ISSUE THREE • 2019
R49,00
THE VOICE OF THE PRECAST CONCRETE INDUSTRY
• Robotics growing the industry • Recycled concrete deserves recognition • Extraordinary precast products
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CONTENTS
COVER STORY
COMPANY NEWS
2 ROBOTICS GROWING THE ROOF TILE INDUSTRY
INDUSTRY NEWS 5
SA CEMENT PRODUCERS APPLY FOR PROTECTION AGAINST IMPORTS
28
16
6
19 MARKETING PRECAST PRODUCTS
29 CAMBRIDGE UNIVERSIT Y RESEARCHES SELF-HEALING CONCRETE
20 REVELSTONE GEARED FOR GROWTH
31 REBEL WITH A CAUSE: HOW SEEKING PERFECTION PAYS
21 PRECAST SANITATION UNITS FOR MPUMALANGA PRIMARY SCHOOL
34 PRECAST IN BOUTIQUE WINERY CONSTRUCTION
9
REACHING OUT ON SOCIAL MEDIA
GLOBAL VIEW
9
CMA HOSTS FIRST ECSAACCREDITED WORKSHOP
22 US PICP CONFERENCE ADVICE: DON’T INSTALL IF YOU CAN’T MAINTAIN
10 STANDARDS, CERTIFICATION AND ACCREDITATION 11 RECYCLED CONCRETE DESERVES OFFICIAL RECOGNITION
PROJECTS
TECHNICAL 23 QUALIT Y FROM THE BEGINNING
37
24 REDUCING RISKS OF HANDLING CEMENT
13 WORLD PREMIÈRE OF CON-TEXTURES SCULPTURE
PRODUCTS
26
14 NEW ADMIXTURE PROVIDES LASTING SEWER PROTECTION 15 EXTRAORDINARY PRECAST PRODUCTS
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 Media Address: 10th floor, Metalbox building, 25 Owl Street, Milpark, South Africa Tel: (+27 11) 883 4627 Fax: (+27 11) 783 2677 Website: www.isikhova.co.za Publisher: Imraan Mahomed Tel: (+27 11) 883 4627 E-mail: imraanm@isikhova.co.za Consulting editor: Raymond Campling Tel: 076 297 2775 E-mail: media@mediasavvy.biz
PRECAST | ISSUE THREE | 2019
39 REHABILITATION OF PARKTOWN STORMWATER SYSTEM 39 PRECAST SPECIFIED FOR ATTENUATION POND 40 MEMBER LIST
Coastal editorial: David Beer Tel: 082 880 6726 E-mail: david.bigsky@gmail.com
ISSUE THREE • 2019
R49,00
THE VOICE OF THE PRECAST CONCRETE INDUSTRY
Subscriptions/Accounts/ Advertising: Thuli Majola Tel: (+27 11) 883 4627 E-mail: thuli@isikhova.co.za Design and layout: Joanne Brook E-mail: joanne@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© 2019. 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:
ON THE COVER Robotics an
are
increasingly
playing impor-
• Robotics growing the industry • Recycled concrete deserves recognition • Extraordinary precast products
tant role in assisting manufacturers to reach ultra-high production speeds with higher-quality products and less wastage. At the forefront of this technology is a company that has been perfecting roof tile manufacturing plants for the past 100 years, ABECE. The Swedish equipment manufacturer is a world leader in producing plants that are approaching nearly 100% efficiency in terms of material usage, reduced waste and high-speed manufacturing.
1
COVER STORY 2
At the forefront of this technology is a company that has been perfecting roof tile manufacturing plants for the past 100 years, ABECE. The Swedish equipment manufacturer is a world leader in producing ultra-high efficiency plants that are approaching nearly 100% efficiency in terms of material usage, reduced waste and high-speed manufacturing. In South Africa the ABECE range of plants is distributed and supported by
ROBOTICS GROWING Robotics are playing an increasingly important role in assisting manufacturers to reach ultra-high production speeds with higher-quality products and less wastage.
overhangs or push marks and leads to less rejects and damages. Tight tolerances After the dual servo knife cuts the tile on the pallet at an exact length it moves to the racking station where it is stacked
the country’s own technology leader,
before being moved to the zero zone
PMSA (non-producer member of the
for acclimatisation and automatically
Concrete Manufacturers Association
transported into the hottest part of the
– CMA), a company which holds similar
curing room.
values and standards as its overseas
Even the high precision automated
counterpart. Over the past decade the
racking system is built for speed with
partnership has driven the brand to be-
specialised wheels for faster, more reli-
come a firm favourite in southern Africa
able movement and less jamming. The
with plants operational throughout South
ABECE racking and de-racking systems
Africa and the sub-Saharan Africa region.
are designed to be the most efficient in the world with hundreds of features built
Blink-of-an-eye
into the system to enable high levels of
PMSA marketing and sales manager,
automation. Precise and minimalistic
Quintin Booysen, says the move to
movement results in less jamming and
automation in all, or some, of the opera-
smoother operation.
tions in a plant is a necessity in order to reach and maintain high volume produc-
Curing efficiently for energy saving
tion. ABECE’s modern plants have all the
The process of curing can be from 7
necessary technology to mix and extrude
into place for extrusion of the tile upper
hours to 24 hours depending on the ce-
high quality concrete, but the real need
surface on a high speed ABECE extruder.
ment content of the tile. Once again, for
for speed mostly takes place after the
The next step of automation starts
extrusion process.
at the servo knife which has both verti-
He explains the process, is mainly too
cal and horizontal movements operated
quick for the eye to see. “To maintain
by servos with no pneumatics on either
production at 140 tiles per minute our
knife for absolute precision and accuracy.
equipment prepares the pallets with a
With closer tolerances the system eas-
micro-quantity of oil which is brushed
ily saves one percent of the concrete
on at just the right quantity for an even
used per tile through cutting off excess
spread.
material to make a perfect tile length,
The ABECE plants are a wonder to see
the excess material is returned to the
in operation. After batching and mixing
extruder to make tiles and reduce any
of concrete the pallet is rapidly moved
waste. Exact dimensions ensures no
PRECAST | ISSUE THREE | 2019
COVER STORY 3
G THE ROOF TILE INDUSTRY speed of production, the racking systems
cycle in a highly automated plant and the
the extruders and servo knives, to the
are efficient and carefully designed to
precision of manufacture, movement and
racking, curing, packing and conveyor sys-
gently handle tiles and reduce damage
handling means that there are hardly any
tems. Nowadays, operators and produc-
when curing.
quality defects and almost zero defects,”
tion controllers can get all the information
says Quintin.
that they need at a glance on screen or
The manufacturer’s innovation extends to curing with an approach that
even via a mobile device in certain instanc-
ensures less energy and effort is taken
Postproduction
es. The operations can then be modified
in the even curing of the tiles. By enclos-
Quintin explains that after curing, de-
and controlled as required, including line
ing the entire curing chamber, the right
pending on requirements for either top-
speed adjustments, power consumption,
environment is created for curing with
coat or through colour tile, it may need
plant parameters and alarms.
no heat losses due to constantly opening
further processing. Here it will either
doors during the loading period.
go to a rotary dryer for top-coated tiles
control stations including:
or straight to packing wherever colour
1. Extruder, knife and conveyor system.
through tiles are manufactured.
2. Racking and Hotbox curing chamber
“The ABECE plants make use of a Hotbox approach that encloses the
Post extrusion, the HMI’s typically
entire plant and uses the heat of hydra-
Robotic packing systems work faster
with capabilities to show quantity of rack
tion to cure the concrete more energy
and more precisely with no scratch
and tiles in the chamber and even col
efficiently. After curing the roof tiles
marks or chipping and less damages.
our of tiles in certain racks if specified.
are de-racked and separated from the
The robots are also able to maintain
3. Packing station (or backend) controls
aluminium or steel pallet. To minimise
production outputs around the clock for
including the rotary drier, loaders and
cement and additional energy for heat-
365 days per year. Depending on require-
up to six robotic packers, as well as
ing, this entire process of curing ideally
ments the ABECE plants offer a choice
the transport conveyors to the fork-
takes 24-hours for an efficient curing
of either a single loader with the ability
lifts in the yard.
“The ABECE plants make use of a hotbox approach that encloses the entire plant.”
to load tiles into packs of 10 at up to
HMI systems also allows pinpoint iden-
70 tiles per minute, or a twin loader for
tification of faults and allows users to find
up to 140 tiles per minute. In instances
root causes of faults down to individual
where clients require smaller packages
sensors. In addition, it provides a visual
for easier onsite handling, the robots can
picture of each section of the produc-
also split tiles into packs of 5.
tion line with visual representations of
Apart from higher speed and flexibility,
Fortunately for owners of existing
products and package them accordingly
plants, each and every section can be
when packaging them onto wooden
addressed separately and can be added
transport pallets.
to existing plants as required.
Human Man Interface (HMI) Through HMI’s all the features of the plant are available through the touch of a button. HMI’s provide a quick interface with the machinery and control everything from
PRECAST | ISSUE THREE | 2019
each process.
the robots are also able to identif y
(Top, from left): Up to six robots can work together in packing; robot small pack; twin loader and robot packing onto wooden transport pallets. (Left): M32 extruder and double knife. (Far left, from top): HMI overview and interface with the plant; HMI view of Hotbox curing room.
INDUSTRY NEWS
SA CEMENT PRODUCERS APPLY FOR PROTECTION AGAINST IMPORTS On behalf of the South African cement producers, The Concrete Institute (TCI)
5
has applied to the International Trade Administration Commission (ITAC) of SA to investigate the surge of imports of low-priced cement. TCI has lodged the application on behalf of AfriSam, Dangote Cement SA, Lafarge Industries SA, Natal Portland Cement Company and PPC. Bryan Perrie, TCI MD, says imported cement is undercutting the industry by at least 45%. When this is combined with unprecedented low levels of demand due to slowed economic growth, the industry is faced with a survival crisis
In addition to the surge in low-priced
which thr eatens to undermine the
imports, a “carbon tax” was introduced in
industrial capacity of the country. “The
June 2019 on the South African cement
• Total imports increased by 139%
cement industry has no option but to
industry’s activities that has increased
request the ITAC to conduct a safeguard
the industry’s production cost. The effect
• Employment in the industry increased
investigation to determine whether the
of this tax translates to a 2% increase
• Imports have exceeded exports by over 50 000 tons during the past year. since 2016. by less than 0,5%.
cement industry requires
in selling prices, putting
• SA represents roughly 1% of total
protection from the surge
the local cement industry
exports from Vietnam, for example,
in imports,” he says.
at a further disadvantage
where exports have increased by 50%
against imports.
in the first half of 2018 to 15 million
tons, according to information pro-
vided by Global Cement.
Net importer Perrie says SA has become
High quality
a net importer of cement
Local pricing reflects the
Perrie believes the South African
with total imports increas-
standards (technical, so-
economy is at a crossroads where trade
ing by 139% since 2016,
cial and environmental)
policy determinations will play a critical
which makes trade remedy
that have been determined
role in determining the industrial direc-
protection vital to ensure
by SA as necessary for lo-
tion of the country. “The key to future
the viability of the cement
cal manufacturing. South
growth lies in achieving greater efficien-
industry. “Local produc-
African cement manufac-
cies within the country’s relevant manu-
ers have the capacity to
turing processes are regu-
facturing sectors. The cement industry
meet the Southern African
lated, from environmental
must compete on a level playing field and
Customs Union’s industrial demand and
impact assessments to strict quality
not be scrambling to survive against
must protect employment, broad-based
controls and from labour and employment
low-priced imports. The sector needs
black economic empowerment [B-BEEE]
regulations to sustainability require-
space to grow, which a successful ITAC
investments and environmental social
ments, and the country is a signatory of
application would provide,” he says.
and governance [ESG] requirements. The
the Paris Accord on CO2 emissions. In support of the application, TCI has
South African cement industry needs to compete on a level playing field and not
outlined that:
against a surge of low-priced imports,”
• A total of 350 441 tons of cement
he declares.
arrived in SA during the second
“The South African cement industry is
quarter of 2019 – the most since the
very competitive. The cement, concrete
third quarter of 2015.
and affiliated industries employ thousands
• Most of the cement landed at Durban.
of South Africans whose jobs would be
The 260 909 tons that arrived there
on the line if local cement production
are an 85% increase on the first
weren’t protected. Importantly, several
quarter of this year.
pr oducers have signif icant B-BBEE
• Im p o r t s f r o m V i e t n am t o t a l l e d
investments which are at stake.”
PRECAST | ISSUE THREE | 2019
301 872 tons.
“The cement, concrete and affiliated industries employ thousands of South Africans.” (Above left): The South African cement industry must compete on a level playing field and not be scrambling to survive against low-priced imports, urges Bryan Perrie, MD of TCI.
INDUSTRY NEWS
This article is meant as a challenge to housing authorities, developers and architects to revisit the past successes of concrete block modular masonry with a view to the positive impact its reintroduction would make in alleviating the housing backlog.
6
Concrete block modular masonry is a long-standing, internationally proven system which can do much to alleviate SA’s housing shortage. It was first specified by the local authorities in the late 1970s and early ’80s in the Western Cape, where it is still being used with great success. However, genuine concrete block modular masonry is rarely practised in other parts of the country these days and its reintroduction will require a reappraisal on the par t of the authorities and construction industry. When f ir st intr oduced to SA by C o l um b i a D C M i n 197 8, c o n c r e t e block modular masonry was based on European and American standards and was subsequentl y SA BS-appr oved. The system is similar to Lego in that a complete range of complementary blocks, such as corners, half, quarter and lintel units are supplied, in addition
and material incurred through chopping
GENUINE CONCRETE BLOCK MODULAR MASONRY: BETTER QUALITY, LESS COST
straight blocks to size, productivity is
system for building 35 000 economic
can top 18 (approx 65m²) houses a day
greatly improved.
houses in Mitchell’s Plain. Two other
during favourable summer months and
Independent masonry consultant
construction companies participated in
12 units a day during the rainy season.
Günter Koch says there were some
the development of Mitchell’s Plain and
notable modular masonry successes
the houses were built efficiently and on
New focus
in the early days of large-scale housing
time. A major initiative in the Western
“As things stand currently in the other
delivery. The City of Cape Town, for
Cape involved the training of novices and
provinces, many housing authorities,
instance, issued Columbia DBL with a
retraining of bricklayers in modular block
architects and specifiers appear to
contract to supply the full modular block
construction and many of today’s highly
have lost sight of modular masonry’s
skilled and ef ficient sub-contractors
economic and quality advantages
were recipients of that training.
and therefore don’t specif y its full
to the standar d modular 400mm straight blocks. Economical solution Properly executed, modular construction i s m o r e e c o n o m i c a l t h a n im p e r i a l masonry. By eliminating wasted time
Thousands of modular block houses
implementation, ie the incorporation of
have been built in Mitchell’s Plain and
complementary masonry units in their
other ar eas in the Western C ape.
designs and specifications. As a result,
Koch observes that the rate of housing
most concrete block manufacturers in
delivery using modular block construction
these provinces have abandoned the production of complementary modular
(Above): A first course of modular masonry using hollow masonry blocks measuring 390 x 190 x 140mm is carefully laid out on damp course sheeting. (Left): A modular masonry house under construction at Kleinmond. Note the angled roof blocks.
masonry products and, instead, are only producing straight blocks,” says Koch. “S h o u l d g e n u i n e m o d u l a r b l o c k construction enjoy a revival in the rest
PRECAST | ISSUE THREE | 2019
with precise block layouts.
after time, the advantages of repetition
there’s a pool of experienced modular
“The benefits of detailed building
block-layers and modular block building
plans are obvious. In the first instance,
“The modular approach is ideally suited
inspectors who could motivate and assist
wastage is minimised by reducing the
to major housing initiatives. The CMA has
in training SME builders to adhere to
need for odd-sized blocks, which is so
detailed modular construction plans on
the correct building procedures. What’s
prevalent in the non-modular approach.
file together with schedules and other
more, the acquisition of modular block
Furthermore, by following a disciplined
information and there are many large-
building skills would provide a spur to the
and identical building procedure time
scale examples of successful modular
establishment and empowerment of small self-help modular, construction-based business enterprises. “Ultimately, national and local authorities should insist on the implementation of proper full-scale modular construction not only at the design and tender process stages, but during the building process
“The modular approach is ideally suited to major housing initiatives.”
and mass production come into play.
masonry in the Western Cape and other parts of the country. In addition, we have leaflets and other written material which provide for and aid the design and application of modular masonry. This is available both online and in hard-copy format,” says Cockcroft. “ T he r apid ur b anisa tion o f S A’s
through their own inspectors and with
population is placing huge demands on
the assistance of NHBRC inspectors.
housing delivery and the reintroduction
Productivity would increase, wastage
of full and proper modular block
would be eliminated and, most impor-
construction would greatly assist in this
tantly, the quality of the finished product
process. But it won’t happen without
would be vastly improved,” adds Koch.
the lead from local government officials and mass housing contractors with the
Correct way
necessary initiative, drive and discipline
Henry Cockcroft, general manager of the
required for a successful outcome.”
Concrete Manufacturers Association NBC (CMA ), says modular masonry hinges on the provision of and adherence to detailed building plans and schedules
WHETHER BUILDING A BOX OR A ROOM ... we have a concrete solution for you!
(Left): A modular masonry house under construction at Kleinmond. Note the L-shaped corner block.
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INDUSTRY NEWS
of the country, the good news is that
7
As CMA members are probably aware,
precast concrete information. It’s a
successful project deliverance using
the association has embarked on a digital
go-to precast portal.”
quality precast concrete.
marketing strategy consisting of new and
Cockcrof t adds that the CMA is
“Due to the ease of this kind of col-
fresh Facebook and LinkedIn content,
constantly looking for ways to pro-
laboration and its advantages, we view
together with exciting new pages that
mote precast concrete as a preferred
this as a massive benefit to anyone
were added to the CMA website.
building medium, but this is impossible
who’d like to participate in this exercise.
CMA general manager Henry Cockcroft
In brief: the wider we cast the net, the
says the social media strategy has been
more advantage it will hold for precast
enjoying frequent engagement, with the
producers, architects, engineers, QS,
new website pages also gaining a lot of
specifiers, contractors and clients alike.
traction regarding site visitors.
“We need your contribution to cre-
“Although we’ve attained satisfactory
ate a valuable resource for our industry
results over the past few months with
and ask you visit our pages. By doing so,
the implementation of the digital strat-
you’ll automatically receive notification
egy, there’s still a void. We’d therefore
of all information disseminated by the
like to invite you to join us in this journey
CMA,” says Cockcroft.
and become part of it,” he says.
See the links below:
“There’s a big need for the distribu-
• LinkedIn – https://www.linkedin.com/
tion of easily digestible precast concrete
company/cmasa/
information, good practice guidelines
without involvement from the busi-
• Facebook – https://www.facebook.com/
and industry-relevant news. The nature
ness sector, corporate and private
of this information being posted will
professionals. “If we have that involve-
• Precast-Need-To-Know – http://www.
benefit each follower of and contribu-
ment, benefits will be delivered to our
cma.or g.za / Home / Pr ecast-Need-
tor to our Facebook page and LinkedIn
members. More than that, we’ll be
To-Know
company page, not to mention our new
creating a valuable resource for built
Hit the Like and Follow buttons to
website pages, which were specially
environment professionals in terms of
become part of the journey on Facebook
designed to provide clean and concise
an information portal which secures
and LinkedIn.
cmanpc/
CMA HOSTS FIRST ECSA-ACCREDITED WORKSHOP The Concrete Manufacturers Association
“We’re planning similar types of work-
held its first Engineering Council of SA-
shops around the country and aim to
accredited course at Emperors Palace
address areas where precast concrete
in Kempton Park recently.
is either being incorrectly used, or where
T he Concrete Pipes, Manholes &
opportunities exist to promote precast
Culverts – Design and Installation Work-
concrete over other construction tech-
shop, presented by well-known industry
niques,” says Henry Cockcroft, GM of
specialist, Alaster Goynes, was held
the CMA.
in conjunction with producer members
PRECAST | ISSUE THREE | 2019
This type of course is used to:
and was aimed at role-players in the
• Sharpen skills.
development of stormwater and related
• Reaffirm current knowledge.
infrastructure, as well as contractors.
• Clear design and installation uncer-
For the first time, Continued Professional
Development (CPD) points were allocated
• Guarantee better service delivery and
to delegates who attended.
tainties with regard to the technology. project completion.
INDUSTRY NEWS
REACHING OUT ON SOCIAL MEDIA
9
INDUSTRY NEWS 10
STANDARDS, CERTIFICATION AND ACCREDITATION While most construction professionals
by the South African National Accredita-
understand that standards are essential
tion System [SANAS] to certify precast
quality-markers, not many could claim
concrete products. Precast concrete
absolute clarity on how they are estab-
can’t be accredited, as some tender
lished, applied and maintained.
documents imply they can.”
C M A’s g e n e r a l m a n a g e r, H e n r y Cockcroft, set about filling in the gaps and
Clarity sought
clearing up misconceptions on standards
Cockcroft explained the process of how
and their relationship to certification and
standards are established in SA. He
However, once the lengthy drafting and
accreditation during a presentation at the
also cleared up another misconception,
approval process is completed, stand-
Cape Concrete exhibition in September.
namely, in whose name a standard is held.
ards are submitted to the DTI for sign-off
Cockcroft took a break from manning the CMA stand to deliver his presentation to delegates comprised largely of construction professionals. He explained that standards are of no benefit unless they are certified. Likewise, certification cannot take place unless officially recognised standards which specif y materials, quantities, safety and testing procedures are in place.
“There’s a strong correlation between quality management systems and the consistent supply of high-quality product.”
by the relevant minister.” There are currently 16 precast concrete product categories which carry a SANS specification and, like CMACS, the SABS is the other body accredited by SANAS to certify precast concrete units complying to these specifications. Details of SA’s precast concrete standards, as well as all CMACS permit-holders, can be viewed on the CMA website.
Certification required
Quality first
He observed that certification is often
Cockcroft also outlined the central role
confused with accreditation. Simply put,
played by quality management systems in
certification is product-related and, if
meeting national standards and certifica-
successful, verifies that a product has
tion requirements. He sketched the audit
met all the specifications of a national standard.
process producers must undergo before Some still believe that the SA Bureau of
gaining certification for their products.
“Some manufacturers sometimes
Standards (SABS) is the custodian of
“There’s a strong correlation between
state that their products are accred-
SA’s standards, whereas it is the De-
quality management systems and the
ited, which is a meaningless claim,” said
partment of Trade & Industry (DTI) which
consistent supply of high-quality prod-
Cockcroft. “Products can only be certi-
fulfils this role.
uct. Producers which adhere to qual-
“The SABS is simply a service pro-
ity management systems enjoy greater
“Accreditation is function-related,
vider. It plays a facilitating role in the
customer loyalty and are generally more
recognising that someone or an organi-
establishment of new standards and the
competitive and profitable,” he said.
sation is qualified to perform a certain
modification of existing standards and
function. For example, the CMA’s Certi-
participates in workgroups comprised
fication Services [CMACS] is accredited
of related producers and professionals.
fied, not accredited.
(Top, from left): Henry Cockcroft, general manager of the CMA, addresses delegates at Cape Concrete and the CMA stand at Cape Concrete.
PRECAST | ISSUE THREE | 2019
INDUSTRY NEWS
Several CMA producer members are using recycled (or, more appropriately, repurposed) aggregates to produce various concrete products – such as bricks and blocks at quality levels equal to the same products made with natural aggregates. Notwithstanding repurposed aggre-
11
gates’ ecological benefits, their use is thus far neither recognised nor encouraged by local authorities such as carbon or mining credits. By contrast, in most of the developed world they are not only acknowledged, but mandatory. “Official recognition of repurposed aggregates and the impor tant role they play in sustainable construction is long overdue,” says CMA general manager Henry Cockcroft. “This is why repurposed aggregates form part of a review being undertaken by SABS and the CMA on the SA National Standard for aggregates.” Care required Sourcing natural aggregate from quarries is considered harmful to the environment in North America, while in Europe, up to 90% of aggregates must be sourced from repurposed aggregates. Even in SA, a complete environmental plan must be submitted and approved before a new quarry can be established.
RECYCLED CONCRETE DESERVES OFFICIAL RECOGNITION who use repurposed aggregates are
requirements for ABT qualification.
“Repurposed aggregate is prepared
more competitive, without any loss in
“B u i l d i n g p r o d u c t s w h i c h h a v e
in precisely the same way as natural
quality. This offers very positive socio-
acquired ABT status are sometimes
aggregate. It’s crushed, screened and
economic spin-of fs, especially in the
more expensive than conventional blocks
graded according to size and stockpiled.
entry-level housing market, where a
and bricks.
Moreover, it’s subject to exactly the same
greater number of houses can be built
quality standards as natural aggregate-
with repurposed bricks and blocks.
based products,” comments Cockcroft. Natural aggregates must be mined using a variety of tools and equipment, and then processed. This approach can be very harmful to the environment, hence the implementation of certain mining and carbon taxes. By contrast, r epurposed aggr egates come f r om existing building material, allowing the conservation of natural resources and eliminating the need for dumping and
“ F o r e x a m p l e , a n A B T- c e r t i f i e d
aggregates earning carbon and mining
building block made with a lightweight
“What we’d like to see are repurposed aggregates earning carbon and mining credits.”
landfill space – a recognised problem in Cape Town and others metros.
Status required
“What we’d like to see are repurposed
material was recently used on a lowcost building pr oject in Cape Town at a price considerably higher than conventional building blocks. Moreover, it had to be transported all the way f r o m J o h a n n e sb u r g, a t a d d i t i o n a l substantial cost to the authorities and the environment. Had a repurposed block been specified on this project, more houses could have been built.
credits. In addition, we believe they
“We feel that repurposed aggregates
should also be recognised by metros
should qualify for ABT status because
Rising prices
as an alternative building technologies
they’re genuinely eco-friendly. There
“Over the past five years, the price of
[ ABT ] material. ABT is used by the
should also be a certification process for
natural stone aggregate has risen by up
authorities to promote, among other
their use and they should be specified in
to 25% and this is reflected in the price of
things, a more environmentally friendly
tender documents,” says Cockcroft.
natural aggregate-based end products.
and progressive way of building, although
However, precast concrete producers
ther e’s still uncer tainty about the
PRECAST | ISSUE THREE | 2019
(Above): Repurposed aggregate.
9 9 5 R d mende Recom ing VAT d lu c n i price
WORLD PREMIÈRE OF CON-TEXTURES SCULPTURE The world’s first large-format carbon concrete sculpture, CON-
TEXTURES, was unveiled in November last year at one of the most important European textile events, the Aachen-DresdenDenkendorf International Textile Conference (ADD-ITC). It consists of two textile concrete shells, each 2,4m high. With a wall thickness of 20mm, the sculpture is carbon-reinforced and was created in exclusive collaboration with Düsseldorf artist Thomas Schönauer. The technical innovation of fibre-reinforced concrete expands the creative possibilities of the artist, allowing the creation of shapes which are not achievable with non-reinforced concrete. Schönauer’s CON-TEXTURES sculpture project incorporates the latest carbon concrete research by Prof Dr Thomas Gries of the Institut für Textiltechnik of RWTH Aachen University (ITA). Working with textile-reinforced concrete is one of the institute’s most important areas of research. The ITA is an ideal partner for Schönauer, who is particularly interested in the filigree possibilities of textile concrete. He has also created other curved concrete sculptures up to heights of 5m and their filigree surfaces depict numerous images such as landscapes, waves and rain. Art and science have always been regarded as opposing disciplines. The CON-TEXTURES project pursues the opposite strategy. Not for nothing do great scientists and philosophers talk about the unity of beauty, truth and goodness.
CON-TEXTURES appeals to anyone with an affinity for art. The sculpture is offered in three different sizes and is being marketed by Düsseldorf gallery Engelage & Lieder. At over 5m high, the largest sculpture has been placed in a public space. Partners are still being sought. Contact Andreas.Koch@ita.rwth-aachen. de if you are interested.
(Above): Prof Dr Thomas Gries (left) and ITA artist Thomas Schönauer at the unveiling of the CON-TEXTURES sculpture at the ADD-ITC.
PRECAST | ISSUE THREE | 2019
PRODUCTS 14
NEW ADMIXTURE PROVIDES LASTING SEWER PROTECTION Concrete additive supplier, Xypex Chemi-
troublesome alternative materials such
components are fixed in a mineral matrix
cal Corporation, has introduced an
as composites, plastics or steel.
within the concrete and will remain ac-
infrastructure-sparing admixture that
“Concrete containing Xypex Bio-San
tive, working indefinitely to kill harmful
provides antimicrobial and waterproof-
C500 maintains all of its original proper-
microbes at a cellular level. It does this
ing properties for concrete products in
ties, including workability, while providing
through the constant release of metallic
sewer environments.
an impermeable surface that remains
ions which open holes in the bacteria’s
MIC-resistant for the duration of the
cell membranes, thus destroying them
lifespan of the concrete,” says Minney.
from the inside.
In certain situations, acid-producing micro-organisms – including the Thiobacillus group of bacteria – are able to eat
Due to its structure, it is an integral
away sewers through microbial-induced
part of the concrete and therefore can
corrosion (MIC), which produces biogenic
never be washed off or wear out. It will
sulphuric acid that reduces the surface
continue working indefinitely for as long
pH of the concrete and leads to rapid de-
as the concrete is in place. This is in line
cay of the infrastructure. The breakdown
with new mandates of infrastructure
of wastewater infrastructure allows leaks
owners who are seeking longer-lasting
to develop, which can ultimately affect the
alternatives to current methods.
integrity of the pipelines and cause the complete collapse of the system.
World leader
While alternatives do exist, including
“Our product is being used widely in
PVC pipes, crystalline waterproofing
markets throughout the world, wherever
and chemical-resistant coatings, these
longevity of infrastructure is required.
have limitations and are not always ideal
It’s a comparati vely cost-ef f ecti ve
for every type of application, especially
means of protecting infrastructure and
large-scale and larger-diameter pipe
provides engineers with real-world solu-
applications. In these circumstances,
tions to extend the lifespan of wastewa-
the simple addition of the powder form
ter infrastructure,” says Minney. “In the past, engineers may have de-
Xypex Bio-San C500 admixture provides (Above, from top): Crystalline growth begins in concrete; crystalline growth completely fills openings.
signed special mixes to try to stave off
Simple procedure
have turned to alternative materials that
Concrete advantages
He explains that the dual-protection
aren’t as effective as concrete and, in
According to Xypex (UK) LLP export
product is manufactured in the form
most instances, are far costlier.
sales manager Stephen Minney, the
of a dry powder that can be added to
“With the addition of our Xypex Bio-San
new admixture is an exciting innovation
concrete manually or through computer-
C500 in precast products, infrastructure
for precasters who can easily extend
controlled batching systems. It can also
can simply be lifted into place and even
their product range and compete in new
be added directly to the central mixer in a
added to grouting to provide true install-
markets. Xypex Bio-San C500 concrete
plant and provides precasters and ready-
and-forget projects for our wastewater
products will have built-in, long-term
mix producers with a product that can
utilities. It also provides exciting new
protection for harsh sewage conditions
be added to their product line-up or for
prospects for our precast community,
where MIC attacks are likely. The additive
special projects, wherever it is required.
who will be better able to compete against
combines potent antimicrobial protection
Upon final curing, the antimicrobial
permanent protection for precast and in-situ concrete structures.
damage for as long as possible, or may
alternative products in future.”
along with the unique crystalline technology of the Xypex Admix C-Series. “It prevents MIC, stops infiltration/ exfiltration of water and provides acidand sulphate-resistance, significantly extending the service life of concrete sewage collection systems and wastewater infrastructure. This, in turn, provides design engineers with the option of using these to extend the life of the infrastructure projects and enjoy the benefits of strong, durable and cost-effective concrete, rather than costly and potentially
PRECAST | ISSUE THREE | 2019
PRODUCTS 15
EXTRAORDINARY PRECAST PRODUCTS Climate change has brought about major
portation points, thereby increasing
changes in weather cycles. The need for
commuter safety and convenience. Rocla
commuters to find shelter from dramatic
also offers concrete taxi rank shelters
rainstorms and the parched heat of
and bus stops, as well as other related
summer has increased the requirement
street furniture such as concrete ven-
The “sloping-back” profile enables road-
for solid, safe and indestructible bus
dor stalls, sanitation units and concrete
rollers to operate right up to the edge
shelters for those using municipal and
street lighting poles. Contractors are
of the pavement without scratching
local transportation.
easily able to transfer the bus shelter
or damaging the kerb face when the
CMA member and ISG Group com-
installation skills to members of local
surfacing is laid.
pany Rocla has developed a virtually
communities, which can form part of
On slower rural roads, the kerb can
indestructible and vandal-proof precast
their community outreach programmes.
provide an element of safety through
concrete bus shelter which offers shel-
impact redirection. On fast-moving
ter from heat and rain, as well as seating
Kerb stones
freeways and highways, the kerb is
in its modular design. The durability of the
When bad weather does occur, it is
more often used for drainage. It is also
concrete product guarantees decades
important to channel the water away
frequently applied near bridges, where
of maintenance-free life, an important
from the road surface with properly
erosion is a possible factor and to
feature for cash-strapped local munici-
developed kerbs and gutter systems.
establish a clear and visible separation
palities wanting to ensure budgets for
The widespread construction of kerbs
of people and motor vehicle lanes.
street furniture are well spent. It also
only began in the 18th century, despite
prevents structural vandalism.
them having been around since the days
Perfect combinations
of Pompeii!
A combination of a Technicrete barrier
The Rocla bus shelter can be supplied with wind walls for one or both sides of
Originally utilised for the beautification
kerb and a C900 gutter section will
the shelter and although supplied in a light
of the city and to separate transportation
convey drain water to the nearest kerb
grey colour, the surface is easily painted
from pedestrians, the humble kerb has
inlet. Road resurfacing requirements will
for advertising, roadside markings and
evolved into an infrastructural necessity
not need realignment with the kerb line
community notice purposes.
– f or example, it pr e vents dr i ver s
either. The Technicrete semi-mountable
Of fering commuters shelter from
from parking on pavements and lawns,
kerb can also be utilised in conjunction
inclement weather, the Rocla solid bus
while providing structural support for
with the C900 gutter section for drainage
shelter can also lead to the creation
pavement edges.
purposes on roadways and elsewhere.
of centrally situated community trans-
“Contractors are easily able to transfer the bus shelter installation skills to members of local communities.” PRECAST | ISSUE THREE | 2019
Another CMA member and ISG Group
The company’s barrier kerbs have
company, Technicrete’s precast barrier
been specified for projects such as
kerbs have been successfully installed
medical centres, national roadways,
on numerous regional infrastructural
pri vate and commer cial r esidential
projects throughout SA due to their
developments, gutter systems and rural
100% local manufacture and excellent
infrastructure upgrading.
quality. The kerb uses the “half-battered” profile. This more vertical face offers a type of barrier to alert motorists that they are dangerously close to the edge.
(Top): Kerbs play an important role in traffic management. (Above): A bus shelter in Gaborone Road, Francistown, Botswana.
COMPANY NEWS 16 The country’s only equipment manufacturer specialising in concrete roof tile plants, Jessop & Associates, is celebrating 30 years of service to the roofing industry. Since launching its original Protile Double Roman tile profile in 1986, the company has gone on to develop a wide range of machines that have become a mainstay of operators across SA and around the globe. After the initial success of the early machines, new developments included the well-known Protile Tuscan, which was among the first to gain wide-
LOCAL MANUFACTURER LEADS THE WAY IN ROOFTILE INDUSTRY
spread local and global success, followed
in 1978. After completing four major
by the Protile Shingle.
tile plant projects with that company,
(Left, from top): The Protile P70HD, capable of extruding 100 tiles per minute and a typical materials handling layout, with bins and conveyors feeding sand and cement automatically into the mixer.
According to Jessop & Associates
I decided to launch Jessop & Associ-
founder, Grahame Jessop, the company
ates and have never looked back. Now,
is the only equipment manufacturer
with 125 tile plant projects in over 30
“The extensive seminar manual and
in Af rica capable of manuf acturing
countries, the Protile equipment brand
notes have since become something of
a n d i n s t a l l i n g sp e c i a l i s e d t u r n k e y
is synonymous with quality in many parts
an industry ‘reference book’, in many
plant and equipment for high-speed
of the world.
instances, while internally, the next
continuous extrusion of concrete roof
“Passing on this vast experience has
generation has also taken up the cudg-
tiles, at speeds of over 100 tiles per
become an ongoing journey for me and
els. My son, Ronald, has also been using
minute. “In fact, there are probably only
led me to develop and present a range
his professional engineering expertise in
three companies worldwide with this
of workshops and seminars specially to
product development for over a decade
capability, with the other companies
develop the skills of plant for local and
now,” says Jessop.
only having local agents who import such
international markets in South America
equipment,” says Jessop.
and Australia. These have been met with
Material anomalies
great success and it’s not uncommon
He adds that in addition to a sound
Right timing
for our South African seminars to be
knowledge of the operation of plant and
“I started my career in the concrete roof
attended by concrete roof tile manufac-
equipment, it is vital to have a good
tile industry with a UK-based company
turers from foreign countries.
understanding of the specific characteristics of raw materials for the extrusion process in this industry. For this reason, one full day of the three-day seminar is dedicated to exploring and demonstrating these criteria. During this time, it is shown that the aggregate gradings alone are of relatively little value. The mineralogy is crucial, as are particle shape and texture, interstitial moisture and water requirements of the aggregates. This information, together
(Left): Grahame Jessop, MD of Jessop & Associates. (Above): Ronald Jessop, director of Jessop & Associates.
with a WET grading analysis resulting in a more relevant FM calculation, minus 75-micron content and characteristics
PRECAST | ISSUE THREE | 2019
COMPANY NEWS
and flow properties tested using a flow cone apparatus, enable an optimal mix blend design for extrusion to be achieved. The concrete roof tile industry is very demanding, requiring the expert assimilation of this data to gain a competitive edge in a market where the variation between an aggregate/cement ratio of
17
3.85:1 and 3.95:1 could make a significant difference to margins. Forming tiles
(Above): The Protile Double Roman Tile, well established in SA since the 1980s. (Right): Aluminium alloy pallet cast under high pressure.
Jessop explains that given the critical mix design parameters, the high-speed
cal. This becomes more apparent at higher
“The risk is high, as is the capital ex-
extrusion process requires precise
extrusion speeds. These high-production
penditure involved. Due to the extreme
control of concrete flow in the extrusion
tile plants need to strike a fine balance be-
extrusion forces, optimal strength-to-
head. The new Protile Double Roman Mk
tween tile body thickness, typically within
mass ratio is crucial for the pallet. Only
VI aluminium pallet, for example, is a far
a tolerance of 11mm ± 0,25mm, and tile
aluminium achieves this, with no flexing
cry from the Mk II Double Roman pallet
depalleting strength, which could be as
of the pallet, in a cost-effective manner,
of the 1980s.
low as 900 Newton at 24 hours testing.
borne out by the fact that after exten-
Since the bottom surface of the
sive research, 95% of the industry uses
concrete roof tile is completely formed
Aluminium pallets
via the detailed design of the aluminium
“Jessop & Associates budgets approxi-
“Should flexing occur – as it does
pallet, a lot of the success in terms of
mately 12 months for the development of
with steel pallets – then the tiles formed
“compaction” or extrusion density lies in
a new or current aluminium pallet design,
won’t conform to stringent roofing
the pallet design.
followed by a further six months for manu-
criteria. They’ll ‘rock’ and have varying
facturing the high-pressure die needed to
overlapping and interlocking gaps. The
cast these pallets,” says Jessop..
less-known advantage of the aluminium
The material flow enabled by the design of the aluminium pallet is, of course, criti-
aluminium pallets worldwide.
COMPANY NEWS 18
is the formation of aluminium stearates during the extreme extrusion pressure to form a physical interface barrier between concrete and pallet, thereby assisting high-speed depalleting of tiles from pallet. Plant projects “Typically, a high-speed tile project will take us 12 months from project confirmation by the client to commissioning of the new concrete roof tile plant. In this time-frame, the detailed plant configuration is finalised, considering any restraints imposed by existing building and other limitations, followed by mechanical plant detailing, followed
(Above): Sophisticated tile curing systems are an integral part of Protile concrete roof tile plant projects.
by manufacturing of the Protile plant
high-energy Eirich mixer and the double-
which were the severe limitations imposed
and equipment. A plant can easily involve
deck vibrating screen, all the equipment
by the available land and buildings.
manufacturing more than 35 individual
is manufactured in the Protile workshop
Tile plants of this nature to produce
Protile items of equipment.
in the Vaal Triangle, pre-assembled and
30 000-40 000 tiles per shift would
then installed on site,” says Jessop.
typically cost R25 million-R50 million,
“There are three distinct project
depending on many variables, such as
sections to be considered – the tile plant circuit (including the extruder), the mate-
Recent projects
the level of automation for the curing
rial handling system (which includes sand
Complete Protile P70HD tile plant projects
chambers and dry tile handling.
screening, weigh batching and mixing)
were recently commissioned for well-
With these and other projects on the
and the tile curing system, including the
structured and managed black empower-
horizon, Jessop & Associates looks set
curing chambers.
ment entities in Gauteng and Limpopo. The
to face the next 30 years of manufactur-
projects had their challenges, not least of
ing excellence.
“With the exception of the specialised
Find our branches at www.technicrete.co.za
p a v in g | mini ng | m as onr y
SUITABLE FOR: • Car parks • Industrial Estates • Retail Centres • Pedestrian areas • Domestic Drives • Motorways | Garages • Service areas
| k erb s | erosi on
protec
APPLICATIONS: • Tongue & groove • Standard grey or traffic calming colours • Precast • Various sizes available • Highest quality
tio n | r et a i
ni n g
w a ll
s|d rain age
Technicrete is a subsidiary of ISG, a leading supplier of innovative infrastructure products to the construction and mining markets in Southern Africa.
MARKETING PRECAST PRODUCTS By Andrew Meyer, andrewisikhova@icloud.com “The times they are
I could sell existing product?” For
a-changing,” sang
example, slabs are now also used
B o b D y l an – an d
for walling. Previously – barring paving
in an ever faster-
and retaining walls – most precast
changing world, we
product was viewed as structural
need to look at how
a n d n o t a e s t h e t i c . T im e s h a v e
we see our product
changed and concrete has become
application. What
fashionable, opening many new doors.
will be needed in
O v e r t h e p a s t f e w y e a r s, n e w
the future and how will we market to our
consumers have begun making new
users? It is said that while we used to
demands and viewing precast concrete
see a generation as 15-20 years, it has
in a very different light. The Museum
now changed to four years.
of Modern Art in Paris, for example,
A product and marketing plan is an
has installed all pipes and conduits on
extremely intensive plan and differs from
the outside, rather than in the walls.
company to company. Developing this
By applying colour to them, this has
involves some crucial steps:
become art in itself. A well-known precast
1. Evaluating your current product
concrete manufacturer in Johannesburg
offering. This needs to be done by
launched a security wall system a few
firstly looking at your sales patterns
years ago. This is a stunning structure
over the past three to four years.
and could easily be used in parking lots
Have sales declined, remained the
or parks, possibly with a bench and light.
same or grown? If they’ve grown,
The precast concrete pipe sector is
then “don’t fix what isn’t broken”.
currently going through difficult times
What product development and re-
and some major players have had to close
search have you done to look at
down. In today’s media, you are always
the needs of your customer s in
confronted by “green issues”. Why does
today’s world?
the pipe sector not use all this free
2. Marketing patterns have changed,
publicity to position precast concrete
and marketing and sales structures
as far more environmentally friendly than
are very different today from what
plastic pipes? Push the issue of more
th e y w er e 10 y e ar s ag o . W hil e
and more plastic being put into our soil
marketing in dedicated trade journals
that isn’t biodegradable. A better option
remains a very effective method of
for pipes is precast concrete, which is
getting the message across, general
biodegradable!
print media, radio and TV penetration
Concrete blocks have mainly been sold
has dramatically shifted. Are you
based on a cost issue, and this has had
using social media and dir ect-
a negative impact on the use of blocks,
response methods to reach your
which are seen by some as the “cheap”
clients? Have you evaluated who
or “second-rate” option. We would be
your potential client base are today,
far better off selling a “quality” product
as opposed to who they were in the
that is sustainable and has good thermo
past and are you reaching them in
qualities, as well as sound insulation.
an effective manner? We live in an era
What is more, concrete comes at a
of branding – how much of this are
better cost per running metre.
you doing?
In summary, I believe we need to
3. Different assuages for precast mat-
look at our product, the applications,
erial: look at the product you manu-
possible new markets and how we sell
facture and ask yourself: “Is there
and market our product in the most
possibly a different market to which
effective way.
PRECAST | ISSUE THREE | 2019
COMPANY NEWS 20
REVELSTONE GEARED FOR GROWTH
the built environment, and we felt that
and inlays in an enticing display. Over
if we couldn’t renew our own space, how
time, it will demonstrate how well our
could we invite others to do so?”
wet-cast cobbles and pavers wear,”
Cape-based cast-stone producer and
and off-shutter concrete with steel clad-
New products
CMA member, Revelstone, believes that
ding and new lighting for an attractive
“A key element in the upgrade was an at-
a bright future beckons the South African
nightfall frontage.
tractive new front entrance which allows
Revelstone’s new façade was modern-
says Cyprianos.
ised by combining Random Stone cladding
cast-stone manufacturing industry.
easier access to our new showroom and
Underscoring its commitment to an
incorporates a modernised step, as well
expanding market, the company launched
as a ramp for wheelchairs and sample
several new products during a PPC-
trolleys,” he explains.
sponsored open day on 2 August. It has
Revelstone’s new product line-up
also invested liberally, adding to its re-
includes three newly-designed granite fin-
cent showroom upgrade with a redesign
ished cobbles (Exeter, Trent and Tuscan),
and makeover of the exterior road-facing
a new flagstone paver (Devon Straight
façade of its HQ premises, Adam House.
Edge) in two sizes, new stone cladding
Moreover, the company is committed to
(Cotswold) and a new kerb/step (Oxford).
upgrading its plant and equipment during
“As always, our new product range
the coming year.
is based on input from the architectural
Founder and chairman Andrew Cypri-
community, consumer demand and mod-
anos says Revelstone was built on op-
ern trends in landscaping design,” says
timism and faith in positive outcomes.
Cyprianos.
Opportunity abounds
producing customised cast-stone prod-
“Everyone warned me when I established
ucts since 1993 for both the domestic
the business 26 years ago that I was
and commercial markets. The company
making the wrong move. The prevailing
uses traditional masonry skills combined
economic and political mood at that time
with modern moulding techniques to
was one of ‘wait and see’, ahead of the
painstakingly produce master moulds
1994 elections, and the business com-
from original stone. This hands-on ap-
munity was holding back on investing in
proach allows the creation of custom-
new ventures. We’re in a similar position
made products, tailored to clients’
today. While others tighten their belts,
specific requirements.
Family-owned Revelstone has been
we believe the current downturn provides the ideal opportunity for renewal and regeneration,” says Cyprianos.
“In addition, we redesigned our road
“We could easily have continued with
verge and parking area, which was relaid
our old showroom and building façade
by Progressive Paving. It showcases
and banked the money. But we’re in the
our full cobble, edging, kerbing, drainage
business of beautifying and remodelling
pavers, demarcation pavers, borders
(Top): Revelstone HQ, Adam House, sports a new façade and paved road verge. (Left, from top): Revelstone chairman Andrew Cyprianos (right), seen here with business consultant Chris Rookledge (left) and Clayton Laue of Paarman Landscapes during the launch of the company’s new product range in August; Tuscan Cobble in three sizes and Cotswold cladding.
PRECAST | ISSUE THREE | 2019
COMPANY NEWS
(Right, from top): Sanitation units donated by Rocla to Sifunindlela Primary School and members of the Mpumulanga Department of Education; Rocla (ISG) CEO Albert Weber shakes the hand of the Sifunindlela Primary School principal; André Labuschagne, product development manager: Rocla; Malebusa Sebatane, marketing & communications manager: Rocla (ISG).
“No school should be without proper functioning and clean sanitation units.
21
It’s called human dignity,” said Albert Weber, chief executive officer of the Infrastructure Specialist Group (ISG) when he recently handed over 16 Rocla precast concrete sanitation units to the Sifunindlela Primary School, based at Kabokweni in Mpumalanga. “At ISG, our corporate social initiative focuses on early learning development projects. At Sifunindlela Primary School, we saw a need for hygienic and safe sanitation units for its very young pupils and we knew we could assist through the expertise that CMA member Rocla has in this sector. Our belief that functional ablution facilities should be provided for young pupils attending educational establishments stems from our belief in the right to basic human dignity. We at ISG and Rocla are proud to have supplied these 16 dignified and safe sanitation units,” Weber said. “We contracted Enviromould Product Solutions for the installation of the toilets. They supplied amenities for upstream water and downstream sewer management. The finished product comprised two sets of toilets for both girls and boys. The seats supplied include a built-in baby-seat to accommodate both pre-schoolers and much older children in primary school. These sanitation units are safe, hygienic and fully functional
PRECAST SANITATION UNITS FOR MPUMALANGA PRIMARY SCHOOL
and replace previously dangerous pit
installation and backfilling of the septic
running water is available, plastic fittings
toilet installations,” commented André
tank and the installation of a 5 000-litre
are used to prevent theft, as these have
L abuschagne, product development
water tank on a raised platform to
no scrap value.
manager at Rocla. “The sanitation unit
gravitationally feed the toilet cisterns.
In the case of leach pit latrines,
itself is cost-efficient. There’s no need
Rocla’s precast concrete toilet unit
the leach pits themselves are also
for any educational establishment not to
is a cost-efficient solution to one of the
manufactured from concrete and
have units such as these installed for its
essential needs in SA’s high-density
supplied together with the toilet unit.
pupils and staff.”
urban and rural communities. The stand-
This provides a system in line with the
Enviromould supplied all associated
alone unit has been developed to be used
Water Research Commission’s findings
sanitation unit fittings such as stop
as either a leach pit configuration or as
for a cost-effective and viable on-site
c o c k s, w a t e r c o nn e c ti o n f i t tings,
a fully water-borne system. The unit is
water-borne system.
infiltrator soak-away chambers, sewer
supplied complete with a high-quality
Sifunindlela Primary is a no-fee public
pipes, water troughs and vent valves,
polymer pivot door and an optional
school and has over 1 100 registered
as well as conducting the excavation,
concrete add-on wash basin. Where
pupils, with over 100 in Grade R.
“Rocla’s precast concrete toilet unit is a cost-efficient solution to one of the essential needs in SA’s high-density urban and rural communities.” PRECAST | ISSUE THREE | 2019
GLOBAL VIEW
US PICP CONFERENCE ADVICE:
DON’T INSTALL IF YOU CAN’T MAINTAIN An entire session was devoted to per-
22
meable interlocking concrete pavement (PICP), which was attended by Prof Neil Armitage, deputy director: Future Water at the University of Cape Town. Regular
Precast readers will recall that Armitage is spearheading research into the
America’s Environmental & Water Resources Institute staged an Operation & Maintenance of Stormwater Control Measures conference from 4-7 August in Minneapolis.
performance of local PICP installations. The American stormwater conference forms part of his monitoring developments internationally and exploration of how they can contribute to sustainable PICP installations in SA. Two factors critical to the future of PICP emerged during the conference. The first is that the American Society of Civil Engineers has announced the launch of
(Above): Prof Neil Armitage, deputy director: Future Water at the University of Cape Town.
a PICP standard which sets the stage for similar initiatives in other parts of the world. The second is that the USA’s
and maintenance guidelines. A detailed
The routine maintenance machines
Interlocking Pavement Institute (ICPI),
guide f or civil and envir onmental
combine blowing with vacuuming, whereas
which champions the use of precast con-
engineers, it provides informative reading
restorative maintenance requires a
crete segmental paving, now advises that
for environmental planners, landscape
sweeper to remove stuck sediment and
unless property-owners are prepared to
architects and architects. Armitage
stones from the cavities between pavers.
maintain their PICP installations, they are
believes that a similar standard would be
The restorative system which gave the
wasting money by installing them.
of benefit locally and part of his research
best results was the Typhoon. Powered by
is geared towards achieving that goal.
a large street vacuum truck, it comprises
One of the speakers during the PICP
two small, wheel-mounted machines, one
Four years in the making, America’s PICP
session was David Smith, the director of
for blowing and one for sucking up debris.
standard, ASCE/ANSI 68-18, covers
ICPI, who has visited SA and is well known
The Typhoon can clean approximately
hydrologic sizing and the structural
to some CMA members and concrete
100m² per hour and Armitage believes
design of PICP, as well as construction
block paving manufacturers. The author of
that one set could probably service all
a book on PICP, Smith presented a paper
PICP installations in the Western Cape.
entitled Best Practice in Maintenance.
Other machines tested included the Ditch
Compiling guidelines
His presentation focused on main-
Witch, a small vacuum machine for small
tenance and the various types of PIPC
installations and the Billy Goat, which is
cleaning equipment currently available on
used for cleaning sidewalks.
the American market, never losing sight of his overriding message that ongoing
Interesting observation
maintenance is essential to the viability
Armitage noted that, unlike the British,
of PICP installations.
Americans tend not to install geofabric under the bedding layer. “This may be due
Maintenance required
to the fact that although one gets the
The ICPI recently tested several PICP
best nutrient and toxin removal with an
cleaning machines and Smith gave some
upper layer of geofabric, clogging occurs
insights into their use and performance.
a lot quicker,” he explained.
He ad v ises tha t in the US A, PICP
A r e c en tl y c omple t e d f our -y e ar
maintenance essentially falls into two
comparative study in the USA between
categories: routine maintenance (which
permeable concrete, permeable asphalt
is designed to delay the onset of clogging)
and PICP has shown that although PICP
and restorative maintenance (which
clogs quickly, it is much easier to clean
is used to unclog clogged or partially
than asphalt or concrete. It is also much
clogged installations).
easier to work with over the long term.
PRECAST | ISSUE THREE | 2019
TECHNICAL
Most precast concrete manufacturers k n o w M ap e i f o r i t s v a s t r ang e o f construction chemicals, admixtures and adhesives, yet few realise that its influence begins far earlier in the construction cycle, with the provision of advanced chemicals that aid cement manufacturers in the production of high-
23
quality cement. In SA and worldwide, Mapei is a major supplier of cement additives and grinding aids that improve the characteristics of cement, thereby enabling producers to increase throughput and so achieve better efficiencies and lower costs per ton of cement sold. Laurence Gopane, Mapei product manager for cement additives, says
QUALITY FROM THE BEGINNING
cement is produced with a complex recipe
starts with lab testing of the specific
of clinker and other ingredients including
raw material.
gypsum, fly ash, slag and limestone,
T his usually r esults in an initial
among others. Every additive is tailor-
prototype of grinding aids, which is then
made for each and every plant to support
tested in the mill and adjusted according
the particular ingredients, as well as the
to the actual outputs and requirements.
manufacturing processes.
In the end, however, the result is the best possible product that can be produced cost-efficiently from each manufacturing
Careful selection
plant. And, for the end user, it results
“Regardless of the mix, even plants within the same organisation may have
facturers rely on these additives to
in the best-quality cement at the best
different recipes with their own unique
achieve their production goals. Needless
possible price per bag or ton.
challenges. That’s where our team comes
to say, since Mapei’s entry into the local
“For contractors and other users,
into its own. We’re able to partner with
market some 10 years ago, the game has
the use of quality cement is critical in
the producer and recommend products
changed and our modern additives have
producing high-quality concrete for local
that will assist in meeting the specific
offered many advantages that ultimately
building sites. It also enables cement
requirements,” adds Gopane.
improve the quality of cement to end us-
producers to keep up with the high
ers,” says Gopane.
demand for quality cement in either bulk
“For example, some additives are
or bags. This is when our team from
grinding aids that improve the grinding action of the mills by preventing particle
Live tests
Concrete Admixtures will be able to add
agglomeration and adhesion to equipment,
He explains that due to the technical
further technical support and benefits,”
and there are different types available that
complexity of the cement manufacturing
says Gopane.
improve the strength of performance.
pr ocess, ther e ar e many dif f er ent
Mapei grinding aids and performance
variables that need to be considered
Giving back
enhancers influence the properties of the
when adding additives. These include the
Mapei also hosts an annual Cement
final cement. Producers are therefore
type of clinker being used, mix ratios of
Additives Seminar which is open to all
able to ‘tweak’ cement to have different
slag, fly ash and other ingredients, as well
cement producers and blenders, whether
properties, such as optimising early
as equipment type, grinding media and a
or not they are current customers.
strengths and late strength gains, etc.
host of other variables.
Specialists and technical consultants
“The country’s large cement manu-
The selection of the cement additive
from the company’s C-ADD division in Milan, Italy, come to SA to interact, educate and present relevant content to the attendees about the cement additives industry. The event sheds light on the latest best practices, technologies and products available to help cement producers keep up with new and challenging demands. The next 2020 Cement Additives Seminar is anticipated to take place during the second quarter of 2020.
PRECAST | ISSUE THREE | 2019
TECHNICAL
As with many other materials, there are potential risks involved in handling or working with Portland cement or mixes made using it. Here Bryan Perrie, MD of The Concrete Institute, provides guidance on how to avoid the effects of unprotected exposure.
24
The composition of Portland cement is such that when dry cement is exposed to water, a chemical reaction called hydration takes place, releasing a very strongly alkaline (and caustic) fluid. This can cause alkali burns and safety measures should be observed. Appropriate precautions are advised to prevent tissue damage when handling fresh mixes containing water and Portland cement. Cement dust, dusts from handling ag-
REDUCING RISKS OF HANDLING CEMENT
gregates and from cutting concrete are easily inhaled. Prolonged or regular exposure to these dusts should be avoided. Some risks Portland cement is a complex combination of compounds which include minute quantities of trace elements. Although South African cements typically contain less than two parts per million of hexa-
“Fine silica dusts created when crushing or handling these aggregates could cause lung problems.�
valent chrome (widely regarded as a safe level), it may serve as an aggravating factor in cases of exposure to alkaline fluids. There have been some reports of allergic dermatitis after exposure to these fluids. When fresh concrete or its bleed water comes into contact with human skin, the alkalis react with the oils and
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TECHNICAL
Regularly wash (at least daily) protective clothing and keep it clean and free of concrete. Wash any areas that have been accidentally splashed with wet concrete as soon as possible, using large quantities of clean water. Ensure that normal and protective clothing does not become soaked with wet concrete or concrete
25
fluids, as this could result in exposure over an extended period, resulting in tissue damage. Cement is an abrasive fine powder and, when handled, some dust may be-
Dust particles
come suspended in the air in the working
Many of the aggregates used in concrete
area. Users should avoid inhaling cement
have high silica contents. The fine silica
dust, as this may cause irritation of the
dusts created when crushing or handling
nose and throat. Cement dust may also
these aggregates could cause lung prob-
cause irritation of the eyes. This will
lems and precautions should be taken to
occur because of the chemical reaction
avoid breathing in such dusts.
of the suspended dust with the moist
Dust from demolishing or cutting
fats in the skin, as well as the proteins
mucous membranes. Airborne cement
hardened concrete may contain un-
in it, causing tissue damage. Other or-
dust should be kept to a minimum to
hydrated cement and could cause the
ganic tissue (such as mucous membrane)
avoid these problems. Should this be
respiratory problems outlined above. In
can also be attacked by strong alkalis,
impractical, then the use of goggles and
addition, if the coarse or fine aggregate
leading to burns that can be severe, so
dust masks is strongly recommended.
used in making the concrete contains
users should try to avoid all unnecessary
crystalline silica, then inhalation of these
contact with these fluids. Where such
fine silica particles could expose work-
contact is unavoidable, suitable precau-
ers to the risk of developing silicosis.
tions should be taken.
A concerted effort should be made to
Roughness and dryness of the hands
avoid generating such dusts. If this is not
after working with concrete is a typical
possible, the use of suitable respiratory
consequence of loss of these oils and
protective equipment is recommended.
fats. More prolonged exposure could
Site workers should also not kneel on
result in irritant dermatitis. It is possible
fresh concrete during placing, compact-
that the effects of trace elements may
ing and finishing operations. If kneeling is
aggravate the condition and lead to an
unavoidable, thick waterproof kneepads
allergic dermatitis. To safeguard against
should be worn with a kneeling board
accidental exposure, appropriate protec-
to prevent the pads sinking into the
tive equipment is strongly recommended.
fresh concrete. In severe cases of alkali burns, a medical practitioner should be
Proper precautions Impermeable gauntlet-type rubber gloves and high-length rubber boots should be worn to prevent direct contact with skin. Trousers should overlap the boots, rather than be tucked into them. Hydrophobic alkali-resistant barrier creams should be applied to the hands and any areas of skin likely to be in contact with fresh concrete. Ordinary barrier creams are likely to be inadequate. These precautions may be ineffective if the skin itself is not clean and free of concrete residue. Even a tiny trace of cement dust remaining in contact with wet skin will raise the pH significantly. For this reason, some authorities recommend the use of disposable gloves and discourage re-usable ones.
PRECAST | ISSUE THREE | 2019
consulted as soon as possible.
TECHNICAL 26
WHERE TO APPLY MODULAR CONSTRUCTION METHODS In many parts of the world there is a big
SA, we also need to ask how we can
(excluding, of course, the time spent
demand for new housing. To meet the
build acceptable housing units within a
preparing modules at the factory).
backlog, numerous countries have put
reasonable time-frame, with a limited
Yet, even if the shor t assembly
together plans to build a high number
budget, while providing a solid foundation
time sounds great, there are some
of low-cost housing units in a very
for living for the future home-owners
downsides. Room-sized 3D modules in
short time.
and tenants.
precast concrete are heavy and may
“However, all these future housing
“As in all projects, everything starts
weigh more than 30 tons. Handling,
units need to meet a range of different
by defining what an acceptable solution
lifting and transportation of such heavy
demands to be acceptable,” cautions
would be and what such a solution
modules is challenging and may cause
Curt Lindroth, area sales director:
should provide. In this case, the question
damage to the finishing or the structure.
Elematic Oyj, based in Finland. Here in
is about what building method and
The end result is often a situation where
materials to choose,” says Lindroth.
the overall cost per built-up square metre is higher than it would have been
3D modules
using a modern, design-focused precast
He adds that in other markets, there is
system.
a growing interest in manufacturing pre-
Using 3D steel moulds for production
designed standard box unit modules at a
at the factory may be applicable to pre-
factory, as this speed up the assembly
manufacturing of bathroom and elevator
on site. For example, a precast concrete
shaft modules. However, it is important
company in Dubai applied the principles of
to keep in mind just how heav y and
modular construction in a villa project. It
complex precast concrete products can
stretched the 3D design to room-sized
be to pre-manufacture. Architectural
3D modules in precast concrete. The
freedom may be very limited if buildings
modules were assembled at the factory
are completely built using 3D moulds.
using precast concrete panels, including
(Top): Building with precast concrete. (Above): Curt Lindroth, area sales director: Elematic Oyj.
finishing, electrical cabling, sockets
Modern precast
and plumbing. Additionally, the modules
Moder n, design-f ocused pr ecast
were transported to the site, where
concrete is suitable for all types of
the villa was assembled in only 48 hours
buildings, including in seismic areas and
PRECAST | ISSUE THREE | 2019
Furthermore, pre-stressed hollow-
state-of-the-art production machinery.
concr ete can be used as the main
core slabs save up to 45% in concrete
Automated functions cover planning,
building material or only partly as a
compared with reinforced concrete floor
monitoring and controlling the process
structural component.
cast in a 3D mould, or a plain cast-in-
of producing building blocks for accept-
When high-quality, energy-efficient
situ reinforced slab. Pre-stressing steel
able buildings.
buildings have been the target, modern,
can also be cut by 30% because of the
An acceptable building for a home
design-f ocused pr ecast concr ete
lower self-weight of hollow core slabs.
should, first of all, be affordable and of
has repeatedly been selected as the
In an average apartment, this means
a decent quality, with sufficient living
construction method. Precast concrete
savings of about 14 tons of concrete
space, good structural stability and
is a pr oven, industrialised building
and more than 250kg of steel. Moreover,
located in a sustainable neighbourhood.
method. Even if installation still takes
pre-stressed hollow core slabs can be
An acceptable home needs to match the
place at the construction site, the main
partly recessed, which makes it easier
expectations of future home-owners
part of the work is transferred from the
to prepare bathroom plumbing.
and tenants.
organised factory conditions. In addition,
Optimised production
life-cycle costs of precast concrete
housing units are still completed with-
Modern automated precast concrete
buildings make them an attractive choice
in a reasonable time, cost-efficiently
production plants optimise an entire
for home-owners. Add to that short
and safely.
precast production process, from 3D
construction time and cost-efficiency
The use of precast concrete offers
building design to the construction site.
of the construction process and you
considerable cost-savings, compared
The production lines feature advanced
have an optimal choice for large housing
with alternative solutions. These savings
software, modern table circulation and
projects,” says Lindroth.
chaos of a building site to controlled,
“To sum up, good quality and low
come from a number of sources. For example, in residential buildings, the span of pre-stressed precast hollow core slabs can be 8-12m. The external insulated precast concrete wall panels can work as the only load-bearing walls.
“The use of precast concrete offers considerable cost-savings, compared with alternative solutions.”
Production plants for thin-walled concrete pipes
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TECHNICAL
in those prone to tornadoes. Precast
27
TECHNICAL 28
CULVERTS FOR WATER, ROAD AND MINING INFRASTRUCTURE CMA member Rocla is a leading precast
Once-off projects
along w i th the pr e c as t b ase – as
concrete product manufacturer able
Along with custom-designed culverts
opposed to casting in-situ – will save
to supply a wide range of culverts for
for once-off projects, Rocla offers two
on project duration and provide quality
infrastructure and other water flow-
distinct ranges of culverts differentiated
assurances on final product.
related projects.
by the type of loading requirements,
The company has recently drawn attention to the requirement for quality
both available with associated precast
Wingwall units
base slabs.
Rocla’s precast wingwall units can be
products when undertaking new projects,
For heavy loading applications, such
used at both the inlet and outlet of
whether it be for water, road or mining
as to provide a waterway below railway
any channeled system making use of
infrastructure. Its unwavering focus
tracks, Rocla’s SATS SAR rectangular
circular or rectangular portal culverts
on quality, along with technical design
portal culverts can be used. These,
for stormwater applications. The natural
expertise in project assessment and
or custom uni ts, ar e also u tilised
f low p a th o f wa ter upstr e am o f a
product design, has paid off in recent
in any application with excessive fill
construction is often wider than the
times, having been successfully used
requirements, with the culvert tunnel at
culvert or pipe structure. Transition
for custom-designed culverts and many
the base of the fill zone, allowing either
sections are then required to receive
major infrastructure developments, such
conveyor or vehicle access.
and direct the flow of this upstream
as the Polokwane Eastern Ring Road and
T he st andar d S A R cul v er ts ar e
the rehabilitation of the D528 in George’s
supplied in lengths of 1,22m and designed
The same is true of the downstream
Valley, Limpopo.
for up to 10m of fill. Culverts required
end of the culvert or pipe section. The
water through the culvert or pipe.
The main function of culverts is to
for loading heights greater than 10m
precast concrete wingwall unit is the
manage the flow of water from one side to
are handled individually and designed
most effective structure to use for
the other of an “obstruction”. This can be
in-house at Rocla’s head of fice. For
the transfer of this water, eliminating
a road, railroad, trail or other structure
traditional loading applications, creating
erosion and creating a smoother flow.
c ons tr uc t e d in ei ther the na tur al
waterways below roads, trails or even
Rocla manufactures a wide range
or designed flow path of the water.
drainage channels, Rocla’s standard
of precast concrete products which
Factors to be considered before design
rectangular portal culverts are the
are ef fective and cost-ef ficient
and installation are the site-specific
preferred solution.
f or all in f r as tr uc tur e and gener al
application and environmental impact
These standard culverts range in
construction project requirements.
(ensuring that erosion is minimised and
size from a span of 450-3 600mm
It has representation in Namibia and
structural damage avoided). Incorrectly
and heights from 300-3 000mm. The
Botswana, in addition to its South
placed or designed culverts can result in
strength classes for these culverts
African presence.
culverts failing, becoming dislodged and,
are 75S, 100S, 150S, 175S and 200S.
in extreme pollution cases, being clogged
If time constraints are a factor for any
by vegetation and sediment.
project, the precast culvert option,
(Above): Culverts manufactured by Rocla.
PRECAST | ISSUE THREE | 2019
CAMBRIDGE UNIVERSITY RESEARCHES SELFHEALING CONCRETE Researchers at the UK’s University of Cambridge are using micro-encapsulation technologies developed by Dolomite Microfluidics to develop self-healing construction materials. The Department of Engineering’s Geotechnical & Environmental Research Group is developing microcapsules containing “healing” agents – such as minerals, epoxy or polyurethane – which can be added to building materials to allow self-repair of small cracks which develop over time. Dr Livia Ribeiro de Souza, a post-doctoral researcher in the group, explains: “Many composite building materials used in the construction industry, such as concrete, suffer fatigue over time, developing small cracks. We’re hoping to overcome this problem by adding microcapsules filled with ‘healing’ agents to the concrete before it’s used. The idea is that, as cracks begin to form, they rupture the microcapsules, releasing their payload and stabilising the material.” Functionalised microcapsules created This approach requires the formation and functionalisation of double-emulsion microcapsules, which the scientific team has been producing with the help of microfluidics. The researchers have been using a Dolomite Microfluidics system since 2014, and find that it offers much better control of particle size and composition than traditional emulsification polymerisation techniques, simplifying the investigation and optimisation of particle properties. The Dolomite system has enabled the researchers to create functionalised microcapsules that bind more strongly to the cement matrix, while also having thinner shell walls and higher core retention, improving their self-healing properties. “It’s good to be able to discuss any issues we’re having with the experts at Dolomite Microfluidics, helping to accelerate our research and move us a step closer to real-world applications,” says Ribeiro de Souza.
A STRONG FOUNDATION FOR INFRASTRUCTURE SUCCESS ROCLA is South Africa’s leading manufacturer of pre-cast concrete products. Surpassing 100 years of product excellence. • • • • • • •
Pipes Culverts Manholes Poles Retaining walls Roadside furniture Sanitation
Including other related products within infrastructure development and related industries. Visit us on
(Above): Dr Livia Ribeiro de Souza using a Dolomite Microfluidics system. (Figure: Dolomite Microfluidics)
PRECAST | ISSUE THREE | 2019
www.rocla.co.za
for our nationwide branches
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
TECHNICAL 31
REBEL WITH A CAUSE: HOW SEEKING PERFECTION PAYS SA’s construction industry is under
Howe v er, f a te inter v ened when he
huge pressure and some of its largest
missed the apprentice enrolment date
His time with SAR and subsequent
companies have gone belly-up. Those who
with Cummins Diesel, and he found
employment were frustrated by several
have stayed the course tend to be fleet of
sanctuar y with (then) SA Railways
army training camps. After his first
foot and better able to adjust to a much
(SAR), where his duties did little to fulfil
stint in uniform, he thought he couldn’t
harsher macro-environment.
his mechanical aspirations: he was a
go far wrong with mining and found
forklift washer, steam engine stoker and
employment on one of the Free State
One survivor is Cape-based precast
electric train-driver assistant.
concrete manufacturer and steel
gold mines as a mine cage onsetter on
fabricator David Timothy. Having always
a shaft which plunged a staggering 4km
valued quality above quantity, Timothy
below the surface.
has used this philosophy to establish
In the wake of his second army camp,
three successful businesses: Cobble
he succeeding in indulging his passion for
& Slab – precast concrete production,
vehicle maintenance when he was offered
Hamblin Engineering – steel fabrication and precast concrete mould production, and Hope Gar den Furnitur e cc – a manufacturer of Edwardian café-styled pavement furniture of global repute. Shunning convention and orthodoxy, Timothy’s achievements have been built on a quest for perfection, exceptional engineering ability, versatility and selfreliance. Before he ventured on his own in 1988, he acquired invaluable, wide-ranging expertise with several engineering enterprises and it was this that gave him the can-do confidence and flexibility which have underpinned the development of his three diverse, yet inter-related businesses. Early days When he left school in 1970, Timothy had his sigh t s se t on b e c oming a very good mechanic like his father.
PRECAST | ISSUE THREE | 2019
(Above, from left): David Timothy stands next to some freshly cast kerbs; pre-stressed Vibracrete posts. (Lef): Part of a patio furniture consignment destined for a castle in Spain. (Below): Cobble & Slab’s storage yard.
TECHNICAL 32
an apprenticeship at a garage workshop
department. In 1983 he was transferred
The first breakthrough came when Marine
in the old Karoo town of Colesberg. This
to Concor’s engineering workshop in
Civils awarded the company the contract
is a period he looks back on with special
Cape Town, where he was put in charge
to manufacture the Gordon’s Bay floating
fondness, because not only did he revel in
of estimating and draughting. During his
jetty, which was manufactured on Libra
the work, but he met and fell in love with
time with Concor, Timothy was intimately
Construction’s premises in Somerset
a Mauritian girl. When she returned to
involved with some of the company’s
West. Timothy had to improvise by using
her home town of Bonaero Park in 1973,
major contracts, including the building
a gantry attached to a neighbour’s wall.
he gave chase – and they were married
of the Matimba Power Station and
soon afterwards.
the supply of steel formwork for the
Steel specialisation A year later, the business relocated
New career Now a husband needing to put food on the table, Timothy found employment as a welder at the first engineering workshop he approached, Engineering Design & Construction (EDC). Two years and another SA Defence Force camp later, he was appointed as a welder with
“The early days were tough and it took several years before the furniture business turned a profit.”
Pimbro Engineering. After another six
to rented premises at SBDC premises in Blackheath, Cape Town, star ting with 100m². As the company grew, its premises expanded to 1 100m². Another breakthrough came when George Cocotos of Libra Construction awarded Hamblin Engineering some structural steelwork. Thereafter, the company began manufacturing precast concrete moulds
weeks of border patrolling, he rejoined
construction of the Du Toitskloof Tunnel
for other precast concrete producers
EDC and – within three months – was
on the N1 between Paarl and Worcester.
such as Cape Concrete, Concrete Units
In 1988, he felt the time had come to
and Rocla. Mor e r ecently, Hamblin
He left EDC for the second time in
launch his own steel fabrication business,
Engineering designed and made all the
1978 to join Concor Construction’s
Hamblin Engineering. Operating out of
component parts for a conveyor system
Johannesburg-based steel fabrication
his garage in Somerset West, he began
at a crockery factory in Blackheath.
workshop as production foreman of
by manufacturing burglar-proofing, steel
In 1992, Timothy was approached by
the cast-in-situ bolts and steel items
gates and other small steel products.
Adrian Hope, who enquired whether a bar
running the workshop.
www.smartstone.co.za
Design
You can
with
of mild steel could be forged and twisted
and Asia. At the time of writing, a large
into an attractive shape. Not having
consignment was being prepared for ship-
done this type of work before, Timothy
ment to a privately owned castle in Spain.
nevertheless accepted the challenge, knowing it wouldn’t take him long to
Next venture
perfect the technique. He didn’t hear
Cobble & Slab was started by Timothy’s
from Hope until six months later, when
son, Shane, who began making wet-cast
the latter approached him again, this
concrete pavers in three sizes. This was
time with a firm order to manufacture
followed by the production of kerbs and
twisted steel frames for the café-style
panels for Vibracrete walling.
pavement furniture mentioned above.
“We then installed a stressing bed
Using a plough shear as a homemade
and began making pre-stressed posts
f u r n a c e, T i m o t h y ’s s t e e l f o r g i n g
for the Vibracrete walling. Again, quality
methodology was more akin to a
was paramount and we adopted the
blacksmith’s forge than a modern steel
same approach to our precast concrete
plant. Long a collector of pre-war heavy-
production as we did to our furniture
duty steel fabrication machinery, Timothy
and steel fabrication businesses. As a
was able to put this antiquated plant to
result, many of our early Cobble & Slab
work and became a supplier of meticulous
customers are still with us. And if we’re
forged metalwork which characterises
unable to supply immediately, our clients
the Hope product range. Part of the
prefer to wait until we can deliver, rather
production process involved making hand-
than buying elsewhere,” he says.
operated jigs for turning out curves and
Although kerbs and Vibracrete walling
scrolls. He also adapted a large pre-war
are the mainstays of Cobble & Slab’s
lathe, which had probably been used for
output, the company will make any
the manufacture of tank parts during
precast concrete product to order.
World War II, to produce metal table-tops.
Besides supplying hardware stores and building contractors, the company also
Making furniture
produces precast concrete products
This manufacturing approach was, as
such as lintels, manholes, various pavers
Timothy readily admits, outdated and
and trench covers for some of the
slow, but it delivered a very high-quality
Western Cape’s larger precast concrete
product which fulfilled his operational
producers.
philosophy of striving for perfection. Three months after he began manufacturing pavement furniture, Timothy became a partner in what is today Hope Garden Furniture cc. He says the early days were tough and it took several years before the furniture business turned a profit. “Fortunately, we were able to crosssubsidise the furniture venture from our steel fabrication and concrete mould production activities and, many years later, from Cobble & Slab, which we began in 2008. Despite a slow start, we never lost faith in what we were doing; nor did we lower our pavement furniture standards. For example, we’ve always used only sustainably forested imported hardwoods for our table-tops and chair linings. Maintaining a consistently high standard is what enabled us to break into the export market,” says Timothy. Hope Garden Furniture’s first export consignment was for a public park in Florence, Italy. Subsequent exports have been
(Above): Some of the café-styled pavement chairs flanked by Roscoe Dean (left) and David Timothy.
to many foreign destinations in Europe
(Below): Wet-cast kerb production.
PRECAST | ISSUE THREE | 2019
PROJECTS 34
PRECAST IN BOUTIQUE WINERY CON Precast concrete has played a crucial role in the construction of a new winery at Cordoba, a wine estate situated on the lower slopes of the Hottentots Hollands mountain range just outside Stellenbosch. Scheduled to process the 2019/ 20
civil engineers), Hennie Kleynhans QS
“One o f our big challenge s was
h a r v e s t, t i m i n g a n d t r o u b l e - f r e e
(quantity surveyors), CSV Construction
c on v er ting the war ehouse in t o an
construction were crucial elements in
(main contractors) and Cape Concrete
integral part of a hi-tech winery. Apart
the early viability of the estate. Cordoba
(precast concrete producers).
from the roof, it was completely gutted
was bought in 2017 by a European
According to Charl de Kock of consultC
consortium on the strength of its ideal
Engineering, meeting all the building and
The upper level of the new building will
soil, cool climate and the outstanding
plant assembly deadlines was vital to the
be used for the early wine-making stages,
quality of its grape varietals. The latter
success of the project.
such as grape-crushing and initial cooling,
will be crafted into exceptional boutique-
and rebuilt,” says De Kock.
“Our schedule was simpl y too
and the lower ground-floor section for
tight to allow for any changes during
maturation and ageing. In addition, a
Process engineering was the focal
construction. Precast assisted us in this
double-storey brick-and-mortar office
point of the project and every element,
regard, which is why we planned its use
building was erected adjacent to the
from the wine processing equipment to
from the outset. Moreover, it’s easier
crushing plant on the upper level.
the precast concrete elements, was
to program and eliminates rain delays,”
custom-designed. This not only meant
he says.
quality wines.
A large volume of earth had to be shifted to create a platform for the
trouble-free construction and plant
new building which has been built on the
assembly, but also proved to be the most
same level as the existing warehouse.
cost-effective option.
The excavation left a soil embankment approximately 7m high, which had to be
Professional input
retained. Rather than build a separate
Unlike many construction projects which
retaining wall, the rear wall of the new
only unearth problems on site and are
structure and half of one of the gable-
then costly to remedy, the planning on
end walls doubled as retaining walls. In
this project accounted for the smallest
addition, half the opposing gable-end
detail and took two years. This is why, when it is completed in February 2020, actual construction and plant assembly will only have taken a year. The project began with the appointment of Schalk Willem Joubert, one of the country’s most experienced winemakers as its managing director, and subsequently a team of professionals with the enviable reputation of having
“The advantage is that once the columns are grouted in position, the props can be removed within 24 hours.”
brought the recently-completed Rupert
elevation was also constructed using precast slabs in order to maintain the building’s architectural symmetry. Upper level T he retaining walls were built with precast panels measuring 7m x 2,4m x 345mm and the void between the walls and embankment was filled with soil and then compacted. The remaining halves of the gable-end walls and the opposing/
& Rothschild Classique Winer y and
Moving earth
some other high-end winery ventures
The 1 600m² winemaking plant has been
on stream. The professional line-up
built on sloping land at the bottom end
is as follows: consultC Engineering
of the estate. It comprises a 1 000m²
(process engineers and principal agents),
twin-storey processing plant and cellar
M a l h e r b e R u s t A r c h i t e c t s, M P r o
which has been attached to an existing
Consulting Engineers (structural and
600m² warehouse.
warehouse elevation wall were built using (Top from left): A precast panel with two protruding feet for vertical alignment; some of the oval columns prior to the assembly of shuttering for the first floor and some of the precast columns at Cape Concrete’s production yard. (Above): One of the column concrete bases showing the templates for rebar alignment.
PRECAST | ISSUE THREE | 2019
NSTRUCTION
considerable amount of time to finetuning our precast designs before the first moulds were built – and having Cape Concrete on board from the outset made
conventional brick-and-mortar masonry
this process much easier. Once the
between the columns.
moulds were made, it was just a matter
A considerable advantage of this
of repeated casting.”
winery’s design is that the upper floor
Structural engineer Henk Burger
and the top of the embankment are level,
of MPro Consulting says the precast
which means grape-laden containers and
panels were installed using inverted
other vehicles can be wheeled directly
construction. This involved first casting
off the embankment onto the upper floor
a blinding layer and then lifting the panels
without the need for an access ramp.
into position with a 130-tonne mobile
Furthermore, the design provides the
crane. Each panel was cast with two
necessary gravity required to move the
360mm x 345mm feet at the bottom
crushed grapes from the upper level to
end, flanked with starter bars. The feet
the ground-level processing section.
came to rest on the blinding layer and
The upper level floor comprises a
steel shims were inserted under them
reinforced in-situ structure supported
for vertical alignment. Once foundation
by 32 6m-high oval precast columns.
reinforcing had been installed, concrete
“Aesthetically pleasing finishes were
was poured around the base of each
important project elements, which was
panel, which remained propped until the
why we opted for oval columns,” says
upper floor section had been cast.
De Kock. “They’re more easily produced with precast manufacture and the nice
Accurate building
thing about them is that when looked at
“The only downside to this approach
side-on, they appear to be only 140mm
was that we had to prop the walls a
thick. And, of course being precast, their
little longer than usual, due to the walls
quick installation enabled the upper floor
being designed as propped cantilevers,”
level to be cast much sooner.”
says Burger.
Precast solution
each vertical joint. These formed ducts
“Given our time constraints, this project
for grouting the panels together.
The panels were also cast with keys on
would have been impossible without the
“It’s much easier to build accurately
use of precast concrete,” says Servaas
with precast walls. Not only is it more
de Kock of Malherbe Rust Architects.
difficult to achieve the same accuracy
“A major advantage is that it can be
with in-situ construction, but it’s also
produced while other building activities
much more time consuming, given that
are underway, which saves time. It may
precast elements can be manufactured
appear more expensive than in-situ on
while preparation work and foundations
a direct item-for-item basis, but when
are continuing on site. Moreover, with
time-saving, quality, reliability and safety
in-situ, every shutter board can be out of
aspects form part of the equation, it
line, so the chance of error is far greater.
wins hands down.
By contrast, in the unlikely event of a
“One of the main challenges in using
precast panel or column not meeting
precast is keeping it modular. We could
design specifications, it can simply be
have opted for innumerable shapes
exchanged for another,” explains Burger.
and sizes, but that would have proved
A dif ferent method was used to
too expensive. Instead, we devoted a
install the columns. They were cast with
PRECAST | ISSUE THREE | 2019
PROJECTS 36
corrugated grouting ducts, rather than
curing, the entire slab was covered with a
columns, there is a third precast and
protruding rebar and were lowered onto
layer of water for 10 days to ensure even
equally important concrete element in
starter bars set in concrete bases and
curing and no cracking. The shuttering
this project: precast concrete wine
then grouted in position.
was only stripped off the deck once the
tanks. Imported from Italy, 10 tanks
concrete was fully cured.
were initially fitted for the first season,
“The advantage of this process is that once the columns are grouted in
Special hard-wearing ceramic tiles
position, the props can be removed within
imported from Germany were used to
24 hours,” says Burger. “However, the
line the floor. To avoid air pockets, they
grouting ducts had to be cast with a
were laid as an integral part of the floor
Fast work
tight tolerance of 2-3mm so that they
structure on a 100mm cementitious
De Kock says concrete wine tanks exhibit
but the aim is to have 36 tanks installed and ready for the next harvest.
could match the starter bar alignment.
far fewer temperature fluctuations than
A nd Cape Concr ete supplied CSV
their stainless steel equivalents, which
Construction with steel templates to
display hot and cold spots.
ensure that the starter bars were cast
“Quality gains using concrete tanks
with the required degree of accuracy
are huge. Stainless steel tanks are
to match the column ducting. Once in
better suited to the initial fermentation
position, the columns were vertically
pr o c ess w hen the w ine’s mo v ing,”
aligned with fibre-cement shims.”.
explains De Kock.
Waterproof floor
will be fully functional by the end of
In order to ensure that the plant One of the major considerations in the
(Above): Precast retaining walls and columns.
February, some of the wine processing
construction of the winery was that
screed. Rated at 35MPa, the screed
equipment was installed in September,
the upper-level floor had to be 100%
was sloped to create falls to stainless
even though not all the building work had
waterproof and it was designed to comply
steel drainage slots so that solids
been completed. Other aspects of the
with that proviso. Cast in- situ with
can be washed off the floor. The tiling
project – such as the building of roads,
high-strength reinforced concrete, the
was done by highly skilled artisans who
the upgrading of water and electricity
floor has a loading capacity of 16kN, or
created channels between tiles for
supply and installation of Wi-Fi – all took
1,6 tonnes per square metre, and binds
water drainage.
place in tandem with the construction of
together with the walls. After the initial
Besides the pr ecast panels and
the winery.
PRECAST | ISSUE THREE | 2019
SUSTAINABLE STORMWATER DRAINAGE AT KIRSTENBOSCH A sustainable stormwater management system and the creation of an attractive paved environment were prime design considerations during a recent upgrade of landscaped areas around a new administration centre at Cape Town’s Kirstenbosch National Botanical Garden. Built on the northern side of the main entrance to the national heritage site for the SA National Biodiversity Institute (SANBI), the new centre houses offices for the institute’s finance, HR and IT departments. The main objective of the stormwater
comprising Vernon Mathews of VMA
system was to control water surges
Architects (the project’s architects and
during heavy downpours. It entailed the
principal agents), project manager Amjad
construction of two attenuation ponds,
Hendricks of Aurecon and environmental
a 340m² permeable interlocking concrete
consultant Jer emy Rose of Inf inity
paving (PICP) parking lot and shoring up
Environmental.
some water courses with gabions. A high-powered team was assembled to design and implement the project,
Aesthetic appearance According to Mathews, the essential purpose behind the landscaping was the creation of an attractive environment in sync with the rest of the garden’s driveways and parking areas. It involved extensive use of exposed aggregate paving, permeable interlocking pavers and grass block paving – all supplied by CMA member, CEL Paving. The exposed aggregate paving was used to repave some 200m of existing asphalt access roads and a 600m network of existing pathways. CEL Paving’s interlocking permeable pavers were used for the PICP parking lot and the company’s grass block paver was laid on (Left, from top): The parking lot paved with CEL Paving’s interlocking permeable pavers and some of the paths paved with CEL Paving’s exposed aggregate and grass block pavers.
PRECAST | ISSUE THREE | 2019
PROJECTS
some of the other parking areas, paths and a bus shelter. “We specified the CEL Paving exposed aggregate pavers because of their high level of consistency in colouring and texture,” says Mathews. “The new pavers are identical to CEL Paving’s exposed
38
aggregate pavers, which were installed on some of the Kirstenbosch driveways and parking areas six years ago and blend in seamlessly with them.” Pond overflows The newly-paved roads were cambered with falls that drain into open-paved channels on both sides. The channels drain into catch-pits which, in turn,
(Above): Part of the access road paved with CEL Paving’s exposed aggregate pavers. The road is flanked by open drainage channels and a small parking lot paved with charcoal-coloured grass blocks.
feed the attenuation ponds via precast concrete pipes. The ponds are linked via a
is full, it discharges into the municipal
subterranean concrete pipe so that when
stormwater system.
aggregate pavers. The PICP parking lot was designed by
the first pond overflows, water drains
Most of the water which falls or drains
Orie Welby and Solomon and comprised
into the second. When the second pond
onto the permeable paving parking lot
a sub-base layer of F50 geotextile (to
infiltrates into the soil. However, during
keep the sand off the bottom layer of
heavy downpours, fin drains channel ex-
aggregate), 250mm of 53mm aggregate,
cess water into a catch-pit which feeds
150mm of 19mm aggregate, a layer of
into the lower attenuation pond.
Fibertex F25, a 6mm layer of bedding
The walls of the attenuation ponds were constructed with gabions filled with
sand, CEL Paving’s interlocking permeable pavers and filler stone.
locally excavated rock, while the bottom
In addition to VMA Architects, other
of the ponds were lined with Armorflex
members of the landscaping professional
blocks supplied by CMA member Inca
team comprised Arwin Bhawan (land
Concrete Products.
su r v e y o r s ), O r r i e We lb y, S o l o m o n & A ssociaISSUtes (ci v il and str uc tur al E TWO
• 2018
Permeable paving
engineers), OVP Associates (landscape
Considerable time, money and resources
a r c h i t e c t s ), M a r t i n & E a s t ( m a i nR49.00
were saved in the paving of the access
contractor) and HC Pav ing (pav ing
road. This was due to an existing sub-
contractor).
THE CM
A – QU
ALITY
CAST
base of 150mm G5 and 150mm G4 aggregate, which was retained. The only fresh material required was a 6mm layer of bedding sand for the exposed
IN CO
NCRET
E
(Left, from top): A section of road paved with CEL Paving’s exposed aggregate pavers and the lower attenuation pond lined with gabions and Armorflex blocks supplied by Inca Concrete Products.
ISSUE
TWO
• 2017
UALITY
A–Q
THE CM
VISIT IS SUU.CO M AND SE ARCH PRECAS T MAGA ZINE FOR CU RRENT AN D BACK IS SUES ISSUE
ONE
• Wor ld beat ing blo • 3D ck ma printed ker house • Exce llence on dis play
CAST
E
NCRET
IN CO
0
R49.0
• 2018
THE
AST
TY C
UALI
–Q CMA
RETE
ONC
IN C
ISSU
E TW O • 20
18
winners ges Award challen • CMA omic tures g econ or struc • Easin convey tion of • Evolu
THE
WANT TO ADVERTISE? CONTACT THULI MAJOLA TEL: 011 883 4627 OR EMAIL: THULI@ISIKHOVA.CO.ZA
PRECAST | ISSUE THREE | 2019 lls g wa tainin s een re r cost • Gr rpiece s lowe ator maste ural • Vibr itect arch • An
CMA
– QU
ALIT
Y CA
ST IN
CON
nical experience and product application analysis, was selected to design and manufacture skew culverts for the Parktown Emergency Stormwater Project in Johannesburg. “A n assessment of the r elevant technical and practical factors is key to the successful design of any element
REHABILITATION OF PARKTOWN
STORMWATER SYSTEM Concrete stormwater pipes have a long lifespan, but it is not infinite. Ageing infrastructure, as well as pipe erosion and corrosion. are all factors that initiate the rehabilitation of stormwater piping systems.
of stormwater rehabilitation projects,”
a curvature that would fit properly into
says civil engineer Muhammad Bodhania,
the existing curved channel. We’re proud
based at Rocla’s Roodepoort offices.
to say that despite the challenges of
“There were numerous technological
the required angle design, we met the
challenges presenting on the Parktown
technical specifications completely”.
project, so meetings were held be-
Rocla supplied 42 straight 2 500mm
tween PGN Civils, the site engineer
x 2 500mm SAR culverts, 19 skew
and ourselves in order to ascertain the
culverts and associated bases.
most appropriate design and product
“We’ve worked with engineers at PGN
to be used for the successful insta-
Civils and WBHO previously on specialised
llation of the replacement skew culverts
projects and they know about our techni-
and bases.
cal, design and manufacturing capabilities,
“The existing stormwater channel
which was why Rocla was chosen to as-
at Parktown has a unique curvature, so
sess and resolve the technological chal-
Rocla had to design and manufacture
lenges of a unique project,” adds Bodhania.
specialised skew culverts that could
The Parktown Emergency Stormwa-
be installed into it. We took the basic
ter Rehabilitation Project started in
design of a standard Rocla culvert, but
February 2019 and is due for completion
manufactured it at an angle to create
in February 2020.
PRECAST SPECIFIED FOR ATTENUATION POND CMA member Technicrete’s erosion con-
runs smoothly on site. Upon excavation of
flexible and sophisticated in design, con-
trol system, which provides an alterna-
the pond’s designated area, unexpected
forms to ground contours (even if set-
tive for a wide variety of erosion control
rock was discovered which had to be
tlement occurs after installation – the
and drainage projects, was recently
removed with chemical blasting before
blocks have a specially tapered design to
specified for a specialised attenuation
the required pond level could be reached.
allow for this flexibility), settles without
pond for waste management company
We halted deliveries of the loose blocks
fracture and requires only limited ground
EnviroServ’s Rosslyn premises.
to site until the blasting issue had been
preparation,” added Van der Berg.
Its Armorflex was used as a lining for drainage channels at aprons, pipe inlets
resolved,” said Luan van der Berg, sales consultant for Technicrete.
Technicrete manufactures the internationally licensed Armorflex system in
and outlets, where it eliminates pipe
“We supplied 7 000m² of blocks for
SA. It is the only system available lo-
undercutting that can lead to severe
the attenuation pond, which will serve as
cally with the facility to wire-tie adjacent
problems such as surrounding bank fail-
a storage for run-off dump water and any
blocks together into long mats. The inter-
ure and siltation downstream.
other excess water components at site.
locking design allows the surface to re-
The Rosslyn project ran from Febru-
The product was supplied in palletised
main flexible to movement, eliminating the
ary-June 2019 and was undertaken by
loose-block form for manual installation,
cracking and spalling issues that plaque
MK Africa Civils. “We’ve worked with MK
which – upon completion – created the
solid concrete surfaces, even when
Africa Civils on other projects, and we
mat formation.
exposed to regular inclement weather.
understand that at times, not everything
“The beauty of the system, is that it’s
The openings in each block and between blocks are perfectly sized to benefit from enough vegetation growth to make the surface appear “natural”, while still maintaining structural integrity. It is suited to other drainage applications such as ditch linings, spillways, headwalls, sediment basins and traps, pipe inlet protection and protective barriers.
PRECAST | ISSUE THREE | 2019
PROJECTS
CMA member Rocla, known for its tech-
39
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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 AFRISAM SOUTH AFRICA (PT Y) LTD TEL: (011) 670 5500/5752 PROVINCE/COUNTRY: GAUT SEPHAKU CEMENT (PT Y) LTD TEL: (012) 684 6300 PROVINCE/COUNTRY: GAUT
PI – Precast Infrastructure PB – Precast Building
ASSOCIATE MEMBERS AF CONSULTING ENGINEERS & ASSOCIATES (PT Y) LTD PROVINCE/COUNTRY: JHB
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
ASPASA TEL: (011) 791 3327 PROVINCE/COUNTRY: JHB
on tel: (011) 805 6742.
PRECAST | ISSUE THREE | 2019
The key solution to finishing concrete surfaces
CHRYSOÂŽFiniSafe CONCRETE FINISHING AID
Extends and facilitates the workability of the concrete surface. Lubricates concrete surface for an easier, faster and better finish. Reduces floating/troweling and blade wear. Facilitates dry shake hardeners application.