Precast • Issue 3 • 2020

ISSUE THREE • 2020

R49,00

THE VOICE OF THE PRECAST CONCRETE INDUSTRY

• Custom-made precast for civils • Baby brick machine boom • Man-made gravel improves concrete

Premium specialist cement

SURETECH has been formulated to provide cost-effective high end concrete and concrete products.

Ideally suited for blending with extenders such as fly ash, slag and silica fume.

USED FOR: Concrete, grouts, masonry products, precast products, RMC, shotcrete and proprietary applications.

Scan the QR Code to visit our website

SURETECH FOR SUPERIOR HIGH STRENGTH REQUIREMENTS

PPC, Ask for it by name.

ppc.africa | 0800 236 368

COMPANY NEWS

2 CUSTOM MADE PRECAST

FOR CIVILS

21 EQUIPMENT SUPPLIER PROVIDES

AFFORDABLE OPTIONS

INDUSTRY NEWS

PRODUCTS

33 TRUSTING YOUR RETAINING WALL

ENGINEER AND CONTRACTOR 35 THE PERFECT TOOL FOR

CRANE PLANNING

CONTENTS

COVER STORY

22 BABY BRICK MACHINE BOOM 25 MANUFACTURING THE LARGEST

CUSTOM JACKING CULVERTS

IN SA

37

5 6

CMA AGM BRIGHTER PROSPECTS BECKON

9

LOCKDOWN REFLECTIONS

15

PROJECTS 40 LANGEBAAN - SALDANHA

BRIDGE REHABILITATION 41 ADDING FLAIR TO NEW

OLIFANTSFONTEIN FIRE STATION

26 28 MAN MADE GRAVEL

IMPROVES CONCRETE

TECHNICAL 30 ADMIXTURES FOR

ALL APPLICATIONS

19 CHEMICAL MANUFACTURER

GROWING WORLDWIDE

32 NEW PLUNGERS FOR BETTER

PAVING PRODUCTS

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, 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 | 2020

44 PRECAST CONCRETE CHOSEN FOR

STEENBRAS WELLFIELD PROJECT

GLOBAL VIEW

17 TCI'S ONLINE TRAINING

PROVING POPULAR

PRECAST is the mouthpiece for the Concrete Manufacturers’ Association - CMA

42 EXPOSED AGGREGATE

PERMEABLE PAVERS FOR CAPE

BUSINESS PARK

46

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

ISSUE THREE • 2020

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© 2020. 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 Twinstar in

Precast

Olifantsfontein

• Custom-made precast for civils • Baby brick machine boom • Man-made gravel improves concrete

boldly goes where others fear to tread by manufacturing all types of custom-designed and cast products for civil engineering contractors. While these one-off jobs are usually avoided by typical precasters due to their complexity, size and resource-intensive requirements,

Twinstar

Precast

is

specially

geared to undertake this type of work and has been doing so for more than six years.

1

COVER STORY 2 Twinstar Precast in Olifantsfontein boldly goes where others fear to tread by manufacturing all types of custom-designed and cast products for civil engineering contractors.

While these one-off jobs are usually avoided by typical precasters due to their complexity, size and resource-intensive requirements, Twinstar Precast is specially geared to undertake this type of work and has been doing so for more than six years.

Not surprisingly, owner-operator Annemerie Coetzee is also known to be one of the most inventive individuals in the industry, having received the 2012 CMA Award for Excellence in Innovation for the design and development of a bomb-proof ATM enclosure.

CUSTOM-MADE PRECAST FOR CIVILS civil engineering contractors (who are

Growing relationships

direct customers) to architects and

Coetzee’s ability to solve problems on

specifying engineers who conceptualise

behalf of clients has also made Twinstar

requirements, as well as precasters and

Precast a favourite of the mainstream

the broader construction industry.

precast manufacturing companies, who

“With 26 years of experience in the

regularly send referrals and make use of

precast industry, I realised there was

her services to manufacture speciality

a gap in the precast concrete market

products on behalf of their clients.

for custom-made products and once-off

According to Coetzee, the company’s

items. In the concrete pipe and manhole

success is due to strong relationships

market, for example, the emphasis is on

within the industry, which range from

high volumes. However, the effort and

time required to design and build onceoff moulds for non-standard products disrupt any normal well-oiled production line and also require additional skills and supervision.

Custom-made

“We remain the only company in SA specialising exclusively in custom-made and one-off precast concrete products.”

“Not all building contractors have the necessary expertise, manpower and facilities to manufacture such products on site. As a result, it’s become our express aim to assist specifying civil engineers

PRECAST | ISSUE THREE | 2020

numerous occasions, but simply could

These polymer products have no metal

complicated sites and situations where

not withstand vandalism and led to the

components and also reduce the safety

currently available precast concrete

continuation of illegal mining activities.

risk of open manholes, as well as the fi-

products simply won’t work.

Since the installation of mineshaft

nancial implications this has for councils

“We strive to be a problem-solver and

slabs manufactured by Twinstar Precast,

and developers. The company manufac-

solution-driven in all aspects of precast

the shafts remain closed and are still

tures manhole lids and frames, as well as

concrete. We’re able to manufacture

completely intact. The design and manu-

stormwater gratings. These components

products ranging in weight from 2kg up

facture of polymer products is another

can be bought as loose items or cast into

to six tons quickly and affordably. Be-

success that dissuades criminals from

the required precast concrete slabs.

cause of the complexity of this type of

stealing covers for their steel content.

COVER STORY

and civil engineering contractors with

3

While the company’s manufactur-

work, we remain the only company in SA

ing facility is situated in the heart of

specialising exclusively in custom-made

Gauteng, deliveries are made across the

and one-off precast concrete products.

country wherever custom precast con-

“We only keep a few fast-moving prod-

crete products are required. Twinstar

ucts in stock which are standard spec in

Precast also offers a service whereby

tenders and drawings. Companies which

crane-mounted trucks assist with the

previously made them have either stopped

placing of slabs during installation.

or have closed down. This has largely given rise to our unique relationship with the mainstream precast concrete companies which make use of certain non-standard products,” says Coetzee.

Real solutions She adds that the company’s biggest achievements include successfully closing old mineshafts in Gauteng, which had been closed by other means on

DYNAMON MS100 THE SUPERPLASTICIZER THAT DEALS WITH THE “GREMLINS” IN YOUR AGGREGATE”.

DYNAMON MS100 is another innovative, high quality readymix superplasticiser which is ideal for use with super absorbent aggregate on site. It has been developed to accommodate various site conditions and raw material characteristics while allowing for extended workability retention When your aggregate is not working with you, trust DYNAMON MS100 to get it back into line.

Learn more at mapei.co.za | Tel: + 27 11 552 8476 | Email: info@mapei.co.za MAPEISA/0410/MSA/01/20PCM/GPG

INDUSTRY NEWS 5

The machines will play an integral part in ensur ing 10 0 % lo c al and 10 0 % quality products remain accessible to the sector and will assist in making a difference to the beneficiaries’ lives and expanding their business.

The business’s decision to make this

MACHINES TO BOLSTER SMMES PPC recently donated six brick- and block-making machines to six SMMEs in Gauteng, Limpopo and Mpumalanga which are long-standing customers of the cement producer.

investment in SMMEs, as part of its En-

as one of its Enterprise Development

in the community. We’re honoured to be

terprise Supplier Development (ESD) fund

beneficiaries and giving us the courage

one of the beneficiaries who’ve received

during a post-pandemic environment, has

to continue improving and building our

a brick-making machine. I’m excited to

proven to be an example of PPC’s ongoing

township/local economy. I see these

see where this partnership will take me

investment in the community.

machines as being a tool that will leave

and other SMMEs who’ve been given the

me in a position to strengthen what

opportunity to excel in their business

Working together

it’s been teaching me for so long,” says

over the past three years.”

“The global pandemic has challenged us

Rachel Msiza, founder of Style Africa

“The continued participation of our

to add sustainable value and convenience

Paving & Cladding in Soshanguve, north

people in the township economy has re-

to the SMME sector. We understand

of Pretoria.

mained a motivator for us to reinvest in

that the challenge for local entrepre-

the entrepreneurial efforts we encounter

neurs is to remain competitive, while

Township economy

daily,” says Lekula. “Now we’ve taken

ensuring that they apply the education

PPC’s long-standing relationship with the

another positive step towards promoting

in producing quality bricks which we’ve

SMMEs in the community has resulted

manufacturing and production efforts

provided over the past few years. Each

in the identification of individuals who

in the township. Our work thus far has

brick-making and paving machine pro-

would be best placed to grow their local

improved the social and economic value

vided will serve as a visual representa-

township economy.

of brick-makers. For this reason, we see

tion of our commitment to provide a

Highlighting the long-term business

the work we do as being key to creating

better quality of life so that they can

impact of the machinery, JX115 Trading’s

an enabling environment for us all. In

take advantage of the niche opportuni-

f ounder, Jo el Msipha, say s: “A s a

recognition of this, PPC is focused on

ties available to them,” explains Njombo

customer of PPC, this machinery shows

ensuring that together, we’re stronger,”

Lekula, MD at RSA Cement.

me that it’s really focused on investing

he adds.

“The sponsorship of the machinery came at the right time: we’re facing a different and unprecedented challenge as SMMEs. Receiving a machine means a lot to my business, as it will assist in growing the company, creating more employment and, most importantly, being competitive.

“We appreciate PPC’s choosing us

PRECAST | ISSUE THREE | 2020

“The continued participation of our people in the township economy has remained a motivator for us to reinvest in the entrepreneurial efforts we encounter daily.”

The CMA (NPC) is on an upward trajectory. This positive outlook came to light during its web-based AGM held on 10 September, when – in addition to bread-and-butter issues – some important feedback critical to positive outcomes was discussed and ratified.

T his included the expansion of and

“One of the major benefits of social

reallocation of shares in the association’s

media platforms is that one can monitor

certification auditing arm, CMA CS; a

the response,” said Cockcroft. “We’ve

successful re-accreditation of CMA CS

seen Facebook contacts grow from

by SANAS; the growth and successful

an average 180 a day in July 2019 to

market penetration of the CMA’s social

around 400 a day a year later. Reach on

media pla t f orms; the appointment

a monthly basis climbed from 830 during

of

the same period to 4 644 and it contin-

three new faces to the board of

directors; and more cost-ef fective,

ues to show steady growth.”

flexible head office accommodation.

T he meeting was led by general

Rapid response

manager Henr y Cockcrof t. Besides

He mentioned that during the lockdown,

chairing it, he spoke about how the

the CMA formed part of the Covid-19

association had managed the lockdown

R a p i d R e sp o n s e t e am, w h i c h w a s

and the steps which had been taken

instrumental in presenting Government

during the past financial year to advance

with a risk-adjusted strategy and was

its members’ interests.

primarily responsible for seeing the construction industry back at work from the beginning of May.

Growing strong

The CMA will be vacating its existing head office accommodation when the

The association has coped remarkably

Another lockdown success was the

lease expires, after which it will use a

well with Covid-19 and the lockdown

securing of SANAS approval for CMA CS

flexible office space system at a con-

to conduct virtual certification

siderably lower cost. The system offers

audits online. This meant cer-

fully equipped workspaces (including

tification work could contin-

boardrooms), as well as the benefit of providing the same facilities in all the

ing the lockdown. In addi-

major commercial centres.

and despite operating under the

RS

NCRETE al

u

Cockcroft explained how,

tion, CMA CS’s three-year

Guest speaker, economist David

audit accreditation expired

Metelerkamp, spoke about the macro-

te

Q

industry looks assured.

ue without interruption dur-

AT I O N

of the precast concrete

U

OCI

its future as the custodian

N

SS

during the past 100 years,

A

A

the country has witnessed

M

worst economic conditions

TURE FA C

CO

INDUSTRY NEWS 6

CMA AGM – BRIGHTER PROSPECTS BECKON

it

over the past year, the CMA has extended its reach through

the social media platforms of Facebook,

re

in August 2020 and during

economic outlook for SA’s construction

July 2020, SANAS spent a week

industry. He identified key risks to the

at the CMA conducting an accredita-

economy and said the country is likely to

y c nc ast in co

tion audit.

default during the next two years if gov-

LinkedIn and Mailchimp. Engineers, ar-

“They pulled us apart and asked every

chitects, quantity surveyors and other

possible question,” said Cockcroft, “but

ernment does not reduce its spending.

professionals are being contacted on a

we passed with flying colours and we’ve

Tough times

regular basis using a different precast

been accredited as a product certifica-

“Covid-19 came at the worst possible

concrete-related theme each month.

tion body for another three-year period.”

time, as the South African economy was already in crisis before the lockdown.

Readymix concrete

While I expect the economy to rebound

More good news is that CMA CS is

next year, albeit off a very low base due

about to extend its reach into other

to pent-up demand, over the longer term

construction-related activities such as readymix. In addition, the company has implemented a quality management audi ting sy stem and w ill soon w ill embark on the certification of quality management systems. Some financial and other inputs are already in place and work will begin as soon as SANAS approval has been obtained.

PRECAST | ISSUE THREE | 2020

der activity, but this figure has dropped

more negative than for the civil sector

negative territory,” said Metelerkamp.

dramatically to 9% post-lockdown. Since

because South Af ricans ar e under

He cited the listed property sector,

restrictions have been relaxed, there

massive financial pressure and becoming

w hi ch h a s b e e n o n e o f th e w o r s t

has been a slight improvement in awards

significantly poorer. Annual per capita

performers on the JSE in 2020. Property

activity. However, any hope of the pri-

income has already dropped to around

funds are down 38%, many tenants are unable to pay their rent and the demand for office space is expected to drop even further in the longer run. JSE-listed contractors lost 80% of their value over the past 10 years and the list of projects out to tender is at its lowest level since

“The association has coped remarkably well with Covid-19 and the lockdown.”

the inception of the data in 1998.

R49 300, down from R53 500, and is expected to deteriorate further.

In addition, the unexpected rebound in the residential property market is unlikely to assist the building sector, as most of the activity is in the built sector, rather than new dwellings. However, there are several major low-cost housing projects

Civil construction nosedived during

currently underway which will bolster

2020 and conditions in the building sector

suppliers to this market sector.

are even worse. Metelerkamp was equally

Ending on a mor e positive note,

pessimistic about government’s ability to

Metelerkamp said he expected inflation

roll out its approximately 50 Structural

to remain below 5% until 2022.

Insulated Panel (SIP) projects, which are

In closing, Cockcroft welcomed three

currently valued at approximately R360

new non-executive directors to the

billion. Some of these projects have been

CMA board: Rupert Strydom of Deranco

on the books for over five years and have

Precast, Francois Alberts of Cemblocks

gone to tender twice or more.

and Christo van Zyl of CvZ Consulting. He vate sector taking the lead with some

said he and his team were very excited

Financial pressure

of the state’s infrastructure projects

that the association had the funding

Metelerkamp noted that before the lock-

seems unlikely, given the lack of incentive

to continue operations and he assured

down, close on 90% of civil contractors

for them to do so.

members that it would be money well

were becoming more positive about ten-

The outlook for the building sector is

INDUSTRY NEWS

I anticipate the economy remaining in

spent in promoting their interests.

7

INDUSTRY NEWS

In trying to limit the spread of Covid-19, authorities worldwide have had the unenviable task of balancing the health benefits of lockdown against the costs.

Lockdown has been particularly severe locally and our economy has sunk to its worst recession in living memory. Borrowing is soaring and the cost of our

9

10-year government debt is higher than our current GDP can sustain. Government has already borrowed $4,3 billion from the International Monetary Fund and more borrowing seems inevitable.

Many businesses have gone to the wall and scores have lost their livelihoods.

With unemployment now above 50%, lowincome earners and the food-insecure face a bleak future. is taking place in and around the Palma

survived and, if so, how did their post-

LOCKDOWN REFLECTIONS

lockdown activity compare with pre-

resume production.

awarded. We are also tendering for some

A gainst this b ackdr op, Pr ec ast conducted a round-robin survey among precast producers to find out how they were coping. Had their businesses

site. Roads are being built, labour camps established, buildings erected and a jetty is being constructed in Pemba. Moreover, some of our tenders have now been

lockdown conditions? Anticipating an

It took us two to three weeks to get

major projects in SA: a student residential

overwhelmingly negative response, we

going, which also involved implementing the

building in Durban and a multi-storey resi-

were pleasantly surprised. Business

new health and safety regulations. During

dential project in Goodwood, Cape Town.

conditions, although depressed, were

the early stages of lockdown relaxation,

We believe government should kick-

not as bad as had been anticipated and

we pushed in-house precast production

start our industry by accelerating some

one company actually recorded its best

at our Westmead plant, because it was

of the infrastructure tenders that were

July sales figure ever.

classified as manufacturing, rather than

issued in January and February. Worth

our cast-on-site activity, which was not.

billions of rands, they involve major

David Kitching,

We managed to convert two projects,

roads in KwaZulu-Natal, Mpumalanga,

general manager:

which were intended to be traditional

Gauteng and the Eastern Cape. As yet,

Bedrock Group

tilt-up jobs, to pure precast. One entailed

none of these dozen or so road packages

As at mid-July, we

the 160km delivery of massive precast

have been awarded. During Level 5 of

wer e operating

columns to Kranskop.

the lockdown, when the construction

at 60% capacity

We have had to postpone our largest

industry was struggling and the issuing

and we should be

project, namely the provision of various

depar tments were not busy, these

back at 100% by

precast concrete elements for the

tenders could have been adjudicated.

mid-September.

development of Mozambique’s natural gas

However, they were not.

Investor and

deposit. At US$150 billion, it claims title

Some of the designs and drawings

property developer confidence took a

to the world’s largest single investment.

issued for many of these projects are

knock during the initial stages of lockdown.

We have submitted over a dozen tenders

copy-and-paste designs from the 1970s

At that time, no-one knew how long it

and before lockdown, we had already

and ’80s. One result of this is that most

would last and some developers must have

invested a considerable amount in setting

freeway bridge beams are specified

been petrified that they had committed

up bases in Palma and Pemba, as well as

as pre-stressed. There are very few

(as in one case, nearly R1 billion for a retail

headquarters in Maputo.

facilities in SA that manufacture pre-

building project) to business sectors which might not have survived.

We lost two months’ turnover during April/May, so effectively 2020 will be a nine-month year for us. The initial

During lockdown, our people were

stressed precast bridge beams, so there

stuck in the worst quarantine facility in

is not much competition. Designers and

Africa. Their living conditions were almost

structural engineers should be looking at

unbelievable.

alternative designs using conventional re-

Subsequently, extensive enabling work

inforcing, which would open up the market

stages of lockdown were exacerbated by the fact that admin and pre-planning project development, which could have continued during lockdown, did not. This meant that when the lockdown was first eased, it took everyone much longer to

PRECAST | ISSUE THREE | 2020

“It took us two to three weeks to get going, which also involved implementing the new health and safety regulations.”

INDUSTRY NEWS 10

to more players. While this would mean

is aware that they have them and that

I do not envy the Government in having

more competition for us, we need to do

lives are at risk. This is intolerable – and

to deal with this pandemic, especially in

things at less cost and faster, to get our

would not be difficult to stop.

a country where unemployment levels

roads built quicker, our railways working

Contractors are being forced to hire

are so high. I am grateful that the

better and our ports operating at higher

a minimum of 15% or 20% of their staff

construction industry is at least back

efficiencies, instead of having projects

complements through these extortionist

at work . O ther industries such as

that drag on for months and years and

groups. The sad part is that those who

tourism and food and beverages are

some that are never completed.

get the work are paid a minimum wage,

really battling and Government has

Our new health and safety environment

while the rest is kept by the business

its hands full keeping them afloat, so

does not help matters. I have always

forum, so people are essentially being

I can understand that they have to

taken issue with the fact that the health

employed, but at the expense of others.

spread themselves very thinly across

and safety industry is self-perpetuating.

If I take on five unskilled and completely

all industries. I would love them to do

The people who work in it have the power

inexperienced people from the local

more for the construction sector, but I

to implement procedures and processes

community, I have to put five Bedrock

know that realistically they can't, so we

that basically keep them and their

people on short time. It makes no sense.

simply have to take care of ourselves.

industry operating. The more complicated

Employment levels stay the same – all

and over-the-top their requirements, the

that changes is where people live.

more it costs everyone in the value chain,

To me, coming to work every day with machines whirring in the background feels like things are back to normal. The only

the contractor, the sub-contractor, the

Lenny Gorgulho,

difference is that we wear face masks

supplier and the consumer.

director: CEL

and keep our distance.

Many of the health and safety re-

Paving Products

Right now, our prime focus is on keep-

quir emen ts being implemen ted f or

Implementing the

ing our core business going and for the

Covid-19 appear to be superfluous or

new health and

time being, we have put the introduction

extreme. Even when they make sense,

safety regula-

of new products on hold. We want to get

implementation appears random and

tions was a lot

through this period with as little dam-

there is no standardisation. Govern-

easier than we

age to our business as possible. Once

ment could have empowered the Master

had anticipated.

things improve and there is greater

Builders’ Association or a consortium

Social distancing

certainty, we will turn our attention to

of construction-related professionals

and isolation have proved fairly easy, due

with issuing standard health and safety

to the fact that our machinery is well

requirements countrywide, which would

spaced, as are the people who operate it.

have simplified matters. Instead, one of

In fact, we had already employed a

our sites currently requires three-ply

health and safety specialist well before

Concrete Units

masks, while at others, two-ply masks

the advent of Covid-19 and she was fully

Business condi-

will do. Other regulations also vary from

briefed on what had to be done. She is

tions are shock-

one site to another.

in charge of our Covid-19 procedures

ing. There is no

My last point concerns the highly

and thanks to her involvement, our

doubt that Cov-

destructive business forums. At the

staff have adapted to the new health

id-19 has had a

end of last year and the early part of

and safety regime fairly well. They all

massive impact on

2020, there was a lot of action among

understand the bigger picture and are

construction industry and government

ultra-cautious about adhering to the

We have coped in various ways. We have

bodies to put a stop to them. Court

regulations. They certainly do not want

terminated some of our limited-duration

cases were held and injunctions filed, and

to go through another shutdown due to

contracts and we made partial payments

it appeared as if their overtly organised

non-compliance.

to our monthly staff during Level 5 of the

new endeavours.

Brian Cook, manager:

our industry.

criminal activity on construction sites

Our core business was operating at

lockdown. We did receive some funding

was being dealt with. Sadly, it still

about 80% capacity before lockdown and

from the Temporary Employee/Employer

continues and every week one site or

we were back at that level shortly after

Relief Scheme (TERS), but it was not

another has a work stoppage because

resuming production. However, much of

nearly enough to cover what it cost to

of their interference.

our post-lockdown activity was based

pay our staff – which was considered quite

A non-profit body that genuinely finds

on pre-lockdown orders. We also saw an

generous, compared with what others in

work for local people is one thing, but the

uptick in demand from our larger retail

our industry were paying.

full force of the law should be brought

store customers.

We are very fortunate to be executing

to bear on mafia-styled groups which

That said, these are very uncertain

a large contract which should see us

prevent a construction site from oper-

times and one does not know what is

through to the end of the year. Come

ating unless the contractor hands over

around the corner. Once these pre-

January 2021, we will have to join the fight

a large extortion fee. It is terrifying for

lockdown projects are completed, things

for a piece of a hugely reduced market

site workers when three or four vehicles

could become much tougher until the

share. We anticipate a blood bath in the

drive up and armed men step out. Guns

pandemic finally dissipates or a vaccine

short-term, but we may stand to benefit

are not brandished openly, but everyone

is found.

if the Department of Mineral Resources

PRECAST | ISSUE THREE | 2020

& Energy is able to accelerate part of the next bidding round for wind towers and solar farms. However, that next round is only scheduled for January 2022, so we expect a challenging year ahead.

Despite this, I remain cautiously optimistic. South Africans have stared down the barrel many times before and the doomsayers are invariably proven wrong. So I would like to believe that this time, they will be proven wrong again. We are a highly resilient society and we fight when the chips are down.

One of my reasons for optimism, strange as it sounds, is SA’s unemploy-

“To me, coming to work every day with machines whirring in the background feels like things are back to normal. The only difference is that we wear face masks and keep our distance. ”

ment figures, which are at their worst levels ever. Government is acutely aware

even easier. Obviously, all our workers

that we are on a cliff edge. One of the

abide by the latest health and safety

ways this can be addressed is through

regulations, including the wearing of face

public works programmes. I believe gov-

masks, frequent hand-sanitising and the

ernment intends adopting this path and

monitoring of temperatures.

spending a substantial amount of money

T he biggest risk to our staf f is

on public works/infrastructure develop-

travelling on public transport. Since

ment over the next 10 years. President

we transport them ourselves from key

Franklin Roosevelt used them during the

points to our factories, we reduced this

Great Depression to reignite the Ameri-

risk by staggering work starting times to

can economy and address unemployment

minimise the number of people in vehicles

in the 1930s, and they worked brilliantly.

at any one time.

I see no reason why they cannot work here as well.

2015 & 2019 FULTON AWARD WINNER

I believe that one of the biggest pr oblems in our industr y is labour legislation and the lack of protection

Chr is van Z y l,

businesses receive during labour unrest.

MD: Mobicast

It is not conducive to good labour relations

We were involved

and is a disincentive to entrepreneurship

in several large

and new investment. I also feel that

housing projects

although the goal o f government’s

w hen the lo ck-

BBBEE regulations are commendable, in

down was intro-

their existing format they are counter-

duced. These

productive to job creation and a healthy

were started up

business environment and should be

again in May and

scrapped. In addition, of course, we would

will continue to completion during 2021.

also like to see government fund more

Mobic ast pr o duc es a f ull r ange

infrastructure projects to stimulate the

o f pr ecast concr e te pr oduc ts ou t

economy and create employment.

of factories in Groot Brak River and Mossel Bay, as well as a limited range in

Silvio Ferraris,

Wellington. Our product base ranges from

CEO: ReMaCon

infrastructure through to decorative

We sold nothing

Tel: Cape Town (021) 386 1923

products for the housing market.

in April and not

Fax: Cape Town (021) 386 2514

By the end of June, we were back

much in May, so

to a staff complement of 75% at both

we ef fectively

our Southern Cape plants, each of

lost two months

which was operating at 70% capacity.

of our 11-month

In the Western Cape, things were a

w o r k i n g y e a r.

little slower, with production at 50%

However, af ter

capacity. No plant is congested, so it has

that, sales picked up very quickly and

been easy to maintain social distancing.

during a three-week period in June, 80%

Also, much of the wet-casting is done

of our stockholding was sold.

outside, which makes social distancing

CONCRETE UNITS

E-mail: precast.ct@concreteunits.co.za Website: www.concreteunits.co.za

Our debtors were not paying on time PROUD MEMBER OF THE CMA

PRECAST | ISSUE THREE | 2020

INDUSTRY NEWS 12

during April and May and we received

We have returned to pre-lockdown

previously disadvantaged, but what I

assistance from the Sukuma Fund and

levels. In fact, sales are even slightly

cannot comprehend is why the ANC

the Reserve Bank Guarantee Fund. This

better. One reason for this is that we are

has not prioritised education. It has

provided bridging finance to keep us going.

becoming less reliant on retaining blocks.

completely failed in this respect. If our

Repayments are only due to begin after

We make specialised mould-cast products

populace is not educated, how can we

a six-month grace period and thereafter,

such as the Yfel for dry bulk separation.

expect to grow the economy?

the loans can be serviced at prime plus

We have also started producing cattle

In the short- to-medium term, things

compound interest over five years. We

feed troughs and we make vandal- and

are very uncertain. Nevertheless, I feel

also received help from TERS and the

thef t-proof vaults for batteries and

more confident than most that the situ-

Unemployment Insurance Fund (UIF) with

electrical components. These products

ation will improve – provided government

salaries and wages and we were given a

now account for 50% of our product mix

gets infrastructure projects moving.

three-month moratorium on the repay-

and by the end of the year, they should

This cannot be done by appointing only

ments of asset financing by the banks.

make up 60% of our turnover.

BBBEE companies. Those companies

Everyone is back at work, apart from

I have followed the economic recovery

with the necessary skills and expertise

the over-60s (including myself), those

strategy presentation by Business SA

should be allowed to tender, with the

who were ill with tuberculosis, etc. We

to government and fully support what it

proviso that if they win contracts, they

have implemented all the Covid-19 rules

aims to achieve.

then use BBBEE-compliant companies as

and regulations and are taking all the

I agree that our labour laws are too

prescribed precautions. In addition to

strict and that unions are given too

sub-contractors.

hand-sanitisers and masks, all surfaces

much freedom. BBBEE requirements

Alex Cyprianos,

such as door handles are sanitised on a

should be relaxed, especially for SMMEs

MD: Revelstone

regular basis and we spray all the toilets

(ie businesses whose turnover is less

T he initial lock-

every second day.

than R100 million). ReMaCon may not

down was not a

We are in the fortunate position that

be BBBEE-compliant, but we employ

b i g w o r r y, b e -

Tembisa is right next to us, so all our

96 people, contribute to the tax base

cause we wer e

employees walk to work. If someone is

and pay VAT – yet we are discriminated

very busy in the

not feeling well, for whatever reason, we

against. I understand the need for

period leading up

send them home for the day.

some form of intervention to uplift the

to it. We agreed

We are there when you celebrate

Need to excel in concrete? Our School of Concrete Technology offers internationally recognised courses for anyone interested in concrete.

Master concrete with us. www.theconcreteinstitute.org.za +27 11 315 0300

breaks so that changing rooms are never

that come July, we could no longer

week lockdown period, based on one im-

full and we have marked where our staff

operate on that basis, so we ramped our

portant condition – that they undertook

can and cannot sit.

capacity up to 75% – and that is where

to stay at home. The real stress started

We remain vigilant and have appointed

when the lockdown was extended: that

someone to ensure all our protocols are

it will remain for the time being.

We are producing over 65 tons a

was when the consequences of no turno-

applied. Temperatures are taken three

day of mixed products. This is sufficient

ver, fixed overheads and all the expenses

times a day and tea and cof fee are

for our current workforce to handle

incurred during a very busy March really

served in disposable cups. We keep full

comfortably. Demand is exceeding what

hit home.

records of when our staff arrive and their

we can produce, which means we are

It has been much worse than we could

temperatures. If someone does contract

essentially making to order. Increasing

ever have imagined and we had no inkling

the virus, we know with whom they were

output at this stage would require more

that we would be shut down for the

in contact and for what length of time. If

people and social distancing would be

whole of April and May. We were not only

any of us develop symptoms, we stay at

more difficult. As the end of the year

worried about our staff and their families,

home until we are cleared by World Health

approaches and our busy season unfolds,

but about surviving as a company.

Organisation guidelines to return.

we may have to revise this strategy.

Fortunately, we have always followed

We had a visit from the Department of

If I had been told at the beginning of

a conser vative business model. We

Employment & Labour for a Coronavirus

June that we were in line to record our

are well capitalised and do not spend

risk assessment in July and it was

best July ever, I would have dismissed

unnecessarily, precisely so that we

very happy with what we are doing.

it as a pipe-dream – but we did. We had

can cope with an unexpected crisis like

Mercifully, we have had no Covid-19

a better start than we could ever have

Covid-19. This meant that we had reserve

mortalities among our staff. Two of our

imagined.

funds to carry us through to the end

office workers were infected, but they

of May. What is more, we enjoy good

recovered and have returned to work.

Our prospects for the remainder of this year and next year are promising,

Post-lockdown, we have benefited

but who knows where we will be in five

from a new marketing strategy which

or 10 years’ time? Things seem very

However, we r eally battled with

was launched at the beginning of 2020.

uncertain over the long term and this

TERS. The Department of Employment &

We focused our marketing efforts online,

discourages investment. Government

Labour is used to dealing with thousands

advertising on Facebook and Instagram.

needs to draw a line in the sand so that

of queries a month, not millions, and it

Working from home during the lockdown,

we can all get on with our lives. Too much

was totally overwhelmed. In the ensuing

people had the opportunity to surf social

uncertainty affects business, which – in

chaos, it kept moving the goalposts,

media platforms for home improvement

turn – affects employment.

adding more security measures, and it

products and our marketing strategy

Moreover, it is critical that govern-

refused to pay our small complement of

played per fectly into this scenario.

ment support local businesses and not

foreign workers, even though they were

Spending more time at home, people

just BBBEE companies. We are 100%

all UIF-registered and legally employed.

became aware of things that needed

committed to SA. Everything about us is

We remained closed on 4 May (the

fixing or upgrading, so although our

South African and only 5% of our raw ma-

start of the first working week after

showroom and factory were closed,

terials is not locally sourced. It hurts to

Level 4 of the lockdown began) because

our products were being promoted

go to a new development, only to see im-

we were not classified as an infrastruc-

online. Our website enquiries shot up

ported products being used and specified

ture project supplier. However, some

and our following numbers on Facebook

by the professional teams. Why? Some

of our clients were given permission to

and Instagram increased substantially.

architects may want natural stone, but

resume projects at the end of May, one

This meant that when we re-opened, we

there is no discernible difference in our

example being the paving of a road in a

already had a healthy order book.

cast-stone product. Government has

relationships with our suppliers, all of whom gave us extended terms.

Franschhoek wine estate.

T her e is de f initely business out

done well by promoting locally produced

Before we re-opened in June, we

there – and it is not only residential.

materials for its own projects, but should

spent a week with a few staff members

It is commercial work as well, with

also support non-BBBEE companies.

setting up everything. We put up clear

the Deloitte Head Office at the V& A

We have 100 families who live off

plastic screens in reception, at all the

Water f ront, the Franschhoek Wine

our business and rely on it for their

customer inter facing points and at

Estate, Durban’s Umhlanga Ridge, the

f u tur e pr ospec ts. We could bu y a

our debtors section and dispatch. We

UC T campus and others keeping us

machine from Europe or China, change

set up sanitising points and prepared

really busy.

our manufacturing and only employ 10

protocols such as restricted access,

Although we hit the ground running

workers instead of 100. However, those

the wearing of masks, hand-sanitising

when we re-opened, we were sceptical

100 families have only us to rely on and

and temperature-screening.

about how things would develop and we

we are committed to operating the way

Luckily, our factory is spacious and

split our workforce into two: Team 1

we do. Government should look after

there are not many high-risk points.

would work for one week and Team 2 for

labour-intensive companies with tax

Most of our staff work at least 2-3m

the next, which meant we were always

incentives and other benefits. By doing

apart at all times, as a standard. We

running at 50% capacity. However,

so, it would stimulate employment and

have staggered starting times and tea

business accelerated to such an extent

grow the economy.

PRECAST | ISSUE THREE | 2020

INDUSTRY NEWS

to pay our staff in full for the first three-

13

INDUSTRY NEWS 15

The Building & Construction Industry Medical Aid Fund (BCIMA) announced that it has grown its membership by 5% through 2020, despite the Covid-19 pandemic and associated hardships.

MEDICAL SCHEME KEEPS GROWING, DESPITE SLOW ECONOMY

According to Phumelele Makatini, CEO

BCIMA offers members in the build-

and principal officer of the scheme, who

ing, construction and civil engineering

was speaking at the company’s recent

industries the following benefits:

benefits launch, it has been one of the

• It is exempt from prescribed minimum

more dif ficult years in our industry,

benefits (PMBs). Originally registered

yet BCIMA has continued to grow its

as a bargaining council, BCIMA volun-

m emb er ship, w h er e as m o s t o th er

tarily converted to a medical scheme

medical aid schemes have lost members

and, over the years, has enhanced

because of the Coronavirus.

its benefit coverage in every successive year.

“We’ve focused our efforts on achiev-

various associations, such as the Bar-

ing this and are pleased to confirm that

gaining Council for the Civil Engineering

• Not having to cover PMBs at cost

we were also able to add further value for

Industry, the Master Builders’ Associa-

means the scheme pays less for the

our members by increasing the scheme’s

tion of SA, the Master Builders’ Asso-

benefits offered and is not subjected

benefits by an average of approximately

ciation North and the SA Forum of Civil

to the unduly high fees charged by

5% across the board. We’ve further been

Engineering Contractors. It’s also the

some providers.

able to keep contribution rate increases

preferred medical scheme for a number

• The average BCIMA member is 28

to a low 4,5% for 2021,” she said.

of unions, including the Building, Construc-

years old, while the pensioner ratio

tion & Allied Workers’ Union, the National

is currently only 1,99%, compared

Performing well

Union of Mineworkers and the

with an average pensioner ratio of

“Over the past five years,

Amalgamated Union of Building

9,55% for open schemes and 6,46%

contribution increases have

Trade Workers.

for restricted schemes.

remained consistently low and

• The scheme offers a single contribution

we work hard to keep them

Broad appeal

rate for a whole family, whether it is

this way. In fact, over the

“These organisations repre-

only the principal member who joins or

past several years, BCIMA

sent a large number of con-

the principal member and his/ her

has had some of the lowest

tractors and employers in the

family. This means members never

annual increases on a consist-

construction sector. They also

need to leave a sick child off their

ent basis – and 2021 will be no excep-

provide a range of services to members

medical cover.

tion,” said Makatini.

of the industry, such as ongoing training,

• Principal members can register all

She noted that BCIMA maintained a

legal services, labour relations, building

their children, as well as their spouse

solvency ratio of 117 – significantly above

codes and standards, and regulatory

or life partner, on the fund without

the industry average and four times

compliance matters that favourably im-

greater than the solvency ratio required

pact the sector and its people.

paying more.

According to Makatini, contributions

by the Council for Medical Schemes,

“Having the support of industry bodies

are based on wage levels, which means

thereby confirming the financial stability

and unions, as well as a number of com-

members never pay more than they

of the fund.

panies and employer groups, is what sets

can afford. “Once you become a BCIMA

“The value BCIMA provides is widely

BCIMA apart as the medical scheme of

member, you can remain one for life. We

acknowledged in the industry, with the

choice for the building, construction and

fund enjoying considerable support from

engineering industries,” she said.

PRECAST | ISSUE THREE | 2020

(Left): Phumelele Makatini, the CEO and principal officer of BCIMA.

INDUSTRY NEWS 16

understand that contractors can end up

consultations with traditional healers.

• BCIMA offers members peace of mind

with no work when companies are between

Furthermore, the scheme has a generous

by providing transpor t cover via

projects. To ensure continuous medical

benefit for homeopathic remedies and

Netcare 911 for emergencies, acci-

cover, BCIMA also provides one member-

over-the-counter medicines.

ship number for life.

dents and trauma incidents.

“BCIMA is passionate about bringing

Benefit highlights

flexible access to quality healthcare for

Tailored solution

• Unlike other schemes aimed at the

the hard-working employees of the build-

“Our rules allow members who’ve joined

lower-income market, BCIMA offers

ing, construction and civil engineering

the fund to temporarily pause their

generous day-to-day benefits, in-

industries – all at a cost they can afford.

membership when a project is com-

cluding R4 400 per principal member

We stand for value-for-money medical

pleted. Members can thereafter re-join

and R9 900 per family for medical

cover and our long and proud service

the fund at a later stage, using the

consultations with general prac-

history to the industry has given us un-

same membership number, without any

titioners and specialists.

derstanding and insight into the sector,

underwriting.

• The medication benefit is extremely

its people and their needs. This makes

“BCIMA understands that working in

competitive. Acute medication has

BCIMA the ideal partner to the sector

the building, construction and engineering

been increased to R6 700 for a prin-

and its employees.

industry means constant changes in

cipal member and up to R11 500 for

work location. The scheme therefore

a family.

doesn’t limit members to consulting

• The chronic medicine benefit has been

sustainability of SA . As one of the

specific healthcare providers. Members

increased to R12 000 per family.

oldest medical schemes in the country,

are offered complete freedom of choice

• The scheme introduced an unlimited

BCIMA is proud of the role it’s played

to see their own GP or specialist. In

benefit for members diagnosed with

in broadening access to healthcare

addition, hospital benefits are available

HIV or Aids.

for South Africans and we hope our

at any private hospital of the member’s

• The hospital limit will increase by

experience imparts helpful learnings to

choice,” explains Makatini.

4,27% to R440 000, which will be

the broader healthcare sector ahead of

BCIMA is also one of the only

supported by an in-hospital ex gratia

the implementation of National Health

medical schemes to provide cover for

benefit in the event of clinical need.

Insurance,” says Makatini.

“Healthcar e is a national asse t which is pivotal to the economic

“BCIMA has continued to grow its membership, whereas most medical schemes have lost members because of Covid-19.”

TCI’S ONLINE TRAINING PROVING POPULAR The Concrete Institute’s School of Concrete Technology is now offering online tuition for one of its most popular and basic courses: SCT10 Introduction to Concrete. The course – aimed at small, medium and micro-enterprises, junior technical and sales staff in the building, construction and allied industries – has attracted strong interest.

John Roxburgh, senior lecturer at the School of Concrete Technology, says the course is essentially designed for anyone who is keen to do more concrete work either for an employer, to start a small business or even for home improvement projects. It offers basic information about various aspects, including: • Concrete properties and materials.

• Receiving and storing concrete materials.

• Transporting, placing and compacting of concrete.

• Batching, mixing and testing of concrete.

• Finishing and surface preparation.

• Protection and curing of concrete.

• Formwork and reinforcement.

• Sand-cement mixes.

• Durability of concrete.

The course is one of 10 now offered online by the School of Concrete Technology aimed at diverse levels of competency in the construction and allied industries. Normally presented at the school over one to five days, in the online environment, the course can be stretched over a few more days to cater for students who need to do most of their studies after work. The lecturers conducting the courses are in contact with the students over various media forms to explain and guide the process.

Rox bur gh say s the online tr aining cour ses ha v e been enthusiastically welcomed. “The lockdown has given people more time to study. They’ve learnt how to use online meeting platforms and the discounted tariffs now offered by the school have also been a major attraction. The fact that we can offer training for a specific company’s personnel – at a suitable time for the client – also means staff productivity can be maximised, as there’s no travel or lecture room time involved. Also, because the lecture sessions are recorded, a delegate who misses a presentation can view it later,” he says.

(Above): Mixing concrete is part of a wide range of essential information contained in the School of Concrete Technology’s SCT Introduction to Concrete course, now offered online at discounted tariffs.

PRECAST | ISSUE THREE | 2020

CHEMICAL MANUFACTURER GROWING WORLDWIDE Leading construction chemical supplier Sika is changing its strategy to better service its wide-ranging customer base in post-Covid-19 times.

South African representation at the company’s recent global Sika Capital Markets Day 2020 was strong, with delegates sharing new strategies from senior management to regional and national offices. The event was held in Zurich and CEO Paul Schuler confirmed the strategic targets for the year 2023.

Under the theme “Weathering the Storm: Emerging From the Covid-19 Crisis as a Stronger Company”, members of group management and Sika experts explained how important trends such as innovation and digitalisation, renovation and sustainability are creating opportunities for the company to gain further market share during the crisis.

Schuler said: “Practically all our national subsidiaries have been impacted by the Coronavirus pandemic. In many countries, the lockdown phase ended in June and restrictions have been significantly eased. Momentum is picking up again in the construction sector. Our local management structure has enabled us to adapt swiftly worldwide to changing market conditions. Thanks to our rapid implementation speed and our proximity to our customers, we’ve been able to seize business opportunities and gain additional market share.”

During the Capital Markets Day, information was provided on the measures with which Sika intends to continue its sustainable growth in the future, despite the Coronavirus crisis. Breakout sessions focused on the key success factors of the business model, namely the focus on innovation, digitalisation and sustainability, the opportunities presented by worldwide infrastructure programmes and the increased demand for renovation, as well as the strengths of the business in the distribution channel.

Schuler said the organisation will continue to be aligned for sustainable, long-term success and profitable growth. By targeting six strategic pillars – market penetration, innovation, operational efficiency, acquisitions, strong corporate values and sustainability – Sika is seeking to grow by 6-8% per year in local currencies until 2023. It is aiming for a higher EBIT margin of 1518% from 2021 onwards and projects in the areas of operations, logistics, procurement and product formulation should result in an annual improvement in operating costs equivalent to 0,5% for the next two years. In addition, the company aims to make all product innovations even more sustainable, while simultaneously increasing performance.

(Top): Sika CEO Paul Schuler has set new targets for the company in the years ahead.

PRECAST | ISSUE THREE | 2020

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

www.rocla.co.za

for our nationwide branches

www.kobramoulds.com

SINGLEBOLT ™ The single piece »Singlebolt™« plunger is the logical continuation of the KOBRA modular system.

facts & advantages » round plunger sleeves » standard and spare parts quickly available » no welds » short plunger – high stability

Best in service life.

TOOLS

MOLDS. Driven by knowledge.

CARE

SERVICE. Powered by experience.

KOBRA MOULDS B.V. • Laan van Hildernisse noord 4C • 4617 AE Bergen op zoom • The Netherlands • Tel: +31 [113] 562 460 • info@kobramoulds.com

COMPANY NEWS 21

EQUIPMENT SUPPLIER PROVIDES AFFORDABLE OPTIONS According to Statistics SA, the coun-

Revaro Concrete Equipment

skid steers, generators, TLBs, excava-

try’s unemployment rate is at an all-time

Products: Brick, block and paver machines,

tors and face mask production machines.

high. The solution to this problem is

concr e te kerb machines, concr e te

entrepreneurship.

mixers (pan, twin-shaft and planetary),

Revaro Materials Handling

Entrepreneurial grow th has now

aggr ega te ba tcher s, machines f or

Products: Standard, all-terrain and

become more crucial than ever before.

lintels, rib-and-block, clock-and-beam,

rough-terrain forklifts.

Most p eople ar gue tha t too many

hollow-core slabs and poles, automatic

un c e r t ain ti e s an d p o li ti c al is su e s

pallet feeders, brick and block splitters,

Revaro Plant Hire

discourage would-be entrepreneurs

concrete roof tile machines, wet block

Rental of quality service and well-main-

from taking the leap of faith. However,

stackers and jaw-crushers.

tained equipment, including front-end

while change can bring uncer tainty

loaders, forklifts and composite pallets.

a n d a n x i e t y, i t a l s o o f f e r s g r e a t

Revaro Brick Pallets

opportunities for renewal and progress.

Products: Composite polymer pallets

Full-maintenance leases are available.

The Revaro group of companies has

(premium and Revaro Gold high-

Revaro Motorsport

ignited start-up businesses, expanded

per f ormance low-f lex ) and ply wood

SSV vehicles for business and leisure

and diversified existing entrepreneurs

pallets (both locally manufactured and

purposes:

and created over 10 000 jobs. Its con-

imported).

• Sniper Series – 200cc and 400cc

crete products range from batchers,

• Falcon Series – 500cc, 1 100cc

mixers, bricks, blocks and paver-making

Revaro Engineering

machines to kerb plants, giving pro-

Products: Wet block stackers, brick block

• Beast Series – 1 000cc

and 1 500cc

spective entrepreneurs a wide range

and paver machines, moulds, batchers

of start-up options to fit their budget.

and attachments.

Entrepreneurial spirit

Revaro Steel

department, parts and workshop as well

According to Reyno van Rooyen, CEO

Products: IBR and corrugated roof sheet-

as a professional sales team and highly

of the Revaro group, entrepreneurs

forming machines (as well as other roll-

trained and experienced technicians to

are precious individuals who identif y

forming machines), PC wire and strand

help with all sales and after-sales, set

opportunities, risk their own money and

and steel coils for roll-forming.

up and install clients’ machines and train

Revaro facilities Revaro has an in-house quality inspection

are true creators of prosperity.

Revaro has positioned itself in the

them using it.

Revaro Construction

Revaro stands for affordable innova-

concrete, precast, agricultural and

S e r v i c e s: R i g g i n g a n d b u i l d i n g o f

tion, creating as many opportunities as

construction industries as a one-stop

structures of business premises, factory

possible and helps with diversification.

organisation, offering exceptional value

and warehouse development (complete

As experts in the industry, it listens to

for money to all types of businesses,

project) and roof sheet manufacturing.

its clients’ business needs and takes

whether new or established.

Revaro comprises several companies

into account their budgets during these Revaro Equipment

difficult economic times. In this way, the

in order to accommodate and differen-

Products: Machinery for construction,

group creates long-term relationships

tiate its vast range of products and

agriculture, brick production and any

based on superior support and service

services:

other commercial use, including loaders,

throughout the business cycle.

PRECAST | ISSUE THREE | 2020

PRODUCTS 22

BABY BRICK MACHINE BOOM While the world’s economies have been

equipment. Simultaneously, people with

brought to their knees by the ongoing

disposable incomes are renovating and

Covid-19 pandemic, PMSA has geared

creating strong demand for precast

for a boom in demand for small brick- and

concrete products.

block-making equipment as people invest their savings to set up plants and create

Robust design

sustainable long-term incomes.

“We designed the all-new Uni Eco Plant,

The company was able to continue

which can work wherever there’s suf-

trading during the lockdown and rather

ficient raw material and standard 220V

than going slowly as demand withered,

mains or three-phase power. Despite its

it looked at creating opportunities for

size, buyers will enjoy the same levels of

people who had lost their incomes due to the pandemic and worked on a plan to provide easy entrance for them into the potentially lucrative brick- and blockmaking business.

Since the easing of lockdown restrictions, the strategy has begun paying off and the newly manufactured equipment is selling rapidly. PMSA marketing and sales manager, Quintin Booysen, says the reasons for the uptick include the reinvestment of retrenchment packages, pensions and even TERS grants that have been used to buy start-up

“We wanted to give new customers the best start with an all-in-one solution that can immediately begin producing bricks and blocks of the highest quality.”

PRECAST | ISSUE THREE | 2020

Opportunity awaits

standard with any of our other equipment.

“Demand for building materials is current-

“Rather than buying cheap imported

ly high and there are shortages of bricks

equipment that’s unsupported locally, we

and blocks around the country. Despite

wanted to give new customers the best

all sorts of alternative building systems,

start with an all-in-one solution that can

the market has found that using bricks

immediately begin producing bricks and

and mortar is still the best way to build

blocks of the highest quality. The new

a house because it’s still the strongest,

plant also shares many of the features of

most attractive and cheapest method.

PRODUCTS

training, service and support that come

23

our bigger ones and comes standard with

“We’ve kept the price of the new Uni

reputation in the marketplace and makes

the top-quality V200 turbine pan mixer,

Eco Plants as low as possible, with a

them more sought after than opposition

robust Uni Eco Static Block machine with

view to helping newcomers break into the

products. Provided the right concrete

high-quality vibrators, roller conveyor,

market. By subsidising these machines

mixes are used and curing and off-packing

high-quality FTC and thermo-composite

and supporting the owners, we know we’ll

are done correctly, the Uni Eco Plants are

plastic pallets.

get a return on our investment in the long

able to produce this kind of consistent

“With a price tag below R300 000

term and will create relationships that

quality and should be the main drivers for

(excluding VAT), the plant can produce up

are ‘built to last’, just like our equipment.

customers to use the PMSA equipment.

to 7 000 stock bricks, or 2 000 hollow

“We expect these machines to last for

Quality will also be a prerequisite for a

blocks, or 4 000 maxi bricks, or 5 000

decades and due to the reliability of the

host of new projects due to be launched

paving bricks per single shift. That’s

equipment, we think owners will find that

by government in 2021 as part of its

amazing, considering that production

they spend far less money on replacing

Covid-19 economic stimulus packages,

costs per brick vary from 60-80c for

machines and spares than they would

of which housing projects make up a big

a stock brick and a price tag of about

if they chose cheap imported varieties.

part. “With the lowest interest rates

110-130c, depending on the location of

That means the operators will have more

in four decades, now’s also the time to

the plant. That’s a gross profit of about

money to expand their plants in future,”

invest in a business venture in order to

R3 500 after expenses per shift and it’s

says Booysen.

build a brighter future,” says Booysen.

likely that a start-up can earn R70 000 gross profit per shift per month,” he says.

Quality first He adds that when it comes to advising new customers, it is important that they understand the fundamentals and do some research in the area in which they want to produce. If everything checks out, they need to understand that consistent quality of units is as important as the number of units produced.

This ensures products earn a good

PRECAST | ISSUE THREE | 2020

“Demand for building materials is currently high and there are shortages of bricks and blocks around the country.”

PRODUCTS

MANUFACTURING THE LARGEST CUSTOM JACKING CULVERTS IN SA When the local municipality of Tshwane required 3m x 3m custom-made jacking

25

box cul ver ts f or a ser v ice deli ver y project at Iscor Heights in Pretoria West, the only company in SA able to design and manufacture culverts to such large specifications was Rocla.

T he culver ts were manufactured with an in-the-wall joint that can be sealed with a rubber ring, if required.

The project – which required 90 large culverts to create two 50m-long tunnels 6m below the road surface in order to provide new water services to the area – commenced in January 2020.

Brendan van Vuuren, sales representative for Rocla, says: “We’ve been involved with the Iscor Heights project since the inception of the tender. We worked closely with Esor, one of SA’s benchmark and civil engineering groups, which was the project’s sub-contractor

“The culverts were manufactured with an in-thewall joint that can be sealed with a rubber ring.”

– in order to ensure that its specifications for these very large jacking culverts were met. The largest jacking pipe Rocla had manufactured previously was 3 000mm x 2 500mm, which was too small for this project. After all the specifications were finalised, the designing process began, which included manufacturing the mould for this specially sized culvert.”

Creative capability “We’ve worked with Rocla on various projects over the years, so we knew that these large jacking culverts would have to be specifically designed and manufactured and that Rocla was the only company with that kind of creative capability,” says Esor director Len Nel. “Af ter many meetings to discuss the design and verif y the technical

size, delivery to site required an abnormal

will certainly become one of Rocla’s

requirements of the jacking culverts to

load permit and they were offloaded into

historical milestones,” says Van Vuuren.

ensure the final product would meet the

the pit with a side boom crane.

loading requirements, the final culvert

Rocla manufactures various culvert designs and base slabs, along with

weighed in at over 10 tons per product

Proud moment

stormwater pipes and other inf ra-

– a major design and manufacturing coup

“Rocla’s extremely pleased to have been

structure products, such as HDPE and

for Rocla.”

involved with this unique project. It

pressure-lined sewage pipes, concrete

T he time-f rame f r om appr oved

stretched our design team’s expertise

poles, manholes, bus shelters, sanita-

product specification and design to

and our manufacturing processes to

tion units and concrete cabins.

mould completion was only 16 weeks for

the limit, but showed that no project

the 90 culverts. Due to their enormous

is too big for us to collaborate on. It

PRECAST | ISSUE THREE | 2020

(Above): Rocla’s extra-large jacking culverts.

PRODUCTS 26

PRECAST DOMINATES IN LARGE Two Depar tment of Human Settle-

units, while SDC is responsible for Phase

ments housing projects, Syferfontein

B2, which involves the construction of

in Pacaltsdorp, George, and Mountain

158 units. ASLA’s project was completed

View, off Louis Fourie Road in Mossel

in September this year and SDC’s will be

Bay, have made extensive use of several

completed in May 2021.

precast concrete elements, the majority

Both contractors have been re-

being supplied by CMA producer member

sponsible for all the civil work in their

Mobicast.

respective sections and have used lo-

Operating out of factories in Mossel

cally sourced sub-contractors for all the

Bay, Groot Brak River and Wellington,

above-ground building work. The 40m²

Mobicast manufactures a wide range

dwellings comply with the latest building

of precast concrete products, including

(Above): One of the Syferfontein double-storey units.

regulations and have been built as either

concrete masonry blocks, suspended rib

(Below): A stepped single-storey unit at Syferfontein roofed with concrete tiles manufactured by CMA member, Eagle Roofing.

single- or double-storey units. Some of

and block flooring, concrete staircases,

the houses are stand-alone, while oth-

paving blocks, kerbing and retaining wall blocks. In addition, the company produces the Smartstone range of simulated stone cobbles and pavers under licence for the Western and Southern Cape.

Its Garden Route plants deliver as far afield as Beaufort West, as well as to Swellendam and Plettenberg Bay. The Wellington factory supplies the greater Cape Peninsula area.

Syferfontein Housing Project The project involves over 1 000 housing units built by several contractors over an extended period at Syferfontein. Royal Haskoning is the project’s consulting engineering company and Mobicast has supplied precast concrete products to two main contractors, ASLA Construction and Simply Do Construction (SDC).

ASLA has built Phase C, which entailed the construction of 679 housing

“The project involves over 1 000 housing units built by several contractors over an extended period at Syferfontein.”

PRECAST | ISSUE THREE | 2020

PRODUCTS 27

COASTAL HOUSING PROJECTS ers are semi-detached. The houses are

have zinc roofs. Mobicast also supplied

finishes and a pitched roof. Mobicast’s

plastered inside and out and come with

some of the precast elements for the civil

140mm cement blocks are being used

ceilings and roof insulation.

works. These included interlocking pavers

for the outer walls and its 90mm blocks

for the roadways and sidewalk pavers, as

for the internal walls. The fire walls be-

well as kerbs and retaining wall blocks.

tween units are being constructed with

NHBRC-approved

190mm blocks.

According to ASLA director Izak van

SDC director Louis Botha says this

Heerden, ASLA used a building typology

contract has run very smoothly, thanks in

which is approved by the National Home

no small measure to the excellent service

Rib-and-block

Builders Registration Council and the

provided by Mobicast. Van Heerden notes

Ruwacon contracts manager, DL Tal-

Department of Human Settlements. It

that ASLA has had a relationship with

jaard, notes that building the floors

entailed building the outer walls between

Mobicast spanning more than 20 years.

with Mobicast’s suspended rib-and-block

“Knowing we can rely on Mobicast to

system is working well. “We’re using

ASLA used 140mm blocks for the

meet our quality specifications and deliver

Mobicast’s precast staircases inside

dividing walls between dwellings and

on time is very important to us,” he says.

all the units, except for dwellings, which

reinforced concrete columns.

are being converted to accommodate

90mm blocks for the internal walls.

SDC’s houses are being built with Mobi-

Mountain View Housing Project

disabled occupants on the ground floor.

cast’s 140mm block for the outer walls

Begun in June 2019, the project is due for

In this instance, external staircases are

and 90mm blocks for the inner walls.

completion in February 2022. Ruwacon is

being used to reach the upper floors,”

Mobicast’s rib-and-block system is be-

the main contractor and Royal Haskoning

says Taljaard.

ing used for the upper-level flooring on

the consulting engineers.

both projects.

Mobicast will also supply 60mm col-

A total of 1 003 housing units are be-

oured and textured interlocking pavers

“Rib-and-block flooring is not only con-

ing built as 45m² double-storey designs

for some of Mountain View’s internal

siderably quicker than in-situ construc-

clustered in blocks of up to 10 units per

roads, while the spaces between build-

tion, but also creates work opportuni-

block. Ruwacon was responsible for the

ings will be paved with the company’s cob-

ties. In the George area, it’s more cost-

preliminary civil work and services. All

ble and stretcher bond pavers. Taljaard

effective than hollow-core construction.

the building work is being done by local

says Ruwacon has worked with Mobicast

Mobicast’s precast staircase is supplied

sub-contractors. Mobicast is supplying

on several other projects.

as part of the rib-and-block package and

concrete blocks, rib-and-block suspended

“It’s always given us good service and

takes less than a day to install,” says

flooring, precast staircases, concrete

Mobicast CEO Chris van Zyl’s door is al-

Van Heerden.

pavers and kerbing.

ways open for discussion about solutions

Ruwacon is building two housing Tiled rooves

models at Mountain View: Breaking New

Some of the single-storey units at Syfer-

Ground units and Finance Link Individual

fontein are roofed with concrete tiles

Subsidy Programme (FLISP) units. Both

manufactured by CMA member, Eagle

are built to the same structural design,

Roofing, while all the double-storey units

but the FLISP units come with additional

PRECAST | ISSUE THREE | 2020

to challenges,” he adds.

(Top, from left): One of the roads at Syferfontein paved with Mobicast concrete block pavers; some completed ASLA houses at Syferfontein and Mobicast blocks rest on rib-and-block decks prior to construction of the upper storey at Syferfontein.

GLOBAL VIEW 28

MAN-MADE GRAVEL

IMPROVES CONCRETE

A Munich-based German company, MultiCon GmbH, has patented a process to produce sand-based granules to replace quarried sand in concrete production, a process with significant environmental and technical benefits.

production of 1 ton of cement produces up to 800kg of CO2. Using our technology, it would be possible to eliminate up to 100kg of carbon dioxide emissions per cubic metre of concrete, which uses 300-400kg of cement.

into made-to-measure pellets in sizes

“O ur t e chnolog y f acili t a t e s the

ranging from 0-16mm in optimal grading

production of multi-material cements

curves. By using the granules and the dual

suitable for the mass application of high-

MultiCon high-speed mixing technology,

quality concretes.”

it is possible to manufacture high-quality

“The manufacture of CO 2 -reduced

concretes that are up to 25% lighter,

concretes has global appeal, but its ap-

harden faster and, as a rule, show greater

plication will require direct collaboration

strengths than conventional standard

with the cement industry,” emphasises Dr

concretes within 24 hours of production.

Helmut Rosenlöcher, MultiCon technical

Quarried sand is a commodity which is

director and inventor of the technology.

becomingly increasingly scarce. Forty

Greener option

billion tons ar e used by the global

Moreover, the conventional production of

Global interest

concrete industry annually and this has

cement produces enormous quantities of

In the Middle East, where the construc-

serious consequences for global eco-

carbon dioxide. MultiCon’s dual concrete-

tion boom continues almost unabated,

systems. Quarrying destroys wildlife

mixing technology reduces CO2 emissions

considerable interest has been shown in

habitats and compromises livelihoods.

by up to 50%. This makes it possible to

the German company’s innovative tech-

produce more environmentally friendly,

nologies. For example, MultiCon has come

high-quality concrete at a lower cost.

to a long-term collaboration agreement

MultiCon’s process combines fine rock flour and/or fine desert sands with mineral binders and special additives to produce

“Our prime objective is to ensure that

pressure-resistant granules for concrete

concrete has a viable future,” says Dr

production. Fine sand is processed

Leopold Halser, MD of MultiCon. “The

(Top): Fine sand is granulated with mineral binders in combination with special additives to form pressure-resistant pellets. (Photo: MultiCon GmbH)

PRECAST | ISSUE THREE | 2020

MultiCon’s processing plants and

in the Middle East – both in the manu-

high-performance mixers can not only

Due to its nature, desert sand has so

facture of CO2-reduced concretes and in

manufacture the sand and gravel needed

far been of no use to the construction

the processing of desert sands.

for concrete, but can also use them to

industry. This sand is too fine, geo-

The rapid spread of this technology

produce high-quality concretes. Expen-

metrically round and the surface of the

globally would constitute a significant

sive and environmentally damaging trans-

granules ground too smoothly. However,

contribution to the goals espoused in the

portation of aggregate to construction

MultiCon’s patented solution renders it

Paris Climate Change Agreement of 2016.

sites then becomes unnecessary.

a resource of the future.

Commenting on a possible CO2 tax in Germany, Rosenlöcher says this would not necessarily add to the cost of building, but should make the construction industry more innovative. “Incentives must be provided so that the use of CO2-reduced cement is directly linked to noticeable

“Quarried sand is a commodity which is becomingly increasingly scarce.”

savings in concrete production,” he says.

More options

Processing unused fine sands is of interest in Europe as well. In northern German regions such as MecklenburgWestern Pomerania and wide regions of Eastern Europe, there are large quantities of previously unusable fine sands.

The conditions in Europe are different from those found in the desert, especially

“The demand for plants for processing

for frost-resistant concretes.

High quality

desert sand in combination with the

“T he results of intermediate in-

MultiCon’s technology enables sand de-

suspension technology is enormous,

vestigations into European fine sand

posits which were hitherto unsuitable

especially in the so-called MENA states

concretes are quite promising and we

for concrete production to be processed

[in the Middle East and North Africa],”

believe that unused fine sand deposits

into made-to-measure gravel aggregates

explains Halser. “The first plants have

can be used in concrete production,”

in perfect grading curves and mix compo-

already been ordered and will soon be

says Rosenlöcher.

sitions. These granules can then be used

set up in Dubai and Egypt. Additional

in MultiCon’s matrix-optimised suspen-

promising business contacts in Jordan,

sion and processed into concretes with

Bahrain, Saudi Arabia and Kuwait have

sustainable properties.

already been established.”

(First published in BFT International)

GLOBAL VIEW

with the largest cement manufacturers

29

TECHNICAL 30

In the past three or four decades, admixtures have become increasingly popular as part of the concrete mix for a variety of reasons. Here Bryan Perrie, MD of The Concrete Institute, outlines the rationale for, and type of, admixtures most commonly used.

Admixtures are chemicals added to the concrete mix to modify some of the properties of the mix, but should never be regarded as a substitute for good mix design, sound workmanship or use of the correct materials.

The most common reasons for using admixtures in concrete are: • To increase workability without chang

ing water content.

• To reduce water content without

changing workability.

• To achieve a combination of the above.

ADMIXTURES FOR ALL APPLICATIONS

• To adjust setting time.

• To reduce segregation and/or bleeding.

var ying amounts of air, others are

Super-plasticisers are used to best

• To improve pumpability.

reasonably consistent in this regard.

advantage in areas of congested re-

• To accelerate or retard the rate of

Where plasticisers are used to increase

inforcement and where a self-levelling

workability, shrinkage and creep will

consistency facilitates placing. For high-

invariably be increased.

strength concretes, they decrease the

strength development at early stages.

• To improve potential durability and

reduce permeability.

water-to-cement ratio by reducing the

• To r educe the total cost of the

Super-plasticisers

T hese admix tur es ar e chemically

Special mixes must be designed for

• To compensate for poor aggregate

different from normal plasticisers and

super-plasticisers and their use must be

properties.

their action is more marked. When used

carefully controlled. Their effect varies

to produce flowing concrete, a rapid loss

from 30 minutes to six hours, depending

Plasticisers

of workability can be expected and they

on the admixture used.

When added to a concrete mix, plas-

should therefore be added just prior to

ticisers (water-reducing agents) are

placing. Super-plasticisers are usually

Air-entrainers

absorbed on the surface of the binder

chemical compounds such as sulphonated

An air-entraining agent introduces air in

particles, causing them to repel each

melamine formaldehyde, sulphonated

the form of minute bubbles distributed

other and de-flocculate. This results in

naphthalene formaldehyde, modified

uniformly throughout the cement paste.

improved workability and provides a more

lignosulphonates and polycarboxylate-

The main types include salts of wood

even distribution of the binder particles

based materials.

resins, animal or vegetable fats and oils,

materials used in the concrete.

through the mix. The main types of plasticisers are lignosulfonic acids and their salts, hydroxylated carboxylic acids and their salts, and modifications of both.

Plasticisers usually increase the slump of concrete with a given water content and can reduce the water requirement of a concrete mix for a given workability by about 10%. The addition of a plasticiser makes it possible to achieve a given strength with a lower cement content. It may also improve pumpability.

However, some plasticisers contain a retarder and can cause problems, if overdosed. While some entrain

“Admixtures are chemicals added to the concrete mix to modify some of the properties of the mix, but should never be regarded as a substitute for good mix design.”

water content by 15-25%.

and sulphonated hydrocarbons. They can be used where improved resistance of hardened concrete to damage from freezing and thawing is required, to add workability (especially in harsh or lean mixes) and to reduce bleeding and segregation, especially when a mix lacks fines.

Air-entrainment may reduce the strength of concrete and overdosing can cause major loss of strength: 1% air

(Above): An admixture played an important part in the construction of the Nelson Mandela Bridge in Johannesburg. Self-compacting concrete, containing a super-plasticiser supplied by Chryso SA, was used to build the towering pylons.

PRECAST | ISSUE THREE | 2020

entr ain lar ger volumes o f air than

concrete, water-retaining structures,

is important that the percentage of air

other types, while increasing ambient

pre-stressed or steam-cured concrete.

entrained during construction is moni-

temperatures tend to reduce the volume

Overdosing with these materials can

tored. Because dosages are typically

of air entrained. The use of ground

cause instant setting of the concrete,

small, special dispensers and accurate

granulated blast furnace slag and fly-ash

resulting in equipment damage. Accel-

monitoring are required.

will reduce the amount of air entrained,

erators work more effectively at lower

while the duration of mixing can also

temperatures.

Di f f er en t t y p es and sour c es o f cement/cement extenders may result in

affect air content.

the entrainment of different amounts of

Retarders

air for the same dose and mix proportions.

Accelerators

These admixtures slow the chemical

A change in cementitious content in

These admixtures speed up the chemical

reaction of the cement and water,

the grading or proportions of the fine

reaction of the cement and water and

leading to longer setting times and

fractions of sand will normally alter the

so accelerate the rate of setting and/

slower initial strength gain. The most

volume of air entrained.

or early gain in strength of concrete.

common retarders are hydroxylated

The amount of air entrained may

Among the main types are chloride-

carboxylic acids, lignins, sugar and some

depend on the source and grading of

based, non-chloride-based and shotcrete

phosphates.

sand in concrete. Forced-action mixers

accelerators. Shotcrete accelerators

They are mainly used when placing

react almost instantaneously, causing

concrete in hot weather (particularly

stiffening, rapid setting and hardening

when the concrete is pumped), to prevent

of the shotcrete.

cold joints due to duration of placing and

Accelerators are used where rapid setting and high early strengths are

(Above): Including admixtures in the concrete mix can substantially improve the pumpability of the concrete.

for concrete that has to be transported for a long time.

required (eg in shaft sinking), where rapid

If a mix is overdosed beyond the

turnover of moulds or formwork is needed

limit recommended by the supplier,

and where concreting takes place under

retardation can last for days. Retarders

very cold conditions.

also often increase plastic shrinkage

A ll chlor ide -b ase d ac c eler a t or s

and plastic settlement cracking, while

promote corrosion of reinforcing steel

delayed addition of retarders can cause

and should not be used in reinforced

extended retardation.

The Latest Technology in Precast Prestressed Concrete Products

Tel: 011 423 2700 / Fax: 011 423 2717 info@elematicsa.co.za / www.elematic.co.za

TECHNICAL

may cause a strength loss of 5%, so it

31

TECHNICAL 32

NEW PLUNGERS FOR BETTER PAVING PRODUCTS German manufacturer Kobra Formen

stresses occurring in the application

homogeneous pressure distribution

GmbH produces moulds for all types of

process during the development phase

results in a higher dynamic load capacity

block machines available in SA, including

of the new individual plunger. In this way,

and thus greater durability, creating

PMSA, MASA, Hess and Birkenmayer,

they optimised the overall design.

added value for re-usable groups.

and has f ur ther r e f ined its bolted

Practical tests have largely confirmed

concrete block mould to produce higher-

these theoretical findings and improve-

Easy maintenance

quality concrete products, as well as

ments have been made, for example, in

In the case of repair and maintenance,

being easier to repair and maintain.

the arrangement of the round sleeves in

the replacement of one or more plunger

The improvements are many and on

the production orientation to facilitate

groups can be done directly in the

the new Singlebolt 2TM extend to the

their assembly and disassembly. This is

concrete block plant by the operator.

plunger, which has been redesigned with

a great advantage, particularly for self-

A suitable offset screwdriver which is

round sleeves that are 114mm long in

assemblers, due to the simplified handling.

usable for all paving stone moulds can

the standard design and arranged in

be procured from Kobra for this. Special

parallel. They are connected directly

modifications of the screwdriver can also

to the bolting plate and tamper shoe

be ordered from Kobra and comprise the

with the help of a cheese-head screw.

extension of the handle and the exchange

A dynamically loadable connection is

of the screwdriver head.

thus created which, compared with the

The company offers customer-specif-

welded variant, guarantees considerably

ic training courses in mould technology

higher flexibility. This means that during

and mould maintenance. These courses

the pr oduction pr ocess ther e is a

focus on the structural properties of

significantly reduced risk of cracking,

the concrete block moulds and the re-

which represents a typical overloading

placement of spare and wearing parts.

pattern with welded plungers.

Workshops both at Kobra’s headquar-

The new individual plunger is

ters in Germany and on-site at the con-

char ac t er ise d by p ar ticular l y high

crete block plant have become standard

stability, which is achieved through the

practice, where required. These can be

length, geometry and arrangement of

Fur thermor e, a comparison was

the plunger sleeves within the mould’s

made with the pr ev iously installed

upper part. Because the components

variants of the Singlebolt 2. The typical

Kobra produces moulds for all kinds

are standardised, spare parts are quickly

crack f ormations that occurr ed in

of pavers, slabs, blocks and kerb stones

available and can be used for the majority

the pr e v ious design ar e no longer

and its moulds are known for high levels

of paver moulds and replaced in just a few

visible in the new development. This is

of precision and durability.

assembly steps.

attributable not only to welding seams having been dispensed with, but also

arranged with Kobra’s Service Department throughout the year.

Thorough testing

to the aforementioned length of the

(Top, from left): Exploded-view Singlebolt and the offset screwdriver.

By means of a finite element method

round sleeves. A short plunger with

(Above): Comparison Singlebolt design variant.

simulation, where a component is divided into a finite number of sub-areas and the overall behaviour of a structure is calculated from the behaviour of the sub-areas using defined algorithms, the Kobra design engineers calculated the

“The replacement of one or more plunger groups can be done directly in the concrete block plant by the operator.”

PRECAST | ISSUE THREE | 2020

TECHNICAL

TRUSTING YOUR RETAINING WALL ENGINEER AND CONTRACTOR

33

Experience counts for every thing in designing and constructing concrete retaining block (CRB) walls that are both safe and economical.

Designing CRB walls requires experience and knowledge of the prevailing site’s geological conditions, as well as

over-designed constructions.

site inspection or before any bulk earth-

what the code of practice SANS 207

ECSA rules state that for any design

works have even been completed, with no

sets out and how it is understood, if any

review, the originating engineer must be

factual basis of the in-situ soil parame-

design engineer hopes to manage the two

notified in writing. SANS 207 states

ters and without obtaining the originating

outcomes successfully.

that every “final” design must be pre-

engineer’s design parameters.

Designing conservatively is easy, but

ceded by a site inspection and soil pa-

Designing and inspecting the con-

the problem this creates is that the dis-

rameters need to be determined, pref-

struction progress regularly go hand-in-

tinction between the speed of construc-

erably by shear box or tri-axial testing.

hand to limit risk. The 30 years’ experi-

tion and scale of economy of CRB walls

It is irresponsible for any design review

ence of both contractor ValCal and design

versus conventional RC or concrete infill

to be based solely on an originating engi-

engineer Silvio Ferraris make for safe and

brick walls can become fuzzy – and it is

neer’s “preliminary” design without the

economical CRB walls, no matter how

the client who ends up paying more for

reviewing engineers having done an in-situ

high or steep.

SPECIALISTS IN RETAINING WALL BLOCK SYSTEMS

Valcal has been installing Retaining Wall Systems since 1993 and is a member of the CMA. Using a variety of retaining wall blocks Valcal can professionally design, supply and install retaining wall systems.

Each project benefits from our years of experience to deliver structurally sound solutions.

Trusted commercial contractors and sub-contractors.

www.valcal.co.za

0828882432

IM/08/2020

YOUR PRECAST CONCRETE SPECIALIST PRODUCTS Storm Water Electrical Markers Water Reticulation Outdoor & Building Polymer Products Mining Solutions Kerb Inlet & Road Products Custom Products SERVICES Moulds Drawings

With us everything is cast in concrete - but solving stormwater problems with it is our forte!

Address: Unit 21, Hunky Dory Business Park, 9 Goedehoop Avenue (M57), Olifantsfontein

Telephone: (012) 670 9083

E-mail: info@twinstar.co.za

TECHNICAL

Whether planning a new factory, plant or warehousing extensions, drawing up ar chi t e c tur al plans or de signs that accurately reflect crane space requirements will save time, eliminate cost wastage and enhance productivity and safety.

Architects, industrial designers and

35

metal building manufacturers can now access vast amounts of crane-related data and the Konecranes electronic crane catalogue by using their Crane Planner tool. The embedded and simple online search tool offers a quick source of referencing of over 1 000 pre-design cranes for correct crane selection, crane space requirements, wheel loads, 3D models and 2D drawings.

Safety first “We believe our Crane Planner tool also functions as an educational tool, in terms of how to minimise total costs

Konecr anes’ Cr ane Planner tool

THE PERFECT TOOL FOR CRANE PLANNING

has been speci f ic all y designed f or

operational placement place operators

of Konecranes’ ongoing investment in

ar chi t e c tur al us e, m ak ing d e sign,

in a possibly unsafe workspace which

technology that allows us to offer high-

comparison and final blueprints for crane

could have major health and safety con-

performance, practical and safe lifting

requirements quicker, more thoroughly

sequences,” adds Berning.

solutions to our customers. It enables

and add value through correct crane selection, installation and improved crane-handling procedures – all factors that impact positively upon safety, a non-negotiable element of crane usage,” says Konecranes MD Emil Berning.

researched and more cost-effective.

optimised performance and is 100% safety-compliant.

“Metal building manufacturers, who need the crane data as a base of the dimensioning of the building, will find the Crane Planner of particular benefit.

“This online tool is another element

us to strengthen our customer relationAccurate research

ships through an improved awareness of

The tool:

“Likewise, the choice of the wrong crane

our services and products and to build

• Offers access to 2D and 3D drawings

type and associated components has

upon our reputation as the preferred

with wheel loads and build-in dimensions.

an immediate impact on a company’s

cane supplier,” says Berning.

• Offers access to over 1 000 pre-

return on investment and performance

levels. Both these elements have a direct

design cranes.

• Creates unique value by providing

technical consultation.

impact on cost-efficiencies at site “Our Crane Planner is a key tool to

• Eliminates downtime for building

ensure that crane planning is accurately

designers.

researched, giving architects access

• Creates tighter co-operation be-

to all the cr i tic al in f or ma tion and

tween builders and consultants.

best-in-design needed to ensure that

• Of fers a hub with brochures and

the r esul ting cr ane inst alla tion is

functional, correctly installed, gives

cross-references from similar cases.

• Optimises the crane and building

process simultaneously, making it a win-win for all parties.

“The application of the crane and

“Our simple Crane Planner tool enables designers, particularly architects and metal building manufacturers, to quickly specify their crane requirements.”

associated lifting systems is an element that should receive more focus in the very early stages of the design of suggested building plans.

Incorr ect space allocation and confined and non-practical

PRECAST | ISSUE THREE | 2020

(Top): Follow-me feature.

(Left): A factory layout Illustration.

*Recommended price (including VAT)

MADE FOR THE UNSTOPPABLES. Power, Robustness, Performance Bosch Cordless Brushless tools are made to run longer and last longer, We don‘t stop until you do.

Bosch Professional www.bosch-professional.com/za/en/

TECHNICAL 37

(Below): Steel fibres in concrete.

FIBRES IN CONCRETE The toughness and tension of concrete made with portland cement can be greatly improved by the inclusion of certain fibres. Here Bryan Perrie, MD of The Concrete Institute, discusses the role of glass and steel fibres in the mix and the characteristics of such concrete Fibre-reinforced concrete can sustain

concentrations of certain fibres may

(2-4GPa) and elastic modulus (70-

loads at deflections or strains much

make the plastic concrete unworkable.

80GPa), but has brittle stress-strain

greater than those at which cracking

characteristics (2,5-4,8% elongation

first appears in the matrix.

Glass fibres

at break ) and low creep at room

• If the fibre content of the concrete

Glass fibres were initially found to be

temperature. Claims have been made

is too low, the fibres will not have

alkali-reactive and products in which they

that up to 5% glass fibre by volume has

a significant effect on the strength

were used deteriorated rapidly. Alkali-

been used successfully in sand-cement

o r m o dulus o f e l a s ti ci t y o f th e

resistant glass containing 16% zirconia

mortar without the cement and water

composite, so it is important to

was successfully formulated in the

clumping together (“balling”).

evaluate published test data and the

1960s and by 1971, it was in commercial

manufacturer’s claims carefully.

production in the UK.

• Fibres should be significantly stiffer

Glass-fibre products exposed to the outdoors have shown a loss of strength

Other sources of alkali-resistant

and ductility – it is speculated that alkali

than the matrix, ie have a higher

glass were developed during the 1970s

attack or fibre embrittlement are pos-

modulus of elasticity than the matrix.

and ’80s with higher zirconia content.

sible causes. GRC has been confined to

Fibre content by volume must be

Alkali-resistant glass fibre is used in the

non-structural uses where it has wide

adequate.

manufacture of glass-reinforced cement

applications. It is suitable for use in

• T h e r e m u s t b e a g o o d f i b r e -

(GRC) products which have a wide range

direct-spray techniques and premix pro-

of applications.

cesses and has been used as a replace-

matrix bond.

• The fibre length must be sufficient.

Glass fibre is available in continuous or

ment for asbestos fibre in flat sheet,

• Fibres must have a high aspect ratio,

chopped lengths. Fibre lengths of up to

pipes and a variety of precast products.

35mm are used in spray applications and

GRC products are used extensively in ag-

25mm lengths for premix applications.

riculture, for architectural cladding and

ie they must be long relative to their

diameter.

It must also be noted that high-volume

PRECAST | ISSUE THREE | 2020

Glass fibre has high tensile strength

components, and for small containers.

TECHNICAL 38

Steel fibres

available. Stainless steel fibres have been

both the wet and dry processes, while

Steel fibres have been used in concrete

used for high-temperature applications.

fibre contents of up to 25% by volume

since the early 1900s. The early fibres

Some fibres are collated into bundles

have been obtained in slurry-infiltrated

were round and smooth and the wire was

using water-soluble glue for ease of

fibre concrete.

cut or chopped to the required lengths.

handling and mixing. Steel fibres have

Concretes containing steel fibre have

The use of straight, smooth fibres has

high tensile strength (0,5-2GPa) and

substantially improved resistance to

largely disappeared and modern fibres

modulus of elasticity (200GPa), a ductile/

impact and greater ductility of failure

have either rough surfaces, hooked ends

plastic stress-strain characteristic and

in compression, flexure and torsion.

or are crimped or undulated throughout

low creep.

The elastic modulus in compression and

their length.

Modern commercially available steel

modulus of rigidity in torsion are also Frequently used

no different before cracking when com-

fibres are manufactured from drawn

Steel fibres have been used in

pared with plain concrete tested under

steel wire, from slit sheet steel or

conventional concrete mixes, shotcrete

similar conditions.

by the melt-extraction process which

and slurry-infiltrated fibre concrete.

Because of its improved ductility,

produces fibres with a crescent-shaped

Typically, the contents of steel fibre

steel fibre-reinforced concrete could find

cross-section. Typically, steel fibres

r ange f r om 0,25-2 % b y v olume.

applications where impact-resistance

have equivalent diameters (based on

Fibre contents of over 2% by volume

is important. The fatigue-resistance

cross-sectional area) of 0,15-2mm and

generally result in poor workability

of such concrete is reported to be in-

lengths from 7-75mm. Aspect ratios

and fibre distribution, but can be used

creased by up to 70%.

generally range from 20-100. (Aspect

successfully where the paste content

It is thought that the inclusion of steel

ratio is the ratio between fibre length

of the mix is increased and the size of

fibre as a supplementary reinforcement

and its equivalent diameter, which is

coarse aggregate is no larger than about

in concrete could assist in the reduction

the diameter of a circle with an area

10mm. Steel fibre-reinforced concrete

of spalling due to thermal shock and

equal to the cross-sectional area of

containing up to 1,5% fibre by volume has

thermal gradients. Corrosion of normal

the fibre.)

been pumped successfully using pipelines

steel fibres could be a disadvantage

Carbon steels are most commonly

of 125-150mm diameter. Steel fibre

in exposed concrete situations where

used to produce fibres, but fibres made

contents up to 2% by volume have been

spalling and surface staining are likely

from corrosion-resistant alloys are

used in shotcrete applications using

to occur.

IMPROVED COMPACTION, FASTER PRODUCTION

SEMI-DRY PRECAST CONCRETE - SIKAPAVERÂŽ TECHNOLOGY Benefits of using SikaPaver:

Enhanced early and high final strength Cost efficient production Colour intensification Reduced efflorescence Economical and ecological concrete products

www.sika.co.za

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

PROJECTS

Due to miscalculations in top-steel requirements on a concrete bridge situ-

LANGEBAAN-SALDANHA BRIDGE REHABILITATION

ated between Langebaan and Saldanha, the Provincial Administration (PA) of the Western Cape was faced with two options: rebuilding the entire bridge at an approximate cost of R9 million over a

40

period of six months, or refurbishing the existing bridge, at an estimated cost of R2 million over a three-week period. It settled on the latter.

Sika products were chosen for the refurbishment by RHDHV Engineers an d th e m ain c o n tr a c t o r s, P o w e r Construction. Longitudinal slots were cut into the bridge deck to accommodate

rods are designed for the structural

new technology on the bridge. It deemed

Sika CarboDur BC-16 carbon fibre rods,

str engthening and incr eased load-

that this was a repair to a brand-new

which were flown into SA at minimal cost,

carrying capacity of concrete, timber

bridge and it did not want a “repaired

as they were exceptionally light.

and masonry. Their tensile strength

structure”. However, Sika technical

The rods were bonded into the slots

is si x tim e s gr e a t er than tha t o f

specialists met with the PA’s head and

with Sikadur-30. The advantages of this

structural r einf or cing, which gives

explained that the proposed repair would

high-performance adhesive are that it is

them the capacity to carry heavy loads.

increase the durability of the structure.

easy to mix and apply, requires no priming

Corrosion-resistant, they come with a

The latter then agreed that this would

prior to application and has high-creep

sanded finish for added purchase and can

be the best option.

resistance under permanent loads, the

be used on trafficked surfaces without

latter being critical to structural ap-

being damaged.

The project was successfully completed within a short period and there is

plications which carry high load volumes.

Initially, the PA of the Western Cape

Sika CarboDur BC-16 carbon fibre

was not keen on the idea of using this

no doubt that the repairs will stand the test of time.

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 o

n prot ec

APPLICATIONS: • Tongue & groove • Standard grey or traffic calming colours • Precast • Various sizes available • Highest quality

tio n | r et a i

ni ng

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.

ADDING FLAIR TO NEW OLIFANTSFONTEIN FIRE STATION The new multi-million-rand Olifantsfontein Fire Station, on which construction commenced in late 2019, has a most impressive forecourt paved by Technicrete Double Zig-Zag (DZZ) pavers and Fig 3 kerbs. The fire station, which is being built by the City of Erkurhuleni, will replace the old one that was built in the 1940s.

Fire station forecourts need durable paving due to the heavy load of fire engine and emergency vehicle traffic. The new

traffic load of a fire station. We found

Olifantsfontein Fire Station will have

these elements with Technicrete, which

housing and forecourt space for five fire

always met delivery scheduling and of-

trucks, three ambulances and a helipad,

fered sound technical assistance.”

making the choice of paver for the station an important factor.

Between February and March 2020, Technicrete supplied 4 400m2 of grey

Technicrete sales consultant Luan

80mm DZZ, 1 807m2 of grey 60mm DZZ

van der Berg says: “Our DZZ pavers are

and 1 000mm of Fig 3 kerbs to the Olif-

particularly suitable for forecourts and

antsfontein Fire Station project. “Being

industrial areas that have regular usage

nearby and having a manufacturing plant

by heavy-load vehicles travelling upon

that always met orders enabled us to

them, such as the Olifantsfontein Fire

meet the deadlines required by Pmash

Station and its large, heavy-laden fire

Project Management,” says Van der Berg.

engines. It’s an economical paver, but still gives the project an impressive forecourt

Wide range

appearance and our Fig 3 kerbs added the

Technicrete’s DZZ pavers are available

finishing touch.”

in a variety of colour tones and sizes Apart from fire station forecourts, they

Experience needed

are ideally suited to domestic driveways,

Pmash Project Management’s site agent,

municipal parking areas, pedestrian

Zikhona Lukani, comments: “We wanted

pavements, pathways and commercial

a manufacturer and supplier of pavers

developments, due to their durability and

for this project that would not only offer

longevity. They are also suitable for petrol

reliable delivery, but had solid experience

station forecourts, industrial and factory

in helping in the choice of paver for this

roads, suburban streets, heavy-duty

distinctive application.

loading bays, platforms and industrial

“The pavers we required needed to be able to withstand the harsh and frequent

PRECAST | ISSUE THREE | 2020

areas used by forklifts and other yellow metal equipment.

PROJECTS 42

Exposed aggregate permeable pavers manufactured by CM A member, CEL Paving Products, have been used for the driveways of Phase 2A of Sandown Square, a secure business park development in Parklands, Cape Town, which has been brought to the market by Milnerton Estates.

Phase 1 of the development was completed in 2018 and the commencement of Phase 2B, which will involve additional permeable paving (PP) driveways, will be demand-driven.

This is the first time CEL’s interlocking exposed aggregate paver has been manufactured in a PP format and it had to be specially configured to facilitate a PP application. CEL also supplied its non-permeable exposed aggregate interlockers for paving the development’s parking bay sections, which extend off the roadways.

Mixed pavers

EXPOSED AGGREGATE PERMEABLE PAVERS FOR CAPE BUSINESS PARK

In addition, the estate’s pavements, which flank the roadways and parking bays, were paved with CEL’s exposed aggregate and polished bond pavers.

Added to the mix, Jura flagstone pavers – manufactured by another CMA member, Revelstone – were used for paving a walkway-cum-patio which abuts the Phase 2A building.

T he ci v il works and pav ing wer e designed by civil engineer Ingrid de Jager of BVi Consulting Engineers.

“This is the first time that CEL’s interlocking exposed aggregate paver has been manufactured in a PP format.”

MLH Architects & Planners, Lovemore & Company, Lanser Civils and Seymour Paving were other members of the professional team.

De Jager says the ratio of permeable to non-permeable paving on the estate is 50/50. “Using rainfall models, we calculated the run-of f of the whole development, which slopes towards the south and each parking bay section was designed to drain into the PP roadways.

Construction of the underground services, roadworks and building was carefully co-ordinated and we held off on the PP work until all the wet works on the building had been completed. This was done to prevent any clogging of the PP installations with sand and/or building dust. As an additional precaution, we placed layers of Bidim geotextile on completed PP sections to prevent the incursion of any clogging material.

(Left): The recently completed parking zone at Sandown Square, where permeable-paved driveways are sandwiched between nonpermeable-paved parking bays.

(Above): CEL’s newly-launched exposed aggregate pavers grace one of the driveways at Sandown Square.

PRECAST | ISSUE THREE | 2020

DID

strata. This was followed by a 125mm layer of G5 aggregate, a 125mm layer of

YOU

cement-stabilised C4 material, 20mm of bedding sand and the exposed aggregate pavers,” says De Jager.

“Kerb blocks 250mm deep wer e used as edging for the parking bay sub-base and as a barrier between the non-permeable and permeable paving sections. We specified G5 aggregate

KNOW?

for the parking bay section to ensure that the kerbing had sufficient support in the event of a truck or other vehicle driving over it.”

In order to accommodate the greater

The only official publication of the CMA

quantities of sub-base materials required for layer works of the PP road-

Distributed in print format

ways, an extra 150mm of sub-strata was excavated. Designed with 30% voids

All issues are available online through Issuu

throughout, the layer works comprise Kaytech A5 Bidim geotextile, 250mm x 53mm aggregate, 100mm x 19mm

Circulated via the CMA, PRECAST and Isikhova Media’s social media platforms

aggregate, A2 Bidim geotextile and 50mm x 6mm bedding stone, topped with CEL’s permeable exposed aggre-

Provides quality networking opportunities

gate pavers. The bottom layer of A5 Bidim was extended up the side of the non-permeable sub-base sections to effectively separate the two sections and prevent any water seepage from the

ISSUE

ONE •

permeable section.

2020

R49,00

Layer works “Once the scaffolding was removed from

Drainage needed

the building, we commenced with the

Drainage from the PP driveway sections

layer works of the non-permeable parking

is ef fected by two perforated pipes

bay sections. In-situ material tested to

which were installed at the bottom of

a G7 standard was used for the sub-

each section. One drains into a catch-pit

THE VO

ICE OF

T CONC

RETE

INDU

STRY

0

ENSU

RING

- Indust

QUAL ITY

ry rep res

g sta ndards

- Provid ing

Two catch-pits at the gable end of the

0

ISSUE ENCY

on and forma

lisatio

higher

effecti

ve cer tifi

cation

ISSUE

ONE

THE

n

E OF

VOIC

THE

AST

PREC

RETE

CONC

STRY

INDU

servic

es

• Aca demic labora • Con tory com crete ing is gre • JHB ener highw ay dec k rep air

building feed surface and roof water via

• 202 TWO

AND CO NSIST

entati

- Drivin

into the municipal stormwater system.

drainage pipe.

ECAS

R49,0

INDUST RY ASSOCIA TIONS

and the other into a manhole. Both drain

an underground pipe into the nearest PP

THE PR

0

R49.0

• 2018

THE

CMA

ST IN

Y CA

ALIT

– QU

RETE

CONC

UCT PRODIFICATION CERT KE Y – YOURALIT Y TO QURANCE ASSU

De Jager says that besides controlling the flow of stormwater into municipal

ISSUE

drainage systems, Sandown Square’s

ONE

• 2019

ry delive ject and ul pro n dem t ccessf ckdow precas • Su post-lo t uses eting projec • Me using P ho • RD

PP system will remove some of the pollutants from the water through

THE

sedimentation and microbial action.

VOIC

E OF

THE

R49.0

0

PREC

AST

CON

CRET

E IN

DUST

Fur thermore, she obser ves that since all PP systems require regular maintenance, BVi provided Milnerton

walls aining costs een ret ece • Gr lower sterpi rators al ma • Vib ectur archit • An

Estates with a maintenance plan to prevent clogging.

(Left): CEL’s polished bond pavers create attractive pedestrian squares between parking bays and Revelstone’s Jura flagstone pavers, bordered with CEL’s polished bond pavers, form an attractive walkway-cum-patio.

PRECAST | ISSUE THREE | 2020

• PM SA inv ests • CM in qu ACS ality take • UC s off T to rese arch drain age

ADVERTISE NOW! CONTACT THULI, RUWAYDA OR IAN ON 011 883 4627

RY

PROJECTS 44

PRECAST CONCRETE CHOSEN FOR

STEENBRAS WELLFIELD PROJECT The Steenbras wellfield is one of Cape Town’s new water programme projects, involving the drilling of 12 production boreholes into a section of the TMG aquifer on sloping land above the dam’s northern bank. The scheme will ultimately contribute a volume of up to 30 megalitres

The City of Cape Town has embarked on a project to bolster its water supply by accessing groundwater from the Table Mountain Group (TMG) aquifer in the area surrounding the existing Steenbras Dam. Situated in the Steenbras Nature Reserve in the Hottentots Hollands mountain range, the dam is one of several essential water reservoirs supplying the city.

a day to the city’s water supply system.

This equipment is securely contained

consulting engineers Zutari (formerly Au-

Each borehole is being equipped with

in pumphouse structures built with

recon), in preference for precast panels.

state-of-the-art electric pumps and

reinforced precast concrete panels,

The reason for the design change was the

control equipment, supplied by main

supplied by Cape Concrete.

potential damage which spilt concrete and contaminated water could inflict on the

contractor Hidro-Tech Systems.

(Above and below right): A pumphouse structure takes shape.

(Below): A partially completed underground valve chamber.

Precast panels

environmentally sensitive eco-system of

The pumphouse structures were originally

the Steenbras Nature Reserve.

designed as in-situ concrete structures,

Each pumphouse structure measures

but this specification was altered by

34m² and consists of four separate

PRECAST | ISSUE THREE | 2020

chambers, constructed on a concrete

with Jointex, a self-adhesive sealer which

base. These were cast in-situ in a very

was used to create a tight waterproof

controlled manner to minimise damage

seal. The roofs were also constructed

to the surrounding vegetation. Kiewiet

with precast panels which were tapered

Viljoen of Hidro-Tech says that besides

to facilitate water run-of f. The roof

being potentially harmful to the environ-

panels were sealed with a polyurethane

ment, activities such as batching on site

sealant and a flexible membrane supplied

and in-situ wall construction would have

by Sika.

taken much longer.

Viljoen explains that it was necessary

“Substantial time-savings were gained

for the pumphouse structures to be wa-

by opting for precast concrete. Once the

terproofed because they hold medium-

flooring was cast, it took only 24-36 hours

voltage transformers, LV motor control

to erect each of the pumphouse struc-

centres and industrial PLCs. They also

tures. What’s more, precast concrete

include vent ducting to prevent internal

panels offer exceptional strength – a very

condensation.

necessary feature in providing for vandaland theft-proof barriers.”

SUBSCRIBE TO

PRECAST FOR FREE

In keeping with the nature-based environment, the precast panels were

the roofs were painted green.

subscription form

UF

ACTURER

S

NCRETE

personnel working at the site. Instead,

The joints between panels were sealed

N

CO

assembly of the pumphouse structures.

A

AT I O N

tially harmed other forms of wildlife and

OCI

been damaged by baboons and poten-

brackets to facilitate a Meccano-style

SS

on the roofs, as it would probably have

the panels came with external steel

A

appeal. Loose cladding was not used

Cast in Cape Concrete’s yard in 13 sizes,

M

clad with natural stone for aesthetic Meccano-style

Q

u

Pr ecast p anels wer e also used to

al

t

e

Team effort

it

y c nc a s t in c o

re

construct 7m² underground flow meter and valve chambers adjacent to the pumphouse structures. The chambers house electronic flow metering equipment and the pipework, which connects the

Yes, I want a FREE subscription to Precast magazine

SUBSCRIBER’S DETAILS:

boreholes to the main feeder pipeline.

Other members of the pr oject’s (Above): One of the completed pumphouse structures.

“Substantial timesavings were gained by opting for precast concrete.”

Mr

Mrs

Ms

Other

professional team included Baseline for civil and construction work and Cape Concrete, precast concrete supplier and pumphouse construction.

First name:.......................................................................................................

Surname: .........................................................................................................

Address: .......................................................................................................... .............................................................................................................................. .............................................................................................................................. ............................................................Code: ....................................................

City: ...................................................................................................................

Telephone: .....................................................................................................

Mobile: .............................................................................................................

E-mail: ...............................................................................................................

(Left): The pumphouse structures were clad with stone-facing to blend in with the surroundings of the nature reserve.

(Above): Steel brackets were used for the Meccanostyle assembly of pumphouse structures.

PRECAST | ISSUE THREE | 2020

Completed subscription forms are to be emailed to: thuli@isikhova.co.za

PROJECTS 46

SCHOOL SPORTS FIELD

RAISED TO NEW HEIGHTS June 2019 saw St Cyprian’s School in Oranjezicht, Cape Town, gain council approval for the upgrade of its Upper Orange field into a hockey pitch of international standard using a hockey 20 ND sand-based AstroTurf.

The boundaries of the upgraded field

with rebar and filled with concrete. The

extended too far to allow for flanking

wall had to retain 1 900 tons of G7 fill

grassed embankments and as the natural

and as the field tolerance was only 6mm,

ground was sloped, a level platform was

particular attention was paid to avoiding

not achievable using cut-to-fill. Instead,

slope failure or settlement.

it was decided to secure the pitch with

“Terraforce was specified as a proven

a retaining wall system provided by CMA

and eco-friendly earth retaining system.

member, Terraforce.

Its walls are cost-effective and, if built

The three-sided wall was designed by

correctly, structurally sound. The client

Integrate Structural & Civil Engineering

was able to include several heritage

and was constructed by Isidima Civils,

aspects due to the many options provided

a Cape-based civil engineering firm and

by the Terraforce system,” says Stiger.

empowerment vehicle of the Martin & (Above and top): The St Cyprian’s retaining wall under construction.

(Below): The completed wall and AstroTurf hockey pitch under construction.

East Group. Zaandré Bredenkamp was

Match-ready

the quantity surveyor.

Isidima completed the installation in late November 2019 and the first few

High wall

matches were successfully played at the

According to Isidima civil engineering

end of the school’s final term, getting a

technician Lucas Stiger, the wall was

thumbs-up all round.

built at heights of 2-5m and at angles ranging from 65° upwards.

“We’re very happy with the Terraforce wall,” says St Cyprian’s facilities manager

“We cast a 25MPa concrete base and

Marelize de Klerk. “The landscaping that

used G7 as backfill material. Geofabric

will take place once schools reopen will

was laid every second or third layer to

finish it off beautifully, although I do

a depth of approximately 3m. Bidem-

like the clean look. To me, it makes a

wrapped outlet pipes were installed

statement about the enormity of the

every 2m. Where the wall exceeded 85°,

project and adds something special to the

the Terraforce blocks were reinforced

appearance and feel of the AstroTurf.”

PRECAST | ISSUE THREE | 2020

Shukuma Bricks (Pty) Ltd

Mobicast (Pty) Ltd PRODUCER MEMBERS Producer Members

Logo

Rocla (Pty) Ltd

Mobicast (Pty) Ltd

ers

Logo

ke BK

PI – Precast Infrastructure

Conframat (Pty) Ltd

A Fick Sement Werke BK

Revelstone (Cape) (Pty) Ltd

Mobicast (Pty) Ltd

PB – Precast Building

Revelstone (Cape) (Pty) Ltd Shukuma Bricks (Pty) Ltd

Rocla (Pty) Ltd

Conframat (Pty) Ltd

AGW Trading T/A Kolbe Blocks

A FICK SEMENT WERKE BK Monier Coverland (Pty) Ltd TEL: (022) 913 1921Corobrik (Pty) Ltd CONFRAMAT (PTY) LTD PROVINCE: WC Coverland (Pty) LtdTEL: (0861)Shukuma 33 5599 Flooring Monier PILLAR: PB PROVINCE: GAUT Monier Coverland (Pty) Ltd Coreslab (Pty) Ltd PILLAR: PB/PI Mobicast (Pty) Ltd

Producer Members

Logo

A Fick Sement Werke BK

Beta Tiles (Pvt Ltd

AGW Trading T/A Kolbe Blocks

olbe Blocks

Monier Coverland Conframat (Pty) Ltd (Pty) Ltd

Shukuma Flooring Systems

MOBICAST (PTY) LTD SystemsTEL: 086 111 2346 PROVINCE: WC PILLAR: PB/PI

Shukuma Bricks (Pty) Ltd

Solid Pave Bricks (Pty) Ltd (Conticrete)

Shukuma Flooring Systems

Corobrik (Pty) Ltd

Conframat (Pty) Ltd

SHUKUMA BRICKS (PTY) LTD TEL: (041) 372 1013 PROVINCE: EC Zittlau Eiendomme (Pty) Ltd t/a PILLAR: PB

Deranco Precast (PtY) Ltd

MVA Bricks cc

Next Page

Berts Bricks Beta Tiles (Pvt Ltd

Coreslab (Pty) Ltd AGW TRADING Eagle Roof Tiles (Pty) Ltd Logo T/A KOLBE BLOCKS TEL: (041) 406 7900 PROVINCE: ECLtd(Pty) Ltd ConframatCorobrik (Pty) Deranco Precast (PtY) Ltd PILLAR: PB

Producer Members A Fick Sement Werke BK Berts Bricks

COROBRIK (PTY) LTD MONIER COVERLAND (PTY) LTD Solid Pave Bricks (Pty) Ltd (Conticrete) Manufacturing (Pty) Ltd TEL: (031) 560Pavecon 3252 TEL: (011) 222 7300/ 7334 SHUKUMA FLOORING SYSTEMS PROVINCE: KZN PROVINCE: GAUT T/A ZITTLAU MVA Bricks cc Next Page PILLAR: PI EIENDOMME (PTY) LTD Zittlau Eiendomme (Pty) Ltd t/aPILLAR: PB Portland Hollowcore Slabs (Pty) Ltd TEL: (041) 372 1933 PROVINCE: EC MVA Bricks cc PILLAR: PB

Next Page

MVA Bricks Coreslab (Pty) Ltdcc Corobrik (Pty) Ltd

AGW Trading T/A Kolbe Blocks

Eagle Roof Tiles (Pty) Ltd

Solid Pave Bricks (Pty) Ltd (Conticrete) ReMaCon Products cc

Pavecon Manufacturing (Pty) Ltd

MVA Bricks Derancocc Precast (PtY) Ltd Coreslab (Pty) Ltd

CORESLAB (PTY) LTD Pavecon Manufacturing (Pty) Ltd TEL: (087) Mobicast (Pty) Ltd232 2462 PROVINCE: LIMPOPO PortlandPILLAR: HollowcorePB/PI Slabs (Pty) Ltd Portland Hollowcore Slabs (Pty) Ltd

BETA TILES (PVT LTD Corobrik (Pty) Ltd TEL: (263) 4333735 Next Page PROVINCE: Eagle ZIMRoof Tiles (Pty) Ltd PILLAR: PB

Beta Tiles (Pvt Ltd

Zittlau Eiendomme (Pty) Ltd t/a

Monier Coverland (Pty) Ltd

MVA BRICKS CC TEL: (012) 386 0050 PROVINCE: GAUT PILLAR: PI

Deranco Precast (PtY) Ltd

Pavecon Manufacturing (Pty) Ltd

SOLID PAVE BRICKS (PTY) LTD (CONTICRETE) TEL: (041) 365 7676 PROVINCE: EC PILLAR: PB

Technicrete (Pty) Ltd

Coreslab (Pty) Ltd

Berts Bricks

Next Page ReMaCon Products cc

Monier Coverland ReMaCon Products (Pty) cc Ltd Technicrete (Pty) Ltd

Eagle Roof Tiles Next (Pty)Page Ltd

DERANCO PRECAST (PTY) LTD Deranco Precast (PtY) Ltd Pavecon Manufacturing (Pty) Ltd TEL: (041) 463 3338

PAVECON MANUFACTURING (PTY) LTD TEL: 087 940 3631 PROVINCE: LIMPOPO PILLAR: PI

Portland Hollowcore Slabs (Pty) Ltd PROVINCE: EC

BERTS BRICKS TEL: (018) Eagle292-1615 Roof Tiles (Pty) Ltd

PILLAR: PB/PI

MVA Bricks cc

C.E.L. Paving Products (Pty) Ltd

Portland Hollowcore Slabs (Pty) Ltd Next Page

Technicrete (Pty) Ltd

Vanstone Precast (Pty) Ltd

Cemblocks (Pty) Ltd

Next Page

C.E.L. PAVING PRODUCTS (PTY) LTD Horizon Brick & Concrete TEL: (021) 905 5998 ReMaCon Products cc PROVINCE: WC | PILLAR: PI

oducts (Pty) Ltd

C.E.L. Paving Products (Pty) Ltd

EAGLE ROOF TILES (PTY) LTD (044) 874 0290 PROVINCE: Pavecon ManufacturingWC (Pty) Ltd PILLAR: PB Portland Hollowcore Slabs (Pty) Ltd

Horizon Brick & Concrete

cts (Pty) Ltd Cemblocks (Pty) Ltd

Cem Brick Manufactures (Pty) Ltd

Horizon Brick & Concrete

) Ltd Concrete Units (Pty) Ltd

Inca Concrete Products Pty Ltd

d

Cem Brick Manufactures (Pty) Ltd Next Page

Concrete Units (Pty) Ltd

ufactures (Pty) Ltd

(Pty) Ltd

West End Cement Bricks (Pty) Ltd

HORIZON BRICK ReMaCon Products & cc CONCRETE TEL: (012) 943 3701 PROVINCE: N/W PILLAR: PB

Vibro Bricks and Paving (Pty) Ltd

West End Cement Bricks (Pty) Ltd

West End Cement Bricks (Pty) Ltd

Inca Concrete Products Pty Ltd

REMACON PRODUCTS CC TEL: (011) 393 5504 PROVINCE: GAUT PILLAR: PI

VIBRO BRICKS AND PAVING (PTY) LTD TEL: (012) 374 5533 PROVINCE: GAUT PILLAR: PB/PI

Lategan Cement Works (Pty) Ltd Lategan Cement Works (Pty) Ltd

tures (Pty) Ltd

PORTLAND HOLLOWCORE SLABS Vanstone Precast (Pty) Ltd Vibro Bricks and Paving (Pty) Ltd (PTY) VANSTONE PRECAST (PTY) LTD VibroLTD Bricks and Paving (Pty) Ltd TEL: (021) 972 1111 TEL: (012) 541 2056/1808 PROVINCE: WC PROVINCE: GAUT PILLAR: PI PILLAR: PB/PI

CEMBLOCKS (PTY) LTD Inca Concrete Products Pty Ltd TEL: (014) 538 0311 PROVINCE: NW PILLAR: PB/PI

Next Page

CEM BRICK Lategan Cement Works (Pty) Ltd MANUFACTURES (PTY) LTD TEL: (051) 433 4479 PROVINCE: F/STATE PILLAR: PB/PI

Revelstone (Cape) (Pty) Ltd INCA CONCRETE PRODUCTS (PTY) LTD TEL: (021) 904 1620 PROVINCE:Rocla WC (Pty) Ltd PILLAR: PB/PI

Revelstone (Cape) (Pty) Ltd

Shukuma Bricks (Pty) Ltd

) Ltd

REVELSTONE (CAPE) (PTY) LTD TEL: (0861) 173 835/ (021) 761 9737 PROVINCE: WC PILLAR: PI

WZ Betonwerke

Rocla (Pty) Ltd

CONCRETE UNITS (PTY) LTD TEL: (021) 386 1923/ (016) 362 2236 PROVINCE: WC/GAUT PILLAR: PB/PI

TECHNICRETE (PTY) LTD TEL: (011) 672 1425 PROVINCE: GAUT PILLAR: PB/PI

Vanstone Precast (Pty) Ltd

ReMaCon Products cc

LATEGAN CEMENT Shukuma Systems WORKS (PTY) LTDFlooring Shukuma Bricks (Pty) Ltd TEL: (021) 873 1154 PROVINCE: WC PILLAR: PB/PI

WZ Betonwerke

Zittlau Eiendomme (Pty) Ltd t/a

Solid Pave Bricks (Pty) Ltd (Conticrete)

PRECAST | ISSUE THREE | 2020

Zittlau Eiendomme (Pty) Ltd t/a

Solid Pave Bricks (Pty) Ltd (Conticrete)

Next Page

WEST END CEMENT BRICKS (PTY) LTD TEL: (011) 851 1005 PROVINCE: GAUT PILLAR: PB/PI

ROCLA (PTY) LTD TEL: (011) 670 7600 PROVINCE: GAUT PILLAR: PB/PI

Shukuma Flooring Systems

MEMBER LIST

Mobicast (Pty) Ltd

WZ BETONWERKE TEL: (057) 733 1626 PROVINCE: FREE STATE

47

MEMBER LIST

Kerneos South Africa (Pty) Ltd

Kobra Moulds B.V.

ucer Annual Member cc

eyePedershaab

Pty) Ltd

48

Logo

NON-PRODUCER MEMBERS Non Producer Annual Member Abel Equipment cc

Logo

Dick King Lab Supplies (Pty) Ltd

Birkenmayer H (Pty) Ltd

ABEL EQUIPMENT CC TEL: (044) 874 1876 PROVINCE: EC

Chryso Southern Africa (Pty) Ltd

Non Producer Annual Member Abel Equipment cc

Logo

DICK KING LAB SUPPLIES (PTY) LTD TEL: (011) 499 9400/ (031) 700 2551 PROVINCE: GAUT/DBN

KOBRA MOULDS B.V. TEL: 003111 356 2460 COUNTRY: NETHERLANDS

QUANGONG MACHINES CO LTD TEL: +865 958 679 9557 COUNTRY: CHINA

HawkeyePedershaab

n Africa (Pty) Ltd

eos South Africa (Pty) Ltd

Birkenmayer H (Pty) Ltd Dick King Lab Supplies (Pty) Ltd

BIRKENMAYER H (PTY) LTD Kerneos South Africa (Pty) Ltd TEL: (011) 970 3880 PROVINCE: GAUT

Chryso Southern Africa (Pty) Ltd

REVARO CONCRETE EQUIPMENT TEL: (011) 794 8271 PROVINCE: JHB MANITOU SA (PTY) LTD TEL: (011) 975 7770 PROVINCE: JHB

HAWKEYEPEDERSHAAB TEL: 00 459645 4193 COUNTRY: DENMARK

Cement Ann Members

Address

AfriSam South Africa (Pty) Ltd

SIKA SOUTH AFRICA (PTY) LTD TEL: (031) 792 6500 PROVINCE: KZN

Kobra Moulds B.V.

CHRYSO SOUTHERN AFRICA (PTY) LTD TEL: (011) 395 9700/ (031) 564 0325/(021) 928 1660 PROVINCE: GAUT/KZN/WC

Dick King Lab Supplies (Pty) Ltd

a Moulds B.V.

Associate Members

KERNEOS SOUTH AFRICA (PTY) LTD TEL: (011) 444 3090 PROVINCE: GAUT

Logo

AF Consulting Engineers & Associates

Associate Members

AF Consulting Engineers & Associates ers & Associates (Pty) Ltd

TERRAFORCE (PTY) LTD TEL: (021) 465 1907 PROVINCE: WC

Concrete Society of Southern Africa

pplies (Pty) (Pty)Ltd Ltd

Members

PAN MIXERS SA (PTY) LTD TEL: (011) 578 8700/ 8600 PROVINCE: JHB

CPI Concrete Plant International

Logo ASSOCIATE Logo MEMBERS

CEMENT MEMBERS

JC Paving Consulting No logo

Concrete Society of Southern Africa

Sekhukhune & Associates No logo Stefanutti Stocks Civils

Concrete Society of Southern Africa

ASPASA

ASPASA

AF CONSULTING ENGINEERS & ASSOCIATES (PTY) LTD CONCRETE SOCIETY OF PROVINCE: JHB Taco Voogt Consulting Engineer CPI Concrete Plant International SOUTHERN AFRICA TEL: (012) 348 5305 PROVINCE: PTA

Young & Satharia Consulting

CPI Concrete Plant International

JC Paving Consulting

No logo

British Precast Concrete Federation British Precast Concrete Federation

Next Page Next Page

Sekhukhune & Associates ASPASA JC Paving Consulting TEL: (011) 791 3327 Stefanutti Stocks Civils PROVINCE: JHBSekhukhune & Associates Stefanutti Stocks Civils

No logo

STEFANUTTI STOCKS CIVILS TEL: (011) 571 4300 PROVINCE: GAUTENG No logo

AFRISAM SOUTH AFRICA (PTY) LTD TEL: (011) 670 5500/5752/5972 PROVINCE: GAUT

TACO VOOGT CONSULTING ENGINEER TEL: (012) 669 0125 PROVINCE: PTA

No logo

CPI CONCRETE PLANT No logo INTERNATIONAL TEL: (02236) 962390 COUNTRY: GERMANY

JC PAVING CONSULTING TEL: (011) 431 0727 BRITISH PRECAST Civil Engineers (Pty) Ltd PROVINCE: JHB CONCRETE FEDERATION TEL: +(44) 116 232 5170 SEKHUKHUNE & ASSOCIATES Contractor Members COUNTRY: UK Decorton Retaining Systems (Pty) Ltd TEL: (012) 346 1945 PROVINCE: PTA

YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS (PTY) LTD TEL: (031) 207 7252 PROVINCE: KZN Logo

Contractor Members

Logo

Decorton Retaining Systems (Pty) Ltd

Friction Retaining Structures (Pty) Ltd

Friction Retaining Structures (Pty) Ltd

ete Contractor Members

Decorton Retaining Systems (Pty) Ltd CONTRACTOR MEMBERS

Friction Retaining Structures (Pty) Ltd

Logo

Powergate Construction cc

Powergate Construction cc Valcal International Export cc

Powergate Construction cc

DECORTON RETAINING SYSTEMS (PTY) LTD TEL: (021) 875 5155 PROVINCE: WC

FRICTION RETAINING Valcal International Export cc STRUCTURES (PTY) LTD TEL: (011) 608 4321 PROVINCE: GAUT

POWERGATE CONSTRUCTION CC TEL: 071 603 5070 PROVINCE: GAUT

VALCAL INTERNATIONAL EXPORT CC TEL: (011) 867 2471 PROVINCE: GAUT

Valcal International Export cc

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

PRECAST | ISSUE THREE | 2020

RENOVATE ENHANCE PROTECT

BEFORE

AFTER

CHRYSO®Conseal Topcoat COLOURED SURFACE HARDENER

VOC-free and durable matt finish.

Provides a permanent seal on all types of concrete surfaces.

Easy to apply and clean in conjuction with CHRYSO®GreenDecap 200.

Increases surface hardness, stops dusting phenomena and neutralizes efflorescence.