ISSUE THREE • 2020
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• Custom-made precast for civils • Baby brick machine boom • Man-made gravel improves concrete
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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
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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
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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.
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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
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AT I O N
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Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Tel: (011) 805 6742 • Email: admin@cma.org.za • Website: www.cma.org.za
PROJECTS
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
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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
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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
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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
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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.