Balau Ceiling Cladding at Hillcrest Corner, Durban

The Owen Kemp Building at Hillcrest Corner, is being refurbished and there are two restaurants coming in to the space which was Mr Price. The entire shop is being revamped and changed to accommodate these two restaurants and we have been appointed to attend to the balau ceiling work, decking and cladding of various entrance ways and some screens. This article will deal with the ceiling work.

A steel fabrication company has installed a steel structure on top of which they have installed roofing material. Our job is to now to clad the underside of the steel purlins and battens using 19 x 68mm balau deck boards with a 90mm gap which will accomodate flush mount LED lights. One can’t attach the balau deck boards directly to the steel structure so we’ve built a mini timber structure on to which we will attach the balau planks. We needed to build it so that the bottom of these boards were flush to the bottom of each I beam as the I beam itself will remain exposed and visible. Cleats and battens were attached to the steel and then painted to match the colour of the steel itself. Deck boards were then fixed to these battens with a 90mm gap. The gaps of 90mm are to accommodate a bracket which will be used to fix LED lights which will be flush with the bottom of our boards. We installed the brackets once we had already installed the boards to make it easier to get the alignment right. We drilled through the board and counter sunk a nut and bolt which will be filled with epoxy to cover the bolt head. The lighting company then installed their lights into those purpose made brackets.

On the long straight section the boards were relatively easy to install as they followed the profile of the roof sheeting which was parallel to the I beams supporting them. At the corner the I beams no longer run parallel to the profile of the roof sheeting so we installed our boards still parallel to the profile of the roof sheeting but mitred at an angle to the I beam resulting in a very neat finish. The difficulty in this type of job is drilling through the 12mm I beams to fix the cleats securely. Also the height slows the job down as one is working above one’s head on scaffolding.

On the screens we need to fix a cleat on the outside of the building between screen steel frame and balustrade. We drilled form the inside using a magnetic drill as the wall of the steel was about 8mm and it was virtually impossible to drill from the outside through 8mm of steel. Still there were at least 300 holes to drill in this manner. It is much easier to install wood on to steel if the steel has been pre drilled before fabrication.

There is still a deck to come below this ceiling and screens at various points. I will follow up with a separate article on these other items.

For a quote on your sun deck or other balau timber cladding or screening please contact us on 031 – 762 1795 or use the contact us form below.

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