Precast • Issue 2 • 2021

CONCRETE MANUFACTURING & CONSTRUCTION ISSUE 2 2021

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IN THIS ISSUE: CMA's Awards for excellence goes digital Cement’s unexpected saviour Back to business with a bang

CUTTING-EDGE APPROACH. CUTTING ZERO CORNERS. QUALITY CEMENT. WHAT GOES INTO IT MATTERS.

Our range of high quality cement is designed for specialised applications where early strength is required. The fine-particle mineral components mean our cement offers improved durability and a superior quality concrete. When you’re putting everything into delivering a quality product, you need quality cement that delivers every time.

Ask for AfriSam.

www.afrisam.com

Creating Concrete Possibilities

| CONTENTS |

Editor’s NOTE Rise of the machines We cannot escape the Fourth Industrial Revolution, nor the Internet of Things and other technological wonders that mould our world and our everyday lives.

Whether through social media interactions, remote-controlled whatevers or the “good, old-fashioned” supervisory control and data acquisition machines that control what we do, when we do it and how we go about it, the reality is that we need technology in order to be competitive in today’s world.

In many ways, the Covid-19 pandemic has fast-tracked our acceptance of new technologies that have the potential to completely change the way we do things. In this issue alone, we feature a number of new technologies that turn “normal” on its head.

For example, the CMA has opened entries to its prestigious Awards for Excellence 2022, only this time it is fully digital and will be streamed live to an unlimited audience.

KSB Pumps and Valves has introduced acceptance testing for large pumps from the comfort of an armchair – saving an entire technical team the cost and bother of being physically present when the tests are performed. Simultaneously, South Africa’s own trusted concrete equipment manufacturer, PMSA, is offering a tech-savvy plant upgrade that can drastically improve production by means of smart technology.

Read on to f ind out more about the new age and how to harness technologies for business.

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Precast Concrete Awards for Excellence to be cast digitally

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Concrete is crucial for post-pandemic revival

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Cement & Concrete SA rises to new heights

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Unexpected saviour for cement sales

CONCRETE MANUFACTURING & CONSTRUCTION ISSUE 2 2021

PRECAST R49,00

INDUSTRY NEWS

COMPANY NEWS

IN THIS ISSUE: CMA's Awards for excellence goes digital Cement’s unexpected saviour

10 Getting back to business with a bang 13 Worrying global raw materials shortage

PRODUCTS 14 Between a rock, a vision and a hard place 16 Acceptance testing from the comfort of an armchair 17 Enabling surface stabilisation between rock bolts 18 Retarder for exposed aggregates

TECHNICAL 19 The Ten Commandments for concrete construction 21 Repairing non-structural concrete defects

Back to business with a bang

ON THE COVER The Revaro Group was founded in 2000 and positioned itself in the precast, wetcast and construction industries as a one-stopshop for machinery and consumables to manufacture all concrete precast products.

The group also supplies a wide range of earth moving and materials handling equipment – including aftermarket and OPM spares and parts – for all equipment mentioned. Their continued growth and expansion over the last 21 years lives up to their brand motto: "Affordable Innovation".

For more info visit www.revaro.co.za or email sales@revaro.co.za.

PRECAST is proudly endorsed by the Concrete Manufacturers’ Association – CMA Concrete Manufacturers’ Association

GLOBAL VIEW 24 POPIA 101 for precasters

PROJECTS 26 A sustainable raised flooring system 28 Precast warehouse completed despite lockdown restrictions 30 Quick and easy PICP infiltration test 32 Concrete wine tanks are winners!

34 Concrete block paving rejuvenates Hermanus CBD 37 MVA interlockers for new storage yard 39 New stormwater drainage system for Hermanus CBDs 42 Production continues during biscuit factory expansion 44 Plastic-lined concrete sewerage pipes

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46 Terraforce for dune rehabilitation 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 © 2021. 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.

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 www.isikhova.co.za Editor: Raymond Campling Tel: 076 297 2775 | E-mail: media@mediasavvy.biz Coastal editorial: David Beer Tel: 082 880 6726 | E-mail: david.bigsky@gmail.com Managing Director: Imraan Mahomed Tel: +27 (11) 883 4627 | E-mail: imraan@isikhova.co.za Pubishing Director: Jason Aarons Tel: +27 (11) 883 4627 | E-mail: jason@isikhova.co.za Director Brand Strategy: Jenny Justus Tel: +27 (11) 883 4627 | E-mail: jenny@isikhova.co.za Media Specialists: Ruwayda Mahomed Tel: +27 (11) 883 4627 | E-mail: ruwayda@isikhova.co.za Thuli Majola Tel: +27 (11) 883 4627 | E-mail: thuli@isikhova.co.za Design and layout: Joanne Brook E-mail: joanne@isikhova.co.za

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| INDUSTRY NEWS |

PRECAST CONCRETE AWARDS FOR EXCELLENCE TO BE CAST DIGITALLY Precast concrete units and projects will take centre stage at the Concrete Manufacturers’ Association’s (CMA’s) biannual Awards for Excellence competition, which is currently being featured on virtual platforms. The winners of the awards will be announced next year.

“It’s become abundantly clear that the digital world is becoming ever more part of our lives and personal engagement is being replaced with virtual meetings, training and events. The Awards for Excellence will therefore also take to cyberspace and reach a far wider audience than is usually the case,” says CMA general manager Henry Cockcroft.

“As one of the most prestigious events on the construction industry’s calendar, which usually attracts entrants from a wide spectrum of disciplines representing precast concrete projects, the show had to go on.

This necessitated the CMA to expand its

digital footprint and align with digital marketing strategies, while exploiting trending social media network marketing opportunities.”

Call to action Cockcroft adds that the countdown has officially begun, with a call to all CMA members and their customers to enter into any one of 15 award categories before 14 January 2022. Entry packs are currently being sent out and entrants can enter as many projects as they like, as long as these feature CMA producer member precast concrete units.

“Any technically outstanding project, no matter how small or large, can be entered, provided one or more precast concrete products were used in its execution. It’s not the size of the project that matters, but rather the way it satisfies the requirements of the award categories,” he says.

“The event promises to offer marketing exposure to our sponsors, entrants and participants, as well as broadening the reach of the CMA within the construction industry by promoting awareness of the possibilities that can be realised through the use of precast concrete.

Where to enter “Full details of this event within the local construction industry are available on the CMA website: www.cma.org.za. The site offers a ‘concept paper’ containing an overview of the format of the competition, as well as a downloadable ‘entry form’ explaining the entry requirements. The site also links to every CMA social media channel to give understanding of how the content will be delivered to the World Wide Web. “We’re looking forward to showcasing the excellence of the precast concrete industry in South Africa to the world!” says Cockcroft.

For queries, tel: (011) 805 6742 or visit: cmamarketing@cma.org.za.

(Top): The Concrete Manufacturers' Association Digital Awards for Excellence are pioneering digital ceremonial content delivery to the world.

(Left): Henry Cockcroft, general manager of the CMA.

“Any technically outstanding project, no matter how small or large, can be entered, provided one or more precast concrete products were used in its execution.”

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| INDUSTRY NEWS |

CONCRETE IS CRUCIAL FOR POSTPANDEMIC REVIVAL After water, concrete is the most used resource in the world and contributes significantly to SA’s standard of living. It is used for a multitude of infrastructural projects, ranging from houses, hospitals, schools and universities to offices, provision of water reticulation and sewers, community dams and reservoirs, as well as road and highway networks. It will also be an essential part of any future “super-city” in SA. Concrete is one of the most durable and cost-effective materials on earth.

This extended lifespan results not only in lower expenditure of energy in building new homes and infrastructure, but also in substantially reduced maintenance and impact on the use of finite resources.

In the long term, concrete’s durability, low maintenance and re-usability have strong positive economic effects. Concrete structures have optimal energy performance

The Auditorio de Tenerife “Adán Martin” in Santa Cruz de Tenerife in the Canary Islands, designed by renowned Spanish architect, Santiago Calatrava Valls, spectacularly shows the creative scope concrete offers.

With adequate infrastructural provision high on the national priority list as the pandemic subsides, concrete will be the one indispensable component for almost all municipal or national government rebuilding and development projects, writes Bryan Perrie, CEO of Cement and Concrete SA (CCSA) with significant benefits in terms of wholelife energy usage.

Life support Up to 4 0% of a l l mater ia ls used in human activity are directed into the built environment. This has a direct and visible impact on the world’s finite resources. In practice, many of the factors affecting the contribution of concrete to sustainable development are interrelated. For example: • The use of cement extenders in the concrete mix has a positive environmetal impact because it reduces the (Left): Concrete is being widely used for bus lanes in South African cities.

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| INDUSTRY NEWS |

amount of cement needed in the mix – and less production of cement means lower CO₂ emissions.

• Concrete also uses other industr y secondary products, resulting in waste minimisation and savings in landfill space.

To achieve maximum sustainability benefits during a building or structure’s life-cycle, the designer, specif ier and owner need to consider many factors during the design, construction, usage and end-of-life phases. This applies not only to saving energy and reducing the use of finite resources, but also to fully applying the other inherent advantages of concrete.

These advantages include: • Local material A ll the primar y materials used in concrete (apart from some sophisticated imported admixtures) are produced locally. Extenders and slag aggregates used in concrete mixes are secondary products that would be dumped if they were not used by the cement and concrete industry. While the cement factories are generally located close to their raw material sources, sources of aggregates and ready-mix plants can be placed close to the areas of demand to reduce the energy required for transport.

• Labour-intensive With unemployment at unprecedented levels, concrete and concrete products in most cases lend themselves to labourintensive construction – whether for small-scale manufacture of concrete products or the use of concrete in various forms of construction. In the provision of human settlements, all the concrete roof tiles, concrete bricks or blocks, concrete kerbs, concrete reticulation poles, concrete block paving and concrete pipes that are used can be installed using labour-intensive construction methods.

• Design flexibility As concrete products and elements can be constructed into any shape and cast in (Above right): Virtually no building site in the world can operate without concrete.

var ious ways, desig ners enjoy an enormous amount of flexibility. The fact that concrete can be constructed in-situ or by precasting – or using a hybrid of the two methods – provides the designer with exceptional creative scope when planning a project, particularly if it needs to be fast-tracked.

• Variety of finishes Using concrete, there are unlimited possibilities for f inishes that can be designed in a range of attractive colours and a multitude of textures. The finishes are incorporated into the concrete during the construction stage, rather t ha n appl ied later a s a sepa rate operation. The use of concrete as the ultimate finish means no other finishing activities such as painting, tiling or coating are required, saving energy and materials at construction stage with lower future maintenance costs. Furthermore, concrete finishes do not emit any toxic or volatile products into the environment and have no detrimental effects on the community during their entire life-cycle.

• Life-cycle cost Various analyses show that because of concrete’s durability, the whole life cost of many projects is lower when it is used as the major construction material. At the end of the usage phase, concrete can easily be recycled and crushed to

produce building aggregate. SA has not yet fully exploited the recyclability of concrete.

• Structural integrity The structural design and construction of concrete elements in buildings (including in-situ reinforced concrete, precast concrete, tilt-up, hybrid construction and post-tensioned concrete elements) have been fully appreciated and ack nowledged by arch itect s, structural engineers and contractors for many years. Well-constructed concrete can last well over a century. For example, the Pantheon in Rome, built in 126 AD, is still in use and has a coffered dome which – almost 1 900 years after it was constructed – remains the world’s largest unreinforced concrete dome.

Last word Concrete of fers many other benef its, including sound insulation, fire-resistance, light ref lectance and roads requiring far lower maintenance and far fewer of the pothole repairs that now plague municipalities. Concrete structures are also beautiful and enhance the aesthetic appeal of any town or city. This age-old material is the cornerstone for providing the infrastructure that can lead SA to a sustainable future.

“As concrete products and elements can be constructed into any shape and cast in various ways, designers enjoy an enormous amount of flexibility. ” PRECAST | ISSUE TWO | 2021

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CEMENT & CONCRETE SA RISES TO NEW HEIGHTS Cement & Concrete SA (CCSA) recently announced that the new consolidated industry body is open for business and is set to take the lead on all matters relating to cement and concrete in South Africa.

A single non-profit entity, CCSA was established through an extensive and thorough process of engagement with various stakeholders to consolidate The Concrete Institute, the Concrete Society of Southern Africa and the Association of Cementitious Material Producers.

“CCSA will grow industry expertise and build capacity by developing and offering courses, seminars and training materials.”

The body will create long-term shared value and industr y growth in SA by driving collaboration, skills development, innovation and the highest standards in sustainable cement and concrete materials and products.

Industry support Bryan Perrie, CEO of CCSA, says it has been mandated to promote and support the industry, drive growth and deliver shared value through a unified platform for cement and concrete.

“At a time when many conflicting and ambiguous messages are shared readily on various platforms, and there’s a proliferation of sub-standard products and services, the need for authoritative engagement with all stakeholders is critical,” he adds.

A new and inclusive membership model will make the portfolio of services offered

by CCSA available to individuals or corporates, either free of charge or at members’ discounted rates. These services include courses presented by the School of Concrete Technology, access to the information centre, attendance at technical events and webinars, publications and hyperlinked listings on various electronic sources.

Into the future Through its members, CCSA will create the opportunity to build a healthier future through a network of influencers. Working with industry role-players to develop the value propositions of cement and concrete is one of the identified objectives of the body. Other goals include promoting the value-creation story of the cement and concrete industry in SA, supporting research as a means of increasing the ongoing expertise

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base and the promotion of industry standards and audit compliance among members and industry role-players.

On a more practical level, CCSA will grow industry expertise and build capacity by developing and offering courses, seminars and training materials. The provision of information, research, advisory and on-site technical consulting services will be another service offering available to members.

CCSA’s dedicated focus on committees will ensure that all relevant areas are addressed with expertise through consultation. The committee structures will empower members to guide and shape many of the services. The branch committees of the erstwhile Concrete Society of SA will be retained to ensure that CCSA has ambassadors in various regions.

“Weʼre excited about the future of the cement and concrete industry in SA. The staff of CCSA are ready to discuss membership options and benefits. We’re poised to add value and unlock opportunities for all members and the industry at large,” says Perrie.

(Above): The CCSA logo.

(Left): Bryan Perrie, CEO of CCSA.

| INDUSTRY NEWS |

UNEXPECTED SAVIOUR FOR CEMENT SALES With comparatively low cement sales volumes as a result of the construction industry downturn, the cement industry has looked towards the sale of bagged cement in rural areas to bolster supply.

Speaking at mining industry association ASPASA’s annual CEO’s seminar, Pieter Fourie of Sephaku Cement said strong sales of specially bagged cement in far-flung areas had played a major role in cushioning the effect of the slump caused by the Covid-19 pandemic and other lingering economic factors.

While the construction industry and consumer markets have taken a hammering in recent years, home improvement and small builder activity has shown growth, with more people staying or returning home, where they are undertaking smaller projects.

Shrinking market The local market is estimated to require 13 million tons of cement per annum, while cement producers are producing 19 million tons of cement. Simultaneously, legal and illegal imports of cements continue to add further pressure to an already over-supplied market.

With two new producers (Sephaku Cement and Mambu Cement) entering the market since 2014, the industry is understandably distressed and the stronger-than-expected demand from rural areas is considered a boon for producers able to reach these markets.

Fourie identified the four most important challenges the market faces at present: 1. Uncertainty. There is a lot of political instability and the economic outlook after the Covid-19 lockdown does not appear to be conducive to growth.

Carbon taxes and power grid failures

also create uncertainty.

2. Sustainability. Most companies in the construction industry are suffering from distressed balanced sheets, reduced margins and a low price situation where prices for bulk cement are at 2014 levels.

3. Over-supply. With the entry of Sephaku Cement and Mamba Cement, the estimated capacit y of the industr y is 19 million tons, imports account for 1 million tons and demand has tapered off to 13 million tons.

4. Opportunity. Despite the challenges, companies need to put strategies in place to deal with arising opportunities.

Large-scale infrastructural development projects are on the cards, consumer spending is on the up and the public and private sectors are realigning their priorities in a post-Covid world.

Planning a comeback Until now, the cement industry has undertaken major cost-cutting exercises and mothballed less economical kilns. Investment has been at a low 16% of market value for some time and will require a major jump-start to get back to pre-2010 World Cup boom figures.

Commenting after the presentation, ASPASA director Nico Pienaar said that these events showed how critical the infrastructure programmes mooted by government were to the construction industry and, by default, to the cement and building material industries.

“With the current low levels of investment in the sector, different approaches are needed and saviours may come from different directions than we anticipated – such as rural bagged cement sales, DIY and home improvements,” said Pienaar.

(Above): The CCSA logo.

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(Left): Bryan Perrie, CEO of CCSA.

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| COMPANY NEWS |

Local concrete equipment manufacturer PMSA has suggested concrete manufacturers follow a phased approach to streamline manufacturing and position themselves to fully capitalise on an inevitable leap in demand for precast units post-lockdown.

Hav ing suf fered var y ing deg rees of f inancial distress during the hard lockdown, concrete manufacturers should look towards optimising their current operations and modernising plants in order to cut input costs and boost production.

Incremental upgrades are not prohibitively expensive, but can have the ef fect of radically improving output volumes.

PMSA marketing and sales manager Quintin Booysen adds that plant upgrades offered by the organisation on most major brands of brick, block and paver-making machinery has the additional benef it of improving productivity of the plant, reducing cement consumption and allowing faster strength gains of concrete products.

Opportunity awaits “While cash flow is tight and money hard to come by, it’s increasingly obvious that companies need to be re-geared for a new way of doing business. Right now, they need to get back to full production, but do it carefully, so that they preserve cash flow while still upgrading and boosting plants.

“These upgrades start with simple measures like new production boards, which give better-quality end products,

GETTING BACK TO BUSINESS

WITH A BANG cement-savings and fewer breakages, and can even improve curing times.

Additional measures could include the installation of moisture measuring systems and control in aggregates and concrete mixers. By not considering and adjusting for moisture in aggregates, you could be partially dosing water in place of aggregate.

Wet aggregate contains water trapped around the aggregate particles and by measuring the aggregate moisture content and adjusting for the moisture, you get a

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“Companies need to get back to full production, but do it carefully, so that they preserve cashflow while still upgrading and boosting plants.”

| COMPANY NEWS |

better ratio of cement to aggregates and ultimately achieves better strength, while reducing cement usage.

“Other important upgrades include vibration systems, which are critical in any manufacturing method, whether ready-mix, wet, brick and blocks or any other manufacturing process. Vibrators help to remove air bubbles in wet mixes and ultimately reduce voids on cured concrete. A more controlled vibration gives better density and compaction for more consistent strength and fewer breakages,” says Booysen.

(Right): Technolog y-block-plants-vibration-page (Left): Technolog y block plants.

(Below): Slim-Line Ludwig moisture control.

Good vibrations “On bigger machines such as 1 400 x 840 board size, our PMSA UltraVibe system has amplitude and frequency settings which can provide the perfect setting for better production and curing. These amplitude and frequency settings can be changed in split-seconds, as required for optimal compaction, cement-savings, higher speeds on machines and better end products.

“Smaller machine types using 600 x 500mm boards can benefit through the fitment of specialised variable speed drives [VSD] to control frequency for better fi lling and our PMSA braking systems can replace old DC braking systems for quicker start and stop speeds.

“Better vibration can also be achieved with VSD systems and in combination, these upgrades can make an older or less advanced plant more productive and able to produce more competitive products by improving strength, using less cement, producing products that are less prone to breakages in the packing stages and providing better all-round control of manufacturing processes.

“Cement prices are on the way up and one way of countering this is to optimise plants and curing processes to allow a reduction in cement in the process. We believe that the more control you have over your plant, the better you’re able to control efficiencies and costs for greater control of your business.

The consolidated cement and concrete industry body is soaring to new heights Become a member – be part of the future

Supplier of choice “Coupled to this, once you have this highly efficient machine running, seconds start meaning something in terms of production, rather than days lost with some inferior products. Concrete manufacturers need a supplier that responds as quickly by providing top-quality service and support

www.cemcon-sa.org.za

| COMPANY NEWS |

to make machines more productive in these types of efficient environments.

“From service and spares to boards and optimisations, you need to make sure your supply chain responds effectively.

Because our long-standing customers usually operate so productively, we have a full range of spares and parts to uphold manufacturing and respond quickly to ensure seamless operation of our plants.

That’s also part of the reason ‘PMSA is built to last’.

“So before buying new equipment to meet surging demand post-lockdown, you may be able to upgrade existing plants and get into a position to supply more and betterquality products more cost-effectively.

Gearing up “We think progressive concrete manufacturers need to be at the front of the queue to upgrade plants and improve productivity to meet surging demands that are already exceeding production capacities in some regions of the country.

“From design through to commission-

• Bonding Agents • Chemical Anchors • Concrete Bonding • Concrete Crack Repairs

PMSA upgrades • Moisture measurement and control in the aggregates and mixer – customers are able to reduce wastage and save 5-10% of cement.

• Improved curing systems – customers can sell newly-produced products sooner, as the strength gain is faster with a curing system. Cement-savings are also an advantage, with 5% or more cement saved with a superior curing solution.

• PMSA composite boards – both FTC and wood plastic composites provide improved compaction of end products, which means cement-savings and lower damages. Cement-savings can be over 10% with a high-quality PMSA composite board.

• UltraVibe vibration systems for large machines result in better product compaction, faster cycle times and cement-savings.

• Cycle times can be improved by up to 15% with a PMSA VSD braking system replacing a DC braking system

ing, an all-new plant can easily take eight months, which means that those who are thinking of ramping up now will only realistically start up their new plants next year – so those decisions need to be fasttracked to shorten the lead times. In the meantime, we suggest upgrading your existing plants.

“With no end in sight for the pandemic,

it’s a good idea to reduce inter-company Covid-19 transmissions through automation of processes. It’s worth noting that almost all production plants can be automated to reduce transmission of the disease, as well as enabling more seamless shift changes and a smaller core team. There are many options and the trick is to fi nd a strategy that works for each specific company,” says Booysen.

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WORRYING GLOBAL RAW MATERIALS SHORTAGE With demand soaring from a revived post-Covid-19 environment internationally, South African concrete and cement additive suppliers are under severe production pressures due to the global shortage of many primary chemical industry raw materials essential for producing concrete and cement admixtures, says Norman Seymore, CEO of the Chryso Southern Africa Group and vice-president of Chryso internationally.

Admixtures and additives – key components of the concrete mix – play a vital role in enhancing concrete performance in terms of strength, durability and material costs, as well as general site productivity. A national leader in the construction chemical industry, Chryso Southern Africa has three major plants (in Boksburg, Durban and Cape Town) producing admixtures and additives that service the cement, ready-mix concrete, precast concrete, new construction and mining industries. abe Construction Chemicals is a subsidiary of the Chryso SA Group.

“This crippling shortage of vital raw materials won’t resolve itself overnight. In fact, we fear that the supply and cost constraints are expected to continue for the foreseeable future,” warns Seymore.

He says the severe shortage of raw materials was caused by a combination of several factors totally beyond Chryso’s control.

They include: • Extremely cold weather conditions in the USA in February this year, which caused production interruptions and force majeure setbacks for many players in the petrochemical industry.

• A severe industrial accident at a major chemical company in Europe, which led to a chain of force majeure declarations, slowdowns and even shutdowns of several chemical production units.

• Scheduled maintenance shutdowns of several key chemical production units throughout the world, which negatively impacted global raw material production capacity.

“The strong rebound in activity in several sectors of the global construction and ancillary industries since the beginning of 2021 has generated strong demand for key raw materials.

“The current raw material cost surge has no connection to the usual market indicators and mechanisms. Chryso is currently experiencing the consequences of this strong imbalance between supply and demand at a global level. We’re doing everything possible to maintain continuity of supply of our products, but the situation will take some time to resolve,” says Seymore.

(Above): An aerial view of the Chryso SA main production plant and head offi ce in Jet Park, Boksburg.

| PRODUCTS |

A start-up precast manufacturing operation with a difference is turning out some unusual products that are proving to be surprisingly sought-after, considering that they are polar opposites of the product they mimic.

Just like its name, the newly-founded company @n.be_love is different and manufactures homeware products, especially pillows, for special occasions or as long-lasting ornaments in display cases, businesses and living spaces. So realistic are the rock-hard pillows that one would be forgiven for mistaking them for soft, downy cushions.

Precast magazine asked the founder and owner of @n.be_love, Neo Mutuma, about her unique hobby-turned-career and her love for concrete as a medium for creating works of art.

Why concrete ?

Through experiment, I’ve found that concrete is not only quite versatile, but also inexpensive. It’s been incredible fun and a new challenge to work with, but I’m now able to create a range of homeware products

BETWEEN A ROCK, A VISION AND A H with it, as can be seen on my Instagram page @n.be_love. Concrete is like a blank canvas for me!

What gave you the idea of starting a decorative concrete business?

My first step into this space was inspired by trying to replicate a small candle-holder I’d seen at a market. I felt it was unreasonably priced and there was a bag of concrete in my garage, so I just made one myself and really enjoyed the process. It didn’t turn out all that well, but over time, I’ve been able to refine the design process for a more desirable outcome.

I then made a bigger version of the candle-holder and a friend of mine saw it and liked it. That encouraged me to create more designs. Through posting on social media, my work’s garnered quite a lot of interest and people have started ordering my creations. I’ve always wanted to own my own homeware brand and turning this range into a business has been a great start to a fulfilling journey.

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What is your background and how did you develop a love for concrete?

My career started out in graphic design and I worked my way up to creative director in the publishing industry. I’ve always loved arts and crafts and creating pieces with different material, so I fell in love with concrete through experimenting.

How did you learn about concrete?

I taught myself through trial and error. I had lots of failures, but also success testing different products, material, brands and blends. I’m still learning. When I started, I didn’t even know there was such a thing as white cement. I’d really only ever seen grey cement. Four months into starting my business, I took an online Domestika concrete furniture designing course, which was helpful in improving the basic techniques I’d taught myself and learning what other tools I could use for a better finish. Fortunately, on social media there are many tutorials to be found and I’m able to expand my learning through watching and developing new ideas.

A HARD PLACE

W hat ca n you tel l us about t he versatility of concrete?

It’s interesting to work with a material that starts off as a powder-to-liquid form and then manipulate it into the shape of your choice, until it cures. It’s a process that allows you creative freedom. We often assume that one can only go so far with concrete and that to be more versatile, one must work with clay or ceramic, but I’ve found that cement is just as versatile when mixed with the correct aggregates.

All of this pushes me to think more creatively. Concrete is fairly easy to sand and chisel once it’s cured and all sorts of paint and adhesives take easily to it, which makes it more interesting for creating new designs. I like the fact that it’s so durable can take heat and water well. I’ve also learnt about its porosity. There are times when it forms air bubbles in a mould, but because of my art form, I don’t mind that – I see it as something that enhances my design and challenges me to explore what I can do with what the concrete offers me. Making mistakes has often led me to discover what other design effects I can create with concrete or how to manipulate it further, after it cures.

Concrete is not normally thought of as attractive – is it?

Certainly not in its raw form, but I enjoy its rustic nature. The products that come from concrete can truly be aesthetically pleasing. It’s thought of as a heav y, immovable construction worker’s material, often seen in an industrial setting, used for buildings and exteriors, but what you can do with concrete design-wise for interior homeware is limitless. It’s not just a functional material – it also produces light, yet solid, long-lasting decorative products.

It’s exciting to discover the attractive designs I can come up with and because it’s not commonly found on dining or coffee tables as functional pieces of homeware, it piques people’s interest to see this. It’s a great base product from which to develop.

Many of my customers are very surprised

“I taught myself through trial and error. I had lots of failures, but also success testing different products, material, brands and blends.”

when they realise what my work is made from and that such beautiful art can be formed from concrete.

How do you make your moulds?

I recycle different plastic and silicone containers. With concrete, v irtually anything can be used as a mould, which is really cool. I’ve experimented with making my own moulds using plastic, cardboard and polystyrene sheets too.

Do you work alone?

A s a sole business-owner, I work on everything from buying raw materials to mix ing, moulding and desig ning, packaging and photography, all the way to delivery. It’s both tedious and exciting, but because it’s all my own, I love seeing my clients’ reactions when they receive their orders.

Do you prefer any specific mix or admixes?

Depending on the finish I’m looking for, I mix different aggregates or additives to my cement like water-proofer, bonding agents, plaster, cement oxides and, of course, always clean water. Other agents – like spirits of salts and acid-based cement cleaner – help me further exploit the material for a polished finish. I also have several techniques for sanding, polishing and shaping the final product.

Tell us about the market for your products.

My main client base so far is 90% female and I’ve noticed that they mostly love to gift other people with items and then come back and buy something for themselves.

People say my products are unique and enhance their spaces. I’ve been approached by shop-owners to stock my homeware and I’m looking forward to that becoming the next chapter in expanding my business. I’d also love to get into the corporate gifting and tourism sector.

How is the product sold/delivered?

Clients contact me through social media (Instagram: @n.be_love) or e-mail: neo@ nbelove.co.za, as well as through WhatsApp (082 714 5947). I’m able to deliver anywhere in South Africa and have also shipped to Swaziland.

PRECAST | ISSUE TWO | 2021

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| PRODUCTS |

ACCEPTANCE TESTING FROM THE COMFORT OF AN ARMCHAIR Local pump manufacturer KSB Pumps and Valves has launched an innovative online procedure that no longer requires customers or their engineering teams to be present when acceptance testing takes place.

The service was initially implemented to curb expenses which are usually incurred through travel and accommodation to test centres. The remote pump acceptance testing has also allowed business to continue as usual during the ongoing Covid-19 pandemic.

According to KSB Pumps and Valves technical manager Friedrich Görgens, acceptance tests and f inal inspection are essential proofs of compliance when purchasing pumps and equipment to ensure the guaranteed values are met. In the past, customers always had to travel to the test facility to witness their purchased pump being tested.

Improved convenience “Online acceptance testing is KSB’s a n s wer to i mprov i ng t he ea se a nd convenience of the procedure. They’re transmitted live via the Internet and are encrypted to be accessible only to required users. The customer sees a live camera view of the pump in the test facility, as well as the characteristic curve being generated

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PRECAST | ISSUE TWO | 2021

live from readings taken and displayed during testing.

“In addition to pressure and flow data, the test software records all further performance data required for a measurement to inspection/testing standard DIN EN ISO 9906, enabling the derivation and assessment of the pump’s efficiency. Additional measurement and recording of bearing temperature and vibration are available.

These are displayed live parallel to the performance and incorporated in the final test report.

“We provide the customer with organisational information, order data sheets

(Above and below): KSB Pumps and Valves recently introduced remote acceptance testing for live testing of pumps and hydraulics via the Internet.

and a precise description of the acceptance testing prior to the procedure. This includes details on the measuring instruments used, as well as the corresponding calibration certif icates. After the acceptance test, KSB displays the results for comment and then e-mails the certificate to the customer within minutes,ˮ says Görgens.

Testing centres Online acceptance testing is available at KSB Pumps and Valves SA’s test centre in Germiston, Gauteng and the facilities can accommodate pump sets with a drive rating of up to 550kW, flow rates of up to 3 000m³/h and discharge pressures up to 60 bar. String tests with the customer’s or i g i n a l motor s , t r a n s for mer s a nd frequency inverters can also be performed.

A YouTube video showing the online test in operation is available at: www.youtube. com/watch?v=2tHxYJGjT_s.

“In addition to pressure and flow data, the test software records all further performance data required.”

ENABLING SURFACE STABILISATON

BETWEEN ROCK BOLTS

Rock bolts are used to stabilise rock excavations in mining, tunneling and civil engineering operations such as concrete dam reinforcements, road cuts and bridge abutments.

A critical element to excavations of this kind is the surface stabilisation between rock bolts to hold unstable or fractured rock masses together. This stability is achieved by using CMA non-producer member Technicrete’s Thin Skin Liner (TSL), a modified, polymer-based, fibre-reinforced, thin sprayed liner.

Wherever precast stabilisation is not an option, the easyto-use kits can be used. They consist of a special liquid which is a blend of powder chemicals and graded silica sand with polypropylene fibres.

The contents of the kit are simply emptied into a suitable mixer or pump with a positive displacement-type pump arrangement, then sprayed onto the cleaned rock face and into open joints and fissures covering all surfaces needing to be supported. Maximum penetration is obtained by spraying directly into any open joints. Compressed air is added at the nozzle to spray the fresh mix, while a 7m delivery hose provides the best effect.

The bonding properties of Technicrete TSL bind the rock faces inside the fissures to provide a more stabilised rock surface and minimise the unravelling of rock mass. The tensile properties of Technicrete TSL spanning across joints and cracks resist shear and direct tensile movement, adding to back pressure in the rock mass for added stabilisation.

In low-stress environments, the bonding and tensile strengths assist in preventing block movements while keeping the rock “beam” intact.

Benefits of Technicrete TSL • It can be rapidly deployed in underground environments, as equipment is easy to handle in confined areas.

• The sprayed-on support is quick to mix and hardens rapidly.

• It can be used as rock support for areal stabilisation of rock surfaces.

• It stabilises friable ground.

• It seals sensitive rock types such as smectite, shale and soft shales against water and humidity.

• It prevents unravelling of fractured ground by holding key blocks in place.

• It seals dams, sumps and drains.

• It provides temporary areal support prior to overcoating with shotcrete, which has a strong adhesion to Technicrete TSL. • It can be safely applied to damp substrates (but not onto surfaces covered in running water).

Specifications Technicrete TSL has a shear strength of >0,25MPa after 24 hours, a tensile strength of >2MPa after seven days, an ultimate bond of shear 1,0MPa and a bond strength of 1,0Mpa.

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| PRODUCTS |

Construction chemical company Mapei has established itself in the local market as a supplier of innovative system solutions and technical services to assist the market.

Mapei’s local technical expertise is backed up by the latest international research, development and production methods, resulting in international standard products ideally catered for the local market.

Mapei SA is known for its impressive range of concrete admixture products and solutions, one of which is Mapetard SS, a water-based retarder used to expose aggregates in horizontal surfaces for aesthetic purposes or construction joints.

From an environmental point of view, Mapetard SS is a suitable alternative for exposed aggregates, as water is the only solvent present.

Application of Mapetard SS during placement or onto freshly placed concrete is an effective and time-saving method of preparing exposed aggregates, finishes or construction joints. The water-based retarder will penetrate the fresh concrete to a depth of 5-15mm, depending on the amount applied. This layer will not be set when

RETARDER FOR EXPOSED AGGREGATES the rest of the concrete has hardened, thus allowing the surface mortar to be washed away around the uppermost aggregates.

When treating exposed horizontal surfaces, a brush or spray may be used to apply Mapetard SS onto the fresh concrete surface immediately after fi nishing. A form oil sprayer may be used for application. The thickness of the coating should be similar to that of a lacquer. Mapetard SS contains a white pigment which makes it easy to see the

thickness and uniformity of the coating over the entire surface. Hosing off the retarded surface mortar with water reveals a clean, rough surface. The aggregates are partially exposed and, in the case of construction joints, will enhance bonding to subsequent layers. Normal consumption is 0,1kg/m².

(Above): Mapetard SS was recently applied at an entrance at Waterfall Equestrian Estate to give the concrete an exposed fi nish.

(Above): Mapetard SS was recently applied at an entrance to the Waterfall Equestrian Estate to give the concrete an exposed fi nish.

| TECHNICAL |

THE TEN COMMANDMENTS FOR CONCRETE CONSTRUCTION With the Covid-19 pandemic having created a survival mode for many smaller and emerging building contractors, it is now more important than ever for site staff to have at least a basic knowledge of concrete behaviour and performance in construction, says John Roxburgh, senior lecturer at the School of Concrete Technology.

Here Roxburgh deals with the importance of 10 topics covered in the school’s popular online training course, SCT10 “Introduction to Concrete”: 1. The properties of concrete: For any successful concrete project, understanding both the plastic and hardened properties of concrete is essential. With the correct plastic properties, staff will be able to transport, place, compact and fi nish off the concrete correctly so that it has the correct hardened properties, which includes strength and durability with minimum shrinkage.

“It is now more important than ever for site staff to have at least a basic knowledge of concrete behaviour and performance in construction.”

| TECHNICAL |

2. Materials for concrete: Knowing the function of each material in the concrete mix – and the consequences these materials have on both the plastic and hardened properties of concrete – is essential in obtaining concrete that will perform well over its design life.

3. Receiving and storing materials: The overall quality of concrete depends on many factors. Often, the receiving, storage and handling of the original materials are overlooked. Contracting staff must know how to prevent contamination of stored materials and have methods in place to ensure they are receiving and using the correct materials.

4. Batching, mixing, and testing concrete: There are specific requirements for accurately batch ing and m i x ing concrete. Control of water content is

probably the most important because the 6. Finishing and surface preparastrength of concrete is strongly related tion: Finishing and surface preparation to the water content. Concrete quality require a unique set of skills, coupled with must be assured throughout practical experience. For and this requires a good proper finishing, staff must working knowledge of the have a detailed knowledge of various tests that need to be concrete technology to apply performed on both the plastic their skills on the surface of and hardened concrete. the concrete in good time.

5. Transporting, placing 7. Protection and curing: and compacting: There Often all other aspects of the is only a limited amount of concrete works are completed time to transport, place and acceptably – and then the compact plastic concrete and curing is botched. For good, contractors’ staff inevitably durable concrete, proper have to work against the (Above): John Roxburgh of the curing is essential. It cannot, clock to ensure that the full for e x a mple, s i mpl y b e School of Concrete Technolog y. potential of the concrete is interrupted and then resumed reached. They need to know how to achieve many hours later. a dense non-segregated concrete – and to 8. Formwork and reinforcement: do so timeously.

Formwork is crucial for moulding the concrete to the correct shape, but is also very inf luential in the final off-shutter f inish. Knowledge of shutter materials and different types of release agents allows contractors’ staff to make the correct decision when it comes to achieving the desired off-shutter finish.

9. Sand-cement mixes: Sand-cement mixes are typically problematic. When there is an excessively high water content, the concrete tends to shrink substantially and is very weak. It is therefore important to know how and where sand-cement mixes should be applied. Often the mixes are used inappropriately and a contractor should be able to advise a client before this happens.

10. Durability: Sustainability is an important consideration in the world today and materials with a low carbon footprint are given preference. Cost-effective concrete is sustainable and has a low carbon footprint, as it does not need excessive maintenance or repair over its service life. It is therefore essential for small, medium and micro-enterprises, as well as junior technical and sales staff in the building and construction industry, to receive training on the matters listed above, as they are all intrinsically linked to concrete durability.

For further information about the “Introduction to Concrete” and other online courses presented by the School of Concrete Technolog y, tel: (011) 315 0300, e-mail: sct@cemcon-sa.org.za or visit: www.cemcon-sa.org.za.

“Sustainability is an important consideration in the world today and materials with a low carbon footprint are given preference.”

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| TECHNICAL |

REPAIRING NON-STRUCTURAL CONCRETE DEFECTS There are essential steps to follow before and during the repair of relatively minor, yet unsightly concrete defects. Bryan Perrie, of Concrete and Cement South Africa (CCSA), outlines what to do – and avoid – when tackling such projects Firstly, repairs to new concrete should be done as soon as possible after the formwork has been removed to reduce differential shrinkage and improve the bond between the orig inal concrete and the repair material. Before doing the repair, all dust and detritus must be removed from the surface to be treated by, for example, washing vertical and near-vertical surfaces with clean water.

For manual repairs, suitable for small areas, feather edging – trying to seamlessly blend the repair material into the existing concrete – should be avoided. The outline of a repair should be cut with a masonry cutting disc or saw to ensure a square edge.

Surface preparation Good adhesion between the original concrete and the repair material is essential and, to ensure this, the surface of the original concrete must be strong, rough and clean. Any loose or weak material must be removed with sharp chisels, driven by relatively light hammers. However, it is important to remove the unwanted concrete in such a way that the remain-

ing concrete is not irreparably damaged.

Sandblasting, which can remove small volumes of concrete, is an excellent means of achieving a rough surface free of loosely adhering material.

In cases where the repair areas are large (say, over 0,1m²) and especially where persons could be injured by falling fragments, it is strongly recommended not to rely solely on adhesion between repair and background concrete, but to provide mechanical fixing. Such fixing should be done with corrosion‐resistant metal devices such as screws or rods, preferably of stainless steel. Fixing devices should be installed after the surface preparation is complete, but before the surface is cleaned.

To ensure strong adhesion of fresh concrete or mortar to a substrate of hardened concrete, the substrate should have enough suction to absorb the water fi lm at the interface, but should not desiccate the repair material. This limited suction can be achieved in different ways, depending on the age and density of the concrete. If the concrete is fairly new – say, within 48 hours of being placed – simply allowing

| TECHNICAL |

the surface to become visibly dry should suffice. Concrete with low absorptiveness does not require pre‐wetting and should be repaired in a dry state.

Primer slurry The substrate should be primed with a slurry immediately before the repair material is placed. The primer slurry should be a mixture of equal volumes of cement and dry plaster sand with sufficient water to achieve a “paint consistency”. Neat cement paste is difficult to mix and is therefore not recommended. Polymer emulsion may be added to the mixing water – one part emulsion to two parts Perfect finishes water is usually satisfactory.

Good compaction is essential in concrete Primer slurry must be applied as r e pa i r s . S em i ‐ d r y m i xe s mu s t b e a thin coating to the substrate, using compacted by heavy tamping and plastic suitable brushes. Do not allow primer to mixes applied with heavy pressure on the accumulate in depressions in the surface trowel or spatula. and prevent the primer from drying before W here appearance is important, applying the repair material. Priming repairs should be finished to match the must therefore be done immediately ahead texture of the surrounding concrete using of repairing and is best done over a small tools such as wooden floats, steel trowarea at a time. Polymer emulsion els, sponges, wire and nylon on its own must never be used as brushes. If colour-matching a primer. is essential, it should be noted Older concrete should be that repairs tend to be darker assessed for absorptiveness by than the or ig ina l concrete wetting the surface: if the water when dr ied out. Therefore is rapidly absorbed, the rate of white portland cement may be absorption would be too high and substituted for about one-third if the water is hardly absorbed, of the grey material if such a the rate is too low. Concrete colour match is required. The (Above): Bryan with high absorptiveness should optimum substitution ratio Perrie of CCSA. be saturated for some hours should be determined by test: before repairs are carried out. Surface carry out a repair in an unimportant water must then be removed, the surface area and assess the colour once the repair allowed to become visibly dry and repairs material has hardened and dried. undertaken straight away. Remember Repairs must be moist-cured for at never to attempt repairs to concrete which least seven days. Plastic sheeting, fixed has a water sheen. along the edges of the concrete with pressure‐sensitive tape, is effective in trapping moisture and ensuring adequate curing.

Good-quality, membrane‐forming curing compounds may also be used, but remember that drying of the concrete repairs may be retarded if these curing compounds are not removed from the surface.

After completion of the curing period, polymer‐modified repairs must be allowed to dr y out completely before being subjected to wet conditions. This allows the emulsion to coalesce and become water‐resistant.

| GLOBAL VIEW |

POPIA 101

By Wendy Tembedza

Renewed marketing efforts are being exerted by almost all companies in the precast concrete supply chain, so it is important to understand privacy rights and using personal information before mass-mailing or communicating with them.

Wit h t he commencement date of the Protection of Personal Information Act (POPIA) 4 of 2013 of 1 July 2021 fast approaching, businesses should be reviewing their use of personal information to determine whether it complies with the Act. It is important to understand that any business which has employees, customers and suppliers must comply with POPI when dealing with personal information.

Below are a few ways businesses can kickstart their compliance exercise: Identify what personal information you process and why Under POPI, a business must be able to justify why it holds personal information based on one of the several justifications set out in the Act. This is a good opportunity for a business to assess what information it collects (whether from employees, customers, service providers or other

FOR PRECASTERS

“All businesses with employees, customers and suppliers must comply with POPIA, which comes into effect on 1 July 2021.” third parties, such as credit bureaux) and review whether that information is really necessary. In this regard, minimality is key – a business should not collect more personal information than is required. Importantly, the term “personal information” is defined very broadly to mean any information that can be used to identify an individual person or another business entity.

Get rid of what you do not need Under POPI, a business cannot keep a record of personal information once the reason for which it was collected no longer exists, unless required by law. For example, unless legally required, a business should not keep personal information of any former supplier once the relationship has ended. Businesses should therefore check whether they are holding onto any old records of personal information that they no longer need and dispose of them in a secure manner. More data means more risk and it is best to purge what is not required.

Look at security Correct management of personal information means that appropriate security must be in place to protect it. POPI requires a business to put in place “appropriate,

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A STRONG FOUNDATION FOR INFRASTRUCTURE SUCCESS

reasonable technical and organisational measures” to prevent loss, theft or damage to personal information. The suitability of security measures will depend on the business and the type of personal information it holds.

Marketing Opt-out marketing e-mails and SMSs are things of the past under POPI. Unless a person is an existing customer, a business cannot send him or her marketing e-mails or SMSs without first obtaining their consent. Any request for marketing consent must include language which is set out in the regulations to POPI. Businesses should therefore review their direct marketing practices.

Go for the easy wins POPI compliance may seem like a daunting task, but there are some “easy wins”. Basic documents used by the business will likely need updating for POPI compliance. These include company privacy policies and employee and supplier contracts.

All these documents should aid the business in proving its compliance with the Act.

ROCLA is South Africa’s leading manufacturer of pre-cast concrete products.

Surpassing 100 years of product excellence.

• • • • • • •

Pipes Culverts Manholes Poles Retaining walls Roadside furniture Sanitation

Including other related products within infrastructure development and related industries.

Visit us on

www.rocla.co.za

for our nationwide branches

| PROJECTS |

A sustainable

RAISED FLOORING SYSTEM

(Right): KBAC installers placing the concrete pavers on top of the InstaCradle rubber cradles made from recycled truck tyres for the balcony installation in Centurion.

(Above and far right): The innovative raised flooring project nears completion on the ground floor of the new M&T property and the completed InstaCradle raised paving area on the third-floor balcony of the new building in Centurion.

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| PROJECTS |

Sustainability is the key feature of a new outdoor raised f looring installation in Centurion which is laid on recycled truck tyres and will harvest vast volumes of rainwater.

K BAC Flooring’s Raised Flooring d iv ision suppl ied a nd i nst a l led t he sustainable InstaCradle raised paving system at a new property development for M&T Development. The innovative application of InstaCradle rubber understructure and raised paving around the public spaces on the ground floor of the building, as well as on its third-f loor balcony, allows the substrate to direct water flow away from the building and be potentially re-used as grey water elsewhere.

Guy Park, who heads the Raised Floor division of KBAC Flooring, says M&T Development approached KBAC for a solution that could deal with water run-off from the exterior extensions which could have posed major problems because of the site of the new building in Byls Bridge Office Park.

Better way “A raised paving solution was opted for so that the sub-floor could be adequately waterproofed and designed in such a way that water is directed to collection drainage points beneath the floor void through slab undulations. By adjusting the InstaCradle system, KBAC’s installers ensured t hat a lt hough t he sub -level deviated in a manner to control the water flow, the final paved areas on top were perfectly level,” explains Park.

The height of the raised paving system’s

“The innovative form of ‘green’ raised flooring is supported by rubber crumb cradles made from recycled truck and car tyres.” concrete paved slab varies from 90-245mm under the concrete pavers. The flooring on ground level outside the building covers 1 406m², while the system on the higher balcony – used as a client entertainment area – is 163m² in extent.

The InstaCradle system, which for this project was specif ied to promote sustainable objectives, is itself exceptionally environmentally friendly. The innovative form of “green” raised flooring is supported by rubber crumb cradles made from recycled truck and car tyres.

The InstaCradle rubber cradles for this project totalled approximately 9,6 tons of recycled truck tyres: this is about 194 radial truck tyres which have been repurposed, instead of landing up in a landfill.

Concrete pavers 600mm x 600mm x 45mm thick were then loosely placed on a combination of InstaCradle rubber cradles and aluminium battens.

“Even the InstaCradle system’s rubber cradles are fully recyclable to provide a genuine ‘cradle-to-cradle’ product. The cradles have a 60-year guarantee and are loose-laid without the need for fixing to sub-floors,” adds Park.

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| PROJECTS |

(Below and bottom): The Equities Property Fund logo was expertly embossed into some of the concrete panelling by Superstruct.

(Right): The completed Imperial Logistics warehouse.

Precast warehouse completed

DESPITE LOCKDOWN RESTRICTION Despite lockdown restrictions, rock-blasting and rain delays, a 17 000m² healthcarecompliant warehouse was constructed for Imperial Logistics in 2020 within the seven-month contractual period.

Developed at Witfontein X57 in Pomona, Gauteng, by JSE-listed Equites Property Fund, the warehouse shell was completed in December using precast columns and tilt-up panelling, cast and installed by tiltup specialist Superstruct.

Other members of the professional team included architects, Empowered Spaces, structural engineers DG Consulting,

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quantity surveyors Schoombie Hartman, Imperial and Lead Logistics Provider Division (formally Resolve Capacity) and main contractor Ndwala Construction.

Lloyd Zacharias, Equites Property Fund project manager, comments: “A substantial advantage of building with precast concrete is that one can get going with the concrete preparation while waiting for council approval. We had to pause all construction work during the April lockdown, but as soon as it was lifted, we were able to begin with the assembly of the precast elements in June.

This major win for the project enabled us to complete the project on time.”

Superstruct supplied 103 columns in heights which varied from 11,75-15,66m.

Seventy-seven panels were supplied in heights from 3,7-10,7m and widths which ranged from 2,3 -10,5m. Twent y-one columns were placed inside the building in three rows to support the roof structure.

The rest were mounted on the building’s

TIONS

| PROJECTS |

“We had to pause all construction work during the April lockdown, but as soon as it was lifted, we were able to begin assembling the precast elements in June. This was a major win for the project and the essential contributing factor in our executing the project on time.” perimeter to support the panels and the roof.

Bruere Visser, managing director of Superstruct, comments: “Under Level 4 lockdown restrictions, we managed to cast all columns shorter than 13m offsite at our manufacturing facility at Lords View, manufacturing only a handful of columns on site.

“When we moved on site, we cast the panels and the few remaining columns.

All columns were cast with protruding starter bars, stitched together with the rebar, which had been cast into the column bases. While the concrete was poured and during a seven-day curing period, the columns were supported with push-pull props. We make it easy for the design team to follow the in-situ rebar design using precast columns because we simply swap the starter bars from inside the footings to inside the columns. Everything else stays the same,” explains Visser.

The panels were cast on site on sacrificial beds which were stack-cast up to f ive panels each. Carefully positioned lifting inserts were cast into the columns and panels to prevent cracking during lifting into position, which was done by a crawler crane. The panels were lowered onto the column bases and then bolted onto the face of the columns with steel brackets and wedge anchors. Besides functioning as exterior walls, the panels act as retaining walls, retaining soil under the warehouse floor to a depth of 2,1-2,45m.

Once the panelling had been installed, it was given a cementitious coating. It binds with and resembles concrete and gives a world-class uniform finish. Unlike naked concrete, it offers consistent colouring. In addition, it is very stable and does not flake.

Superstruct was founded in 2018 by Bruere Visser. Its f irst project was a 33 000m² BMW warehouse in Midrand.

Since then, the company has completed over 50 projects in greater Johannesburg and the Cape Peninsula.

“Our core business is the construction of warehouses for clients who intend keeping their properties for a long time. Clients who want to leave a legacy tend to use us, as they appreciate the superior properties of precast concrete,” says Visser.

(Left and above): The Imperial Logistics warehouse takes shape with precast columns and panels supplied by tilt-up construction specialist, Superstruct.

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| PROJECTS |

“Armitage believes PICP has an important role to play in stormwater control.”

(Above): The wetted patch of the Modified Swift test.

(Right): Six litres of water are poured into the Modified Swift test bucket.

(Below): Twenty litres of water are poured during the ASTM Standard test.

One of the requirements for maintaining a permeable interlocking concrete paver (PICP) system is a reliable, user-friendly method of testing water infiltration rates.

This was one of the reasons UCT Permeable Paving Workshop leader Prof Neil Armitage and civil engineer, Peter Wium, as well as other members of the PICP workshop, spent a morning in February testing infiltration measurement devices at Cape Town’s Blue Route Mall shopping centre. Videos of each test were also made for the benefit of workshop members unable to attend.

Three devices were tested: the Mod if ied Stormwater Infiltration Field test ( Mod i f ied SWIFT), the Modified Simple Infiltration test (SIT) and the American Standard test (ASTM Standard). They all gave similar values.

Quick and easy PICP INFILTRATION TEST

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At approximately 35 000m², the Blue Route Mall’s parking area is the country’s largest PICP site. Installed in 2013, it has also been the best maintained and, as such, was the perfect setting for the infiltration tests.

The Modif ied SWIFT test is based on Australia’s SWIFT test for permeable paving. It involves filling a bucket mounted on three 60mm legs with six litres of water and placing the bucket over the area to be tested. A plug at the bottom of the bucket is pulled, allowing the water to drain onto the PICP surface. The greater the area covered

by the water, the lower the infiltration rate and vice versa.

T he wet ted area is est i mated by multiplying the length of the major axis of the damp area with its right-angled minor axis (ie, the area of the smallest rectangle enclosing the wetted area) and then reading off the associated infiltration from a plot linking this to infiltration.

In the original SWIFT test, which was developed by Prof Terry Lucke of the University of the Sunshine Coast, Queensland, Australia, the infiltration was

| PROJECTS |

determined by counting only fully wetted pavers – the smaller the number, the higher the infiltration rate. However, as Armitage points out, this method is problematic, as counting pavers is hard to do in practice, leaving out partially wetted pavers seems somewhat arbitrary and – most significantly – pavers come in different sizes.

The Modified SIT test, developed at North Carolina State University, USA, uses a rubber-lined 1m² steel frame. It involves pouring nine litres of water into the ring and measuring the time it takes for the water to infiltrate into the paved surface. One of the problems with this test is that leakage occurs. Also, if there is any slope, the water ponds on the downstream side, distorting the flow patterns. However, as a relative test, it performs as well as the others.

The “gold standard” for PICP testing is the ASTM Single-Ring Infiltrometer Standard test, but this takes far longer to execute and uses much more water (20 litres). It involves pouring the water into a metal cylinder which is first sealed onto the paved surface with plumber’s putty.

Water is poured at a rate which maintains a constant 50mm level at the bottom of

the cylinder. The rate at which the water is poured equates to the rate at which the water enters the paved surface.

Using the least amount of water by far and much the quickest, the Modified SWIFT test is the most appropriate method for multiple on-site testing.

Commenting on the results, Armitage says this is good news for property-owners with PICP installations because in the Modified SWIFT test, they have a reliable,

(Above): Pouring nine litres of water during the Steel Ring test.

easy-to-use testing mechanism.

“What these tests prove is that the Modified SWIFT test is a more than adequate measurement technique. It might not be quite as accurate as the ASTM Standard test, but that level of accuracy isn’t required for establishing whether maintenance is required – and, if it is, the level and intensity of the maintenance to be performed.

“The knowledge that there’s a simple and inexpensive method of testing PICP installations should encourage propertyowners to begin maintaining their sites.

“Currently, most South African PICP systems aren’t maintained. Among the few that are, only one or two receive the regular upkeep needed for sustained infiltration and stormwater control performance. Unless PICP systems are cleaned regularly by removing dust, sand and detritus which accumulates in the aggregate between the paving blocks, they clog up and are eventually no better than conventional paved surfaces,” says Armitage.

Peter Wium, who designed the Blue Route PICP installation, says the site is maintained regularly.

“Every year we clean about one-quarter of the site on an ongoing, rotating basis.

The Blue Route site is unusual in that virtually all the roads and parking areas are covered with permeable paving at a run-on ratio close to 0 – ie, there’s negligible flow from surrounding areas. It provides very effective stormwater control. Most PICP sites have substantial run-on ratios, although I’d discourage anything greater than 1 (permeable paving area) to 3 (nonpermeable paving area).”

Armitage believes PICP has an important role to play in stormwater control.

“It not only manages stormwater flows, but – if it’s installed correctly – assists greatly with the removal of pollutants from stormwater run-off. And unlike asphalt roads, which require major repair or even complete rebuilds after 15-20 years, PICP systems can be rejuvenated at minimal cost,” he says.

For further details about the Blue Route tests, contact Professor Armitage at: neil.armitage@uct.ac.za.

(Left): Measuring the axes during the Modified Swift test.

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Concrete wine tanks

ARE WINNERS! Wine producers are turning to precast concrete tanks for fermentation and maturation. There are several reasons for what is becoming a global trend, but the overriding factor is the production of wines which are more integrated and complex.

They are also softer, fuller-bodied and have more mouth feel – some of the other reasons several South African wine estates are riding this wave.

Marketed by Ikapa Concrete and produced by Cape Concrete, locally produced precast concrete wine tanks have been available for the past five years. Ikapa has supplied concrete tanks to over 40 local estates, the first delivery having been to the Alheit Vineyards in February 2015.

Cape Concrete makes the full range of concrete tanks for Ikapa. It includes the egg-shaped (Eon) 1 520-litre unit and rectangular tanks in four sizes: 2 550 litres, 6 000 litres, 8 000 litres and 10 000 litres.

During the first quarter of 2021, Cape (Top): Waterkloof Estate wine-maker Nadia Barnard.

(Above left): Some of Waterkloof Wine Estate’s egg-shaped wine tanks.

(Left): Noble Hill proprietor and wine-maker Kristopher Tillery and his 10 000-litre concrete tank duo.

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“The micro-porosity of concrete allows microscopic amounts of oxygen into the wine, resulting in the same type of gentle oxygenation found in barrel fermentation.”

Concrete produced 14 Eon tanks and two Kian 10 000-litre tanks.

Cape Concrete factory manager Johan Nel says precast concrete wine tank production requires a complex concrete mix design.

“One can’t use additives or chemicals, just raw concrete, and getting the slump and workability right without the use of polymer additives or any bleeding is quite tricky. We use a granite-stone aggregate, washed dune sand and chlorine-free water.

The water is sourced from an underground reservoir at our factory and is purified through reverse osmosis,” he explains.

I k apa manag ing d irector Doug ie Atterbury says there is a growing demand for locally produced concrete wine tanks.

“The micro-porosity of concrete allows microscopic amounts of oxygen into the wine, resulting in the same type of gentle oxygenation found in barrel fermentation.

But concrete allows for a better expression of the fruit, as the wines don’t suffer from reduction.

“Moreover, oak barrels are becoming very expensive and normally last only three to four years, whereas concrete tanks can

last up to 40 years and longer. When we began producing tanks locally, we imported all the stainless steel components attached to them from Europe, but now we’re sourcing most of them locally,” he says.

Commenting on the egg-shaped tanks, Atterbury explains that they assist with the oxygenation process.

“The thermodynamics of the egg shape aids fluid movement and reduces pressure on the lees. It also aids the deposition of lees across a larger floor area than in barrel maturation and no stirring is required.”

One of the users of the Ikapa eggshaped tank is Waterkloof Wine Estate in Somerset West. Wine-maker Nadia Barnard says the egg-shaped tanks are ideal for holding lees in suspension and, very importantly, fine lees. “This adds length and complexity and helps create elegant wines,” she adds.

Waterkloof installed 15 egg-shaped tanks in 2017 and uses them for the fermentation and maturation of Sauvignon and Chenin blends, as well as Chardonnay, Pinot Noir and some other varietals.

Producing up to 500 tons a year in 30 varietals, Waterkloof ’s vines are grown using bio-dynamic farming techniques.

It is one of a handful of South African wine estates doing so. Based on holistic farming methods, as espoused by Austrian philosopher Rudolf Steiner, the estate exports 90% of its output, mainly to the UK and European destinations, but also to Africa, the Middle East and. more recently, the USA. Another Ikapa tank-user is organic bout ique w i ne est ate Noble H i l l i n Simonsberg-Paarl, which installed two 10 000-litre tanks in 2019, one for white and the other for red wine production.

“We use the tanks for fermentation and maturation. We chose them because concrete gave us oxygenation and maturation without any oak overlay,” explains proprietor and wine-maker Kristopher Tillery. “ We’re usi ng t he wh ite t a n k for maturing our Chenin Blanc. The first wine produced in this tank has a good palate weight and it’s retained its freshness and liveliness very nicely. There’s very little lees settlement and the wine remains fairly turbid during the maturation period. This means we get good contact throughout the maturation period, but we do remove it for settling.”

Atterbury says another advantage of concrete is that it is neutral, so it imparts no flavours of its own. “What’s more, it’s easy to clean and will consistently deliver the same flavours year after year,” he adds.

(Top): New egg-shaped concrete wine tanks are readied for delivery at Cape Concrete.

(Above): Newly installed tanks at Mimosa Wines, Montagu.

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| PROJECTS |

Situated in the heart of the central business district (CBD), High St in Hermanus has been upgraded from a traditional asphalt, kerb and pavement through-road, where the car was king, to a shared street with an integrated living space for pedestrians, cyclists and vehicles. Kerbing has made way for open stormwater channels which, in conjunction with the new road and pedestrian layouts, have been paved with concrete block paving (CBP) supplied by CMA member CEL Paving Products.

High St’s upgrade forms part of an overall framework plan commissioned by the Overstrand Municipality in 2016.

Developed by Gapp A rch itects, t he framework focuses on revamping the CBD, the treatment of public spaces and traffic flows. As one of several development opportunities, the framework identified High St as an important historic route and, as such, recommended transforming it from a traditional shop-and-go precinct into a recreational space.

Hedwig Crooijmans-Lemmer from Gapp Architects and Urban Designers says the Overstrand Municipality has taken the framework plan on board.

“The municipality’s actively promoting the Hermanus CBD and it recognises the important role the quality of the public space plays in promoting tourism and stimulating the CBD’s economy,” she says.

“Business and restaurant owners have suffered from the introduction of shopping malls on the outskirts of the town. Given that High St and the CBD have a lot to of fer, we believed that, packaged differently, the area had great potential to pull back the shoppers and tourists.

We reasoned that encouraging them to linger and sample High St’s unique mix of shops, boutiques, restaurants and coffee shops, at their leisure, was the best means of achieving this goal.

“Before drawing up our High St plan, we developed a public space manual based on the principles outlined in the overall framework. The manual speaks directly to international best-practice standards in outdoor urban environments and covers aspects such as colour, materials, the principles of greening and the creation of better pedestrian locations.

“By providing more leisure space, we wanted to encourage shops and restaurants

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Concrete block paving

REJUVENATES HERMANUS CBD

| PROJECTS |

“By providing more leisure space, we wanted to encourage shops and restaurants to spill out onto the sidewalks. We took our cue from other sections of Hermanus which have been redeveloped over the past five to 10 years, including some of the earlier paving projects.” to spill out onto the sidewalks. We took our cue from other sections of Hermanus which have been redeveloped over the past five to 10 years, including some of the earlier paving projects. We looked at Gearing’s Point and Market Square, where the paving was well received by the local community and has held up well, and we decided to create a sense of place in High St using the same visual language. That was why we chose CEL’s concrete pavers, which had been used on the earlier projects.”

The High St upgrade was implemented in conjunction with the installation of a new stormwater drainage system and both projects were handled by main cont r a ctor Meyer B eton Siv iele en Boukontrakteurs. In addition to new piping, seven sustainable urban drainage section (SUD) areas were installed at various points along the 300m street.

Measuring approximately 1,5 x 5m, the SUDs allow some of the stormwater to drain back into the ground, rather than into the stormwater system. The SUDs

have been pla nted w it h i nd igenous shrubs, flowers, ground and trees and will be flanked with benches built with natural stone and wooden seating.

“We’ve also constructed a pergola at the intersection of High and Dirkie Uys Sts. Facing onto High St, it’s integrated with the adjacent pavement and creates an attractive focal point. It will house market stalls and be used for events such as the annual whale festival.

“The number of parking bays has been reduced in High St, which is always a contentious issue. However, our public space initiative has enjoyed good support from local officials, politicians, businesses and organisations such as the History Society,” says Crooijmans-Lemmer.

The new stormwater network, designed and managed by Element Consulting Engineers, forms part of Overstrand’s new stormwater master plan for Hermanus.

“It was during the planning phase of the stormwater network that we learnt about the High St Revitalisation Project,” says

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Element civil engineer Uli du Toit.

“To eliminate unnecessary expenditure and disruptions to the residents and businessowners in High St, I proposed that both projects be implemented simultaneously. It made no sense to resurface High St twice, with asphalt after the pipe installation and again a few months later with concrete block paving. So Element and GAPP integrated their design proposals and coordinated the installation and positioning of elements such as the stormwater network, paving, SUDs, trees, bollards, benches, pergola footings, etc.

“Moreover, while our structural engineers provided valuable input in optimising the pergola’s design, our electrical engineers were involved with the design of new streetlights, as well as the relocation and replacement of aged electrical underground cables prior to the installation of the concrete pavers.”

Precast concrete stormwater pipes for the entire CBD stormwater upgrade project, which ranged from ø450-ø900 mm, supplied by CMA member Rocla.

“Measuring approximately 1,5 x 5m, the SUDs allow some of the stormwater to drain back into the ground, rather than into the stormwater system.”

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| PROJECTS |

MVA Interlockers

FOR NEW STORAGE YARD A new storage area for newly manufactured vehicles at Ford Motor Company SA’s Silverton assembly plant in Pretoria has been overlain with M VA Bricks’ I nterlocker, a ha rd-wea r i ng 6 0 m m interlocking concrete block paver. The project was completed in December 2020, three months ahead of schedule.

Designed by ViKO Consulting Engineers and covering just over 58 000m², the newly-paved area forms part of an expansion project at the plant and provides a visually appealing parking surface for 2 100 completed vehicles awaiting domestic and international shipment.

It increases the current and shipment yard, all done in interlocking pavers, from 146 000m² to 204 000m². Until the fourth quarter of 2022, it will store Ford Rangers, Everests and Range Raptors. However, from the first quarter of 2023, it will only store the Ford Ranger, but in much larger volumes.

Ryan Prinsloo of main contractor, PR Projects & Civil Works, says the paving involved the excavation of unsuitable soil which was removed from site and rehabilitated.

“The sub-base comprises 150mm of compacted G5 aggregate and bedding sand. In addition to its interlocking paver,

MVA supplied us with channel kerbing for the edging of the paved surface.

“The paved area is sloped, draining stormwater into V drains which were constructed with concrete to falls. Concrete plinths were installed for the construction of carports, which were roofed with solar panels.”

MVA general manager Brennan Small says interlocking concrete block paving is the ideal surface for vehicle storage.

“The interlocking action of the MVA interlocker facilitates excellent load distribution. Interlocking creates a strong bond between the pavers, which makes them resistant to movement under traffic. And by spreading the load, interlockers lower base-layer requirements.

“What’s more, interlockers are skid-resistant and perform well with stop/start traffic and the turning/slewing of wheels.

They’re also resistant to petrochemicals and other contaminant spillage and their outstanding durability means they’ll last for many years,” says Small.

Like other types of concrete block pavers, interlockers can be removed to allow access to services and then replaced without visible evidence of the removal.

(Top): MVA interlockers during the laying of Ford SA’s new vehicle storage area.

(Above): MVA interlockers were used to create a hardwearing surface for Ford SA’s new vehicle storage area.

(Left): Ford SA’s new vehicle storage area.

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New stormwater drainage system

FOR HERMANUS CBD

A new stormwater drainage system has been installed at South Africa’s whalewatching hotspot. A substantial increase in non-permeable paved surfaces and buildings over the decades, combined with an increase in the intensity of rainfall, meant that the CBD’s original ø300mm stormwater drainage system could no longer cope and the area’s High St and Main Rd had f looded on at least three occasions during the previous eight years.

The new system comprises a combination of 450mm, 525mm, 750mm and 900mm (Above): Tertius Retief of Element Consulting Engineers inspects the outlet structure and the construction of gabions around the ø900mm pipe outlet above the entrance to the ø450mm exit pipe.

(Left): A section of ø750mm pipe installed in Dirkie Uys St between High St and Main Rd.

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diameter concrete piping supplied by CMA member Rocla, as well as a short section of HDPE structured wall pipe which was installed under luxury apartment block Hamewith Penthouse.

Hermanus falls under the jurisdiction of the Overstrand Municipality. In 2013, Dennis Hendr iks from the council’s E n g i ne er i n g S er v ic e s D e pa r t ment com m i s s ioned E lement C on su lt i ng Eng i neer s to develop a stor mwater master plan for the town’s CBD and industrial area. When the first funding was allocated by the municipality in 2018, Element Consulting Engineers proceeded with a detailed design of the stormwater network based on the guidelines outlined in the masterplan. Pipe-laying in the CBD section, which was handled by main contractor Meyer Beton Siviele en Boukontrakteurs, commenced in May 2020 and was completed in February 2021.

New piping was installed along High St, Main Rd and Dirkie Uys St. A section of ø525mm Class 100 pipe was run over 45m from the eastern end of High St to the point where it intersects with Dirkie Uys St. Similarly, a 117m portion of ø525mm pipe was installed from the western end of High St to the same intersection. Both feed into a ø750mm pipe which was installed at right angles to High St and runs from the High St/Dirkie Uys junction for 52m to Main Rd, where it links into a ø750mm pipe at right angles. The Main Rd pipe drains in an easterly direction for 43m, ending at one of the road’s trapped low points outside the entrance to Hamewith Penthouse. There is no overland escape route for large volumes of stormwater from this point and it is here

“The new system traps most litter before it enters the stormwater system, but some debris does get through, especially via the kerb inlets in Main Rd. To counter this, a steel grid was installed into the exit-pipe opening into which the ø900mm pipe discharges.” that additional grid-inlet catch-pits were installed and the stormwater piping system was increased to ø900mm.

“Initially, the proposed route for the ø900mm pipe was all the way down Main Rd in an easterly direction towards the Marine Hermanus Hotel,” says civil engineer Uli du Toit of Element Consulting Engineers. “However, after investigations and then consultations with the owner, we agreed to redesign the pipe layout and route

it under the Hamewith Penthouse building.

This resulted in a considerably shorter route from Main Rd to the outlet, which is located off Marine Drive, and reduced the Main Rd installation/closure period.

“Constructed as a concrete frame structure, Hameworth Penthouse is supported on concrete footings and columns. Consequently, we were able to route the ø900mm HDPE structured wall pipe through the ground-floor driveway without jeopardising the structural integrity of the building’s foundations. We opted for lightweight HDPE pipes due to a limited overhead clearance, which precluded the use of large construction plant for lifting much heavier concrete pipes.

“Another consideration in favour of the HDPE option was that the building’s vehicular loading is considerably lower than loading on public roads. The HDPE (Above): A manhole under construction where the new ø750mm and ø900mm pipes intersect under the existing ø300mm piping.

(Left): The flooding Main Rd’s trapped low-point during heavy rainfall. (Photo by Johan Pretorius)

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pipe is linked to a ø900mm concrete pipe which runs under Marine Drive and the Marine Drive parking lot to a newlycreated outlet structure seaward of the parking lot,” says Du Toit.

“The ø900mm pipe discharges stormwater from the outlet structure into an existing ø450mm exit pipe. The outlet structure was positioned over and drains into a cavity which we cut into the exit pipe. The pipe descends to the shoreline at a steep angle, which gives it the capacity to handle large volumes of stormwater.

However, should it become blocked or reach its full capacity – for instance, during a once-in-50-years storm – any overflow will discharge down the embankment into the sea. In anticipation of this occurrence, gabion boxes were installed to act as energy dissipators to protect the embankment from severe flood erosion.”

The new drainage system has been installed with grid inlets in High St and a combination of grid and kerb inlets in Main Rd. In addition to the new stormwater drainage system, High St is undergoing

a facelift and the old tarmac road surface and kerb system has been replaced by concrete block paving laid on the road and pavement surfaces. These are interspersed with open stormwater channels which were covered with the same concrete block paving, supplied by CMA member CEL Paving Products. Although Main Rd has retained its tarmac and kerbing system, grid inlets have been added for additional drainage capacity.

The new system traps most litter before it enters the stormwater system, but some debris does get through, especially via the kerb

inlets in Main Rd. To counter this, a steel grid was installed into the exit-pipe opening into which the ø900mm pipe discharges.

According to Nollie Meyer, managing director of Meyer Beton, the installation of the stormwater system presented several challenges.

“The existing stormwater, sewer, water and electrical utilities had been randomly installed from the time Hermanus gained municipal status in 1904 and only limited as-built drawings, indicating where these services had been installed, were available.

The fact that the new stormwater pipes had to be laid below and above all of these existing services complicated and slowed the installation process. Moreover, the in-situ soil conditions in the installation area comprised mainly 400MPa rock which had to be excavated using a metapinion, concrete compressors and electric breakers,” says Meyer.

(Above): Excavation for the ø900mm HDPE structured wall pipe underway in the undercover parking at Hamewith Penthouse.

| PROJECTS |

Production continues during

BISCUIT FACTORY EXPANSION Production was not interrupted at biscuit producer Continental Brands when Peikko SA’s precast concrete building framework and bolted-connection system was used for converting ground-floor factory/warehouse buildings into multi-level structures.

Continental Brands is adding 7 000m² to its Johannesburg-based factory over two phases, providing additional production, storage and office space. Phase 1 extension took place in 2020 and added a 2 000m² mezzanine level above the ground-floor factory (Block A). Phase 2, which is earmarked for completion by the end of 2021, will see the addition of two floors to an adjacent warehouse (Block B) and the construction of a new building on open ground situated between Blocks A and B. The open-ground building is being attached to the extended Block B to form a seamless three-storey structure.

Both extension phases were designed

by Marco Riccardi Architectural Design.

Principal partner, Marco Riccardi, says the expansion will enable the doubling of output from two to four production lines and will provide for any future expansion of production and storage space.

“We looked at various construction op-

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“Speed of erection, column strength and the use of as few columns as possible were some elements which informed our decision-making process.” tions. Speed of erection, column strength and the use of as few columns as possible were some elements which informed our decision-making process. Besides fulfilling these criteria, Peikko is part of a renowned international brand, which was a selling point. However, the fact that production could continue during construction was the clincher,” he says.

Having successfully extended Block A using the Peikko system, Peikko SA was appointed to design and manage the construction of Block B’s precast concrete framework, a process which was begun in March and completed at the end of April 2021.

The project involved using precast concrete columns and hollow-core slabs in combination with five Peikko products:

anchor bolts, column shoes, delta beams, hidden corbels and copra anchor couplers.

The project’s only in-situ construction elements were the structural toppings on the hollow-core slab flooring and the construction of stub columns and flooring on the ground level of the open-ground section.

“We prepared a 3D model so that the client could see the precise column placement.

We then drew up a detailed engineering plan which included column design and the placement of rebar, column shoes and the levels of the hidden corbels,” says Peikko project engineer Winston Visser.

(Top): The partially completed open-ground section of Block B. (Left and right): Piekko’s delta beam installation.

| PROJECTS |

The columns were precast off-site by Ludikon Construction and the hollow-core slabs were produced and installed by CSS Concrete Slab Supplies.

“The extension of Block B’s factory section involved a top-down construction process. It was begun by cutting the surface bed of the factory’s existing ground floor and casting mini-pile caps with anchor bolts. Columns 12m high were then lowered through the roof onto the mini-pile caps, a process which involved threading the anchor bolts through the column shoes attached to the bottom of the columns.

Steel nuts were then screwed onto the anchor bolts to hold the columns securely in position. The installation and securing of the 12m columns inside Block B only took a day,” says Visser.

Once the ground-f loor columns had been installed, construction of the second floor was begun. The second floor was constructed before the fi rst floor so that when the existing steel roof of the ground floor unit was removed, the ground floor would

not be left at the mercy of the elements.

Delta beams were attached to anchor bolts on top of the 12m columns and hollow-core slabs were laid on the delta beams. The former process was done in the morning and the latter in the afternoon. Once the

hollow-core beams were in position, they were covered with a reinforced in-situ structural topping The steel roof of the ground-floor building was then removed and the construction of the fi rst floor was begun. It followed a similar process to the construction of the second floor, except that the delta beams

were attached using hidden corbels which had been inserted inside the 12m columns.

The next phase involved installing 22 7,5m perimeter columns and one 9,5m central roof column using anchor bolts and column shoes. Copra® anchoring couplers were precast into the top of the columns to provide for the installation of a structural steel roof.

The construction of Block B’s openground section used the same material mix and construction process as the extension of the existing ground-floor factory. However, it involved traditional bottom-up construction using three sets of columns which measured just under 6m each. It also involved raising the floor of the open-ground section by 1m above ground-level to tie in with the existing factory floor.

“The Peikko system is transforming the South African construction landscape,” says Riccardi. “We have several international clients who are moving in this direction. Besides saving time, it complies with SA’s health and safety requirements.”

| PROJECTS |

Plastic-lined concrete SEWERAGE PIPES With a country in constant development, be it new commercia l or resident ia l projects or the maintenance or upgrading of existing roads, pipes and stormwater systems, a crucial factor is the application of water and sewerage systems and related products that offer developers and local municipalities the longevity and high quality required.

With a history spanning over 100 years, CMA member Rocla has been a leader in the manufacture and supply of sewerage and water systems and has worked with local municipalities and civils contractors throughout South Africa. The technical expertise and assistance that Rocla offers in the water and sewerage sectors, in particular, put it in a good position to assist on projects from inception to completion.

One of the flagship products from Rocla is its reinforced concrete pipe with HDPE lining, which offers sewerage projects the same advantages as a conventional concrete pipe or a plastic pipe in that it maintains its shape under load and is resistant to acid attack. Exposed concrete in the joints of a pipeline need to be protected against corrosive gases and Rocla has designed an HDPE capping strip which is welded over the joint of the pipe after installation.

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It is generally 200mm wide and the same thickness as the lining used in the pipe.

This t y pe of unique H DPE -lined pipe was recently commissioned for the Polokwane Waste Water Project and 19km of HDPE piping was supplied.

Several projects Rocla a lso manufactures reinforced concrete pipes with sacrificial layers. The host pipe may be manufactured from dolomitic aggregate and ordinary portland cement or siliceous aggregate and ordinary portland cement. The sacrificial layer may be made from dolomitic aggregate and ordinary portland cement or dolomitic aggregate and calcium aluminate cement.

The exposed concrete in the joints of a pipeline need to be protected against

“The protection is for the full wall of the pipe and eliminates extra joint sealing.”

corrosive gases and Rocla recommends joint sealing processes to avoid sewer corrosion activity. Projects such as the Nellmapius Ext 22 low-cost housing contract near Mamelodi commissioned nearly 3 000 precast steel mesh-reinforced concrete stormwater pipes of various nominal diameters from Rocla for the 6km stormwater pipeline being constructed.

Rocla was selected to manufacture and supply all the stormwater (spigot and socket) and interlocking pipes for Waterkloof Quarry, an old 58ha landmark, situated on the border of Waterkloof Ridge and Monument Park near Pretoria which was developed into an upmarket retirement estate. It was Rocla’s manufacturing capability which made it possible to meet the tight deadline associated with the quarry development.

Full protection Reinforced concrete pipes with Xypex BioSan C500 are supplied for 300-600mm pipes. Xypex Bio-San C500 is a uniquely designed admixture for integral, long-term

protection of concrete in harsh sewerage conditions which has high levels of H2S that cause microbially induced corrosion in pipelines. The protection is for the full wall of the pipe and eliminates extra joint sealing.

For t he r e c ent D ie pk lo of s e wer upg rades, 2 715 piping product and associated supplies comprising RJ pipes, rubber rings, manholes, cover slabs and concrete lids were sourced from Rocla due to the quality of its manufacturing processes and fi nal products.

Accessories for sewerage and water projects include pipes with access holes, bends (Rocla can supply custom-made bends of up to 30˚), spigot and socket pipe systems, manhole chambers with HDPE lining and reducer and cover slabs.

On these types of projects, the Rocla design, engineering and technical team del iver s pre-site desig n a nd on-site application advice, when required. This way, Rocla ensures that the correct solution is selected and installed, giving the client a maximum return on their investment.

(Far left): Indigenous HDPE Pipes (Left): Pipes with access holes

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Nhoxani Beach (Peaceful Place) is a prime waterfront housing estate situated on the magnificent Santa Maria peninsula, which juts into the Bay of Maputo in Mozambique.

Over the past four years, seven beachfront accommodation sites have been developed as part of the estate. These sites are situated on a 430m sand-laden strip which abuts an indigenous forest, carefully preserved by the owners of the concession property.

High concentrations of sand-borne silicone on one of the sites meant that measures to prevent wind and water erosion were urgent requirements. During the winter months, the erosion was further aggravated by local fi shermen who sought refuge on the site and burnt brushwood to keep warm.

After some online research, Nhoxani developer and shareholder Mike Braby contacted Ter raforce to d iscuss t he environmental benefits of its earth-retaining and erosion control systems.

An agreement followed and as soon as a wall design was in place, Terraforce L11 retaining blocks were trucked to Maputo from EFS Construction, a Terraforce licensee manufacturer based in Mbabane, Eswatini. The blocks were then shipped by dhow to Santa Mar ia, under the supervision of Terraforce-recommended contractor Ben van Schalkwyk of BRW Projects, who designed the wall and (Right): The neatly terraced wall constructed with

Terraforce block.

(Below): One of the retaining walls at Nhoxani Beach under construction.

Terraforce

FOR DUNE REHABILITATION managed its installation.

Van Schalkw yk explains that the installation was no easy feat. “The wall itself covers 400m² and was designed with four 3m-high interconnecting terraces, the highest point reaching 12,4m. Getting the concrete foundations placed (each terrace had its own foundation) proved challenging, as the dune bank was constantly collapsing.

An agri-drain was placed behind the wall

to prevent water build-up. We also placed Bidim behind the wall, as well as cementstabilised backfi ll – all the way to the top – to provide extra stability.”

After completion, the retaining wall was painstakingly planted with indigenous vegetation by local labour. It took another couple of years for construction of the development to begin, during which the wall stood the test of time, without incident.

Braby adds that the overall result exceeded expectations. “The retaining wall design, in consultation with engineers and environmentalists, created an excellent solution, while also establishing a building footprint big enough for a medium-sized house. This outcome was only possible thanks to the stabilisation of the dune using the Terraforce block. The building technology used for the house, employing robust stilted gum-pole foundations, facilitated elevated floors with stunning views. I’m happy with the way it all turned out.”

(Top): Indigenous vegetation covers a section of the wall.

(Above): Terraforce blocks are offloaded from a dhow.

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PAVECON MANUFACTURING (PTY) LTD TEL: 087 940 3631 e n rete PROVINCE: LIMPOPO | PILLAR: PI n tone re

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

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EAGLE ROOF TILES (PTY) LTD TEL: (044) 874 0290 e on ro t

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

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

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

HORIZON BRICK & CONCRETE k Br k t TEL: (012) 943 3701 PROVINCE: NW | PILLAR: PB

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

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RIETSPRUIT CRUSHERS (PTY) LTD TEL: (017) 801 1912 PROVINCE: MPUMALANGA PILLAR: PB/PI

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CEMBLOCKS (PTY) LTD TEL: (014) 538 0311 PROVINCE: NW | PILLAR: PB/PI

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VANSTONE PRECAST (PTY) LTD TEL: (012) 541 2056/1808 PROVINCE: GAUT | PILLAR: PB/PI

PROVINCE: WC | PILLAR: PB

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C.E.L. PAVING PRODUCTS (PTY) LTD TEL: (021) 905 5998 or on Br k PROVINCE: WC | PILLAR: PI

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ECOCRETE TRUST TEL: (051) 435 3590 PROVINCE: GAUT | PILLAR: PB/PI

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

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CAPE CONCRETE WORKS (PTY) LTD TEL: (021) 905 1200 PROVINCE: WC | PILLAR: PB/PI

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SHUKUMA FLOORING SYSTEMS T/A ZITTLAU EIENDOMME (PTY) LTD TEL: (041) 372 1933 PROVINCE: EC | PILLAR: PB

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

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MOBICAST (PTY) LTD t t TEL: 086 111 2346 PROVINCE: WC | PILLAR: PB/PI e t

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DERANCO PRECAST (PTY) LTD TEL: (041) 463 3338 e on ECn | PILLAR: t rn t PB/PI t PROVINCE:

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n o ow ore COROBRIK (PTY)ortLTD e t e TEL: (031) 560 3252e on ro t n PROVINCE: t t KZN | PILLAR: PIPROVINCE: LIMPOPOe| PILLAR: on ro t PB/PI

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BETA TILES (PVT) LTD TEL: (263) 433 3735 e | PILLAR: on PB ro PROVINCE: ZIM

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CORESLAB (PTY) LTD TEL: (087) 232 2462

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on r tWERKE t t A FICK SEMENT BKoro r k TEL: (022) 913 1921 on r t t t PROVINCE: WC | PILLAR: BrPB k

Producer Members

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CEM BRICK MANUFACTURERS (PTY) LTD TEL: (051) 433 4479 PROVINCE: F/STATE | PILLAR: PB/PI

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L ATEGA NS CEMENT WOR K S (PTY) LTD TEL: (021) 873 1154 PROVINCE: WC PILLAR: PB/PI

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

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

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

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INCA CONCRETE PRODUCTS (PTY) LTD o t t TEL: (021) 904 1620 Z tt en o e t t t e e tone PROVINCE: WC | PILLAR: PB/PI

k

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SHUKUMA BRICKS (PTY) LTD TEL: (041) 372 1013 rete PROVINCE: EC | PILLAR: PB

t t

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ont rete

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PRECAST | ISSUE TWO | 2021

47

Kerneos South Africa (Pty) Ltd Birken ayer H (Pty) Ltd

| MEMBER LIST | hryso Southern Africa (Pty) Ltd

Kobra Moulds B.V.

er Annual Member c

Logo

NON-PRODUCER MEMBERS Abel

Non Producer Annual Member ui ent cc

Logo

Birken ayer H (Pty) Ltd

hryso Southern Africa (Pty) Ltd

y) Ltd

keyePedershaab

Africa (Pty) Ltd

Abel

Non Producer Annual Member ui ent cc

Birken ayer H (Pty) Ltd

ick Kin Lab Su

lies (Pty) Ltd

CVZ CONSULTING TRAINING TEL: 083 701 4167 PROVINCE: GAUT

ABEL EQUIPMENT CC TEL: (044) 874 1876 PROVINCE: EC(Pty) Ltd ick Kin Lab Su lies

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

Logo

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

BIRKENMAYER H (PTY) LTD TEL: (011) 970 3880 HawkeyePedershaab PROVINCE: GAUT

MANITOU SA (PTY) LTD TEL: (011) 975 7770 PROVINCE: JHB

hryso Southern Africa (Pty) Ltd

eos South Africa (Pty) Ltd

ick Kin Lab Su

lies (Pty) Ltd

(Pty) Ltd B.V. alies Moulds Associate Members Associate Members

Consulting Engineers & ssociates

ers & ssociates

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

OLI ELECTRICAL VIBRATORS (PTY) LTD TEL: (011) 392-1054 PROVINCE: JHB

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

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

Taco Voogt Consulting Engineer

rica

JC PAVING CONSULTING Young & Satharia Consulting Concrete Society o Southern

Concrete Society AF CONSULTING ENGINEERS & o Southern ASSOCIATES (PTY) LTD PROVINCE: JHB

SP S

rica

TEL: (011) 431 0727 PROVINCE: JHB

rica

CP Concrete Plant nternational

SEKHUKHUNE & ASSOCIATES TEL: (012) 346 1945 PROVINCE: PTA

C Paving Consulting

No logo

Se hu hune & ssociates

No logo

Ste anutti Stoc s Civils

No logo

ASPASA hu hune & ssociates TEL: (011) 791Se3327 PROVINCE: JHB C Paving Consulting

Cement Ann Members No logo

AfriSam South Africa (Pty) Ltd

Ste anutti Stoc s Civils

No logo

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

Se hu hune & ssociates

Ste anutti Stoc s Civils

Ne t Page

BRITISH PRECAST CONCRETE FEDERATION TEL: +(44) 116 232 5170 COUNTRY: UK

Ne t Page

Contractor Members

Civil Engineers (Pty) Ltd

Address

STEFANUTTI STOCKS CIVILS TEL: (011) 571 4300 PROVINCE: GAUTENG

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

Logo

Decorton Retaining Systems (Pty) Ltd

Friction Retaining Structures (Pty) Ltd

CONTRACTOR MEMBERS

CEMENT MEMBERS

Powergate Construction cc

te

No logo TACO VOOGT CONSULTING ENGINEER TEL: (012) 669 0125 PROVINCE: PTA

CP Concrete Plant nternational

CONCRETE SOCIETY OF SOUTHERN AFRICA TEL: (012) 348 5305 PROVINCE: PTA

CP Concrete Plant nternational C Paving Consulting

ritish Precast Concrete ederation ritish Precast Concrete ederation

REVARO CONCRETE EQUIPMENT TEL: (011) 794 8271 PROVINCE: JHB

Logo

ASSOCIATE MEMBERS Logo Concrete Society o Southern

SP S

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

Logo

Consulting Engineers & ssociates (Pty) Ltd

Members(Pty) Ltd

HAWKEYEPEDERSHAAB TEL: 00 459645 4193 COUNTRY: DENMARK

Kerneos South Africa (Pty) Ltd

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

PLEASE NOTE: The member list was correct at the time of

Valcal International Export cc

going to print. If your details have changed, DECORTON RETAINING SYSTEMS (PTY) LTD TEL: (021) 875 5155 PROVINCE: WC

48

PRECAST | ISSUE TWO | 2021

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

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

please contact Rita at the CMA offi ces on tel: (011) 805 6742.

We’ve got the solution for the perfect surface quality

C

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CHRYSO®Dem range Our range for release agents deliver easy demoulding of concrete during delayed or immediate demoulding of all types of moulds.

CHRYSO release agents are primarily used to improve concrete finish quality whilst protecting and extending the life of moulds or formwork.

IM/02/2021

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

It’s always the last piece in a puzzle that goes missing!

That’s ‘cause we’ve got it!

TWINSTAR PRECAST solves those difficult, one-off jobs that make civil engineering & construction challenging.

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

Telephone: (012) 670 9083

E-mail: info@twinstar.co.za