Precast • Issue 4 • 2022 by Isikhova Media

CONNECTING CONCRETE & CONSTRUCTION ISSUE 4 2022

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FOR 130 YEARS For 130 years we’ve cemented our legacy as a reliable and supportive Pan-African industry partner, with a range of hard working, 100% local, 100% premium quality products. Today, our products remain as proudly South African and unshakeable, as the people who use them. Thank you, Mzansi!

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Heavy lifting – precast safety Ready-mix round-up

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| CONTENTS |

Editor’s NOTE Most South Africans would agree that we like to make our own news, so despite the drag of the public sector on our industry, the latest market trends are looking remarkably good. Koketso Shabalala, head underwriter at Santam’s SHA Division, told Precast that increasing investment in new construction was a function of need, business development and private-sector optimism. The good news is that we are also seeing actual movement for the f irst time in years. This indicates sincere good faith from government, w ith many private construction majors and associations reporting active requests for assistance, accompanied by realistic risk apportionment, in forming partnerships to unlock our project backlog. This could be the time to hold tight, remembering that change is inevitable. We have done it before and we can do it again – so let the projects flow!

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| CONTENTS |

COVER STORY CONNECTING CONCRETE & CONSTRUCTION ISSUE 4 2022

PRECAST R49,00

Building Africa’s future

INDUSTRY NEWS

PPC 130

years

6 10 12 13 14 15 16 19

Upswing in demand for slabs and walls for Western Cape social housing Mix design plays critical role in delivering sustainable projects The global precast modular housing boom Zimbabwe’s housing solution to include hempcrete Global MoU spells out a greener African concrete future CCSA’s bold contribution to sector and development Concrete capital investments for sustainable corporate citizenship New beany block chosen for major Port Shepstone road upgrade

PROJECTS 20 The art of lifting heavy precast components

FEATURE

22 WSP in Africa helps redefine what warehousing should look like 24 Fibre-force: putting the fight in concrete 26 The precast ready-mix round-up 2022

IN THIS ISSUE: Building Africa’s future – PPC celebrates its 130th year in business 0800 236 368 | www.ppc.africa

@PPC_Africa

PPC Ltd

Heavy lifting – precast safety Ready-mix round-up

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ON THE COVER As PPC celebrates its 130th year, its clear carbon reduction strategy is well on its way. From greener fuels to production technologies, the company's executives have set out a clear timeline.

PRECAST is independently published by Isikhova Media (Pty) Ltd 10th Floor, Metal Box, 25 Owl Street, Milpark, South Africa Tel: +27 (11) 883 4627 www.isikhova.co.za Pubishing director/Editor-in-chief: Jason Aarons E-mail: jason@isikhova.co.za

PRODUCTS 30 32 34 35

UNSHAKEABLE

Stormwater made to measure Exploring foamed concrete as a value-add Extended concrete benefits Australian admixture adds green value to SA’s concrete sector

TECHNICAL

Editor: Nicholas McDiarmid Tel: 067 672 2503 E-mail: nicholas@isikhova.co.za Director: Brand strategy: Jenny Justus E-mail: jenny@isikhova.co.za Operations director: Thuli Majola E-mail: thuli@isikhova.co.za Creative director: Joanne Brook E-mail: joanne@isikhova.co.za

36 Crafting the perfect indoor parking lot floor

GLOBAL VIEW 38 A builder’s app for all seasons

Managing director: Imraan Mahomed E-mail: imraan@isikhova.co.za Sales manager: Ruwayda Mahomed Tel: 072 383 3203 E-mail: ruwayda@isikhova.co.za Copy editor: Anne Phillips Media sales: Tel: +27 (11) 883 4627 / 083 450 6052 / 072 383 3203

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The views and statements expressed in this publication are not necessarily those of the editor or the publishers and neither the publishers nor the editor 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© 2022. 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.

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| COVER STORY |

How is PPC responding to the quest for sustainability? We have 11 cement factories in South Africa, as well as operations in Botswana, t h e D RC , E t h i o p i a , Rw a n d a a n d Zimbabwe, and it is vital to understand the full scope of the challenge. A key initiative to contextualise the response meaningfully in Africa was the compilation of the inaugural PPC/GIBS Building Africa Report 2022, an overview of which was presented at the African Smart Cities Summit in June this year. Climate change is a reality, as is the pressing need to meet the UN Sustainable Development Goals. In a world of rapid change, PPC recognises the need to respond proactively within our spheres of operation, while remaining relevant and profitable. The PPC/GIBS report addresses the realities of and opportunities for achieving carbon-neutrality within an evolving market for cement on the continent. Key highlights in the report Essentially, the report – compiled in conjunct ion w it h GI BS’s Centre for African Management and Markets – is futuristic and, beyond cement, considers what sustainable and smart construction will look like for the next generation. The full report (which can be downloaded at www.ppc.africa) sets the scene with an overview of the major players in the African cement market. It also considers growth potential for African infrastructure, the African Continental Free Trade Area, the leg islative env ironment, funding mechanisms and the need for inclusivity. In addition, it has fascinating case studies using hybrid concrete. Where does Africa’s built environment stand today? Africa is a vast continent of 55 countries and more than 2 000 living languages, which makes it a complex trading environment. Investment in African infrastructure has remained constant, at just over 3,5% over the past decade. By comparison, China’s spend is more than double that percentage. Even more revealing, cement consumption in China from 2011-2013 was greater than that consumed by the USA in the entire 20th century. Africa needs a major ramp-up and far greater collaboration.

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BUILDING AFRICA’S FUTURE

How can this potential be unlocked? Funding is not a problem. However, some 80% of infrastructure projects fail at the feasibility and business plan stage. Institutional capacity and planning skills are urgently needed and a focus on publicprivate partnerships would help as well. Policy certainty, good governance and improving intra-continental trade will automatically drive new investment. Nuts and bolts include better supply chains, transport and logistics and facilita-

PPC celebrates its 130th year in business this year and, with its substantial presence in Africa, it has the muscle to lead the industry through the vital transformation to sustainability

| COVER STORY |

believe are measurable and achievable. The 2050 objectives set out in our TCFD will be led by the next generation of PPC leadership.

tive customs agreements. Embracing the Fourth Industrial Revolution is imperative. What are the main takeaways from the report for PPC? PPC demonstrated its strategic commitment to sustainability with the release of its first Task Force on Climate-Related Financial Disclosures (TCFD) report in November 2021. I nt e r v e nt ion s i nc lu d e d how w e w i l l manufacture cement in future, including artificial intelligence to enhance efficiencies. How we include renewables in our energy mix is another area of investigation. We believe PPC can be carbon-compliant, while pushing the boundaries towards net zero.

How is PPC addressing carbonneutrality? We know that a collective response to climate change is essential. However, the roadmap must be realistic. Our starting point was to see the need for change as an opportunity, rather than a forced and punitive measure. PPC has set out on its journey to achieve a greener transition by progressively adding new technologies and processes. These will be ramped up over time and incorporate innovations as they come to market. An example is green hydrogen as an alternative fuel source. While still in its infancy, green hydrogen is sure to accelerate in its development and adoption, with SA emerging as one of the leading producers. Going forward, PPC’s executives have drawn up a timeline from now until 2030. We have set challenging targets which we

What are some of PPC’s current sustainability interventions? Overall, we are investigating a 7-10% recycled tyre substitution for coal as part of our net-zero contribution, while at the same time reducing our energy bill. Waste has a value. While we need government to step forward and make this a sustainable process locally, we estimate that 60-70% of domestic solid waste can be converted into a usable energy source. We also want to increase the use of f ly ash as an extender. This serves two purposes: reducing the clinker (the most expensive element in cement production) and solving landfill issues for coal-fuelled power stations. PPC currently has a fly ash recovery operation at one of Eskom’s power stations and is pursuing others. We are also researching the adoption of geopolymers as a binder. Geopolymers have the potential to pass on a 30-40% reduction in carbon dioxide in some concrete applications. A lternat ive build ing technolog ies are another major focus area for the organisation. Potential examples include the use of wood chips as an aggregate in concrete, alongside glass and steel fibre applications. In closing Decarbonisation should be welcomed as an opportunity to foster innovation. In this respect, government and business need to collaborate more to ensure that sustainability targets are aligned with our development goals.

“We know that a collective response to climate change is essential. However, the roadmap must be realistic. PRECAST | ISSUE FOUR | 2022

| INDUSTRY NEWS |

UPSWING IN DEMAND FOR SLABS AND WALLS FOR WESTERN CAPE SOCIAL HOUSING

Western Cape Premier Alan Winde and Provincial Minister of Infrastructure Tertius Simmers conducted an oversight visit and hand-delivered title deeds to senior residents of the Vredebes Housing Project in late September this year. As South Africa continues to commemorate Public Service Month, the day’s proceedings began with a walkabout and inspection of the construction at the Van Brede Bridge over the Dwars River on Voortrekker Rd in Ceres. A boost for the local concrete market The construction at this site will see the widening of the existing reinforced concrete piers and the construction of new reinforced concrete barriers to allow for cyclists and

pedestrians, as some of the associated upgrading items. The project commenced in December 2021 and is scheduled to be completed in December 2023 at a budget of R66 million. The premier lauded those involved in the project for their foresight in infrastructure development projects such as this. “We must constantly think ahead as our province’s population grows,” he said. The next stop on the itinerary was a door-to-door hand-delivery of title deeds by the premier and Simmers at the Vredebes Housing Project. This project has seen nearly 230 top structures built, with 1 756 serviced sites. “I’m delighted to have this title deed, which will allow me to leave a legacy behind for my grandchildren. I’d like to thank the premier and the minister,

“The construction at this site will see the widening of the existing reinforced concrete piers and the construction of new reinforced concrete barriers to allow for cyclists and pedestrians, as some of the associated upgrading items.” as well as the Witzenberg Municipality, for their efforts,” said title deed recipient Katriena Sass. “We’re not just handing over title deeds; we’re giving these senior citizens hope and dignity,” said Winde. “These homes are now officially theirs and my hope is that they’ll make a positive change in their lives and those of their children in the future.” (Left): The Zwelihle Housing Project in Hermanus, Western Cape. (Above): The "Breaking New Ground" housing programme provides opportunities to expand on existing homes.

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Broadening the scope of public housing The oversight visit was concluded with the showcasing of the new housing offering, the incremental housing pilot project. This pilot showhouse is a product intended for beneficiaries who may not qualify for a standard Breaking New Ground unit or existing government subsidy schemes. It is a model of delivery that leads to secure tenure, which could include ownership and is one of the Western Cape government’s interventions to upgrade informal settlements in an integrated manner. This offers an individual the opportunity to build and expand on a formal structure which is provided by the department. “The Ceres Vredebes incremental housing project offers beneficiaries much more: they can build onto the precast units, adding value to their assets. They can also start small businesses from their homes, generating economic activity and jobs in their community,” said the premier. “We’re thrilled with the progress of the Van Brede Bridge, which will allow for much more mobility and accommodation

of all road-users in the safest way. It was once again an honour to see the smiles on the faces of the title deed beneficiaries,” said Simmers. Incremental delivery The incremental housing project site already has 500 serviced sites and has been approved by the National Housing Builders' Reg istrat ion Council. It is envisaged that incremental housing can

(Above): Peri-urban and rural housing projects are getting much-needed attention.

help deliver 10 000-20 000 units each year. “Today we’ve seen the deliver y of infrastructure in its entirety, through innovation. This will positively contribute to the building of our prov ince and economy, for the benefit of our residents,” added Simmers.

TECHNOLOGICAL INNOVATION IN THE CONCRETE INDUSTRY STARTS WITH MAP PRODUCTS. • • • • • • • • • • • • • • • • • • • Learn more at mapei.co.za Tel: +27 11 552 8476 Email: info@mapei.co.za

Precast concrete plasticising admixtures Ready-mixed concrete plasticising admixtures Extended workability polymers Set retarding admixtures Hardening accelerators Viscosity modifying admixtures Form release agents Synthetic ﬁbres Pozzolan-activity mineral additions Permeability-reducing admixtures Water-repelling admixtures Anti-washout admixtures Expanding agents Drying shrinkage-reducing admixtures Clay mitigating admixtures Pumping aides Air entraining and foaming agents Concrete rescue packs Evaporation-retarding admixtures

| INDUSTRY NEWS |

MIX DESIGN PLAYS CRITICAL ROLE IN DELIVERING SUSTAINABLE PROJECTS A renewed foc u s on i n f r a st r uct u re has been welcomed by South African contractors, but the urgency of many projects places significant demands on inputs like ready-mix. “This is where admixtures play a vital role in ensuring that ready-mix concrete performs to the highest standards while meeting fast-track schedules,” says Michelle Fick, business unit development executive for concrete aesthetics and key accounts at Chryso Southern Africa.

Fluid concrete pumped 50m high for the bridge columns of the Nelson Mandela Bridge.

Getting the best from materials Fick emphasises the importance of durable concrete in giving structures their expected lifespan, thereby delivering value for money for end-clients. Large ready-mix pours are central to many of these projects and enhance the pace of construction. “For instance, in a recent reservoir project with multiple large pours, Chryso was able to contribute to a concrete mix design that ensured low shrinkage, while achieving a durable and watertight concrete,” she says. “Our products helped to keep the heat of hydration as low as possible and prevent cracks from plastic shrinkage.” The latter was addressed by using a shrinkage inhibitor in the wall footing, floor slab and roof slab. To assist with the healing of possible leaking cracks and construction joints, a cementitious crystalline concrete waterproofing admixture was added to the

(Above): Jet accelerators proved invaluable for Gautrain’s extensive shotcrete tunnel lining.

“Road-building and upgrades rely on a variety of precast concrete components such as culverts and pipes, where curing time directly affects the pace of production.” (Left): Concrete mix treated with crystalline waterproofing admixture on site for the Vlakfontein Reservoir.

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mix. The dolomitic aggregates that were used to produce a lower co-efficient of thermal expansion also had a low water demand; a high-performance, water-reducing super-plasticiser was therefore used to reduce water content. Using admixtures to integrate precast components Road-building and upgrades rely on a variety of precast concrete components such as culverts and pipes, where curing time directly affects the pace of production. Here, says Fick, Chryso offers its accelerator range to speed up the curing process and reduce the turnaround time of each precast item. There are also superplasticisers to improve the durability and workability of concrete with reduced water and cement. She explains that these solutions are also important in high-rise buildings where concrete is pumped to great heights, making for rapid progress. For a recently completed skyscraper in Sandton, the ready-mix included Chryso Omega 140AFR, a hybrid plasticiser/super-plasticiser, as well as Chryso® Optima 100 super-plasticiser. The result was a mix with a 180mm slump which could be pumped 200m high. Curing compounds are another important product range enabling more time-efficient construction, with various bases including wax, resin, acrylic and water for different applications. This ensures effective curing with a minimum of effort and manpower. Locally developed solutions “Key to the application of our admixture solutions is our research and development laboratory in Johannesburg,” says Fick. “Our resources here include a valuable database of past projects, aggregates and cement types from around the country, allowing us to rapidly develop and apply solutions for contractors and readymix suppliers.” She notes that this database can provide guidance for a project’s concrete mix, drawing on the experience of previous projects in the same area using the same sources of aggregate and sand. This allows Chryso to speed up the identification of the most suitable admixture for that specific application.

(Above): SCC concrete tailor-designed for the curved column bases of the Soccer City Stadium. (Left): Michelle Fick, business unit development executive for concrete aesthetics and key accounts at Chryso Southern Africa.

| INDUSTRY NEWS |

THE GLOBAL PRECAST MODULAR HOUSING BOOM The Business Research Company offers the Precast Construction Global Market Report 2022 in its research report store. It is the most comprehensive report available on this market and will help gain a truly global perspective, as it covers 60 geographies. The regional and country breakdowns section gives an analysis of the market in each geography and the size of the market by region and country. It also compares the markets’ historic and forecast growth, while highlighting important trends and strategies that players in the market can adopt. A modular market The precast construction market consists of sales of precast construction by entities (organisations, sole traders and partnerships) that refer to a building material made by casting concrete in a re-usable form. Precast construction technology comprises various precast elements and some customised elements that are standardised and designed for stability. It consists of the large panel, frame, slab-column system with the shear wall and beams, among others. The purpose of precast construction is to build and design substantial buildings that can manage loads better by avoiding the need for additional columns and beams. S o m e k e y pr e c a s t c o n s t r u c t io n market players are CRH plc, Bouygues Construction, Larsen & Toubro Ltd, Taisei Corporation, Balfour Beatty plc, Kiewit Corporation, Laing O’Rourke, Julius Berger Nigeria PLC, Red Sea Housing Ser v ices, the ACS Group, Elematic, LafargeHolcim, Coltman Precast Concrete Ltd and Cemex SAB de CV. Precast market continues its rally The precast concrete market size is projected to grow from US$144,6 billion

(Above): The uptake in modular housing is increasing both bespoke and standardised precast concrete elements, benefitting housing markets from social housing to architect-designed homes. (Below): Innovations in precast technologies have transformed the global modular home market.

in 2022 to US$198,9 billion by 2027. The growth of the market is attributed to the reduced construction time, improved productivity, reduced construction cost and less environmental impact. The growing need for cost-effective, safe and green construction material is expected to drive the demand for precast concrete. Columns and beams In terms of value, the columns and beams segment is projected to lead the precast concrete market. This is attributed to its extensive use in both non-residential and (Left): Modular housing options have raised the standard of social housing globally, including in South Africa.

PRECAST | ISSUE FOUR | 2022

residential end-use industry. The growing construction industry, coupled with the rising need for cost-effective, efficient and rapid construction processes, is expected to dr ive the demand for the precast column and beams. Moreover, the growing demand of residential construction due to urbanisation and increasing non-residential construction spending by governmental authorities in emerging economies of Asia Pacific, the Middle East, Africa and South America will drive the market demand during the forecast period. Precast elements In terms of value and volume, the elemental construction segment is projected to lead the precast concrete market. Factory-made precast elements ensure excellent finish, strength, dimensional tolerances, adequate consistency and quality controls. Building an entire structure using precast elements expedites construction, reduces time on site and defects, reduces labour cost and lowers propping and scaffolding costs. All these factors contribute to elemental construction being the most popular construction type among builders and contractors.

ZIMBABWE’S HOUSING SOLUTION

TO INCLUDE HEMPCRETE The government of Zimbabwe sees a role for hemp in construction after securing a $63 million line of credit from an African fund to develop eco-friendly buildings. National Housing and Social Amenities Minister Daniel Garwe said the financing would help the country meet its target of raising 220 000 housing units by 2025, indicating that hempcrete, precast concrete slabs, reclaimed steel and ferrock would be used in the initiative. The f inancing is from Nairobi, Kenya-based Shelter Afrique, a pan-African financial institution that supports the development of the housing and real estate sector in Africa. Zimbabwe is a shareholder in Shelter Afrique, also known as the Company for Habitat and Housing in Africa. New technologies “Government migrated from only using bricks-and-mortar strategies to the application of new technologies in housing delivery,” said Garwe. “We developed some technologies and consulted countries abroad where these technologies had been applied, including Dubai and South Africa.” The government is starting the process of building a factory to turn out green building materials with separate funding from Shelter Afrique, according to the minister. In its efforts to mitigate the effects of climate change, Zimbabwe last year upped its commitment to greenhouse gas reduction from 3340%, meaning the country would curb emissions to roughly 45 million tons across all sectors of the economy. Opportunity to proffer financing options and structures Under the housing ministry’s tender programme, participating companies bring their own financing to develop designs they submit for approval. In the project’s first phase, four developers will be assigned to a province and produce a minimum of 100 blocks of flats at a rate of 20 units per month. Zimbabwe’s government earlier this year announced a separate $377 million project to deal with a housing shortage by constructing affordable homes. An economy in need of special thinking More than 1,5 million Zimbabweans have been on a housing waiting list for years, many of them for more than a decade. Promises of home-building often come ahead of elections, which are set for next year. The Shelter Afrique loan facility has been extended to CBZ Bank Ltd, Banc ABC, ZB Financial Holdings, FBC Bank Ltd and CABS for the construction of houses.

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T he Globa l Cement and Concrete Association (GCCA) and the United Cities and Local Government of Africa (UCLG Africa) have signed a Memorandum of Understanding (MoU) at Africa Climate Week 2022 in Gabon that will see increased collaboration towa rd s deca rbon isi ng cement a nd concrete industries on the continent, thus building sustainable and resilient cities and communities. The MoU was signed by UCLG Africa’s secretar y-general Jean-Pierre ElongM bassi and the GCCA’s director of concrete and sustainable construction Andrew Minson. The agreement sets out how both parties will work together to strengthen stakeholder advocacy towards net zero carbon emissions and encourages local governments to take policy action towards decarbonisation targets. Key targets T h r ou g h t he a g r e e m e nt , t he t w o organisations will focus on an initial five pilot cities to scope out opportunities and challenges. The parties will jointly organise events that strengthen advocacy for the involvement of local governments. The MoU also includes agreements on joint efforts to accelerate net zero across A frica and the cement and concrete industry. Both parties will aim to help make low carbon cement manufacturing investable in Africa, as well as stimulate demand for low-carbon concrete products and cultivate a fruitful environment for circular and net zero manufacturing across Africa. Embracing innovation To reach these objectives, both parties will work to ensure African cities have more capacity to embrace innovative cement products and that these cities can be mobilised effectively to join the Net Zero by 2050 efforts. The GCCA and UCLG Africa will also look to build stakeholder support for multi-level governance in urban planning and housing across Africa.

GLOBAL MoU SPELLS OUT A GREENER AFRICAN CONCRETE FUTURE

(Above): Sustainable concrete innovations, like these precast bricks, achieve rapid market penetration in many African countries.

The MoU meets a key pillar of the G C C A’s 20 50 Net Zero Road map, launched last year, which outlines the central role policy-makers must play in achieving these objectives.

Change is not a choice “As the world faces an unprecedented climate crisis, the need to accelerate decarbonisation efforts becomes clearer each day. Last year our industry made a milestone net zero global commitment to reduce our carbon footprint to zero by 2050. Crucial to this commitment is supporting and driving change across the continent. Our MoU marks an important next step in tailoring efforts to ensure a greener concrete future,” says Thomas Guillot, the GCCA’s CEO. “With the ever-growing need for greener construction methods, we’re excited to enter this agreement with the GCCA to accelerate action towards a decarbonised cement and concrete industry. Through this collaboration, we’ll be able to align the actions and ambitions of local government with industry to create demand for lowcarbon concrete and maintain our path to net zero by 2050,” adds Elong Mbassi.

“Both parties will aim to help make low carbon cement manufacturing investable in Africa, as well as stimulate demand for low-carbon concrete products and cultivate a fruitful environment for circular and net zero manufacturing across Africa.” 14

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| INDUSTRY NEWS |

Cement & Concrete SA (CCSA), which was launched in March 2021, has had an impressive and eventful journey during its first 17 months of operations. Significant achievements • Membership uptake has been rewarding, with over 50 companies joining as members and around 600 individual members listed on the database. • The 10th edition of Fulton’s Concrete Technolog y was launched and sales of this seminal reference book are brisk, both locally and internationally. • The Memorandum of Incorporation for CCSA has been approved by the Companies and Intellectual Property Commission. CIPC, an agency of the Department of Trade & Industry, is the body that governs all registered entities in South Africa in terms of the Companies Act. • YCRETS 2021, a new CCSA initiative to promote concrete research, showcased 24 technical presentations from young concrete researchers, engineers and technologists. This project led to the first SA Young Concrete Researcher Award being presented. • The 2022 Fulton Awards, presented every two years for excellence in concrete design and construction, was launched and 24 world-class entries participated. • Fifteen CONCRETEFiX webinars were hosted, covering a wide spectrum of subjects and reaching both local and internal audiences. • A new CCSA “Emerging Contractors” membership category was created for this important part of the construction industry and the national economy. • The Western Cape, KZN and inland branches of CCSA are active in their respective regions, with key functions and initiatives including site visits and technical meetings. • A novel “Careers in Concrete” initiative, first introduced by the KZN branch to promote diverse career opportunities in the concrete industry, is also scheduled for the Western Cape. The resources of CCSA are readily available to assist in infra-structural developments in all parts of SA. These services cover:

CCSA’S BOLD CONTRIBUTION TO SECTOR AND DEVELOPMENT • Education and training CCSA’s School of Concrete Technology offers a wide range of internationally recognised courses, ranging from the basic Introduction to Concrete to the highly acclaimed Advanced Concrete Technology course. The school temporarily amended its operating model to accommodate online education when pandemic lockdowns prevented live classes, but is now again offering both online and classroom-based education. CCSA’s comprehensive Information Centre is one of the largest and most respected sources of informat ion on concrete in the Southern Hemisphere. It is widely used by the construction industry and students as a valuable reference source for technical information.

• Consulting CCSA offers invaluable advice on concreterelated issues, including on-site visits by technical staff. Dozens of consulting assignments were completed since the entity was launched. Its members have access to all services, either free or at special member discounted rates. A range of membership options is available at different fee levels, with associated benefits. Non-members can also make use of these services at full rates, but are invited to join the many companies and individual members who are already benefiting from the full value proposition of being part of CCSA’s unified platform for cement and concrete. (Above): Hanli Turner, busines development manager at CCSA

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| INDUSTRY NEWS |

CONCRETE CAPITAL INVESTMENTS FOR SUSTAINABLE CORPORATE CITIZENSHIP Even as South Africa’s construction sector struggles through difficult cycles of low profitability and declining capacity, it needs responsible and sustainable companies to maintain momentum. After almost nine decades in business, AfriSam’s legacy has been to demonstrate the value of good corporate citizenship, according to the company’s sales and marketing executive R ichard Tomes. AfriSam began its journey as Anglovaal Portland Cement Company in 1934, with a cement plant in Roodepoort, Gauteng. An argument for quality, especially in tough times “The time since then has seen many changes and we’re proud to have grown stronger, with our customers confirming that we’re still their preferred choice,” says Tomes. “Even with the depressed state of the construction sector, our focus on quality and sustainability means we can continue to (Right): Partner agreements with emerging contractors are essential to the sector’s development. (Below): Shifting to sustainable concrete production begins at plant level.

“He believes that the extensive investment in cement plants, ready-mix facilities and quarries over the years laid the groundwork for AfriSam’s considerable contribution to the country’s infrastructure.” 16

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| INDUSTRY NEWS |

serve the market to world-class standards.” He believes that the extensive investment in cement plants, ready-mix facilities and quarries over the years laid the groundwork for AfriSam’s considerable contribution to the country’s infrastructure. As Anglo Alpha, it had become a fully vertically integrated construction materials business i n t he 19 9 0 s t h rough t he st r ateg ic incor poration of aggregate producer Hippo Quarries and ready-mix company Pioneer Concrete. When the country reentered the international community postdemocracy, the company was acquired by the multi-national Holcim group, further augmenting its access to world-class expertise and best practice. “The learnings gained as part of the Holcim group were valuable in positioning AfriSam where it is today,” he says. “Our access to global research and the sharing of technical expertise further enhanced the expertise of many staff still with the business.” Channeling global standards Tomes emphasises the large capital commitments which AfriSam has historically made in the country’s productive capacity. Often located in remote areas due to their need for limestone deposits, cement (Below): Clearly packaged concrete products make cleaner products an easy choice.

plants must be built for optimal longevity to justify the investment, he explains. These facilities – such as AfriSam’s Ulco and Dudfield plants – operate not just as production facilities, but as integrated settlements. Building sites as social structures “We’ve been able to serve the nation’s requirement for vital cement supplies by maintaining entire village environments at these sites, including schools, houses, churches and other services,” says Tomes. “These facilities must be carefully managed and maintained, both for sustainability and to make it attractive for our staff to live and work there.” There is also an ongoing commitment to education and training, to ensure that all plant is professionally operated and systematically serviced while creating opportunities for future generations. A stronger future Looking further ahead, AfriSam has taken a leading role in the sector to reduce carbon emissions. Aiming at producing carbon-neutral products, the company has already made signif icant progress in offering the market a range of lowercarbon cements. It is also considering renewable energ y sources at some its plants, to reduce coal usage.

Cement your road ahead Strong and steady sets the pace for constructive progress on the road ahead as we build the future from the ground up. Lay steadfast foundations with leading quality cement produced on Africa’s beautiful playground.

Sephaku Cement, Powered by Dangote Cement. www.sephakucement.co.za E+I 8873

Call us on 0861 32 42 52

| INDUSTRY NEWS |

NEW BEANY BLOCK CHOSEN FOR MAJOR

PORT SHEPSTONE ROAD UPGRADE A new block system, specifically designed to enhance roadway drainage, has been installed in the recent upgrades to Nelson Mandela Drive in the Port Shepstone CBD, KwaZulu-Natal. “The Beany Block was specified by the project engineers,” says Pieter Bodenstein, MD of Margate Construction, which was appointed to complete the Nelson Mandela Drive upgrades. “It’s a versatile product which addresses the need for a system that allows both roadway and kerb drainage. System components “The Beany Block system’s easy to install and offers an uplifting finish to the roadway. The system’s been applied to both sides of the roadway. It’s very presentable and neat and we’ll be utilising it throughout the project, which is due to be completed in February 2023.” The Beany system consists of a series of base clocks of standard channel section and top blocks of inverted channel section, with an opening in one side face, collecting water horizontally into the channel section. When laid end to end, they form kerb and/ or surface water drainage units strong enough to withstand normal traffic-loading. “We’ve supplied in excess of 1 000 of both standard top and base blocks, as well as mountable units for driveway access and special blocks that transition between standard and mountable to the Nelson Mandela Drive project,” says Ritesh Singh, sales consultant for Rocla in Newcastle, KZN. “The quantities required for this project, coupled with relatively short lead times, meant that we needed to mobilise

production capacities from more than one of our nationwide branches.” Kerb and stormwater substitutes “Rocla pulled out all the stops to ensure that we had sufficient product on site for installation. It actually supplied the full quota of Beany Blocks for the entire project in advance. I’ve worked with the company before on a project that required its culverts and have always been impressed by its ability to understand the challenges faced by contractors on site. Rocla’s reliability and professionalism have given it the good reputation it has within the industry,” says Bodenstein. The Beany Block is a substitute for kerbs, stormwater pipework (channel equivalent to and replacing 250-300mm-diameter pipes), kerb inlets and parts of footways. The system also reduces contractual claims, as damaged services are less likely to occur compared with conventional drainage because excavations involved in the installation of the blocks are shallow. Applicat ions for the Beany Block are numerous and include those where high-inlet capacity is required, wide carriageways, as a division between vehicle and pedestrian/bicycle lanes with drainage from both sides, parking areas, taxi ranks and bus depots, wash bays and vehicle service areas, median islands and industrial areas, drainage around buildings and walkways and toll plazas.

(Above): The Beany Block system is particularly suited to projects with short lead times.

| PROJECT |

THE ART OF LIFTING HEAVY PRECAST COMPONENTS The lifting of any precast product requires the use of special equipment and substantial planning and knowledge. All of these equipment components interact with one another to allow for safe and effective lifting of a product. The failure of any one component could lead to an unsuccessful lift, with potentially devastating effects on human life, the product or other items in the surrounding environment. Components of a safe and successful lift The necessary parts include machinery and rigging components: • Overhead crane, forklift, travel crane, etc. • Lifting anchors and shackles – swift lift pins, utility anchors, cable hooks, etc. • R igg ing equipment – lifting bars, straps, chains, cables, slings, hooks, clevises, etc. Typical cranes in precast plants include overhead cranes, gantry cranes and/or jib cranes, which are subject to occupational

health and safety standards. The key areas of attention include safe storage unit, assembly, operator training and designation, as well as oversight. Load management is crucial. Crane safety Frequent inspect ions include v isua l examinations by the operator or designated per son, w it h record s not requ i red. Inspection inter vals var y from daily to week ly to monthly, depending on present usage patterns, yet they should be performed on all operating mechanisms, including normal service (monthly), heavy service (weekly to monthly) and severe service (dailhooks and chains). Operation items such as brakes, limit switches, pendant controls, etc must be checked. Inspections by appointed persons must be documented, with records kept of apparent external conditions to provide the basis for a continuing evaluation. Inspection intervals depend on present

usage patterns, viz: normal service (annual), heavy service (semi-annual) and severe service (quarterly). All components such as loose bolts or rivets, worn sheaves or drums, cracked or distorted parts, excessive wear, etc must be inspected. NB: The inspector will determine whether disassembly of a crane is warranted by visual conditions noted during each inspection. A working example C orest r uc, a lea d i ng des i g ner a nd erector of precast concrete structures, has bolstered its crane fleet with a new 150-ton crawler crane. The crane, which complements a 100-ton crawler crane and other smaller units in the company’s fleet, has already been put to service on one of Corestruc’s many precast concrete reservoir projects, following a period of extensive load-testing. Corestruc’s tried and tested rigging and erection capabilities are an essential part of the company’s precast concrete

(Left): Investment in specialist heavy lifting equipment is on the rise in South Africa, along with increasing uptake of heavy precast concrete infrastructure components.

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“Typical cranes in precast plants include overhead cranes, gantry cranes and/or jib cranes, which are subject to occupational health and safety standards.” value offering, which ensures that tight production schedules are maintained when erecting these water-retaining structures. Completed in a fraction of the time it would take using conventional cast-in-situ methods, some of these precast concrete reservoirs are up to 50ML in size. The mechanic's view Elmon Mdluli, a seasoned Corestruc mechanic, is part of the team responsible for keeping the company’s cranes in tip-top condition and was involved in the load-testing to ensure that the machine was ready for service. “Our cranes, especially the 100-ton and 150ton units, are the workhorses on site, lifting and placing the many different precast concrete elements that constitute the roof and the wall of the structure,” he says. “This is done as and when the elements arrive on site, according to a strict predetermined work programme. The 150-ton unit is definitely up to the task at hand. It has a standard boom reach of 82m and a luffing jib of 31m, providing the clearance we need to work in builtup areas, where limited space can be challenging. The cranes have also been equipped with our own lifting tackle that’s been designed by Corestruc’s engineering team for the efficient handling of the various precast concrete elements that make up these reservoirs.”

The crane is a Fushion QUY 150c. Mdluli says that Corestruc decided to procure it because it offered good value for exceptional functionality. “Chinese equipment manufacturers have become extremely competitive over the years, providing solutions that get the job done at an affordable price. A case in point is our 100-ton SANY crane, which is also manufactured in China. It continues to meet our expectations in terms of high reliability and performance. Chinese machines are definitely up to standard and they’re supported in the field by our own technical team.” Certainly, the acquisition of a new crane by Corestruc is indicative of the company’s healthy order book and outlook. Opt ima l va lue from t he right choice “This additional crane in our f leet provides us with the necessary capacity to keep pace with the high demand for our unique solution for fast-tracking the construction of reservoirs. This is at a time when municipalities are investing heavily in addressing a backlog in water infrastructure,” says Willie de Jager, MD of Corestruc. (Above): Training and monitoring of correct procedures and handling techniques are essential for the health and safety of the lifting crew. (Left): Lifting and handling of heavy precast concrete elements on site need careful planning, posing unique challenges that differ greatly from the factory floor.

| FEATURE |

WSP IN AFRICA HELPS REDEFINE WHAT WAREHOUSING SHOULD LOOK LIKE WSP in Africa successfully delivered the last of the new distribution centres rolled out by Shoprite across South Africa: the mammoth 135 837m² Whitey Basson Distribution Park (previously called the Shoprite Distribution Centre Cilmor) situated close to the Cape winelands, in Cape Town. Shoprite’s continuing growth saw the need for this new facility, which will distribute dry groceries, refrigerated perishables, fresh produce and frozen goods. Project team WSP’s team in Africa worked closely with SLT Architects and project manager SiVEST to ensure that the Whitey Basson Distribution Park pushed the boundaries of conventional warehousing and redefined the stereotypes of what these buildings should look like. Curved lines were introduced for the

roofs, mimicking the surrounding rolling hills and effectively pulling the sides of the building down to a more accessible scale. While reducing the perceived height of the buildings, the shapes provide structural and rainwater run-off benefits. By stepping the building on plan as well as on elevation, a uniquely elegant vista was created that would not dominate the daily commute of those living in the area. The development boasts clever engineering in every detail, including optimised structural design, innovat ive constr uct ion techn iques, smart energy systems and highly efficient centralised cooling. Concrete innovation Comprising covered space in 20 buildings, the Shoprite development represents one of Africa’s largest and most technologically advanced distribution centres. Tilt-up

concrete columns were used as the main structural element on the three largest warehouses, which span a total roofed area of 104 084m². These comprise: • >75 000m² dry-goods warehouse. • 34 735m² refrigerated building. • 10 547m² returns centre. The dry goods building features two safety stores of about 1 100m² each which were designed to contain a fire for two hours, thereby protecting the surrounding infrastructure. Tilt-up techniques Tilt-up describes a construction technique in which predominantly vertical concrete elements such as columns and walls are cast flat on the ground and on site, near their final position. Once cured, they are hoisted into position. By contrast, more traditional

“The design of the buildings and the subsequent construction methodology were centred around safe and fast erection on site, delivering a light, yet failure-tolerant structure.”

(Above): The Atterbury Group's Rubicon warehouse was an early adopter innovative construction techniques for warehouses.

PRECAST | ISSUE FOUR | 2022

| FEATURE |

precast concrete elements are cast off site and must be transported to site. Some of the columns were 26,56m high, SA’s largest precast tilt-up to date. • Each column weighed up to 44 tons. • 148 columns were used to build the main warehouse. • 39 columns were deployed in the construction of the return-goods building. • Tilt-up panelling comprising 48 panels and covering a total area of 4 155m² was used in the assembly of the safety store’s external walling.

This configuration allowed optimised utilisation of the material and produced a girder that was easier to handle on site due to the lateral and torsional stiffness of the box-shaped assembly. T he t r usses for t he a mbient warehouses were classic lattices made from equal angle chords and web members. To provide a f lat f ixing surface for the refrigeration panels, the trusses for the refrigerated buildings were also boxed lattices with channels as chords.

Structural steel foresight For WSP in Africa, structural steel was the natural choice to realise the large open-span roof structures and curved architectural features of the new facility. The operational design required a 32 x 32m internal grid for the ambient warehouses and 24 x 24m for the refrigerated warehouse. No construction material but structural steel could achieve the same construction economics for these lightweight, large-span roof structures under the given programme constraints. The design of the buildings and the subsequent construction methodology were centred around safe and fast erection on site, delivering a light, yet failure-tolerant structure. The buildings are stabilised by large cantilevering concrete tilt-up columns that were constructed during the fabrication period of the steel.

Making connections The connection design and detailing, especially for the girder-to-column and truss-to-girder nodes, also aimed at a reduction of risk during the erection process. T he appoi nted specia l ist steel contractor, Mazor Steel, delivered 2 963 tons of structural steel on time and to the highest quality standards, following a strict safety plan under the constant scrutiny of main contractor Stefanutti Stocks, which achieved over one million lost-time injury-free manhours on this project. The size of the structure and the resulting rainwater run-off lengths of the dry goods building supported the choice of a curved roof structure for these buildings. As a result of the curve, the roof angle increases with increasing run-off length, thus improving run-off performance of the roof. The project was completed on time and within budget, while impressing with outstanding design and way-leading quality of works.

The structural work T he g i r der s wer e bu i lt up f r om horizontally orientated UB chords laced with double equal angle web members.

(Above): Training and monitoring of correct procedures and handling techniques are essential for the health and safety of the lifting crew.

| FEATURE |

Including stiff natural or synthetic fibres in the concrete mix can significantly augment its strength, says Bryan Perrie, CEO of Cement & Concrete SA (CCSA). Concrete made with Portland cement is relatively strong in compression, but weak in tension. This can be overcome not only by the usual insertion of conventional rod reinforcement, but also by the inclusion of enough stiff fibres in the mix. The fibres alter the behaviour of the f ibre-matrix composite after it has cracked, thereby improving its toughness. Perrie says that for the effective use of fibres in hardened concrete: • The fibres must be significantly stiffer than the matrix. • The fibre content must be adequate. • There must be a good fibre-matrix bond. • The f ibres must have a high aspect ratio, ie their length must be in the correct relation to their diameter. There are natural and synthetic types of fibre, with steel and glass versions the most commonly used. Steel Steel fibres have been used in concrete since the early 1900s. The early fibres were round and smooth and the wire was cut or chopped to the required lengths. The use of straight, smooth fibres has largely disappeared and modern fibres have either rough surfaces, hooked ends or are crimped or undulated through their length. Modern commercially available steel fibres are manufactured from drawn steel wire, from slit sheet steel or by the meltextraction process, which produces fibres with a crescent-shaped cross-section. “Typically, steel fibres have equivalent diameters (based on cross-sectional area) of 0,15-2mm and lengths from 7-75mm,” explains Perrie. “Carbon steels are most commonly used to produce f ibres, but fibres made from corrosion-resistant alloys are also available. Stainless steel fibres have been used for high-temperature applications.” Some fibres are collated into bundles using water-soluble glue to facilitate handling and mixing. Steel fibres have high tensile strength (0,5-2GPa) and modulus of elasticity (200GPa), a ductile/plastic stressstrain characteristic and low creep.

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PRECAST | ISSUE FOUR | 2022

(Below): Brian Perrie, CEO of CCSA.

FIBRE-FORCE: PUTTING THE FIGH Steel f ibres have been used in conventional concrete mixes, shotcrete and slurry-infiltrated fibre concrete. Typically, the content of steel fibre ranges from 0,252% by volume. “Fibre contents over 2% by volume generally result in poor workability and fibre distribution, but can be used successfully where the paste content of the mix is increased and the size of coarse aggregate is no larger than about 10mm,” says Perrie. Steel fibre-reinforced concrete containing up to 1,5% fibre by volume has been pumped successfully using pipelines of 125-150mm diameter. Steel fibre contents up to 2% by volume have been used in shotcrete applications using both the wet and dry processes. “Steel fibre contents of up to 25% by volume have been obtained in slurry-

“Some fibres are collated into bundles using watersoluble glue to facilitate handling and mixing.”

| FEATURE |

(Left): Steel-reinforced concrete has significant application in bespoke precast concrete designs, widening the scope of potential structures.

(Above): A clos-eup of steel filaments in concrete, combined with plasticisers, which adds strength and flexibility.

HT IN CONCRETE

inf iltrated f ibre concrete. Concretes containing steel fibre have been shown to substantially improve resistance to impact and show greater ductility of failure in compression, f lexure and torsion. The elastic modulus in compression and modulus of rigidity in torsion are no different before cracking, compared with plain concrete tested under similar conditions. Because of its improved ductility, steel fibre-reinforced concrete finds applications where impact-resistance is important. Fatigue-resistance of the concrete is reported to be increased by up to 70%,” adds Perrie. “The inclusion of steel fibre as a supplementary reinforcement in concrete could also help reduce spalling due to thermal shock and thermal gradients. However, the lack of corrosion-resistance of normal steel fibres could be a disadvantage in exposed concrete situations where spalling and surface staining are likely to occur.” Glass In their initial form, glass fibres were found to be alkali-reactive and products in which they were used deteriorated rapidly. However, alkali-resistant glass containing zirconia was successfully formulated in the 1960s and was soon in commercial production. Alkali-resistant glass fibre is used in the manufacture of glass-reinforced cement (GRC) products, which have a wide range of applications. “Glass fibre is available in continuous or chopped lengths. Fibre lengths of up to 35mm are used in spray applications and 25mm lengths are used in premix applications. GRC products are used extensively in agriculture, for architectural cladding and components, and for small containers,” says Perrie. (Left): These steel-reinforced, concrete-filled screws are a excellent example of combining potentiality to maximise strength.

| FEATURE |

(Below): From watery recycling to clinker substitutes, cement manufacturing is where greening concrete begins.

By Nicholas McDiarmid, editor

THE PRECAST READY-MIX ROUND-U It appears we are seeing out 2022 with some good reasons for hope and planning for a better 2023. Building plans passed and approved are significantly up, even by pandemic standards, and there is gover nment act ion on projects w it h private-sector co-operation that, frankly, we have not seen before. It all bodes well. When it comes to the very substance of the precast industry, cost control, quality, carbon foot pr int and innovations in concrete ready-mix are the constants that keep changing and need regular updating.

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When it comes to cement… One of our cement producers, AfriSam, has been very focused this year on reviewing and optimising its sustainable production capabilities. From cement substitution to recycled water, AfriSam’s ready-mix facilities are a hotbed of continuous env i ron ment a l i mpact reduct ion. Supplementary cementitious materials combined with optimal use of existing extenders equate to a high-performing 45% substitution rate, while the use of chemical activators enhances this figure.

The use of recycled water for batching purposes leads to CO₂ reduction benefits by marginally lowering the total binder content. Utilisation of more technologically advanced admixtures further enable overall cementitious reduction, while maintaining strength performance and improving durability. Measuring, managing and tweaking “AfriSam’s continuous emission monitors installed at our cement manufacturing facilities provide us with real-time information

| FEATURE |

emissions data for close to 20 years. The ability to analyse this kind of valuable information and generate trends means we’re able to run efficient systems and further improve our efficiencies.” AfriSam recently installed a low NOx burner at its Dudfield cement plant and, combined with well-maintained f ilter bags, the plant emissions are below the legislated norms. Green cement AfriSam’s forward-looking approach to its impact beyond the factory wall has already changed the game. For the construction industry and society as a whole, its operations, products and institutional wisdom are major assets in its path towards sustainability. “Customers and developers can now make informed choices and it’s becoming common practice for developers to request low-carbon composite cements, (Right): Concrete mixer trucks are rapidly evolving, with chassis design and mixing barrels capable of larger loads and better slumps reducing traffic impacts and resulting in better mixes and more agility at delivery site.

especially if these developments are looking to be graded by the Green Buildings Association,” notes Govender. “AfriSam cement allows developers to claim credits for the use of ‘green’ building materials, should these be required and although the uptake of green buildings in SA has been slow to date, our sponsorship of the SA Architecture Institute’s awards has helped change the minds not only of developers, but of the individuals designing a building – the architects themselves.” Challenging imports Njombo Lekula, MD of PPC Cement RSA, has cited the real-world impacts of cement imports on the industry and how the company has adjusted: “We’ve seen the impact of imports on our business and our economy at large. The SA market is set up to produce around 19 million tons of cement annually and the total demand in the country is estimated at

(Below): The management of stockpiled concrete and rubble from demolition sites and demolished structures is key to recycling of existing concrete.

UP 2022

“Much of our work in the cement laboratory is focused on the growing global concern to reduce carbon dioxide emissions from cement manufacturing.”

on kiln emissions at any given point,” explains Nivashni Govender, environmental specialist at the company. “The old adage, ‘You can’t manage what you don’t measure’, holds true. Small tweaks in raw material inputs, fuel sources and differing grades of coal impact what comes out of the stack at the other end. Having the opportunity to measure such changes when the process is tweaked has led to our having exceptional

PRECAST | ISSUE FOUR | 2022

| FEATURE |

around 13 million tons. This is a challenge for us, as it’s resulted in us having to mothball some of our operations due to low demand and high imports. I believe that public and private collaboration are key to changing the trajectory of the construction and built environment. “As a strategic partner in the construction industry, our mission is to empower people to experience a better quality of life through the provision of a competitive product portfolio, superior customer service and going beyond just selling a product. Being agile in our responses to changing circumstances and collaborating with stakeholders to create the necessary enabling environment, internally and externally, have helped sustain our business,” adds Lekula. “As SA’s largest cement producer, we recognise our role as an enabler and technology partner and the vital importance of publ ic , pr iv at e a nd c om mu n it y collaboration. We also recognise the global threat of climate change and the immensity of the challenges associated with achieving net zero emissions by 2050. We’re committed to reducing our carbon footprint and participating in the collective actions needed to address key barriers to decarbonisation. “Furthermore, where possible, we’ll take a leadership role in the use of waste as a fuel source, as evident in our recent successful introduction of tyres at our De Hoek factory in the Western Cape and the use of biomass fuels in Rwanda.” The right mix for concrete slabs “The mix for pumping aims at reducing the

“Of course, cement’s the main contributor to concrete performance, so it’s vital that we understand exactly what impacts are achieved by the changes we can make.” abrasion or friction of the concrete on the machinery,” says PPC Materials executive Dave Miles. “It will therefore have a slightly lower content of stone, probably in the region of 100-150kg/m³ fewer stones and slightly more sand, to achieve more paste in the mix. It looks fluffier or more cohesive and also has a slightly higher slump. Its

slump will be in the region of 100-150mm, so it’s easier to pump. As for maintaining that slump from plant to site, we use admixtures for workability retention – but there isn’t a big difference in the end product. “The two main differences between the two concrete types lie in their workability and stone content. With regard to laying out a slab, it doesn’t make any significant difference which concrete is used in its performance, as long as the engineer’s taken the differences into account with their slab design,” explains Miles. “The main difference that needs to be considered is that the pumped concrete will have slightly more shrinkage because there’s a slightly higher water content and a higher paste content. The engineer takes that into account in the steel design in the bigger spans. However, in the majority of deck slabs in any building, there’s no difference in performance, strength-wise.” Where a contractor has specialised performance criteria for the end product, PPC Materials’ technical team designs bespoke mixes. Home-grown tech Local admixture specialist company Chryso Southern Africa has made considerable investments in its laboratory facilities over the past year, with emphasis on greening concrete. The latest expansion within (Above and left): New additives are facilitating clinker supplementation and alternatives, including the use of rubber pellets derived from discarded tyres.

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| FEATURE |

its Centre of Excellence in Jet Park near Johannesburg has been a cement laboratory, in which the company has invested extensively. According to research and development manager Mpume Mlalazi, these investments will continue into 2022 to ensure the latest tools are available. “Much of our work in the cement laboratory is focused on the growing global concern to reduce carbon dioxide emissions from cement manufacturing,” says Mlalazi. “We're also now fully equipped to align with international standards in cement testing.” Chryso Southern Africa’s other facilities include a research and development laboratory for new product formulation and evaluation, a concrete laboratory conducting physical tests to evaluate concrete properties, a quality control laboratory and a colour laboratory. There are also satellite laboratories at the company’s Cape Town, Port Elizabeth and KwaZulu-Natal branches to support customers. Among the equipment recently acquired is an isothermal calorimetry and permeability tool, in addition to basic tools

for cement-setting time, specific surface Blaine, pycnometry and cement compressive strength determination auxiliary equipment. “Our cement laboratory works closely with cement industry players and supports our customers with product development

(Above): The right mix factors in the desired finish.

to find solutions for their ever-changing applications,” says Mlalazi. “Of course, cement’s the main contributor to concrete performance, so it’s vital that we understand exactly what impacts are achieved by the changes we can make.”

This is why Chryso Southern Africa’s wide breadth of facilities – combined with its depth of expertise – is so effective, with its cement and concrete laboratories under one roof, she explains. Whatever is achieved in the cement laboratory can be closely assessed and tested in the concrete laboratory. “As experts in the field of admixtures, we have the necessary chemistry knowledge and products to help customers drive their sustainability agendas and meet their carbon reduction targets,” says Mlalazi. She highlights that Chryso Southern Africa re-invests at least 4% of its sales revenues into research and development each year, emphasising that the laboratory capacity plays a strategic role in supporting customers’ key concerns into the future. These include carbon emissions, clinker factors, cement performance and energy-saving. The exciting projects underway in its cement laboratory include research into the potential for limestone calcined clay cement (LC3) to drastically reduce carbon dioxide emissions during the manufacturing process.

• Tel: + 27 11 822 2320 • Fax: + 27 11 822 2354 • e-mail: cindy@ashak.co.za

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| PRODUCTS |

(Above and left): Twinstar Precast manufactures the full range of stormwater components, to almost any specification.

STORMWATER MADE TO MEASURE Twinstar Precast – one of South Africa’s best-k nown custom precast concrete manufacturers – was founded in 2014 with the express aim of assisting specifying civil engineers and civil engineering contractors with complicated sites and situations where currently available precast concrete products would not work. Among its most successful products, for both local government and private developers, are stormwater-related structures – and much of this success is due to its ability to design and deliver to almost any specification. Stormwater made to measure Twinstar Precast will cast your stormwater-related slabs to your requirements. These slabs are designed and manufactured according to your needs in terms of shape and size. Here is what they do: • Light duty, medium duty, heavy duty or extra-heavy duty applications. • For shopping centres, distribution centres, parking areas, residential areas and much more. • We offer the service of casting in cast iron grating, as well as polymer gratings. • Slabs for junction boxes can be made in any shape and size to fit your specific stormwater junction box.

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Stormwater channels Twinstar offers a range of stormwater channels, including half-round, equal leg or U-channels, taper chute channels and other stormwater drainage channels. Channels can be cast for use as open channels or with angle iron inserts to accommodate grids. Stormwater specifications Twinstar manufactures an array of standard stormwater channels, while specialising the

casting channels to suit your specific needs. Equal leg or U-channels can be cast to a height and width which are custom-made to suit your site conditions and flow capacity. Channels are also cast in medium or heavy duty, depending on the application. Extra-heavy-duty channels to take heavy-duty vehicle traffic can be cast with (Below): Twinstar’s specialty inlet slabs for the Johannesburg Roads Agency.

| PRODUCTS |

angle iron supports to fit gratings that will accommodate shopping centres and distribution centres, as well as transport and logistic yards. Water channels and V-drains Twinstar manufactures: • D7 channel 750mm long 320 x 88. • D9 channel 500mm long 450 x 180. Its precast V-drains are cast to suit site requirements, while carrying standard V-drains 1 200mm wide x 1 000mm long. Any other V-drain will be quoted on request and the length will be determined by the size required and the calculated weight. The Twinstar “can-do” list The capabilities of Twinstar Precast have been acquired through both trial and error, as well as the willingness to try new solutions. The fundamentals that underpin its unparalleled reputation include: • Mou ld - m a k i n g , i nc lud i n g s t e e l , fibre-glass and polyurethane moulds. • The ability to tool up and supervise the precise process for each unique job. • Highly skilled specification and procurement of the right materials for every job, with the supplier network to guarantee each one. • The ability to ensure a functional mould and moving from potential timeframes to precise delivery commitment on ly when a mould is completely strippable. • Specialised experience in manufacturing the plinths, transformer and distribution boxes and cable markers for wind farms. • Geared for private-sector construction requirements. • Manufacture of standardised products for the public transport, infrastructure and housing sectors. • Laser-writing into the mould for masslabelling of concrete components.

(Left and below): From U-channels and V-channels to other stormwater drainage channels, all can be cast for use as open channels with accommodations for grids.

“The capabilities of Twinstar Precast have been acquired through both trial and error, as well as the willingness to try new solutions.” excellent crane that enables us to deliver large concrete products in segments, to the great advantage of our clients. We guide the placement and fitting of the product and will be on site, if necessary.”

Cast in delivery Founder and director Annemerie Coetzee sums up the Twinstar commitment: “We’ve deliberately kept our operations sized for the work we deliver,” she explains. “I know exactly what we can commit to and precisely how to achieve the best outcomes for each client. We make our own moulds and have one truck with an

PRECAST | ISSUE FOUR | 2022

| PRODUCTS |

EXPLORING FOAMED CONCRETE AS A VALUE-ADD By Jan de Beer on behalf of Cement & Concrete SA (CCSA) Foamed concrete is the most popular of all low-density concretes in developing countries, mainly because of its low capital expenditure on equipment and the ready availability of its principal materials, says Bryan Perrie, CEO of CCSA. Developing markets “Foamed concrete can be produced on a small scale, even at site level, and is relatively easy to place and finish without heavy or expensive equipment. It’s been used as a structural material in schools, apartments and housing developments in countries such as Brazil, Singapore, Kuwait, Nigeria, Botswana, Mexico, Indonesia, Libya, Saudi Arabia, Algeria, Iraq and Egypt,” he says. Foamed concrete is a cementitious material, with a minimum of 20% (per volume) foam entrained into the plastic mortar. However, as no coarse aggregate is used, the term “concrete” is basically inappropriate, he explains. It is produced by entrapping numerous small bubbles of air in cement paste or mortar. The principles Mechanical foaming can take place in two principal ways:

• By pre-foaming a suitable foaming agent with water and then combining the foam with the paste or mortar. • By adding a quantity of foaming agent to the slurry and whisking the mixture into a stable mass with the required density. Perrie says the most commonly used foam concentrates are based on protein hydrolyzates or synthetic surfactants. These are formulated to produce air bubbles that are stable enough to resist the physical and chemical forces imposed during mixing, placing and hardening. Self- compact ing, freeflowing and pumpable “Foamed concrete is self-compact ing, free-f low ing and pumpable, so it’s easy to place in inaccessible places. It has good thermal and acoustic properties and is frost-resistant. However, it’s too weak for direct exposure to traffic and hail and should be protected by a wearing layer,” he says. “It’s standard practice to classify foamed concrete according to its dry density. The density is determined from oven-dried specimens and the actual density of foamed concrete would usually be higher than this density, as there’d

“Foamed concrete is a cementitious material, with a minimum of 20% (per volume) foam entrained into the plastic mortar.” generally be evaporable water present in foamed concrete. The presence of water in foamed concrete elements also results in an increase in thermal conductivity.” Cellular concrete systems Since the introduction of cellular concrete systems to the construction industry almost six decades ago, its use has been almost exclusively limited to non-structural void-filling, thermal insulation, acoustic damping and trench-filling for reinstatement of roads and building blocks. In the Netherlands, foamed concrete has been used not only for level corrections in housing developments, but as a fill material where ground subsidence has taken place and as a founding layer for roadworks on very weak soils. “Historically, foamed concrete has been perceived to be weak and non-durable, with high shrinkage characteristics. In the past, unstable foams have resulted in foamed concrete not being suitable for reinforced structural applications. However, the development of protein hydrolisation-based foaming agents and specialised foam-generating equipment has improved the stability of the foam, making it possible to manufacture foamed concrete for structural applications,” says Perrie. “Nevertheless, it’s important to ensure that the air entrained into the foamed concrete is contained in stable bubbles that remain intact and isolated to ensure that the permeability of the cement paste between the voids isn’t increased.” (Above): Brian Perrie, CEO of CCSA. (Left): The primary advantage of foamed concrete is the ability to place it in hard-to-reach places.

PRECAST | ISSUE FOUR | 2022

| PRODUCTS |

Including extenders to the concrete mix offers several important advantages, says Bryan Perrie, CEO of Cement & Concrete SA (CCSA). Among the benefits derived from the now widespread practice of adding ground granulated blast-furnace or corex slag, fly ash or silica fume to the concrete mix are: • Cost savings: Extenders are generally cheaper than Portland cement. • Technical benefits: Extenders improve the impermeability and durability of the hardened concrete and often improve the properties of concrete in its fresh state. • Sig n i f ic a nt benef it s to reduc i ng greenhouse gas emissions, as most extenders are secondary products from other processes. “Portland cement extenders are all less reactive than Portland cement. This can affect the rate of early-age strength gain, causing a ‘fine-filler’ effect, which impacts the rate of heat development due to cementing reactions. Substituting a Portland cement extender for part of the

EXTENDED CONCRETE BENEFITS

cement in a concrete mix may reduce the rate of strength gain at early ages. The extent of the reduction increases with increasing substitution level,” explains Perrie. “Extremely fine extender particles act as nuclei for the formation of calcium silicate hydrate which would otherwise form only on the cement grains. This f ine-f iller effect brings about a denser and more homogeneous microstructure of the hardened cement paste and the aggregate-paste interfacial zones, resulting in improved strength and impermeability. The extent of the fine-filler effect depends on the content of extremely fine particles in the extender. Fine particles of filler materials, such as limestone, can also exhibit the fine-filler effect.” He says concrete in which part of the Portland cement is replaced by an extender produces heat at a rate slower than that

of a similar concrete made with only Portland cement. The slower the rate of heat development, the lower the temperature rise and therefore the less the likelihood of thermal cracking. “However, it should be remembered that improvements to the properties of hardened concrete brought about by extenders can only be fully realised if the concrete’s properly cured,” he cautions.

(Above): The fine-filler effect resulting from fine particle extenders brings about a denser and more homogeneous microstructure.

| PRODUCTS |

AUSTRALIAN ADMIXTURE ADDS GREEN VALUE TO SA’S CONCRETE SECTOR First Graphene Ltd says it has signed a distribution agreement with the South African-based Nanoproof Glade Chemicals Joint Venture ( JV) to expand the sales reach of PureGRAPH® graphene across multiple markets in SA, with a particular focus on the concrete segment. The distribution agreement has a four-year term and includes a minimum commitment of five tons of PureGRAPH® AQUA and powder products within year one to maintain exclusivity for the South African ready-mix mortar and concrete market segment. Partner deals target concrete admixtures First Graphene previously signed a collaboration agreement with the Nanoproof Glade Chemicals JV for the development of PureGRAPH®-enhanced concrete admixtures, which has resulted in successful product development of a range of products. The new agreement is a further key step in First Graphene’s strategy to help the cement and concrete industries achieve a 25% emission reduction by 2030. These emission targets are driving global demand to develop greener solutions within the cement and concrete segments. First Graphene has partnered with several tier one and two industry partners across multiple facets of the cement/concrete materials market to develop PureGRAPH®-enhanced solutions that will help the sectors achieve greener outcomes. Durability and strength with less cement By add ing low dosages of P ureGRAPH®-enhanced concrete admixtures to the concrete mix design, significant increases in strength and durability properties can be achieved. Due to this increase in performance, the amount of cement used in the concrete mix can be reduced, thus decreasing the carbon footprint of the concrete produced. Nanoproof and Glade Chemical Man-

(Above): Nanotechnolog y has led to impressive innovations in the use of graphene as an effective admixture and plasticiser, with the capacity to replace clinker. (Left): Australian research has reached SA's shores, with a new joint venture set to offer the precast market effective and sustainable options.

ufacturers, which both specialise in the development of high-performance solutions for the construction and related industries, formed the joint venture for the purpose of developing the enhanced admixture. Samples and trials A range of PureGRAPH®-enhanced concrete admixtures developed by the Nanoproof Glade Chemicals JV is now available for early-stage sampling and trials through the Nanoproof Glade JV for the SA market and through First Graphene for markets outside the country. “ T he add it iona l ag reement w it h Nanoproof Glade Chemicals J V is a significant further step for First Graphene as we implement our go-to-market plan to become the world’s leading supplier of graphene-enhanced cement and concrete solut ions,” says First Graphene M D

and CEO Michael Bell. “Nanoproof Glade Chemicals JV was quick to develop a range of admixture solutions and, with its significant penetration into multiple South African market segments, will help expand our reach into the market in that part of the world. “At the same time, First Graphene now has access to a range of admixture products that can help us pursue additional commercial opportunities in the high-value cement and concrete segments.” High-value concrete enhancements “We’re excited to enter into this new ag reement w it h Fi r st Graphene, a s a natura l extension of our prev ious development agreement, to now pursue multiple commercial opportunities with our range of PureGRAPH®-enhanced concrete admixtures,” says Nanoproof Glade Chemical Manufacturers JV owner Alex Smith.

PRECAST | ISSUE FOUR | 2022

(Above, right and below): Surface preparation equipment includes floor grinders, diamond saws and sand-blasters.

Longevity, coupled with minimal maintenance, are key outcomes of using the right methods and tools

CRAFTING THE PERFECT INDOOR There are over 570 construction projects in Africa worth over US$450 billion. After energy, the next greatest sector is transport, with projects that include roads, airports and railways worth US$280 billion. That amounts to a great number of moving people, more and more of whom – as populations become more Westernised – are opting for indoor entertainment in malls, shopping centres, sports centres, etc. In that situation, parking cars outside often results in unbearable heat inside the vehicle. As

PRECAST | ISSUE FOUR | 2022

PARKING LOT FLOOR a result, indoor parking lots are more in demand than ever before, the requirements for which are vastly different from those for outdoor ones. Surface preparation When creating an indoor parking lot, the part that has to bear the brunt of wear and tear is the floor. How can we create a park-

ing lot floor that lasts for years? The answer, according to Lionel Zietsman, national sales manager at Husqvarna Construction Products (HCP), is surface preparation. As the term implies, this refers to the many methods and treatments used to ready a concrete surface before applying a sealing coat of epoxy. This can be done with several materials, but in parking lots,

| TECHNICAL |

the substrate, or underlying surface, that requires prepping is concrete. Old coatings, dust and residue, surface imperfections, organic matter, oxidation and other contaminants must be removed to ensure efficacy of the new coating. Creating the desired concrete surface profile Various steps go into ensuring that a concrete surface is ready for coating, many of which involve HCP’s world-leading surface prep equipment like floor grinders, diamond tools, scarifiers, shot-blasters and dust-collectors. For new floors, the process to follow is the complete removal of the surface’s concrete laitance, levelling the floor and creating the desired concrete surface profile (CSP) – ie, its roughness – suitable for the best adhesion of the coating to the concrete. For old floors, however, it is necessary to completely remove the previous coatings using special diamond tools from HSP and then grinding to create the desired CSP suitable for the best adhesion of the coating to the concrete. 1. Profile the surface: Understand how best to do the surface preparation and what tools will be required. 2. Work on a blank canvas: Take off the laitance of the new concrete surface and/ or the existing coatings on old floors. A blank canvas is necessary for a longlasting parking lot floor. 3. Remove other contaminants: Remove oil, grease, chlorides, etc which are common in places with heavy,

“Applying coating on a dry surface is the only way to ensure its best performance. If a coating is not dry, its drying time is affected and, as moisture evaporates, microscopic holes can form in it.” slow-moving vehicle traffic, but cannot be left on a surface which is being readied for coating if the paint is to adhere to the substrate completely and remain in good shape. 4. Flatten loose portions: Any area that may peel, f lake or disintegrate should be cleaned from the surface. Grinding or abrasive blasting eliminates these loose materials from it. 5. Final surface profilometry: Once all the contaminants have been removed, the floor must once again be prof iled to determine what type of coating and process will result in the best outcome. 6. Dry the surface: Applying coating on a dry surface is the only way to ensure its best performance. If a coating is not dry, its drying time is affected and, as moisture evaporates, microscopic holes can form in it. During African summers, humidity is also an important factor to consider — each coating will have a different requirement. Without a dry surface, flash corrosion can occur,

which cannot be covered, even with a second coating. “Surface preparation equipment only makes money when it’s functional. It needs to be professionally maintained to ensure that it retains quality, longer service life and reliability. For this, regular general inspections must be done,” advises Zietsman. “Our competent staff at HCP have extensive knowledge and experience. They’re constantly improving our machines in the Husqvarna Service Centre. Our clients always get quick and professional service with original parts.” S e lec t i n g t he r i g ht equ ipment and tools Richard Hugh from Super Flooring has extensive experience in all floor surfaces, including in indoor parking; “Many factors affect the quality of a parking lot floor, but none as much as surface preparation. The accurate, timely and proper preparation of the substrate inf luences the durability of the epoxy coating. For surface prep to be a success, a well-structured and knowledgeable team equipped with professional machines and tools is necessary. The equipment you use forms the basis of this and should enable you to perform at your maximum potential and profitability,” he says. (Above): For surface prep to be a success, a wellstructured and knowledgeable team equipped with professional machines and tools is necessary. (Left): Priming a concrete floor prior to applying a coating.

PRECAST | ISSUE FOUR | 2022

| GLOBAL VIEW |

A BUILDER’S APP FOR ALL SEASONS

It has been more than one year since Tétris Design x Build launched its global sustainability code. Tango Matoti, head of Tétris Workplace Optimisation, presented key insights from the code’s success over the past year at the API Summit 2022 held at the Marriott Hotel in Melrose Arch, Johannesburg, in late September. She was joined by Bernard Tyler, Tétris design and build director for EMEA. The simplest way to track sustainability Launched in 2021, the Tétris Sustainability Code is an app used for its Tétris design and build projects that documents a simple assessment of the sustainability goals of each one. The dashboard highlights what was planned in the design and what was delivered by the project, allowing clients to

PRECAST | ISSUE FOUR | 2022

use this review to highlight and quantify all steps taken in delivering more sustainable working environments. “The beauty and benefit of the Tétris Sustainability Code are that it’s broadened the sustainability conversation. The code isn’t a rigid compliance system, but an agile tool to enhance an organisation’s sustainability journey, wherever it may be on that journey. We’ve found the code also enables other areas of the business – it’s a strategic lever in the race for talent, while giving a clear picture of where immediate sustainability action can be taken,” explains Tyler. In 2022, sustainability in the workplace has taken on a deeper meaning than just green design, encompassing significant social and corporate governance goals. Social responsibility has become a key driver behind decision-making and there is

greater concern about giving back to local communities, creating a circular economy and sourcing locally. The Sustainability Code The Sustainability Code is a platform for Tétris’s clients to express to employees their commitment to sustainable workspaces. The score gives measures and places a value on the gap between what the team aimed for and what they achieved. • It enables a clearer understanding of design challenges that need to be overcome for sustainable project delivery to occur. • It measures improvement, quantifying how intervention enhances the space through increased application of lowimpact materials that amplify the quality of air, light, water, comfort and nature.

| GLOBAL VIEW |

• It inspires a mindset of innovation and an appreciation for sustainable applications at every stage of a project, enabling experimenting with ways of doing things better. • It puts ideas into practice. Responsibility for g reen desig n a nd pract ice is shared, moving beyond lip service to a client brief and becoming an ingrained practice, rather than a reaction to market trends. • It elevates awareness of sustainable design globally. Working across 18 countries on an annual average of about 4 000 projects globally, the Tétris group makes a demonstrable impact. Measurable results Letting the numbers speak for themselves, we are pleased to share the following from the assessments made on our most recent 30 projects across the EMEA: • 185 000m² of sustainable working spaces were created, with 23 of the projects achieving sustainability certification. • 100% of the projects re-used some of their furniture and 63% provided spaces to support diversity and inclusion. • 50% installed air sensors and 80% utilised sanitary fittings with consumption labels and water meters to measure total usage. • 83% leveraged layout, material and furniture selection to minimise acoustic distractions.

(Above): The Tetris Sustainability Code is anything but a compliance tool; it meaning fully captures the journey of sustainable construction, providing datadriven tools for constant improvement.

• 96% went beyond plants by using elements that maximised the connection between humans and nature, such as photographs, natural patterns, shapes, textures, colours, images or sounds. Practical recognition and function For the first time, Tétris has been awarded a Platinum medal in recognition of our sustainability achievements and is therefore in the top 1% of over 90 000 companies that were assessed by EcoVadis, the world’s largest and most trusted provider of business sustainability ratings. Despite this noteworthy accolade, we recognise that there is still much to achieve in designing and building sustainable spaces that cater for the future while meeting the needs of today. Although the challenges presented by climate change can feel insurmountable, the key lies in the realisation that positive change can be incremental. Simply by taking small steps, we can collectively reduce our carbon footprint and it does not matter where we start, as long as we start. A concrete future It is critical for global businesses to realise that there is no choice but to become sustainable, as the costs of neglecting

“Although the challenges presented by climate change can feel insurmountable, the key lies in the realisation that positive change can be incremental.”

(Above): A core principle built into the technolog y is the granular experience building on site, bringing real world data to bear on the evolution of sustainable concepts to sustainable best practice. (Below): The Tetris app brings together the complexities of sustainable construction considerations in one responsive dashboard.

sustainability will be far higher in the long term. Yet sustainability in the built environment is about more than going g reen to reverse cl imate change. It must express employee well-being and social responsibility, as well as enabling diversity, becoming the foundation of every company’s culture. As we move into 2023, we look forward to even greater levels of collaboration. Sustainability cannot be achieved in isolation, as the solutions are multi-faceted. We will need to share knowledge, leveraging each other’s thinking, technology and ideas to truly herald an era of sustainability.

PRECAST | ISSUE FOUR | 2022

| FEATURED |

TECHNOLOGICAL INNOVATION IN THE CONCRETE INDUSTRY STARTS WITH MAP PRODUCTS.

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PRECAST | ISSUE FOUR | 2022

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