Precast Issue 1 2015 by Isikhova Media

ISSUE O E • 201

THE CMA – QUALITY CAST IN CONCRETE

FACTURER

S AS

NCRETE CO

• Durban Bluff project puts watertight jacking pipe to the test

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• Concrete masonry pitfalls and solutions

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• CMA’s new Executive Director

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CONTENTS

COVER STORY 14 WATERTIGHT JACKING PIPE PASSES TOUGHEST TEST

PEOPLE & EVENTS 4

CMA FEEDBACK SESSION PUTS MEMBERS IN THE PICTURE

NEW EXECUTIVE DIRECTOR TAKES OFFICE

AWARDS FOR EXCELLENCE 2016 PREVIEW

12 LATEST CMA MEMBERS

28 26

INDUSTRY FORUM 30 Industry news from Kaytech, Rocla, Echo, Birkenmayer, Mapei and Sika

FEATURE STORIES 16 CONCRETE MASONRY PITFALLS AND SOLUTIONS 21 PRECAST PRODUCTS USED EXTENSIVELY IN WATERFRONT PROJECT

Postal Address: PostNet Suite 8612, Private Bag X32, Kempton Park, 1620 Tel: +27 11 805 6742

outer

Design, layout and production: Joanne Brook

which is taking place under the Transnet Freight Rail • CMA’s new Executive Director

• Concrete masonry pitfalls and solutions • Durban Bluff project puts watertight jacking pipe to the test

them. No person connected with the publication

Fax: +27 11 783 2677 Website: www.isikhova.co.za Publisher: Andrew Meyer Tel: +27 11 883 4627 Cell: 082 456 5175 E-mail: andrewm@isikhova.co.za

PRECAST | ISSUE ONE | 2015

cast in conc

Reserve

near

Wentworth

Station in The Bluff, Durban. The project is being handled by Franki Africa, one of the most difficult

publishers nor the CMA accept responsibility for of this journal will be liable for any loss or damage

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publication are not necessarily those of the

Postal Address: PO Box 651793, Benmore, 2010, South Africa

storm-

ing the pipe jacking process

The views and statements expressed in this editor or the publishers and neither the

diameter)

water drainage pipes dur-

Tel: +27 11 883 4627 E-mail: joanne.studio@isikhova.co.za

Publishers: Isikhova Publishing & Communications

Tel: +27 11 883 4627

Two of five 100m (1 800mm

Advertising: Wally Armstrong Cell: 083 701 3278 E-mail: legweak@mweb.co.za

IATIO

Website: www.cma.org.za

THE CMA – QUALITY CAST IN CONCRETE

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E-mail: admin@cma.org.za

ON THE COVER

ISSUE O E • 201

Tel: +27 11 883 4627

Fax: +27 86 524 9216

Journalist: Julian Kraft

Physical Address: 16 Horn Street, Chloorkop, Kempton Park, 1620

28 GREENLOCK EARTH BLOCK MAKES GAUTENG DEBUT

NCRETE

PRECAST is the official journal of the Concrete Manufacturers Association NPC (CMA)

26 REMACON SCORES A HIT WITH MODULAR WALL UNITS

22 LOCAL BOY MAKES GOOD IN US HOME PAVING MARKET

below-the-water-table pro-

sustained as a result of action following any

jects the company has undertaken in recent years.

statements or opinions expressed herein. The

The pipes were manufactured by CMA member,

Concrete Units, and are being installed below the

be reproduced or transmitted in any form or by

water table in ground which consists of running

any means, electronic or mechanical, including

sand and the consistency of soup. Butt-ended

photocopying, recording, or any information storage retrieval

joints, steel bands and O-rings ensure that the

system, without prior written

pipes are watertight and have improved alignment

permission from the publishers.

characteristics.

PEOPLE & EVENTS 2

CMA FEEDBACK SESSION FOR 2014 SHOWS THE WAY AHEAD The Concrete Manufacturers Associa-

Installation certification

the QCTO to work with it in establishing

tion’s annual Feedback Session was held

Last year the CMA commissioned Tjeka

one and thereafter devise a training

at Emperor’s Palace in Kempton Park,

Training Matters ( T TM), a specialist

programme leading to certification of

Gauteng, on February 18.

training company for the construction

installers qualifying through it.

The purpose of the Feedback Session

industry with branches in Krugersdorp

As part of the morning session Graham

was to supply CMA members with infor-

and Henley-on-Klip in Gauteng, to inves-

Smith, General Sales Manager, Technical

mation about the latest developments

tigate how installers of retaining blocks

Sales, of Sephaku Cement, set out the

relating to precast concrete, as well as

and paving blocks could obtain certifica-

latest advances that have been achieved

update them on the CMA’s activities and

tion as a first step towards establishing

by Sephaku in growing its business.

initiatives in the past year and what it

standards of proficiency for this work

plans to do in the current year.

and thereby discourage use of unquali-

Awards for Excellence

fied installers.

The Feedback Session also included a

The morning session opened with the focus on upcoming changes in concrete

The presentation by Frans Toua, TTM’s

presentation by Monique Eggebeen,

standards that are due to be introduced

CEO, was on a proposed model for instal-

Managing Director of the Echo Group,

in South Africa shortly, and a move by

lation certification.

who chair s the CM A’s Awar ds f or

the CMA on behalf of the industry to

For brick paving he suggested that,

Excellence committee, about the plans

provide the means of ensuring that

among various training options that are

that are being put into effect to stage this

installers of precast retaining blocks and

available, installers seeking certification

prestigious competition, which will culmi-

paving are properly qualified to do so.

would be best advised to obtain training

nate in a gala evening in February 2016.

Bryan Perrie, Managing Director of

via a skills programme registered under

She pointed out that it is not yet cast

the Concrete Institute, who is Chairman

the Construction Education & Training

in concrete and members are welcome to

of some of the SA Bureau of Standards’

Authority (CETA).

make suggestions about its content – the

committees on concrete standards, gave

However, no training standard for

a presentation on the pending changes

installers of concrete retaining block

to codes, specifications, standards and

structures currently exists, Toua pointed

test methods.

out. The CMA could consider approaching

Awards categories, for example – and any

(Top): CMA technical committee Chairman Taco Voogt during his presentation to the Feedback Session.

PRECAST | ISSUE ONE | 2015

The project is to be taken further in

Another major initiative undertaken

the current year with the creation of a

by the CMA on which a presentation was

committee to oversee its development,

given at the Feedback Session was on the

including seeking funding for it.

proposed creation of a dynamic digital site

System Pavers in the USA. • Discussion meetings with cement producers and other CMA member companies. • Development of a quality manage-

called “World of Precast”, in which all CMA

Achievements

members’ products and services will be

Taco Voogt, Chairman of the CMA’s

accessible to customers and users.

technical committee, opened the after-

ment guidelines booklet due for publication shortly. • Production of a wetcast

Justin Kretzmar and Jason Roberts

noon session with a short presentation

of Infrastructure Specialist Group (ISG),

in which he provided information about

• Production of a manhole manual.

who have researched the concept on

pending changes to specific precast

• Precast magazine, the CMA’s

behalf of the CMA, presented a variety

concrete codes and standards, adding

official journal, and the CMA’s

of options as to how it may be struc-

to what Bryan Perrie of the Concrete

website continued to gain in

tured and designed to be as user-friendly

Institute covered earlier.

as possible.

Following a presentation by Financial

concrete manual.

readership and popularity. • T he CM A continued to gr ow its

They displayed some typical features

Director John Simpson of the CMA’s

it would contain. A user would be able to

financial report for the past year, retiring

Members were formally introduced

navigate the site to get an overview of

Executive Director Wally Armstrong

to Frans Minnaar, who succeeds Wally

the “World of Precast”, in which three-

outlined what the association has done

Armstrong as Executive Director. He

dimensional “fields” and cross-sections

and achieved in that period.

spoke about the initiatives the CMA

of structures where precast elements are deployed could be seen. From there they would be able to zoom in further to the products and services and their

These included: • Participation in the Totally Concrete exhibition. • Presentations to producers in

respective specifications, as required in

the Western Cape, Eastern Cape

the various applications.

and Botswana.

The “World of Precast” site would also provide links into members’ websites.

• Paving seminar by Larry Green, head of home paving installers

PEOPLE & EVENTS

other aspects relating to it.

membership throughout the year.

intends to pursue and introduce in the current year. Armstrong will continue to work closely with the association as Marketing Consultant. The CMA also bade farewell to Pam Zukor, Office Manager and PA to the Director, who has retired after 13 years of service.

PEOPLE & EVENTS 4

CMA’S NEW EXECUTIVE DIRECTOR TAKES OFFICE

PAM ZUKOR RETIRES FROM THE CMA

Frans Minnaar, who has many years of

was adopted in South Africa. While at

experience in quality assurance for pre-

the bureau he also served in several

cast concrete products, has taken office

senior management posts relating to

Pam Zukor has r e-

as Executive Director of the Concrete

civil engineering.

tired after 13 years

Manufacturers Association (CMA).

He subsequently worked for several

at the CMA as Office

His appointment took ef fect at

precast concrete manufacturers in qual-

Manager and PA to

the beginning of March 2015. His

ity assurance and management posts.

the Director.

predecessor Wally Armstrong, who

On two separate occasions, spanning

She joined the CMA

has held the post for just over two

a total of 16 years, he operated quality

in January 2002 and

years, has left to pursue other business

assurance consultancies of his own, with

retired at the end of

interests, but continues to work for the

clients that included prominent precast

CMA as Marketing Consultant.

concrete product manufacturers, Eskom

Minnaar, 60, spent over 10 years with

and the mining industry.

February this year. Bidding farewell to her on behalf of the association and its members at the

the SA Bureau of Standards (SABS).

One of his first tasks at the CMA

close of its Feedback Session in Febru-

He obtained a qualification as a civil

is completing the preparation of a

ary, Financial Director John Simpson

engineering technician while there and

quality management systems guide-

paid tribute to her for her loyal and

worked as a standards inspector and ISO

lines booklet to assist members and

dedicated service.

auditor – one of the first ISO auditors in

prospective members to establish

“Pam has been with us through thick

the country after the international ISO

their own systems. Another will be to

and thin. She has great rapport with

Quality System Certification Scheme

establish and launch an accreditation

members and I recall many circumstances

assessment scheme to help members

in which she was cool and calm. She had

meet the quality, health and safety and

an unmistakable way of being able to

environmental regulations applicable to

cope with difficult situations and we

their businesses.

appreciate what she has done for the

A third envisaged goal on which

CMA,” he said.

Minnaar has set his sights is to establish

Zukor recalls that she was called “The

an independent test laboratory to serve

Karate Kid” for a long time, following

the industry.

an incident in which then Director John

“Some of these are long-term pro-

Cairns and a colleague phoned her for

jects that may take several years to get

help as they had got themselves locked

off the ground. Broadly speaking, I am

inside the CMA’s offices. She found the

looking to extend the range of services

security staff unable – or unwilling – to

offered to our members wherever pos-

do anything, so she took charge of the

sible. We are in constant communication

situation herself by kicking in a window

with members to establish what they

pane. This did the trick, as it enabled

want,” he said.

the two men to clamber out to freedom.

TRIBUTE TO ARMSTRONG At the CMA’s recent annual Feedback

He commended Armstrong for his

transformed many of the programmes

Session to provide members with an

tireless energy and enthusiasm, com-

run by the CMA – Simpson cited the

update on progress to date with the

bined with a powerful drive

fact that the website had

association’s various programmes and

“to get the job done”. “He’s

“grown in leaps and bounds”

initiatives, Financial Director John Simp-

an action man – a Duracell

under his directorship, for

son paid tribute to Wally Armstrong for

Bunny on steroids!” Simp-

example – and introduced a

what he has achieved during his term of

son quipped.

number of new ones that

office over the past two years as Execu-

Armstrong was popular

have proven highly success-

in the industry and did a

ful, such as the magazine

In particular, he deserved to be credited

great job recruiting new

Precas t and the CM A’s

for putting the CMA back onto a sound

members and winning back

par ticipation during the

financial footing after finding it in “a parlous

the trust of previous mem-

past two years in the Totally

state” when he took office, he said.

bers who had left. He also

Concrete trade exhibition.

tive Director.

PRECAST | ISSUE ONE | 2015

TUMI DLAMINI LEAVES MBSA FOR HARVARD STUDIES Master Builders South Africa (MBSA) has announced that Tumi Dlamini’s three-year contractual term as its Executive Director ended on 28 February 2015. Dlamini will shortly be departing for the USA, where she has enrolled at the Harvard Kennedy School of Government to study for a Master in Public Administration degree. In a notice to stakeholders, MBSA President, Neil Cloete, said that since taking over the reins on 1 March 2012, Dlamini had played a significant role in raising the profile of MBSA and Women in Construction, opening dialogues with government and other public institutions, implementing transformation initiatives and generally delivering on the strategy of MBSA to ensure that it remained the “Leading Body in the Building Industry”. Cloete advised MBSA stakeholders that until the appointment of a new Executive Director, Operations Director Pierre Fourie would manage the affairs of the organisation. “Mr Fourie has 25 years’ experience with MBSA and is well placed to manage the affairs of the organisation during the transition period,” he added.

(Above): Tumi Dlamini, MBSA Executive Director for the past three years, has enrolled at the Harvard Kennedy School of Government to study public administration.

FACTURER

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NCRETE

SOC

Silverton Precast (Pty) Ltd Established 1998

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MANUFACTURERS OF Precast Bridge Beams, Road Barriers, Light Mast Bases, Toll Gantry Elements AESTHETICS • STRUCTURAL INTEGRITY • OUTSTANDING SERVICE

Precast concrete barriers, Lintels, channels, slabs Tel: +27 12 804 4525 Fax: +27 12 804 9673 Mob:+27 83 354 6823 E-mail: george@silvertonprecast.co.za

Preparations for the Concrete Manu-

and initiatives, Monique Eggebeen, the

• Technical Excellence Award

facturers Association’s Awards for

Echo Group’s Managing Director, who

• Innovation Award

Excellence competition, in which the

chairs the CMA’s awards committee,

• Precast for Life Award

best products and other innovations and

outlined the plans that have been put

The competition rules allow for more

developments relating to precast con-

in place for the competition, which will

than one entry per competitor – in the

crete are showcased and given worthy

culminate in the award presentations in

same categories and/or in different ones.

recognition, are well underway.

February 2016.

Eggebeen urged CMA members to

At the CM A’s Feedback Session

A list of award categories has been

come forward with entries and also in-

to update members on progress with

drawn up by the committee. These are sub-

vited nominations for judges. The panel of

the association’s various programmes

ject to possible change in response to re-

six to eight judges will comprise mostly

quests or suggestions by CMA members.

presidents of various industry-related

The six award categories are applica-

The awards gala event is set for

sections, Building and Infrastructure,

February 20 at a venue in Gauteng still

resulting in a total of 12 awards – except

to be arranged.

in the unlikely event of the panel of judges

Those serving on the awards com-

deciding not to make an award in a par-

mittee with Eggebeen are John Cairns,

ticular instance.

a Consultant and former Director of the

The award categories as currently

Monique Eggebeen

associations.

ble to both of the industry’s major sub-

CMA, Kgomotso Modise, Operations

envisaged are:

Director of the Echo Group, Vincent

• Aesthetic Award

Erasmus, Key Accounts Manager of PPC

• Sustainability Award

and Gert van Wyk, Marketing Manager of

• Community Upliftment Award

the Bosun Group.

PEOPLE & EVENTS

PREPARATIONS WELL UNDERWAY FOR AWARDS FOR EXCELLENCE 2016

The Infrastructure Specialist (IS) Group,

special needs learners. Their enthusiasm

comprising Technicrete, Rocla (both

and dedication to learning new skills are

workplace and is expensive.” She added that the skills training

CMA members) and Ocon Brick, recently

a remarkable reflection of their passion

the school provides for learners with

funded a Golf Day for customers and

to succeed.”

special educational needs affords them

colleagues to help raise funds for a

Renée van der Merwe of Roodepark

special school in Gauteng that caters

School said: “The national curriculum

the opportunity to become economically

to learners who are mildly intellectually

is adapted to meet the needs of our

Van Zyl said the IS Group will continue

disabled (MID).

learners and our technical curriculum

to help raise funds for and create aware-

The Roodepark School focuses on pro-

is outcomes-driven. The equipment we

ness of the school’s training programmes

viding training in practical vocational skills,

require is the same as that found in the

for MID learners.

active and part of productive society.

including welding, brick-laying, woodwork, panel-beating and spray-painting. “ T h e R o o d e p a r k S c h o o l gr e a t l y assists the technical development of those learners with special needs,” said Christo van Zyl, Sales and Marketing Director for the IS Group. “After visiting the school and seeing the amazing products the learners were creating, we decided that we should assist in creating an awareness of their activities, not only among our group, but among suppliers and customers as well. “The Golf Day was a token of our belief in what the school is achieving for these

Some of the IS Group’s personnel and customers at the Golf Day staged to raise funds for the Roodepark School.

PEOPLE & EVENTS

IS GROUP SUPPORTS LEARNERS WITH SPECIAL NEEDS

PEOPLE & EVENTS 10

NEW CMA MEMBERS Six companies have recently become

Uganda, as well as sales agents in Nigeria,

Pegaso Stampi

members of the Concrete Manufacturers

Tanzania, Angola and New Zealand.

Pegaso Stampi, based in Poggibonsi,

Association.

Hydraform has a well-established

Italy, manufactures moulds for concrete

They are Enviro-Cast, a manufacturer

reputation as an innovator in alterna-

elements which it supplies to all parts

of a range of precast concrete products

ti ve building technologies. T hr ough

of the world through agents based in all

that include kerb stones and building

continuous research and development

continents.

bricks, Hydraform International and

with leading institutions, it developed an

Operating since 2002, the company

Quadra, both manufacturers of concrete

interlocking building system for produc-

specialises in the production of moulds

block-making and other equipment, Taco

tion of dry-stack interlocking building

for a wide variety of dry-cast concrete

Voogt Consulting Engineers, Pegaso

blocks. This cost-saving system com-

elements made in vibropresses.

Stampi, a manufacturer of moulds for dry-

pletely eliminates the need for concrete

cast concrete products and Quangong

or steel columns in building construction

Machinery, a leading Chinese concrete

and reduces the use of mortar in 70%

block machine manufacturer.

of the building structure.

Enviro-Cast Established in early 2014, Enviro-Cast initially focused on the manufacture of precast concrete kerb stones for the civil industry. It has subsequently extended its range to include building bricks and blocks, cobble stones, flagstones, pool copings and interlocking and bevel paving. Enviro-Cast’s main factory is in Meyerton, Gauteng, and it has a smaller plant

Hydraform’s best-selling block-making machine, the M7MI Super 3.

A few samples of the numerous dry-cast products made using Pegaso Stampi moulds.

in Pretoria. It operates a laboratory to

Quadra

ensure that its bricks and blocks meet

Quadra, a manufacturer and supplier of

Quangong Machinery

the applicable quality standard of the SA

concrete block-making and block grinding

Quangong Machinery (QGM), a leading

Bureau of Standards, pending accept-

machines, handling systems and wet-

Chinese manufacturer of concrete block-

ance of its application for the SABS mark

cast production lines, was established

making machines, was established in

of approval.

in 1993 and is based in Contamine sur

1979. The company, based in Quanzhou in

Arve, France. It operates a sales branch

China’s Fujian province, has branch offices

in Brazil.

in Brazil, Algeria, Libya, Zambia, Saudi

The company owns a fleet of trucks for transporting aggregates and other materials used in its manufacturing

Arabia, Oman, India, Indonesia, Singapore

processes and for delivery of product

Taco Voogt Consulting Engineers

to customers.

Taco Voogt, head of civil engineering con-

QGM’s product range encompasses

sultancy Taco Voogt Consulting Engineers,

block-making machines, ready-mix con-

is already well known to most CMA mem-

crete batching plant and AAC block plant.

bers as the Chairman of the association’s technical committee. The company, established in 2008, offers expertise in the use of various

and Russia.

In 2014 the company purchased leading German concrete block making and multi-layer machines manufacturer Zenith Maschinenfabrik GmbH.

precast concrete products, including hydraulic and pavement engineering, soil and embankment stabilisation and erosion control. Some of Enviro-Cast’s products at its Meyerton factory.

Voogt is a Civil Engineering Master’s graduate from the Delft University of

Hydraform International

Technology in the Netherlands and worked

Hydraform International, based in Boks-

mainly in dredging and port engineering

burg, Gauteng, has been in operation

in West Africa and the Caribbean before

since 1988.

settling in South Africa. Prior to setting

It is a leading manufacturer and

up his consultancy, he worked for several

supplier of interlocking brick and block-

large construction and civil engineering

making machinery in southern Africa and

contractors and a precast concrete

has a branch sales office in Kampala,

product manufacturer.

One of the Zenith block-making machines produced by Zenith Maschinenfabrik of Germany, which was acquired last year by Quangong Machinery of China.

PRECAST | ISSUE ONE | 2015

COVER STORY 12

PRECAST | ISSUE ONE | 2015

railway lines, with two large in-situ cast concrete chambers at each end to evenly distribute the stormwater flow into and out of the pipes. The construction of the chambers and of a new culvert that ties into the existing stormwater system form part of Franki’s contract, which is scheduled for completion in June this year. “The challenge here is that the pipes are to be installed 6 m below the ground water level, where the ground consists

A precast concrete jacking pipe with watertight joints developed by CMA member Concrete Units at the request of Franki Africa, the leading geotechnical engineering company in Africa, has demonstrated its effectiveness in a jacking contract Franki is currently engaged on at Durban’s Bluff area.

of running sand with the consistency of

Franki’s requirement was for jacking

this case than in the previous contracts

pipes with leak-proof joints. It required

in which they have been deployed. “The

them for use in pipejacking projects where it was necessary to jack below the water table. Concrete Units designed the new pipe in consultation with

soup,” commented Byron Field, Franki’s Contracts Manager for pipe-jacking projects. Preparation prior to jacking has consequently been a prolonged process, involving the installation of a de-watering system along the full length of the jacks and sheet piling around all the new chambers and culvert works. Having pipes with watertight joints was shown to be even more critical in

T that it would have

sand is so fine that it would have flowed through the joints of ordinary jacking pipes,” Field said. The pipes used in the Bluff contract

Pretoria-based pipe design specialist

were manufactured and supplied by Con-

company Pipes.

crete Units’ Meyerton plant, whereas the

Franki has successfully deployed the pipes in several jacking contracts in the Western Cape since Concrete Units started manufacturing them in 2012.

joints of ordinary jacking pipes.”

pipes used in the earlier contracts in and around Cape Town were manufactured and supplied by the company’s Cape Town facility, which initiated their development.

The latest contract is one of the most

est point of the Bluff area, has been sub-

T he joint design in the new pipe

difficult below-the-water-table jacking

ject to heavy flooding for many years due

represents a departure from the in-the-

contracts the company has undertaken in

to the inadequacy of the existing drainage

wall joint design of most conventional

recent years. Awarded by eThekwini Mu-

system. The railway lines that give access

jacking pipes. The new pipe has a butt-

nicipality’s stormwater division in August

across the reserve to the shunting yards

ended joint with a steel band cast into

last year, it is an upgrade of the storm-

at Wentworth Station, as well as adjacent

it to provide a close fit for the receiving

water drainage at the Transnet Freight

buildings, are often flooded.

pipe-end, which is equipped with an O-ring

Rail Reserve near Wentworth Station. This area, which is situated at the low-

The new system being installed by

to seal the joint. The tight tolerance of

Franki consists of five 100 m-long pipe-

the joint in the new pipe also improves its alignment characteristics compared with the conventional product. For the Bluf f contract, Concrete Units’ Meyerton plant manufactured and supplied Franki with a total of 500 m of 1 470 internal diameter pipes in individual pipe lengths of 2,4 m. (Left): Some of the watertight pipes specially designed and manufactured by Concrete Units for Franki Africa to use in jacking projects below the water table. (Above): The start of two of five 100 m-long concrete pipelines forming part of the new stormwater drainage system being established in the Transnet Freight Rail Reserve in Durban’s Bluff area.

PRECAST | ISSUE ONE | 2015

COVER STORY

WATERTIGHT JACKING PIPE IN ACTION

lines installed side-by-side under the

TECHNICAL 14 Precast concrete masonry units have

“Concrete masonry is prone to mois-

to the life-cycle and operating costs of

come to the fore in building construction

ture movement that is generally not

a building and can compromise durable

today, mainly because of the cost-sav-

well understood,” stated Crofts, who is

construction. By creating an awareness

ings they offer and their greater variety

Principal of the Pretoria-based company

of the behaviour of concrete masonry and

and flexibility compared with traditional

FSC Consulting Engineers.

manufacturing specifications, the con-

masonry materials. But the trend has

“Defects caused by moisture move-

struction of durable concrete masonry

been accompanied by problems associ-

ment in concrete masonry walls can add

building envelopes can be ensured by ap-

ated with the increased incidence of

plying relevant details and specifications.

water ingress into building structures.

“Appropriate design, workmanship

In a paper entitled “Sustainable Con-

and an understanding of the behaviour of

crete Masonry in South Africa” present-

concrete masonry materials are the cor-

ed at a national symposium on Concrete

nerstones for sustainability and resource

for a Sustainable Environment, organised

conservation,” he emphasised.

by the Concrete Society of SA, masonry consultant Fred Crofts set out most

Advantages

of the errors in concrete masonry con-

Concrete masonry has undoubled advan-

struction that lead to damage resulting from water ingress. He also presented remedies for addressing these problems.

tages over other building materials and DPC detail of a collar-jointed foundation wall (Courtesy NHBRC)

also meets many of the requirements for sustainable building.

construction of houses. Modular planning of large-format concrete masonry units in walls, normally referred to as blocks, further increases

TECHNICAL

aimed at improving productivity in the

productivity. “However, the importance of suitably trained block masons cannot be over-emphasised,” stated Crofts, “The provision of affordable hous-

units will be protected from moisture

adding that the user of modular door and

ing poses a major challenge in South

movements and minimise maintenance if

window frames is also essential.

Africa. Concrete masonry is playing an

the abutting backfill material under floors

increasingly prominent role due to its

can be isolated to prevent direct contact

Life-cycle costing

competitive price over other traditional

with foundation walls with a vertical

“Life-cycle costing, as well as life-cycle

materials. Ease of site manufacturing,

waterproofing application.

assessment of buildings, are other

availability of suitable aggregate and

“An exterior waterproofing appli-

terms that have become commonplace.

the reduction of transportation costs

cation may be sought to remedy the

Where sustainability embraces con-

also contribute towards this trend,” he

problem, but this only addresses the

ser vation of energy and the use of

commented.

symptom and continuous maintenance

r enewable, r ecycled, non-toxic and

of the foundation wall will be required,”

abundant materials, it is necessary to

Crofts stressed.

ensure that the masonry envelope also

C oncr e te masonr y units can be easily manufactured to the strengths and dimensions required. They offer the

“Blistered paint on walls due to damp

added advantages of material savings and

has become the norm, rather than the

In South Africa little attention has

thermal and rain penetration benefits.

exception. Masonry plinths are being

been given to this essential requirement.

Quality assurance has also helped to

built lower with har dly any gr ound

Frequently the waterproofing quality, function and durability of masonry have

ensur e that good-quality concr ete masonry units are produced. Crofts said history has shown that non-durable masonry wall construction places great economic burdens on owners, and wastes energy, materials and resources. Eaves, canopies and other forms of overhangs have traditionally been used to protect walls from rain, but their use has declined. Flat roofs have become mor e f r equent and, wher e pitched roofs still prevail, eave overhangs have diminished. The absence of gutters and downpipes results in roof drainage being discharged onto wall surfaces. The omission of weather-steps at thresholds

be made durable,” he said.

“Defects caused by moisture movement in concrete masonry walls can add to the life-cycle and operating costs of a building and can compromise durable construction.”

been sacrificed to save costs or for aesthetic reasons. Most of the problems still experienced with concrete masonry relate to ingress of moisture into walls. Other causes are as a result of manufacturing defects, such as insufficient curing and the use of chemically unstable waste products. ”Poor workmanship also compounds stress build-up in walls and results in cracks. Incorrect mixing of masonry mortar, re-tempering mortar past the recommended setting times of cement, u sing m a s o n r y u n i t s o f di s sim il a r materials in the same wall and failing to cross-bond the stretcher-bonded leaves in collar-jointed walls all exacerbate the

directs surface run-off onto unfinished sur faces, causing ingress of water

clearance, thus placing the DPC too

into floor slabs and walls, while the

close to the ground. In coastal zones

problem,” he added. The attainment of successful masonry

omission of drip ledges at slab and lintel

rain penetration at the junction of

depends on adequate design, sound

soffits allows rainwater to run back onto

window frames with walls has been due

construction practice and specification

wall surfaces. Furthermore, unfinished

to inadequacies in the detailing of the

of materials. T he development of

horizontal surfaces of walls, including

DPC at jambs or sills.”

bond between the masonry units and

parapet walls, are the origin of damp. The

To facilitate durable designs of the

the masonry mortar depends on the

application of render over the damp-proof

masonry envelope and ensure a lower

masonry materials and texture of the

course (DPC) of foundation walls is the

life-cycle costs, a number of changes

unit. Good workmanship is dependent in

source of rising damp in walls.

need to be applied, including the use of

turn, on access to accepted norms of

new manufacturing specifications that

local detailing practice.

“Today it has become vogue to provide rendered and painted foundation walls using porous concrete masonry in direct

are in line with sustainable building.

C oncr e te masonr y shr inks upon

In recent years the sustainable use of

drying and curing after manufacture and

building materials has come into effect,

is also subject to reversible moisture

“P o o r - q u a l i t y p o r o u s c o n c r e t e

accompanied by reductions in costs of

movement, for which allowance needs

or high water absor p tion masonr y

building materials, as well as changes

to be made if defects are to be avoided.

contact with the soil,” he pointed out.

PRECAST | ISSUE ONE | 2015

TECHNICAL

Concrete masonry is not subjected to

covers reinforced, prestressed and

Collar-jointed wall

a high rate of initial water absorption

confined masonry. The four parts cover

An example of incorrect masonry con-

(IRA), as found with fired clay masonry,

the rules for reinforced and unreinforced

struction practice that leads to water

and should not be wetted when laying. At

masonry, structural fire design and

ingress and subsequent damage is in a

coastal zones the walls should be covered

detailed rules for lateral loading.

collar-jointed foundation wall where the

“The significance of the adoption of this

rendered application is continuous with

standard is that it is less descriptive than

the DPC not protruding. Generally, this

the local standard and declares critical

detail is applied incorrectly, with the

SANS 1215 governs the manufacture

design values for moisture movement and

render applied over the DPC; a horizontal

of precast solid and precast hollow

compressive strengths, thus allowing the

crack will delineate the location of the

concrete masonry units in South Africa.

consumer to select a unit in accordance

DPC with rising damp present.

Requirements are laid down for shape,

with his requirements,” Crofts stated.

with plastic during rain. The use of control joints placed at

predetermined positions is essential.

A n accep table al ter na ti v e is to

appearance, colour, surface texture,

provide a V-joint in the rendered surface

dimensions, shell and web thicknesses,

delineating the horizontal DPC’s location,

squareness, compressive strength,

thus preventing damp from bridging over

drying shrinkage, expansion on rewetting

the horizontal moisture barrier.

and soundness. Appendices contain

Other conditions where moisture in-

details of an efflorescence test and

gress may occur, and the measures that

materials recommended for use in the

should be applied to prevent this, include:

manufacture of the units.

• Provision of control joints. If control joints are not contrived and neatly

Non-compliance

detailed, random cracks will appear,

Some manufacturers provide compres-

causing more points of entry for water.

sive strength test results and market

Concrete masonry generally shrinks as

their units as SANS-compliant without

it cures – a process that occurs over an

fulfilling the other requirements, espe-

extended period. Installed materials which

cially drying shrinkage and expansion on

are too rigid to absorb this shrinkage

rewetting. Concrete masonry conforming

must be provided with movement joints

to SANS 1215 has drying shrinkage limitations which range from 0,06%-0,08%

Fred Crofts

at regular intervals. They should also be installed where differential movement

for normal and high-shrinkage units re-

The lack of attention to architectural

can arise between parts of the structure

spectively, with wetting expansion limited

and construction details during the

differently affected by temperature or

to not greater than 0,02%.

construction of the masonry envelope

moisture content, or parts constructed

The consequence of non-compliance

is often the direct cause of moisture-

in different materials.

with drying shrinkage and expansion on

induced movement and rising damp in

• Damp of ten occur s thr ough the

rewetting limits, together with poor

concrete masonry.

inner wall surface as a result of human

detailing, can result in random cracks

The watertightness of the masonry

activities and condensation. Examples of

in walls, thereby adversely affecting the

wall is dependent on the quality of

such sources of moisture are unvented

life-cycle costing of the masonry envelope.

masonry used and the workmanship

heaters and gas ovens, combined with

Movement in walls due to moisture

applied to rule the bed and perpend

poor coating applications on the internal

is also covered in SANS 10145, the

joints. A pr otecti ve r endering and

surfaces of the walls.

Code of Practice for Concrete Masonry

coating is an impor tant application

• Hollow concr e te block wor k . T he

Construction. The stresses in walls in

to f acilitate water tightness where

control of moisture-induced movement

normal residential dwellings are small and

poor-quality masonry units are used.

in hollow concrete blockwork is more

are of minor consequence if there are no

E xcessi v e mo v ement in a masonr y

critical, since the blocks are laid in shell

durability considerations.

wall c an also incr e ase the r isk o f

bedding to reduce rain penetration into

South Africa is to adopt Eurocode 6

ingress of moisture. Vertical mortar

the internal block surface. Shell bedding

and supporting standards for the design

joints, in particular, are not adequately

results in a reduction in the strength of

of masonry structures. This standard

compacted to prevent rain penetration.

a wall. The use of block reinforcement

The risk is increased if the mortar

or reinforcement that aligns with the

i s o f p o o r qu ali t y. I f t h e p e r p e n d

mortar in the shell bedding is imperative,

joints of masonry are filled and ruled

together with the provision of vertical

inadequately, the rain penetration will

control joints.

cause damp patches on the internal face

• Balustrade/parapet walls. Parapet

of the wall. Water-repellent solutions

walls should be waterproofed on the

are often applied to reduce the risk

top horizontal surface, using a precast

of rain penetration in existing walls.

concrete coping or waterproofing a

The effectiveness of these coatings is

rendered surface. It is good detailing

compromised when cracks occur.

practice to provide a slope inwards to

“I expect great strides to be made in reducing life-cycle costs for masonry envelopes.”

PRECAST | ISSUE ONE | 2015

wall surface.

boundary walls also apply.

accessories, such as wall ties and ma-

Guidance for the spacing of vertical

sonry reinforcement, and the minimum

• Free-standing boundary walls. These

control joints in horizontal lengths of

level of protective coating to be used in

are subject to moisture ingress due to

walls is given in SANS 10249 and the

the various types of construction and

the omission of a DPC at foundation

Concrete Manufacturers Association’s

exposure conditions.

level and the exposed surface at the

Masonry Manual. Guidance is also given

The protection of reinforcement from

top – the omission of the DPC here

to modify control joint spacing with the

corrosion provided with masonry work

being a structural necessity to ensure

inclusion of masonry reinforcement.

is lower with higher water absorption

bond between masonry units and

concr e te masonr y uni ts and w hen

mortar to facilitate lateral stability

Slip joints

weaker masonry mortar is required. In

of the wall. The use of masonry units

The provision of slip joints and vertical

these cases, special attention should

with low water absorption is better

bond breakers between the suspended

be given to the galvanising requirements

suited to this application. The ingress

reinforced concrete slab and the masonry

of the steel.

of water onto concrete masonry at

support allows the free movement of

Crofts concluded by saying that there

foundation level can be prevented by

the slab when subjected to concrete

is a greater awareness today among

applying a “chemical DPC” (ie mixing a

shrinkage and creep. T he failure of

specifiers, developers and contractors

proprietary waterproofing agent into

this slip joint causes mechanical lock

about the moisture behaviour of concrete

the masonry mortar) or can be treated

between the masonry support and the

masonry materials.

with a water-repellent solution. The

slab, resulting in a horizontal crack line

“Together with good building practices

same can be done to the top of the wall,

on the exterior rendered surface of the

outlined in current SANS pertaining to

or a precast concrete coping can be

wall. It is therefore prudent to pro-

construction works of masonry walling

provided. Vertical control joints have to

vide a deeply recessed V-joint in the

and cement plaster, I expect great

be provided at regular intervals. In the

external rendered surface to delineate

strides to be made not only in addressing

case of free-standing retaining walls,

the soffit of the slab and to control this

the pressing need for the provision of

the vertical surface in contact with the

crack formation.

affordable housing, but also in reducing

soil has to be waterproofed, while the

SANS 10164: Part 2 gives guidelines

provisions as applied to free-standing

with respect to the type of masonry

TECHNICAL

direct rainwater away from the exterior

life-cycle costs for masonry envelopes,” he said.

E ER E H SIT K B IC E L C RW FO

Various examples of precast concrete 2 the V&A Waterfront’s Silo district, currently under construction and 201

building, while No 6 Silo will be developed

looking at using precast concrete stairs

as a mid-scale internationally branded

on Nos 3 and 5 Silos. They will speed up

hotel with approximately 220 beds.

construction and give us a better-quality

Precast concrete products that have been used so far include sheet piles

The historic grain silos are being con-

finish,” he explained.

verted into the architecturally innovative

” We a r e al s o in v e s t ig a t ing t h e

Zeitz Museum of Contemporary Africa art.

installation of precast concrete cladding

The design by Heatherwick Studios will see

on some of the facades and we will be

some of the silo tubes cut away and others

using precast concrete stormwater

retained to form viewing galleries.

piping for the drainage of the precinct.”

deployed in a new 2 750 m 2 parking-

David de Villiers, Project Director for

One of the more challenging applica-

bay basement and culverts used to

Mace International, project managers for

tions was in the design and implementa-

construct a sea water service corridor

the various developments in the district,

tion of geotechnical solutions for the

under Fish Quay Road.

said precast concrete is to be used

construction of lateral support for the

wherever possible.

new parking basement. This was handled

The Silo district, situated at Cape Town harbour’s old grain silos, is already

“In addition to the sheet piling and the

by Franki Africa and involved the use of

home to the 18 000 m² six star green-

Fish Quay Road corridor elements, we are

precast concrete sheet piles and post-

rated No 1 Silo, which made extensive

tensioned anchors.

use of aesthetically pleasing concrete

A n t o n S t o l l, S e n i o r C o n t r a c t s

cladding, and No 2 Silo, a luxury residential

Manager for Franki Africa, said the sheet

apartment complex.

piling operation entailed the delivery of

The new development involves the con-

a wide variety of products and services

struction of Nos 3-5 Silos and will feature

on a site which was hampered by strong

environmentally sustainable building tech-

tidal flows, varying rock profiles and

niques, as applied with Nos 1 and 2 Silos.

restricted access.

No 3 Silo will comprise a structure

“The site’s geology comprised im-

with 78 one-to-four bedroom luxury

por ted f ine silty and clayey sands,

apartments, No 4 Silo will house a Virgin Active Classic Health Club and No 5 Silo will be a 13 500 m² AAA-grade office

together with rock fill overlying highly Franki executing concrete sheet pile wall installation as part of the Silos district project.

fractured grey wacke residual rock. A r eas of beach zones or sand and shelly fragments were also encountered in areas above the residual rock, which varied in depth from ground level to 13 m,” he said. The piling took place on the northern and eastern ends of the basement where driven concrete sheet piles with grout socks and anchors were installed. CMA member Concrete Units of Cape Town supplied 228 precast concrete sheet piles, ranging from 9-13 m in length, which were installed to create a 206 m wall. Grout socks were installed between the concrete sheets to prevent water seepage. Temporary anchors will be installed to support the sheet piles once excavation of the basement begins.

PRECAST | ISSUE ONE | 2015

PROJECT

PRECAST CONCRETE DEPLOYED EXTENSIVELY IN V&A WATERFRONT ‘SILO DISTRICT’ PROJECT

INTERVIEW 20

SOUTH AFRICAN MAKES GOOD – CHANGING THE FACE OF US HOMES Expat South African Larry Green has single-handedly revolutionised the US home paving market.

new methods for recruiting and training,

success. As those who attended his

initiated new marketing strategies and

seminar discovered, the initiatives he

put into effect new ways of retaining cus-

describes here make for an instructive

tomers, following sales leads, and more.

case study which local companies may

During the past 20 years spent in

In October last year the Concrete

California, the former founder of local

Manufacturers Association (CMA), in co-

precast concrete block paving company

operation with CMA members Bosun and

Why did you choose to leave South

SA Paving has transformed the US

Smartstone, arranged for Green to run

Africa when you had a flourishing paving

market by introducing new ideas and

a one-day seminar in Gauteng for CMA

business here?

approaches to home paving, building a

members to give them insights into his

The country was in the grip of sanctions

multi-million-dollar paving installation

highly successful business methods – at

and the political climate, especially after

management business in the process.

the same time demonstrating how a “lo-

former President PW Botha’s 1985 Ru-

His company, System Pavers, today

cal boy” made good in the USA’s reputedly

bicon speech, was precarious, to say the

operates throughout California, Oregon,

highly competitive business environment.

least. I led an incentive trip to Israel with

Washington and Colorado, executing

In the following interview with Pre-

some of my sales people in 1988 and took

about 5 000 home remodelling projects a

cast, Green identifies some of the key

the opportunity of visiting Ackerstein

year. He has introduced a raft of exciting

str a tegies behind S y stem Pa v er s’

Industries, one of the world’s largest

use to their benefit.

paving manufacturers. They had set up a paving factory in California which was losing money and I was invited to run the company with an option to buy the residential marketing and installations division. I moved over in October 1992, but soon realised that it was not going to work, as the company was essentially bankrupt. I was then introduced to a concrete paving block manufacturer, Angelus Block, run by third-generation Italians. T h e o w n er o f th e c omp an y, Mar i o Antonini, suggested I start a paving company using his pavers. He helped me get System Paving going in Newport Beach by setting up a $100 000 line-ofcredit. I was joined by Doug Lueck, who had been in the industry for some time and we have been working together for 22 years. Could you describe your business model? We adopted a model similar to the one we had first used in South Africa. Essentially, we are a marketing, sales and project management organisation aiming at middle- to upper-income families. We don’t manufacture, nor do we employ

Larry Green

“Relationshipbuilding really works – it’s proven itself over and over again.”

labour to install the paved surfaces we

clients loved the transformation. In those

sell. We source high-quality pavers from

early days, we used radio endorsements

manufacturers and all laying work is done

which made us sound like a much bigger

by sub-contractors who follow strict

organisation than we were. We had to

best-practice installation protocols

travel a long way to meet with custom-

set by us. Moreover, we supervise the

ers and traffic was so bad in Los Angeles

installation process and maintain a

that we found we could only manage one

hands-on approach with the client.

appointment a day.

I transferred my family to the USA

In 1995 we completed a huge bus

early in 1993 and they underwent a bap-

terminal project in Los Angeles and

tism by fire. I mean this both literately

we had to import 1,3 million paving

and figuratively, because shortly after

block bricks from England. This was

their arrival, we experienced widespread

an incredibly challenging project which

fires, flooding and an earthquake. How-

involved putting up a 100% performance

ever, the latter proved a blessing in

bond. We grew up on that job.

disguise because many driveways and

Notwithstanding our success in the

other paved areas were destroyed and

commercial sector, we preferred the

the cost of installing paving was covered

residential paving market and in 1998

by insurance.

we decided to focus on it exclusively. It was at that point that we really started

In your presentation, you said you were

to grow.

surprised to find that very few American homes were using concrete block

You extended your footprint into other

paving (CBP).

states such as Oregon, Washington and

Yes, we found many beautiful homes in

Colorado, as well as some East Coast

California, but most of them had stamped

states. You also began franchising. Can

concrete driveways and they looked

you elaborate?

dreadful. Driveways were lifting every-

Neither the East Coast nor franchising,

where and we realised we had to educate

which we attempted on a small scale,

people about why CBP was preferable.

really worked for us. However, our limited

Once they were re-paved with CBP, our

exposure to franchising taught us some

PRECAST | ISSUE ONE | 2015

INTERVIEW

valuable lessons about structure and systems and it helped us with recordkeeping and installation standards, as well as selling and training methods. It was then that we realised we had to become a training organisation. There being no model we could follow, we had

to develop our own programmes. Our peak years were reached in 2007 and 2008, when we were doing ±5 000 projects a year. It was then that we were approached by a large private equity group to buy us out for an insane number. It would have meant gearing the company heavily and I didn’t want to be a CEO with so much debt on the books. Then in October 2008, the financial markets started to crash and by 2010 sales had dropped to 35% of where they so our focus is on providing excellence to

had been. Despite this, we only posted a loss in 2009, a year in which our ratio of marketing spend to sales increased from 8% to 17%. We survived this period by developing a sub-set of outdoor products and transforming ourselves into a lifestyle company. A drought in 2010 led us to

“If you’re not failing some of the time, you’re not pushing the envelope.”

differentiate us from our competition. We aim f o r p e ak j o b p e r f o r m a n c e and perfection. This involves ongoing training and translating our mission into systems and processes. We spend 1,7% ($2 million) of revenue on skills development and we’ve proved that it impacts positively on the bottom line.

promote synthetic turf and water features and we also introduced built-in

Could you expand on this?

We wouldn’t be able to fulfil our mission

barbecues, other outdoor elements and

In the old-school paving installation

without it.

landscape lighting. A landscape archi-

model, doing one job well and never having

Our training is not confined to those

tectural division followed recently, as

to go back defined success. Our model is

in the field, but involves everyone in the

did greenscapes and plants. We are now

based on long-term relationships which

company. It entails centralised core

finding that the more lifestyle products

are grounded on the 25-year warrantee

training of all the basic skills, as well as

we sell, the greater our CBP sales.

we offer on paving installations. It’s not

leadership development. Sales people

Part of our survival strategy involved

just the paving blocks which are covered,

are flown in from our nine dif ferent

using our database to reach people to

but the labour and installation work as

offices to our training centre in Santa

whom we had already sold, as well as to

well. We always use aggregate in our

Ana, California and we pay them a basic

those who were on our list, but who had

sub-base layers 50 mm to 200 mm deep,

salary during the training week. Although

not bought from us. We felt that once

together with geofabric reinforcement,

our paving crews are sub-contractors,

people knew and trusted us, we could go

and this ensures that our work lasts a

we train them how to lay pavers in line

back and do other business with them

long time. We monitor the progress on

with our standards and specifications,

– and this worked.

our various projects very closely and

which are the highest in the industry.

Baby boomers formed the largest

each project manager oversees 2,5

Incidentally, we also teach them how to

segment of our market and as the stock

projects at any given time. I visit our

manage their accounts – in other words,

market recovered, so did the demand

sites randomly and the greatest joy I get

how to make money.

for home improvement. Sixty percent

out of this business is hearing what the

of housing in the USA is over 30 years

customers have to say.

We use role-playing and videos extensively in sales training. We cover

old and outdoor living has become the

Setting the highest possible stand-

problem-solving, creativity and new

fastest-growing segment in the home

ards in all facets of our business helped

product induction. Leadership manage-

improvement market. We are back at our

build relationships with our clients.

ment, culture inspiration, motivation,

pre-recession peak levels and projected

Relationship-building really works and

follow-up evaluation, chairing meetings

growth is at least 10%, if not 15-20% a

since 2010 it’s proven itself over and

and corrective action are also part of

year. I am more excited about the work

over again.

our curriculum. Additional training includes advanced sales techniques, sales

that I do now than I’ve ever been. You mentioned earlier that you have

manager to branch manager training, and

Winning and maintaining the trust of

become a training-based organisation.

construction manager training.

your customers is obviously crucial to

What does this entail?

the long-term viability of your business.

Ours is a low-barrier-to-entry business,

Our sales people undergo a role-play test at the end of the first week and

PRECAST | ISSUE ONE | 2015

the pass mark is 80%. However, we

our internal database marketing efforts

give those who don’t make it a second

as low as 2-4%. Relationship marketing

chance, but they must achieve 80%

is clearly the most effective cost of

in order to continue working for us.

acquisition tool we have.

We insist on this figure because we need highly skilled sales people for our

Tell us how you measure

business model to work, which is based

client satisfaction.

on closing 25% of our leads.

Customer satisf ac tion is wher e it

One of our biggest challenges is finding

all happens. We use a thir d-par t y

people to promote and replacing those

organisation, Guild Quality, to contact

who leave us. We have two full-time

our customers and we pay them $30

recruiters and we examine personality

for every survey. These surveys are our

profiles very closely before we hire.

best marketing tool by far and we post the results on our website absolutely

How do you generate sales leads?

seamlessly. Every one of our projects

We use several tools, many of them

is surveyed based on a set of criteria

linked to relationship-building. These

we want measured. We score between

include phy sical mailshots, emails,

92-95% of customers willing to re-

referrals, door-to-door canvassing, radio

commend us and we build these scores

advertising, newspaper adver tising,

into the incentives and bonuses for our

home improvement shows, seminars,

sales people and project managers.

newsletters and sweepstakes. All our leads are channelled into a large database

What message would you like to leave

which we work continuously. Referrals

our readers?

are very important to us and we give

I believe that failure is an important

$500 for each successful referral. We

component of success. If you’re not

also offer $10 000 towards a lifestyle

failing some of the time, you’re not

project for five successful referrals.

pushing the envelope, which is something

We source much of our information

we all have to do if we want to excel.

on potential leads from data companies.

One of our main drivers is our core

They give us a sense of market size and

belief that we are creating a better

of our share of it. We rank the cities in

living environment. It guides all of us at

which we’ve done the most revenues and

System Pavers every working day and it

we give them the highest priority. We

underpins all our decisions. Moreover,

also assess how people live in our high-

we believe that if we excel at what we

value areas, the size of their properties

do and do it better than anyone else, the

and their equity in the property.

money will take care of itself. We don’t

The sales yield of our various market

sell on price, but on emotion and sharing

tools is analysed regularly. This costs us

special times with family and friends in a

around 8% of revenue, on average, with

beautiful environment.

PRECAST | ISSUE ONE | 2015

PRODUCT 24

FLEXIBLE MODULAR WALL SYSTEM

PROVES A WINNER “YFEL”, an innovative modular precast concrete wall unit developed by retaining block producer and CMA member ReMaCon Products 1 months ago, has won acceptance by a variety of industries requiring easy-to-assemble and moveable walls for containing and separating different types of products. YFEL – so called because of its inverted “Y” shape and its resemblance to the Eif fel Tower in Paris – was devised by ReMaCon because of its flexibility of application in numerous dif ferent industries that are not the obvious target for precast concrete products. “Our first three sales already confirm this diverse demand,” commented Silvio Ferraris, the company’s Managing Member. “One is for shipping company Grindrod Intermodal, which purchased mainly 4 m-high YFELs – the largest in our range – to contain and separate a variety of locally mined high-value minerals such as chrome and ferro-manganese in granular and powder form it holds in storage at its Bluff Road, Durban, and Denver, Johannesburg, premises prior to export.” Another is for Remade Recycling, a Germiston-based company that recycles various waste materials, mainly paper. The order from Grindrod Intermodal was placed in September last year for a total of 367 YFELs, comprising 164 x 4 m units for Bluff Road and 179 x 4 m units and 24 x 3 m units for the Denver facility. The 4 m units supplied to both storage sites include special corner units that are designed to intersect a YFEL wall at right angles to provide for establishment of a series of separate adjoining enclosures. ReMaCon completed delivery of the Bluff Road units in February and of the units for Denver in March this year. The YFEL wall units are transported on site and put in place using a forklift truck or crane.

PRECAST | ISSUE ONE | 2015

Purchasers of the units are provided with

it can be easily and quickly installed and

instructions for installing the walling, for

reshaped in accordance with changing

which either forklift trucks or a crane is

requirements for dividing and storing

used to lift and place them. The YFELs

pr oducts of many dif f er ent kinds,â&#x20AC;?

are designed to hold support pins used

Ferraris explained.

for this purpose. Remade Re c y cling or der e d o v er

The units are manufactured in heights ranging from 1,2-4 m.

60 x 1,8 m-high units that have been

In addition to the YFELs, ReMaCon,

shared among its Kya Sands, Pretoria

b ase d in K emp t on P ar k, G au t eng,

and Kempton Park sites. In all but one

manufactures and supplies a wide range

instance, they have been installed in

of precast concrete retaining blocks and

external areas to optimise the use of

also produces a near-vertical retaining

space for storage of waste paper, plastic

wall system, manufactured under licence

and other recyclable materials.

to a UK-based company, which is suitable

The single different application is at the

for use mainly for retention of large earth

Kya Sands facility west of Johannesburg,

embankments of up to 20 m high, such as

where some of the YFELs have been

mine tip walls and any near-vertical high

installed in place of the bottom sections

wall structure.

of the sheet metal-clad sides of a waste paper storage shed as protection from forklift trucks, which previously damaged the walls while operating inside the shed. The third purchaser of Y FEL wall units is a chemical company in North West Province. ReMaCon supplied over 100 x 4 m YFELs along with a number of corner units for establishment of a series of separate enclosures for storage of various materials involved in the companyâ&#x20AC;&#x2122;s production processes. The YFEL is particularly well suited for storage of dry bulk materials. â&#x20AC;&#x153;Its great advantage over conventional storage methods, which invariably comprise fixed built-in structures, is that (Right): A special corner YFEL unit, as shown here, intersects the wall at right angles to provide for separate adjoining storage enclosures. (Below): Grindrod Intermodal is using 4 m-high YFEL wall units to separate high-value minerals stored at its Durban and Johannesburg depots prior to export.

PRECAST | ISSUE ONE | 2015

AROUND & ABOUT 26

ULTRA-VERSATILE EARTH BLOCK

LAUNCHED IN GAUTENG A member of the CMA, West End Cement Bricks (WECB) of Westonaria, Gauteng, recently launched an exceptionally versatile earth block G E

“This is a very versatile, multi-purpose earth block,” commented Pieter Theron, WECB’s CEO. “Due to its unique flexible design, it can be laid in closed mesh formation, in standard layout or in what we call ‘economical layout’, each depending on

WECB, best known in the province as a

what the particular application is. The

producer and supplier of pavers and hol-

closed mesh layout would be used typi-

low blocks, manufactures and supplies

cally for road building to provide maximum

a variety of precast concrete products

strength and rigidity, the standard layout

developed in-house, as well as a range

is best suited for stormwater channels

of retaining wall blocks under franchise to the Cape Town-based

blocks to tie them tightly together.

and similar applications, while the

“The profile of the blocks is not uniform

open format economical layout

in shape on every side, so they have to be

allows ample space to al-

laid in a particular way in relation to each

The new G8 earth

low for soil and grass

other. Therefore, to prevent confusion

block is also a Green-

between the blocks.

and make the installation process as

lock-designed prod-

This is the ideal solu-

easy and quick as possible, every block

uct, which has already

tion for various soil-

has a distinctive mark on one corner as

won favourable atten-

stabilising applications

a guide to the installation team for how

such as embankments, parks

it should be positioned in relation to the

Greenlock Group.

tion and proven successful in the Western Cape since being introduced there in 2008. WECB, which has the exclusive franchise for

and other open areas where the soil may be at risk of being washed away if left unprotected.”

others,” Theron pointed out. WECB produces the G8 blocks in two compressive strengths: 25 MPa and

Greenlock products in Gauteng, com-

As its name implies, the “economi-

menced production of the G8 earth block

cal” layout offers cost savings through

In addition to the Greenlock products,

in October 2014.

the use of fewer blocks to cover a given

pavers and hollow blocks, WECB also

area compared with the other two lay-

produces and supplies solid building

out options.

bricks and maxi-bricks.

The G8, which comes in a single standard size of 340 mm x 340 mm x 100 mm

35 MPa.

and weighs 18,5 kg, is designed for use

If the user seeks to achieve greater

in a variety of applications that include

rigidity and stability than already provided

(Top): The new earth block used for road paving.

paving of roads and stormwater drains, as

by the four-way locking block design,

well as for earth-stabilisation purposes,

metal or plastic cables may be threaded

such as on embankments and in wetlands.

through holes that are provided in the

(Above): West End Cement Bricks’ Production Manager Denver Rambaros (left) and Sales Manager Rudi Brits display the new G8 Earthlock block at the company’s Westonaria plant.

PRECAST | ISSUE ONE | 2015

CMA member, Durban-based BrickCast Industries, best known for its precast concrete block paving products, has made a breakthrough into the specialised but growing market for near-vertical retaining wall blocks.

installed alongside the access road to

The company, which introduced a near-

precast concrete retaining blocks that

the top of the wall meets up with the main walkway giving access into the building’s lower floor,” explained Sean Sewnaath, BrickCast’s CEO. The three 550 m-long retaining walls the office park are all 3 m high. The retaining wall contract is scheduled for completion in May 2015. In addition to the specially-designed

of 20 m at an angle of 86˚.

vertical block of its own design in mid-

The retaining walls for the Milkwood

BrickCast developed for its near-vertical

2014, landed a contract in November,

Office Park comprise four separate walls.

retaining wall system, the system features

involving the design manufacture, supply

One is located immediately adjacent to

a polyethylene geo-grid system together

and installation of over 2 000 m2 of re-

the office block and flanking one side

with a blanket-like synthetic fabric that

taining walling at the Milkwood Office Park

of the parking area under the building,

are laid under the block courses at regular

currently under construction at Umhlanga

while the other three retaining walls

intervals to tie the wall securely against

Rocks on the Kwazulu-Natal North Coast.

are situated alongside the access road

the ear th embankment. A drainage

leading up to the complex.

system to prevent the accumulation of

Its client is United African Marine Shipping, owner of the Milkwood Office

“The 5,5 m-high x 90-m long parking

water is also installed at the base of the

Park development, an addition to its

area retaining wall forms an integral

wall, which is built securely on a starter

vast property portfolio in the Umhlanga

part of the building design as it not only

base concrete block foundation.

Rocks area. BrickCast’s product is a gravity interlock system that enables a retaining wall to be built up to heights in excess

“The parking area retaining wall forms an integral part of the building design.”

AROUND & ABOUT

BRICKCAST MAKES A BREAKTHROUGH

encloses one side of the parking area, but

AROUND & ABOUT 28

TELKOM USING AVENG INFRASET CONCRETE POLES TO WARD OFF VANDALISM Telkom has found prestressed concrete poles to be highly effective in discouraging and preventing cable theft. The telecommunications utility is now

from them to multiply in coming months,”

Infraset plants in the country – the other

making use of precast concrete poles

commented Samantha Chetty, Sales

being its Brakpan, Gauteng, plant – that

supplied by CMA member Aveng Infraset

Consultant: Construction Products, at

manufacture and supply prestressed

in place of traditional timber poles to

the Effingham facility.

concrete poles for lighting and related

support phone lines in areas where cable theft is rife.

“A further incentive is that, even when the poles are not likely to be targeted by

purposes, such as the application now being put into effect by Telkom.

It first put the concept to the test

cable thieves, they have the advantage

Among a range of other products the

in early 2013, when it embarked on a

of durability and a much longer life-span

Effingham plant produces are masts used

pilot project in KwaZulu-Natal’s (KZN’s)

than timber poles,” she added.

for electrification purposes, including

South Coast area of Braemer, using

The Effingham plant is one of two Aveng

electric lines for railways.

prestressed concrete poles manufac-

Prestressed concrete poles and

tured and supplied by Aveng Infraset’s

masts are maintenance-free and have

Effingham, Durban, plant. A total of 400

a high strength-to-weight ratio, making

x 7 m poles were supplied.

them easy to handle and transport.

Telkom’s strategy was to run the

Aveng Infraset’s poles and masts,

pilot project for 10 months to enable

which are based on a unique design, are

it to prove itself. Having done so, it

available in a wide range of strengths and

has followed up by placing a further five

sizes. They are ideally suited to applica-

orders with Effingham since February

tions such as power transmission, distri-

last year for poles for installation in two

bution, telecommunications and overhead

other areas in KZN and three areas in

electrical equipment for railways.

the Eastern Cape. The first of these orders was for 500 x 7 m poles for installation in the Lusikisiki area near Port St Johns in the Eastern Cape. The next two orders consisted mostly of 7 m poles as previously, but also

(Left): A worm’s-eye view of one of the concrete poles alongside the wooden pole it has replaced. (Below): Samantha Chetty, Sales Consultant: Construction Products, of Aveng Infraset’s Effingham facility with two Telkom site foremen during erection of concrete poles the company has supplied to replace wooden telegraph poles.

included taller poles to provide for dips in undulating landscape encountered at these locations. An order placed with Effingham in September for poles destined for Sinembe on KZN’s North Coast near Tongaat comprised 657 x 7 m poles, 14 x 9 m poles and two 10 m poles. The company received a further order in November for poles for Kenterton near Ixopo in KZN, consisting of 380 x 7 m and 20 x 9 m poles. Telkom subsequently placed orders in December and January for Mthatha and Grahamstown in the Eastern Cape, for 550 x 7 m poles and 75 x 7 m poles respectively. “Telkom is satisfied that our poles contribute a lot towards solving the vandalism problem, so we expect the orders

PRECAST | ISSUE ONE | 2015

INDUSTRY FORUM 30

TRAINING CAN DISPEL COSTLY CONCRETE TECHNOLOGY MYTHS Misconceptions abound in South African

tion. The American-produced DVD deals

add more cement;

concrete technology – and training is

with the most common concrete miscon-

8. The stronger the mortar or plaster,

the only way to dispel these myths that

ceptions in the US construction industry.

the better;

produce flawed concrete requiring costly

“Interestingly, these American myths

9. “Integral” waterproofing admixtures

remedial action, says John Roxburgh,

differ quite substantially from those we

are an absolute necessity for concrete

lecturer at The Concrete Institute’s

encounter while lecturing at the School

water retaining structures; and

School of Concrete Technology.

of Concrete Technology. I would say the

10. It is impossible to produce very strong

Roxburgh says the Information Centre

top 10 South African ‘old wives’ tales’,

concrete using cement with a strength

of The Concrete Institute stocks a DVD

or misguided philosophies, that crop up

class rating of 32,5N.

called Top 10 Myths in Concrete Construc-

during school classes are:

“Those with some knowledge of con-

1. Be very careful not to over-vibrate

crete technology will realise that many

concrete;

of the above views are actually partially

2. “I have 30 years’ concreting experience

true. But the alarming fact is that far

– so I know everything about concrete”;

too many people involved in concrete

3. Adding more stone to concrete makes

production do not seem to know which

the concrete stronger;

are partially true and which are absolute

4. Extended cements always take longer

myths,” Roxburgh adds.

to set and gain in strength;

The School of Concrete Technology

5. Just add salt to your concrete to

is South Africa’s leading provider of

make it waterproof (very popular among

education in concrete technology with

farmers);

its broad spectrum of courses, and

6. To make concrete stronger, simply add

caters for a wide variety of educational

more cement;

needs within the construction, mining

7. To make concrete more durable, just

and concrete-related industries.

Terraforce, a CMA member, provides

regular intervals with geo-grid for extra

first-class engineering, management

reinforcement.

and specialist technical service to users of any Terraforce products, aiming to

Thaba Moshate Hotel & Casino in Burg-

set industry standards and make a

ersfort, Mpumalanga:

significant contribution to safe retaining

Terraforce rock-face walls are in the

wall design throughout South Africa and

p r o c e ss o f b eing ins t all e d ar o un d

the world. To illustrate the scope of this

the swimming pool ar ea and along

service, we are highlighting some of the

embankments on the property. Two

projects utilising Terrasafe, currently

Sasol Garage Complex, Mthatha,

rows of cheaper grey blocks are used

under construction:

Eastern Cape:

below ground level, followed by a row of

This particular site had a relatively new

smooth, flat face blocks (to facilitate a

The new International Convention Centre

gabion wall installed that had collapsed

neat finish where paving meets this level)

and five-star resort, eZulwini, Swaziland:

and damaged the concrete columns

and then continued with rock-face blocks

At this prominent R500 million project

supporting the building overhanging a

in Kalahari colour.

in Swaziland, the Terraforce walls were

steep embankment. The client requested

designed as terraces, with the first level

an alternative design and out of a few

being 2m, followed by 4m steps up to a

options, settled for the Terraforce

total height of 18m. The first terrace

system. T he Terraf orce walls were

is being constructed with reinforced

d e si g n e d a t 8 0 째 f o r b e t t e r sl o p e

concrete infill at 85째 and the 4m steps

stability and to simplify construction

ther eaf ter, at 80 째 with r einf or ced

due to the limited head space under

concrete infill. Double skin walls are also

the structure. About two-thirds of the

utilised at specific places, for additional

wall is constructed with a double skin

strength. Geogrid reinforcing to the

of blocks, partially filled with reinforced

backfill is specified at intervals.

concrete and tied into the back-fill at

INDUSTRY FORUM

DESIGNING SAFE RETAINING WALLS

BIRKENMAYER MACHINES INSTRUMENTAL IN BLOCKMAKING COMPANY’S SUCCESS Rustenburg-based block-making company

with the plant assembly and we feel this

Cemblocks recently acquired an additional

a key contributing factor to its equip-

two Birkenmayer (CMA member) block-

ment’s durability,” said Francois Alberts,

making machines to increase its produc-

Cemblocks’ CEO.

tion capacity to 13 million bricks a month.

“Despite its age, the plant continuously

Cemblocks has only ever used Birken-

delivers 1 500 pallets of product per day

mayer machinery during its 32 years in

in nine-hour shifts and we have only had

business and attributes its success, in

to replace the PLC once.”

part, to quality equipment and the sound back-up support Birkenmayer provides.

B i r k e n m a y e r ’s M o n i k a H o w a r t h commented:“An endorsement of this na-

The current equipment of Cemblocks,

ture proves the durability, reliability and

which supplies contractors and retailers

consistency of Birkenmayer brick- and

within the greater Rustenburg area,

block-making machinery and parts.”

comprises a VB1, purchased when the

Cemblocks’ product range comprises

company began production, a VB4, two

solid large blocks, maxis, stock bricks,

VB5 block-making machines and one VB6.

several paving products, retaining wall

“The VB1, purchased in 1981, is a me-

blocks and rock-face bricks. Cemblocks

chanical miracle. Birkenmayer assisted

also manufactures customised products.

INSULATING COMPANY USES MAPEI PRODUCT ON SOWETO CHURCH ROOF Multi-Dex 2000 of Edenvale, Gauteng, an

lated bituminous polymer membranes,

approved applicator of Mapei sealants,

as well as unprotected liquid bituminous

adhesives and chemical products for build-

coatings, from UV sunlight.

ing, recently completed refurbishing the

“We have been using Mapei products

9 000 m² roof of the Universal Church of the

for about three years now,” commented

Kingdom of God in Orlando West, Soweto,

Botha. “We regularly use the silver protec-

using one of Mapei’s insulation products.

tive paint, the Mapelastic cementitious

“We have tackled a number of difficult

waterproofing mortar products, as well as

projects, but this job was especially in-

other waterproofing products in its range.”

teresting and challenging,” said Warren Botha, Director of the company. “We were working 18 m off the ground and experienced delays as a result of high winds that made it unsafe to handle the sheets of insulation and torch-on waterproofing. Added to this, the roof was dome-shaped and presented a 35-50˚ gradient that was difficult to measure, let alone work on. “In spite of this, we still managed to complete the project in seven weeks. For the final protective finish, we used Mapei’s Polypaint Alu, which is easy to apply and gives reliable and exceptionally good results.” Mapei’s Polypaint Alu is a versatile, water-based, effective silver paint designed to protect talc, sand and granu-

A bird’s-eye view of work in progress during insulation of the domed roof of the Universal Church of the Kingdom of God in Orlando West, with Mapei’s silver Polypaint Alu applied as the final protective finish.

CMA member Rocla was contracted to

the quality of the pipes. These are huge

supply a part of the 1 100 m of jacking

pipes that have an approximate mass

pipes for two of the 19 sections for un-

per metre of 5 680 kg/m and a mass of

derground construction to the upgrades

8 518 kg/pipe.”

for the Palmiet Pumping Station to Sig-

The Rocla 100D jacking pipe used on

nal Hill Reservoir project currently being

the project has a nominal diameter of

constructed for Rand Water.

2 500 mm and a proof load of 250 kN/m.

Two contractors, Wepex and Esor,

Steel pipes will be inserted into the

are using Rocla’s 100D jacking pipes

jacking pipe for extra support and for

on the project, which commenced in

their anti-corrosion properties.

April 2014 and is due for completion in November this year. “The Palmiet/Signal Hill project is an

sified to SANS 677. The self-compacting

18-month one with hard rock alongside

concrete renders a good surface finish

residential and national roads needing

and the vertical cast process applied

to be blasted,” said Luke Woodhams,

in its manufacture ensures consistent

Contracts Manager: Pipe Jacking Divi-

thickness throughout the pipe wall, as

sion for Wepex.

well as providing excellent compaction

“Rocla had the right pipe with good

A Rocla 100D jacking pipe.

The Rocla 100D jacking pipe is made from self-compacting concrete and clas-

and bonding to the reinforcement.

availability. Its product is of an excellent

Self-compacting concrete contrib-

quality and we are very pleased with

u tes towar ds incr eased sa f e t y on

its service.”

the job by eliminating the need for con-

Anton Naudé, Director of Pipejacking

solidation. It is also cost-effective as

for Esor, commented: “The jacking pipes

it offers improved pumpability, higher

need to be able to last the lifespan of the

labour ef ficiencies and shorter con-

project, which they will easily do due to

struction times.

INDUSTRY FORUM

ROCLA SUPPLIES JACKING PIPES FOR WATER PIPELINE

INDUSTRY FORUM 34

LAFARGE SOUTH AFRICA’S WHITE CONCRETE SOLUTION FOR CHEVRON HEADQUARTERS When Chevron South Africa, a leading

ArteviaT M decorative concrete is

r ef iner and marketer of petr oleum

a high-qualit y str uc tur al concr e te

Standing back to appreciate the

p r o d u c t s, l o o k e d f o r a l a n d m a r k

combining durability and low maintenance

overall ef f ect, the superb Chev r on

sustainable design for its new

with a high standard of aesthetic finish.

building gleams like travertine marble.

headquarters in Century City, Cape

The product is produced with an integral

While initially it has been expensive

Town in 2011, Louis Karol Architects

UV stable colour pigment.

to cr eate, the monolithic ex ternal

team to ensure a successful outcome.”

& Interiors proposed a “naked” white

“We believe the Chevron project in-

structure will only require cleaning

c oncr e te building – bu t the clien t

volved the largest volume of white con-

every seven or eight years. “We are

was initially sceptical that the local

crete ever used in the Western Cape,”

overwhelmed by the outcome,” enthuses

construction industry could successfully

commented Johann van der Merwe,

architect, Silke. “The building looks

build a major structur e in white

Contr acts Manager f or Ste f anutti

beautiful and demonstrates that in

concrete. As the concrete solution,

Stocks. “The extent of the challenges

partnership with Lafarge’s technical

Lafarge South Africa, a member of the

that had to be addressed was hard

resources, the local building industry

CMA, proposed its innovative ArteviaTM

to envisage, but Lafarge Cape Town

has the construction skills to create a

decorative concrete.

Readymix worked closely with us as a

world-class result.”

KAYTECH INTRODUCES CONCRETE CANVAS CMA member Kay tech has signed a

roll. It allows concrete construction

distributorship agreement with Concrete

without the need for plant or mixing

C anvas SA to suppl y geosy nthe tic

equipment.

cementitious composite mats into the

The concrete is pre-mixed so there

South African civil engineering industry,

is no need for mixing, measuring or

including road and rail applications.

compacting: just add water.

ing a safe plastic failure mode. It is available in two thicknesses, CC5 and CC8, which are 5 mm and 8 mm thick respectively. Concrete Canvas can be laid at a rate of 200 m 2 /hr – about 10 times

Concrete Canvas is used specifically

Concrete Canvas consists of a three-

f aster than conventional concr e te

for the lining of culverts, channels, slope

dimensional fibre matrix containing a

solutions. It is available in shorter rolls

protection and remediation of existing

specially formulated dry concrete mix. A

for applications with limited access. The

concrete structures.

PVC backing on one surface of the mat

speed and ease of installation make it

Concrete Canvas is a flexible con-

ensures the material is completely wa-

more cost-effective than conventional

crete-impregnated fabric that hardens

terproof. The material is hydrated either

concrete, with less logistical complexity.

on hydration to form a thin, durable,

by spraying or by being fully immersed in

Concrete Canvas is a low-mass, low-

waterproof and fire-resistant concrete

water. Once set, the fibres reinforce the

carbon technology using up to 95% less

layer. Essentially, it is concrete on a

concrete, preventing cracking and provid-

material than conventional concrete for many applications. Key properties include: • The PVC backing on one surface of the GCCM ensures that the material has excellent impermeability. • The fibre reinforcement prevents cracking, absorbs energy from impacts and provides a stable failure mode. • It is twice as abrasion-resistant as standard OPC concrete, has excellent chemical resistance, good weathering performance and will not degrade in UV. Concrete Canvas has good drape characteristics and will closely follow the ground profile and fit around existing infrastructure. While unset, it can be cut or tailored using basic hand tools. Concrete Canvas being installed for channel lining.

PRECAST | ISSUE ONE | 2015

CHRYSO GROUP APPOINTS ANGOLAN DISTRIBUTORS The Chryso Southern Africa Group has entered into an agreement with the Luanda-based company, Lunapa, for the distribution of the Chryso range of admixtures and ancillary concrete performanceenhancing products in Angola. Lunapa, based in Benfica, Luanda’s industrial zone, has been operating for the past five years as a supplier of imported concrete admixtures for the construction industry. Business Development Manager of Chryso SA, Luis Ferreira, says the construction industry in Luanda has been extremely active in the past few years and the growth is expected to expand further into Angolan cities and rural areas as the need for new infrastructure is being addressed by the government. T he appointment of Angolan distributors is the latest development in a concerted effort by Chryso Southern Africa to boost exports to the rest of Africa. Chryso and abe products are currently being used on several major African infrastructural development projects, particularly Zambian mining, commercial, industrial and fuel industry projects – and in Mocambique, where the Nacala Rail Corridor and other industrial and commercial developments have, for example, led to major orders. There are distributors for Chryso/abe operating in several African countries, including Mozambique, Zambia, Botswana, Namibia, Ghana and now also Angola. Chryso SA is also planning to establish distribution outlets in Tanzania, Kenya, Uganda and the southern part of the DRC. Norman Seymore, Vice-president of the Chryso Group globally, recently said the group had decided to concentrate more on exports to the sub-Saharan African market about three years ago, when a special Business Development division, concentrating mainly on African and Indian Ocean islands sales and distribution, was established. “Our quest to boost exports is now showing the results we sought, with the growth in exports to Africa, particularly to neighbouring states, growing by 25% in total last year. The growth showed that the Chryso SA Group must continue to seek increased representation in sub-Saharan Africa. We are also planning to establish production facilities in east and west Africa,” he stated. Luanda, the capital of Angola, is experiencing an upsurge in construction activity.

PRECAST | ISSUE ONE | 2015

Echo prestressed hollow-core slabs have

was the main contractor and DSM

SIKA ACQUIRES DURO-MOZA OF MOZAMBIQUE

been used to roof a second storey added to

Consulting Engineers was the engineering

CMA member Sika has acquired the

MTN’s Data Centre in Centurion, Gauteng.

consultancy involved.

assets of Duro-Moza, a Mozam-

The extension followed the use of

The prestressed roof slabs are 250

(CMA member) Echo slabs to roof the

mm deep with spans of between of 2,2-

original single-storey building built in

11,5 m. They are designed to carry live

The transaction will accelerate

2012. The second storey has been built

loads of 10 kN/m² and dead loads of 2,5

t h e d e v e l o pm e n t an d m ar k e t

on top of the prestressed slab roof of

kN/m². They are mounted on precast

penetration of Sika Mozambique,

the original structure. Grinaker-LTA

inverted T-beams measuring 420 mm

which Sika founded last year.

cialised mortar and tile adhesives.

deep and 630 mm wide, which Echo

The acquisition provides Sika

subcontracted to ENCON to design and

Mozambique with an ideal start

Civilcon to manufacture.

in the market, giving immediate

The beams have been installed on

access to its own production

6,5 m-high r einf or ced cast-in-situ

facility and to an established cus-

concrete columns, most of which feature

tomer base in the fast-growing

rebar that protrudes through the slab

construction sector.

roof to support solar panels and other plant to be mounted on the roof.

(Above): The MTN Data Centre’s second storey under construction, showing the Echo prestressed slabs installed to roof it.

bique-based company producing spe-

Maputo-based Duro-Moza has developed a comprehensive prod-

A lightweight politerm screed-to-falls

uct range covering plasters, tile

has been installed over the slabs, followed

adhesives, dry shakes, grouting and

by a second screed covering to take a

concrete repairs.

dual layer of waterproofing.

INDUSTRY FORUM

MTN DATA CENTRE EXTENSION ROOFED WITH ECHO PRESTRESSED HOLLOW-CORE SLABS

MAKE SURE YOU

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E ER ITE H S CK EB I CL R W FO

MEMBERS LIST 40

PRODUCER MEMBERS A FICK SEMENTWERKE BK Tel: 022 913 2370 Province/Country: Western Cape Pillar: PB AVENG MANUFACTURING INFRASET (12) Tel: 011 876 5500 Province/Country: Gauteng Pillar: PB/PI BASS BEAMS Tel: 031 784 1920 Province/Country: Kwa-Zulu Natal Pillar: PB BAY BRICK Tel: 035 792 5218 Province/Country: Kwa-Zulu Natal Pillar: PB BOSUN BRICK (2) Tel: 011 310 1176 Province/Country: Gauteng Pillar: PI BRICKCAST INDUSTRIES CC Tel: 031 507 5525 Province/Country: Kwa-Zulu Natal Pillar: PI C.E.L PAVING PRODUCTS Tel: 021 905 5998 Privince/Country: Western Cape Pillar: PI CAST INDUSTRIES Tel: 011 316 2375 Province/Country: Gauteng PB/PI CIVIL WORKS Tel: 011 903 7023 Province/Country: Gauteng Pillar: PI CONCRETE UNITS (2) Tel: 016 362 2236/021 386 1923 Province/Country: Western Cape/ Gauteng Pillar: PB/PI CONFRAMAT Tel: 0861 33 5599 Province/Country: Gauteng Pillar: PB/PI COROBRIK PTY LTD Tel: 031 560 3111 Province/Country: Kwa-Zulu Natal Pillar: PI DERANCO PRECAST Tel: 041 933 2755 Province/Country: Eastern Cape Pillar: PB/PI EAGLE ROOF TILES PTY LTD (4) Tel: 044 874 0290 Province/Country: Western Cape Pillar: PB ECHO GROUP (3) Tel: 011 589 8800/8899 Province/Country: Gauteng Pillar: PB ENVIRO–CAST PTY LTD Tel: 016 004 0018 Province/Country: Gauteng Pillar: PI FASTDECK PTY LTD Tel: 002677 3971974 Province/Country: Botswana Pillar: PB INCA MASONRY PRODUCTS (2) Tel: 043 745 1215 Province/Country: Eastern Cape Pillar: PB/PI KEYSTONE WALLING Tel: 082 850 3512 Province/Country: Gauteng Pillar: PB/PI

LATEGAN CEMENT WORKS Tel: 021 873 1154 Province/Country: Western Cape Pillar: PB MARLEY ROOFING (6) Tel: 011 316 2121 Province/Country: Gauteng Pillar: PB MOBICAST PTY LTD Tel: 044 874 2268 Province/Country: Western Cape Pillar: PB MONIER ROOFING SOUTH AFRICA (10) Tel: 011 222 7300 Province/Country: Gauteng Pillar: PB MVA BRICKS Tel: 012 386 0050 Province/Country: Gauteng Pillar: PI PANDA GROUP (2) Tel: 00267 244 2107 Province/Country: Botswana Pillar: PB/PI PORTLAND HOLLOWCORE SLABS PTY LTD Tel: 021 972 1111 Province/Country: Western Cape Pillar: PB

ASSOCIATE MEMBERS ASPASA Tel: 011 791 3327 Province/Country: Gauteng ARQ CONSULTING ENGINEERS PTY LTD Tel: 012 348 6668 Province/Country: Gauteng BRITISH PRECAST CONCRETE FEDERATION Tel: 044 116 253 6161 Province/Country: United Kingdom CONCRETE SOCIETY OF SOUTH AFRICA Tel: 012 348 5305 Province/Country: Gauteng ILIFA AFRICA ENGINEERS PTY LTD Tel: 012 362 1473 Province/Country: Gauteng JC PAVING CONSULTING Tel: 011 431 0727 Province/Country: Gauteng SEKHUKHUNE & ASSOCIATES Tel: 012 993 4776 Province/Country: Gauteng SNA CIVIL & STRUCTURAL ENG Tel: 012 842 000 Province/Country: Gauteng

HAWKEYE PEDERSHAAB Tel: 00 45 9645 4040 Province/Country: Denmark HYDRAFORM INTERNATIONAL PTY LTD Tel: 011 913 1449 Province/Country: Gauteng KAYTECH Tel: 031 717 2300 Province/Country: Kwa-Zulu Natal KERNEOS SOUTHERN AFRICA PTY LTD Tel: 011 444 3090 Province/Country: Gauteng KOBRA MOULDS B.V. Tel: 003111 356 2460 Province/Country: Netherlands MANITOU SA PTY LTD Tel: 011 975 7770 Province/Country: Gauteng OCEM Tel: 0039 055 658 0120 Province/Country: Italy PAN MIXERS SA LTD Tel: 011 578 8600/8701 Province/Country: Gauteng QUADRA Tel: 0033 67941 2644 Province/Country: France

REMACON PRODUCTS CC Tel: 011 393 5504 Province/Country: Gauteng Pillar: PI

SARMA Tel: 011 791 3327 Province/Country: Gauteng

REVELSTONE (CAPE) PTY LTD Tel: 021 761 9739 Province/Country: Western Cape Pillar: PB

TACO VOOGT CONSULTING ENGINEERS Tel: 079 505 7840 Province/Country: Gauteng

SAMJUNG INDUSTRIES LTD Tel: 0082542607722 Province/Country: Korea

ROCLA (12) Tel: 011 670 7600 Province/Country: Gauteng Pillar: PB/PI

THE JOB CLUB Tel: 012 661 1099 Province/Country: Gauteng

SCHLÜSSELBAUER TECHNOLOGY GMBH & CO KG Tel: 004377357144 201 Province/Country: Austria

TERRAFORCE PTY LTD Tel: 021 465 1907 Province/Country: Western Cape

SIKA SOUTH AFRICA PTY LTD Tel: 031 792 6500 Province/Country: Kwa-Zulu Natal

TJEKA TRAINING MATTERS Tel: 011 665 2777 Province/Country: Gauteng

TECHMATIK S.A. Tel: 00484 803 690 811 Province/Country: Poland

YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS Tel: 031 207 7252 Province/Country: Kwa-Zulu Natal

CEMENT MEMBERS

SHUKUMA BRICKS Tel: 041 372 1013 Province/Country: Eastern Cape Pillar: PB SILVERTON PRECAST PTY LTD Tel: 012 804 4525 Province/Country: Gauteng Pillar: PB SMARTSTONE (13) Tel: 011 310 1161 Province/Country: Gauteng Pillar: PB SOUTHERN PIPELINE CONTRACTORS Tel: 011 914 8500 Province/Country: Gauteng Pillar: PB/PI SWAKOP TILES CC T/A NAMIB ROOF TILE COMPANY Tel: 00264 6446 3717 Province/Country: Namibia Pillar: PB TECHNICRETE (6) Tel: 011 674 6900 Province/Country: Gauteng Pillar: PB/PI TOPFLOOR CONCRETE (2) Tel: 021 951 7700 Province/Country: Western Cape Pillar: PB VANSTONE PRECAST PTY LTD Tel: 012 541 2056/1808 Province/Country: Gauteng Pillar: PI WEST END CEMENT BRICKS PTY LTD Tel: 011 851 1005/1063 Province/Country: Gauteng Pillar: PI

NON-PRODUCER MEMBERS

QUANGONG MACHINERY CO. LTD Tel: 00865 958 679 9299 Province/Country: China

AFRISAM SOUTH AFRICA 011 670 5500 Gauteng

ABEL EQUIPMENT Tel: 044 874 1876 Province/Country: Western Cape

LAFARGE INDUSTRIES South Africa Pty Ltd 011 657 0000 Province/Country: Gauteng

ASH RESOURCES PTY LTD Tel: 011 657 0230 Province/Country: Gauteng

PPC LTD Tel: 011 386 9000 Province/Country: Gauteng

H BIRKENMAYER PTY LTD Tel: 011 970 3880 Province/Country: Gauteng

SEPHAKU CEMENT Tel: 012 684 6300 Province/Country: Gauteng

CHRYSO SOUTHERN AFRICA PTY LTD Tel: 011 395 9700 Province/Country: Gauteng

CONTRACTOR MEMBERS

DOUBELL BRICK MACHINES Tel: 041 585 9060 Province/Country: Eastern Cape DELTA BLOC SOUTH AFRICA PTY LTD Tel: 011 024 4604 Province/Country: Gauteng

DECORTON RETAINING SYSTEMS Tel: 021 875 5155 Province/Country: Western Cape FRICTION RETAINING STRUCTURES PTY LTD Tel: 011 608 4321 Province/Country: Gauteng POWERGATE CONSTRUCTION Tel: 071 603 5070 Province/Country: Gauteng

DICK KING LAB SUPPLIES Tel: 011 499 9400 Province/Country: Gauteng

PYW PAVING Tel: 031 903 1736 Province/Country: Kwa-Zulu Natal

ENVIROTAN Tel: 011 452 7906 Province/Country: Gauteng

VALCAL INTERNATIONAL EXPORT Tel: 011 867 2471 Province/Country: Gauteng

PI - Precast Infrastructure PB - Precast Building (...) - Number of branches

PRECAST | ISSUE ONE | 2015