This residential project in Sunset Beach, Milnerton, required the addition a new floor above the existing garage. Cobute supplied its precast shutters for beams, slab and staircase, designed by Pr.Eng. Mark Labrum.

The Cobute precast interlocking systems

The Cobute systems are designed as R.C. precast permanent shutters, minimising shuttering on site, allowing to save time on carpentry work. This therefore contributes to making the installation much faster than other systems, with great structural performance.

The Cobute precast decking

The slab system consists of three modular elements that interlock with precision; precast ribs, panels and polystyrene blocks, which act as void formers, while contributing to thermal and acoustic insulation of the structure.

For this project, the slab system was designed at 250mm thickness for the surface and 200 mm thickness for the balcony, allowing for a 50mm weather step. In addition, Cobute supplied its beam-in slab system, which consists of multiple ribs without panels. Its purpose is to cater for point loads on the floor above.

Beam-in-slab by Cobute to provide additional reinforcement for point loads.

Beam-in-slab by Cobute to provide additional reinforcement for point loads.

The Cobute precast stairs

The staircase designed by Cobute consists of modular elements that create the outer shell of the structural element. The left and right girders provide the sides with a waist depth that varies according to the engineer's specifications; the precast panels create the stair soffit with the interlocking ribs, while the risers are connected with the use of bending wire. Lastly, the tread is cast with the concrete pour. 

The components are reasonably light, and easy to manoeuvre on site without the use of lifting equipment. The Cobute staircase has no standard dimensions and each unit is custom-made to suit the individual project specifications. However, no round or spiral shapes can be accommodated. 

Concrete stair by Cobute after the concrete pour

Concrete stair by Cobute after the concrete pour

Cobute precast beams

The precast shutters for beams consists of two L-shaped elements of precast concrete, with reinforcement cast in, to dramatically reduce carpentry costs as well as minimise the need for timber shutters. UCT laboratory tests show that the beam shutters are as good, if not slightly better than conventionally cast in-situ beams, in both shear and bending.

Beam installation and shuttering before casting. 

Beam installation and shuttering before casting. 

We are glad our shutters could add value to the project by delivering a premium structure while reducing both resources and time spent on site. 

Get in touch to see how Cobute can add value to your next building project!