ISSUE THREE • 2018
R49.00
THE VOICE OF THE PRECAST CONCRETE INDUSTRY
• New path for CMA • SABS board fired • Precasters work smarter
2
PALLETS CAN MAKE OR BREAK AN OPERATION
19
INDUSTRY NEWS 5
NEW PATH FOR THE CMA
7
CMA AGM
8
GROWTH IN INSURED CONSTRUCTION ACTIVIT Y: 2017 VS 2016
11 TECHNICRETE TURNS 50 13 CMA CONCERNED OVER FIRING OF SABS BOARD 14 USE BUILDING SLUMPS TO TRAIN STAFF
28 GUIDELINES ON USING CEMENT AND CONCRETE SAFELY AND SENSIBLY 29 CONCRETE ROADS SAVE FUEL 30 PREVENTATIVE MAINTENANCE ENSURES DURABILIT Y
20 CHEMICAL SOLUTIONS FOR DIFFERENT CONCRETE NEEDS
32 WATER CONSERVATION AND PERMEABLE PAVING: LOCAL GOVERNMENT MUST LEAD THE WAY
21 PRECASTER OFFERS MODERN FORMING SOLUTIONS
35 RESEARCH TO BENEFIT PRECASTERS
1
COMPANY NEWS 22 WESTERN CAPE BRICK AND BLOCK PRODUCER GEARED FOR GROWTH
36
23 NEW OWNERS FOR OCON BRICKS
PROJECTS
15
38 EARTHFORM: THE PERFECT SOLUTION 39 SA’S CONSTRUCTION INDUSTRY TILTS UP
25
GLOBAL VIEW 16 ADJUSTABLE EXTRUDER SOLVES MAJOR CHALLENGE OF AMERICAN PRECASTERS
40 CONCRETE ROOF TILES ON THE RISE AT SATARI COUNTRY ESTATE 41 PRECAST CONCRETE PAVING SPURS ECONOMIC GROWTH IN SALDANHA
PRODUCTS
AROUND & ABOUT
42 PRECAST CONCRETE PAVILION SEATING FOR SA’S OLDEST SCHOOL
18 NEW HIGH-CAPACIT Y POWERED PALLET TRUCK
26 CONCRETE CONFERENCE UNITES THE INDUSTRY
43 N2 SECURITY WALL CONSTRUCTED WITH PRECAST CONCRETE
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.co.za
PRECAST | ISSUE THREE | 2018
Coastal editorial: David Beer Tel: 082 880 6726 E-mail: david.bigsky@gmail.com
ISSUE THREE • 2018
R49.00
THE VOICE OF THE PRECAST CONCRETE INDUSTRY
Advertising: Linda Meyer Cell: 083 626 8814 E-mail: linda.precast@gmail.com Subscriptions/Accounts/ Advertising Admin: Thuli Majola Tel: (+27 11) 883 4627 E-mail: subscriptions@isikhova.co.za • New path for CMA • SABS board fired
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© 2018. 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:
• Precasters work smarter
ON THE COVER PMSA offer the widest range of production boards for brick, block and paver machinery while ensuring they are high-quality and fit for purpose. Recent supplies include GMT pallets to Van Dyk Stene, resulting in cement reduction of over 20% and Composite UP Advanced boards at Cape Brick for vapour-curing chambers.
CONTENTS
TECHNICAL
COVER STORY
COVER STORY 2
PALLETS CAN MAKE OR BREAK
AN OPERATION Optimisation of pallets in the manufacturing process is one of the most cost-effective and easiest ways to boost output and improve the quality of products made with the existing machinery.
has focused a great deal of attention on
materials transmit vibration better
studying the characteristics and per-
for faster mould-filling and settling.
formance of different types of pallets on
This means production speeds can be
local production lines. This has also led to
increased on machinery using the right
the company stocking and selling a wide
pallet for the job at hand.
This often-overlooked element in the manufacturing process is, in fact, one of
are one of the most basic parts of
the most important, as the pallet serves
the production cycle, yet they hold
as the foundation of any production
an important key to achieving better
process and requires a perfect match
efficiency and savings on cement and
between the equipment used, the mix
materials. Drawing on recent studies, he
design and the type of product being
also reveals some of the criteria which
produced. Unsurprisingly, a well-matched
make a pallet good and the different
pallet will produce better-quality products
requirements for varying types of plants.
range of pallets suitable for most produc-
“However, lightweight products or
tion lines and manufacturing conditions.
shallow moulds may require different
Quintin Booysen, sales and marketing
vibration transmission and may benefit
manager of PMSA, explains that pallets
more from smoother surface finishes
more quickly than less suitable types. One company that understands the
Different requirements
importance of pallet selection is local
“When considering which pallets to use,
equipment manufacturer PMSA (non-
it’s important to start with the most
producer member of the CMA), which
important factor: production efficiency. Here one needs to consider factors such
(Top): UPplus Pallets with pavers during production process.
as the rigidity and density of the material
(Right, from top): UPadvanced Pallets up close; GMT Pallet up close.
pallets and understand that denser
used in the manufacturing of different
PRECAST | ISSUE THREE | 2018
COVER STORY
or the use of ultra-durable polymers that provide benefits in demoulding and surface finishes. Next, one needs to consider the environment in which the products are being manufactured and cured as it may be corrosive, acidic, hot, cold, humid or have other issues that require considerations over and above pure production-related issues,” says Booysen. “Temperature, mould depth, special mechanical requirements and a host of other factors may also play a role and need to be identified before making the final decision. Lastly, the price needs to be weighed up against the
“It’s not always the price that determines the quality or suitability of the pallet: rather, it’s the application.”
3
produced, as well as being sealed and impervious to moisture ingress from the steam-curing chamber.
per formance and durability of each
Wide range
Problem solved
pallet being considered. Although an
“A s a r e sul t, P MS A h a s c ar e f ull y
Another manufacturer, Van Dyk Stene,
individual price tag may sway close
selected a range of pallets for nearly
has opted for PMSA Glass Mat Thermo-
decisions, it should never be used as
all applic a tions and r equir emen ts.
plastic (GMT) pallets for its outdoor
the only determinant, as it’s far more
These include cost-effective MyWood
plant. These proved to be better than
important to consider the total cost of
A d v an c e d C omp o si t e an d M y Wo o d
wet off-sawn pallets, with no treatment
ownership and production requirements
UP Plus pallets, which are made from
required for moisture and fungus. In this
in the long term.
European pine, lar ch or spruce, or
application, the GMT pallets proved to be
the hybrid MyWood Advanced option,
the perfect balance between low-cost,
Different applications
which are coated with a durable plastic
wet off-sawn wooden pallets and pricier
“With pallets ranging from R2 800
composite outer layer. Due to higher
laminated ones.
for European composite plastic types,
density on European-grown timber,
Van Dyk also found that the smoother
to just R280 for locally grown, wet,
these imported pallets provide better
surface of the GMT pallets reduced
off-sawn pallets (for a typical 1 400
transmission of vibration than local pine
damage and ongoing maintenance to the
x 840 x 42mm pallet), and everything
ones and are longer-lasting, all-round
pallet feeder, compared with wet off-sawn
else in between, it’s easy to see how
performers for general use.”
pallets. The higher density of the PMSA
manufacturers can get confused about
Customers like West End Bricks
GMT pallets transmits vibration better,
the better option. Suffice to say that
(producer member of the CMA) have used
translating to a better compaction
neither the price nor the perceived
them with great success, adds Booysen.
with less voids and, ultimately, better
quality are the crucial deciding factors:
“The MyWood UP Plus boards have been
strengths. This has allowed the company
rather, the application is.
perfect for us and lasted more than
to reduce cement mix ratios by at least
“For example, heavy products may re-
10 years on our plant,” says plant
20%, compared with the previously used
quire a denser wood with less deflection
manager Denver Rambaross. T hese
wet off-sawn pallets.
and lighter product with high abrasion
pallets are easily maintained for internal
“There are so many factors to consid-
characteristics may benefit through
curing rack plants and are not subjected
er when buying a pallet that it really does
polymer types such as PVC that have
to excessive mechanical or varying
pay to rather speak to our Sales Techni-
better wear-resistance. Alternatively,
environmental factors, whereas other
cal Division, which will be able to advise
wet off-sawn pallets may be an alterna-
manufacturers may have to opt for
on the best solutions for specific plant
tive in low-wear environments with dry
hardwood or solid plastic composite
types and conditions,” adds Booysen.
climates that don’t need ongoing fungus
alternatives, or the top-per forming
and moisture treatments.
hybrid Advanced option from MyWood.
“Buyers also need to know whether
The UP Advanced hybrid pallets are an
the pallets are going to be handled
economical solution that incorporates
manally or mechanically, as this also
the rigidity of wooden pallets into an
plays a role in determining their required
encapsulated plastic bonder upper and
strength and weight. So do temperature
lower production surface. These are also
ratings, as curing treatments or even
manufactured with individual planks and
climate extremes may require differ-
have growth rings orientated vertically,
ent characteristics. Surface finishes,
which add strength and rigidity to the
thickness tolerance and other factors
pallet. They are proving to be a success
can also lead to end product variances
at Cape Bricks, where the pallets’
and therefore need to be monitored,”
extra rigidity and high wear-resistance
says Booysen.
are ideal for the heavy products being
PRECAST | ISSUE THREE | 2018
(Top): UPplus Pallets up close. (Above): PMSA GMT Pallets – Van Dyk Stene (Western Cape).
INDUSTRY NEWS 5
NEW PATH FOR THE CMA Henry Cockcroft, newly-appointed general
That doesn’t mean
manager of the Concrete Manufacturers
we’ll be relaxing our
Association, is determined to give the
standards, though:
association a louder voice than ever
rather, we’ll be communicating with
before and fulfil its mission of making
small businesses and educating them
precast concrete the building material of
on the need to adopt national standards
choice in every town and city throughout
when it comes to making products and
southern Africa.
the importance of being affiliated with
Over the past five years, the as-
associations like the CMA.
sociation has been in a period of flux,
“There’ll also be a focus on growing
constantly adapting to changing and
membership among medium and large
e v er -toughening economic cir cum-
corporates and listening to the require-
stances. Having been ably steered by his
ments and concerns of both our members
predecessors, Cockcroft feels the time
and non-members, in order to learn and
is right to complete the transformation
adapt accordingly. With a broad base of
of the association into a fully self-sus-
members in all regions and supplying a
taining entity with a broad membership
wide variety of products, our other focus
representing every precast concrete
will be on making consumers aware that
manufacturer in the sub-region.
there’s an association looking out for the
“As part of the bigger picture, we have our sights set on representing the
industry which can assist with finding quality producers,” says Cockcroft.
(Above): Henry Cockroft, CMA general manager.
We’ll also be making these publications available through various retail channels,
entire industry, upholding standards and the good name of our industry, as well as
Industry manuals
as w ell as t o e duc a tion f acili tie s,
influencing users and specifiers to make
“ To assist member s, we’ll also be
specifiers, engineers and architects.
precast concrete products the materials
resurrecting the use of CMA publications
“I feel that a lot of work needs to be
of choice for all their construction
which will either be updated and refreshed
done for our industry to re-ignite a love
requirements. And these aren’t just pipe-
or simply r eprinted, if they’r e still
for precast concrete. As the new GM of
dreams: we’ve formulated a marketing
relevant. These are among the most
the CMA, I can assure our members that
plan that will help us achieve these and
valuable reference sources in the entire
achieving these goals is my passion and
other goals that we’ve identified and set
industry, whether it be for structural
that our team will strive to make this an
at board level,” he says.
concrete masonry, manufacturing units
association for everyone.
or precast of all shapes and descriptions.
“In the months to come, our members
Growing support
will also see that we’re embarking on a
“In future, it’s going to be all about
marketing strategy designed to offer
working together to find ways of pro-
maximum benefit to members, while
moting the use of concrete, specifically
maintaining much lower-key branding for
precast concrete in industry. Moreover,
the CMA. We hope this will indirectly
we want to promote our members and
increase the popularity of the CMA as
grow the reputation of the CMA so that
an industry association.
professional bodies, users and end users
“S im ul t a n e o u sl y, w e’ll c o n t in u e
specify CMA membership before buying
ser ving on various panels and work
precast concrete products.
groups to ensure that the CMA and its
“In order to grow our appeal, we’ll
producer members influence standards
also begin reaching out to SMMEs which
and ensure the delivery of consistent,
haven’t traditionally had the resources
high-quality precast concrete solutions
or inclination to become members.
to the industry.”
PRECAST | ISSUE THREE | 2018
CMA AGM The CMA AGM which was held in Germiston recently gave the new general manager, Henry Cockroft, the opportunity to share past successes and cast light on the future vision of the association with its board members. Topics of discussion included another clean audit for the association, funding challenges in the year ahead, ideas to grow the association’s membership and funding base, as well as revenue-generating opportunities, including sponsors, CMA CS and training. It also offered the opportunity to bid retiring executive director, Frans Minnaar, farewell and congratulate him on his achievements. Special mention was made of his steadying the ship at the CMA during his two-year tenure, as well as his efforts to reach out to all sectors of the industry in order to specify CMA members’ precast concrete as the building material of choice. Perhaps the biggest “thank you” was for his efforts in launching the CMA CS, which – since its establishment – has provided the industry with a much-needed means of certifying products where traditional means were failing. CMA CS also provides the association with a means of funding its existence and relying less on donations and sponsorships.
PRECAST | ISSUE THREE | 2018
INDUSTRY NEWS 8
GROWTH IN INSURED CONSTRUCTION ACTIVITY: 2017 VS 2016 Statistics showing insured project values
health of the country. With so many
recorded from 2006-2008 – a period
can offer construction professionals in-
sectors and industries dependent on
dur ing which inf r astr uc tur e spend
sights into the industry and provide useful
the construction sector for their ad-
was markedly higher in preparation
information when planning for the future.
vancement, this monitor recognises that
for the 2010 Fifa World Cup in SA.
Some of the latest data available
inherent value and aims to interrogate
Projects included power generation
from Bryte Insurance on the trends for
some of the trends noted,” says Juan-
projects, upgrades of airports, roads and
major construction projects shows an
Pierre Holmes, head of the specialised
stadiums, as well as the construction of
increase in projects from 2016-2017,
property division at Bryte.
new stadiums.
but a tapering trend towards 2018.
“We launched our inaugural monitor
T he Bry te Construction Activity
in October last year and this is an
High activity
Monitor analyses long-term insured
updated version which provides a much
Looking specifically at 2017, a major
construction projects data within the
mor e concise v iew. I t anal y ses an
spike in construction activity is reflected
South African market and provides a
expanded time-frame, but also includes
in Q1, followed by a tapering in activity
high-level overview of activity within the
reformulated parameters to look at the
over successi ve quar ter s. O verall,
country’s construction sector. It also
sector more closely, rather than the
2017 activity during each quarter was
measures the change, on a quarterly
extended value chain. Going forward,
greater than the corresponding periods
basis, in insured construction projects
we aim to release the monitor annually.”
in 2016. Increases of 50%, 45% and
undertaken by small, medium and large
T he Br y te Construction Activity
61% are noted in Q1, Q2 and Q4 2017
Monitor, expressed in rand value terms,
respectively, compared with the same
shows that the value of 2017 projects
periods in 2016.
construction entities. Financial health
is estimated at R61 billion, while in
In addition to general heightened
“As one of the economic engines of the
2016, this figure was R42 billion. This
constr uc tion ac ti v i t y ( p ar ticular l y
country, SA’s construction sector is an
is, however, substantially lower than
within the mining sector), the growth
important gauge of the general financial
the insured construction activity values
in 2017 may have been supported by
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INDUSTRY NEWS
rising inflation, which translated into increases in labour and constructionrelated costs. Other factors that may have impacted increases include the heightened awareness of risks after the Southern Cape fires and multiple extreme weather-related flooding incidents. Within the broader South African con-
9
text, a contradictory trend is noted, with a slow-down in construction activity in 2017 compared with 2016. Unfortunately, 2018 is not expected to fare much better in terms of the number of projects, but actual costs will continue to climb due to currency fluctuations, high rates of borrowing and an all-time high petrol price, among
(Above): Graph 1 depicts gross value insured, expressed in annual frequency from January 2001-December 2017. The series on the graph highlights changes over the 17-year period to provide a view of trends.
other factors. Already, Johannesburg has
technologies should also be re-evaluated.
continues to constrain the construction
experienced the highest construction cost
“Overall efforts by government to
sector and indicates a need for greater
inflation (which increased by 6%) on the
stabilise the national economy also augur
private-sector investment. The muted
continent in 2018.
well for the progress across key sectors,
construction activity is also depicted by
including construction. The proposed
the challenges facing construction com-
Tough times
budget of more than R800 billion for
panies, with many increasingly seeking
“We’r e seeing a tough 2018, with
public infrastructure development, which
consolidation within the sector.
decreased government spending, low
may not be as major as those seen
W i t h f o u r o f t h e t o p si x l a r g e
business confidence (exacerbated by
before, will continue to be vital in igniting
construction companies losing 50-75%
corruption, policy uncertainty, labour
sustainable growth within the sector.”
of their share price in 2017, and some losing in excess of 90% of their value as
challenges, etc) and decreased foreign di r e c t in v e s tm e n t . W h il e a m aj o r
Long drop
at June 2018, these alarming losses are
turnaround for the construction sector
In relation to GDP, the National Trea-
likely to have caused irreversible change,
may not be on the cards, sustained
sury’s public-sector infrastructure spend
as it may be too late for some key players.
growth is expected in successive years,
– which is the greatest funder of con-
Another trend is the diversifying focus
which will be spurred by a continued,
struction activity in the country – shows
of some medium to large construction
prudent focus on cost,” says Holmes.
a declining trend since 2009. This trend
sector players who are exploring op-
“The need to proactively manage the construction business’s risk portfolio becomes increasingly important and insurers and brokers will maintain a vital role in this process. A review of current and future risks, together with mitigation measures, must be scrutinised and solutions reassessed. Equally, the business’s capacity to seamlessly and successfully incorporate innovative processes, practices and
“We’re likely to see an increase in the number of smallervalue construction projects over the coming years.”
portunities that can supplement growth outside SA’s borders. However, this comes with its own challenges, including the tightening of import and export of services, stronger regulatory governance in certain neighbouring countries and a shortage of technical skills. Tread carefully Elaborating on opportunities for the construction sector, Holmes adds: “Investors will remain very circumspect. However, we’re likely to see an increase in the number of smaller-value construction projects over the coming years. This could potentially be due to government/ businesses looking to break down largescale, complex construction projects into smaller undertakings that are less challenging to finance and manage. It could also be spurred by the need to better manage project delays (from approvals to execution) and facilitate shorter turnarounds.
(Above): Graph 2 depicts gross value insured, expressed in quarterly frequency from January 2016December 2017. The series on the graph shows changes thereof.
PRECAST | ISSUE THREE | 2018
“Government’s investment in renewable energy projects as part of the REIPPP
INDUSTRY NEWS 10
programme and the ongoing focus on
Revolution) is crucial and can be
pr ic e -sensi ti v e, bu t the danger
housing are some examples. The residen-
valuable across multiple functions
of seeking the lowest cost could be
tial property construction market will also
within the constr uction sector.
contending with costs which are many
need to continue growing substantially
Adopting enabling technologies for
times higher for uninsured or under-
over the next decade to address the de-
operational and cost-efficiencies could
insured projects – in the event of a
mands of a growing urban South African
also be a key ingredient in aiding
claim – as well as the knock-on effects
population, which is estimated to rise to
growth – regardless of how small the
70% of the total population tally.”
project may be.
of the loss. • Empowering the youth to address the
Despite the anticipated decrease in
• Seek ing the ex per tise o f a r isk
increasingly apparent skills gap within
large-scale insured activities, project
management professional to
the sector must also be a priority.
values are expected to be higher (as
thoroughly map out exposures, and
On-the-job training and other skills
outlined above), as well as the number
present holistic solutions to plug
development opportunities need to
o f smaller -scale pr ojec ts. Gr adual
them, can have substantial long-term
become more widely available to the
incr eases in conf idence within the
benefits. Some businesses are highly
future leaders of our country.”
sector (following a 17-year low in 2017), a stronger-performing rand and greater investments in advanced technologies that drive process and cost-efficiencies will contribute towards this trend. Skills gap Holmes of fers tips for construction businesses to support business and economic progression. “Businesses within the sector must focus on: • Meaningfully integrating physical and digital technologies (which are the basis of the Fourth Industrial
(Above): Graph 4: Public-sector infrastructure spend.
Graphic source: National Treasury
INDUSTRY NEWS 11
TECHNICRETE TURNS 50 Technicrete, long-time CMA member
change to simply Technicrete, an iconic
and one of the leading manufacturers of
brand which has stood the test of time.
precast concrete products in SA, turns 50 this year.
In 2013, the Infrastructure Specialist Group (ISG) was formed after Murray &
It was originally part of the Concor
Roberts unbundled Technicrete, Rocla
Group launched in 1948 by Jurgen
and Ocon Brick, which joined the ISG
fers a complete range of precast con-
Schultz, who in 1968 saw a gap in the
Group. A new executive team for ISG
crete pavers, kerbs, erosion protection
market for the manufacture and applica-
was established, led by Albert Weber,
systems, drainage, retaining walls and
tion of precast concrete products. The
the current chief executive officer (CEO).
concrete masonry solutions which have
group launched Concor Technicrete as
“The Technicrete brand is iconic
applications for both commercial and
a new division that would focus totally
in SA and southern Africa. It’s known
on this new range of precast offerings.
for quality products that have been
“Our people are at the core of our
So strong was Schultz’s belief in the
manufactured using the latest available
success. Without their commitment to
precast market that he obtained exclu-
technologies, backed up by a superior
our brand and customers we wouldn’t be
sive rights to manufacture Deckwerk
plant workforce and sales team,” says
here 50 years later. It’s our people who
blocks in SA. They were used in the suc-
Weber. “Celebrating Technicrete’s 50th
live our core values of care, respect, in-
cessful construction of the Magoebas-
birthday is a major milestone in our his-
tegrity, accountability and commitment
kloof, Fanie Botha and Bloemhof Dams, all
tory as a company and in my role as its
to the delivery of quality products and
of which were lined with these purpose-
CEO. I’m extremely proud that it’s still
services,” says Weber.
design blocks from Technicrete. The suc-
considered a preferred supplier to most
“We’re committed not only to the
cess of Concor Technicrete products on
commercial and residential projects of all
continued upskilling of our own staff, but
these projects is what established the
dimensions and that it’s grown to meet
also to the upliftment of local workforces
division as a major industry player.
the often stringent requirements of our
through knowledge transfer in areas
ever-changing times.”
where we supply or manufacture our
As a result, it received a contract to
residential developments.
products. We wish to make a meaningful
line a canal from the Kukane River in then Ovamboland (now Northern Namibia) to
Still growing
contribution to the infrastructure and
Oshakati. Fifty years and thousands of
Over the past five decades, Techni-
people of this country.”
projects later, the rest, as they say, is
crete has grown both operationally and
Technicrete history.
product-wise. From small beginnings
CMA member
to the construction of the company’s
Technicrete is a fervent member of the
Past and present
first major plant at Randfontein, the
Concrete Manufacturers Association
In 2006, Concor was acquired by Mur-
establishment of nine other country-wide
(CMA) in SA and adheres to the ISO
ray & Roberts and Concor Technicrete
manufacturing facilities followed.
9001:2015 Quality Management System.
became an independent company within
The product range has also expanded
Despite congestion within the precast
the group. This resulted in the name
from Deckwerk to a catalogue that of-
concrete product market, the company
PRECAST | ISSUE THREE | 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
IF YOU THINK PRECAST CONCRETE, THINK CMA
A
N
UF
ACTURER
S A OCI
NCRETE
SS
M
PRODUCER MEMBERS.
CO
AT I O N
al
t
e
Q
u
it
y c nc a s t in c o
re
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
– based on its history – has always had the edge. Its unique attributes include: • A strong historical foundation which allows it to build on its trust marks of heritage and credibility. • Delivery on key promises of quality and product service, for
A strong foundation for infrastructure success
which it is highly respected. • A depth of knowledge based on the experience it brings to the business environment and customer base. Technicrete’s involvement in initiatives around SA and southern Africa includes major civils projects, medical facilities and universities, residential upgrades, upmarket residential estates, motor vehicle dealerships, large commercial buildings, shopping complexes, infrastructural projects and health clubs. Durable solution “In 1978, the Aggeneys mining township was established in the Northern Cape. The Technicrete Zig-Zag Block Pavers are still there in good working order, nearly 40 years later – that’s a good-quality product for you!” says Weber. “We’ll continue playing a major role in the supply of precast concrete products as infrastructure around the country continues to be upgraded. Private-sector commercial and residential property developments still reflect as a growth industry and I believe our service, competitive pricing and product quality will continue giving us the edge, making us a preferred supplier for at least the next 50 years.”
CMA CONCERNED OVER FIRING OF SABS BOARD The Concrete Manufacturers Association stands ready to assist the precast concrete industry with required certification of products in the event that the SABS will not be able to do so. This is the word of CMA general manager Henry Cockroft in response to the dismissal of the entire South African Bureau of Standards (SABS) board of directors due to its failure to exercise its fiduciary duties in terms of the Standards Act and the Public Finance Management Act. The decision was made by the Minister of Trade & Industry, Rob Davies, recently, after he had received numerous complaints regarding a lack of service delivery by the SABS. “This may have a ripple effect through the SABS and could affect service delivery throughout its different business units, including concrete manufacturing and products. It’s our fear that members who still make use of the SABS for certification of products may once again find themselves in a position where these are delayed or mislaid, which is exactly why we launched our own certification service nearly two years ago. “For those producers that are concerned or who are still struggling to obtain new permits or renewals from the SABS, we’re happy to inform them that the CMA CS is available to issue certificates with the SANAS Accreditation number and logo on it, like any other accredited certification body. With this comes the added assurance that we’ll always maintain the high-
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.
est standards for our certification services,” says Cockcroft. “The CMA CS Mark of Approval is the mark you can trust for genuine compliance with SANS specifications.”
PRECAST | ISSUE THREE | 2018
Visit us on www.rocla.co.za for our nationwide branches
INDUSTRY NEWS 14
USE BUILDING SLUMPS TO TRAIN STAFF
and necessity for repairs and damage
tor, to name just a few potential careers.
to reputations. There’s no doubt that
“The SCT has structured a progres-
trained staff make construction compa-
sion of course levels that will allow
nies more competitive,” says Roxburgh.
prospective students to join at a level which matches personal competency.
Competency required
There can be no short-cuts to becoming
He also points out for that small build-
a good concrete technology practitioner
ers and emerging contractors who
and the school has all the educational
The construction industry should use
lack substantial concrete technology
requirements to help trainees meet
slumps to train staff in order to gain
competency, there is very
a competitive edge when work volumes
little chance of their com-
increase again, urges John Roxburgh,
panies performing to speci-
Courses available
lecturer at The Concrete Institute’s
fications and establishing a
T he SC T 2019 education
School of Concrete Technology (SCT).
sound business foundation.
programme offers 16 differ-
He says the volatility of the South
“Spending money now on
ent courses, all developed to
African construction industry is virtu-
training by the SCT – SA’s
meet the various needs of
ally unmatched, with slumps and booms
oldest and most internation-
the concrete and concrete-
always the norm. “Right now, the in-
ally respected facility for
related industries.
dustry’s decidedly struggling, with work
education in concrete – is
The prestigious Advanced
scarce and many experienced employees
an investment in the future
Concrete Technology diploma
being retrenched to make ends meet.
of any company.
course (SCT50) will be pre-
their specific goals.”
The SCT firmly believes that employers
“The slump in the con-
should first consider using the current
struction industry shouldn’t
sented in the first half of
lean order book period to upskill their
deter those seeking a career in concrete
is globally recognised as the leading
staff in concrete technology.
2019. This diploma course
technology, as there are still many oppor-
qualification in concrete technology and
“Concrete work on site is usually a
tunities available. SA urgently requires
examined by the UK-based Institute of
major cost component in building con-
competent concrete practitioners and
Concrete Technology. Roxburgh urges
tracts. With trained staf f who are
sales specialists in admixtures, con-
those with the required experience to
competent in all relevant aspects of
struction chemicals, ready-mix concrete,
tackle this career-boosting course and
concrete practice, contracts could
precast concrete, concrete repairs, ce-
register for it as soon as possible.
be carried out more economically and
ment production, aggregate production,
quickly, with fewer costly site errors
testing laboratories and the mining sec-
(Above): John Roxburgh, lecturer at The Concrete Institute’s School of Concrete Technology.
PRECAST | ISSUE THREE | 2018
INDUSTRY NEWS
Building contract administrators should take note: more than half of disputes relate to late, partial or non-payment, warns Uwe Putlitz, CEO of the Joint Building Contracts Committee (JBCC). The JBCC is a non-profit company which represents building-owners and developers, professional consultants
15
and general and specialist contractors, who all provide input for the compilation of JBCC agreements (contracts) that por tray the consensus view of the committee’s constituent members. Putlitz says many potential site disputes could be avoided by the administrator following the “notice” procedures within defined timelines in the contract. “This includes the employer paying the contractor a certified amount in full by the due date so that the contractor can timeously pay subcontractors and suppliers. Without a signed standard form contract, it’s very difficult to deal with disputes. Contrary to common belief, there’s no need to repeat legal principles in every standard form contract – but it’s important to clearly define the rights and obligations of the parties.” The contract administrator’s role is
ADMINISTRATOR PLAYS VITAL ROLE IN AVOIDING BUILDING CONTRACT DISPUTES
vital for the smooth running of building
procedures to be followed. “Standard
projects. “For standard form contracts
form contracts generally assume that
used in the building industry, a neutral
the parties will act in good faith and deal
party is usually appointed to administer
with their respective obligations fairly to
a contract on behalf of the parties. This
build a specified facility within a defined
neutral party – traditionally paid by the
time for an agreed amount of money.
employer – is usually referred to as the
“However, that only happens in a
principal agent, engineer, employer’s
perfect world. In modern times, such a
agent or contract administrator.”
predictable scenario is only likely when buying shares through a broker on the
Putlitz says the contract administrator must:
stock exchange, where the scope and
• Administer the contract and regularly
value of the transaction are known and
report to and liaise with all parties
execution occurs immediately on receipt
involved.
of payment – all done electronically –
• Be proactive to anticipate events
leaving no room for disputes.
that may delay the works and/or
“But in most building contracts,
attract additional costs.
there are many unpredictable elements,
• Attend and record all proceedings.
whether climatic or logistical – such as
“I f ther e ar e no r e c or ds, w hen
“The contract administrator must also
late delivery of materials and goods – to
timelines are missed it’s almost im-
be able to interpret all this information to
complicate matters and spark disputes.
p o s si b l e t o d e a l w i t h d i sp u t e s
gauge its significance in future. He or she
Where disputes arise within the para-
promptly and fairly without incurring
should determine whether the information
meters of a contract, they should be
significant legal costs,” says Putlitz.
may become ‘evidence’, should a dispute
resolved in terms of the dispute resolu-
• The significant volumes of information
arise later. If so, this information must be
tion provisions of that contract. Litiga-
continuously generated by all involved
protected against loss, fire or vandalism
tion should be avoided, if possible, as it’s
must be read, understood and dealt
for future reference.”
very expensive and time-consuming, with
with promptly. The information should also be systematically filed so that it can reliably and speedily be retrieved in hard- or soft-copy format.
PRECAST | ISSUE THREE | 2018
So what happens if the scope, time and value of a contract change?
no guarantee of an equitable settlement,” cautions Putlitz.
Putlitz says standard form contracts provide for this by describing specific
(Above): JBCC CEO Uwe Putlitz.
GLOBAL VIEW 16
ADJUSTABLE EXTRUDER
SOLVES MAJOR CHALLENGE OF AMERICAN PRECASTERS Mid-States Concrete Industries in Illinois, USA, saves up to $20 000 (approximately R244 000) a week at its hollow-core production plant. The new adjustable extruder of E9 series from Elematic enabled simultaneous manufacturing of non-standard narrow hollow-core slabs on the same production line. No more saw-cutting, dust, noise and injury risks. Mid-States Concrete Industries was
of narrow slabs or, as they are called
faced with a problem, which is actually
there, filler pieces of non-standard width.
very common all over the USA. Besides the fact that the design of the hollow-
Residential projects
core slabs has its own specifics in that
Narrow slabs are also very useful in
country, the erection of slabs on the
small residential housing sites and in
construction site is also done in a differ-
tight areas of a hollow-core construc-
ent way from, for example, the way it is
tion site like mezzanine. The largest cost
done in Europe. It is common practice for
for the hollow-core contractor on such a
some narrow space to be left at the end
site is the crane. Downgrading the size
of the floor slab system, when finishing the slab run with standard pieces.
(Top and above): The Elematic extruder in action.
of the crane and narrow, smaller slabs for smaller jobs saves both the contrac-
In Europe, longitudinally cut slabs are
a precast manufacturer to rip standard
used as well, but not very narrow pieces
slabs into narrow pieces and deliver them
tor and the customer money. Traditionally, manufacturing of non-
as cast-in-situ is used to close such
for erection to the site. That is why Mid-
standard widths of hollow-core concrete
gaps. In the USA, the contractor expects
States constantly needs a large number
slabs means a huge amount of rip-saw
PRECAST | ISSUE THREE | 2018
sible to cast two slabs of different width simultaneously on the same production line. It is possible to divide the standard slab in two identical or two asymmetrical slabs. Hollow-core slabs of various dimensions can be profitably produced with less time and effort. With a basic setup, one can produce slabs with widths of 600-2 400mm, thicknesses of 1606 500mm and lengths of up to 24m. Mid-States received the adjustable extruder in June 2017 and started production right away. “The filler machine not only responded to the specific needs of Mid-States, but also to specific needs that every hollow-core producer has in the USA,” says Wolff. The benefits of the E9 extruder include: • Reduction in scrap. • Huge cost-savings. • Increased efficiency on the plant floor. • Quality of the surface and edges of the filler pieces. • Less camber differential. • No time-consuming, noisy and dustysaw cutting required. • Improved workplace safety and lower injury risks. The South African context cutting, which is a time-consuming,
Elematic’s area sales director Mika
noisy and dusty operation. The result is
Reunanen, who regularly visits SA,
a slab with saw-cut edges which do not
says: “While our extruders are already
look as good as machine-finished edges.
operational in SA, the benefits – besides
Furthermore, noise and dust cause
solving the problems experienced by
workplace safety and health issues.
Mid-States Concrete Industries – have
“This is a very common problem. When
enabled the hollow-core factories to
you cut a piece off a four-feet section, it
cast at a faster speed and across two
creates a lot of scrap, because you have
lanes, thereby increasing production and
to throw the other piece away. A company
output. Feedback verifies that Elematic
carries the costs from this operation of
extruders exceed expectations, both re-
approximately $10 000-$20 000 [approx-
garding the quantity of metres of slabs
imately R122 000-R244 000) per week],”
produced per minute and their quality.”
says Mike Wolff, vice-president of safety and plant operations at Mid-States.
Hollow-core slabs are generally used for flooring of both commercial buildings and homes. Using an adjustable extruder
Problem solved
for their production is an economical
Elematic’s new filler machine, the modi-
solution for meeting the varying dimen-
fied version of the E9 series extruder,
sional needs of concrete slabs. It speeds
solves this problem perfectly. A special
up production and increases profitabil-
nozzle and a few more parts added to
ity, while eliminating the laborious and
the standard E9 extruder make it pos-
dusty sawing process.
“It enables the hollow-core factories to cast at a faster speed and across two lanes, thereby increasing production and output.” PRECAST | ISSUE THREE | 2018
PRODUCTS 18
NEW HIGH-CAPACITY POWERED PALLET TRUCK Material handling solutions provider
ibility of even the bulkiest loads and
ers and/or employees are in the vicinity
Combilift has launched a new high-
their surroundings. The operator’s
of operating forklifts. It’s our intention
capacity powered pallet truck
position also eliminates any pos-
to significantly expand our pedestrian
for the South African market.
sibility of crush risk when working
forklift range, as can be seen with the
in confined areas and prevents
launch of the Combi-PPT. This forklift of-
product damage.
fers safer operation, maximum operator
The truck is suitable for use in the precast concrete manufacturing industry and comes with stand-
“W i th th e in tr o du c -
visibility and narrow aisle performance.”
tion of the Combi-PPT,
The Combi-PPT’s automatic folding
ard lift capacities of 3 000kg and
very heavy loads can
platform is an added benefit for operators
6 000kg, with higher capacity models
us now be handled us-
when large distances have to be covered
from 7 000-16 000kg avail-
ing these walk-behind
in a warehouse or production plant. The
able on request. It is a fur--
machines, ensuring
power steering, dual rear-wheel drive and
ther addition to the Irish
high levels of safety
AC motor technology make it effortless
while guaranteeing efficient
and stress-free for operators: it “glides”
procedures even in confined spaces,”
across the floor, even when moving very
operator’s platform enabling
according to Martin McVicar, managing
heavy loads and its manoeuverability
stand-on or walk-behind operation.
director of Combilift.
enables tight corners to be negotiated
company’s growing pedestrian range, with the optional
The Combi-PPT includes a feature com-
“Combilift developed its first pedes-
safely and easily. A range of optional
mon to all Combilift’s pedestrian models:
trian models (the Combi-WR, Combi-WR4
fork lengths, widths and configurations
its unique, patented multi-position tiller
and the Combi-CS) in response to an
is available, in line with Combilift’s policy
arm. This enables the operator to stand
industry demand to move away from ride-
of supplying customised solutions for
at the side of the unit, rather than at the
on forklifts. As a company, we’re seeing
individual customer requirements.
rear (as is the case with other walk-behind
a growing demand for pedestrian trucks,
brands), giving operators excellent vis-
driven by safety concerns where custom-
(Left): The new Combi-PPT pallet truck.
The thin line between success and failure of forklifting operations can most often be traced back to the quality of advice
PRODUCTS
CHOOSING A FORKLIFT FOR PRECAST YARDS offered by the equipment supplier at the time of the original purchase.
19
With a bewildering number of types of machines for mixed and varied applications and with diesel, gas or electric options, the decision to buy a forklift is not necessarily a straightforward one. In reality, it requires considerable thought and technical knowledge to make the right choices based on current and future requirements. This is particularly true of the precast industry, where a simple product change or pallet size can have a big impact on the type of forklift required. It is therefore not surprising that SA’s best-known forklift brand, Linde M a t e r i a l s H a n d l i n g S A ( L M H S A ), continues to invest heavily in training its front-line sales and service staff to help
types, to ensure the right selections
its customers make informed decisions
can be made for each new customer,”
when buying forklifts and remain well-
says Klerck.
informed throughout the life-cycle of the equipment procured.
(Above): Linde Materials Handling SA is investing heavily in staff training to ensure customers get the best advice possible when buying forklifts.
offer products and solutions that improve Future-proofing
the efficiency and cost-effectiveness of
He adds that in addition, the training
the customer’s operations has become
International training
helped the sales sta f f under stand
a critical success factor in our industry,
LMHSA sales director Deon Klerck says
modern new solutions that are available
as companies ar e looking f or ways
the most recent training initiative was
to customers, including the company’s
to improve their cost base and gain
aimed at the company’s sales force,
latest Linde Connected Solutions, a
competitive advantages,” says Klerck.
who underwent intensive training from
sophisticated communications and data
“It also enables us to build better
two of the German company’s overseas
tracking system deployed for the purpose
long-term partnerships with clients and
training professionals. “In order to have
of increasing the efficiency, safety and
help them increase the profitability of
a substantial advantage in today’s mar-
profitability of warehouse operations.
their operations.”
ketplace, we have to give the right advice
Lithium ion batteries will also be
quickly and in such a manner that our
introduced in SA in the near future
customers understand all the require-
and although they cost mor e than
ments to make a successful purchase.
conventional lead acid ones, they last
“That’s why this training was geared to
much longer and charge very quickly. As a
help our sales professionals understand
result, their life-cycle cost is significantly
the precast concrete industry and dif-
less than that of conventional batteries
ferent market types, as well as storage
and they provide big opportunities for
and warehousing practicalities and a host
customers in terms of productivity and
of intricacies, to further build upon their
value for money.
knowledge base. Through our overseas
Practical workshops were also held,
trainers, we also want to expose them
giving the sales force the opportunity
to worldwide best practices and solutions
to drive the warehouse trucks. This
that can be applied locally as well.
helped translate theory into practice by
“The course comprehensively covered matching storage requirements to dif-
physically demonstrating the features and benefits of the equipment.
ferent forklift ranges from very narrow aisle trucks to order pickers, reach
Long-term commitment
trucks, stackers and even powered pallet
“Equipping our sales force with in-depth
trucks. It also examined appropriate uses
knowledge to recommend the right
for reach trucks, stackers and other
product for a particular application and
PRECAST | ISSUE THREE | 2018
(Left): Elematic’s new Plotter E9.
PRODUCTS 20
The concrete manufacturing sector faces a plethora of different demands daily for concrete applications. Chemical company Chryso Southern Africa applies solutions to ensure that these needs
CHEMICAL SOLUTIONS FOR DIFFERENT CONCRETE NEEDS modify concrete rheology to provide the
include fibres for cohesive mix to limit
Common issues such as durability of
required lubrication within the pump line,
rebound and shotcrete accelerators to
concrete due to shrinkage cracking can
reducing pump pressures and improved
improve build-up.
be addressed with a range of products
concrete flowability and providing better
Fibre-reinforced concrete is ideal
that reduce early and long-term drying
workability retention for long pumping
for limiting the formation of cracks and
shrinkage, while the company’s fluid
distances.
for improving surface quality; it can
are met.
Optima range combats the effect which
For concrete mortars, Chryso admix-
even provide an alternative to mesh
shrinkage-reduced admixture may have
tures can improve plasticity, cohesion
reinforcement. Super-plasticisers are
on the strength of the concrete.
and adherence, and prevent infiltration of
part of the offering, as fibres tend to
Pumping concrete over long horizontal
water, plastic shrinkage cracking, as well
reduce the workability of fresh concrete.
or vertical distances causes the danger
as the segregation of fine cement and
Impermeable concrete for waterproof
of concrete stiffening in the line, which
sand particles. Shotcreting is another
or under water applications can be
can disrupt the pumping operation. The
common application that can be enhanced
achieved to r educe water content
company’s product ranges, however, can
by the right concrete; available solutions
and water-cement ratios, as well as admixtures that block pores in concrete. In situations where vibration is not possible to compact concrete, selfcompacting concrete is the answer and the correct product will allow high fluidity, ease of placing and finishing, with extended slump retention, if required. Chryso’s extensive range of solutions is based on leading-edge research and can be produced in 26 facilities worldwide, each equipped with sophisticated technology for precision manufacturing. (Above, from left): Chryso admixtures are used in concrete pumping applications; Chryso’s range of admixtures has changed the face of construction by broadening ready-mix options for designers and contractors. (Left): Increased concrete workability is easily achieved using Chryso admixtures.
PRECAST | ISSUE THREE | 2018
Two years after introducing its Spartan precast concrete formwork system to the local market, local distributor RMCS
PRODUCTS
PRECASTER OFFERS MODERN FORMING SOLUTIONS has established a growing customer base of precasters who are making use
21
of the system to manufacture a wide range of products. The Spartan system provides a faster solution for the precast manufacturing and tilt-up construction industry with its lightweight, magnet-connec ted formwork which can be easily rebuilt af ter use to cast dif ferent shapes and sizes. with the addition of various lengths and profiles. According to Louis Aylward, managing director of Rebar Mesh & Construction Supplies (RMCS), the snap-together system is steadily finding favour, as it
(Above): Good finishes on the 2Ten Hotel add a quality feel of the exterior.
saves a considerable amount of time on
(Left, from top): Precast lifting anchors provided ease of placement of heavy precast units at Lanseria Airport; a tilt-up anchor and clutch.
set-up. This enables users to redeploy manpower and efforts to other parts of the process, which considerably improves productivity. It is also valuable
“T he system’s user -f riendly and
on projects where units vary in size and
we ultimately manuf actur ed 365
shape, such as decorative cladding.
balustrade panels which are decorative and functional. We also used form-liners
2Ten Hotel
to create semi-circular grooves on the
O n e o f t h e l a t e s t p r oj e c t s t o b e
face, which is towards the airport. We
completed with the Spartan system
used eight different sizes, starting with
was by CMA member CoreSlab, where it
the widest ones and going down to the
was used to cast a series of slabs and
smaller sizes, and cut the form-liner
cladding in large 2,7m x 5m and 150mm-
to fit.
thick sizes for the newly-constructed
“Through the use of the system, we
2 Ten Hotel in T hohoyondou. Wher e
saved about 50% on labour and 30% on
necessary, the panel sizes also had to
enabled the casting crew to redeploy
mould costs. Time and labour go hand in
vary to allow for perfect fitting and it is
the other workers into more productive
hand and savings of both are significant.
here that the Spartan System proved
areas, as required.
More importantly, you don’t need skilled
This combination translated to a
labourers to do the resetting each day.
According to Jaco de Bruin, managing
considerable cost-saving on the project
Demoulding is very simply achieved by
dir e c t o r o f C o r e Sl ab, th e sy s t em
and, in addition to these benefits, the
removing the magnets and then removing
accounted for significant time-savings
company will be able to clean and re-use
the panels. It’s a developed-world solution
on the project. Due to the lightweight
the moulds on future projects.
and, in the right application, is a game-
invaluable.
changer,” says Wesley Sevenster, Allasso
aluminium construction and easy-to-
Construction general manager.
assemble, magnetised jointing system,
Lanseria Airport
the moulds could be prepared by one
Another interesting project undertaken
person instead of the usual three. This
by Allasso Construction was the supply
Flexible solution
of concrete elements for the extension
“We’re pleased with the results being
of Lanseria Airport parking garages.
achieved by customer s using our
Here the manufacturer made extensive
system and it’s easy to see why,” says
use of the RMCS Spartan system, as
Aylward. “It enables higher volumes to be
well as its unique lifting anchors to more
produced from relatively small casting
safely transport the heavy fresh-cast
yards. It also requires less, meaning
concrete units throughout the curing
that workers can be used elsewhere
period, as well as for the transportation
to boost productivity. But the most
and placement of the units on site.
decisive benefit is its flexibility.”
“Through the use of the system, we saved about 50% on labour and 30% on mould costs.” PRECAST | ISSUE THREE | 2018
COMPANY NEWS
WESTERN CAPE BRICK AND BLOCK PRODUCER GEARED FOR GROWTH Based in Piketberg, midway between Cape Town and Clanwilliam, CMA member,
22
Fick Sementwerke produces a diverse range of concrete blocks, bricks, pavers and retaining wall blocks. Founded in 1995 by the current owner and managing director, Anton Fick, the company recently invested in new plant and equipment to increase production capacity. Demand for the company’s products began to outstrip supply from 2007 and a decision was taken to halt the production of pavers so that the demand for bricks and blocks could be met. At
(Above): Fick Sementwerke financial manager Felecia Paulissen, seen here with the company’s founder and managing director, Anton Fick. (Right): The new plant at Fick Sementwerke.
one stage, the company was working extended hours and over weekends.
Good decision
“Seventy percent of our range goes to
“When the market was still rampant
the farming community and the remain-
– demand doubled between 2007 and
der is supplied to independent retailers
2017 – we decided to re-introduce
which operate in towns within a 100km
paving blocks. Last year, we installed
radius of our plant and sell to the resi-
impor ted high-qualit y block-mak ing
dential market. However, we sometimes
equipment,” he added.
supply as far afield as Springbok, some 450km away,” says Fick.
“The new plant has tripled our overall production capacity and paving block
I started by making blocks and over the
(Below): CRB blocks prior to delivery.
years, the business has grown to the extent that it now occupies six adjacent
also supply an imperial brick in several
properties in Piketberg.
MPa ratings. “Our Concrete Retaining Block [CRB]
High standard
for retaining walls comprises the stand-
“We currently manufacture to the SANS
ard L12, which we make under licence
standard, but we’re not accredited. We
to Terraforce in smooth and rock face
operate on a philosophy of continuous
finishes and in tans and greys. Retaining
quality improvement and I spend much
walls built with CRBs are in their infancy
of my time in the plant, ensuring that
in this area – most people still prefer
our products are made to the highest
brick walls. Notwithstanding, we’ve
possible standards.
supplied blocks to rooibos tea farmers
“Our measurement deviations either
in Clanwilliam who used them for building
equal or better SANS’ standard de-
level platforms for the construction of
viations and we’re seriously considering
production began in January this year.
storage sheds and we are currently sup-
implementing the CMA’s Certification
Due to unforeseen circumstances such
plying farmers in the Calvinia area. We’re
and Mark of Approval system. We also
as the drought in the Western Cape
even supplying CRBs to a private house
aim to set up our own testing laboratory
and a general downturn in construction,
in Constantia, Cape Town.”
as soon as possible and we’re currently
product of f take has fallen, so we’re
in the process of installing a semi-auto-
currently not working to full capacity.
Long history
Nevertheless, we believe the downturn
A fifth-generation Piketberger, Fick says
will be short-lived and that it won’t
his family has been producing bricks and
b e long b e f or e demand incr e ase s.
blocks in the town for the past 60 years.
Dam levels are rising and farmers are
“My father owned a transport company
benefiting from this year’s better rains.
and during the quiet winter months, he
“O ur p a v ing r ang e c omp r ise s a
kept his staff busy by producing bricks
bevelled 50mm rectangular block and
and blocks as a sideline. I used to work
two interlockers, a 60mm and a heavy-
in the yard driving the front-end loader
duty 80mm, both available in a variety of
and forklift trucks in my school holidays
colours. We supply four masonry blocks,
and I learnt a lot about brick production
all of them 390mm long and 190mm high,
from the people working in the plant. My
in varying widths of 90mm, two in 140mm
father closed the plant in 1993 to focus
and one in 190mm, and we produce a
solely on the transport business.
maxi brick in varying strengths. Our maxi
“While his transpor t business
bricks are cast with cylindrical voids,
continued to demand his full attention in
which are popular in the Western Cape
1995, I founded Fick Sementwerke as a
and are used for building cavity walls. We
means of attaining financial independence.
mated palletising system,” says Fick.
NEW OWNERS FOR OCON BRICKS CMA member, the Infrastructure Spe-
group, and therefore decided to sell
cialist Group (ISG), has announced the
Ocon Brick.
sale of clay brick manufacturer Ocon
“On behalf of the IS Group, I’d like to thank management and the entire team
“With the strong demand for Tech-
at Ocon Brick for their dedicated con-
Brick to Willem Pienaar and
nicrete- and Rocla-manu-
tribution to its success during the past
his partner, Mike Koch.
f actur ed pr oducts in the
five years that they’ve been part of it.”
A lb er t Web er, C E O o f
industry and with govern-
Rocla and Technicrete are key manu-
ISG, says: “ISG r egularly
ment’s commi t ted spend
facturers and suppliers of precast
evaluates and reviews its
on infrastructure, we see a
concrete products that service the in-
op er a tional ac ti v i tie s t o
bright future for the busi-
frastructure building and mining sectors
ensure that our long-term
nesses. Both brands ar e
nationally and in neighbouring countries.
strategies and objectives
well-established industr y
Rocla celebrated its 100th birthday
remain on track . Af ter a
leaders and our long-term
in 2017 and Technicrete celebrates
careful analysis, the board
s tr a t eg y is t o gr o w and
50 years of operation this year.
decided to focus on the core business
further enhance our service offering to
that Rocla and Technicrete afford the
the industry,” he adds.
PRECAST | ISSUE THREE | 2018
(Left): Albert Weber, CEO of ISG.
COMPANY NEWS
(Left): Freshly cast masonry blocks.
23
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FOR FREE subscription form The precast concrete industry is one of the mainstays of the economy, garnering sales in the R-billions and employing hundreds of thousands. Most precast products meet international standards and some enjoy world-first status, having been invented and developed locally. While the industry has much to trumpet, there are also areas of concern such the non-compliance of standards by some producers, inadequate designs and the shoddy application of precast products. Precast aims to offer a balanced mix of editorial, focusing on those areas of which all South Africans can be justifiably proud, as well as those which require remedial attention. Whatever the focus, the magazine will, like its parent organisation, the CMA, always strive to foster a culture of excellence and cutting-edge innovation in all sectors of our industry. Yes, I want a FREE subscription to Precast magazine SUBSCRIBER’S DETAILS: Mr
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(Below): CRB walls under construction at the Phase 2 Courier Guy distribution centre project in Kya Sands, Gauteng.
COMPANY NEWS
(Left): The 3 700m² CRB wall at the new Cummins Southern Africa Regional Distribution Centre site at Waterfall Park, Midrand, MVA Bricks’ first major CRB project.
25
MVA INJECTS NEW LIFE INTO CRB WALL MARKET Pretoria-based concrete block paving
a rounded half-moon face and is designed
and precast concrete kerb producer and
for upmarket commercial walls in closed-
CMA member, MVA Bricks, has taken the
faced designs. A heavier block, it has a
concrete retaining block (CRB) wall mar-
much greater load-bearing capacity and
ket by storm. Since launching two block
can be deployed in walls with wall face
types, the MVA-7 and the MVA-13, the
angles which vary from 60-90˚.
company has won at least half a dozen
“The MVA-7 has a locking mechanism
major CRB wall projects in Gauteng and
which restricts its usage to wall faces
Mpumalanga. It has also supplied numer-
of 60-75˚. However, it can be modified,
Founded in 1995, MVA Bricks also
ous smaller projects.
as it was for the Cummins project,
produces a range of concrete block pav-
high loadings and pressures,” he says.
“Production began in June last year,”
where one section of the wall was built
ers which are available in various sizes,
says MVA general manager Brennan
at an angle of 85˚. This was necessary
shapes and colours. The production of
Small, “and our first major order followed
because of space constraints and to
kerbs began in 2005 using pressed cast-
shortly thereafter, when we supplied the
accommodate an attenuation pond at
ing to achieve exacting and highly durable
new Cummins Southern Africa Regional
the footing of the wall.”
quality standards.
Distribution Centre & Filtration Plant
Small adds that a third block, LokBlok,
MVA has a fully accredited SANS
development in Waterfall Park, Midrand,
was launched in July and two orders have
standard for its pavers and kerbs and is
with 26 000 MVA-7 blocks. These were
been delivered.
producing the CRB blocks to SANS stand-
used in the construction of a CRB fill-wall facing on a large building platform.
ards while it awaits SABS accreditation. Product range
“We maintain an in-house laboratory
“Since then, we’ve delivered MVA-7
“The LokBlok comes with a tongue-and-
and we test our products on a daily
blocks to several other major retaining
groove configuration, which allows the
basis. Our results are at hand within
wall projects: the Courier Guys Phase
blocks to interlock positively. This means
24 hours and form the basis of our on-
2 distribution centre development in
they’re well suited for high walls up to
going quality analysis. This means we’re
Kya Sands (24 000); a new Builders
90˚. LokBloks come into their own on
able to tell very early on whether our
Warehouse in Midrand (19 000); a new
walls in excess of 8m – heights which
products meet our required strength
industrial park on the R21 near Oliver
require a very specific block because of
ratings,” says Small.
Tambo International Airport (12 000); a new industrial park in Nelspruit (8 000); and Thulamahashe Plaza, some 200km from Nelspruit (3 400).” Economical construction Small says the MVA-7 has a flat face and was designed for economical, open-faced wall construction. As its name suggests, it is generally used on the basis of seven blocks per square metre, although this can be increased to a 10-block configuration when required. “The MVA-13 is quite different. It has
PRECAST | ISSUE THREE | 2018
(Above): MVA Bricks’ general manager, Brennan Small, stands next to one of the CRB walls at the site of the new Cummins Southern Africa Regional Distribution Centre.
AROUND & ABOUT 26
CONCRETE CONFERENCE UNITES TH A united industry is a stronger one that
our concrete professional bodies.”
is better able to represent its members
SARMA’s Johan van Wyk agreed,
through periods of high growth, while
adding that associations have to move
maintaining its solid structure in times
with the times and become more relevant,
of adversity.
with added benefits for members and a
This was the overriding message of
louder voice within policy and economic
The Concrete Conference 2018, which
frameworks. By combining the strengths
was held in Boksburg recently as the first
of the industry bodies, it will be possible
of its kind to fully involve representative
to provide more value for members.
or ganisations o f the concr ete and
“What excites us unites us!” he said.
cement industries. The events therefore gave local and international speakers the
Long road
ability to address a combined audience of
Adding to the discussion, TCI’s Bryan
members of The Concrete Institute (TCI),
Perrie said the pooled resources of the
the Concrete Society of Southern Africa
five organisations will make for a robust
(CSSA), the Concrete Manufacturers
organisation which will have different
Association (CMA), the Southern Africa
agendas for different disciplines, but the
Readymix Association (SARMA) and the
same end-goal of making concrete the
Association of Cementitious Material Producers (ACMP). Opening the conference, Richard Tomes of AfriSam, the main sponsor,
building material of choice. on board. We need to support industry
“At present, the individual industry
associations such as these here today
bodies draw funding from the same major
and obtain funding to keep them going.
stakeholders and these can’t continue
said that a unified industry is essential
“For example, Afrisam is the only
funding them, as they have in the past.
for the industry to make headway. “The
cement producer which is a member of
A single co-ordinated body would be more
entire construction industry needs to
SARMA right now and, in my opinion,
agile and eliminate duplicated costs. It
plan for the future and map a way forward
it’s simply not right that it funds this
could also continue providing the key
that involves all professional bodies. It’s
association by itself. It’s time other
activities that were previously provided,
therefore extremely important that the
role-players and suppliers to these
and more.”
concrete industry finds its unified voice
industries star ted contributing. If
In closing, Perrie said that a lot of
to help shape construction in future and
not, we’ll also eventually be forced to
work still needs to be done to unify the
address challenges that face this end of
withdraw our funding and the industry’s
concrete associations and consultations
the sector,” he said.
own association may be faced with
with members and business studies are
closure as a result. It’s time for other
still being conducted to work out the
role-players to step up and support all
finer details.
Strong voice “If we don’t get our act together soon, our infrastructure will collapse: this has already started happening at some levels within our municipalities and state-owned enterprises. However, in order to make positive changes, we need everyone to be
“The entire construction industry needs to plan for the future and map a way forward that involves all professional bodies.” PRECAST | ISSUE THREE | 2018
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TECHNICAL 28
John Roxburgh, lecturer at The Concrete Institute’s School of Concrete Technology, provides some guidelines on mixing and using concrete in a safe manner: The composition of portland cement is such that when dry cement is exposed to water, a chemical reaction called hydra-
GUIDELINES ON USING CEMENT AND CONCRETE
tion takes place, resulting in an alkaline mixture that can be caustic. This could cause alkali burns on the skin, so safety measures should be observed to prevent fresh concrete or its bleed water from coming into contact with the skin. Roughness and dryness of the hands are a typical result of exposure to cement, so to safeguard against accidental skin exposure, appropriate protective equipment is strongly recommended. This
SAFELY AND SENSIBLY Concrete is the world’s most widely used building material. Workers in every sector of the construction and precasting industries, as well as DIY enthusiasts, handle portland cement and wet concrete every day. However, as with most materials, there are potential risks involved in working with portland cement or mixes made using it.
includes wearing impermeable, gauntlet-
in the working area and is inhaled by
if this is not possible, the use of suitable
type rubber gloves and high-length rubber
every person on site, potentially causing
respiratory protective equipment such
boots. Trousers should overlap the boots,
irritation of the nose, throat and eyes.
as dust masks is recommended.
rather than be tucked into them.
For this reason, every attempt should be
Particular care should be taken to
It is also recommended that hydro-
made to keep airborne cement dust to a
ensure that:
phobic, alkali-resistant barrier creams
minimum. If this is impracticable, the use
• Normal and protective clothing does
be applied to hands and any other areas
of goggles and dust masks is strongly
not become soaked with wet concrete
of skin likely to come into contact with
recommended.
or concrete fluids, as this could result
fresh concrete. Ordinary barrier creams
Many of the aggregates used in con-
in exposure over an extended period,
are unlikely to offer adequate protection,
crete have high silica contents. The fine
resulting in tissue damage that can be
especially if the skin itself is not clean
silica dusts created when crushing or
particularly severe and even disfiguring.
and free of concrete residue. Even a tiny
handling these aggregates could cause
• Workers do not kneel on fresh con-
trace of cement dust remaining in con-
lung problems and precautions should be
crete during placing, compacting and
tact with wet skin could burn it. For this
taken to avoid breathing in such dusts.
finishing operations. If kneeling is
reason, some authorities recommend
Dust from demolishing or cutting
unavoidable, thick, waterproof knee-
the use of disposable gloves, rather than
hardened concrete may contain unhy-
pads should be worn and a kneeling
re-usable ones.
drated cement and could cause respira-
board used to prevent the pads from sinking into the fresh concrete.
Other organic tissue (for example,
tory problems. In addition, if the coarse
mucus membrane) can also be attacked
or fine aggregate used in making the
• Protective clothing should also be
by strong alkalis, leading to burns that
concrete contains crystalline silica, the
regularly and properly washed to keep
can sometimes be severe.
inhalation of these fine silica particles
it clean and free of concrete. Any
The use of cement inevitably creates
could expose workers to the risk of de-
areas that have been accidentally
dust, particularly in operations such as
veloping the occupational lung disease,
splashed with wet concrete should
handling aggregates or cutting concrete.
silicosis. A concerted effort should be
be rinsed clean with water as soon
The dust becomes suspended in the air
made to avoid generating such dusts, but
as possible.
PRECAST | ISSUE THREE | 2018
CONCRETE ROADS SAVE FUEL With the fuel price constantly rising, the lower fuel consumption offered by concrete pavements should be an important factor in future road transport planning, says Bryan Perrie, MD of The Concrete Institute.
and full tractor-trailer unit – ranged from
Because of the social and ecological impor-
lifetime of a busy freeway.
0,8-3,9% in four out of five periods in the year. This was found in results with a field of reliability of 95%.” Perrie adds that an average fuel-saving of 2,35% would represent an immense difference in overall fuel consumption and emissions of greenhouse gases over the
tance of reducing fossil fuel consumption,
Laboratory research by the Transport
several studies and research projects con-
Research Laboratories in the UK, commis-
cerning the effect of pavement type on the
sioned by the Highways Agency, was carried
fuel consumption of industrial goods vehicles
out to determine the effect of the rigidity
and cars have already been carried out. The
of the pavement on fuel consumption. The
best-known study is that of the National
reduced deflection of concrete pavement
Research Council (NRC) of Canada.
led to a 5,7% reduction in rolling resistance,
“The Canadian NRC did a series of four
also resulting in fuel-savings. Similar results
investigations. These were progressively
have been obtained from extensive research
extended with additional test phases on
done in Sweden, Japan and the American
various types of pavements and vehicles
states of Texas and Massachusetts.
in different seasons and using a variety of
“Apart from the type of pavement, even-
statistical models. Reduced fuel consump-
ness and surface texture are also important
tion in heavy goods vehicles was seen in all
factors influencing fuel consumption. The
phases for concrete pavements, compared
quality of the finished concrete surface
with asphalt pavements,” says Perrie.
plays a crucial role: a good-quality and
“The final phase – which was also the
evenly-laid concrete pavement retains these
most complete and evaluated a range of
qualities for decades. A concrete pavement
pavements with various degrees of even-
with undulations or uneven patches will
ness and included observations made in
require difficult and expensive treatment
all seasons – revealed the smallest differ-
to obtain the desired ride quality,” explains
ences, but still showed that the fuel-saving
Perrie.
on concrete pavements compared with asphalt pavements – both for an empty
PRECAST | ISSUE THREE | 2018
(Below): Work in progress on concrete pavement construction in KwaZulu-Natal.
TECHNICAL
PREVENTATIVE MAINTENANCE ENS The durability of concrete structures, including precast, can be greatly increased by a proper preventative maintenance and repair programme, says
30
Warren Trew, Gauteng sales manager: General Construction of a.b.e. Construction Chemicals. Trew says many key South African building and civil structures have eroded with age or due to neglect, misuse, wea ther f ac tor s, r ebar cor r osion, extraneous loading and natural disasters. “Neglecting the need to introduce proper repair and maintenance systems for these structures results in reduced capital value and wastage of resources, which could lead to poor quality of life for communities. With large parts of SA currently experiencing devastating drought, the need for adequate maintenance of water reservoirs and dams, particularly, comes to mind. (Left): Repairing deteriorated concrete and restoring its structural integrity should form part of the initial design, says a.b.e.’s Warren Trew.
SURES DURABILITY “In a sustainable built environment,
“Experience is vital for this diagnosis
structural maintenance is non-negotia-
and for planning concrete repairs. While
ble. As soon as a concrete structure is
there’s a high level of expertise that
completed, the need for a maintenance
goes into concrete construction, the
programme must start. Maintenance
skills, understanding and experience
shouldn’t be driven simply by the need to
required to repair damaged or deterio-
correct defects that occur over time,
rated structures are decidedly differ-
but should be undertaken early enough
ent from those required to build new
to avoid them,” he states.
structures. That’s why it’s important to consult reputable suppliers of con-
Dire need
crete repair products – companies that
Crew says that concrete is a durable,
can offer not just the product, but also
but not eternal material and will de-
provide advice on its suitability, as well
teriorate over time, requiring repair
as the system and procedures to be
or replacement, especially in zones
followed for concrete repair projects.
where chloride ingress or carbonation are a reality. Repairing deteriorated
Crack repairs
concrete and restoring its structural
“Among the most common challenges
integrity should consequently f orm
of concrete rehabilitation are crack
part of the initial design – but these
repairs, patching, using strengthening
measures are frequently only resorted
methods (instead of repairs) such as
to once emergencies arise.
carbon fibre plate or wrap, and generally
“ T he f ir s t s t ep in a suc c ess f ul
choosing the most appropriate repair
repair project involves early damage
materials for an ef fective long-term
assessment and arriving at a proper
solution. A decision should also be taken
diagnosis. The owners shouldn’t wait
on whether strengthening methods
until the concrete shows obvious signs
should be opted for, instead of repair.
of distress. The most crucial aspect
Fortunately, the range of concrete re-
of the repair process is the evaluation
pair products available today has made
stage. To properly repair any damage,
it possible to economically refurbish
it’s impor tant to understand what
structures that just a few decades ago
caused the problem and then determine
would have had to be demolished and
the correct method of repair.
rebuilt. The input from specialists in concrete rehabilitation – and the selection of the correct products – will avoid common pitfalls of concrete repairs,” observes Trew. He says a.b.e. Construction Chemicals’ range of concrete repair products is based on epoxies, synthetic resins, silanes and cementitious materials. Applications include flexible slurries and coatings for protecting and waterproofing the concrete parts of bridges, silos, building and water containment structures against attack from their en v ir o nm en t . “a .b .e . c an sup p l y a wide range of products – as well as professional advice – on projects such as concrete crack injection, fairing, reprofiling, priming, mortar repair and the rehabilitation of spalled concrete surfaces, to name just a few requirements of concrete repair procedure
(Above): Warren Trew, a.b.e Construction Chemicals Gauteng sales manager: General Construction.
PRECAST | ISSUE THREE | 2018
which could save the owners thousands, if not millions, of rands.”
TECHNICAL
By John Cairns, independent paving consultant SA is one of the world’s water-scarce regions. Prey to recurring droughts, there is rarely a period in which one or more of the country’s provinces is not in
32
the grip of an extended dry period. Cape Town’s recent disastrous drought is just one such example. Being a global destination, the city’s critical water shortage drew international interest, but it was the entire Western Cape region and not just Cape Town which was declared a disaster area in 2017. The drought in the Western Cape should act as a wake-up call for SA, underscoring the need for water to be treated as a precious and vulnerable resource. Cape Town came perilously close to Day Zero and the same set of conditions could easily prevail in other regions. Rather than wait for a disaster to occur, regional and local governments should lead the way through mandating a broad swathe of water conservation measures, including permeable paving. By way of example, the German government takes permeable paving so seriously that
WATER CONSERVATION AND PER
LOCAL GOVERNMENT MUST
any impervious, hard-standing surface
Reducing costs
characterised by a higher frequency
attracts additional rates and taxes.
Permeable paving also offers economic
of storms and a longer rainy season.
Besides water conservation, the main
advantages by minimising the costs of
T he stud y r ecommended tha t new
benefit of permeable paving is that it
surface drainage works and reducing the
proper ty developments be carefully
reduces the negative impact of imper-
demands on stormwater sewerage. In
designed to ensure that run-off from
meable surfaces on aquatic ecosystems
addition, it is suitable for flat areas with
new developments is maintained at pre-
through stormwater management and
limited falls, such as container terminals
development levels. Correctly designed
pollution control. With the exception of
and roof decks. And, unlike other water
and installed, permeable paving meets this
Cape Town, which has legislated its use
conservation systems such as swales
objective and is particularly effective when
along with other water conservation
and attenuation ponds, it allows full
existing stormwater drainage systems
measures, the rest of SA pays scant
land usage.
are operating near or at capacity.
heed to the system: permeable paving
A study by the Johannesburg
Although this was only a recommenda-
installations in other provinces number
City Council f ound that the city is
tion, some permeable paving projects have
no more than a dozen.
experiencing an increase in annual rainfall,
been undertaken in Johannesburg. In some of the city’s first installations, the designers appeared to lose sight of the fact that the materials used in the construction of permeable paving are vastly different from conventional paving, particularly the bedding material beneath the pavers and the jointing material between the pavers (see Figure 1). In at least two installations, conventional bedding and jointing sands, rather than small aggregate, was used. (Top): The voids between permeable paving blocks are clearly visible at the 45 000m² Blue Route Mall parking area in Cape Town. (Left): A permeable paving system takes shape on a parking lot on the West Campus of the University of the Witwatersrand. The system comprises layers of stone, membrane and paving block.
PRECAST | ISSUE THREE | 2018
procedures which assess impacts on
the aggregate used to fill the joints or
water quality.
drainage apertures. Polluted material
Permeable paving should be consid-
can therefore be easily and economically
ered when:
removed and replaced. Several European
• Stormwater and sewer systems are
installations – such as car and bus parking areas at the Prater Football Stadium in Vienna – have been in service for 15 years and more, with only routine maintenance. In Australia, a permeable paving system has been developed for domestic driveways. Rainwater collected from
close to capacity. • There are limitations on the extent of impermeable cover. • There is insufficient space for both vehicle use and attenuation ponds. • Water quality and pollution control are primary design objectives.
the driveway and the roofs of adjacent
For these reasons, permeable paving
houses is channelled onto the driveway’s
provides an option especially relevant to
permeable surface and stored in a tank
urban roads. However, it has also been
under the paving. By means of an im-
successful in heavily trafficked applica-
mersible pump, this water is used for all
tions, such as container yards.
non-potable applications in the houses and for watering the gardens.
Design of permeable paving Several distinct engineering require-
RMEABLE PAVING:
LEAD THE WAY
Typical regulations for new urban paving
ments must be addressed in design-
developments
ing p e r m e ab l e p a v ing . I d e all y, th e
These include:
methodology should embrace the
• Limits on the extent of
following objectives:
impermeable areas. • On-site retention of rainwater. • Control of the discharge rate.
• Flood mitigation by r etention or detention, ie water quantity. • Water quality improvement by
• Control of the discharged water quality.
filtration or retention, ie water quality.
• Measures to reduce sedimentation
• Water conservation by collection and
and/or pollution. • Increasingly, measures for harvesting and re-using rainfall.
re-use, ie water harvesting. • The ability to carry traffic. An overview of permeable paving de-
To meet such requirements, best
sign is given in figure 2. This figure shows
management practices include controls
that, in contrast to conventional paving,
for reducing or managing pollutants,
permeable paving involves two parallel
procedures for the proper disposal of
design requirements, structural design
waste and the use of flood management
and stormwater management, each of
Figure 1 Bedding sand is not the best material, as it limits the flow rate of water through the pavement and leads to surface flooding during heavy storms. Offshore research Studies in the UK have shown that permeable paving yields significantly lower initial and whole-of-life costs than asphalt or cast-in-place concrete surfaces. Moreover, initial concerns about the long-term maintenance costs of permeable paving due to clogging have largely been allayed by tests in Europe, North America and Australia. These tests indicate that permeable paving can achieve a service life in excess of 25 years without maintenance and, more importantly, that pollutants mainly
PRECAST | ISSUE THREE | 2018
TECHNICAL
accumulate in the upper 25-50mm of
Figure 2: Methodology of permeable pavement design.
33
TECHNICAL
which is likely to require different paving
3. No infiltration: Where there are
thicknesses. Clearly, the designer must
contaminated flows or issues of
The range of water management outputs
opt for the greater thickness.
soil salinity. Here an impermeable liner
should include:
needs to be placed between the per-
1. Storage size requirement to achieve
The principal design questions are: 1. What is the design life of the pavement? 2. How fast can the pavement accept
34
meable pavement and the sub-grade, and drainage pipes are required to remove infiltration. (See figure 3.)
rainfall? This depends on the paver Water infiltration and treatment
drainage materials, and the type of
Three issues must be considered in the
base and sub-base.
design of pavements:
3. How fast will the pavement drain?
1. Stormwater management: How much
This is related to the type of base and
water can infiltrate the pavement over
the position of the water table.
specified performance targets. 2. Peak flow rate for selected storm events at the site. 3. Site-critical storm duration.
type, the cross-fall, the bedding and
sub-base, the type of sub-grade and
Water management outputs
a given time and where will it go?
4. Average annual reduction in pollutant load. 5. Average annual harvesting/ re-use capability. Structural design
2. Pollution control: What is the quality
As mentioned above, the pavement
4. How much water can the pavement
of the effluent leaving the pavement?
thicknesses required for stormwater
retain and for how long? This will de-
3. Water harvesting: How much water
management normally differ from those
pend on the thickness and permeabil-
can be stored and re-used?
ity of the pavement layers. 5. How thick should the pavement be to
needed to carry traf fic. This means that, in addition to water manage-
Water quality, harvesting and re-use
ment, traffic flows and loading must
carry traf fic? Here the resilient
There are two approaches in controlling
be considered in the structural design.
properties of the permeable pavement
water quality. The first of these is to
Worldwide, permeable paving has already
materials are paramount.
filter the stormwater and then release
been successf ully used in pr ojects
it into the local government drainage
ranging from car parks to roads, ports
Cross-section selection
system. The second is to filter and re-
and container yards. Accordingly, any
As shown in figure 2, the first step in
tain the stormwater on site, allowing it
structural design procedure should
permeable paving design is to determine
to slowly percolate into the underlying
be capable of handling a wide range of
how the water will be controlled and man-
soil. Factors that must be considered
traffic conditions, while utilising the full
aged within the pavement system. This
here include:
range of new materials which are avail-
entails choosing the right cross-section
• Pollutant input concentration
able for the construction of permeable
and pavement materials. Broadly, three scenarios need to be considered: 1. Total infiltration: Where the water is
characteristics. • Pollutant removal efficiency characteristics.
paving surfaces. It is also important to note that in any new development, only part of the paved surface needs to be
allowed to flow into the sub-grade and
• Historical rainfall data.
permeable. Engineers must structure
water table. Although sub-surface
• “First flush” pollutant characteristics.
their designs based on an appropriate
drains can sometimes be omitted,
• Build-up/wash-off of pollutants.
ratio of permeable to non-permeable in
they are only feasible on permeable sandy soils. 2. Partial infiltration: Where the permeable paving is founded on impermeable clay, sub-grade provision must be made to drain the water from the site using drainage pipes. Moreover, a filter fabric must be used to prevent clay fines from contaminating the base and sub-base.
Monthly demand characteristics are
order to ensure that all stormwater is
the main consideration for water har-
channelled to and drains into the perme-
vesting (re-use).
able surface.
“The drought in the Western Cape should act as a wakeup call for SA.”
Conclusion P er me able p a v ing is an imp or t an t technique for achieving water-sensitive urban design and should be mandated by SA’s provincial and local authorities. There is now sufficient data to allow permeable paving designs for all types of applications. The design engineer needs to identify retention and detention requirements, predict outflows to the surrounding catchment, integrate the project as a node in existing catchment management procedures and design software, and ensure it is compatible with water quality monitoring programmes. All these factors should be rated as very important by municipal engineers for
Figure 3
whom water-sensitive urban design is a basic requirement.
PRECAST | ISSUE THREE | 2018
A joint initiative of the City of Cape Town and the Southern Africa Readymix Association (SARMA) is underway Until now, no specific standards have
irrigation and isn’t disallowed, according
facturing, which relies heavily on a reliable
existed to allow the use of anything but
to national standards, nor is provision
supply of it. Water shortages can result
“potable” water in the process. How-
made for it in SANS 51008 water for
in either the closure of concrete manu-
ever, the recent drought in the Cape
making concrete because, until now, no
facturing plants or in manufacturers
Town region has spurred concerned
specific testing’s been done.
seeking alternative methods of obtaining
SARMA members to join forces with the
“As a result, we’re currently compiling
water. In the Cape, the drought even led
Cape Town Municipality in using effluent
a testing which will enable us to run an
to manufacturers sinking hundreds of
water instead.
eight-week study and collate results, in-
boreholes throughout the region. This
According to SARMA director Johan
cluding chemistry and all the parameters
could eventually lead to the concentra-
van Wyk, if a suitable solution can be
surrounding the water. We can then
tion of salts which can render the water
found, it will not only have a positive effect
monitor its effect on the mixing, setting,
unusable to future generations for drink-
on water supplies and the environment,
curing and strengths of the concrete.
ing or agricultural purposes.
but will also reduce the cost of water for construction by as much as 75%.
“This will then be compared with
“As the guardians of future genera-
current concrete standards and data
tions, we feel it’s our responsibility to
to make a finding. Our preliminary find-
find sustainable, alternative means of
Safe usage
ings have been positive and offer hope
manufacturing concrete,” says Van Wyk.
“In this instance, effluent water doesn’t
for a major evolution in the way we make
refer to sewage, but rather to water from
concrete in dry climatic regions.”
sewerage plants that’s gone through all
TECHNICAL
RESEARCH TO BENEFIT PRECASTERS
35
“The finding we make on effluent water will be made available on completion of the research and best practices will be
cycles of treatment except naturalisa-
Seeking alternatives
shared with all concrete manufacturers
tion in a maturation pond,” explains Van
The construction industry is a major
via internal communications, as well as all
Wyk. “This type of water is often used for
water-user, particularly concrete manu-
forms of media at our disposal.”
We are there when you need support
Need help with your concrete? We offer a free advisory service for general concrete queries. Perfect concrete with us.
www.theconcreteinstitute.org.za +27 11 315 0300
TECHNICAL 36
CONCRETE OFFERS UNMATCHED
STRUCTURAL INTEGRITY S construction offers for the creation of infrastructure, says Bryan Perrie, MD of The Concrete Institute (TCI). He says the strength of concrete ele-
concrete. In the case of reinforced con-
Ensuring concrete integrity and du-
ments in buildings is well understood
crete, the quality of the cover concrete
rability is essential in using the equity
by structural engineers, architects
is extremely important in protecting the
already in the existing structure. It also
and contractors. This includes in-situ
steel reinforcement against aggressive
prevents the need to re-invest in materi-
reinforced concrete, precast concrete,
agents and fire. This zone of concrete is
als and energy prematurely.
tilt-up, hybrid construction and post-
intended to act as the barrier between
tensioned concrete elements.
the reinforcing steel and external ag-
Sustainable solution
“South African design and construc-
Concrete’s energy-efficiency is shown
tion codes regulate the structural re-
in many ways. The use of local materi-
quirements of concrete buildings, which
als in production of concrete minimises
ensure that concrete structures are
fuel costs for handling and transporta-
safe and have the capacity to cope with
tion and, once in place, concrete offers
any permanent, imposed, wind and earth-
significant energy-savings over the
quake actions. For common spans, the
lifetime of the structure. Most of the
relatively high mass of concrete floors
primary materials used in concrete are
leads to natural damping and low vibra-
produced locally. Cement extenders and
tion. For more stringent criteria, such
slag aggregates used are secondary in-
as for laboratories or hospital operating
dustrial products that would otherwise
theatres, the additional cost to meet
have required dumping. While cement
stricter vibration criteria is negligible,”
factories are generally located close to
adds Perrie.
the location of the necessary raw materials, sources of aggregates and ready-mix
More durable
plants can be placed close to the areas
Concrete is renowned as one of the most
of demand, thereby reducing the energy
durable materials on earth, ensuring lon-
required for transport.
gevity in any structure. This not only low-
“The materials used in concrete also
ers the expenditure of energy in building
gressive environments and its quality is
make efficient use of natural resources
new infrastructure or housing, but also
of primary importance in durability con-
and, again, the potential for recycling
reduces maintenance and the impact on
siderations. Good material choice, mix
at life-end saves quarrying of finite re-
the use of finite resources.
proportioning and sound construction
sources. Concrete mixes for ready-mix
practice are essential to ensure durable
plants and precast yards are designed
concrete,” stresses Perrie.
specifically to use aggregates sourced
“The first line of defence against deterioration is good-quality, impermeable
PRECAST | ISSUE THREE | 2018
buckling or yielding,” says Perrie.
(Left and below): The flexibility of concrete as a building material – both externally and in interiors – has inspired designers the world over.
largely maintains a building’s strength
major impact on the energy usage over
smoke damage also reduce the magnitude
the lifetime of a busy highway. A major
of insurance claims. Concrete structures
Canadian study showed a 2,35% fuel-
generally remain intact after a blaze,
saving by using concrete roads, with a
allowing for relatively quick repair and
subsequent reduction in the emission of
re-occupation, saving time and costs,
polluting gases.”
as well as finite resources.
Fire-resistant
Good-looking
Perrie says another benefit of concrete
“Fire-damaged concrete buildings usually
is that it does not burn or emit any
don’t require demolishing or rebuilding,
toxic substances during a fire. It will not
so concrete structures protect life and
produce smoke or drip molten particles,
preserve property, contributing to en-
from local quarries – and, more recently,
which means it is fire-resistant. Unlike
hanced social and economic performance
also from recycled concrete – which re-
other construction materials, therefore,
of the built environment – an important
duces fuel costs for transporting these
its use in structures means they do not
consideration for all property-owners,
materials,” explains Perrie.
require fire-proofing or additional pro-
such as municipalities,” adds Perrie.
“The embodied energy in the construction of a structure is usually minimal,
tection, provided they are appropriately designed.
Concrete’s inherent fire-resistance restricts smoke from spreading and during a fire. After a fire, the continuing structural strength and reduction in
TECHNICAL
(Far left): The structural strength of concrete elements such as precast concrete (pictured) is well-known to all in the South African construction industry.
37
“When aesthetic qualities such as design flexibility and variety of finishes
compared with the energy likely to be
“This eliminates the time, cost, ad-
are added to the sustainability benefits
consumed during the life or use phase
ditional materials and labour required to
of concrete, it’s easy to understand why
of a structure. In the case of roads and
provide separate fire protection mea-
it’s the preferred building material among
transport infrastructure, any aspect
sures. During a fire, the concrete cover
property-owners, developers, designers
reducing fuel consumption will have a
will protect the steel reinforcement from
and contractors.”
ENDING EROSION Technicrete Armorflex erosion control system provides an alternative for a wide variety of erosion control and drainage projects. When your project calls for protection that can withstand severe applications and climatic conditions, with quick installation with no in-situ concrete or even under water, Armorflex from Technicrete is the engineered solution. Suitable for:
Specially designed:
•
•
• • • •
Rivers, Estuaries, Dams, Reservoirs Areas subject to wave action Access roads Parking areas Stormwater drift crossings
• • •
Compressed concrete blocks (solid or vertical holes
or horizontal cable ducts)
Interlocking system Partial taper of each block Various sizes of blocks available
paving | mining | masonry | kerbs erosion protection | retaining walls | drainage www.technicrete.co.za Technicrete is a subsidiary of ISG, a leading supplier of innovative infrastructure products to the construction and mining markets in Southern Africa.
Tel: 011 674 6900 Maxi call: 0861 266 267
RPOJECTS 38
EARTHFORM: THE PERFECT SOLUTION When a couple in Thohoyandou, Limpopo,
“I knew that Manie Troskie from En-
the embankment be cut back and the soil
decided to build their dream retirement
gineered Interlock Solutions [EIS] was a
stockpiled to provide space for the geo-
home, they were faced with an unex-
specialist concrete block retaining wall
synthetic reinforcement and drainage.
pected challenge – soil erosion due to the
contractor with many years of experience
high-lying area of their land.
in the design and building of concrete block
Good result
A Google search highlighted CMA
retaining walls, as he’s a regular customer
“This is the biggest residential retaining
member Technicrete’s Earthform re-
of ours. Due to the massive size of the
wall project we’ve undertaken to date,”
taining wall blocks as a solution. Meet-
project and the challenging terrain, I re-
adds Troskie. “Over 20 000 grey Earth-
ing Technicrete at its Polokwane office
ferred the couple to him for the retaining
form blocks were needed to complete
offered the couple the erosion solution
wall installation and design.”
the Thohoyandou project. The house
they required. “Our Earthform retaining wall blocks
was situated off the main tarred road Economical design
– and this is where the expertise of the
are ideal for the kind of challenges the
“EIS designed and constructed the
Technicrete drivers came to the fore,
couple was facing. The longevity of the
retaining wall in various stages. The
as they battled dirt roads, sometimes
product has stood the test of time on
critical area was in front of the house,
in rainy weather, and still delivered on
many projects where soil erosion has
where 80mm-wide tension cracks had
time, without breakages.
been vast due to flooding,” says Peter
already developed. There was a risk of
“The access to stock as required and
Hilton, sales consultant for Technicrete
this embankment collapsing. A total slip
competitive pricing were other factors
in Polokwane.
failure would have had a major impact on
that made working with Technicrete a
the structural integrity of the house.
win-win situation during the eight months
Soil erosion
The in-situ embankment was cut back
it took to complete this project. The
Due to the magnitude of the project, Hil-
to the required design distance for the
couple involved were very happy with the
ton travelled to Thohoyandou to assess
geosynthetic reinforcement and drainage
end result in terms of erosion control and
the site and take the required measure-
to be installed. The soil was stockpiled for
final appearance.”
ments, which took over two hours. The
re-use,” says Troskie.
Earthform retaining wall blocks can
house, large enough to accommodate
“The fill wall was constructed in two
be stacked up to 7m high, provided that
four children and extended family, was
terraces, each 3m high. The terraces
sufficient geosynthetic reinforcement,
built high up in the magnificent, hilly area
were of a more economical design so-
erosion control layers and drainage are
of the region, affording the property
lution and provided a softer look for
installed in the reinforced fill section
exquisite views, but heavy rains were
landscaping. There were various smaller
directly behind the blocks.
causing massive soil erosion on the
terraced walls constructed on both sides
Plants or vegetation suited to the
chosen site.
of the house. One wall was constructed
style of the Earthform retaining wall
as a 7m-high continuous wall that flared
blocks should be planted facing outward
out into three smaller terraces.
of the front face of the wall and require
“Earthform gives embankments a natural support, while protecting the land from collapsing due to erosion,”
“The wall behind the house in the cut
says Hilton. “Additionally, it provides an
section was also designed as a two-
attractive and practical finish in steep
terrace wall. The bottom section was 5m
areas that are dif ficult to maintain
high and the second wall 3m high. There’s
through the creation of plantable retain-
an access road to the neighbour’s prop-
ing walls.
erty on top of the wall. This required that
little maintenance. The blocks are available in Autumn, grey and plum.
(Above): The Thohoyandou family house with Earthform erosion blocks to prevent erosion of the relatively steep property.
Ten years ago, tilt-up construction could only claim fewer than 10 proE years back, its use was random and T ±50 for the current year heralds a big leap in the right direction.
a European construction design which
panels were erected without columns
called for precast columns and precast
for support. In this instance, they are
column foundations. Bedrock suggested
held in place by the roof, while the panels,
its in-situ foundation system, which
in turn, support the roof structure. In
involves casting columns with protrud-
other instances, panels were erected in
ing rebar, as an alternative. Once the
combination with columns, both of which
columns have been lifted into position and
support the roof.
The reason for the upsurge isn’t hard to find. Property designers and developers
precast foundation and rather than
the panels against the inner-facing sur-
are always on the look-out for improve-
convert to a foreign methodology, we
face of the columns, with two panels
ments in quality, accuracy and, above all,
suggested an in-situ foundation,” says
abutting at the middle of each column.
speed – and tilt-up ticks all these boxes.
Bedrock manager David Kitching. “The
We did this at the request of the ar-
vertically aligned, concrete is poured into
“In sections where columns and panels
the foundation cavity around their base.
were combined, the panels weren’t posi-
“This is the way we’ve always done
tioned on the outside of the columns, as
it, as it eliminates the transport of the
they normally are. Instead, we mounted
Tilt-up construction, which involves
chitects, who wanted smooth surfaces
casting large panels or columns horizon-
on the inside of the building. Moreover,
tally on site, did not gain wide traction
we cast the roof mounting plates inside
until the advent of the mobile crane after
the panels to give a nice, flush finish and
World War II, which allowed builders to lift
we cast the roof brackets above ceiling
the massive panels into position. It was
level so that they were also concealed,”
also then that ready-mix concrete was
explains Kitching.
introduced, making tilt-up an even more
“In another section, we integrated an
viable proposition.
in-situ mezzanine level into our concrete
Over the years, industry experts
panels. This was achieved by casting our
have refined the tilt-up process and in
panels with rebar protruding at right
1986, the Tilt-up Concrete Association
angles from the top of the panels. Then,
(TCA) was founded in the USA to create
when the mezzanine formwork was as-
processes and standards for the indus-
sembled, it was linked longitudinally into
try. Today tilt-up accounts for as much
our rebar.”
as 75% of new one-storey commercial
These variations in design and con-
building construction in the USA.
struction demonstrate the flexibility of
SA’s first tilt-up project is said to
tilt-up and how easily it can be adapted
have taken place in 1984 and involved
to the requirements of numerous design
the construction of Myrther House, an
options.
office building in Pinetown which is now
T he Isipingo Retail Development
occupied by the Department of Labour.
project is being constructed above a (Above): Tilt-up panels mounted flush to create a smooth finish at Junction Mall. The panels are mounted against the inner surface of concrete columns, rendering the columns invisible from the inside of the building.
fully functional railway line and could not
in the greater Durban area. Today SA’s
European engineers had no problem with
and erected by Bedrock as a complete
largest tilt-up practitioner is the Bedrock
our alternative proposal and it sailed
structural concrete frame.
Group. Also Durban-based, it entered the
through their approval process.
And the first company actively involved in this precast building method was Durban-based Tilt-Up Technologies, an outfit which focused on industrial parks
market in 2013 and now commands 65%
have been executed without the use of precast concrete in the form of columns, beams and panels, all designed, supplied
Kitching advises that erecting a wall
“The Atlantis project was unusually
with tilt-up is faster than traditional
complex because the columns had to be
construction techniques, thereby accel-
As of mid-July 2018, 28 tilt-up pro-
cast with corbels in different positions
erating the overall building process and,
jects had been completed in the coun-
and heights. They also required steel
at the same time, providing exceptional
try’s three major cities. Bedrock’s tally
brackets, which were cast into the
levels of strength and quality.
numbered 18: seven in Cape Town, six in
columns at precise positions for roof
Durban and five in Johannesburg. Other
frame support.”
of the market.
“The other trades can begin work earlier on a tilt-up project, which allows
suppliers accounted for three projects
The construction of Junction Mall,
greater overlapping of project phases.
in Cape Town, five in Johannesburg and
a new shopping centre in Philippi, is a
And, being reinforced, a tilt-up wall is
two in Durban.
good example of the alternate use of col-
better able to withstand the battering
Pegas, a R1,3 billion fabrics manufac-
umns and panels for roof support at the
from forklift trucks and delivery vehicles,”
turing facility in Atlantis, was based on
external elevations. In some sections,
says Kitching.
PRECAST | ISSUE THREE | 2018
PROJECTS
SA’S CONSTRUCTION INDUSTRY TILTS UP
39
CONCRETE ROOF TILES ON THE RISE AT SATARI COUNTRY ESTATE Increasing numbers of concrete tiles are being used to roof private houses and apartment blocks at Satari Country Estate. Located on the outskirts of Somerset West, just off the N2 highway, Satari offers a tranquil countryside setting with schools, shops and other communal conveniences within easy reach. At the time of going to press, CMA member Monier Coverland had supplied its black Elite concrete roof tile for the roofing of approximately 60 houses and four apartment blocks. The houses are being built by UVest in two-to-four bedroom designs and the apartments in one-to-three bedroom layouts. The Elite tiles were installed in combination with doublesided Radiant Shield, yielding a combined R-value of R1,59. Over 90% of the Satari houses built with concrete roof tiles have exposed trusses, a feature in keeping with the rustic environment of this tranquil estate. Danie Hattingh, regional manager of Monier Coverland Cape Town, says that besides their obvious aesthetic attributes, concrete roof tiles offer several other advantages. “They’re one of the most cost-effective roofing materials and are largely maintenance-free. They don’t need painting, nor do they rust. They also have good thermal properties and don’t require as much insulation material as steel roofs do to meet legal thermal roofing requirements.” Monier Coverland has been manufacturing concrete roof tiles for the past 69 years and is part of the BMI Group, the largest manufacturer of flat and pitched roofing systems in Europe.
(Top and above): Pitch-perfect: Monier Coverland’s black Elite concrete roof tiles complement these houses at Satari Country Estate; an apartment block at Satari Country Estate attractively roofed with Monier Coverland’s black Elite concrete roof tiles.
PRECAST | ISSUE THREE | 2018
In one of the largest paving projects to date, the roads in the country’s fourth Industrial Development Zone, Saldanha IDZ, have been surfaced with Concrete Block Paving (CBP).
41
Eight metres wide and 4,3km long, the roads and adjacent sidewalks were paved with 2,2 million concrete block pavers manufactured by Vredenburg-based precast concrete manufacturer, Van Dyk Stene and 11 000m of kerbing produced by associate company, Vredenburg-based Van Dyk Precast. The rationale behind the choice of CBP for this project was that it supports the main driver of the Special Economic Zone (SEZ) programme, namely job creation.
“By contrast, laying CBP required no machinery and could be done by small
(Above): One of the CBP roads at the Saldanha IDZ, which generated jobs and commercial opportunities for the local community.
contractors using local labour. Moreover, Local benefit
all the paving blocks, kerbing and other
responsibility and technical perspective,
“The SEZ aims to stimulate the local
materials required for the construction
and we’re very pleased that the whole
economy through international invest-
of the roads were available locally, includ-
project was contracted locally. The roads
ment. However, the Saldanha IDZ made
ing the materials for the manufacture of
were paved with 80mm interlocking
a strategic decision not to wait for job
the CBP. This meant that the total value
blocks and the pavements with a 50mm
creation through investment alone, but
of the project could be earned by the
rectangular block. These and the kerbing
to kick-start the process during the
local economy, which resulted in a mas-
were manufactured by Van Dyk Precast.
infrastructural development of the es-
sive multiplier effect.
tate,” says Hannes Marais, Executive: Infrastructure & Environmental Planning of the Saldanha IDZ. “We followed an approach which would create as many jobs and local contracting opportunities as possible during the development phase and paving our roads
“Laying CBP required no machinery and could be done by small contractors.”
with CBP was one of the ways we could achieve that objective.”
“We employed two small contractors to do the laying of the pavers. One was a sole provider on this project and today he owns a registered company.” Roadworks “Power Group was the main contractor responsible for the main excavations and the laying of the stormwater and sewer
Maintenance-free
pipes, but was obliged to sub-contract
Marais says he and his colleagues
“The other benefit was that, if laid prop-
certain portions of the work to local small
worked through some design scenarios
erly, CBP is largely maintenance-free and
businesses, including the CBP contrac-
with engineers and using CBP presented
has a longer lifespan than its asphalt
tors. Power built the roads to upper sub-
several advantages.
equivalent. It also offers the opportunity
base level and thereafter smaller local
“Although CBP was only slightly more
of running pipes and cabling under the
contractors handled the side drainage,
expensive initially, our projected lifespan
paved surface post-construction of the
the kerbs, the sidewalks and, of course,
costs were very positive. And in terms
paved surface. This is done by simply
the paving of the roads. It would have
of job creation, asphalt had several dis-
lifting the pavers before digging and then
been easier to give Power the whole
advantages. For starters, only the big
re-laying them, with no visible evidence of
job, but we wanted to create as many
contractors are equipped to handle this
their removal. Asphalt, by contrast, must
opportunities as possible for the local
type of project, which requires very ex-
be dug up and replaced with fresh mate-
community and economy,” says Marais.
pensive plant and equipment. Moreover,
rial – a wasteful process which leaves an
Saldanha was over 120km away from
ugly scar on the road.
the nearest asphalt plant in Contermans Kloof near Cape Town.
PRECAST | ISSUE THREE | 2018
PROJECTS
PRECAST CONCRETE PAVING SPURS ECONOMIC GROWTH IN SALDANHA
“The roads were designed with open V-drains and single cross-fall drainage,
“We believe we took the right deci-
because the area’s very hard calcrete
sion in opting for CBP, both from a social
sub-strata meant we weren’t able to
PROJECTS
justify the installation of sub-surface
vided our lower sub-base construction
drainage. Stormwater runs across the
matched the upper sub-base, our surface
roads and drains into open channels.
tolerances were more than adequate to
“That hard calcrete sub-strata of the Western Cape gave us a unique
42
support the upper layer of bedding sand and paving blocks.
road-building advantage. It meant we
“In the end, our sub-base comprised
didn’t require two sub-grade layers and
two 125mm layers of G5 material im-
three sub-base layers. Rather, we only
ported from one of the local quarries.
needed two supporting layers, a selected
Had we used asphalt, we would have
sub-grade layer and a sub-base layer,
required an additional base of G2 or G1
which saved us a lot. In fact, we were
material, not to mention losing out on
able to dispense with a whole 300mm
numerous job creation opportunities,”
layer of sub-grade. We found that pro-
says Marais.
Precast concrete seating, manufactured and installed by CMA member Concrete Units, has been used in the construction of a new rugby pavilion at the country’s oldest school, Cape Town-based South African College High School (SACS). The school also happens to be the alma mater of Concrete Units manager, Brian Cook.
PRECAST CONCRETE PAVILION SEATING FOR SA’S OLDEST SCHOOL Situated in arguably the country’s most
were challenging and the seats had to
scenic school campus at the foot of Table
be delivered around the perimeter of the
damage to the field,” says Cook. “We also had to take particular care
Mountain and Devil’s Peak, the pavilion
field and then placed from there. This
to get our storage dimensions correct
was designed by Vivid Architects and
situation wasn’t made easier by a wet
in order to minimise any creep that
built by main contractor Brice Construc-
Cape winter and we did our best to man-
might have occurred immediately after
tion. The pavilion houses VIP seating on
age the soggy conditions and minimise
lifting. If the storage positions had been
the upper level and stepped concrete
too wide, the seats would have sagged.
seating below.
Conversely, if they’d been too narrow,
The concrete seating comprises 54
they would have hogged. Each seating
of f-white bench-style units with the
unit was also provided with weep holes
seating and foot support elements cast
for drainage purposes.
as a single unit. Apart from six units
“And given that the seats are on
which were 3,5m long, all the seats
public display, it was important that
measured 5m and weighed 1,6 tonnes
we achieve exceptionally high-quality
each. Actual seating sections were
smooth finishes without any blemishes
100mm thick and had recessed upstands
and we achieved that objective.”
for greater comfort. The seats were installed on an embankment by the Concrete Units instal-
T he s t adium w as r e ad y f or the SACS/Paarl Boys’ High School match in late July.
lation team using a crane mounted on the delivery truck and were attached to in-situ concrete footings built by Brice Construction. “As there was no access from behind the pavilion, offloading and installation
(Above): The Table Mountain plateau and Devil’s Peak (right) form the perfect backdrop for the new rugby pavilion at SACS. (Left, from top): Off-white precast concrete seating benches were used in the construction of a new rugby pavilion at SACS in Cape Town; the seating has high-quality, smooth finishes without blemishes.
PRECAST | ISSUE THREE | 2018
PROJECTS 43
“Parts of the fence were stolen,” says Concrete Units manager Brian Cook, “leaving gaps through which taxis and other vehicles could access Borcherds Quarry Rd illegally, directly off the N2. Moreover, the security of the area was severely compromised and it was these two factors which motivated the Borcherds Quarry CID to invest in a precast concrete security wall. “After various types of wall systems had been explored and priced, we were appointed by the CID to provide a turnkey wall installation. This involved designing the wall, casting its component parts and doing the assembly work ourselves. “The wall comprises a combination of solid pre-stressed panels [5 860mm x 2 400mm x 100mm) mounted between reinforced precast concrete H-section poles that are 3,2m high. We began construction in June at a rate of two slabs and three poles a day and the wall was completed by the end of September. “The panels were pre-stressed and we had to take particular care to ensure that the pre-stressed steel wire was precisely positioned dead-centre to avoid
N2 SECURITY WALL CONSTRUCTED WITH PRECAST CONCRETE A solid precast concrete wall has been constructed by CMA member, Concrete Units, for the Borcherds Quarry Community Improvement District (CID) close to Cape Town International Airport and a stone’s throw from various informal townships across the N2. Six hundred and
any ‘banana’ bending of the panels. Our production schedule meant that panels had to be removed from the moulds every
barrier between the Borcherds Quarry industrial area and the N2 highway.
second day, and this required a concrete
upright position until they were mounted
The poles were then plumbed with a spirit
which delivered high early strengths and
as part of the wall.
level and we used a long bar to measure
“The concrete poles were normally
the correct distance between the con-
reinforced and mounted in a square me-
crete footing and the top of the poles,”
“Before the panels were removed
tre concrete footing 850mm deep. All
says Cook.
from the moulds, the latter were tilted
the holes were dug by hand and we gave
to a vertical position. This was done
the foundation a 50mm blinding layer to
(Top left): A recently completed section of the wall.
because the panels weren’t thick enough
provide a working surface. Wooden planks
to sustain horizontal lif ting. Af ter
were used to align the flat face and give
demoulding, the panels were kept in an
us a centre line for mounting purposes.
(Above, from top): A precast panel is lowered into position by a mobile crane during construction of the wall; members of the Concrete Units wall construction team during preparation of a pole foundation.
a final strength of 55-60MPa to prevent wire slippage.
PRECAST | ISSUE THREE | 2018
MEMBER LIST 44
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 BANZI TRADE 31 (PTY) LTD T/A BRICKIT TEL: (011) 023 6708 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BETA TILES (PVT) LTD TEL: (263) 433 3735 PROVINCE/COUNTRY: ZIM PILLAR: PB BOSUN BRICK BRITS (PTY) LTD TEL: (012) 250 1711 PROVINCE/COUNTRY: NW PILLAR: PB/PI BOSUN BRICK MIDRAND (PTY) LTD TEL: (011) 310 1176 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BOSUN BRICK PORT ELIZABETH (PTY) LTD TEL: (041) 405 0100 PROVINCE/COUNTRY: EC PILLAR: PB/PI C.E.L. PAVING PRODUCTS (PTY) LTD TEL: (021) 905 5998 PROVINCE/COUNTRY: WC PILLAR: PI CEM BRICK MANUFACTURERS (PTY) LTD TEL: (051) 433 4479 PROVINCE/COUNTRY: FREE STATE PILLAR: PB/PI CEMBLOCKS (PTY) LTD TEL: (014) 538 0311 PROVINCE/COUNTRY: NW PILLAR: PB/PI CIVILWORKS (PTY) LTD REAL TIME INVESTMENTS TEL: (011) 903 7023 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CONCRETE UNITS (PTY) LTD TEL: (021) 386 1923 PROVINCE/COUNTRY: WC PILLAR: PB/PI CONCRETE UNITS (PTY) LTD TEL: (016) 362 2236 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CONFRAMAT (PTY) LTD TEL: (0861) 33 5599 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CORESLAB (PTY) LTD TEL: (087) 232 2462 PROVINCE/COUNTRY: LIMPOPO PILLAR: PB/PI COROBRIK (PTY) LTD TEL: (031) 560 3111 PROVINCE/COUNTRY: KZN PILLAR: PI DERANCO PRECAST (PTY) LTD TEL: (041) 463 3338 PROVINCE/COUNTRY: EC PILLAR: PB/PI EAGLE ROOF TILES (PTY) LTD TEL: (044) 874 0290 PROVINCE/COUNTRY: WC PILLAR: PB ECHO FLOORS (PTY) LTD TEL: (011) 668 1900
PROVINCE/COUNTRY: GAUT PILLAR: PB ECHO PRESTRESS (PTY) LTD TEL: (011) 589 8800/8899 PROVINCE/COUNTRY: GAUT PILLAR: PB ECHO PRESTRESS DURBAN (PTY) LTD TEL: (032) 947 3067 PROVINCE/COUNTRY: KZN PILLAR: PB ENVIRO-CAST (PTY) LTD TEL: (016) 004 0018 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI HORIZON BRICK & CONCRETE TEL: (012) 934 3701 PROVINCE/COUNTRY: NW PILLAR: PB KEYSTONE WALLING CC TEL: 082 850 3512 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI LATEGAN CEMENT WORKS (PTY) LTD TEL: (021) 873 1154 PROVINCE/COUNTRY: WC PILLAR: PB/PI MARLEY ROOFING (PTY) LTD TEL: (011) 316 2121 PROVINCE/COUNTRY: GAUT PILLAR: PB
TECHNICRETE (PTY) LTD TEL: (011) 672 1425/670 7600 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI TOPFLOOR CONCRETE (PTY) LTD TEL: (021) 951 7700 PROVINCE/COUNTRY: WC PILLAR: PB VANSTONE PRECAST (PTY) LTD TEL: (012) 541 2056/1808 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI
CIVILPRO ENGINEERING SOLUTIONS (PT Y) LTD TEL: 083 226 2567 PROVINCE/COUNTRY: JHB
ZITTLAU EIENDOMME (PT Y) LTD T/A SHUKUMA FLOORING SYSTEMS TEL: (041) 372 1933 PROVINCE/COUNTRY: EC PILLAR: PB NON-PRODUCER MEMBERS ABEL EQUIPMENT CC TEL: (044) 874 1876 PROVINCE/COUNTRY: EC
BIRKENMAYER H (PT Y) LTD TEL: (011) 970 3880 PROVINCE/COUNTRY: GAUT
MVA BRICKS CC TEL: (012) 386 0050 PROVINCE/COUNTRY: GAUT PILLAR: PI
CHRYSO SOUTHERN AFRICA (PT Y) LTD TEL: (011) 395 9700/ (031) 564 0325/(021) 928 1660 PROVINCE/COUNTRY: GAUT/ KZN/ WC
PANDA (PTY) LTD TEL: (00267) 244 2107/8 PROVINCE/COUNTRY: BOTS PILLAR: PB/PI
DECCAN DIE CASTINGS (PVT) LTD TEL: 91 80 28524121 PROVINCE/COUNTRY: INDIA
ROCLA (PTY) LTD TEL: (011) 670 7600/7634 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI SHUKUMA BRICKS (PTY) LTD TEL: (041) 372 1013 PROVINCE/COUNTRY: EC PILLAR: PB SILVERTON PRECAST (PTY) LTD TEL: (012) 804 4525 PROVINCE/COUNTRY: GAUT PILLAR: PI SMARTSTONE (PTY) LTD TEL: (011) 310 1161 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI SOUTHERN PIPELINE CONTRACTORS (PTY) LTD TEL: (011) 914 8500 PROVINCE/COUNTRY: GAUT PILLAR: PI
ASPASA TEL: (011) 791 3327 PROVINCE/COUNTRY: JHB
WEST END CEMENT BRICKS (PT Y) LTD TEL: (011) 851 1005 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI
MONIER COVERLAND (PTY) LTD TEL: (011) 222 7300/7334 PROVINCE/COUNTRY: GAUT PILLAR: PB
REVELSTONE (CAPE) (PTY) LTD TEL: (0861) 173 835/(021) 761 9737 PROVINCE/COUNTRY: WC PILLAR: PI
AF CONSULTING ENGINEERS & ASSOCIATES (PT Y) LTD TEL: (079) 245 0900 PROVINCE/COUNTRY: GAUT
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ASSOCIATE MEMBERS
VIBRO BRICKS & PAVING (PTY) LTD TEL: (012) 374 5533 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI
MOBICAST (PTY) LTD TEL: 086 111 2346 PROVINCE/COUNTRY: WC PILLAR: PB/PI
PORTLAND HOLLOWCORE SLABS (PTY) LTD TEL: (021) 972 1111 PROVINCE/COUNTRY: WC PILLAR: PI
TERRAFORCE (PT Y) LTD TEL: (021) 465 1907 PROVINCE/COUNTRY: WC
DICK KING LAB SUPPLIES (PT Y) LTD TEL: (011) 499 9400/ (031) 700 2551 PROVINCE/COUNTRY: GAUT/ DBN FIBERTEX SOUTH AFRICA (PT Y) LTD TEL: (031) 736 7100 PROVINCE/COUNTRY: KZN HAWKEYEPEDERSHAAB TEL: 00 459645 4193 PROVINCE/COUNTRY: DENMARK KERNEOS SOUTH AFRICA (PT Y) LTD TEL: (011) 444 3090 PROVINCE/COUNTRY: GAUT KOBRA MOULDS B.V. TEL: 003111 356 2460 PROVINCE/COUNTRY: NETHERLANDS MANITOU SA (PT Y) LTD TEL: (011) 975 7770 PROVINCE/COUNTRY: JHB PAN MIXERS SA (PT Y) LTD TEL: (011) 578 8700/8600 PROVINCE/COUNTRY: JHB
CONCRETE SOCIET Y OF SOUTHERN AFRICA TEL: (012) 348 5305 PROVINCE/COUNTRY: PTA CPI CONCRETE PLANT INTERNATIONAL TEL: (02236) 962390 PROVINCE/COUNTRY: GERMANY ILIFA AFRICA ENGINEERS (PT Y) LTD TEL: (012) 362 1473 PROVINCE/COUNTRY: PTA JC PAVING CONSULTING TEL: (011) 431 0727 PROVINCE/COUNTRY: JHB SARMA TEL: (011) 315 0300 PROVINCE/COUNTRY: JHB SEKHUKHUNE & ASSOCIATES TEL: (012) 346 1945 PROVINCE/COUNTRY: PTA TACO VOOGT CONSULTING ENGINEER TEL: (012) 669 0125 PROVINCE/COUNTRY: PTA YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS TEL: (031) 207 7252 PROVINCE/COUNTRY: KZN CONTRACTOR MEMBERS BUFFALO RETAINING WALLS CC TEL: (016) 366 1801 PROVINCE/COUNTRY: GAUT DECORTON RETAINING SYSTEMS (PT Y) LTD TEL: (021) 875 5155 PROVINCE/COUNTRY: WC FRICTION RETAINING STRUCTURES (PT Y) LTD TEL: (011) 608 4321 PROVINCE/COUNTRY: GAUT POWERGATE CONSTRUCTION CC TEL: 071 603 5070 PROVINCE/COUNTRY: GAUT VALCAL INTERNATIONAL EXPORT CC TEL: (011) 867 2471 PROVINCE/COUNTRY: GAUT CEMENT MEMBERS
QUANGONG MACHINES CO LTD TEL: +865 958 679 9557 PROVINCE/COUNTRY: CHINA
AFRISAM SOUTH AFRICA (PT Y) LTD TEL: (011) 670 5500/5752/5972 PROVINCE/COUNTRY: GAUT
SIKA SOUTH AFRICA (PT Y) LTD TEL: (031) 792 6500 PROVINCE/COUNTRY: KZN
PPC LTD TEL: (011) 386 9000/9091/626 3150 PROVINCE/COUNTRY: GAUT
TECHMATIK S.A. TEL: (0048) 608 422 300 PROVINCE/COUNTRY: POLAND
SEPHAKU CEMENT (PT Y) LTD TEL: (012) 684 6300 PROVINCE/COUNTRY: GAUT
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 THREE | 2018