Precast • Issue one • 2018

ISSUE ONE • 2018

R49.00

THE CMA – QUALITY CAST IN CONCRETE

• Green retaining walls • Vibrators lower costs • An architectural masterpiece

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2

HIGH-TECH VIBRATION IMPROVES/LOWERS COSTS

INDUSTRY NEWS 5

IS SLOW PAYMENT BECOMING THE NEW NORMAL

6

POOR QUALIT Y CONCRETE IS DANGEROUS & WASTEFUL

7

IMPROVING CONCRETE SKILLS

18 PERMEABLE CONCRETE

PROVIDES A SOLUTION FOR

PRESERVING WATER 20 BENEFITS OF FIBRE REINFORCED CONCRETE

9 A NEW FOCUS ON INFRASTRUCTURE

31 DONKIN VILLAGE REJUVENATES

USES COBBLE PAVERS FOR

A MODERN TWIST

CONTENTS

TECHNICAL

COVER STORY

FEATURE

1

30 PAVING THE WAY FOR A PORT

ELIZABETH CAR DEALERSHIP

21

PRODUCTS PROJECTS

10

23 MODERN ARCHITECTURAL MASTERPIECE 27 READYMIX CONCRETE

CONSIDERATIONS FOR

INFRASTRUCTURE PROJECTS

33 36 EROSION CONTROL SOLUTION

FOR MIXED-USE PROPERT Y PARK 37 PRECAST ELEMENTS ENHANCES

SILO PROPERT Y DEVELOPMENTS 38 REPAIR OF THE SPUR AT

CAPE TOWN HARBOUR 40 BOTSWANA ROAD UPGRADE

12 BRING ON ELEMENT OF GREEN

WITH RETAINING WALLS 12 PRECAST CONCERNS

41

COMPANY NEWS 14 DECORATIVE CONCRETE

OPTIONS ON THE INCREASE

28

15 MAPEI GEARS FOR GROWTH 16 DEVELOPMENT TRENDS FOCUS

ON SUSTAINABILIT Y

PRECAST is the mouthpiece for the Concrete Manufacturers’ Association - CMA Concrete Manufacturers’ Association Physical Address: Office 0400, Standard Plaza Building, 440 Hilda St, Hatfield, Pretoria Postal Address: Post Net Suite 334 Private Bag X 15, Menlo Park, 0102 Tel: (+27 11) 805 6742 Fax: (+27) 86 524 9216 E-mail: admin@cma.org.za Website: www.cma.org.za Publishers: Isikhova Publishing & Communications Postal Address: PO Box 651793, Benmore, 2010, South Africa Tel: (+27 11) 883 4627 Fax: (+27 11) 783 2677 Website: www.isikhova.co.za Publisher: Andrew Meyer Tel: (+27 11) 883 4627 E-mail: andrewm@isikhova.co.za Consulting editor: Raymond Campling Tel: 076 297 2775 E-mail: media@mediasavvy.biz

PRECAST | ISSUE ONE | 2018

42 PERMEABLE PAVING PROVIDES

A STORM WATER SOLUTION IN

MITCHELLS PLAIN

Coastal editorial: David Beer Tel: 082 880 6726 E-mail: david.bigsky@gmail.com

ISSUE ONE • 2018

R49.00

THE CMA – QUALITY CAST IN CONCRETE

Advertising: Wally Armstrong Cell: 083 701 3278 E-mail: wallyarmstrong@outlook.com Subscriptions/Accounts: Thuli Majola Tel: (+27 11) 883 4627 E-mail: subscriptions@isikhova.co.za Design and layout: Joanne Brook E-mail: joanne.studio@isikhova.co.za The views and statements expressed in this publication are not necessarily those of the editor or the publishers and neither the publishers nor the CMA accept responsibility for them. No person connected with the publication of this journal will be liable for any loss or damage sustained as a result of action following any statements or opinions expressed herein. The same applies to all advertising. Precast© 2017. All rights reserved. No part of this magazine may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage retrieval system, without prior written permission from the publishers.

Endorsed by:

• Green retaining walls • Vibrators lower costs • An architectural masterpiece

ON THE COVER PMSA’s UltraVibe vibration system provides far greater consistency, improved product quality and lower maintenance over old mechanicallyoperated versions. The new system also offers greater precision and better control of the vibration process. PMSA also offers a free evaluation to customers running large board block machinery, to see if the UltraVibe can be fitted onto their existing machinery.

COVER STORY

The new technology is innovative and versatile The UltraVibe vibration system has substantial advantages over the old mechanically-operated version, including f ar gr ea ter consistency, impr o v ed product quality and lower maintenance.

2

The new system also offers greater precision and better control of the vibration process. Four electric motors drive four vibration shafts, as opposed to the two-vibration motor and shaft combination used in the old system.

The two-vibration system functioned on a stop-start basis, which not only made the intensity and duration of the vibration process more difficult to control, but required more power. The new UltraVibe system has four shafts, which spin continuously, driving four vibration boxes. The motors and shafts operate in pairs, each pair running in opposite directions to the other. This cancels out all vibration force, resulting in a neutral or non-vibratory mode. When vibration is required, the angle of the paired shafts will automatically adjust in under 0,2 seconds, and by up to 150˚, to generate the required level of vibration frequency and amplitude.

UltraVibe can be run at extremely high speeds. As the motors are computercontr olled and ser vo-assisted, the intensity and duration of the vibration c an b e m an ag e d w i th f ar gr e a t e r a c c u r a c y. T h e P L C m o n i t o r s a n d controls the motors continuously, and

HIGH-TECH VIBR

IMPROVES QUALITY A When it comes to manufacturing paving and precast concrete products, keeping costs in check without compromising quality is key. Cape Townbased CMA member, C.E.L. Paving, has retrofitted an UltraVibe vibration system onto an existing RE 1400 concrete block casting machine. This system, comprising a new table and vibrators, was designed and built by Pan Mixers South Africa (PMSA), and is driven using computer-controlled servo motors imported from Germany.

when necessary, can self-correct in milliseconds. Several programme modes

easily change from the production of

a not infrequent occurrence, a bearing

allow for various combinations of shaft

paving blocks, which weigh a collective

would fail very quickly if the nipple was

speed, amplitude and vibration intensity.

90kg, to kerbstones which weigh 400kg

not replaced and maintenance staff didn’t

collectively. With the old system, any

grease the bearings.”

Versatile system

change in production runs would result in

He explains that it can take a day,

PMSA sales and marketing manager,

considerable downtime. With UltraVibe,

or one-and-a-half production shif ts,

Quintin Booysen, shares that production

it’s a keyboard rather than mechanical

to replace a bearing, not taking into

versatility is a major plus. “One can

exercise, and takes seconds as opposed

account the cost of the repair itself.

to hours, to alter amplitude and force on

“With UltraVibe each shaft runs in a

the vibration table.”

sealed oil bath, so the bearings are

C.E.L. Paving managing director,

permanently lubricated. We’ve been

Claude Gorgulho, says that the UltraVibe

running the new system since June 2017

system will pay for itself in under a year.

with no downtime incidents. Had the

“A lthough gr eater consistency and

open vibration boxes still been in place,

product quality are important purchase

we undoubtedly would have had a bearing

considerations, the kicker for us was the

replacement every three months.”

fact that UltraVibe is over engineered

(Above): Walter Ebeling (left) and Robert Ebeling (right), joint managing directors of PMSA.

and requires far less maintenance. For

Smart operation

example, the shaft bearings of the old

Gorgulho adds that UltraVibe uses self-

system required manual lubrication using

limiting software to prevent it from over-

grease guns. If a grease nipple broke off,

revving. “It has massive power reserves

PRECAST | ISSUE ONE | 2018

(Left): Servo Motors for high torque, lower power consumption and fast reaction times.

leg to implement upgrades, which can completely transform an old plant into a modern production line,” says Ebeling.

“Provided the machines were supplied

high capacity block machine, which they

by any of the recognised manufacturers

will be launching later this year. Equipped

in Europe, the USA, South Africa, or by

with PMSA’s latest technology, the Ultra

quality-orientated companies, we can do

3000 will have a production capacity of

a lot to optimise them.”

up to 250 000 stock or bevel pavers per nine-hour production shift.

E b eling adds Ul tr aV ib e long-li f e sealed vibrators are an prime example.

“They can be supplied in either a two

Cost effective

vibrator stop/start configuration or,

PMSA managing director, Walter Ebeling,

as in the case of C.E.L, in a four-motor

says they are passionate about helping

continuously running configuration with

manufacturers recognise how they can

fully-adjustable speed control.” Even

set themselves on a new growth path,

machines that are 20 to 30 years old

simply by upgrading key components

can be upgraded to a high standard and

in their manufacturing processes and

produce consistent quality, as long as

investing in appropriate technologies.

they are still in good condition. “If they

“It doesn’t need to cost an arm-and-a-

are of inferior quality, have not been well

RATION SYSTEM

looked after, or are simply not worth

AND LOWERS COSTS

upgrading, we can supply brand new PMSA machines,” says Ebeling.

“We fully understand that not all companies are in a position to buy one of our fully-automated VB4X, RE1400, Ultra 3000 plants, but that does not mean that they can’t compete with the

and can generate a force of 15 tonnes

best producers in terms of consistency

vibration at 55 hertz – far more than we

and quality. Whether we supply one of

could or would use. When the system

our brick, block, kerbstone or roof tile

was first installed we ran a test at 80%

manufacturing machines, or optimise

intensity, which made our entire building

and upgrade customers’ existing plants

shake. And because it provides continual

– they can be assured of our dedication

feedback, it doesn’t allow us into the

to help them produce the best possible

danger zone.”

products in a cost-effective and efficient

A n added bonus, says Gorgulho,

manner,” assures Ebeling.

is that their moulds are lasting 60% longer due to the precision-controlled

Technical support

vibration. Given that they cost up to

P MS A o f f er s a f r e e e v alua tion t o

R200 000 apiece, this is a substantial

customers running large board block

saving. “Finally, UltraVibe allows us to

machinery, to see if the UltraVibe can

run stronger and faster using a more

be fitted onto their existing machinery.

controlled vibration for longer periods.

PMSA also provides additional upgrade

This gives us a denser product and opens

solutions to improve end-product quality

up new market possibilities for us. We

and plant productivity.

can now offer our customers a wider and much heavier range of products – a

PMSA is Africa’s largest manufacturer of

win-win all round.”

concrete brick, block and paving machinery,

Booysen says that versatility of

and supplies concrete pumps, planetary

the system means that the UltraVibe

and twin-shaft mixers (Eurostar), turbine

system can be used to upgrade a wide

and counter-current rapid pan mixers

range of machinery and makes. Currently,

(PMSA), moisture measuring systems (Franz Ludwig), oxide dosing systems (Finke

PMSA is upgrading two German-built

Dosiertechnik), kerb stone machinery

Schlosser block machines with f ull

(Wil El Mil Engineering), concrete pipe

UltraVibe systems in Johannesburg. They

machinery (BFS Casagrande), mixing

are due to be installed and commissioned shortly. The UltraVibe system will also be used on the new PMSA Ultra 3000 ultra-

PRECAST | ISSUE ONE | 2018

(Above, from top): Maintenance free, sealed UltraVibe vibration boxes; Induction Motors during R+D testing as an alternative to Servo Motors

and weigh batching plants (PMSA) and production pallets (MyWood).

COVER STORY

(Far left): UltraVibe during R+D testing at PMSA.

3

EIRICH R-TYPE MIXERS + HYDRONIX MOISTURE CONTROL = TOTALLY CONSISTENT CONCRETE WITH EVERY BATCH

HYDRO CONTROLAUTOMATES MIXING A. BATCH IN MIXER B. CEMENT DISCHARGE BY TIMER C. MONITORED FLAT LINE FOR DRY MIX AND MOISTURE MEASUREMENT D. WATER DISCHARGE E. MONITORED FLAT LINE FOR WET MIX F. TIMED DISCHARGE

COST SAVINGS WITH EIRICH RV19 INTENSIVE MIXER SAVINGS IN CEMENT, PIGMENTS, ENERGY, WATER AND REJECT RATES HAVE BEEN REPORTED FOR 30 YEARS. PRECISE BLENDING AND HOMOGENOUS MIXES ARE ACHIEVED WITH SHORT MIXING TIMES. CONCRETE QUALITY AND SURFACE FINISH SPECIFICATIONS RISE CONTINUOUSLY. THE EIRICH R-TYPE MIXER IS BEST SUITED TO THIS DEMANDING ENVIRONMENT.

EIRICH RV19 INTENSIVE MIXER: INCLINED PAN CREATES STRONG VERTICAL MIXING ACTION AGITATOR BLADES BREAK UP LUMPS AND DISTRIBUTE WATER WATER AND CEMENT IS DRAWN THROUGH THE MIX BY A VORTEX CREATED AT THE SHAFT COMBINED FLOOR AND WALL SCRAPER DIVERTS MATERIAL INTO THE PATH OF THE AGITATOR FLOOR SCRAPER ALSO ASSISTS WITH FAST DISCHARGE

H. Birkenmayer • Website: www.birkenmayer.co.za • Tel: +27 11 970 3880 • E-mail: sales@birkenmayer.co.za

IS SLOW PAYMENT BECOMING THE NEW NORMAL? Demands for fast-track construction coupled with delays in payment, are two of the major challenges facing the South African building industry at the moment, says Uwe Putlitz, CEO of the Joint Building Contracts Committee (JBCC).

JBCC is non-profit company representing building owners and developers, professional consultants, and general and specialist contractors, who all provide input for the compilation of JBCC agreements (building contracts).

Over the years the building industry has drastically changed.

Gone are the days of the craft-orientated builder, whose staff carried out the bulk of the work. Today, this is done by specialist subcontractors, such as precast concrete manufacturers, who often use sophisticated manufacturing and installation techniques. This means that work is completed at a faster rate than previously.

Vicious cycle “This need for speed and utilisation of outside resources, pose new challenges for the building contractor,” says Putlitz. He adds that training and retaining qualified staff is not easy in an uncertain economy. Retrenchments at the end of a project are common, as there is not a steady workflow, largely due to political uncertainty, both locally and internationally.

“Without timeous payment, contractors are not going to retain the services of qualified subcontractors for future contracts. Yet, prompt payment in the industry remains problematic as many owners/employers simply do not pay on time, and do not honour regular payment commitments in full, by the due date,” says Putlitz. “This causes a ripple effect, where subcontractors and suppliers are not paid, leading to insolvency and unemployment. The Construction Industry Development Board (CIDB) is seeking to manage this problem by introducing best practice guidelines to eliminate ‘pay when paid’ practices in the industry but proper implementation could still take a long time.”

Putlitz says JBCC agreements include payment-commitment criteria already. “But agreements can be changed, and stipulated payment dates simply be ‘unilaterally’ removed at the negotiation stage. Faced with the prospect of late payment, or no work at all, the other party, usually the subcontractor, will reluctantly have to accept the amendments, or simply lose his or her appointment. That’s hardly the definition of a unilateral agreement, but it’s often the case.”

He adds that: “Sad to say, it’s the specialist subcontractor who often struggles to find a regular flow of work and then to get paid in full, and on time. And yet the building industry continues to ignore the important role of subcontractors. They are being treated shabbily. The skill of subcontractors is essential for the industry to perform satisfactorily. Subcontractors deserve to be treated as an integral member of the construction team. It’s time that this starts to happen.”

PRECAST | ISSUE ONE | 2018

INDUSTRY NEWS

POOR QUALITY CONCRETE IS DANGEROUS AND WASTEFUL Poor quality concrete wastes time and

will judge a contractor’s work. Attrac-

Durable concrete will have a low main-

money, ruins contractors’ reputations

tive concrete calls for precision of work

tenance cost over its lifecycle.

and could even be dangerous, warns John

and a good off-shutter finish.” And;

6

To produce quality concrete, the necessary preparations are important.

Roxburgh, lecturer at The Concrete Institute’s School of Concrete Technology.

“The correct concrete mix design that

Roxburgh says it is sadly a fact of life

meets the required strength, durability

that the contracting fraternity pleads

and workability requirements, must be

poverty when it comes to doing a project

formulated. And a suitable mix design

properly but then ends up having to find

can only be found by trial testing. Mock-

funds to fix disasters later. “In concrete

ups of the formwork, which represent

works, this is especially true. By not

the shape of the actual formwork in the

getting the job right the first time, the

project, should be made. The concreting

contract is going to run over time and

teams should practice on these mock-ups

costs will escalate drastically,” he states.

to develop the correct placing techniques

Roxburgh says concrete quality typi-

and to ensure the correct surface finish to the concrete,” says Roxburgh.

cally encapsulates three elements:

He adds: “For concrete with high dura-

• Firstly, the concrete must perform

structurally. It should have the cor-

rect strength and required deforma-

tion properties;

• Secondly, it should be aesthetically

bility, good site practice is vital and this (Above): Concrete quality is essential when it comes multi-billion rand projects, such as the Berg River Dam, (pictured above) before the current devastating drought hit the Western Cape.

should include a thorough curing regime.

Curing can never be rushed. Quality supervision will also go a long way towards producing quality concrete. Concrete

pleasing. “Of course, there will be many

cases where aesthetics is irrelevant,

• Lastly, and this is the element of

producers should provide clients with

such as in foundations. But in exposed

quality often overlooked, how well the

evidence of their concrete’s quality by

concrete, appearance will be important

concrete will perform over time within

having an intensive testing programme

and will often be the only way a client

the environment it has been placed.

at SANAS accredited laboratories.”

INDUSTRY NEWS 7

IMPROVING CONCRETE SKILLS

specify concrete strength for projects, will do very little to meet the needs of modern concrete construction.”

Concrete is considered to be a key in-

high-performance concretes including

He believes there is also a strong need

frastructure material, yet not enough

high strength, self-compacting, roller-

for engineers in the more specialised

civil and structural engineers enrol

compacted, and low-density concretes.

fields of concrete technology and con-

at the School of Concrete Technology

struction. These include concrete pave-

(SCT), at The Concrete Institute (TCI),

Energy saving

ments and industrial floors design, con-

to study this subject in depth, says John

Roxburgh says: “Concrete structures

crete repair and rehabilitation, concrete

Roxburgh, lecturer at SCT.

are now also being designed with full

forensics, dam building, underwater

Roxburgh says this apathy regarding

life cycle goals to minimising energy

concreting and precast concrete design.

engineers expanding their knowledge

use, maintenance costs and ensure full

of concrete is of major concern. He

recyclability of the structure at the

Training courses

believes strong arguments can be put

end of its useful life. In specifying and

“All these fields require concrete tech-

forward as to why engineers should spe-

designing sustainable and durable con-

nology education far exceeding anything

cialise in concrete technology. One such

crete structures, an engineer now more

t augh t dur ing a uni v er si t y degr e e

reason is the fact that globally, concrete

than ever needs a sound knowledge of

course. Concrete technology education

is the most abundantly used construc-

concrete technology.”

will most certainly broaden the career

tion material, with about one tonne of

Roxburgh adds that on the socio-

opportunities of any civil engineer and

concrete cast per person worldwide per

economic front, there has been an in-

it is time the engineering profession

year. “At some point, civil or structural

creasing reliance on the lowest tender

realises this,” Roxburgh adds.

engineers will have to specify, design or

system for selection of contractors, and

For this reason SCT will again present

build with concrete,” Roxburgh adds.

a decline in the skills and knowledge base

a wide spectrum of training courses in

Changes within the construction in-

in the construction industry. “Cost-ef-

concrete technology this year, ranging

dustry and global climate, have resulted in

fective, sustainable concrete solutions

from introductions to concrete for raw

engineers requiring a greater knowledge

that make use of modern concrete tech-

beginners, to courses that will provide

of concrete technology. “Sustainability

nology to mitigate skills shortage and

the platform to the highest qualifica-

is an issue that is now an essential part

lack of expertise on site, will be of great

tion in the world of concrete: Advanced

of concrete construction. Atmospheric

advantage. For engineers to merely

Concrete Technology.

carbon dioxide has increased by over 50% in the last century, with climate change evident in our everyday lives. To boost sustainability initiatives, the cement and concrete industry now makes substantial use of cement extenders and

PRECAST | ISSUE ONE | 2018

“To merely specify concrete strength for projects will do very little to meet the needs of modern concrete construction.”

INDUSTRY NEWS 8

Roxburgh says the courses include

with the client,” says Roxburgh.

qualification in concrete technology, to

specialist training on subjects, both

He adds that the SCT special one-day

basic and advanced: from understanding

course for RMC drivers covers aspects

what concrete is all about, to making

such as the strength of concrete; the

concrete bricks and blocks, procedures

effects of hot or cold weather on the

Training centres

and checks for delivery of readymix

transport of concrete; delays, contami-

Courses are generally offered in Mid-

concrete; batching con-

nation or spillage during

rand, Durban and Cape Town. However,

crete; designing and build-

transport; and the effect

the training can be tailored to accom-

ing roads and pavements;

of water addition to their

modate clients’ specific requirements

structural designing and

load; and the correct way

and staged anywhere in Southern Af-

building; laying industrial

of washing out the truck.

rica. Special training can be carried out

floors on the ground; as

“The tuition is typical of

onsite for a minimum of 10 students.

well as tuition for labora-

how we structure cours-

The school can also provide experts to

tory testing staff.

es for specific industry

lecture on concrete technology at uni-

needs,” says Roxburgh

versities and other appropriate training

Specialist skills

However, at the top

be presented by the SCT for examination

by ICT, in 2019.

institutions.

“There is a need to know

end of the technological

Roxburgh adds: “SCT courses have,

more about concrete at all

scale, the school is hop-

over many decades, established an

levels in the building sec-

ing f or str ong suppor t

unmatched reputation for quality and

tor. It is perhaps not gen-

this year for its online,

are presented by experts in their field,

erally known, for example, that special

e-learning SCT 41 and 42 Concrete Tech-

backed up by practical demonstration

skills are required for what would appear

nology & Construction courses, which

in the TCI training laboratory. The con-

to be a routine job: driving a readymix

are offered on behalf of the Institute of

struction and concrete industries are

concrete (RMC) truck. But RMC drivers

Concrete Technology (ICT) in London; as

wise enough to entrust staff training

need to know basic concrete technology

well as the SCT 30 Concrete Technology

only to the school.”

for the transporting of concrete and

course. These are essential preparatory

are invariably frontline staff members,

courses for the Advanced Concrete

interacting on behalf of their company

Technology Course, the world’s leading

(Left): John Roxburgh, lecturer at the School of Concrete Technology, believes more engineers should specialise in concrete technology.

Building material producers, under the

He adds: “Roads also play a big role in

banner of CMA-Associate Member,

the development of a country and SAN-

Industry associations also play an

ASPASA, believe that a new focus is

RAL has just launched its Horizon 2030

important self-regulatory role within

required on infrastructure development

strategy which promises ‘Building a bet-

the industry and often, this is the only

in South Africa.

ter South Africa through better roads’.

assurance that there is regarding impor-

The association represents about 75%

It also states its vision to ensure that

tant considerations, such as legal and

of the quarries and mines in South Africa

national road transport system delivers

environmental compliance, and health and

that produce key materials for concrete

a better South Africa for all.”

safety compliance, as well as measuring

and other construction projects. It wants

Pienaar explains that this is good

cement, concrete or bitumen, etc.

standards for quality and other technical

to encourage better coopera-

news. “ASPASA suppor ts

tion between all role-players

these views and would like

Like the CMA, ASPASA also upholds

involved in the planning and

to expand on this, by stating

standards for existing and would-be

delivery of all forms of infra-

that this vision is long over-

members. In addition, technical commit-

structure, such as precast

due. As the representative

tees set standards for quality-related

concrete products used in

body for the vast majority of

issues and work with the likes of SANRAL

the construction of roads,

materials used to construct

to develop acceptable quality criteria for

railways, dams, pipelines and

roads, we are 100% behind

infrastructure of the future.

buildings.

this initiative and further-

ASPASA director, Nico Pienaar, says the current crisis regarding water short-

more, want to be involved in

Skills development

the planning and implemen-

Of interest to some of the CMA members

tation of these initiatives

may be the numerous workshops and

alongside all other professional bodies.”

formal training courses run by ASPASA

(Above): Aspasa director Nico Pienaar

ages throughout the Cape provinces and

requirements.

elsewhere in the country, clearly shows

that aim to ensure that member organi-

that there is an urgent need to improve

Professional partners

sations have access to the latest global

water management structures with new

He adds that industry professionals

techniques and best practices regarding

dams, reservoirs, desalination plants,

and representative bodies, such as the

aggregates.

pipelines and other infrastructure.

CMA, should form the nucleus of future

“With state spending back on track

infrastructure programs in order to

and the economy set to recover from

Future focus

work towards real attainable goals. For

years of paralysis, we urge Government

“Although this type of infrastructure

example, if there is consensus among

and all role players to get together and

does not happen ‘overnight’, predictions

professionals that a bridge, harbour

work towards improving the state of our

of water shortages had been made a

or dam wall needs to be built, then it is

industry in the short, medium and long

number of years ago and may have been

imperative to deal with professionals in

term. ASPASA is committed to reach-

avoided if providers and planners worked

every link of the project. This includes

ing our country’s goals now and in the

more closely together,” says Pienaar.

material suppliers such as aggregates,

future,” Pienaar concludes.

“Stopping advertising to save money is like stopping your watch to save time.”

– Henry Ford

DON’T MISS OUT! ADVERTISE IN OUR NEXT ISSUE.

Contact Wally Armstrong on tel: 083 701 3278 or Linda Meyer on tel: 083 626 8814

INDUSTRY NEWS

A NEW FOCUS ON INFRASTRUCTURE

9

PRODUCTS 10

PRECAST CAN SAVE ON CONSTRUCTION MATERIALS With increasing competition in the con-

and production lines, recently showcased

buildings,” ex plains P r ak ash Shah,

struction industry, the promise of more

the benefits of prefabrication in the

Head of Technical Support at Elematic.

economical manufacturing methods and

affordable housing sector at the Expo

“Modern plants are scaled to meet the

up to 30% material usage onsite, en-

held at Gallagher Estate, Johannesburg.

precast need. The same production

sured that the Elematic stand at African

Addressing Expo delegates, Elem-

line allows the manufacture of precast

Construction and Totally Concrete Expo

atic’s area director, Curt

products from affordable

last year, was a busy one.

L indr o th said: “Pr e f ab-

to high-end housing, as well

In-roads into the supply of affordable

rication in the concrete

as for factories and office

housing in South Africa have been made,

industry has been around

complexes.”

however, there is still a long way to

since the 1970s. It offers

go regarding the delivery of quantity

many positives, such as:

Faster solution

housing required across the country.

reduced costs; design effi-

“At our technical training

This, coupled with the requirement to be

ciencies; housing longevity;

workshop at the Expo, we

cost-effective in the current economic

a reduction in manpower,

highlighted the benefits of

downturn, is where prefabricated walls,

time and ma t er ials, as

prefabrication, particularly

floors, frames and foundations can offer

w e ll a s gr e a t er s a f e t y

regarding af fordable

substantial savings on material usage,

on site.” He adds that by

amongst other benefits.

using local raw materials, it offers a

Africa can benefit from this technology,”

Elematic from Finland, a leader in the

faster construction speed. This was

says Lindroth. He explains that advances

manufacture of precast concrete plants

showcased by a recent project in India,

in precast technology and design over

where using conventional construction

the years have opened up a range of

methods, it was only possible to supply

possibilities for housing and the planning

15x1,000 sq. ft. apartments in a month.

of urban environments. South Africa,

“The prefabricated structure supplied

and other developing countries can make

45 apartments of the same size in the

good use of this technology, resulting

same period,” Lindroth adds.

in a greater number of houses within a

“We believe that prefabrication is a cost-effective way forward towards quickly solving this enormous demand.”

“Precast is a modular building system

housing projects and how

shorter time period, while still making

based on ready-made, factory manuconnections. It is a smart and industri-

(Top): Elematic supplied technology to produce 100 000 affordable housing units in Bismayah New City in Iraq.

alised way to construct cost-efficient

(Above): Elematic’s area director, Curt Lindroth.

factured components and intelligent

PRECAST | ISSUE ONE | 2018

Prefabrication removes the need for shuttering and scaffolding, requires less

curity for occupants. The prefabricated concrete panel is impact resistant and difficult to break or cut through.

• Arabian Ranches, UAE – 1 041 Villas Lindroth adds: “A number of large cities in Africa, South America and India are

transportation to site and less materials

Offering corrosion resistant prop-

experiencing rapid population growth. In

and equipment. Prefabricated elements

erties, prefabricated concrete is also

Kenya for example, the Kenyan Govern-

are easily installed with cranes, and

fire-proof, rot-proof and rust-proof. The

ment is committed to ensuring every

offer better quality control and safer

components of precast concrete make

citizen has access to affordable housing.

working conditions. No brickwork is

in inedible, which means termites, rats,

The Indian Government has announced

needed, less steel is consumed and

mice and other vermin, will not threaten

a ‘Housing for All’ smart cities pro-

prefabrication offers a longer building

the precast structure.

gramme. The South African Government

lifespan with less maintenance.

The construction site is dry and clean,

Recent Projects Suppor ted with

believes the supply of adequate housing

Elematic Technologies

is a basic human right. These are big

as there is no curing required at site,

• Naya Raipur, India –

challenges that face government. We

which makes water and energy savings

believe that prefabrication is a cost-

achievable. Even in extreme weather

• Bismayah New City Project, Iraq –

effective way forward towards quickly

conditions, no waterproofing is required

solving this enormous demand.”

4 000 housing units 100 000 housing units

f or the pr e f abr ic a t e d s tr uc tur e s.

A major positive is the simplicity of assembly, which requires the minimum amount of joints.

Sustainable manufacture Precast concrete’s components make it a natural choice in achieving sustainability in new buildings. The structures need no chemical treatment, thereby eliminating fumes. Additionally, it is a solid and secure structure, offering se-

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significant financial savings.

11

PRODUCTS

A need exists for aesthetically pleasing

12

don’t want to feel “trapped in a concrete

yet practically engineered retaining wall support systems, particularly in the construction of commercial and retail business parks, where cut and fill methodology is generally required.

Employees and visitors to these parks jungle”. The current trend is to design these environments with more “green” technologies, creating a healthier and more aesthetically-pleasing environment.

Florawall interlocking retaining wall blocks, produced by CMA-member, Technicrete offers landscapers, horticulturalists and architects an earth-retaining structure, that doubles as a decorative element with an aesthetic fluted

and It provides an uninhibited root and

BRING IN AN ELEMENT OF GREEN WITH RETAINING WALLS

water penetration system.

Horizontal curves following the site plan

neering Codes must be adhered to

can be formed by simply rotating the

and advice from site engineers or the

units as they are placed.

company’s technical suppor t team

face. Simple to install, this is a highlyeffective retaining structure. Flora and deep-rooted plant life can be planted in each block to create a decorative finish

The interlocking method of construction makes it ideal for all retaining wall requirements, including gravity and rein-

W i t h o u t e ngin e e r ing in p u t, t h e

should be sought.

blocks can be stacked up to six layers

The interlocking blocks can be supplied

Granular backfill should be placed

high (1.5m), with the bottom block

in a length/width/height of 300mm x

behind each successive tier of blocks

below ground level, provided the ground

410mm x 250mm configuration, whilst

and a fertile mixture used to fill each

and back f ill mater ials ar e suitable

the non-interlock ing option can be

unit. Angles of between 51° and 90°

with no additional loads applied at the

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against the vertical can be constructed

top of the embankment. When a higher

sizing. Both are available in autumn blend

by stepping back the units as required.

wall is required, local bylaws and Engi-

and grey colouring.

forced wall designs.

SOLUTION TO SEMI-DRY PRECAST CONCERNS T he consistent quali t y o f super ior

The SikaPaver range offers improved

threat due to the highly competitive en-

compaction of semi-dry concrete and

vironment of the construction industry.

compensates for normal production

Weakened concrete mixes and acceler-

variations. Greater quality consistency

ated production processes have led to

means lower rejection rates due to poorly

wide variations in concrete densities

compacted paving blocks, which saves on

which, in certain instances, are clearly

labour and raw material costs.

evident in early mechanical wear, and/or efflorescence.

The use of innovative admixture technologies, such as the SikaPaver range, can assist in overcoming these concerns.

According to CMA member Sika, the

The SikaPaver range offers: • Improved compaction of the semidry concrete • Balancing naturally occurring variations • Greater quality consistency

good compactibility of fresh semi-dry

• The minimisation of rejects

concrete is key to achieving extended

• Savings on base materials (cement,

durability and aesthetic consistency.

(Above): Precast paving blocks manufactured using SikaPaver admixtures.

short, consistently high quality levels.

semi-dry precast paving blocks is under

pigments, aggregate and sand)

Better compactibility also results in

• Fewer complaints and claims

higher fresh densities, increased green

• Increased durability of the

strengths and high final strengths. In

paving blocks.

PRECAST | ISSUE ONE | 2018

COMPANY NEWS 14

The trend towards decorative concrete, and two significant acquisitions at the end of 2016, have seen CMA-member,

DECORATIVE CONCRETE OPTIONS ON THE INCREASE

the CHRYSO Group, expand its aesthetic concrete product range.

in the production of decorative concrete.

DIY and consumer market channels.,”

The concrete additives group acquired

These products have an established

says Seymore. “The Beton Academy

Moderne Methode and Beton Academy.

reputation for quality stamped, polished

will address industry specific needs

A c c or ding t o CE O o f the CHR Y SO

and micro-topping concrete. Extremely

with regard to producing decorative

Southern Africa Group, Norman Seymore,

thin concrete coatings are used to cre-

concrete and give concrete applicators

this will allow it to expand its offering to

ate a stabilised sand, granite, marble or

the confidence to use our products.”

both the retail and industrial sectors.

metallic effect. Resin, as well as stam-

Moderne Methode has a 13-year

pable overlays, can also be achieved. The

legacy in the de c or a ti v e c oncr e t e

Beton Academy is used to instruct and

pr oduct market in France and has

train decorative concrete applicators in

a considerable global r each. T he

the use of these products and systems.

company manufactures and distributes

“Moderne Methode will enhance

a comprehensive range of products,

CHRYSO’s existing product range, as well

innovative tools and systems that assist

as add certain technologies to a.b.e.’s

We are there when you learn

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COMPANY NEWS 15

MAPEI GEARS FOR GROWTH Construction chemical manufacturer,

“The new advanced manufacturing plant,

as well as a wide range of specialised

Mapei South Africa, has unveiled its

supported by smart technical teams, as

construction and related chemicals. Both

impressive new local manufacturing

well as support infrastructure, such as

liquid and powder products are manufac-

facility in Germiston, where it expects

laboratories and training facilities, is

tured at the Germiston plant, and are

to manufacture a wide range of products

the culmination of these requirements.”

available in handy retail-orientated pack-

to meet burgeoning demands expected

He says: “Despite the recent tough

ages or in bulk capacity for largescale

over the next 15 to 20 years.

economic conditions, we have invested

contracts.

Since entering the market in 2011,

heavily into the construction industry,

All products are manufactured ac-

the company has earned a sound

with the knowledge that we will be best

cor ding to r elevant standar ds and

reputation for technical expertise. This

positioned to support the industry when

endorse the highest possible compli-

has led to a growing customer-base and

the economy picks up and the construc-

ance towar ds sustainable env ir on-

significant slice of market share. Its

tion industry booms again. With this

mental practices and standards. This

focus on quality has also paid dividends

kind of infrastructure in place, we will

is carried across through all training

and moved the manufacturer to become

easily meet the requirements of the

courses and seminars offered at the

one of the leading local suppliers of

retail industry, contractors

company’s state-of-the-art

construction chemicals and adhesives

and professionals, who are

onsite training facility. Global

in Southern Africa.

currently planning largescale

experts are also regularly

projects and vast infrastruc-

brought in to share their

ture upgrades.”

skills with contractors, in-

Mapei South Africa general manager, Antony Of fenberg, says the growth of the company is largely as a result

stallers, as well as building

of its customer-centric approach and

Big player

unique focus on quality. “While growing

Of fenberg adds that while

the business in South Africa, we have

Mapei South Africa’s new

Wide range

carefully noted the requirements of the

manufacturing facility puts

“Whether it be cement

market, as well as individual customers,

it right up there with the

to develop solutions that meet their

biggest construction chemical and

concrete manufacture or cured product

current and future needs.”

adhesive manufacturers in the country,

repairs and finishing, we are in a position

its method of ser vicing customers

to produce technical solutions that meet

National standards

will remain customer centric. “As a

the market’s requirements. With our

Offenberg adds: “We found that top of

family-owned business, we will always

vast skills set, we are a multi-faceted

our customer wants was for high-quality

take a considered and caring approach

solutions provider that competes with

products to be widely available with

to meet customer requirements. Our

construction chemical suppliers across

sufficient stock available to complete

technical staff evaluate requirements and

all phases of the construction timeline.

pr ojects any wher e thr oughout the

make recommendations based on their

Our focus on technical ser vice and

sub-region. In addition, they needed

own technical skills and the combined

training truly sets us apart,” Offenberg

the assurance that the products meet

intellectual property of our global group.”

concludes.

international as well as SABS quality

Customers will have access to the

standards.”

company’s vast product range that in-

industry professionals.

production, down-the-line

Offenberg explains that they moved

cludes: additives used in the manufacture

(Above): Mapei South Africa general manager, Antony Offenberg.

swiftly to meet these requirements.

of cement, concrete additives, adhesives,

(Top): Mapei’s new facility in Germiston.

PRECAST | ISSUE ONE | 2018

GLOBAL VIEW

DEVELOPMENT TRENDS FOCUS If there’s one question that niggles at the world’s global conscience, it’s how can we better protect our planet?

16

There is a movement towards energyand water-saving technology and other sustainable solutions. The construction and development industries, including precast concrete manufacturers, are becoming more aware of environmental issues and are implementing measures at the planning stages.

“Everything about development today is about sustainability and energy-wise innovation,” says Nicholas Stopforth, managing director of Amdec Property Development. “There’s a strong push towards incorporating green construction materials and utilising all available innovative technologies. It is most certainly a global trend for good reason, as we need to reduce our impact on the planet.”

(Above): Conceptualised view of Harbour Arch in Cape Town.

forward is to create innovative solutions

for innovation in our latest developments.

Investor support

that will benefit the overall success of

The demand for social responsibility from

The good news is that investors are

new developments.

a consumer perspective, and investors

also taking notice of this shift. The way

“We have responded to that demand

calling for sustainability, are impacting

ON SUSTAINABILITY our choices,” explains Stopforth.

T h e A m d e c G r o up is k n o w n f o r developing Johannesburg’s iconic and a w ar d-w inning mi xe d-use pr e cinc t Melrose Arch. Their latest project is Harbour Arch on Cape Town’s foreshore area of the CBD, with the first phase due for completion by the end 2020.

At 5,8 hectares, this development will be the largest of its kind in the

and bars, are within walking distance.

city. It represents an investment of

This is modelled on the global trend

approximately R10 billion, and is expected

for walkable precincts, such as Darling

to take 10 years to complete.

Harbour in Sydney and Battersea Power

The Harbour Arch precinct, with six individual tower blocks and 200 000

Station in London.

“Not only does this type of develop-

square metres of usable space, is

ment take a load off the transport

set to elevate Cape Town regard-

network, but it’s all about being

ing forward-thinking sustainable

able to live, work and play in a

development. A key focus area

precinct which is safe

will be eco-friendly innovation.

and secure,” explains

Integrated green building ini-

Stopforth.

tiatives include: refuse recycling, water-saving devices and rainwater harvesting, a centralised

T his new urbanism trend is gaining significant traction in

district cooling facility, and

South Africa, with developments

low-energy LED lighting.

like Melrose Arch, Menlyn Maine,

Urban reality

as prime examples.

2015 FULTON AWARD WINNER INNOVATION IN CONCRETE

Century City and now Harbour Arch, Stopforth explains that Harbour Arch

He concludes that the first phase

reflects the current trend of new ur-

is expected to create up to 2 500

banism. All daily requirements, such as

employment oppor tunities. O verall,

apartments, shops, gyms, restaurants

construction alone, could generate up to 12 000 jobs. Beyond that, two Marriottbranded hotels destined for the site should secure around 400 permanent jobs, with retail and lifestyle spaces holding further potential for permanent positions. The site will also offer boutique office space, upmarket residential apartments, and more.

CONCRETE UNITS Tel: Cape Town (021) 386 1923 Johannesburg (016) 362 2236 Fax: Cape Town (021) 386 2514 Johannesburg (016) 362 2235 E-mail: precast.ct@concreteunits.co.za precast.jhb@concreteunits.co.za Website: www.concreteunits.co.za

“Everything about development today is about sustainability and energy-wise innovation.”

PROUD MEMBER OF THE CMA PRECAST | ISSUE ONE | 2018

TECHNICAL 18

PERMEABLE CONCRETE PROVIDES A SOLU Permeable concrete ground surfaces could play a vital role in preserving water in drought-ravaged South Africa, says Bryan Perrie, managing director of The Concrete Institute.

Perrie explains that using per vious concrete or permeable block paving in roads and parking areas can allow rain and other water sources to percolate through, thereby replenishing natural underground water resources. “Boosting aquifers in this manner is important during prolonged spells of drought – particularly when concern has already been expressed about the alarming diminishing of our underground water volumes.”

While currently under-utilised in South Africa, pervious concrete and permeable block paving naturally filter out pollutants that come into contact with it. “This is in contrast to the voluminous run-off from impervious surfaces that inevitably ends up in surrounding

UTION FOR PRESERVING WATER streams, rivers and dams, resulting in

developments (including parking and roof

grease and chemical pollution hazardous

areas); increased green space requirements;

to animal and human life.” Perrie says that

and the implementation of “storm water

pervious concrete can be used in place

utility districts” that levy an impact fee on

of retention ponds. “This will reduce the

a property owner, based on the size of the

number and size of drainage infrastructure

impervious area.

elements, saving both materials and energy,

Furthermore, to reduce the level of pol-

as well as reducing future maintenance,”

lution from storm water, developers have to

Perrie adds.

provide systems that collect the first flush of rainfall, usually about 25mm, and “treat”

Great invention

the pollution in this rain, prior to release.

Perrie explains that the American Ready

Pervious concrete pavements can reduce

Mix Concrete Association (RMCA) has de-

or even eliminate runoff.

scribed pervious concrete as an “innovative

By capturing the first flush of rainfall and

building material, with many environmental,

allowing it to percolate into the ground, soil

economic, and structural advantages’’.

chemistry and biology can then “treat” the

In fact, the proper utilisation of pervious

polluted water naturally. Storm water re-

concrete is a recognised Best Management

tention areas may be reduced or eliminated,

Practice (BMP) for providing first-flush

allowing increased land use. Furthermore,

pollution control and storm water manage-

by collecting rainfall and allowing it to filter

ment by the U.S. Environmental Protection

through, groundwater is replenished, peak

Agency (EPA).

water flow through drainage channels is

American studies have found that oil

reduced, and flooding is minimised.

that drips onto a pervious concrete pavement, is contained as a coating on the

Green building

large surface area of the void system. This

In America, factoring impervious concrete

is also contained at the location of any

into new property developments has the po-

geotextile fabric separating the pavement

tential of earning credits in the U.S. Green

from the sub-base or sub-grade support.

Building Council’s Leadership in Energy &

Hydrocarbons, such as oils, then become

Environmental Design (LEED) Green Building

a food source for many naturally-occurring

Rating System.

bacteria and fungi. This is then biodegraded

Pervious concrete pavement is also ideal

into simpler chemical components that are

for protecting trees in a paved environ-

released into the atmosphere. “Research

ment. Plants often have difficulty growing

shows that 97,6% to over 99% of oils intro-

in landscaped areas covered by impervious

duced into pervious pavements are trapped

pavements and sidewalks, as air and water

and biodegraded instead of ending in rivers

struggle to reach their roots. However,

and dams,” says Perrie.

when pervious concrete pavements or side-

USA storm water regulations set lim-

walks surround plants and trees, the veg-

its on the levels of pollution in American

etation receives more growth-stimulating

streams and lakes. To meet these regula-

air and water, without impacting vehicular

tions, local officials have considered two

and pedestrian use of the paved areas.

basic approaches:

Perrie adds: ‘’Proper ty owners and

• To reduce the overall runoff from an

developers should also strongly consider

pervious concrete, purely for economic

area; and

• To reduce the level of pollution contained

reasons. These pavements and sidewalks

can provide decades of service, with little

in runoff.

or no maintenance requirements.”

Reduce runoff Efforts to reduce runoff include: zoning ordinances and regulations that reduce the number of impervious surfaces in new

(Left): Permeable concrete roads and pavements could play a vital role in preserving water in drought-ravaged South Africa, says Bryan Perrie, managing director of The Concrete Institute.

“Research shows that 97,6% to over 99% of oils introduced into pervious pavements are trapped.”

PRECAST | ISSUE ONE | 2018

TECHNICAL 20

BENEFITS OF FIBREREINFORCED CONCRETE Globally, a growing range of polypropylene fibres has been developed to suit a wide range of concrete applications, including those in the manufacture of precast concrete.

Locally, South Africa is right on trend.

reduced construction time. There are

CMA-member, Chryso Southern Africa,

also savings on storage and transport,

has been able to create the right fibre-

and fewer health and safety hazards as-

reinforced concrete mixes in its laborato-

sociated with the handling, cutting and

ries, by selecting the most suitable fibre

placing of mesh.

and optimising the fibre dosage to suit the particular application. Chryso is also

Plastic shrinkage

able to utilise a design service offered

Fibre reinforcing can effectively address

harmful chemicals from penetrating the

by Adfil for Chryso Macro Fibres, which

the problem of plastic shrinkage and plas-

concrete. It makes concrete more resist-

promises a cost-effective solution with

tic settlement cracking. These problems,

ant to abrasion, by improving concrete

reduced construction time.

have in the past, led to costly remedial

strength through a low water/cement

As steel fixing is avoided, the benefits

measures or even whole slab replacement.

ratio. Using fibres also promotes the ef-

of fibres over using reinforcing steel,

While micro fibres provide crack-width

ficient hydration of cement and improves

include: lower costs, less labour and

control during the pre-hardening phase,

the bonding of the cement matrix, deliv-

Chryso Macro Fibres control cracks in the

ering a more durable concrete surface.

(Top): Optimising the fibre dosage to suit different applications.

(Right): Micro fibres provide effective crack control in concrete during the pre-hardening phase.

(Below): Macro fibres can be anchored in concrete on both side of a crack to effectively “sew� the two sides together preventing the crack from widening.

concrete once it has hardened.

Impact resistance is another charac-

Fibre reinforcing also improves the

teristic that is enhanced by the use of fi-

durability of concrete in a number of ways.

bres. This is due to the high level of energy

To resist corrosion, fibres make concrete

absorbed in the de-bonding, stretching

less permeable, preventing water and

and pulling out of fibres after the cement matrix has cracked. The concrete also becomes more resistant to freezing and thawing, as the fibres prevent the influx of water. When water penetrates concrete pores and then freezes, it will expand and damage the concrete.

Including fibres in concrete makes for a more cohesive mix through mechanically binding the cementitious material together, reducing waste and avoiding any balling and clogging in pumps and pipes.

PRECAST | ISSUE ONE | 2018

Through its strong technical support for manufacturers of precast concrete products, admixture company, Chryso Southern Africa, has been able to assist precast manufacturers to improve their cost per cubic metre and boost their bottom lines.

the strengthening process. Our product

With global research and development

of taking a holistic view of the value added

research and development. It’s central

behind its solutions, the CMA-member

by CHRYSO admixtures and additives, so

laboratory, based in Sermaises, France,

aims to help manufacturers improve their

that solutions can be measured in terms

is manned by about 55 researchers, while

efficiencies, whether by extending the

of the cost per cubic metre of concrete

CHRYSO Southern Africa has nine local

workability of their concrete, increasing

used, rather than the cost per litre of

laboratories.

its strength, or enhancing productivity

chemicals used.

range includes chemical accelerators that reduce the time required to steam the product, or eliminate the use of steam altogether,” explains Sepotokele.

CHRYSO invests 3% of its sales in

through strategic technical interventions.

He says CHRYSO’s solutions can save

“We look at the customer’s produc-

on the quantity of cement used, electric-

tion facility and seek ways to optimise

ity consumed and labour required. These

processes, not only in terms of concrete

factors all contribute to the final cost per

mix designs, but where possible, in other

cubic metre of concrete used in precast

plant processes that can be improved,”

applications. This means that any savings

says Kabelo Sepotokele, sales manager

can potentially boost profitability.

(precast segment) at Chryso Southern

“Manufacturers of concrete pipes, for

Africa. “We recommend a particular

instance, must ensure they are achieving

product only after considering the ma-

the quickest possible turnaround of each

terial used, analysing the customer’s

unit, as this has significant cost implica-

requirements, and assessing options to

tions for the business,” he says.

suit their application.”

“The use of steam is a common method

Sepotokele highlights the importance

V I H Y

of increasing temperatures to accelerate

TECHNICAL

IMPROVING PRECAST COST TO BOOST PROFITABILITY

21

(Above): Precast concrete manufacturers have access to chemical expertise to help improve their concrete.

M a s t e r f l e x

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NO NEED FOR DAMAGE TO RETAINING WALLS WHEN BARRIERS GET HIT!

The Deltabloc system with crash tested tension beam and absorption link system has no effect on the concrete block retaining wall when impacted; the wooden post guardrail system pushes into the top of the retaining wall when impacted causing what could be serious damage to the wall, and vehicles breaching.

2018 WINNERS

THIS PUBLICATION IS SPONSORED BY:

02 CMA AWARDS FOR EXCELLENCE 2018 - WINNERS

THE SPONSORS

We would like to thank our sponsors for their support.

CMA AWARDS FOR EXCELLENCE 2018 - WINNERS 03

MESSAGE FROM THE EXECUTIVE DIRECTOR The Association was recently restructured into two operating divisions: Marketing and Quality Assurance. The marketing division under the Concrete Manufacturers Association NPC promotes the use of precast concrete products in the correct way and the quality assurance division under the CMA Certification Services company which certifies precast concrete producers for the CMA’s Accreditation and Mark of Approval.

The CMA Mark is aimed at producers who manufacture products under well controlled conditions and to the highest quality standards for which there are SANS specifications and who require certification for their products.

It is a great honour to host this year’s Concrete Manufacturers Association Awards for Excellence competition, which has steadily become a highlight on both the precast concrete, as well as the built professions’ calendars.

Introduced in 1985, the event’s chief purpose has always been to recognise excellence in the creative use of precast concrete products and honour those involved in their application, either through design or construction, or both.

This is the Association’s 16th competition. It is based on projects in which technical and aesthetic excellence, among other aspects, are critically assessed by a panel of independent judges drawn from the full scope of construction professions. Held biannually and open to all members, the event provides an excellent vehicle for Southern African designers and project developers to establish themselves as trendsetters across several disciplines, and in doing so, to gain national recognition.

Since the last competition in 2016, the industry has endured difficult times, so it is encouraging to see so many entrants in this prestige competition where our producers, as well as end-users have the opportunity to enter their achievements into a competition for excellence in the manufacture and application of precast concrete products.

Requirements for the CMA Mark of approval include basic compliance with the Occupational, Health and Safety Act, a fully implemented quality management system and applicable quality specifications based on random product analysis. Products are tested on site with the manufacturer’s own calibrated equipment. Independent analysis at accredited laboratories is also initiated from time-to-time.

I am also pleased to note that CMA website has been re-engineered with a reference register and marketing guide, as well as a list of CMA Certification Services mark holders providing CMA members and CMA CS mark holders with a valuable supplementary marketing and branding platform.

to ensure all categories of production can participate. This is echoed by the 89 entries which range through the scope of precast concrete products produced by our members. Perhaps, even more encouraging, is the standard and overall quality as well as the diversity of this year’s entries. It certainly bodes well for the industry and is something in which all South Africans can take pride.

Congratulations to the trophy winners you truly deserved your awards. And to those of you who entered projects which were certainly worthy of an award but were pipped to the post by some exceptional projects, I extend my heartfelt compassion.

On behalf of the CMA our thanks go to the judges and the sponsors without whom the competition could not have taken place.

The judges had to give up a day of their busy schedules and we know that judging a competition of this nature is never easy, particularly when so many of the entries were potential award winners.

A special vote of thanks must go to our anchor sponsor, PPC, as well as supplementary sponsors whose involvement right from the outset underpinned the planning and execution of this competition.

Finally, I would like to thank the staff members of the CMA for their unstinting commitment in ensuring the success of this year’s Awards and the gala dinner celebration.

Another marketing activity which certainly assisted the Association and its members to gain valuable exposure in the precast concrete arena is The Concrete Conference. Last year was the first event in which the CMA participated, and it proved to be a valuable tool to interest would-be members. Its value as a platform to showcase the CMA’s offerings and introduce some of our members participating in the exhibition again this year is unbeatable. The CMA is proud to be one of the hosting partners of the event.

In paging through these winning projects, I have no doubt that you will come to appreciate the role that such a competition plays in recognising, saluting and indeed fostering the world-class standards attained in the production of precast concrete products by CMA producer members and the installation of these products by renowned contractors.

Further cause for optimism is this Year’s Awards for Excellence competition’s new approach to categorise the competition

Frans Minnaar Executive Director Concrete Manufacturers Association

04 CMA AWARDS FOR EXCELLENCE 2018 - WINNERS

AESTHETICS EXCELLENCE WINNER PAVING • CATEGORY 1 ALICE LANE PHASE 3, JOHANNESBURG Project Description: This high-rise building in the heart of Sandton could easily feel like an object plonked down from outer space. With her design, the landscape architect intended to create “life” in an otherwise monotone urban landscape and in turn, a sense of belonging for the building itself. Combining concrete pavers of different sizes in an elaborate laying pattern created a 3D effect. Integral to the design in a mainly grey palate, is the selective use of ground pavers that derives their colour from the aggregate used in the concrete and exposed by the manufacturing process in addition to other wet cast and dry cast concrete textures.

The outcome of an elaborate design is totally dependent on its construction. The detailing by the paving contractor was exceptional and the quality of installation is what makes this project truly remarkable.

Judges’ Comments: Excellent diversity in product variety. Creative use of patterns.

The project compliments the ambiance in which the buildings are located.

Product Information: Urban Range of Pavers in various finishes.

Project Team: Architect: Paragon Architects Landscape Architect: Ochre Office Engineer: L&S Consulting Quantity Surveyors: Quanticast Quantity Surveyors Main Contractor: WBHO Construction Entrant/Manufacturer: Bosun Midrand

OVERALL WINNER 2018

AESTHETICS EXCELLENCE WINNER ROOF TILES • CATEGORY 2 EASTLANDS, BENONI Project Description: The roof tile manufacturers secured the roof tiles for the Eastlands Lifestyle Estate outside Benoni. Perspective Slate Grey White Farmhouse tiles where specified on the project. The tile compliments the general architecture in the development and enhances the relaxed feel the lifestyle estate wanted to create. The quality of workmanship on the roofs can clearly be seen in the photos and it adds to the professional look and feel the developers where looking for.

Judges’ Comments: Excellent and interesting colour selection. This compliments the buildings and surroundings very well and contributes to overall aesthetics.

Product Information: Perspective Slate Grey White Farmhouse Roof Tiles Project Team: Architect: Francois Marais Engineer: Nelius v/d Merwe Quantity Surveyor: Mornay Coetzee Main Contractor: Delmar Entrant/Manufacturer: Monier Coverland

CMA AWARDS FOR EXCELLENCE 2018 - WINNERS 05

AESTHETICS EXCELLENCE WINNER RETAINING WALL BLOCKS • CATEGORY 3 HOUSE WYLIE, JOHANNESBURG Project Description: The client requested that steep land-sculpted retaining walls be designed and constructed for their bed and breakfast lodge. The retaining wall had to maximise limited space against the Northcliff slopes, allowing for a driveway, parking space above, a swimming pool and a cottage below. The brief stated that it had to be attractive looking and reflect soft features complementing the house.

The decision was made to use the closed face retaining block wall system, with a sand colour and split rock face texture, to accommodate some of the steep wall faces up to 80° angles. The shallowest angle was 60°. All the walls were designed using geofabric reinforced fill behind the blocks and terraces were formed to create a shapely curved and colourfully landscaped garden.

In addition to the retaining walls, bending access stairs were constructed using precast step elements creating an easygoing tread stairway to link the pool and cottage to the main house above.

The completed retaining wall with its combination of creepers, shrubs and numerous flowering plants planted in and around the walls, resulted in a beautiful finished work of art blending in the main house with fabulous views over the forested Johannesburg suburbs.

Judges’ Comments: The retaining wall introduces a sense of the Northcliff hills to the property. The modular design of the wall face contributes to the overall aesthetics.

AESTHETICS EXCELLENCE WINNER CLADDING - LARGE PANELS • CATEGORY 4 CAPE TOWN INTERNATIONAL AIRPORT, CAPE TOWN Project Description: This project is an example of how precast concrete bush cladding can be used to mimic natural rock, in this instance in portraying an African scene on a mural in the international departures hall at Cape Town International Airport. Based on inspirational input from a conceptual team, the mural design was executed by an artist.

Once the concept and its ensuing design had been approved by the client, the artist transferred the design to the wall which measured 25m x 2.5m. This process involved identifying the shape, size and colour of each cladding block and its precise position, much like a jigsaw puzzle.

Product Information: Terraforce L11 Blocks – Sand Colour in Split Rock Face Texture Multi Step Elements for Stairs with Bull Nose. Sand Colour.

Before site work began only dry walling separated the departures hall from the adjacent chamber. Therefore, to provide a structure which would support the weight of the cladding, a wooden framework, covered by chicken mesh and bonding cement was constructed against the dry walling.

Project Team: Owner: Brian Wylie Engineer: Silvio Ferraris Entrant/Manufacturer: Remacon Products

Produced in three colours, Autumnstone, Charcoal and Robben Island, and cast in individual moulds, some of the cladding blocks were cut by hand to achieve a faithful rendition of the design.

Judges’ Comments: The African landscape embodied in a wall! Very creative use of a familiar precast concrete product.

This project brings the beauty of art to the precast concrete industry.

Product Information: Viking Random Cladding – Random Mix Project Team: Owner: ACSA Entered by: Revelstone Main Contractor: Matrix Communications Entrant/Manufacturer: Revelstone

OVERALL WINNER 2018

06 CMA AWARDS FOR EXCELLENCE 2018 - WINNERS

AESTHETICS EXCELLENCE WINNER BEAUTY FOR LIFE • CATEGORY 7 GOLD REEF CITY, JOHANNESBURG Project Description: This project is 16 years old having been completed in March 2001. The pictures tell the story here – the appropriate choice of paving blocks, the design layout, detailing excellence and the professional manner in which the contractors addressed the project.

The term contractors are used advisedly here because in a sense this project was a family affair involving a father and son team. The son handled the initial negotiation and managed the first phase of the contract and his father completed the project between the beginning of February 2001 and the middle of March.

The paving blocks show little, if any, sign of wear, which bears testimony to their inherent quality and outstanding durability.

Judges’ Comments: Exceptional example of longevity.

AESTHETICS EXCELLENCE WINNER WET CAST STONE • CATEGORY 5 CONSTITUTION HILL URBAN RENEWAL PROJECT, PORT ELIZABETH Project Description: The Donkin Street/Constitution Hill Urban Renovation project is part of an ongoing initiative to rejuvenate the historical heart of the Nelson Mandela Metro and CBD. The Metro’s abundance of cultural and historical elements truly come to light in this founding suburb of the Bay. The Urban Renewal Project honours and maintains a lot of the traditional design elements that were part of the establishment of this part of town. The designer therefore opted for cobbles in a mixture of sizes and textures in earthy colours. These cobbles complement the smooth modern design elements in the streetlights, cast concrete mouldings, raw steel railings and fittings.

Judges’ Comments: Textures and colours compliments the natural surroundings.

Contextuality is very appropriate. A picture pretty project.

Product Information: Huguenot Cobble Charcoal and Sandstone of various sizes.

Legogote Sandstone of various sizes.

Project Team: Owner: VMMI Properties (Pty) Ltd Main Contractor: Pave Co Entrant/Manufacturer: SmartStone Port Elizabeth

Product Information: Village Cobble Concrete Pavers in Tan colour Project Team: Owner: Tsogo Sun Architect: Northpoint Architects Sub-Contractor: RS Paving Entrant/Manufacturer: Aveng Infraset Product Description: Village Cobbles

THANK YOU! WE THANK OUR MARK HOLDERS FOR THEIR SUPPORT Obtain your quality assured and SANS Certified precast products from the following vendors:

Deranco Blocks (Pty) Ltd Port Elizabeth

3 Sixty Precast Concrete (Pty) Ltd - Bloemfontein

Marx Concrete Pipes Port Elizabeth

Aveng Infraset Rossway

Remacon Products Midrand

Aveng Infraset Wadeville

Rocla De Aar

Bosun Brits

Rocla Port Elizabeth

Bosun Midrand

Shukuma Bricks (Pty) Ltd Port Elizabeth

Bosun Port Elizabeth

Vanstone Precast (Pty) Ltd Rosslyn

Cemblocks Rustenburg

Vibro Bricks and Paving Laudium

Conframat Bricks Vanderbijlpark

Vibro Bricks and Paving Swavelpoort

CMA CERTIFICATION SERVICES (PTY) LTD a SANAS accredited conformity assessment body

CONTACT CMA CERTIFICATION SERVICES TO ARRANGE YOUR SANS MARK ASSESSMENT

Physical Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Postal Address Post Net Suite 334, Private Bag X 15, Menlo Park, 0102 Tel: (011) 805 6742 • Email: admin@cma.org.za • Website: www.cma.org.za

08 CMA AWARDS FOR EXCELLENCE 2018 - WINNERS

ENGINEERING EXCELLENCE WINNER PAVING • CATEGORY 1 MOUILLE POINT AND SEA POINT PROMENADE, CAPE TOWN Project Description: The City of Cape Town commissioned a team of engineers to select the most suitable product to re-surface the entire stretch of the Promenade. The process involved the open invitation for manufacturers to submit samples to best withstand the harshest of environments. The product was to endure not only intensive foot traffic, but the constant, unforgiving battery of waves from the Atlantic Ocean. All submissions were laid in the same stretch of area and were monitored over a two year period by the team of City engineers. The most durable pavers were then specified for Phase 1 of this project.

The 200x100x70mm pavers chosen were specifically engineered in such a way to ensure the durability, texture and water resistance of the blocks. The specification called for the pavers to be manufactured with a topping surface, integrally bound to the body of the units, which was to be smooth and uniform in texture and colour. A waterproofing admixture was used to ensure longevity of the pavers, through water absorption not exceeding 2%. The ability of the pavers to resist water absorption has resulted in salt crystals from the seawater being deposited on its surface. This ensures the longevity of the pavers by the fact that the salt is not able to degrade the concrete from within. The lefthand side of image 06 was taken during the violent June storm which battered the coastline and was recorded as Cape Town’s worst storm for 30 years. The image on the right was taken the week following the storm. The result being that the precast concrete products used for the paved application performed precisely to which it had been engineered.

Judges’ Comments: Performed technically excellent under very harsh coastal conditions.

Product Information: Grey Bond Pavers Charcoal Double Cobbles Tan Bond Pavers Project Team: Engineer: Ingerop Main Contractor: Exceo Entrant/Manufacturer: C.E.L Paving Products

ENGINEERING EXCELLENCE WINNER INFRASTRUCTURE • CATEGORY 2 GROOTGELUK COAL MINE, LIMPOPO Project Description: Eight 60E1 1 in 9 secant geometry turnouts in standard Cape gauge have been supplied to Grootgeluk coal mine for the construction of an upgrade of private rail siding to provide access to an expanded loading facility.

Up until the advent of this project, S60 / UIC60 / 60E1 1 in 9 secant geometry turnouts were constructed with timber sleepers. Timber sleepers are no longer a viable option as they are scarce and more expensive than their concrete equivalent.

Concrete sleepers do not require any maintenance and last a lot longer. Moreover, their incorporation into the new 60E1 secant geometry turnout has facilitated a more modern design such as adjustable guard rails and flexible fastening systems.

This design complies with the requirements to manage 32 tonnes axle loads.

By using the flexible fastenings on the 60E1 1 in 9 secant geometry turnout, it allows for a limited amount of rail movement and reduces the lateral forces. It is a crucial factor to the performance of the turnout because it reduces sleeper fatigue and cracking, especially under heavy axle load conditions.

Consulting engineers have welcomed the new 60E1 1 in 9 secant geometry turnout because it can be applied on several other rail networks, for example, to replace worn turnouts at the Richards Bay Coal Terminal.

Judges’ Comments: Very practical and appropriate precast concrete application.

Simplicity and the low maintenance requirement is appreciated.

Product Information: 1:9 60 E1 Secant Turnouts in Grey Concrete Project Team: Owner: EXXARO Sub-Contractor: Voestalpine.com Entrant/Manufacturer: Aveng Infraset

CMA AWARDS FOR EXCELLENCE 2018 - WINNERS 09

ENGINEERING EXCELLENCE WINNER RETAINING STRUCTURES • CATEGORY 3 COASTAL PROTECTION WORKS, STRAND Project Description: Sections of a seawall adjacent to Beach Road in Strand were breached between in 2006 and 2007, causing damage to pavements and streetlights, and threatening to flood basements in some of the side streets.

The choice of precast concrete units for building the seawall was an engineering decision based on the need to build quickly and to achieve high standards in durability and finish qualities.

Manufacturing precast elements in a factory away from the marine environment made it easier to achieve the high specifications on a consistent basis. It was also more cost-effective.

The amount of water and wind-blown sand which could overtop the walls were crucial research elements. Given that this is a holiday destination, aesthetic considerations also played a significant role in the design brief.

The project called for a very high standard of concrete and the mixes were designed in-house by the manufacturer. Based on four durability indices the concrete mix designs were submitted to the concrete laboratory at the University of Cape Town for quality assessment and verification.

Judges’ Comments: Outstanding application of precast concrete in a harsh marine environment. This project demonstrates exceptional and innovative design a and engineering.

Product Information: Bespoke Retaining Wall L-Block Units Bespoke Copings

ENGINEERING EXCELLENCE WINNER BUILDING ELEMENTS • CATEGORY 4 NORTH EAST PARKADE – FOURWAYS MALL, JOHANNESBURG Project Description: The construction of North East Parkade, where the bulk of the structure comprises precast concrete, marks a significant point of departure for the South African construction industry.

It is the country’s first precast parkade and its largest precast framed structure to date.

The design team took up the challenge of proposing an alternative design using precast columns, beams and slabs as the main structural elements.

Other precast elements included crash barriers/balustrades, stairs, retaining walls and a roof for a truck tunnel. Precast concrete elements not only made for faster building practice, but enabled construction to take place in a confined space.

Moreover, these elements were sufficiently light to be lifted into position by tower crane.

Hidden column and beam connections were critical in complying with the architectural design criteria and these had the added advantage of simplifying the installation process.

Project Team: Owner: City of Cape Town Engineer: Mott Macdonald PDNA Main Contractor: Civils 2000 Entrant/Manufacturer: Concrete Units

The use of specialised design software enabled the creation of fabrication drawings as part of the original design package and this simplified the overall project management process. The end result is a functional and aesthetically pleasing end product.

OVERALL WINNER 2018

Judges’ Comments: This project broke the mould for design and construction of structured parking. It is an example of efficient streamlined engineering.

Product Information: Echo Prestressed Floor Slabs of various sizes Echo Prestressed Wall Slabs of various sizes Project Team: Architect: ABC Architects Engineer: WSP South Africa Quantity Surveyor: Quanticost Quantity Surveyors Main Contractor: Mota-Engil Contraction South Africa Entrant/Manufacturer: Echo Prestress (Pty) Ltd Floor Slabs

10 CMA AWARDS FOR EXCELLENCE 2018 - WINNERS

ENGINEERING EXCELLENCE WINNER PRECAST STRUCTURES • CATEGORY 5 BURGLAR PROOF CONCRETE BOXES, MEYERTON Project Description: Burglar proof precast concrete boxes. The design specification was to manufacture a burglar proof vault. The product is coated with a thermal white paint. The precast concrete strength is 100 MPa. Judges’ Comments: Showcases definite functionality advantage.

Product Information: Precast concrete burglar proof box in the form of a cube Project Team: Entrant: Afrisam Manufacturer: Enviro-Cast

ENGINEERING EXCELLENCE WINNER PRODUCT INNOVATION • CATEGORY 6 NEW RETAINING WALL BLOCK, MIDRAND Project Description: A patent (2016/00519) was granted to the inventor of this retaining wall block in May 2017. There are two main criteria for a patent, namely, that the invention must be novel and that it should hold clear benefits over existing products in the market.

This in itself is proof of innovation.

Amongst its benefits are: 1. A critical aspect with retaining wall blocks is consistency in block heights. SANS 508, specifies dimensional variances of not more than ±3mm.

Why block heights are important • Lines that are not level are displeasing.

• Blocks placed on top of an uneven layer will lead to stress points between blocks of different layers.

• Once unevenness has commenced, it is not easy to correct in following layers, leading to slow and costly installation.

• Geotextiles placed between uneven rows of blocks could be ripped out.

This block guarantees tolerances within half a millimetre or six times more accurate than the outer limit of the SANS as it is manufactured in a different way to all other retaining wall blocks commercially available in South Africa.

2. This block offers superior crushing strength compared to most standard concrete retaining blocks. The crushing strength is derived from various design elements including the unique V shape stiffeners in the block. Because of the superior crushing strength, the construction of retaining walls of 50 blocks high is possible. The bottom row will still be twice as strong as required as a safety factor. This was tested using finite stress analysis software.

Judges’ Comments: The block has an elegant design and impressive appeal.

Product Information: New Retaining Wall Block Project Team: Entrant/Manufacturer: Bosun Midrand

CMA AWARDS FOR EXCELLENCE 2018 - WINNERS 11

ENGINEERING EXCELLENCE WINNER PRODUCT INNOVATION 100+ • CATEGORY 7 AMATOLE MUNICIPALITY SANITATION PROJECT, BUTTERWORTH Project Description: Affordable movable precast concrete toilets Judges’ Comments: Extremely functional example of precast concrete. Durability, versatility and ease of assembly is impressive.

Product Information: Patented lightweight textile matt sandwich reinforced precast concrete panels, inclusive of high tensile steel or GF reinforced ribs. Available in various sizes but not smaller than 950mm in width.

Project Team: Entrant: Afrisam Manufacturer: Rocla (Pty) Ltd

OVERALL WINNER 2018

ENGINEERING EXCELLENCE WINNER FUNCTIONALITY FOR LIFE • CATEGORY 8 BELLVILLE VELODROME, CAPE TOWN Project Description: The Bellville Velodrome is a multi-purpose venue, developed as part of the South African Olympic bid for 2004. The stadium has capacity for 6000 seats and 7800 standing visitors. The stadium, completed in 1997, has in the past 20 years hosted a multitude of events which include major sporting, religious, musical and political events.

Grey 80mm interlockers were supplied for the external parking and delivery areas, whilst 200x100x50mm grey bevelled pavers were supplied for the internal walkways and access points.

The venue welcomes an average of 48 000 visitors per month.

The external interlockers have been subjected to pedestrian traffic and daily truck deliveries, with heavy duty truck and trailer deliveries each weekend.

The installation remains in good condition with no sagging or shifting visible. Visually the pavers, internally and externally, have experienced fair wear and tear over the period. A certain amount of abrasion to the surface has occurred, but remains uniform and well within accepted norms.

Concerts, renowned for having not only significant foot traffic, but for also providing the harshest of environments with regards to spillage of high fat and high acid food and beverages.

The maintenance would then require the application of highly abrasive cleaning products. In this regard, the pavers have performed exceptionally well under the conditions considering the length of time of use. Both the internal walkways and external parking have shown incredible resistance to wear and tear - with over 11.5 million visitors having traversed the paving over the years.

Judges’ Comments: The proof is in the pudding! After all the years and traffic, the condition is still brilliant.

Product Information: 80 & 60mm Grey Interlocking Pavers Grey Bond Pavers Project Team: Owner: City of Cape Town Main Contractor: DW Projects Entrant/Manufacturer: C.E.L. Paving Products

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WE INVITE ALL PRECAST CONCRETE MANUFACTURERS TO JOIN US *

CONCRETE MANUFACTURERS ASSOCIATION Physical Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Postal Address Post Net Suite 334, Private Bag X 15, Menlo Park, 0102 Tel: (011) 805 6742 • Email: admin@cma.org.za • Website: www.cma.org.za

* TERMS AND CONDITIONS APPLY

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PROJECTS 23

Completed in 2015, the house is a prime example of how precast concrete can be successfully used for form and function. In this case, it has been used in a structure that responds to its rugged mountainous and coastal setting in dramatic fashion.

Situated on a ridge above Cape Town’s Atlantic Seaboard, the site commands stupendous views of Lion’s Head and Robben Island to the north, and Camps Bay

MODERN ARCHITECTURAL

MASTERPIECE

Precast concrete has played a major role in the construction of OVD 919, a spectacular, open-plan home, designed by international award-winning architectural firm, Stefan Antoni Olmesdahl Truen Architects (SAOTA). and the Twelve Apostles to the South.

The house was built by DDC Construction (main contractor) and the precast concrete elements were supplied by Cape-based World of Decorative Concrete (WODC). Although most of the walls and floors were cast in-situ – requiring a high degree of structural and services co-ordination – extensive use was made of precast concrete.

Beautifully practical The client’s brief called for a design that would bridge the building’s essential functions, insular family home (Top and left): Precast panelling cover the walls on the concrete pergola and pavers cover the floors of the entertainment area.

PRECAST | ISSUE ONE | 2018

PROJECTS

and expansive enter tainment area.

Construction materials with varying textures were deliberately selected to emphasise the uncluttered, contemporary nature of the architecture.

A colour palette was established upfront to emphasise the homogeneity in all

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the building forms, This was reinforced by the use of two key materials: a terrazzolike monolithic floor finish, used through-

“The house is a prime example of how precast concrete can be successfully used for form and function.”

these special aggregates were not available in Cape Town and were finally sourced in an old diamond mine on the North West coast. Then there was shrinkage and cracking to contend with, due to the small size of the aggregates.

Close collaboration between SAOTA, global building products manufacturer, Lafarge, and WODC, led to the development of the right concrete mix. It took nu-

out the main living area, and an off-white pigmented concrete, which was used for the walls and ceilings. The floors ensure seamless continuity between the internal and external living areas and coherence with the sandblasted concrete walls, as do the precast ceiling beams, which were installed both internally and externally.

Commenting on the project, Johan Coetzee, CEO of WODC, said that designing an exposed aggregate off-white concrete had its own set of challenges.

“The only way to achieve the off-white weathered appearance was the use of a white cement concrete mix infused with 6-9mm pebbled aggregates, which would be exposed by supplied sandblasting.”

However, Final material will not be for print/publication until such time as approval is received. Please return fax to: 086 509 4850

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Tel: 011 674 6900 Maxi call: 0861 266 267

PROJECTS

merous colour samples and performance/ casting tests until a mix was achieved that ensured consistent finishes for the off-shutter and precast concrete.

“Another challenge was that after we had cast 60% of the precast concrete elements, the supply of aggregates was abruptly halted and we had to find an

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alternative supplier. We eventually found the same type of gravel in the diamondrich Kimberley area,” adds Coetzee.

Ribbed ceiling The entire house was sandblasted to expose the aggregate, resulting in a robust, tactile and understated building

(Far left): Precast beams created a continuous flow between internal and external areas.

(Above) Precast pavers surround the pool area and cover the frame-like concrete pergola above the pool.

material in harmony with its environmental context. Internally, the weathered,

blinds, 32 beams had to be cast using

skirting. In addition, massive precast

sandy concrete creates a warm, com-

individual moulds.

panels attached to hinged steel frames

fortable ambience.

Initially, it was thought that an in-situ

were installed as housing for large sliding

The most dramatic use of precast

ribbed soffit could be used to create

doors. The panels can be opened to allow

concrete was a ribbed ceiling, a first

the ceiling, but thorough investigation

the doors to be serviced.

for South Africa, which created visual

showed this was not a viable option. Each

Precast concrete was also required

continuit y between the indoor and

beam weighed 835kg and only 14 could

for recessed external skirtings and pav-

outdoor entertainment areas. Requir-

be delivered to site at a time. They were

ers. The entertainment area, which in-

ing 92 precast beams, the ceiling’s

not stockpiled on site as double handling

cluded all the coping around the swimming

strong horizontal plane accentuated

would have increased the risk of damage.

pool, was covered with precast pavers,

the panoramic view. Beam casting had

Instead, they were hoisted off flatbed

as was the roof of the concrete pergola

to be done to extremely tight tolerances,

trucks by crane and carefully lowered into

above the pool.

as there was only 15mm of play across

position. Every beam was then manually

the full ceiling area. The beams were

adjusted to ensure perfect alignment.

cast in a double L shape, which allowed

Lafarge also developed a special exposed aggregate concrete mix for the steep driveway. This surface extends

them to provide shuttering for the

Other elements

into the garages, where the surface

casting of the reinforced roof above

Other precast elements included clad-

was polished. In addition, all the bollards

them. In order to accommodate the

ding on the indoor staircases to match

and curbs were precast and installed by

various services, such as lighting, HVAC,

the terrazzo-like floor finish, panelling

WODC to match the look of the exposed

audio visual, glazing and motorised

on some of the walls and some recessed

concrete driveway.

(Above): All internal stairs were clad in precast panelling to match the polished terrazzo-like floors.

PRECAST | ISSUE ONE | 2018

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Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Tel: (011) 805 6742 • Email: admin@cma.org.za • Website: www.cma.org.za

PROJECTS

Mistakes in the way readymix concrete is specified, ordered and received, can have far-reaching effects on product delivery for infrastructure projects in terms of its usage and future performance.

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According to CMA Associate member association, the Southern Africa Readymix Association (SARMA), it is imperative that those responsible for the procurement and placement of concrete on precast sites become familiar with the correct processes and procedures to follow, when dealing with this most versatile of building materials.

“There are hundreds of different types of readymix available for different applications in the manufacture of precast concrete products. There are also numerous factors, such as workability, that

READYMIX CONCRETE CONSIDERATIONS FOR INFRASTRUCTURE PROJECTS

can influence the success of this type of concrete on site. The interface between (Above): Concrete delivery on site.

the purchaser and professional readymix

(Left): Readymix testing.

company therefore needs to be accurate and measured,” says SARMA director,

wheelbarrows, it is important to know

Johan van Wyk.

that the average mixer carries at least 90 wheelbarrow loads, so cannot possibly be offloaded by a couple of labourers with

Getting specifications right “I t i s e s s e n t i a l t o e s t ab li sh t h e

wheelbarrows,” says van Wyk.

credentials of the readymix supplier

“When dealing with freshly delivered

upfront and ensure that they are properly

readymix, timing is of the essence. As

accr edited. By selecting a SA RM A

a rule you have seven minutes per cubic

member, for example, the specifier

metre to offload and place the concrete.

is assured that the company has the

If the truck stands for too long, the con-

necessary in-house technical skills and

crete may begin to set and change its

technical support to be able to ensure

workability characteristics, which may affect the result. Also, you may be charged

that concrete supplied is fit-for-purpose and complies with Sans 878: 2004 which

staff of readymix suppliers visit the site

demurrage if the truck has to stand longer

is the specification used for generic

to look at the practicalities and identify

than the allocated time. Discuss and

readymix concrete,” explains van Wyk.

possible pitfalls.”

agree upon the rate of delivery required,” recommends van Wyk.

“Thereafter the technical attributes of the concrete can be laid out and

Exact requirements

agreement sought on the type of testing

Van Wyk says it is imperative that techni-

Site access

to be conducted on site. The specifier

cal specifications need to be clear regard-

Lastly, says van Wyk, make sure that

then needs to spell out the workability

ing the strength and characteristics of

the correct manpower and equipment is

characteristics and delivery points for

the concrete. This includes how much

allocated to accept the concrete on the

the different types of concrete ordered.

is required, where and when, as well as

delivery date and time. He adds that you

The method of discharge needs to be

workability and consistence (slump) of

need to ensure site access in terms of

made clear, as well as method of con-

concrete delivered. The readymix supplier

physical space and how close the truck

veying the concrete once delivered on

also needs to be informed regarding the

can get to point of discharge.

site,” he says.

type of equipment that will be used to

Van Wyk adds that it is important to

receive the concrete.

Van Wyk says: “Discuss the curing regime and agree on testing requirements,

revert to the specification and have dis-

He adds that the method of plac-

method and frequency of tests to be done,

cussions relating to exact requirements

ing the concrete on site also needs to

who should be present and the procedures

on site. “If the project requirement is for

be highlighted. “Discuss a plan for how

to be followed, if the tests fail at any point

large numbers or complex types of prod-

the concrete will be moved around the

in the delivery, placing and curing of the

ucts, then it is wise to have the technical

site. For example, if it is to be moved via

concrete.”

PRECAST | ISSUE ONE | 2018

PROJECTS

South Africa’s first precast concrete

28

ventionally designed using cast in-situ

parkade, comprising seven storeys and a total floor area of 65 000m², has been built as part of an expansion and revamp of the Fourways Shopping Mall in Fourways, Johannesburg.

North East Parkade was initially conon site technology. However, time constraints and a need to minimise disruption to traders and their customers were important design considerations. This prompted the design team to investigate and to then propose an alternative design using precast columns, beams and slabs as the frame’s main structural elements.

Together with other precast elements, such as crash barriers/balustrades and stairs, they would be combined with castin-place concrete, to create a hybrid construction system.

Besides being faster and and less disruptive to retail activity, precast construction would be propless and would allow the early occupation of the lower floors, while the upper levels were still under construction. Moreover, its fast, repetitive modular construction technique and consistent f ac tor yproduced quality would yield superior productivity and improved safety on site.

Massive undertaking These factors persuaded the Fourways Mall o w ner s, A c c eler a t e P r op er t y F un d, t o m ak e his t o r y b y b uil ding South Africa’s largest precast framed structure to date.

PRECAST CONCRETE PARKADE CHARTS NEW TERRITORY FOR LOCAL CONSTRUCTION C M A m emb e r, E c h o P r e s t r e s s, manufactured the slabs (78 000m²), which were used for the flooring and r etaining walls. Echo was also the prime mover in the switch from in-situ to precast construction and played a major role in the precast engineering input which was crucial to the success of the project.

According to Echo Technical Director, Daniel Petrov, hidden column and beam connections were critical in complying with the architectural design criteria and these had the added advantage of simplifying the installation process.

“Precast structures of this type will become indistinguishable from those constructed using non-precast methods”

“Vertical load transfers up to 900 t/column were facilitated by purposedesigned connector bolts and shoes, which enabled the columns to be simply bolted together. The columns were cast

PRECAST | ISSUE ONE | 2018

(Far left): An aerial view of North East Parkade.

w ill become indistinguishable f r om those constructed using non-precast me thods. Designer s ar e no longer

PROJECTS

(Left): The completed third floor showing the columns, beams and fourth floor slabs.

obliged to work within tight constraints.

Due to the availability of an increasing number of precast elements, they are now able to incorporate greater variety and design complexity in their buildings,” adds Petrov.

Continuous investment Petrov says that the North East parkade is a functional and aesthetically-pleasing end product, which will surely be classified as one of South Africa’s ground-breaking structural applications. “ T he tr ue v alue o f this f lagship project is yet to be fully realised and it should promote greater liaison between the precast producer and the design team. However, it already represents a significant shift towards prefabricated construction methodology and is encouraging construction professionals to take a fresh look at the benefits of (Left and below): Various sections of the parkade under construction.

precast.”

specialised software for the creation

and upcoming gener a tion o f y oung

of construction drawings. This resulted

professionals in the correct use and

in fabrication drawings being made

appreciation of precast construction

a v ailable as par t o f the specialist

is one of our primary objectives as

design process and further reduced

professionals and North East Parkade

the complete project time cycle. Close

will provide a valuable reference point

cooperation between Precon and the

for South African professionals and

in two-storey lengths to minimise the

overall project engineers, WSP, ensured

educator s who ar e invol ved and /or

number of joints. As soon as the columns

that all structural details were well

considering similar projects.

were secured in position, rectangular

coordinated and complied with WSP’s

beams were seated on steel billets,

requirements.

Petrov adds: “Educating the current

He concludes: “Moreover, continuous investment and innovation by the South

which had been cast into the columns.

“With the advances in construction

African precast concrete industry will

Thereafter, the placement of the slabs

technology and techniques available

pave the way for ever more complex

onto the beams could follow immediately,”

today, precast structures of this type

layouts and external treatments.”

said Petrov.

Tight specifications Only 475mm deep, the shallow beams were designed to suit the restricted 3 060mm floor-to-floor height. A floor screed was applied as a structural component and enhanced the stiffness of the beams by more than 200%. During load testing under a live-load application, this resulted in deflections of not more than 2mm on a 7 850mm beam span.

T he detailed structural design was carried out by Precast Concrete Consultants (Pr econ), who utilised

PRECAST | ISSUE ONE | 2018

29

PROJECTS

PAVING THE WAY FOR A PORT ELIZABETH CAR DEALERSHIP Approximately 14 000m² of concrete block pavers have been supplied by Eastern Cape CMA member and CMACS mark holder,

30

Shukuma Bricks, for the paving of paths, driveways and a car park at a new Toyota dealership in Fairview, Port Elizabeth.

Shukuma supplied its interlocking grey paving blocks in thicknesses of 80mm and 60mm, the former to handle heavy vehicles in the trafficked areas and the latter for the paving of the pedestrian walkways. The paving was laid in a herringbone pattern on a base of imported and cement stabilised G5 aggregate, by paving contractor, Rand Civils.

Shukuma MD, Werner Zittlau, shares that the company manufactures pavers in a fully automated plant in compliance with SANS 1058 standards.

“All our pavers are tested for tensile splitting, abrasion, and compression.

(Above) The newly paved truck bay at a Toyota dealership in Port Elizabeth.

quality of our product range.”

Our plant includes an RE 1400, the East-

ger car, which rotates 180˚ (a South

ern Cape’s first fully-automated static

African first); a custom-designed cur-

Besides interlocking pavers, Shu-

type block machine and one of only four

ing chamber; as well as automated and

kuma’s product range includes bevelled

in South Africa. We also use automated

vertical stacking,” says Zittlau. “This

pavers, stock and maxi bricks and build-

raw material mixing; an automated fin-

ensures complete consistency in the

ing blocks.

DONKIN VILLAGE REJUVENATION USES COBBLE PAVERS FOR A MODERN TWIST

A strong foundation for infrastructure success

Cultural and historical elements are key in the Donkin Village/ Constitution Hill Urban Renovation project, which forms part of an ongoing rejuvenation initiative in the historical heart of the Nelson Mandela Bay Metro and CBD. While adhering to clean lines of its original design elements, the Urban Renewal Project gave CMA member, SmartStone Port Elizabeth, an opportunity of participating in the modernisation of this historic area.

The developer chose SmartStone Port Elizabeth’s Huguenot cobble and Legogote cobble pavers in various sizes to create the new look.

“Cobbles are as easy to install as a standard brick, but come with more elegant and refined finishes,” remarks SmartStone Port Elizabeth co-owner, Mimi Rupp.

Chosen for its engineered precision and rough, rustic texture, the Legogote cobble was used for the sidewalks, public areas and walkways. It was off-set against smooth modern design elements in the streetlights, cast concrete mouldings, raw steel railings and fittings.

“Cobbles are traditionally used in one size, with a gap between each stone, however, the Donkin Village design employed four sizes laid flush with one another. This gave the road and pavements a contemporary look with an old-world feel. Moreover, the use of colour and texture the area was carefully considered and our sandstone cobbles were chosen to complement the natural stone hues found in the original

I15457

brought the space up to date,” says Rupp. “The entire redesign of

foundation walls.”

The inspiration is simple. “The smoother, almost weathered stone texture of the more traditional Huguenot cobble, harks back to an era of cobbled streets, horse-drawn carriages and promenades. It was the ideal choice for this hilly area’s many access roads and parking areas,” explains Rupp. “As a contrast to the Legogote sandstone, charcoal cobbles were chosen for the roads for a contemporary and hard wearing look.”

ROCLA is South Africa’s leading manufacturer of pre-cast concrete products. Surpassing 100 years of product excellence, including pipes, culverts, manholes, poles, retaining walls, roadside furniture, sanitation and other related products within infrastructure development and related industries.

Visit us on www.rocla.co.za for our nationwide branches PRECAST | ISSUE ONE | 2018

INSTALL

CERTIFIED

PRECAST CONCRETE

PRODUCTS TO OBTAIN A LIST OF CERTIFIED SUPPLIERS, CONTACT CMA CERTIFICATION SERVICES OR VISIT WWW.CMA.ORG.ZA. Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Tel: (011) 805 6742 • Email: admin@cma.org.za

YOUR MARK OF QUALITY IN PRECAST CONCRETE

PROJECTS 33

In stark contrast to the developed world, South Africa’s construction industry has been slow in adopting precast concrete as its primary building material. Therefore, when one of the country’s leading contractors embraces precast concrete as the main structural element on a major project such as Shoprite’s giant new distribution centre in Cape Town, it foreshadows a sea-change in the country’s construction methodology.

Comprising 123 000m² of covered space in 20 buildings, the Shoprite development represents one of Africa’s largest and most technologically-advanced distribution centres. Tilt-up concrete columns were used as the main structural element on the three largest warehouses, which span a total roofed area of 104 084m2. They comprise a massive 75 061m2 dry-goods warehouse, an 18 476m² refrigerated building, and a returns centre of 10 547m². The dry goods building features two safety stores of around 1 100m2 each, which have been designed to contain a fire for up to two hours, thereby protecting the surrounding infrastructure.

Sebastian Dockter, a director with WSP, led the structural design team on the project. Stefanutti Stocks Building Western Cape was the main contractor and the Bedrock Group handled the casting and erecting of the tilt-up columns and panels.

(Top): Precast concrete columns in the dry goods warehouse.

(Right, from top): The massive 65 061m² drygoods warehouse, the largest of 20 buildings at Shoprite’s new distribution centre; a row of newly installed tilt-up concrete columns prior to the pouring of blinding concrete.

PRECAST | ISSUE ONE | 2018

PRECAST TILT-UP CONCRETE SUPPORTS MASSIVE SHOPRITE DISTRIBUTION CENTRE

PROJECTS

Cast and lift “By definition, tilt-up describes a construction technique in which predominantly vertical concrete elements, such as columns and walls, are cast flat on the ground and on site, in close proximity to their final installation point. Once

34

cured, they are hoisted into position.

By contrast, more traditional precast concrete elements are cast off site and must be transported to site,” explains Dockter.

Some of the columns were 26,56m high, SA’s largest precast tilt-up to date.

They were stepped from 1957 x 600mm to 1000 x 600mm and weighed up to 44 tonnes each.

(Above): A line of tilt-up concrete columns in the refrigerated warehouse.

It took 148 columns to build the main

Eight specialised inserts were cast

warehouse, where column heights varied

into the columns to facilitate lifting into

The concrete used for both the columns

between 7,1m and 21,75m; the higher

position by a giant mobile crane. The in-

and the panels was identical and achieved

columns also being stepped. Forty-six

serts allowed the columns to be tilted in a

a strength of 30Mpa. It was supplied by

columns, 13,5m to 16,5m high, were used

controlled manner using a pulley system,

Ciolli Ready Mix and comprised 19mm

to build the safety store, and 39 columns

which made the process relatively easy.

stone and a 100mm slump. This high

were deployed in the construction of the

Weighing 37 tonnes apiece, the panels

slump rate made the concrete more

return-goods building. In addition, tilt-up

were 14,995m (five storeys) high and

workable and facilitated a rapid produc-

panelling, comprising 48 panels and cov-

6,2m wide. Like the columns, they were

tion rate.

ering a total area of 4 155m², was used

cast close to the point of installation

The columns were reinforced with a

in the assembly of the safety store’s

and hoisted into position by the same

pre-fabricated reinforcement cage. The

external walling.

mobile crane.

column-base starter bars protruded

Quick up-time

A NAME TRULY CAST IN CONCRETE

GAUTENG | KZN | WESTERN CAPE

PRECAST CONSTRUCTION SOLUTIONS HEAD OFFICE: (011) 589 8800 WWW.ECHO.CO.ZA

and shimmed to ensure a 100% verti-

preparation of the base casting opera-

cal alignment. The foot of each column

tion. The largest bases for the main grid

was given a 25mm tolerance to enable

stability columns measured 10 x 5m and

optimised accuracy during the shimming

were 1.3m deep. Temporary structural

process. Levels and positions of the

blindings, which supported the full weight

columns underwent a final survey, using

of the columns in their temporary posi-

theodolites and laser levels, before the

tions, were reinforced at the centre.

go-ahead was given for pouring the bases.

Column feet with several sleeves were

“Another advantage of precast col-

added to the bottom of the columns

umns is in the positioning of roof steel

to facilitate the tilt-up methodology.

hold-down bolts. With in-situ construc-

Moreover, the sleeves allowed foundation

tion bolts must be installed 21 metres off

reinforcement to be passed through the

the ground, an extremely difficult exer-

column feet for additional stability.

cise. By contrast, it’s much easier to get

According to Dockter, there are

the bolts aligned correctly when working

several advantages in using precast con-

at less than a metre off the ground, as

crete for column construction. The most

one does with tilt-up. This is what enabled

noteworthy include: simpler construction

Bedrock to cast the hold-down bolts into

procedures, the increased accuracy of

the top of the columns with a high degree

cast-in items and a concomitant reduc-

of accuracy,� said Dockter.

tion in risk.

Bedrock general manager, David Kitching, said that due to the size of the cranes

Safe environment

and their respective cost, meticulous

“Tall concrete columns are safer if cast

planning was paramount to the success of

on the ground, and once erected, of-

the project: “Preplanning is crucial to the

fer the same structural properties as

proper installation process and ensures

equivalent in-situ concrete columns. The

that the efficiency of the mobile cranes

structural design of a tilt-up or an in-situ

and rigging teams is maximised.�

column is virtually the same. However,

from the bottom of each column, in

the actual construction sequence is reversed. Instead of constructing the base and then casting the columns, the columns are cast on the ground, lifted into position and the base constructed

G e n u i n e

c o m p e t i t i o n

around them,� says Dockter.

He adds that in preparation for the base pours at Shoprite, the columns were held in position by adjustable steel stays

i s

good

for

the

c o n s u m e r

(Right): A tilt-up column during the alignment process.

(Below): A tilt-up concrete column is lowered into position by a giant crane (220t lifting capacity).

Imitators are

NOT

TERRA FORCE

Find your nearest supplier www.terraforce.com PRECAST | ISSUE ONE | 2018

Te l : 0 2 1 4 6 5 1 9 0 7

PROJECTS

According to C.E.L. sales consultant, Peter Visser, the area required limited ground preparation using a grader, as EarthLock’s interlocking design means the blocks are self-aligning. Geofabric was laid in the stormwater channel to prevent water erosion.

“Additional structural strength was

36

achieved by cabling the blocks together

EROSION CONTROL SOLUTION FOR

with eight gauge wire. They can also be matted or anchored and the blocks are

MIXED-USE PROPERTY PARK

lows them to follow the contours of the

CMA member, C.E.L. Paving Products,

velopment offers easy access and high

ground,” says Visser.

has supplied 13 000m² of EarthLock

visibility exposure in a gross bulk lettable

“Moreover, they can be laid in two

road and erosion control blocks for lin-

park of 300 000m². Cast at 35MPa

different patterns, the standard layout

ing a low-flow stormwater channel and

and 100mm thick, the Earthlock blocks

at 8,35 blocks per square metre, or the

steep access roads at Richmond Park,

were laid over a six-week period by

closed-mesh layout using 8,8 blocks per

Cape Town.

main contractors, Burger and Wallace

square. Both allow the growth of vegeta-

Construction.

tion such as grass. The standard layout

Situated on 84 landscaped hectares

designed with a light chamfer, which al-

of land, Richmond Park is currently under

Johan Veldsman, a site agent for

provides a permeable soil-filled surface

development by Bethel Property, Quibic

Burger and Wallace Construction, said

area of 25% and the closed-mesh vari-

and the Richmond Communal Property

Earthlock was specified for the project by

ant is 18%.”

Association as a mixed use retail, light

the project engineers, Lyners Consulting

industrial and office park.

Engineers. This is due to it being a high

Straddled by two major ar terial

quality block with good strength proper-

routes, the N7 and the M14, the de-

ties and multiple on-site usage options.

(Above, from left): One of the pond access roads paved with C.E.L.’s Earthlock road and erosion control block; a stormwater channel at Richmond Park is lined with C.E.L.’s Earthlock road and erosion control blocks on top of geofabric.

pavers • tiles • cobbles • cladding • coping • kerbing • landscape products

Silo V&A Waterfront Cape Town Custom Made Pool Copings

House Stellenbosch Kent Cobble

www.revelstone.co.za

Franschhoek Village Centre Ravine Tiles

Cape Town International Airport Viking Random Cladding

0 8 6 1 1 RE VE L 7 3 8 3 5

HEAD OFFICE • FACTORY • SHOWROOM AT ADAM HOUSE, ORION ROAD, NERISSA ESTATE, LANSDOWNE, CAPE TOWN

PROJECTS 37

PRECAST ELEMENTS ENHANCES SILO PROPERT Y DEVELOPMENTS

AT V&A WATERFRONT Creating a fresh design, precast concrete has been used in the construction of three new buildings at Cape Town’s V&A Waterfront, No. 3 Silo (apartment building), No. 4 Silo (gym and retail space) and No. 5 Silo (office space). These buildings front onto a circular plaza, which is paved with precast concrete cobbles and flagstone pavers, most of which was supplied by CMA member, Revelstone.

Lloyd Rubidge, a partner of Van Der Merwe Miszewski Architects, who designed the three buildings, says that the intention was to create an ambiance of “external” street space within the silo.

The cobbles were edged with high grade non-slip porcelain tiles. This street space design in the building’s main atrium was accentuated with the use of exposed

Designed by Van Der Merwe Miszewski

and 12th floor decks. A smaller version of

precast concrete masonry on some of

Architects and Makeka Design Lab, No.

the Jura paver was also used as capping

the walls, which together with the Jura

3 Silo achieves a high degree of sustain-

for a lily pond on the eighth floor.

cobble pavers, resonate with the semi-

ability, without compromising utility,

The plaza was covered with a combi-

comfort or aesthetics. Built as three

nation of pavers, including Revelstone’s

towers separated by the lifts and stairs,

York cobble and Devon cobble pavers. The

its architecture echoes the adjacent

former has a rounded stone textured

Grain Silos redevelopment. This develop-

finish, which resembles traditional Eu-

“Precast elements have formed a crucial

ment, encompassing the Silo Hotel and

ropean granite cobblestones, while the

element of the overall materials pool for

the Zeitz Museum of Contemporary Art

latter is ideally suited to large volumes of

these buildings and assisted us in ex-

Africa, will open to the public in September.

nautical and industrial aesthetic of the Waterfront.

Varied materials

tending the Waterfront’s semi-industrial

No. 3 Silo features two upper-floor

aesthetic,” says Rubidge.

swimming pools. One forms part of the

“We wanted to avoid monotony, which

eighth floor sundeck and the other holds

is why we varied our choice of materials in

centre stage in the entertainment area on

terms of design size and colour. However

the deck of the rooftop penthouse (12th

in the main, we opted for muted colours,

floor). Both pools are fringed with Revel-

as these don’t detract from other plaza

stone’s purpose-made charcoal-coloured

attractions, such as boutique shops,

coping, which was post acid-etched to provide a non-slip surface. The two pools command spectacular views over the Waterfront, City Bowl and Table Mountain.

plant life and open-air cafés, restaurants (Above): Jura straight-edge pavers cut a path across a section of garden in the Silo Plaza.

and public spaces.”

heavy traffic. A larger version of the Jura

the Silo district included concrete pan-

Other forms of precast concrete in

straight-edge paver with a rough textured

elling on No. 1 Silo, which was supplied

Creative pavers

surface, was used to create a path across

by CMA member, Concrete Units, and

Revelstone’s Jura straight-edge paver

the flowerbed feature in the plaza.

precast concrete benches supplied by

was used extensively as design elements

In a break with conventional paving

at No. 3 Silo. It covers a path leading

practice, Revelstone’s external Jura cob-

from the inside of the building to the

ble paver was used for both the internal

sundeck on the eighth floor, and on the

public area flooring and the external pav-

outer ledge which surrounds the eighth

ing requirements of No. 5 Silo.

PRECAST | ISSUE ONE | 2018

Classicstone.

(Top, from left): Revelstone’s Jura paver was used extensively on the eighth and 12th floor sundecks; inlaid with Revelstone’s York cobble, this is one of several paved octagons outside the Zeitz Museum of Contemporary Art Africa.

PROJECTS 38

REPAIR OF THE SPUR AT CAPE TOW The Spur, a minor breakwater that pro-

NEC3 project manager, Adrian Guerrini

experts from engineering consultants,

tects Cape Town harbour’s main break-

from the main contractor, GMC, as the

PRDW South Africa, who handled the

water armouring, has been repaired using

construction project manager, as well as

design aspects as well as the project’s

precast concrete Dolos units, manufac-

technical and quality supervision. Anton

tured by CMA member, Concrete Units,

Holtzhausen was the project designer and

a sub-contractor to Guerrini Marine

Marli Geldenhuys, the resident engineer.

Construction (GMC). The Spur obstructs

Siyakhatala Safety was responsible for the

the migration of rock material and rubble

safety, health and environmental services.

from the adjacent beach towards the Dolos slope of the main breakwater.

Scour erosion

The FEL-4 project, which was under-

The Spur was first completed in 1989,

taken on behalf of Transnet National Port

using 431 Dolos units. Over the years,

Authority (TNPA), was completed the end

storms and turbulent seas have resulted

of January. The professional team con-

in cumulative damage. An investigation by

sisted of Mishka Prinsloo of TNPA as the

the CSIR in 2014 estimated that the South

“The mix had to be adjusted with a superplasticer to maintain the slump.”

Spur sustained 66% damage whereas the Mid-Spur had sustained 23% damage.

When the Spur was first built, two layers of 25 tonne Dolos units were packed on the slope and 27 tonne reinforced units were placed at the toe.

Individual toe units were chained to the top of the Spur and the cap of the Spur was protected with a single layer of 20 tonne concrete blocks.

T h e o v er all s t ab ili t y o f th e t o e mechanism of the South and Mid Spurs was initially compromised due to the displacement of some of the toe units by scour erosion. A significant massive storm in 1997 resulted in approximately 5 0 % d a m a g e t o t h e S o u t h S p u r.

Thereafter, progressive damage took place until the 66% mark was reached (Top): Newly cast Dolos units in the casting yard of Concrete Units.

(Left): A 400-tonne crane swings a 25 tonne Dolos into position and lowers it into the sea.

(Right): Dolos units prior to placement on the Spur breakwater.

PRECAST | ISSUE ONE | 2018

ing all marine growth from the seabed

Concrete for the manufacture of the

units had been destroyed.

so that the broken Dolos units and large

Dolos units was designed to have a high

rocks could be identified for removal.

stone content and a low water content to

Innovation

Lugs were drilled into the larger debris

ensure that the minimum mass require-

In order to prevent a recurrence of scour

to facilitate their easy removal by crane.

ment was achieved. As a result, the mix

erosion to the repaired Spur, a two-

A piling crane was used to break up the

had to be adjusted with a superplasticer

metre underwater trench toe was ex-

remaining boulders into cobbles and

to maintain the slump. Particular care

cavated into the rubble by a piling crane.

gravel, and a dredge pump removed this

had to be taken with the compaction due

This was to protect the new row of toe

material from the trench.

to the high stone content.

recommended by the PRDW team during

Critical Requirements

Correct curing

the FEL-3 detailed design project, after

The new Dolos units were lowered into

Once the Dolos units were cast, they

testing a number of options in a CSIR

position by a 400-tonne crane with a

remained on their soffits for two days

physical modelling study.

38 metre reach. Toe-layer Dolos were

to attain the necessary flexural strength

guided by a diver into predetermined

required for lifting. In addition, the Dolos

positions on the seabed. The remaining

units had to be painted with a resin-

Dolos units were placed randomly on top

based curing compound within one hour

of the toe layer.

of stripping, to ensure minimum moisture

Dolos units. The innovative approach was

The toe area was prepared by remov-

WN HARBOUR

Critical requirements for the manu-

loss. The curing used was pigmented to

facture of the Dolos units included:

indicate to the engineer that the curing

• A minimum of 98% of the nominal

compound had been applied.

weight (25 tonnes)

After 28 days, the Dolos units were

• A 28-day flexural strength of 4MPa

transported at night to site between

and a 2MPa flexural strength when

7pm and 11pm, and were offloaded by

removed from the soffit form

the 400 tonne crane. Future Dolos units

• A 28-day cube strength of 40MPa

movement at the Spur will be monitored

• No cracks.

by aerial photographic surveys.

PROJECTS

by which time an estimated 50 Dolos

39

PROJECTS 40

BOTSWANA ROAD UPGRADE Kwena Rocla, part of the Infrastructure Specialist Group (ISG) of companies, was recently awarded the contract to supply culverts and inverted base slabs for the upgrading of the Gaborone to Boatle Road project.

The project will upgrade the road to a dual

traffic volume and congestion on this

carriageway standard in Botswana. This

route, while limiting major disruptions

forms part of the Botswana Government’s

to local business and residents. We have

economic stimulus programme and is

previously worked with CCC/CSCEC JV

expected to take two years to complete.

on projects, and believe that our ability

Having started in March 2017, the

to assist them meet project challenges

19,4km dual carriageway upgrade of Boatle Road upgraded will continue to be operational, however there is 24-hour traffic management in place to help cope with the high volume of traffic.

Kwena Rocla were chosen to supply culverts and inverted base slabs to the

is what makes our relationship, a strong

project due to the overall suitability

and mutually beneficial partnership.”

of the products for the project. The

Drainage works, pedestrian and cattle

company will supply 7 696 rectangular

underpasses will also be constructed,

portal culverts of varied dimensions with

along with the installation of street light-

inverted base slabs for the project.

ing and traffic signals.

Mbuya Basoli, sales and marketing manager for Kwena Rocla commented: “The project aims to improve the high

(Above and left): Kwena Rocla is supplying culverts and inverted base slabs for the upgrading of Botswana’s Gaborone to Boatle Road project.

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Concrete storm water pipes, manufactured by CMA member, Aveng Infraset, are being used for the Kommetjie Main Road and Ou Kaapse Weg Infrastructure and Services Upgrade in the Noorhoek /Sun Valley area of the southern Cape Peninsula.

The project is due for completion in January 2020 and is being undertaken for the Transport and Urban Development Authority of Cape Town (TDA).

Other aspects of the project include: road widening, an increase in fresh water piping and the installation of fibre optic cabling.

Approximately 3km of storm water piping is being laid in four diameters: 300mm class 100D; 375mm class 100D; 450mm class 100D; and 600mm 75D. Aveng Infraset is delivering the pipes as they are required on site by Martin & East, the main contractor. The other main member of the professional team is HHO Consulting Engineers.

A 1,7km storm water pipe section is being laid from the Fish Hoek, Kommetjie and Simonstown intersection towards the v illage o f K omme tjie. A 1,2k m stretch is being installed from the same intersection, along the Ou Kaapse Weg towards Noordhoek.

Francois Rossouw, the Mar tin & East on-site production agent, said that pipes made with precast concrete were specified because concrete is the strongest and most suitable material for this application.

“Concrete pipes can be designed and tested to meet any loading conditions and pr o v ide excep tional dur abili t y.

Moreover, they won’t rust, burn, buckle or deflect,” he says.

“One of the main challenges of the project was accommodating existing services in the new road layout. We used a software programme called Pipe Maker, which helped us plot the 5-6km of existing services and re-plan its layout to suit the new road works and storm water drainage. The electrical cabling was particularly tricky and its relocation delayed the project by eight months.”

The concrete pipes are being laid in 1,5m deep trenches and are aligned using laser beams backed up with theodolites. Manholes are being constructed with a combination of clay brick and concrete pipe.

(Left): Aveng Infraset’s precast concrete pipes are being used for the Kommetjie Main Road and Ou Kaapse Weg Infrastructure and Services Upgrade, due for completion in January 2020.

PRECAST | ISSUE ONE | 2018

PROJECTS

CONCRETE PIPES USED FOR CAPE INFRASTRUCTURE UPGRADE

41

PROJECTS 42

PERMEABLE PAVING PROVIDES A STORM WATER SOLUTION IN MITCHELLS PLAIN Permeable Concrete Paving Blocks (PCPB), supplied by C.E.L. Paving Products, has been used in a stormwater management and pollution control installation at Watergate Centre, a new 20 000m² shopping centre developed

by S. Giuricich Holdings (Pty) Ltd.

“The installation means that the development places no additional burden on municipal storm water drainage.”

The centre, found in Mitchells Plain, Cape Town, was completed towards the end of November 2017. The permeable paving system was considered to be the most cost-effective method of complying with Cape Town’s Sustainable Urban Drainage Systems (SUDS) regulations, by the centre’s structural/civil engineers, Sutherland Consulting Engineers.

The installation means that the development places no additional burden on municipal storm water drainage,

CONCRETE

MOULDS STEEL FIBREGLASS POLYURETHANE SILICONE 082 774 4657 Unit 8, Ken Smith Industrial Park, Rand Street, George Industria

www.concretemoulds.co.za

thereby achieving its prime objective. All rainwater is either infiltrated into the ground under the permeable paving or,

(Top): One of the permeable paving sections under construction at Watergate. The three layers of stone as well as some of the geotextile fabric are clearly visible.

(Above): Completed permeable paving parking sections at Watergate Shopping Centre.

additionally, during heavy downpours, into the storm water system via fin drains.

Starting from the bottom, the per-

The system’s layered sub-base structure

meable layered structure comprises:

of stones and locally-manufactured geo-

200mm in-situ sub-soil compacted to

textile membranes filters out most of

95% MOD AASHTO DENSIT Y (100%)

the pollutants, including hydrocarbons,

FOR SAND); Fibertex F-25 SA fabric; a

phosphorus, nitrogen and heavy metals.

250mm lower sub-base of 53mm stone; a

The Watergate permeable paving

100mm upper sub-base of 19mm crushed

system was designed by Icon Consulting

stone; Fibertex F25 SA fabric; 50mm of

Engineers, with the installation conducted

6mm clean bedding grit installed under

by civil contractor, Neil Zaaiman. The

and between the PermeLock paving

catchment area for the permeable paving

blocks (see Figure -1).

design is 32 704m². It comprises ±25

At 8 600m², the surface area covered

interlinked permeable systems, which

by the PCBP system is 26% of the catch-

cover a combined surface area of 8 600m²

ment area of 32 704m², which includes

and serve as parking zones for shoppers.

tarred access roads and the roofing, and

PRECAST | ISSUE ONE | 2018

30% voids), more than double the WQv

area. This ratio created by Icon using

treatment requirement of 443m³. The

the Georgia Strormwater Management

ratio for the contributing drainage area

Manual as a guideline to calculate the

(excluding the permeable paving area)

Water Quality volume WQv = P x Rv x A

to the permeable paving surface Ac/Ap

• P being the rainfall depth for the 0,5

was recommended at 4:1, as there is fair

year R1 24 hour storm event +

amount of roof run-off, which tends to be

18,9mm derived from the CoCT cli-

low on sediment. Therefore the achieved

mate change rainfall grid

ratio of 3:1 satisfies and exceeds the

• Rv being the volumetric runoff co-

PROJECTS

is more than sufficient to drain the whole

43

recommended ratio.

efficient expressed as 0,05 + 0,009,

Fin drains (300mm) were installed

(I=Impervious are percentage) = 0,05

along the full length of each permeable

+ 0,0009 x 74% = 0,716

paving section in the centre of the lower

the permeable paving surfaces at Wa-

T hus WQ v = 0,0189 x 0,716 x

sub-base layer. These link into fin drains

tergate will require ongoing maintenance

that run at the sub-soil level and drain

to keep the drainage voids between the

Icon’s design allowed for a WQv stor-

into the municipal storm water system.

pavers clear.

age volume of 903m³ (8 600m² x 0,35 x

According to Nichol Jordaan of Icon,

32 704 = 443m³.

(Above): A large parking section nears completion.

“Inspections should take place on a continuous basis and particular notice should be taken of ponding, which can indicate possible blockages or damage, and areas where stormwater pipes discharge directly onto pavers. Regular sweeping should take place every month and heavyduty cleaning, with a mechanical street sweeper, should take place twice a year.

Pavers should be lifted every five years to inspect substrate layers for any possible

Figure-1: A typical permeable paving construction with a fin drain.

damage,” advises Jordaan.

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PRODUCER MEMBERS A FICK SEMENT WERKE BK TEL: (022) 913 1921 PROVINCE/COUNTRY: WC PILLAR: PB AVENG INFRASET (PTY) LTD TEL: (011) 876 5100/872 1713/ (012) 652 0000 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BETA TILES (PVT) LTD TEL: (263) 4333735 PROVINCE/COUNTRY: ZIM PILLAR: PB BOSUN BRICK MIDRAND (PTY) LTD TEL: (011) 310 1176 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI

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CEMENT MEMBERS

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PLEASE NOTE: The above member list was correct at the time of going to print. If your details have changed, please contact Rita at the CMA offices on tel: (011) 805 6742

PI – Precast Infrastructure PB – Precast Building

PRECAST | ISSUE ONE | 2018