recognised for its many achievements in the industry.

“This included a review of the products to create efficiencies in product manufacture and installation. Because of the distance that products were to travel by road, we also orchestrated the design of several specific packing crates.” – John Staunton (Manager of Business Support Service).

G.James’ Head Office is charged with the role of being the central point of direction for the branches with regards to technical advice, administrative services and major project logistics & coordination. This responsibility is assisted in the fact that the Head Office is in close proximity to the Group’s major manufacturing facilities at Eagle Farm.

Maroochydore Branch

Maroochydore supplied the entry door frame, highlights and sidelights made with the new 472 Series, as well as Crimsafe screens.

The Emmegi machines located in most G.James factories allows fine work to be done faster and more accurately.
G.James Maroochydore branch – Maroochydore Road, Kunda Park, Queensland

“For 12 months, the Darwin Defence Accomodation has been keeping our commercial and Crimsafe departments with a constant flow of work. The Emmegi CNC machine has been vital part of the processing for the doors required on this project” – Darren Mahoney (Branch Manager)

Bundaberg Branch

Bundaberg worked on 475 Series fixed louvre grill and top hung sliders, Crimsafe screens for the 246 Series sliding doors, and 475 Series hinged Doors.

G.James Bundaberg branch – 49-51 Enterprise Street, Bundaberg, Queensland
Glazing packed and ready to be picked up.
Single LEAP glazing in production

“It has been amazing to see the various number of branches working together to have all items made, packaged and then transported to Darwin (without damage) ready for installation all within the tight time frames. “ – Damian Perry (Estimator)

KDC

KDC (or the Knock Down Components factory in Brisbane) cut and processed assembly kits for the 246 Series sliding doors.

KDC specialise in making components for mass production.
The KDC Crew, each with a piece of Darwin Defence Project framing.
G.James KDC – Shed 21, 2 Schneider Road, Eagle Farm

“We have only had to replace two door frames due to transit damage which demonstrates our attention to detail and ability to supply component parts to the correct specification on time to allow for efficient project management ongoing.” Jason Claridge (Branch Manager)

KDC typically make standard glazing packages for nationwide distribution.

Riverview

Riverview provided framing for the 472 Series fixed glazing and hinged doors.

“Riverview are accustomed to national distribution, being the only manufacturers of double hung windows, so coordinating this project was not out of character.  It did allow us to contribute our other skills and it was fantastic to be a part of such a combined effort.” – Ben Driessen (Branch Manager)

Loading the trucks at Riverview is easy with purpose built loading bays.
G.James Riverview branch – 15 Verrall Street, Riverview, Queensland
One of the Riverview factories houses older styles of glass that are becoming rare to find.

Along with Double Hung Windows, Riverview have a stock of unusual glass types and patterns that are invaluable to replacing period style glass.

Woodridge

Woodridge took care of the 048 Series fixed and awning windows.

“The scale of work for this job saw our manufacturing processes streamlined. It is good to know just how much work we are capable of doing.” – Garry Fulton (Branch Manager)

Production of 048 fixed and awning windows at Woodridge
Glazing frames at the Woodridge branch in production
G.James Woodridge branch – 23 Kingston Road, Woodridge, Queensland

Woodridge produces almost all products made by G.James products (except double hung), and services the area from south of the Brisbane river to the top of the Gold Coast and out to Manly and Redland bay. They also make a lot of commercial products for Western Australia, and supply 048 series hopper windows to other branches and departments.

Glass Department

The Glass Department in Brisbane manufactured all the glass for the project.

“Our glass department is built to take mass orders of this size, so implementing it was not a problem.  It is good to work on this scale of project, knowing we are contributing to such a large G.James effort.  It is what makes G.James the company we are – we have the ability to take on this kind of work as we have the most sophisticated and modern technology available to us.” – Tony Evans (Operations Manager)

G.James Glass Department – Shed 23, 2 Schneider Road Eagle Farm
The vast scale of which they process glass in the glazing sheds is an impressive sight.

The sizeable glass operations produce many different types of glass – from sizing annealed, coated and tinted, to manufacture of laminated, toughened, printed, patterned as well as IGU’s.

Mechanical and Transport Division

Mechanical and transport departments provided transport for all the components to be brought to Brisbane for coordination and shipping to site.

“We coordinate this type of work all the time – the volume of this job was quite large, however, and meant strict management of delivery – the right products at the right time.” – John Erskine (Transport Manager)

The transport division is fully equipped – including a weighing bridge.
G.James Transport division – 30 French Street, Eagle Farm, Queensland
Crates of material ready to be loaded up for Darwin at the transport shed in Eagle Farm.
Trailers being prepared for deliveries.

Transport run a fleet of trucks up and down the East Coast of Australia (Sydney to Cairns) to service delivery of the full range of G.James products.

Darwin

Darwin – project coordination and implementation.

” We would never have been able to pull it off without the support of all the other branches that got involved and helped us make this job a reality. To everyone – thanks, it was greatly appreciated.” – Scott Harris (Branch Manager)

Darwin operations manufacturing for the defence project.
G.James Darwin Branch – 97 Winnellie Road, Winnellie, Northern Territory

On Site

The products, when ready, were transported to Darwin, and fixers were sub contracted to carry out the vast workload at installation.   Attention to detail was essential as all the glass for this project was site fitted because of additional fixings in the glazing pocket required to meet the high local wind loads.

Project status

The project is in its final stages, and is projected to be complete by the end of this year (2013).  Coordinating our resources to achieve higher rates of product supply is not a new service performed by G.James.  We are capable of performing this kind of logisitical coordination to make this scale of projects feasible. G.James welcomes discussion to assess how we can provide solutions for any similar large projects.

Eagle Farm Bus Depot – A G.James All Rounder

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G.James, Gossi Park and QuickAlly Access Solutions at the Bus DepotA project showcasing the many products G.James Glass & Aluminium and affiliates produce, is due to open next week. Facets of the G.James organisation, including metal fabrication, Gossi Park & Street Furniture, glass and QuickAlly Access Solutions scaffolding, have made their own way to be part of a humble bus depot.

The Eagle Farm Bus Depot has been recently constructed on Schneider Road in Brisbane. It spreads out over a large area that is mainly car park, or bus park, for the automotive fleet. The industrial surrounds of the location require an outdoor area that is visually protected, yet bright and airy. These qualities were put in place by architects Nettleton Tribe and built by Adco, with landscape work sub contracted out to Penfold Projects.

The variation of heights gives a relaxed feel to the structural lines.
A vibrant professional feel resonates from the clean lines.

Setting the scene in an industrial neighbourhood

The brilliant colour of the louvres dominates the skyline, blocking out the surrounding visual hubbub of transport. The powder coat colours chosen, Dulux Duratec Intensity Yellow and Interpon Ultriva Sensation Gloss orange stand out from the background colour, Dulux Zeus Silver Grey. They are randomly alternated, and square and elliptical profiles were used to enhance the arbitrary nature of the feature screens.

The light and shadows play with the lines and edges creating an optical illusion that more colours are used than just the two.
Two very distinct shapes make up the patterns.

The south side of the building uses horizontal louvres. It overlooks the parking spaces for the buses.  The horizontal lines making it easier to see through these to monitor the movements of the buses coming and going, while still allowing the colour and striation to make a visual impact.

The space created is bright and spatious, lending to a pleasant area to spend breaks.
Sunshine bright even under cloudy conditions.

The north side of the building has an outdoor seating area that uses vertical louvres as a fence like barrier. They vary in height to follow the incidental theme, making the area less formal and lending more interest.

Quick Solutions

G.James Joinery or Light Metal Fabrication Department won the tender through Adco to coordinate the design, manufacture, production and installation of the louvres.

Barely discernible except on closer inspection, the louvre joints have a small gap to allow for expansion and contraction.
QuickAlly’s aluminium mobile scaffold was used to access to the top of the posts and higher louvres.
The QuickAlly ute happened to be parked in front where their customers were at work on the bus depot.

The on site installation was sub contracted to a company that utilise the QuickAlly aluminium mobile towers scaffolding system. They used this to access the top of the posts and higher louvres (or higher end of the louvres in the vertical areas). It was an ideal situation for the mobile scaffolds, as their height is adjusted simply to meet the level of the work area. They are lightweight and able to be manoeuvred easily along the louvres providing a safe, secure platform to do the installation from.

Creating atmosphere

The finishing touches, to make the place welcoming and user friendly, were provided by Gossi Park & Street Furniture. Gossi’s products were specified by the architect, Nettleton Tribe, and were coordinated through Penfold Projects.

An area is provided for breaks, where it is easy for large groups to gather.
4 of these are used – two in each area for recycling and general waste.
Using Aluminium with a timber look gives you a longer lifespan with a consistent finish.

21 settings are scattered in two areas, using Access Tables and Parkway Seats. Access Table are disability compliant, and positioning of the Parkway seating allows enough space for wheelchair use.

The “planks” of the furniture have been powder coated a reddish brown for a timber look – a colour called Headland. The frame and legs are powder coated Shale Grey – a matt metallic look. Using aluminium planks provides a longer lasting, low maintenance product, and the powder coat will allow it to retain its original look. Please note, these products are in shaded areas. Using powder coat in the sun can cause the products to heat up to uncomfortable levels.

There are four BCC waste bin enclosures to house garbage bins provided – two to each area for recycling and general waste. They are ideal for concealing waste, and easy to empty. They are the preferred bin used by the Brisbane City Council for their ease of use and stylish design. The furnishings and landscaping of the area exudes a pleasant vibe for professionals to take time out and congregate.

The light and reflections enhance the vibrant feel.
Flanked by horizontal louvres on the south side, the alcove is flanked by G.James glass through to Gossi Park furniture and the vertical louvres on the North side.
G.James products are used by many companies, and we dont know where all the product ends up, unless we see it.

A glass choice that is no surprise

On site another sub contractor has independently chosen our product for use in the buildings glazing. The overall impact of all the products that have come together under separate circumstances is a delightful find. It is good to know the quality and professionalism of G.James service and products are utilised and appreciated by many, and can come together in jobs such as these for some spectacular results.

Gasworks – A Modern Development with a Heritage Heart

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Gasworks building developmentOngoing development of a historical site located at Newstead (Brisbane), sees it transforming in stages to a new mixed use precinct. The name derives from the sites original use – the gasworks, and part of the project is to protect the heritage listed gasometer located prominently amid the gasworks buildings.

Originally built in 1863, the gasometer once stored gas in a large bladder contained within its frame work.  The Gasometer has been fully restored ensuring the ornate pinnacles and lace work beams stand as equal alongside its newly constructed neighbours.  It creates a unique contrast set amidst the strong lines and bold shapes of the modern architectural features of the Gasworks building development.

Designed by the same team that worked on the adjacent Energex building – Architect Cox Rayner and builders FKP, the buildings in this phase of construction comprise of Building A on Skyring Terrace (five storeys) and Building E on Longland St (three storeys).

Ornate pinnacle at sunset.
The Gasometer is heritage listed
The profile of the lace work makes a delightful silhouette.

G.James Role

G.James Glass and Aluminium supplied and installed glazing facades, doors, windows and some extruded sun hoods. Building A has a proposed 5 star green star rating – so energy efficiency, acoustics and air infiltration were important design factors. As such, products with proven test results were selected for use.

Building A

Building A comprises ground floor shop front retail with four upper levels of offices. The offices utilise the flush glazed 651 series glazed with IGUs made up of green glass with a low E coating for energy efficiency, a 12mm air space, and 6mm clear glass internally. This also assisted in achieving a better acoustic rating.  Spandrel panels were made with a green ceramic painted surface – a premium spandrel glass option  that maintains the look set by the vision area.

Well lit clouds light up the façade at sunset.
One of the few areas of large green expanse left in the area is overlooked by Gasworks building A

Building E

Building E was a combination of two levels of residential apartments along Longland Street, two levels of office space along the breeze way between the buildings, and a retail shop front precinct on the ground level. The offices in building E utilize the 650 series, also flush glazed, but to accommodate 11.52mm laminated glass. The glass has a low E coating and the same colour, but didn’t require the same level of acoustic rating or energy efficiency. The office glazing also incorporated architectural features such as glass fins for extra strength and sun hoods for protection.

The residential apartments use a range of glazing styles. Fixed framing used the 650 series system with 265  series awning windows spaced across the facade. Balconies feature four side supported 550 series balustrades with access through 445 series sliding doors.

Building E is on Longland St.
Balustrades, awnings, fixed windows and sliding doors are scattered along this frontage.

Shopfront Design Problem

The retail areas required a centrally glazed pocket, but the opening size and wind loads exceeded the constraints of the current system.  As many architects are looking for options to make windows larger, the decision was made to replace the current aluminium vertical members, the mullions, with a stiffer option. The new design also incorporated the ability to strengthen it further. This new addition to the G.James range is used extensively throughout the Gasworks project.

The strip of retail walk way along Skyring Terrace.
Maximising views inside and out

Practically Completed

Practical completion was achieved on the 3rd August, 2013, however there are still minor works, interior fit outs and landscape work under way.  Building E has been designed so a residential tower can be constructed above it in the future.

The Gasworks project is an aesthetic feast, and well worth a look if you are in the area. Please consult the interactive map project to get the location and a summary of the project information.

The twists in the sun shade and streaks across the glass façade make for a distinctive frontage.
The west elevation takes advantage of the views towards the river.
East view looks back towards the city, and over the gasometer.
The location of the gasometer is directly to building A’s right on Skyring Terrace.

IGUs. A sound acoustic solution?

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sound and noise acoustic control with IGUsInsulating Glass Units (IGUs) or double glazing, have been a popular solution to control noise, but they aren’t the only, or even the best solution in many cases. The aim of this article is to explain how acoustic problems are identified, assessed and provide solutions to properly address them.

Acoustics

The acoustic performance of façades is becoming more important in building design, and not surprisingly is included as part of the Green Star rating process. Although it is a small part, it’s raising the profile of sound reduction and the need to find better solutions to the increasingly worsening noise problems in today’s society.

To better understand how to mitigate sound, it is beneficial to have an awareness of a few key ideas; how sound is transferred, the way different noises are measured, know about the principles to minimise the variety of sources and coordinating appropriate solutions. Prior knowledge makes finding a solution a lot quicker and easier when you are consulting a professional.  Using advice to compare test results, it is imperative to know the difference between glass only and window system results if you want sound acoustic solutions.

Determining sound factors

Noise sources in the vicinity of a project need to be identified to best determine the most efficient glazing solutions. Look for risk sources, some examples of which are below;

  • Traffic noise from vehicles – cars and/or trucks
  • Trains
  • Planes and flight paths
  • Trams
  • Boats
  • Entertainment venues
  • Industry – a warehouse, factory plant, a truck depot up the road

For each source, be aware of the proximity and direction it will be coming from.  Future changes that will affect sound transfer must also be considered – empty or older blocks that will be used for building development, planned roads and motorways to be constructed, or a feature that may be removed to expose the project to heightened noise distribution. This information will be assessed by an acoustic engineer or glazing contractor looking at the requirements of the project.

The two main properties that contribute to disturbance from noise are the frequency and intensity level at various frequencies, or volume. Both influence the selection of appropriate glazing systems for a project.

Frequency

Sound travels as sound waves (variations in pressure) that have different frequencies. When the sound wave hits an object, this will be absorbed, transferred or reflected dependant on the properties of the object and the frequency of the sound. Below is a table that describes the frequencies associated with different noises;

Frequency distribution

Volume

The inherent volume or loudness of noise is measured in decibels (dB). Following is a table that gives you an idea of how loud different noises are;

comparison of sound

 Acoustic fact:

The human ear cannot distinguish a change in noise level of 3dB or less.

Different types of glass will assist deadening the various frequency and sound levels. To decide what the best solutions are, the window systems need to be comparable.

Measuring how much a glazing system suppresses noise

The current standard unit that is used to nominate the amount of acoustic insulation achievable is the Rw. An Rw rating is applied to many products to compare its capability to reduce sound against similar products. However, the nature of glazing systems means that frequency plays a large part in the transference of sound. So correction factors are applied to the Rw and expressed as Rw(C, Ctr).

Using Rw Data results:

When looking at results, ensure you understand what the Rw rating applies to.  Glass only data will give you just that – a figure for the glass.  It will not be comparable with a whole of system framing. Glass only data has a higher figure, and misrepresents the effectiveness of the desired glazing solution.

Rw

The Rw, or weighted sound reduction index, is a material or system’s ability to reduce sound transferring through to the other side, of a window or wall. As a rough guide, an increase of 1Rw reduces the sound perceived on the other side by about 1dB.

Rw(C, Ctr)

The correction factor for the Rw takes frequency into account. Medium to high frequency noise like conversation, and faster traffic (travelling more than 80kmh) are nominated as the C number. Low to medium frequency sound like urban traffic and planes flying overhead are the Ctr figure.
If a project has a requirement of Rw = 32(-1,-4), then the Rw = 32, the Rw+C = 31 and the Rw+Ctr = 28. The noise frequency distribution determines the correction factor figure to be used. If the predominant noise source affecting a project is traffic noise, being a low frequency problem, the Rw+Ctr figure is used. In this case, the figure to achieve is 28. If a window system is rated at Rw30(-2,-2), the Rw+Ctr = 28, therefore achieving the above requirement. The Rw number should always be used with correction factors.

Testing the Acoustic Performance of Glazing Systems

Testing is done by accredited organisations in an acoustic laboratory. The testing space consists of two rooms of known acoustic properties separated by a wall with a high sound insulation. The rooms are constructed of thick block work with the entire laboratory sitting on airbags to isolate it from ground vibration. An opening is made in the wall for the glazing system. One of the rooms is set up as a source room, and one is the receiving room. The difference in noise level measured between the rooms is used to calculate Rw, C and Ctr figures that are attributed to the system tested.

Acoustic Solutions

There are several acoustic principles that are applied to the design of glazing systems to obtain the best performance to guide you in choosing the optimal glazing products.

Glazing design

Keeping sound out is like keeping water out – any gaps provide a path by which the acoustic efficiency of a system is reduced. Even the smallest crevice or notch out of a system makes a difference. Glazing systems can be riddled with gaps – good systems minimise these as much as possible. Testing is the only way to know how any system will perform.

Product selection

Restricting sound penetration is only as good as the barrier’s weakest point. Opening or operable parts of a façade are the hardest places to control sound, but improvements in technology are minimising the issue. With changes in door design to allow for access according to AS 1428, it is good to be aware these points are made weaker, acoustically.  With glazing developments, there are solutions to help minimise this issue.

Window systems with a positive closing force are more effective at blocking out sound. Awning windows and hinged doors generally perform better than sliding windows and doors.

Acoustic seals can be used to improve glazing performance and achieve a better Rw rating. The only way this can be accurately assessed and used for compliance, is if the glazing system is tested with the acoustic seals.

An air gap between the glass panels in a glazing system can provide a degree of sound reduction dependant on the size of the air gap. Typical IGUs with an 8, 10 or 12mm air gap, the improvement is marginal. Larger double glazed air gaps are much more effective, with 50mm being the “sweet spot” with only marginal improvement beyond this. These large air gap systems are generally the best performing of any glazing system.  Jockey sash systems can also be used to create large air gaps but have size restrictions and may cause internal condensation issues.

Laminated glass can provide equivalent or better performance than a standard air gap IGU. Typically the thicker the laminate, the better the acoustic performance. Specifically designed acoustic interlayers are now available that provide an increase in performance in standard interlayers

Looking for assistance with acoustic design

Window fabricators can help you understand the acoustic performance that their products provide. If you are aware of the nature of noise pollution in the vicinity of your project, then it’s a matter of matching the correct products to minimise this problem. Look for new technology becoming available to better deal with the increasing noise issues in today’s society.

When using window acoustic data, ensure you are discussing whole of window system data. There is a lot of glass only data available, but it’s the frame that is typically the weakest acoustic point of a glazing system. The glass only data will not give you a proper representation of noise control.

5 Points to Remember

  1. Understanding Rw(C,Ctr).
  2. Gaps in Systems = sound transfer. Minimise these weak points, especially in operable glazing.
  3. Larger air gaps in between glazing layers helps acoustically.
  4. Familiarity with latest technology in sound reducing products like acoustic seals and interlayers.
  5. Test results need to be comparable. Look at whole glazing systems, not glass only test results.

Helpful Links

For further information on the subject, please refer to the suggested following resources:

Generic and Custom Plastic Extrusions, Gaskets and Seals

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PVC extruded plastic gasketThe G.James Glass and Aluminium Plastics department has been operating since 1995, and started out manufacturing just 2 products for in house use. Type and quantity of manufacturing has been growing steadily ever since. Commercial sale of products initiated 5 years ago, and now supports several industries.

G.James Extrusions

The industries that G.James manufactures PVC plastic extrusion for include – building and construction, automotive, commercial refrigeration, marine, shop front, internal fit outs and railways to name a few. They come in a range of colours and PVC types, from rigid, semi rigid and flexible, including nitrile or rubber modified and TPV (Thermo Plastic Vulcanite) or Santoprene equivalent (this has the same properties, characteristics and function, but without the Santoprene brand name) as well as Santoprene, if its specifically required. Co extrusions (extrusions made from two different materials) and bushfire (BAL) rated extruded gaskets are also available.

The G.James facilities are capable of large scale commercial production. The production lines can produce up to approximately 2000m of plastic extrusion an hour – depending on the size and shape of the profile. Products are designed up to 100mm in Circumscribing Circle Diameter (CCD). At peak times, it will use up to 40 ton of material a month – and that’s not at full capacity.

A range of extruded shapes in Flexible, Semi Rigid and Rigid PVC.
PVC dies for snap in and infill extrusions are an economical choice.
G.James generic products are held in stock to supply projects and branches as required.

Extrusion design

After initial contact, the design process involves an in depth look at what is required – the use, appropriate material for the conditions – sun and weathering, heat and chemical exposure. Identifying potential issues and mitigating them, or troubleshooting issues that may have occurred previously. Assessing die design and making a more effective proposal are all looked at prior to signing off drawings for a die to be made. Die trials are run and the resulting profile measured up for quality assurance purposes before commercial runs begin.

This process can take up to a couple of months if there is a lot of design involved, but is usually less. Ordering plastic extrusion has a two week lead time, but standard runs or more urgent requests can be processed to cater to customer needs.

Quality

During the design process

Efforts are made to ensure the die design is as beneficial and cost effective to the customer as possible. For example, a recent job started out with a profile design from a customer that required considerably expensive tooling and production costs.  Working with the customer and making a few die modifications, these costs were brought down by 60% . No impact was had on the effectiveness of the extrusion.

As an initial saving, G.James can arrange to have the tooling price amortised into the production price per metre to offset the lump sum.

Use in situ

18 years of experience by the PVC extrusion manager, Jason Clarke, ensures personal service from someone who knows how to make it work. Trouble shooting feeding problems, stopping gaskets from “popping” out of position, gasket “wave” problems and better shape design are among other issues that are addressed.

The gasket on the right is a gasket with a “wave” problem that was brought in by a customer. The straight gasket on the left is a G.James solution in a quality correction design process.
A 200mm length of plastic extrusion is carefully cut and assessed to make ensure the gasket is made correctly.

Point of manufacture

A length from every roll of extruded plastic is tested to ensure a quality product. Measurements are taken and information is recorded and stored so it can be tracked back to when and how it was made. Materials that work into other G.James products are also trialled for a suitable fit on completion to ensure a whole of system customer service.

The shadow graph enlarges the shape 10 times to provide accurate measurements.
18 years of experience by the PVC extrusion manager, Jason Clarke, ensures personal service from someone who knows how to make it work.

Back end quality control

G.James conduct investigations into existing scenarios that are having problems. Extrusion and glass checks, incorrect use and out dated design issues can be looked at to assess the cause of any issues. Advice is given on the findings, whether it is a change in plastics die design, or other members that are found to be out of tolerance.

Manufacturing Process

It’s a short but interesting manufacturing process. The material comes in pellet form that is control fed through a hopper into a spiralling screw or ram. The pellets are heated, mixed and compressed as they are fed through the spiralling screw, and finally forced through the die into its final shape. After the gasket is extruded, it is immediately cooled in chilled water, and then dried before being cut into designated lengths and boxed, or rolled onto a spool.

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Recycling

All off cuts of plastic extrusion are recycled on site. They are shredded and prepared to go through the same hopper feed and production process. As a quality control issue, recycled material is only used on non-structural gaskets, such as fly screen splines.

All off cuts of PVC extrusion are recycled on site. It is shredded and prepared to go through the same hopper feed and production process.
The screw has 3 sections, the first, heats the pellets, the second mixes the molten mixture and the third controls the flow to ensure the material oozes out consistently.
This is the last part of the second section of the ram that ensures all the mixture is molten and well combined.

Brisbane designed and made, supply is distributed Australia wide, with much of our standard range available off the shelf at any G.James branch. For more information on product and supply, call the PVC manager, Jason Clarke, on 0403 352 703 or 07 3815 4908. Keep up to date by looking up the PVC page on the G.James website.

51 Alfred St – Efficiency in commercial design

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51 Alfred St A green star accredited office block constructed in one of Brisbane’s growing commercial areas, 51 Alfred St comprises of a ground floor retail space with 8 levels of office space above.

51 Alfred St, Fortitude valley was constructed by Blackwatch Projects, to the design of Willis Greenhalgh Architects. The sustainable design intended to minimise its carbon footprint was a urban friendly solution to council and the community. It includes a smart foyer, featuring floor to ceiling full height glazing on two street frontages, and superb views to the city above level 2.

G.James Role

Development of the project went from initial “design in principle” early drawings to installation of the finalised glazing products. The project had a short time frame, and lead times for manufacture and installation had to be carefully managed.

Known for its location, the street number is prominently positioned.
The south western face has vertical sunshades, composite cladding and a two tone spandrel area.
On the corner of Alfred and Julia Streets

The building incorporates shopfront glazing from ground floor to level 1 that used the 850-500 and 650-500 series framing systems. Hinged doors are 475 or 476 series, with 445 series sliding doors (as on some upper levels, also). G.James picked up the cladding package for the ground floor columns, which was made and fitted by the G.James Joinery department. QuickAlly, G.James scaffolding division assisted with providing access to entry the shop front entry glazing.

Upper levels utilizes the 651-500 curtain wall suite. The design had to allow for the addition of randomly placed aluminium horizontal and vertical fins that use different shapes in keeping with the difference in direction. There are also composite cladding positioned irregularly across the southern face, and frames the edge of the eastern face.

All of the differences in cladding and sun shading incorporated into the curtain wall, made for a wide variety of specialist panels.  This required coordinating the transportation and installation of the panels to be highly organised. Careful design, preparation and on site works were given particular attention at the corner feature to achieve the seamless angled cladding and glazed finish that spans the full height of the buildings office area.

The north face has horizontal sun shade louvres.
The reflection gives you an idea of the view from the building.

Glazing selection

IGU’s were used in the vision areas of the tower to combat city noise and provide sufficient thermal and solar efficiency to achieve the green star accreditation.

The spandrel area uses a colourlite backing on clear glass to achieve the opaque finish. Charcoal and White were used to keep in theme with the buildings monochromatic scheme that highlights the slash of copper that makes the corner feature stand out.

Installation

There was no tower crane available for this job, so all of the framing hoisted into the floors from a crane on the street below.  Including the “Spider Hulk”, the name of the lifting crane that positions the panels into place.

51 Alfred St

“Spider Hulk” is the name of the machine that lifts the panels into position on the building.

Early design intended the framing to be fixed into cast ins – a quick and minimal fixing method that utilizes the concrete structure to enclose and support the framing. Later changes, however, meant that the frame fixings were redesigned and engineered to be fitted with bolts into the concrete.

The ground floor was site glazed as the size of the glazing was so large. There was also a curtain wall panel that needed to be site glazed. This requires extra safety measures and some specialised techniques to carry out.

Blackwatch had a tight program which was run like clockwork. It enabled overall job satisfaction with the resulting installation of the work performed by G.James, and we look forward to working on further projects together.

Project update: Icon Ipswich

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Aerial view of Icon IpswichThe Ipswich City Heart building is the first stage of developer Leighton Properties‘ $1 billion Icon Ipswich project. Designed by Cox Architecture, it is a 42m high, nine-storey office tower which comprises 15,000 square metres (sqm) of commercial space together with 750sqm of ground floor retail and 200 car parks. The building is an A-Grade commercial development, and is targeting a 5 Star Green Star and a 4.5 Star NABERS rating. Nearly all of the office space in the building has been leased to the Queensland government for a term of 15 years. Construction on the project is being overseen by Hutchinson Builders. 

G.James’ Role

G.James has been engaged to supply and install window wall and curtain wall along the height of the building. G.James is also providing structural glazing to the basement, ground and upper ground floors, as well as a structurally glazed roof-lite to level 1.

Visual Mockup

Prior to starting on site, G.James constructed a visual mockup to provide a full-scale representation of the colour selection as designed for the building. The mockup allowed colour selections to be seen in proper context, under natural lighting, to ensure the building gives the desired visual effect.

The Façade

G.James is using the 546 series system with black anodised framing for the window wall on the western façade with independent vertical sunshades installed between structural slabs. These vertical fins are in 5 special anodised colours (listed below) which are selectively positioned on each floor to create a pattern.

  • Sapphire Matte Tornado Red
  • G.James Residential Bronze
  • AAF Maroochy Sand
  • G.James Champagne Bronze
  • G.James Matte Gold

G.James is using our 546 series system with black anodised framing for the curtain wall to the eastern façade, incorporating gold metallic Alpolic projections and black anodised horizontal sunblades.

The southern and northern faces of the building are a mixture of both window wall and curtain wall fully encapsulating the floors.

The vision glass used in the building is made up of Solarplus DLE55 Low-E glass on green, configured in argon filled IG Units.

The shadow boxes are made up of 6mm green heat-strengthened glass, using 5 different colours (listed below) of backing sheet selectively positioned on each floor to create a pattern.

  • Dulux PVF2 Mars Red
  • Dulux PVF2 Gold Dust
  • Dulux PVF2 Brassed Off
  • Dulux PVF2 Wax Way
  • Dulux PVF2 Blonde Girl

PVF2 paints have an excellent service life and are highly resistant to fading. These properties make PVF2 finishes a low maintenance finish of choice for large projects.

Current Status

G.James started site installation in late January, and will continue until approximately May. Overall, construction on the building is progressing well, the concrete structure of the building has been completed and  practical completion is expected to be third quarter of 2013.

UTS Broadway – Visual Mockup & Prototype Testing

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UTS Facade Mockup - differente angle

This stunning building juts across the skyline.

Image courtesy of Architects:
Denton Corker Marshall Pty Ltd.

About UTS Broadway

G.James has been working towards readiness to install the facade since winning the job last year. Recently G.James has been conducting tests using full scale mockups of sections of the façade to test both the appearance and function of the façade.

Visual Mockup

The visual mockup stands 7.6 metres tall and 6.8m metres wide, each panel is 3.8 x 1.4 metres &  weighs approximately 290kg. The aluminium screens for each panel weigh an additional ~90kg. The completed façade will be somewhat larger than our mockup – standing a full 14 stories tall. The visual mockup is for testing the appearance only – the actual facade (as well as the prototype for engineering tests) uses extrusions purpose made for the UTS project – around 30 new extrusion dies have been made to produce the extrusions for the this project.

What do we do with the mockup after we’re finished?

The visual mockup will remain on site until the mockup rig is needed for a few project. G.James typically creates a similar mockup for a new project every couple of months.

Engineering Tests

G.James has also created a prototype on our engineering test rig to carry out a range of engineering tests. The test setup is a sealed chamber, with the external side of the facade mockup covering the ‘open’ side. The chamber contains jets to spray water, and pumps in/out air to increase or decrease the pressure in the chamber. The tests conducted measure the performance of the facade under both positive and negative pressures, as well as against the penetration of water.

Positive pressure vs. Neutral pressure

Static Pressure Structural Testing

This test measures deflection at various points of the facade using potentiometers fixed to a frame parallel to the internal face of the facade. The deflection is measured under both positive and negative static pressures, across a range up to the test maximums. These pressures simulate the loading the facade will receive from wind. The pressures used for the test differ from project to project, and are determined with a site analysis by engineers. Deflection must stay within certain bounds to meet Australian standards – though these vary on the exact makeup of the facade. In the photograph to the right the deflection of the glass in a structural test results in distortion of the reflection in the glass (comparison against neutral pressure below).

Static Pressure – Air Infiltration

Air infiltration rate measures the amount of air penetrating the facade at a given pressure. This is necessary to determine air conditioning requirements for the building – the amount of air infiltration has a large effect on the efficiency of the building.  The amount of air infiltration is measured by pressurizing the chamber, whilst a plate with a hole of known size is fitted in the chamber. The rate of air flow out of the pressurized chamber is then measured. The facade face is then completely sealed off with plastic, and the flow of air is  re-measured. The difference between the two measurements is the amount of air that was penetrating the facade.  This test carried out with both negative and positive pressures. The rate of air infiltration must be within certain bounds to meet Australian standards.

Water Penetration

Water penetration tests spray water onto the surface of the facade at a rate of 3L/m2/minute. Tests are conducted with a range of constant pressures applied to the chamber, and also with a range cyclic pressures as the water is sprayed. Water penetration is not quantitatively measured, the cause of any leaks found must be rectified.

Façade installation commencing soon

G.James is anticipating starting on site at UTS Broadway in the first quarter of 2013.

Newington College – Sesquicentenary Building Project

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The new curtain wall at Newington College

G.James has recently finished work on the Sesquicentenary Building Project at Newington College in Bankstown, Sydney. The bulk of this project comprises two new combined buildings – The Lawrence Pyke Science Centre and The Tony Rae Resources Centre Library. The project was designed by Budden Nangle Michael & Hudson Architects, and builder A W Edwards was contracted to construct it.

Foyer to the building.G.James’ work on the project comprised the design, supply and installation of windows, doors, curtain walls, glass walls, glass canopies, a glass greenhouse, aluminium cappings and soffits– utilising our 850-500, 651, 451, 475 and 476 Series frames. Jockey sashes from our 150 Series were required for most windows, and some windows also featured curved heads. G.James’ Sydney Commercial Façades division carried out the work on this project.

Noise Reduction

Acoustic laminate was used extensively throughout the project to minimise disruption to classes from external noise. Typically 12.76mm acoustic laminated glass was used externally and 10.76mm clear Low E coated ccoustic laminated glass was used internally in jockey sashes and internal skins. This was an important consideration as Newington College sits directly below the approach flight path into Sydney Airport with approaching aircraft flying very low directly above the school.

Curtain Wall Glazing

Curtain wall glazing.Four “curtain wall” sections were defined by the Architect and included in G.James’ scope of work. Two of these were fabricated as 850-500 Series structural glazed curtain walls. The Stair glazing used the 850-500 Series structural glazed frame as a window wall fitted between steel horizontal supports. Coloured back glass was used to infill between the frames and hide the steel. Jockey sashes and secondary frames were used behind these frames to create large cavities for acoustics. On one curtain wall an additional 850 Series frame was used as an internal frame to provide the nominated 400mm airspace.

Dual skinned Curtain Wall

The most prominent feature of the building is the final curtain wall  – pictured at the top of this post. This is a dual skinned arrangement with the outer skin built out from the building by a metre with three horizontal steel trusses. The glazed height of this wall is approximately 9.4m and is glazed with pieces of glass each approximately 4.7 m high by 2m wide – weighing a hefty 300Kg. This glass is supported by glazing channels top and bottom, and also by 15mm annealed glass fins vertically. The internal glazing skin comprises G.James’ 450 Series frame fitted with the flush face to the inside and incorporating jockey sashes fitted in-line with the fixed glass for access and maintenance. The metre wide cavity between the glass is ventilated and includes 600 mm wide horizontal and vertical automated tracking sun shades installed into this space by another contractor.

G.James has also supplied and installed soffit linings below this glazing, metre wide cappings over the cavity, and also to the other curtain walls. Several glazed awnings and a glazed greenhouse were also completed.

Official Opening

The buildings will be officially opened in July as part of the 150th anniversary celebrations at Newington College.

UTS Broadway glass & aluminium façade

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This stunning building juts across the skyline.

Images and content courtesy of Architects: Denton Corker Marshall Pty Ltd.

We are proud to announce that G.James will be manufacturing the futuristic glass and aluminium façade for the University of Technology (UTS), Sydney Faculty of Engineering and Information Technology building.

This challenging assignment will add to the growing list of landmark Australian buildings which G.James has contributed to. G.James will manufacture the curtain wall, window wall and distinctive aluminium sun shades for the project.

Manufacturing of the façade will commence in October 2012.

The Project

The UTS Broadway is a part of the UTS master plan to redefine the Ultimo campus and will house the Faculty of Engineering and Information Technology.

The design of the structure will add twelve levels of teaching & research laboratories, extra lecture theatres, seminar rooms and academic offices, while leaving ample pedestrian access through the ground level.

The striking design is described best by architects Denton Corker Marshall Pty Ltd:

The surface of each plate is creased to form a series of ‘gills’, visually reinforcing the sense of plate as skin and creating a semi-transparent screen. Further permeability is established by perforating the skin of each plate. Using the ‘1’s and ‘0s’ of binary code, the alphabetical character string for ‘University of Technology Sydney Faculty of Engineering and information Technology’ is translated and re-worked to create a perforated pattern on the skins.

The 14 level construction will be the first 5 star green rated building on campus, and has a focus on environmentally sustainable practises.

The design is intended to reduce energy requirements by 30–45% with features such as night purge ventilation, an under-floor air distribution system, and the iconic binary sunshade. Daylight and fresh air are utilised to reduce dependence on air conditioning and artificial lighting.

Current Progress

Demolition, which included the removal of three existing buildings to make room for the structure, was completed in October 2010.

Excavation for the building has now finished (over 60,000 cubic metres were removed from the site), and the first footings have been poured, as well as concrete for the car parks.

The project, expected to cost $170 million, is scheduled for completion at the end of 2013.

About the Architects

In July 2009, UTS announced the winning design, submitted by Australian architectural firm Denton Corker Marshall, from over 60 international entries.

Selected by UTS representatives, the City of Sydney, and the New South Wales Department of Planning, the design for the Information Technology and Engineering building was chosen for its aesthetic appeal, as well as its functionality and sustainable qualities.