Variegated Precast Concrete Façade at the V&A Waterfront
As one of the leading precast concrete manufacturers in Cape Town, we were delighted to be appointed to work on the Investec new office development at the V&A Waterfront. Our team at Cape Concrete was tasked with delivering a unique, variegated precast concrete façade, which would not only provide a low maintenance aspect but also age appropriately and authentically, giving the building a unique look and feel.
The design of the precast façade presented its own challenges. We were appointed in October 2022 and the design was not complete before construction had begun. However, working closely with Sutherland Engineering, we were able to fulfill the design requirements for the façade and deliver a final product that exceeded the client’s expectations.
Despite this setback, our team was determined to deliver a top-quality product. The scourged panel required a CNC cut HDPE liner and the scourged lines ran vertically. Due to the different heights of each floor, we had to cut the liner from floor to floor, resulting in a horizontal hairline that became highly visible. However, through collaborative efforts with Igual Project Managers, WBHO, and SVA International, we were able to apply Keim, a product for blending concrete colour variations, and hide the horizontal line on the panels.
Our team also overcame corrosion concerns, given the building’s proximity to the ocean and the Port of Cape Town, by ensuring that the hanging steel hanging brackets received both a galvanized and epoxy coating. With support from Azeez Davids and the Hilti Engineer’s, we were able to source and procure the necessary equipment and solutions to get the job done to the highest standard.
Still under construction one can start to see the architect’s idea taking shape into what is a blend of glass and variegated concrete beautifully applied to this very unique facade.
The initial design called for a thicker panel, but we were able to reduce the panel thickness, thus offering the client a cost-saving solution.
To meet the demands of the main contractor’s program, we decided to increase the strength of the concrete mix, and apply steam curing, thus enabling us to double cycle our moulds daily and cast two products per mould per day. This required an 18-hour shift in our factory, but our team rose to the challenge and delivered on time.
This landmark building, featuring 535 panels in various finishes, including charcoal, green charcoal, normal concrete, scourged/corrugated, and grinded, culminates in an interesting and eye-catching look and feel. The volume of concrete used was 220m³. The project is scheduled to be completed in early April 2023, which makes it a remarkable 6-month, precast program.
We would like to take this opportunity to thank all the professionals and companies involved in the project for their hard work and dedication. Special thanks to Liam Walton and Sean Couzyn from Sutherland Engineering, Ben Day from Igual Project Managers, Mark Brooks and Greg Durheim from WBHO, Azeez Davids and his engineers at Hilti and Wolfgang Höger from Keim. We truly appreciate their contributions to the success of the project.