Precast • Issue 2 • 2015

ISSUE TWO • 2015

THE CMA – QUALITY CAST IN CONCRETE

• New home for CMA • Pushing production with self-compacting concrete • Pioneering prestressed slab manufacturer celebrates 20 years

2

ECHO PRESTRESS CELEBRATES 20 YEARS OF PRESTRESSED SLAB PRODUCTION

7

TOTALLY CONCRETE EXHIBITION

8

NEW CMA MEMBERS PRECAST GROWS AS HATS ARE SWAPPED

9

NEW CMA FAMILY ADDITION

31 CONCRETE BOX CULVERTS

ADDED VALUE

16 NEW BRICK PLANT INSTALLED

BY SHUKUMA BRICKS

33 PAVER PRODUCTION BOOST 33 MEMBERS’ MANHOLE MANUAL 35 BRIDGE PARK – JURAPAVER

PROJECTS

PEOPLE & EVENTS

8

16 JNR TRAFFIC TRAINING

SUPPORTED BY TECHNICRETE

GLOBAL VIEW

21 TYRE FACTORY FAST-TRACKED

37 TRENDING ACROSS THE GLOBE

WITH PRECAST

AROUND & ABOUT

25 CENTENARY ROAD

EXPANSION PROJECT

11 RAPID TRANSPORT SEMINAR

HOSTED BY CMA

1

18 PUSHING PRODUCTION

24 HOUSING PROJECTS TIME

SHAVED OFF THROUGH

PRECAST SLABS

41 ZIMBABWE’S MODERN

PIPE PLANT

12 TOTALLY CONCRETE FLY’S THE

FLAG AND GETS A NEW HOME

43 WATERPROOFING RETAINING

WALLS & ROOFS

13 ANCHOR SPONSOR

45 A GOOD YEAR FOR ISG

13

25

46 PRECAST PRODUCTS

FOR AFRICA 47 BEYOND 2020 GROWTH PREDICTION 48 MEMBER LIST

TECHNICAL 27 CURING CONCRETE IN WINTER 28 MAKING CENTS WITH READYMIX 29 AGGREGATE

STANDARDISATION CALL

PRECAST is the official journal of the Concrete Manufacturers Association NPC (CMA)

Advertising: Wally Armstrong Cell: 083 701 3278 E-mail: legweak@mweb.co.za

Physical Address: Office 0400, Standard Plaza Building, 424 Hilda St, Hatfield, Pretoria Postal Address: PostNet Suite 8612, Private Bag X32, Kempton Park, 1620 Tel: +27 11 805 6742 Fax: +27 86 524 9216 E-mail: admin@cma.org.za Website: www.cma.org.za

Design, layout and production: Joanne Brook Tel: +27 11 883 4627 E-mail: joanne.studio@isikhova.co.za

ON THE COVER

ISSUE TWO • 2015

the cma – QUaLItY caSt IN cONcRete

stressed Prestress,

con-

is

celebrating

its 20th year. The company a

nu

facturer

was founded in 1995 and is s

n

• Pushing production with self-compacting concrete • Pioneering prestressed slab manufacturer celebrates 20 years

iatio

• New home for CMA

soc

ily those of the editor or the publish-

hollow-core

crete slab pioneers, Echo

The views and statements expressed in this publication are not necessar-

One of South Africa’s pre-

as

Publishers: Isikhova Publishing & Communications Postal Address: PO Box 651793, Benmore, 2010, South Africa Tel: +27 11 883 4627 Fax: +27 11 783 2677 Website: www.isikhova.co.za

42

30 ADDING LUSTRE TO A

GAUTENG SHOPPING CENTRE

m

15 ATTAINABLE QUALITY – CMA

PRODUCTS

ncrete

14 WORKING WITH THE

CONCRETE INSTITUTE

co

INDUSTRY NEWS

Q

ua

lity

cast in conc

re

te

today South Africa’s larg-

ers and neither the publishers nor

est prestressed hollow-core

the CMA accept responsibility for them. No person

slab producer, as well as

connected with the publication of this journal will be liable for any loss or damage sustained as a result

being the largest company

of action following any statements or opinions ex-

within the Echo Group. The

pressed herein. The same applies to all advertising.

group itself enjoys the status of being the largest

Precast© 2015. All rights reserved. No part of this magazine may be reproduced or transmitted in any

hollow-core slab producer in the Southern Hemi-

form or by any means, electronic or mechanical, in-

sphere and is nationally represented with factories

Publisher: Andrew Meyer Tel: +27 11 883 4627 Cell: 082 456 5175 E-mail: andrewm@isikhova.co.za

cluding photocopying, recording, or any information

in Durban, Cape Town and two in Gauteng. With the

Consulting editor: Raymond Campling Tel: 076 297 2775 Email: media@mediasavvy.biz

Endorsed by:

PRECAST | ISSUE TWO | 2015

storage retrieval system, without prior written permission from the publishers.

CONTENTS

COVER STORY

skills pool for in situ construction diminishing and quicker construction times becoming a prerequisite, the future call for precast construction products is growing and Echo Prestress is perfectly positioned to capitalise on market trends.

COVER STORY 2

ECHO PRESTRESS CELEBRATES

OF PRESTRESSED SLAB PRO One of South Africa’s prestressed hollow-core concrete slab pioneers, Echo Prestress, is celebrating its 20th year. The company was founded in 1995 when a factory was built in Kempton Park to manufacture prestressed hollow-core slabs. Like all green-shoot business ventures there was no guarantee that the market was ready for a substantial increase in prestressed slab production, especially as in those days the South African construction industry was still largely wedded to what it had been taught and knew best - in situ construction.

second factory in Gauteng, Echo Floors.

Moreover, it is the only South African company to offer both prestressed and reinforced hollow-core slabs.

Raising awareness Echo Prestress managing director, Monique Eggebeen, says that from the outset it was realised that a process of education was required if prestressed hollowcore was to make a significant impact on

However, Echo Group’s founder and

(Above): Some of the installed Echo prestressed slabs at the MTN data centre’s second-floor extension project in Centurion.

the South African construction industry.

current chairman, Peter Lord, was

“This was a task we undertook to do

convinced that certain sectors of the

ourselves and we began by conducting

market were ready to convert to pre-

plant tours. We found that almost

stressed hollow-core construction, given

everyone, from contractors to engineers,

its substantial economic and technical

had never seen the prestressed hollow-

benefits. The fact that Echo Prestress is

core slab manufacturing process before.

today South Africa’s largest prestressed

Precast construction was not a subject

hollow-core slab producer, as well as the

covered by universities and over the

largest company within the Echo Group,

years we have gone to considerable

bears testament to his foresight. The

lengths to lecture third- and fourth-year

group itself enjoys the status of being

engineering students on the application

the largest hollow-core slab producer in

and benefits of the technology. This

the Southern Hemisphere and is nation-

p r ogr amm e is s till ongo ing an d in

ally represented with factories in Durban

addition to lectures, we conduct factory

(Echo Durban), Cape Town (Topfloor) and a

tours and in-house presentations.

PRECAST | ISSUE TWO | 2015

constantly challenge ourselves, especially

S 20 YEARS

ODUCTION

“The first thing we look at on any project is whether prestressed hollow-core would be the most suitable technology.

Sometimes we find that a hybrid solution, where prestressed slabs are combined with in situ construction, works best.

And in some instances we recommend combining prestressed slabs with other forms of precast concrete such as beams and columns.

on a technical level. This has resulted in

“We work very closely with construc-

new applications such as security walling

tion professionals to make sure we meet

and retaining walls, as well as composite

all their design criteria, both aestheti-

construction suitable for steel and

cally and structurally. Our in-house de-

concrete frame structures.

sign facility and our technical department

“As market leaders, we need to dem-

examine aspects such as slab depth,

onstrate that we are the most techni-

reinforcing, spans and loading, which is

cally advanced hollow-core slab producer.

why all our slabs are purpose-made for

Internal skills development and in-house

every project. We also take responsibil-

training plays an important role in this

ity for slab installation so that when we

regard. They ensure that our personnel

walk off site, the contractors have a

are up to the mark in all aspects of our

completed working platform.

industry. Knowing that we have a highly

“We also maintain a close liaison with

skilled workforce gives us tremendous

principal site engineers and this saves

confidence to penetrate and establish

the developers time and money. And

new markets,” says Eggebeen.

where appropriate, we make recommendations on how best to apply prestressed

Solution provider

technology to their projects. For exam-

Echo marketing director, Melinda Es-

ple, they may have used 340mm in situ

terhuizen, cites another reason why

flooring and in certain instances we might

Echo Prestress has grown the demand

propose 250mm prestressed slabs as a

for prestressed hollow-core slabs. She

viable alternative.

“Furthermore, we run seminars in

says the company is no “slab pusher”,

“It’s taken us a long time to tap into

collaboration with the Concrete Manu-

but offers a complete service-orientated

the industrial and commercial construc-

facturers Association NPC [CMA] and

flooring solution.

tion markets and our policy of educating

we’ve brought international experts such as Kim Elliott to South Africa for this purpose. We have also formed a CPD seminar and conference facility through the South African Institute of Architects and those who attend these presentations earn CPD points,” says Eggebeen.

Set in quality Another aspect of Echo Prestress’ pioneering role was the introduction

students and construction profession-

“I believe we’re a step ahead of the market and we constantly challenge ourselves, especially on a technical level.”

als is now bearing fruit. We form longterm relationships with our customers through our total solution service offering and by providing them with consistent quality,” observes Esterhuizen.

Addressing the housing shortage Down the years Echo Prestress has made a substantial contribution to solving South Africa’s housing shortage.

of the SABS mark for the prestressed hollow-core slab manufacture. “ T h e S A B S m ar k o f f er s a hug e marketing advantage and once again, we worked hand-in-hand with the CMA in introducing a standard. We are very proud of our association with the CMA and have run several other projects with the association.

“Besides manufacturing to the SABS st andar d, we ar e ISO 90 01 20 08 management system-compliant. I believe we’re a step ahead of the market and we

PRECAST | ISSUE TWO | 2015

COVER STORY

(Clockwise, from far left): Echo Gravity Retaining Walling (EGRW), a new concept in retaining wall systems, seen here at Green Cross Medical Centre in Chloorkop, Kempton Park; Clearwater Park, Boksburg, where Echo Prestress hollow-core slabs were used to fast-track the development; an Echo prestressed slab is lowered into position at The William, a middleincome high-density residential development in northern Johannesburg; some of the installed Echo prestressed slabs at the MTN Data Centre’s second-floor extension project in Centurion.

(Above): The William, a middle-income high-density residential development in northern Johannesburg.

3

upper-level flooring in multi-storey apart-

meant earlier completion times and

seen South African professionals making

ment blocks at two Gauteng retirement

substantial cost savings. As Rodney Gray,

increasing use of precast hollow-core

villages, Featherbrooke Hills Retirement

managing director of Balwin Properties,

slabs for the construction of multi-

Village and Olivedale Retirement Village.

says: “Prestressed hollow-core slabs

storey buildings and for the extension of

Another is The William, a middle-income

provide us with fantastic quality and high

existing structures.

high-density residential development,

standards which far outweigh in situ or

Some recent housing projects in-

where 110 eight-unit apartment blocks

beam-and-block flooring. In fact, precast

clude the supply of precast concrete

were constructed in northern Johan-

concrete is what makes high-density

hollow-core slabs for the construction of

nesburg. Other recent projects include

housing viable for us.”

(Above, from top): Gabions add aesthetic appeal to this Echo security wall at Waterfall Estate in Midrand; some of the installed Echo prestressed slabs at the MTN Data Centre’s second-floor extension project in Centurion.

Jabulani, a high-density sectional title

One example of prestressed slabs’

development in Soweto, and Fleurhof, an

diversity is security walling. Several walls

integrated housing project south-west

have been erected, one of the latest

of Johannesburg.

being a wall for the Scaw Metals Group.

The MTN Data Centre, Phase 2, which

The wall was commissioned after other

necessitated the addition of a second

types of security walling proved fallible

floor, is an example of how prestressed

by being repeatedly breached.

flooring can be used to add a storey

Eggebeen believes that the prospects

to an existing building, saving time and

for prestressed hollow-core slab growth

money. Commenting on the MTN project,

in southern Africa are extremely bright

Esterhuizen said that precast hollow-

and that during the next 10-15 years the

core slabs are to the construction

market will enjoy substantial growth. Part

industry what cellphones are to modern

of the reason is that the skills pool for

communications – fast, flexible, multi-

in situ construction is diminishing. Other

functional and cost-effective.

factors include quicker construction times, superior sound insulation and

Urban densification

thermal proper ties, as well as the

The use of hollow-core slabs by several

consistent quality that an SABS certified

high-density housing developers has

prestressed factory provides.

COVER STORY

Esterhuizen says the 21st century has

5

SEEN AT TOTALLY CONCRETE

PRECAST | ISSUE TWO | 2015

awareness of precast concrete and

This year was the third in which the

was quite simple – increased demand for

CMA has exhibited at Totally Concrete.

stand space from members.

PEOPLE & EVENTS

BIGGER WORKS BEST AT TOTALLY CONCRETE

alerting would-be members to what the CMA can offer them.

This year’s stand spanned 27m², three times as large as the first 9m2 stand in 2013 and 9m2 larger than last year’s 18m² stand. The reason for this

7

The exhibition has worked well for the

“Our stand had considerable visual

association and its co-exhibitor member

appeal,” said Wally Armstrong of AMA

tions – Concrete for Life and 14 member

companies, generating interest and

Marketing, who has organised all three

companies displayed their banners as co-

Totally Concrete exhibitions. “We find

exhibitors together with the CMA. These

the larger stands definitely worthwhile.

were: Aveng Infraset; Bosun; Brickcast;

They are more inviting, attract more

Civil Works Group; Concrete Units; The

people and generate more interest with

Echo Group; ReMaCon; Rocla; Smart-

more companies, more banners and more

Stone; Southern Pipeline Contractors

products on display. I see no reason why

and Technicrete, as well as some foreign

next year’s exhibit can’t be even bigger.”

members, including Denmark’s Hawkeye

The theme for the CMA’s 2015 ex-

Pedershaab, Fast Deck from Botswana

hibition was Precast Concrete Solu-

and Poland’s Techmatik.

PEOPLE & EVENTS 8

NEW CMA MEMBERS Three companies have recently joined the

Ascon Laboratories, have demonstrated

Concrete Manufacturers Association to

that Vaka’s product range exceeds the

be part of the exciting drive to promote

Standards Association’s minimum qual-

the use of precast concrete and ensure

ity requirements.

quality and reliable services become the

Simstone (Pty) Ltd recently joined the

norm in the industry.

CMA as a quality manufacturer of civil

The new members include CPI worldwide

engineering, designer and non-standard

trade journals for the concrete and pre-

precast products. Established in 2004,

cast concrete industry. The journals are

the company has grown rapidly to become

published in 13 different language editions in more than 200 countries worldwide.

(Above): Vaka concrete batching plant in Zimbabwe.

a significant player in the precast product manufacturing industry and supplies

These trade journals, with their practical

egorisation of topics addressed in sep-

products both locally and abroad. Their

editorial reporting on research, production

arate sections. The editorials include

head of fice is situated in Meyerton,

and applications, are specifically address-

product information and case stories, as

Gauteng and they also have a branch in

ing the decision-makers of the concrete

well as technical and scientific articles

Humansdorp in the Eastern Cape.

and precast concrete industry.

about concrete technology, concrete

The company uses advanced concrete

products/cast stone, concrete pipes and

equipment and technology to design a

manholes, precast concrete, reinforce-

broad range of products ranging from

ment technology, ready-mix concrete,

kerbstone to stormwater solutions, road

international events and much more.

furniture, as well as electrical and agricul-

All issues show a comprehensive cat-

Another exciting addition to the CMA

tural products. It also has a range of de-

is Vaka Concrete which was founded in

signer products that includes everything

Harare, Zimbabwe in 2012. Vaka Concrete

from cladding to flagstones and more.

manufactures concrete bricks and pavers

There is little that the company cannot

in a variety of colours at present, while

manufacture at its plant as long as raw

concrete blocks for low-cost housing and

materials pigments and viable quantities

perimeter walling will be added to its prod-

are available and can be ordered.

uct range during the course of this year.

Vaka’s plant uses the latest mixing technology from CMA member, Berkenmayer, which together with high-quality raw materials, ensures the quick and homogenous mix essential to consistent product quality. Independent testing by the Standards Association of Zimba(Above): A recent cover of CPI journal.

bwe, Northern Testing Laboratories and

(Above): Simstone Humansdorp yard.

PRECAST IS GROWING Having been at the helm of Precast

David will also continue to contribute a

style of editorship whereby stakeholders

magazine for over a decade, editor David

number of articles to each issue of the

are encouraged to communicate and sub-

Beer is swapping the fast pace of Johan-

magazine and readers who have grown to

mit their stories for possible inclusion in

nesburg city life for the more relaxed

enjoy his relaxed and informative writing

our magazine.

environs of Cape Town and surrounds. At

style will still be able to receive their

the same time he has decided to hang up

regular fix of David’s work.

Further bolstering the crew at Precast is the recently retired executive

the editor’s hat and concentrate on pur-

Taking up the cudgels of editor will be

director of the CMA, Wally Armstrong,

suits closer to home, choosing rather to

experienced trade and technical writer

who has kindly volunteered his expertise

wear the mantle of coastal region editor.

and media consultant, Raymond Cam-

to market the magazine to businesses

By taking a step away from the helm,

pling, who will continue to bring readers

who want to promote their products and

David will have more time with friends and

the latest local and international news

services to the industry. Wally’s “little

family while simultaneously having more

from the precast concrete and related

black book” of role-players in the indus-

time to spend on other business pursuits

industries. With a good eye for news and

try will be tapped to ensure that all who

and with coastal stakeholders in the pre-

a willingness to serve and promote the

need to market their businesses in the

cast industry. As coastal region editor,

industry, Raymond promotes an inclusive

magazine are able to do so.

PRECAST | ISSUE TWO | 2015

WELCOME ABOARD, RITA Members of the Concrete Manufacturers Association, who have called or visited the association’s offices lately, will have been greeted by the ever cheerful and helpful latest addition to the CMA family, Rita Naude.

Rita has joined the association as administration manager with a special focus on running the office efficiently and (Above): Rita Naude.

ensuring members’ and stakeholders’

requirements are dealt with in an effective manner. Another important aspect of her job deals with communications and ensuring the association’s website is kept up to date with the latest information and news.

“I have worked most of my career in service-related industries and that is why I place such a high emphasis on customer service and assisting stakeholders in an efficient manner. Relationships are everything to me and wherever I have worked, I always strived to build relationships that are based on service, trust and respect. The CMA’s doors are always open to assist our members and I look forward to being of service to the industry,” says Rita.

WIND FARM PROJECT RECEIVES HIGH ACCOLADES The CMA has congratulated Concrete Units for its outstanding win and commendation at this year’s Fulton Awards in which the company took top honours in the Concrete Innovation category and received a further commendation for its Gouda Wind Farm project.

The project represents a first in South Africa for the use of precast concrete in the construction of wind turbine towers and proves the versatility of the material for even the most difficult applications. Concrete Units was able to ensure that cost-ffective and efficient structures were constructed with the ability to maintain structural stability at a height of 100m supporting massive 170-ton turbines and blades moving at high speeds.

Brian Cook of Concrete Units says the award and commendation in the category for civil engineering structures with a value greater than R100 million is hugely satisfying.

“We put in long, hard work and had many challenges, including the use of pumped self-compacting concrete and the implementation of European EN206 standards to our manufacturing work on the project.

“We are innovators and prefer the big, heavy and tricky precast jobs and this was a particularly tough one,” Brian concluded.

PRECAST | ISSUE TWO | 2015

CMA HOSTS EKURHULENI RAPID TRANSPORT SEMINAR The Concrete Manufacturers Association

Construction work on all phases in-

(CMA) recently hosted a South African

volves building: trunk complementary and

Road Federation (SARF) seminar on the

feeder routes at an estimated cost of

Ekurhuleni Metropolitan Municipality’s

R1,2 billion; bus stations (R200m); bus

(EMM) Integrated Rapid Transport Net-

stops; street lighting (R190m); depots/

work (IRPTN).

holding areas (R200m); walkways and

The seminar was presented to SARF

cycle lanes (NMT) (R100m); pedestrian

members and some CMA producer mem-

bridges (R60m); Intelligent Transport

bers by Philip du Plessis, divisional head:

Systems (R400m) and a Transport Man-

BRT Infrastructure of Ekurhuleni’s Depart-

agement Centre.

ment of Transport Planning & Provision.

Eighteen-metre buses will be used

He outlined how Ekurhuleni’s IRPTN will

for the trunk route and 12m standard

improve public transport between Tembisa

buses will be used for the feeder and

in the north and Vosloorus in the south, as

complementary routes, as well as for the

well as serving the metro’s towns.

trunk route during off-peak periods.

EMM’s IRPTN is being funded by the National Treasury and will address prob-

Opportunities abound

lems such as: congested roads; unsafe

Du Plessis said that the corridors with

public transport vehicles; limited bus

the highest demand for improved public

services and an ageing public transport

transport ran between Tembisa and Ger-

fleet. The construction of Phase 1, which

miston and the industrial areas west of

runs from Tembisa to Vosloorus, began

OR Tambo International Airport. He took

in April 2014 and is due for completion in

several delegates on a guided tour of the

2017. The first buses are scheduled to

completed works, including pedestrian and

begin running in mid-2016.

cycle lanes which have been incorporated into an existing road network.

Project on track

CMA executive director, Frans Min-

The seminar covered the overall project’s

naar, said that the seminar has alerted

operational and business plans, as well as

SARF and CMA members to the opportu-

its infrastructure components, system

nities for the supply of road infrastruc-

management, marketing and brand manage-

ture and other materials required for the

ment, industry transition and the owner-

construction of Phase 1 and subsequent

ship, funding and procurement of bus fleets.

EMM IRPTN phases.

(Above): Philip du Plessis addresses a SARF seminar on Ekurhuleni Metropolitan Municipality’s Integrated Rapid Transport Network (IRPTN).

PRECAST | ISSUE TWO | 2015

PEOPLE & EVENTS 12

FLYING THE FLAG AT TOTALLY CONCRETE CMA member Techmatik SA was one

machine, the WIB 1411, which was based

machines. These advantages reduce en-

of the CMA member companies which

on in-depth market research. Ongoing

ergy consumption by as much as 30%.”

participated in this year’s Totally Concrete

improvements based on Jadar and cli-

exhibition at the Sandton Convention

ents’ requirements saw the introduction

Operator appeal

Centre. Director of International Sales

of new machines such as the HP 3000

Techmatik’s machines are compact and

Department, Marcin Nowakowski, flew

PRO and SHP 5000 PRO C. We employed

allow full automation and visualisation of

out from Poland to man the stand and

experienced people who had spent many

all production stages for quick identifica-

promote Techmatik’s state-of-the-art

years working on manufacturing block-

tion of problems. The company provides

precast concrete production machinery.

making machines at Jadar and its design

after-sales back-up service and support,

Interviewed by Precast, Nowakowski

department introduced new solutions

to solve problems related to the produc-

said that Techmatik recently celebrated

with enhanced output and production

tion. Furthermore, the company provides

its 10th anniversary when an open day

qualities,” said Nowakowski.

operator training in Jadar plants and even

was held in Poland for 500 guests from

The company’s portfolio has since

helps select raw materials and material

more than 50 countries on 24 October

grown to become substantially more

mixes on behalf of its clients. The company

last year. Guests were able to view the

varied and currently includes equipment

delivers its block-making solutions directly

HP 3000 PRO and its flagship SHP 5000

such as: moulds for the production of

to several hundred customers worldwide.

PRO C. In addition, they were able to

paving blocks and decorative concrete

watch palisade production on the Multi

products, modern high-performance con-

1200 PRO universal concrete block

crete block machinery, complete process

machine, as well as highly sophisticated

plants, concrete mixing plants and vari-

concrete block shapes and textures

ous machines used for the manufacture

using new high-precision machinery and a

of other precast concrete elements .

fully automatic line for splitting concrete for various products.

Commenting fur ther, Nowakowski said that all production lines are

Nowakowski said that Techmatik

equipped with advanced, state-of-the-

was founded by its former president,

art vibropress machines, which ensure

Tadeusz Kupidura, who previously had

high output, reliable repeatability and

over 20 years’ experience in paving stone

superior product quality. “Our equip-

manufacture at Jadar, one of Poland’s

ment is designed for high-performance

leading producers of paving stones and

and efficient production in conjunction

concrete elements. Both companies are

with steel pallets. This ensures re-

now successfully run by his son, Dariusz.

duced cement usage of around 20%.

Furthermore, we use linear bearings to

In-house development

ensure precise product height. Moreo-

“Techmatik initially produced concrete

ver, our hydraulics are integrated into

pavers. Shortly thereafter, an R&D De-

our machine frames to save space and

partment was created and the company

our innovative and individual vibration

began building its own concrete block

tables limit vibration on the production

(Above, from top): Some of the visitors at Techmatik’s 10th anniversary celebrations last year; the 10th anniversary cake is cut by Techmatik president, Dariusz Kupidura.

NEW HOME FOR CMA With demand for precast concrete

The move is part of the association’s

connected office space, will allow us to

products growing steadily, the Concrete

plan to reach out to existing and new

reach out and react more quickly to the

Manufacturers Association (CMA) has

members in order to bring services clos-

needs of the market,” concludes Frans

moved to modern, more easily acces-

er to the public, while improving commu-

Minnaar, executive director of the CMA.

sible premises to allow members better

nications between members, users and

T he new address of the CMA is:

access to information and the services

the association alike. Simultaneously,

Office 0400, Standard Plaza Building,

offered by the association.

the CMA announced the appointment

424 Hilda Street, Hatfield, Pretoria.

Situated in Hatfield, Pretoria, the

of Rita Naude as administrative manager

The telephone and fax numbers remain

premises chosen to house the association

to manage the association’s day-to-

the same.

are just minutes away from main arterial

day operations.

Concrete Manufacturers Associa-

roads between Johannesburg, Ekurhuleni

“We are committed to making our

tion: Frans Minnaar. Tel: 011 805 6742.

and the West Rand and a short walk away

services more convenient and Rita’s ap-

Email: director@cma.org.za. Web: www.

from the Gautrain’s Hatfield station.

pointment, as well as the move to a more

cma.org.za

PRECAST | ISSUE TWO | 2015

PEOPLE & EVENTS

The anchor sponsor of the 2016 CMA Awards for Excellence competition is South Africa’s leading cement supplier, PPC. Now in their 44th year, the awards recognise and promote excellence in the use of precast concrete and provide the ideal platform to honour those profes-

13

sionals who have excelled in its diverse applications.

According to Vincent Erasmus, key account manager at PPC: “We are passionate about investing in initiatives and projects that advance excellence in concrete and we always strive to bring our customers innovative, industry-first products and services. The awards are

ANCHOR SPONSOR FOR AWARDS

the most prestigious event on the precast

CMA Awards Committee chairperson

concrete calendar and celebrate some of

an d E ch o P r e s tr e ss MD, Moni qu e

deadline of 16 October,” said Eggebeen.

Judging of the awards will take place

the industry’s outstanding achievements.”

Eggebeen, says that the gener ous

in November and trophies and commen-

As the leading supplier of cement and

sponsorship of PPC will ensure the

dation awards will be presented at a

related products in southern Africa, PPC

awards are successful. “We are ex-

gala dinner ceremony at Summerplace in

Ltd has nine manufacturing facilities and

tremely gratef ul to PPC and other

Johannesburg on 23 April 2016.

three milling depots in South Africa, Bot-

sponsors. It is thanks to them that the

Follow PPC on Twitter: @PPCisCe-

swana and Zimbabwe. Related products in-

planning and detailed organisation of the

ment, like us on: www.facebook.com/PPC.

clude aggregates from quarries in Gauteng

event is already in an advanced stage and

Cement and visit us at: www.ppc.co.za.

and Botswana. PPC Lime supplies metal-

competition entries are already being

lurgical grade lime and burnt dolomite.

received, well ahead of the competition

PRECAST | ISSUE TWO | 2015

(Above): PPC’s Dwaalboom factory.

INDUSTRY NEWS 14

WORKING WITH THE CONCRETE INSTITUTE Members of the Concrete Manufacturers

The Concrete Institute – through its

most respected sources of information

Association should work with industry

respected School of Concrete Technol-

on concrete in the Southern Hemisphere

bodies such as The Concrete Institute

ogy – offers a range of internationally-

and is widely used by the industry and

(TCI) to obtain independent,

recognised courses including

students as a valuable reference source

unbiased information, advice

Intr oduc tion to C oncr e te;

for technical information. The information

and publications, as well as

Making Concrete Bricks and

centre is equipped with state-of-the-art

accredited and internationally

Blocks; Mortars, Plasters,

computerised information systems and

recognised training on con-

Screeds and Masonry; Con-

produces a number of valuable publica-

crete technology.

crete Practice; Concrete Tech-

tions. It can also provide information

It was f ounded in 2013

nology; Concrete Structures:

about forthcoming relevant seminars

by three of South Africa’s

Analysis & Design; Properties

and conferences on concrete technology.

leading cement producers:

of Concrete for the Structural

AfriSam, Lafarge and Sephaku, following the demise of its predecessor, the Cement &

(Above): Bryan Perrie, managing director of The Concrete Institute.

Designer and Constructor and the highly acclaimed Advanced Concrete Technology course.

Concrete Institute (C&CI), and has since

Specific courses can be tailored to cli-

become a valuable ally to the industry as

ents’ needs and presented on site as

C&CI was for seven decades.

well. The next Advanced Concrete Tech-

TCI is mandated to offer vital services

nology Course will commence in Janu-

to the concrete industry that includes:

ary 2016, with two examinations to be

Education and training: With the severe

written in July 2016. Applications to

skills shortages facing the construction

enrol for this course close in December

sector, education and training are es-

2015. A comprehensive Information Cen-

sential requirements for the future of

tre: Inherited from the renowned C&CI

a qualified and suitably skilled industry.

facility, this is one of the largest and

(Above): The Concrete Institute can provide advice on any concrete problem, from building a fish pond in the garden to the construction of concrete highways (pictured).

E ER ITE H S CK EB I CL R W FO

In a bid to raise the overall standard

new guidelines give them the opportunity

of companies in the precast concrete

to prepare and implement their own

industry, the Concrete Manufacturers

QMS,” says CMA executive director,

Association (CMA) is preparing guidelines

Frans Minnaar.

for companies to prepare and implement

At a glance, the QMS guidelines include input on: QMS documentation requirements • Quality policy statement

their own quality management systems

Quality matters

• Quality objectives

(QMS) based on ISO principles.

“In order to raise the overall standards

• A quality manual

Once implemented, formally assessed

within the industry, we need to appeal to a

• Other documents required for effec-

and approved by the CMA’s panel of

broad base of producers and ensure that

tive planning, operation and control

experts, the self-implement-

membership is attainable to

ed QMS will allow companies

all. The guidelines serve as a

to obtain full membership

framework only and the onus

Mandatory procedures

of the association without

still remains on the company

Procedures that must be documented:

the need f or some times

to design and implement a

• Document and data

costly assistance of exter-

system that works for them.

nal consultants.

“If they are able to adopt

• Records

control procedure

• Control of records procedure

“CMA producer member-

and abide by the required

• Internal audit procedure

ship curr ently r equir es

standards, then they will be

• Control of non-conformance procedure

that the producer either

regarded as a quality pro-

• Corrective and preventive

carries the SABS mark or

ducer and qualify for mem-

action procedure

alternatively operates with a recognised

bership of the CMA. In addition, the

Thereafter customised documenta-

quality management system [QMS] such

CMA may also assist companies with

tion and procedures need to be put in

as ISO 10 005 or one based on ISO

the implementation of the QMS should

place according to the operational scope

9001. In some instances costs preclude

they require the assistance of the as-

of the business and types of products

would-be members from joining and the

sociation’s panel of experts,” says Frans.

produced.

MAKE SURE YOU

SECURE YOUR SPOT

Don’t miss out! Book your advertising space in the next issue of Precast magazine.

Contact Wally Armstrong for more information Tel: 083 701 3278 E-mail: legweak@mweb.co.za

THE CMA – QUALITY CAST IN CONCRETE

INDUSTRY NEWS

MAKING QUALITY ATTAINABLE

15

INDUSTRY NEWS 16

TECHNICRETE SUPPORTS JUNIOR TRAFFIC TRAINING CMA member, Technicrete, has supplied

ings. The South African Road Traffic Sign

run by the Johannesburg Emergency

precast concrete bevelled pavers which

Manufacturers’ Association (SARTSMA)

Management Services and the Johannes-

were used to replace damaged concrete

refurbished all the sign boards with new

burg Metropolitan Police Department.

surfaces at the Rhodes Park Junior Train-

miniature signs, and SARF member Men-

The centre is due to be officially opened

ing Centre in Kensington, Johannesburg.

tis Sales supplied the guard railing.

by the City of Johannesburg Public Safety

The rehabilitation of the centre is a

As soon as the refurbishment of the

MMC, Sello Lemao, once an adjacent ser-

South African Road Federation (SARF)

site has been completed, it will be jointly

vice building with catering and ablution

initiative. SARF approached the CMA for

facilities has been refurbished.

assistance with the resurfacing of the

CMA director, Frans Minnaar, said

miniature road network and the CMA in

that the CMA was pleased to have

turn invited Technicrete to participate.

assisted with this project. “Given South

Besides supplying the pavers, Techni-

Africa’s dismal road safety record, any

crete also paid for the paving work which

contribution we can make, no matter

was done by Hennie Construction.

how small, is worthwhile. Moreover,

As well as organising the rehabilitation

precast concrete block paved roads with

process, SARF is supplying 15 bicycles

their excellent anti-skid properties make

and helmets to be used by trainees. SARF member Ennis Flint did the road mark-

(Above): It was a team effort to refurbish the Rhodes Park Junior Training Centre.

a valuable contribution to better levels of road safety,” said Minnaar.

SHUKUMA BRICKS INSTALLS NEW BRICK PLANT CMA member, Shukuma Bricks, has

speedy turnaround times when switch-

Shukuma’s plant also has fully auto-

installed a new concrete brick and block

ing between the manufacture of various

mated pallet and product handling. Wet

manufacturing plant at Greenbushes,

products such as blocks, stock bricks,

blocks or other product on the produc-

Port Elizabeth. Central to the new plant

maxi bricks and pavers.

tion board are stacked up in a stacker

is the RE 1400 brick- and block-making

“The plant also has a topping feed

(elevator). Once a fully loaded set of

machine, which was supplied by another

for colouring the top layer of pavers.

bricks or blocks has been accumulated,

CMA member, PMSA.

Moreover, production parameters can be

it is transferred onto racks in the cur-

The RE 1400 is the largest pre-

changed using a touch screen interface

ing chamber.

cast concrete brick- and block-making

while the machine is in operation. This

Before strapping day-old blocks or

machine produced by PMSA. It has a fully

allows us to instantly adapt to changing

bricks, they are packed onto a slat

automated production capacity of up to

moisture content and aggregate con-

conveyor using a packer head which

165 000 bricks per nine-hour shift and

sistency instantly without having to halt

automatically stacks the pr oducts

offers a range of batching configurations,

the production cycle.”

into the correct pack size, ready for

wet and dry-side production handling and

Moisture in the aggregate is com-

strapping. After strapping, which is fully

pensated for by use of a microwave

automated, the slat conveyor transports

According to Shukuma managing

moisture-sensing measurement probe.

to the outside storage yard for further

director, Jacques Bellingham, the new

The RE 1400 comes standard with lin-

curing. The whole plant is monitored and

plant will be producing 95 000 pavers per

ear transducers and servo-proportional

managed from the control room through

nine-hour shift to best-practice quality

hydraulic valves which provide high-per-

the use of a supervisory control and data

standards. “One of the advantages of the

formance closed-loop control. Two 7,5kW

acquisition system (SCADA system). This

RE 1400 is that it allows us to change

shaft vibrators allow vertical directional

provides visual animated graphics of the

moulds swiftly and effortlessly using

vibration, and a variable speed drive pro-

machine and plants operation. Machine

the mould-changing arm. This ensures

vides frequency control.

parameter control and data capture

production board handling.

Shukuma’s wet-side conveying sys-

allow for remote control of the plant in

tem is fitted with a quality testing sta-

addition to retaining historic and daily

tion which rejects products that fail

data for management of the plant.

the required standard. Wet concrete

Shukuma Bricks is currently in the

can easily be returned to the mixing

process of applying for the SABS mark

station and rotary brush cleans the fine

in accor dance with SA NS1215 and

edging on top of hollow blocks to give a

SANS1058 standards. All products are

perfect finish every time. Newly formed

tested at Shukuma Bricks’ fully equipped

wet blocks can be pre-sprayed with a

in-house laboratory to ensure compliance

fine mist spray to add additional surface

with SABS standards. The company is a

water where required.

level 2 B-BBEE contributor.

PRECAST | ISSUE TWO | 2015

PROJECTS

PUSHING PRODUCTION WITH SCC Southern Pipeline Contractors, a CMA member, has re-engineered a large part of its Boksburg manufacturing facility to make faster self-compacting concrete for its large-size cast products.

18

The improved production output has recently enabled the company to meet the supply criteria for a number of large-scale projects where speed and reliability of supply were of paramount importance to the success of the projects.

By embracing new technologies in concrete, the company’s engineers have also begun developing new products for different industries that enable large precast structures to be cast within the controlled environment of its factory and transported to site as required, rather than being cast in situ.

(Left): Products with a diameter of 350mm and larger are produced with SCC. (Above): Plinths installed at the mine.

Precast plinths According to SPC sales manager, Steve Delport, one of the most challenging

From a project management perspective,

Upskilling workers

was the supply of approximately 700

the project is able to roll-out at a fast,

From a health and safety perspective,

concrete plinth structures to support

steady pace without the need for tons

SPC general manager, Louis-Xavier

steel pipelines on a mine in the North

of formwork on site, nor the logistics of

Havard, says the shift to self-compacting

West Province. The nearly one-ton plinths

getting fresh concrete to often remote

concrete has been a success as moulds

needed to be delivered in accordance

or difficult-to-reach places,” says Steve.

are simpler and do not need heav y

with the contract fast-track schedule in

equipment to vibrate and level the

order to keep pace with the construction

moulds. This makes for a far quieter and

of the pipeline.

simpler working environment, with fewer

“We developed the concept to replace

requirements for hands-on labour. As a

in situ cast plinths and simplify the con-

result, workers can be redeployed to

struction process. Instead of excavating,

more productive applications elsewhere

pouring a foundation and then curing it

in the factory. Another advantage for

for a week or two before erecting shut-

workers is the requirement to upskill and

ters and forms to cast the plinth, our

train staff at all levels to work with more

offering is simply transported to site and fixed onto the foundation. Once in place, construction activities can resume and it is immediately ready to bear a load.

“The project is able to roll-out at a fast, steady pace without the need for tons of formwork.”

advanced mixes and processes.

“We have retrained our staff to be

(Above): Steve Delport stands alongside a mould that has been specially adapted for the use of selfcompacting concrete.

more specialised in the casting process.

He explains that the project required

their habits to understand self-compact-

500mm x 800mm x 1 000m-high

ing concrete and take full ownership of

plinths to be manufactured according

the moulding process from start to fin-

to tight specifications at the factory.

ish. The end result of the re-engineering

The comparatively simpler moulds were

of our production lines has been the

then manufactured and mixes designed

creation of a safer and healthier working

according to the specifications. Upon

environment, improved productivity and

completion of the moulds, casting began

the added benefit of producing products

in earnest and the delivery of the plinths

of a higher quality with better aesthetics

took place as scheduled without incident.

and finishes,” concludes Louis-Xavier.

By working with them, we have changed

PROJECTS

projects undertaken by SPC recently

19

PROJECTS 21

PRECAST CONSTRUCTION FAST-TRACKS TYRE FACTORY

the intumescent paint that would have been required to render the steel fireproof for two hours.

Fire resistance The columns, walls and beams were essential structural components and were cast on site to a strength rating of 30Mpa by Bedrock using its own moulds. Concrete roof beams were specified for two critical functions: they met the two-hour fire rating, and they could be used to secure the walls in position. One of the reasons why the

Tilt-up walls and other precast concrete elements have been used to construct a 2 600m² tyre factory in Ladysmith, KwaZulu-Natal. Successfully completed in April 2015, the factory is owned by Sumitomo Rubber Industries, which manufactures tyres under the Dunlop and Khumo brands.

steel/masonry option was rejected was that steel did not meet the required fire rating. However, the roof itself was comprised of standard steel sheeting material because the concrete walls were deemed sufficient to contain a fire

Tyre vulcanising requires high tempera-

for the specified period.

tures, which meant that the building

T he building was erected in two

had to be built with a three-hour fire

phases. Phase 1 involved casting and

rating. The design engineer, William

erecting the 12,6m-high columns and

Smith of Bosch Projects, submitted

Phase 2 entailed casting the wall panels

three construction options to meet

and roof beams and then placing them into

the fire rating: in situ concrete walling;

position. The columns only took a day to

clay-fired double-skin masonry supported

erect and the wall panels and beams were

by structural steel; and an integrated

installed seven weeks later over a period

precast concrete alternative comprising

of 50 hours – a massive time saving.

columns, roof beams and tilt-up walling.

T he precast building, which took three as opposed to five months to complete, of f ered substantial time savings. This, together with a R5 million saving and superior finishes, sealed the contract and tilt-up specialist, P ine t o w n -b ase d B e dr o ck, w as ap pointed to handle the on-site casting and erection of the precast concrete elements. The R5 million saving excluded

PRECAST | ISSUE TWO | 2015

“It was pleasing to note that the perimeter wall panels were utilised as structural elements and not just cladding.”

The 12 internal columns stabilise the perimeter walls panels by connecting the spine and eave beams between the columns and walls. Once they had reached 20Mpa, the columns were installed in two 72m rows (six columns in each) (Above left): Push-pull braces are installed as temporary support for a wall panel prior to the installation of concrete roof beams.

(Top): Installed concrete roof beams tie in and support the tilt-up wall panels at the Sumitomo Rubber Industries factory.

PROJECTS

which ran 12m apart and 12m in from

structural elements and not just cladding.

Kitching said the design work can

the two longitudinal walls. Each column

“To maximise savings, the Sumitomo walls

make or break a tilt-up project, which

had protruding starter bars for anchor-

should ideally have been cast on the build-

has to be done properly from inception.

ing purposes and 400mm x 800mm U-

ing’s finished floors, thereby negating the

“The consultation service we provide is

shaped slots at the top end which were

cost of sacrificial casting beds.

essential to determine the lifting insert

used to hold the longitudinal roof beams

“Bedrock Group champions the use

positions, the casting-bed locations

of tilt-up technology and we actively

and the crane positions, because any

promote its use by clients, professionals

miscalculations may result in financial

Sacrificial beds

and construction companies. We’d like to

loss. Due to pr ecise planning, the

The columns were anchored by bearing

see the technology grow to the extent

erection of the Sumitomo Industries

pads which measure 3m x2m x 600mm

that it becomes the preferred solution

building ran like clockwork.

(depth) and weigh 75 tons. In addition to

for every client. In addition to being a

securing the columns in a vertical posi-

manufacturer, we regard our prime role

Developing skills

tion, each bearing pad supports two 38-

as being a supplier of tilt-up technology,

“We would like to see main contractors

ton panels. Once the columns had been

hardware and expertise. We prefer to

casting the structural elements under

placed in position on top of the structural

do the consulting and preliminary design

consultation with Bedr ock with us

blinding in each footing cavity, temporary

work and to provide the hardware, namely

providing rigging teams to erect the

braces were used to support the columns

the formwork, specialist lifting inserts,

precast structural elements. One of

during the pouring of concrete and during

the push-pull braces, the bond breaking

the reservations about the technology

the subsequent curing process, which

liquid and the specialised rigging team.”

is that contractors are reluctant to lift

in position (see caption 1).

22

took seven days.

As with the columns and roof beams, the wall panels were cast on sacrificial concrete casting beds. Once the concrete had been poured into the panel moulds, the exposed surface was power-floated to a steel-float finish. The remaining three sides presented with equally smooth offshutter finishes. After the first concrete wall panel had cured overnight, it was used as the casting surface for the next panel.

This process was repeated four times, leaving a stack of five panels to cure.

“We’d like to see the technology grow to the extent that it becomes the preferred solution for every client.”

40 tons of concrete, whereas our trained rigging teams do it daily. This means that contractors could pour the concrete and make their own panels and columns and Bedrock or another company could lift and place the elements.

“Ultimately, our goal is to see all large envelope buildings such as warehouses, distribution centres, factories, shopping malls and so on being built with precast tilt-up. There is far more work than we can handle and this is why we are happy to teach other contractors how to

A total of 32 wall panels, measuring

use the technology. It is through this

6m (width) x 12m (height) x 200mm

inclusive approach that precast tilt-up

(thick) and 43 roof beams measuring

construction will become the norm,”

400mm (width) x 12m (length) x 900mm

concluded Kitching.

(depth) were cast. Very tight tolerances within 5mm were maintained as this was critical to ensuring that all three precast components lined up accurately.

Once the panels had been lifted into position, they were founded on bearing pads

(Left): All three precast concrete elements, the columns, the tilt-up walling and the roof beams, can be clearly seen in this image.

(Below): A close up showing precast concrete columns on the right and tilt-up concrete wall panels on the left.

measuring 1 800mm x 500mm (depth) and were supported with push-pull braces until the roof beams were attached to them, thereby securing them permanently in position. The panels at the gable ends were not supported by the roof beams and were bolted onto the columns. In addition to handling the base concrete and the footings, the main contractor, Ladysmith Construction/Stefanutti Stocks JV, erected the roof and fitted out the building.

Tilt-up expertise Commenting on the project, Bedrock managing director, Greg Kitching, noted that the perimeter wall panels were utilised as

PRECAST | ISSUE TWO | 2015

OUR DOOR

IS OPEN BECOME PART OF THE FUTURE

WE INVITE ALL PRECAST CONCRETE MANUFACTURERS TO JOIN US *

* TERMS AND CONDITIONS APPLY

www.cma.org.za

CONCRETE MANUFACTURERS ASSOCIATION Address: Office 0400, Standard Plaza Building, 424 Hilda Street, Hatfield, Pretoria Tel: (011) 805-6742 • Fax: (086) 524-9216 • Email: admin@cma.org.za • Website: www.cma.org.za

PROJECTS 24

Elematic SA’s precast hollow core concrete slabs have once again proved their worth when it comes to time-saving and efficiency on a building project. The Benonibased manufacturer has supplied 30 500m 2 of concrete slabs for Madeira Isles – a massive housing project in Danville, Pretoria – and has helped reduce the construction time by six months.

Madeira Isles is a 500-unit development covering a total of 40 700m2 of floor area. It is made up of 14 apartment blocks comprising four floors each. The apartments are divided into 56 threebedroom units, 388 two-bedroom units and 56 single-bedroom units. All units have been developed for the rental market. The project broke ground in November 2013 for completion in mid-2015.

Boutel Projects was the main contractor and was responsible for the contract as a whole on behalf of the client, ESS. Boutel has been in operation in its current form since 2013, but grew out of a large and well-established plastering and tiling firm. By introducing experienced directors, management and staff, Boutel’s founder, Americo Pimentel, positioned the firm to be able to take on medium-sized commercial construction projects with a view to building a reputable construction company.

Need for speed When Boutel was appointed to build Madeira Isles, the original plan was to use traditional concrete slabs for the flooring. “We were concerned about the speed at which the project had to be done,” explains Pimentel. “For us to complete the project in the specified time period, we realised that we had to go the precast route and that was when we contacted ESA to get involved in the project negotiations.”

PRECAST SLABS SHAVE TIME OFF HOUSING PROJECTS “For us to complete the project in the specified time period, we realised that we had to go the precast route.”

planned and six months of construction time was shaved off the original expected completion date. “Using ESA’s products gave us substantial time savings, and the quality of the product is excellent,” says Pimentel. This is the second project that Boutel Projects has completed with ESA and the working relationship has proved mutually fruitful.

Craig Webber, director at ESA, says that his company’s intention right from

He adds that the biggest challenge

difficulty was in maintaining accurate

the outset has been to deliver a top-

the contractors were going to face on

measurements on each floor and keeping

quality product and service to clients

site was that two other trades needed

the building square,” Pimentel continues.

and to develop long-term working rela-

to complete their work first, in order for

Because ESA’s slabs are manufac-

tionships. “We are proud to be able to

the precast slabs to work as intended.

tured at its factory off site and are

take on a project of this magnitude and

“There was brickwork to be done and

produced to exact tolerances, there

deliver benefits for our clients. We look

the steel structure had to be completed

was little room for error on site. Despite

forward to working on more projects with

to support the precast concrete. The

these challenges, work progressed as

Boutel,” he says.

PRECAST | ISSUE TWO | 2015

Work has commenced on the Centenary Road expansion project, which is the first phase of the R84 billion Modderfontein New City development in north-eastern Johannesburg.

ments, “said Wayne Oliver, Technicrete

CMA member Technicrete was awarded

interlockers form an economical and

semi-mountable, mountable and rectan-

the contract to supply double zig-zag

hard-wearing surface offering longevity

gular kerbing is available. DZZ interlocking

(DZZ) interlocking paving blocks as well as

that will most definitely be required,”

paver applications range from domestic

kerbs for the Centenary Road expansion,

says Green.

driveways and commercial developments

sales representative.

Technicrete kerbs are ideal edge restraints and in addition to barrier kerbing,

which – when completed – will provide a

“Technicrete is delighted to have

through to heavy-duty loading bays and

much needed east-to-west road access

been awarded this prestigious contract

container terminals where forklifts and

with the K113 provincial road.

it is testimony to the fact that our

similar equipment are in regular use. The

ProBuild site agent, Wayne Green,

products are of a high quality while still

Modderfontein New City project is due

says: “T his is the f irst phase of a

being cost-competitive. Our 60mm DZZ

for completion in 2024.

massive project and Centenary Road,

interlocking paving blocks are well suited

when completed, will be carrying a very

to industrial and factory roads, making

large amount of traf fic. One of the

them particularly suitable for the Cente-

reasons Technicrete was chosen was

nary Road upgrade. We started to sup-

the quality and durability of its products

ply the 8 820m2 of grey DZZs in March

in conjunction with good service, delivery

2015, and this will continue through

and reliability.

to October of this year. We are also

“We have used Technicrete products

supplying 8 500m of 1 000mm barrier

before, with one three-year-old project

kerbing along with 16 000 units of grey

still in 100% per fect condition. Its

garden kerbing. All of these products

concrete precast kerbs are ideal for

are available in various colourings and

a project of this nature, while its DZZ

dimensions to suit a client’s require-

PROJECTS

CENTENARY ROAD PAVED

(Above): Centenary Road under construction in Modderfontein.

25

TECHNICAL 27

CURING CONCRETE IN

WINTER

greatly increases the risk of negative effects on strength and surface cracking compared with concrete cured at, say, 21°C. It is therefore recommended not to expose freshly placed concrete to extremely high temperatures, particularly during the early stages of curing.

Getting it right

Environmental conditions, particularly ambient temperatures, must be considered to achieve successful curing of concrete, says Bryan Perrie, managing director of The Concrete Institute.

concrete must be protected because

Temperature, relative humidity and

the detrimental effect on freshly placed

wind speed all affect the rate at which

concrete can be severe. “In areas where

moisture is lost from the surface of

particularly cold winters are experienced,

newly-cast concrete.

“In other areas, where the winter

than the rate at which bleed water can

Perrie says that like most chemical

mornings are very cold and the days

rise to the surface. Cracks may then

reactions, the rate of cement hydration

much war mer, concr e te should be

occur over the reinforcement closest

is affected by temperature. Hydration

placed during the morning to derive the

to the surface and, if left unattended,

stops at temperatur es just above

maximum benefit of the more amenable

act as channels for ingress of moisture

such as at very high altitudes, concrete

“The rate of moisture loss could cause

work should ideally be scheduled for

plastic shrinkage cracking, which occurs

during warmer days.

when the rate of evaporation is faster

freezing point and the concrete may suf fer damage due to the expansive action of the water forming ice in the pores of the concrete.

“At temperatures below 5°C, early strength is severely retarded and,

and other aggressive agents to the

“At temperatures below 5°C, early strength is severely retarded.”

whenever possible, care should be taken

reinforcement. Precautions against plastic shrinkage are required if the rate of evaporation is greater than about 1kg per m2 per hour,” Perrie states.

Finally, in dealing with the influence of the environment on the curing of

to avoid exposing fresh concrete to such

temperatures during the day. In some

concrete, relative humidity (RH) also

cold conditions. In cold weather, the

cases, the aggregates may be too cold

has a strong influence. “A very low RH

effect of wind chill on curing should also be

to add directly into the mixer, as this

increases the moisture gradient between

considered. This could make the surface of

could have a retarding effect on strength

the concrete and the air, so moisture

the concrete considerably colder than the

development,” Perrie advises. “So it’s a

loss becomes rapid. Particular care

air temperature would suggest.”

good idea to heat the mixing water and

must be taken in these conditions to

add it to the batched aggregates before

prevent excessive surface moisture loss

the cement is added to the mixer.”

resulting in a permanent impairment of

Timing is everything In winter, many parts of South Africa

Conversely, attempting to cure con-

experience freezing temperatures and

crete at temperatures of over 65°C,

PRECAST | ISSUE TWO | 2015

the quality of the resulting concrete,” he adds.

TECHNICAL

readymixer. As long as the concrete is properly specified, tested and handled on site, then incorrect mixes can simply be turned away. Likewise, concrete failures should be rectified by the concrete supplier if the concrete does not perform to specifications,” says Johan.

He adds that in most

28

instances, plants will also notice a signif icant improvement in consistency as readymix suppliers generally produce concrete in a carefully controlled and r egula t e d en v ir onmen t, enabling them to produce the same consistency of concrete time and again.

In addition, different products that require different mixes can be cast simultaneously from dif ferent mixers, whereas on-site batching and mixing plants usually find it difficult to do the same.

Insist on quality readymix

WHEN READYMIX

MAKES CENTS Small and medium-sized companies can double their production runs in certain instances by simply switching to readymix concrete instead of using traditional site mixed concrete.

The use of readymix concrete may not suit everyone, however, as large plants can cope mor e easil y with var y ing concrete requirements and may use quantities that are not feasible to be transported. Likewise, small plants using small moulds or producing low-strength products may not derive any benefit.

It also pays to use only SARMAaccredited suppliers who are regulated and comply to strict criteria set down by the association. In addition, companies have to undergo annual audits to prove

This is according to Johan van Wyk,

addition, manpower can be redeployed to

compliance with quality, as well as health,

general manager of CMA member

key production, storage or after-sales

safety, environment and road safety

Southern Africa Readymix Association

support duties.

requirements.

facilities have limited space and waste

Avoiding spoilage and waste

out! By dealing with SARMA-accredited

much of the available area for the storage

“Contrary to popular belief, it is also likely

members, CMA members can be assured

of sand, aggregates and concrete, as well

to cut the overall cost of concrete, as the

of consistent quality and high levels of

as having to cordon off areas for batching

exact quantity required can be ordered

service. Readymix also offers the benefit

and mixing of concrete.

and used as and when required. This has

of using less space, reducing labour,

When one calculates the amount

the potential to limit wastage and avoid

reducing capital equipment expenditure,

of space lost to actual pr oduction

surpluses or shortfalls occurring on the

eliminating waste and transferring the

activities, it makes sense to rather use

production line. Offsite mixing also limits

risk of making concrete to a third party

this area for production and leave the

the possibility of theft and spoilage of

supplier. Likewise, it allows faster start-

actual manufacture of concrete to a

products stored on site, which in many

ups and gives precast manufacturers

professional supplier. By concentrating

instances may be difficult to ascertain

agility in the design of mixes to produce

on the core business of casting and

or calculate.

many different types of products at the

(SARMA), who says that some production

“Quality in usually means quality

curing of products, plant operators can

“Another impor tant benefit that

add production lines, curing areas and

should be considered is the trans-

more to boost product throughput. In

fer of risk from the precaster to the

same time,” concludes Johan.

(Above, from left): Readymix concrete pour; Johan van Wyk, general manager of Sarma.

PRECAST | ISSUE TWO | 2015

CALL FOR AGGREGATE

STANDARDISATION Aggregate grading specifications are being reviewed by representative bodies in order to move the construction industry in Southern Africa towards tighter specifications that can be uniformly adopted by all sectors.

At the helm of the review process is

sation is required and that appropriate

CMA member Aggregate & Sand Pro-

tests and training need to be developed

ducers Association of Southern Africa

to ensure these can be accepted and

(ASPASA), which is seeking a common

implemented across the board.

grading system to be used across the board when ordering or specifying ag-

Consistency is needed

gregates for any purposes. At present

“Sampling methods need to be agreed

buyers can quote either SANS or the

upon and best practice should dictate

dated TMH or other specifications when

that all sampling be done in collabora-

ordering materials, leading to some con-

tion between the supplier and parties

fusion among suppliers and users alike.

responsible for specifying the mate-

“We have been approached by the

rials. With the right processes and

country’s major users of

pr ocedur es in place, it

aggregates including road

becomes easier to comply

agencies, metr opolitan

with clients’ requirements

and smaller municipalities,

and also to keep a record

as well as major consulting

of what was supplied.”

engineering firms to move

Pienaar says laborato-

the industry towards a

ries will also have a role to

common standar d. Ag-

play and will need to work

gregates make up by far

according to strict crite-

the largest component of

ria laid out in the specifi-

materials used (by volume) for any standard type of

(Above): Nico Pienaar of Aspasa.

cations to test materials.

The adoption of uniform

construction project. It is used to make

standards is the only way of ensuring

concrete, build paved roads and stabilise

consistent quality of materials is pro-

ground, etc.

duced to meet increasingly stringent requirements for building materials. The

Widely varying methods

association is therefore investigating

“But different professions have adopted

the use of a neutral professional labo-

their own standards and this leads to

ratory that will be used in the event of

problems wherever projects overlap

disputes arising to ensure fairness.

or where responsibility for projects

“We therefore urge all professional

is shared among companies who use

bodies in all industries – including con-

different standards.

sulting engineers, civil engineering con-

“In other instances, it may disadvan-

tractors, civil engineers, architects and

tage suppliers who produce products

specifiers – to make their voices heard

in accordance with opposing standards

and to support ASPASA,” he concludes.

and have equipment geared to producing aggregate products to these standards.

In the past aggregate suppliers have supplied aggregates to a certain specification, yet their products have been rejected at great cost and we want to avoid this where possible,” says Nico Pienaar, director of ASPASA. Speaking at a specially convened workshop of ASPASA, civil engineer Jacques Smith of GoConsult says that formali-

PRECAST | ISSUE TWO | 2015

(Above): Jacques Smith of GoConsult.

PRODUCTS

CMA member Aveng Infraset’s newly launched Villa, a dry-pressed flagstone paver, and York Cobble, a dry-pressed cobble paver, have been used to enhance the walkways at Jean Crossing, a recently completed shopping centre situated off Jean Avenue in Centurion, Gauteng.

30

Pick n Pay is the anchor retailer; the centre’s other well-known brands include Dis-Chem, Mugg & Bean, Burger King, McDonald’s and Nando’s. A total of 2 460m² Villa pavers and 405m² of York Cobble pavers were specified for the project. In addition, the open car park which flanks the centre was paved with 22 500m² of Aveng Infraset’s interlocking G-Blok pavers and about 2 000m² of York Cobbles, the latter h a v ing b e en use d t o dem ar c a t e a pedestrian walkway through the car park.

The pavers were specified by JL Design Architects and the paving contract was awarded to Pave Corner to Corner by the project’s main contractor and developer, Mike Buyskes Construction. According to Aveng Infraset landscape products sales manager, Brennan Small, this is the first time that both pavers have been used on a major project.

Perfect mix T he pa v ing pr oduc t mi x compr ised 2 250m² Villa Marble ( 250 x 500 x 60mm) which were combined with 210m² Villa Tan pavers (250 x 250 x 60mm). Four hundred and five square metres of York Cobbles in grey and charcoal were used for flower-bed edging and as accent lines between the Villa pavers.

Hennie Langeveld of Pave Corner to Corner said the Villa flagstone and

ADDING LUSTRE TO GAUTENG SHOPPING CENTRE

provides us with excellent personal and

York cobble combination of fered an

ing block plant manufacturers and our

aesthetically pleasing finish and was

new plant has introduced new, and in

more cost-effective than a wet cast

many instances, unique product options

paving alternative.

for landscape architects and other con-

back-up service, was an added bonus,” commented Langeveld.

Advanced manufacture Small says Villa and York Cobble pavers are manufactured at Aveng Infraset’s new Masa plant at Rossway, Midrand.

“Masa is one of the world’s most technically advanced paving and retain-

“The architects were impressed with

struction professionals. In addition to

what we achieved on this project and

the Villa and York Cobble ranges, it has

complimented Pave Corner to Corner

extended our landscape product offering

and Mike Buyskes Construction on our

to include exposed aggregate pavers and

combined input. The fact that Pave

kerbs. Moreover, the plant has also been

Corner to Corner also enjoys a good

used to upgrade our existing landscape

relationship with Aveng Infraset, which

paving range,” concluded Small.

(Above): Various combinations of Aveng Infraset’s Villa flagstone and York Cobble pavers enhance the pavement areas at Jean Crossing. The York Cobbles were used for flower-bed edging and as accent lines between the Villa flagstones.

steel production pallets for enhanced vi-

The state-of-the-art plant includes

(Left, from top) Aveng Infraset’s York Cobble pavers were used to create an attractive pedestrian walkway at the Jean Crossing car park; Aveng Infraset’s G-Bloks form an attractive and durable surface at the Jean Crossing car park.

bration transference, in-line washing and sealing, ageing and waving techniques and a specially insulated curing chamber. It also boasts a brand-new colour blending facility which is faster and more accurate than earlier-generation blenders.

PRECAST | ISSUE TWO | 2015

Joined segments of 32m of culverts lowered into place following overnight excavations.

MORE ADDED VALUES WITH CONCRETE BOX CULVERTS The use of concrete box culverts is

dia, zero-impact techniques have been

increasing around the world as a result

developed using regular concrete box

of the versatility of the products and

culverts to minimise impact on rail and

fast installation techniques that require

traffic systems. Techniques developed

less preparation than traditional culvert

by the company enable them to install

installations.

culverts rapidly overnight, if required,

Thanks to the built-in integrity of the

to avoid traffic ongestion.

box culvert, new installation techniques have been developed which add further

Quick and easy

value to the construction industry by

After the evening peak-hour traffic, the

dramatically reducing the installation

contractors rip the road, excavate and

time of underpassings of railroads and

place joined lengths of culverts in time

busy roadways.

to open the roads for morning traffic.

Thanks to pioneering efforts of Ital-

The concrete box culverts are made in

ian precast concrete producer, Coprem

segments of up to 2m length and these

srl, in the city of Bottanuco in Lombar-

are then joined with post-tensioned steel wires next to the worksite. The full-length monolithic structure is then simply lifted into place once the excavations have been done.

A couple of Coprem’s most prestigious zero-impact projects include a 32m underpassing of the A4 freeway formed by 16 sections of 1,25 x 2,0m culverts with a thickness of 25cm and total monolithic weight of 160 tonnes.

Another project involved a 12m underpassing of the A8 freeway formed by six sections of 2,75 x 3,0m culverts with a

(Above): Torben Mørch, HawkeyePedershaab director of global marketing.

PRECAST | ISSUE TWO | 2015

thickness of 25cm and a total monolithic weight of 100 tonnes.

PRODUCTS 32

Precast box culverts

load from the post-tensioning process.

The concrete box sections are manufac-

According to Torben Mørch, director

tured by the vertical precast process

of Global Marketing at HawkeyePeders-

using semi-dry concrete and vibration

haab, the use of concrete box culverts

machinery from the precast equipment

is increasing around the world and

machinery supplier and CMA member

he believes that sharing experiences

HawkeyePedershaab. This process allows

between the precast industries around

for casting concrete boxes with very high

the world can bring new and exciting

concrete strength able to withstand the

business opportunities from across

(Left): Joined segments of up to 18-20 metres of culverts can be placed in a single operation.

(Below): Drycast box culverts being manufactured using equipment from HawkeyePedershaab.

the globe.

“Actually, the boxes are made as standard box culverts with just a duct for the post-tension wire arranged in each of the four corners. Obviously, a lot of engineering is put into the design and planning of such a job, but the value for the local authorities who do not have to divert traffic for a longer period of time is enormous.

“HawkeyePedershaab has a long history in South Africa, with equipment installed at several of the precast factories in the country. By bringing new techniques and technologies to the country, we are hoping to provide our clients with innovative product offerings to stimulate and improve the market segments in which they operate,” Torben concludes.

BOOSTING PAVER PRODUCTION CMA member Enviro-Cast has acquired

in March this year. The second machine

a second Birkenmayer VB5 paving block-

began producing in June and will enable

making machine to meet strong demand

the company to meet increased demand

for concrete pavers from contractors

for interlocking and bevelled pavers.

and retailers within the greater Johan-

MD, Francois Uys, says that all

nesburg, East Rand and Vaal Triangle area.

Enviro-Cast’s products undergo strin-

Enviro-Cast was founded in 2014

gent daily tensile, strength and abra-

when it began manufacturing precast

sion tests in accordance with SABS

concrete kerbs together with wet cast

SANS1058 (2012) standards in its own

pavers such as cobbles and flagstones.

in-house laboratory.

The company later invested in its first Birkenmayer VB5 machine, commissioned

(Above): The Enviro-Cast storage yard in Meyerton, Gauteng.

MANHOLE MANUAL FOR MEMBERS The Concrete Manufacturers Association NPC has added a further manual to its existing list with the publication of a precast concrete manhole manual.

The publication provides guidance for specifying bodies, consultants and contracting organisations to the relevant SANS standards.

The manual was compiled by Tony Dutton, a professional engineer with contributions and input f r om CM A pr oducer members Aveng Inf raset, Civilworks, Concrete Units, Rocla and Southern Pipeline Contractors.

It is available from the CMA at a minimal charge. For more information or to buy a copy of the manual, contact Rita on tel: 011 805 6742 or email: admin@cma.org.za.

PRECAST | ISSUE TWO | 2015

PRODUCTS 35

JURAPAVER SPECIFIED FOR BRIDGE PARK Cape-based CMA member, Revelstone,

Cyprianos added that the Jura range

has supplied its Jura paving range for

forms part of Revelstone’s Engineered

the exterior surfaces at Bridge Park, a

product range, first launched in Sep-

new R450m office precinct development

tember 2014. “Our Engineered product

situated at Century City in Cape Town.

range offers architects and developers

This prestigious project involves the con-

tailor-made products which harmonise

struction of two “green” buildings with

with and offset some of the unique design

a combined space offering of 18 049m².

properties found in today’s architecture.

Revelstone director, Alex Cyprianos,

We kicked off the range with our Jura

says over 5 000m² Jura straight edge

pavers and tiles these were followed by

precast concrete pavers (680 x 440

parapet capping, pool and pond edging,

x 45mm) were supplied for paving the

Devon steps, kerbing and the new per-

perimeter walkways, as well as the

forated drainage paver.”

upper-level terraces.

The professional team on the Bridge

The charcoal, grey and carbon col-

Park project comprised: principal agent

oured pavers complement the dark glass,

– DHK Architects; quantity surveyor –

steel and concrete facades of the two

AECOM; consulting structural engineers

buildings. In addition, Revelstone’s suite

– Aurecon Group; consulting electrical

of complementary paving products which

and mechanical engineers – Aurecon

included Jura edging, special demarcation

Group; contracts manager – Murray

pavers, Devon steps, perforated and

& Roberts Construction and paving

etched straight edge pavers, as well as

contractor – Highland Paving.

steel-reinforced pavers for stormwater

Bridge Park is being jointly developed

drainage, were installed at Bridge Park.

by Growthpoint Properties and the Rabie

Cyprianos said the Jura straight edge

Property Group as Phase 1 of a Century

pavers were specified by the architects,

City expansion programme on Ratanga

DHK Architects, for three essential

Road in the Bridgeways precinct. It has

reasons: “Their straight edges make

been registered for a Green Star SA

them ideal for the straight jointing as

Office Design V1 rating with the Green

specified by the architects; safety –

Building Council of South Africa. There

the pavers come with a user-friendly

are three other “green” office blocks

non-slip finish; ease of maintenance –

at the Bridgeways Precinct and when

steel-reinforced pavers which can be

Bridge Park is completed, Bridgeways

easily lifted for cleaning purposes were

will be the first fully “green” precinct in

specified for the stormwater channels.”

South Africa.

PRECAST | ISSUE TWO | 2015

(Top, from left): One of the custom-designed demarcation pavers; Revelstone’s Jura straight edge precast concrete pavers clearly showing the straight jointing as specified by the architects.

(Above, from top): Jura edging kerb; a perforated Jurapaver; Jura tile versatility – as shown here, they can be cut and used for cladding, steps and risers.

GLOBAL VIEW 37

PRECAST IS TRENDING

ACROSS THE GLOBE Overseas trends reveal that precast concrete manufacturers are becoming more innovative in their approach to supplying products that harness all the benefits of precast concrete and potentially lighten the load of construction and building contractors.

tural materials to the degree that most

In addition, the advent of white cement

“There has never been a more exciting time to be involved in the precast industry and we are looking forward to a wave of innovation.�

and allowing more complex shapes to be

and improved post-tensioning techniques

concrete blocks for low-rise buildings,

using advanced new materials are over-

as well as ultra-lightweight concrete

Infrastructural advantage

coming previous strength and service-

precast products using carbon fibre

Looking at precast trends across the

ability problems.

reinforcing grids to save weight for

and v ar ious admi x tur es ar e gi v ing concrete extraordinary strength and appearance characteristics, leading to the increased use of precast concrete for architectural and decorative purposes.

Considering the limitations and complexities of casting forms in situ, the continuous advent of precast alternatives under factory conditions has enormous benefits and has the potential to evolutionise the construction industry to keep pace with the fast-moving nature of the 21st century.

large-scale infrastructure will be based on precast designs for faster and more efficient erection in future.

Already, self-compacting concrete is simplifying moulding of precast products cast. Reactive powder concrete is allowing more workable, ultra-strong concrete mixes without the need for coarse aggregates and can be manufactured with staggering compressive strengths of over 30 000psi, while tensile strength can be added with the inclusion of steel and synthetic fibres.

On-site logistics On the building front there are evolutions a-plenty, with lightweight aerated

globe, there is a clear move towards

Ultra-strong, fire- and corrosion-

precast for large-scale infrastructural

resistant post-tensioning materials

projects such as bridge decks, walls and

combined with new concrete mixes have

Load-bearing and insulated walls are

large-scale floor slabs, etc, where new

the potential to industrialise infrastruc-

currently in demand for domestic and

PRECAST | ISSUE TWO | 2015

structural purposes, as well as shipping and on-site handling.

GLOBAL VIEW

industrial building projects with the virtues of modular building becoming apparent across the developing world and in places like China, where high-rise apartments are making use of loadbearing walls cast on site, as well as insulated outside walls for unmatched

38

thermal properties.

Insulated concrete form (ICF) walls which use wood, polystyrene and other rigid materials, which is cast-in-place with concrete to assist insulation, is ensuring precast concrete remains a top contender for green building projects.

Simultaneously, tilt-up construction methods are becoming increasingly popular across the globe with “factory built” residential and industrial developments making greater use of these methods.

Inside and out A p ar t f r om w alls, pr e c as t er s ar e tak ing car e of internal structur es such as modern, aesthetically pleasing

“We are also seeing our members becoming more innovative and producing pioneering products to enter perceived niche markets, rather than relying on the same old product ranges.”

staircases and storage areas, as well as

stairs of different sizes and dimensions

floors and decor. The interior of a building

are being manufactured according to

is perhaps the most easily overlooked

standard sizes, while off-catalogue varie-

environment for the use of precast

ties are available with a longer lead time

materials, although – from a practicality

and obvious cost penalty, which in many

perspective – the interior fitting of a

instances is easily outweighed by the

house with precast products makes

convenience of precast. Precast counter

sense for contractors.

tops, bathroom fixtures and cladding

Staircases, for example, present many

products are also increasing in popularity

on-site problems for the builder, as floor-

and are eagerly used wherever precast

to-floor heights are different and radiuses

manufacturers make these available.

of curved stairwells can be a challenge.

Extensive propping and shuttering is usu-

Beautiful concrete

ally called for and needs to be designed and

The reason for the popularity of concrete

constructed by skilled individuals.

interior decor is largely as a result of

The in situ construction of a staircase

strides in the usage of concrete and

takes up a massive amount of space for

cement materials to enhance the beauty

materials and formwork, while concrete

of the product. White cement, colourful

spills and careless barrow-handling add to

aggregates and new polishing techniques

the mess and congestion in the very place

are making concrete precast products

where easy access to upper floors would

aesthetically desirable.

tical fibre to concrete mixes and lends a

enhance efficiency and project completion.

Even translucent “see-through” con-

new angle to the properties of concrete.

By comparison, precast concrete

crete is possible with the addition of op-

Thanks to this and other advances in concrete and precast technology, almost every part of a building can be supplied in precast form, from foundation piling to floors, walls, roofs, fitting and decor.

Infrastructural precast products are also set to make an even bigger impact on the construction industry with everything from roads to water infrastructure, earth stabilisation, bridges, dams and many others being manufactured by precaster. It seems the only limits to precast concrete today are of our own imaginations.

PRECAST | ISSUE TWO | 2015

Local market is positive

make them feasible. We are also seeing

In South Africa the call for simpler and

our members becoming more innovative

more efficient building and construction

and producing pioneering products to

methods is driving demand for new types

enter perceived niche markets, rather

of products to replace conventional

than relying on the same old product

bricks and mortar, as well as cast in

ranges,” says Frans.

situ structures.

He adds that building products in-

This has resulted in construction

cluding concrete window frames espe-

professionals working more closely with

cially for coastal regions, aesthetically

precast concrete manufacturers to

pleasing flooring products, concrete

develop systems that serve their needs

stone cladding and modular building

and addresses the challenge of meeting

systems using precast concrete prod-

ever-growing backlogs in infrastructural

ucts are some of the popular areas of

and housing developments, despite

development at present.

critical skills shortages.

According to Concrete Manufac-

Infrastructural assistance

turers Association (CMA) executive

Large construction and infrastructural

dir ec tor, Fr ans Minnaar, pr ecast

concrete products are also getting

concrete not only has the potential

more innovative, with new systems

to dramatically speed up

being developed and

construction, but also

adopted locally and from

lends a strong element of

abroad. The continued

professionalism to a pro-

adop tion o f sel f- com-

ject with factory-made

pacting concrete is also

quality assured products

driving higher efficiency

being used in on-site con-

among manuf actur er s

struction. Local concrete

who are able to operate

manufacturers also have

with more flexibility as

the infrastructure and

a result of the simpler

know-how to meet re-

requirement for moulds

quirements for products

and less cost-intensive

that meet specifications

resources required.

for performance, as well as aesthetics.

Innovation is key

(Above): Frans Minnaar of the CMA says precasters are beginning to work more closely with construction pundits.

In many instances, new techniques and additives are making previously impossible prod-

“The CMA is increasingly seeing mould

ucts possible and are allowing concrete

makers designing moulds to meet

to be used more widely for infrastruc-

increasingly technical architectural

tural application in power generation,

requirements and we are seeing pre-

chemical treatment plants and other

cast companies becoming more flexible

difficult applications. In addition, hybrid

in the types of products that they are

systems that make use of in situ cast

prepared to make for clients.

concrete in combination with precast

“Simultaneously, however, they need

products have the potential to make

to be mindful of the potential market

use of the best of both worlds for prac-

for their creations and weigh up the

ticality, speed and cost-effectiveness.

pros and cons of making an expensive

“There has never been a more excit-

mould for a potentially limited market.

ing time to be involved in the precast

At the moment there is a big market

industry and we are looking forward to

for well-made cladding products and

a wave of innovation among our CMA

even furniture that blends seamlessly

members. We are upbeat about the

with interior and exterior designs.

future of precast and encourage the

“We are even seeing manufacturers

construction and building industries to

making one-off products for specific

work with our members to find work-

clients and getting really innovative

able solutions to their challenges,”

with their mould designs in order to

concludes Frans.

PRECAST | ISSUE TWO | 2015

AROUND & ABOUT

Managing the maintenance budget within a Sectional Title or Full Title managed property throws up many challenges for the Trustees or Estate Managers, not least the requirement by owners that value for money and quality of work are achieved. Irene Glen Estate, in Centurion,

40

chose CMA member Technicrete paving for their road renovations instead of resurfacing it with tar.

Estate Manager Zelda Meyer says: “The main driveway around Irene Glen Estate needed some repair work, and we were faced with the dilemma as to whether we should resurface with asphalt

SECTIONAL TITLE CHOOSES PAVERS OVER TAR

or tar, or look towards using paving bricks.

The upgrade/repair and maintenance

replacing them with new pavers is what

offer not only an elegant appearance but

factors, going forward, were a deciding

gave Technicrete the edge at Irene Glen

also an economical solution. They are availa-

factor that made us go with the Techni-

Estate. One only replaces the section

ble in Grey, Autumn, Terracotta, Plum, Slate

crete Double Zig-Zag [DZZ] interlocking

under review, not the entire driveway,

and Tan colour options,” says Coetzee.

paving. Should maintenance be required

which ensures that the good and pro-

“The decision to use the DZZs on

in the future, we merely need to remove

fessional appearance remains intact,”

our road was also based on longevity –

the paving in question as opposed to re-

says ZS Coetzee, Technicrete’s Sales

interlocking pavers correctly installed

surfacing sections which always leaves

Consultant for the project.

will last longer than asphalt – and the

indentations and a non-unified appear-

“We supplied 17 000m2 of 60 DZZ

ease of upkeep. We believe the paving

ance. It made budgetary sense to use the

grey interlocking pavers to the estate’s

has been a worthwhile investment for

paving option”.

contractor, Vesles Civils. Our DZZs are

Irene Glen Estate, and we are happy with

“The simplicity of removing any dam-

exceptionally hard-wearing and form a

the finished look. It looks neat, tidy and

aged interlocking pavers and merely

continuous smooth surface overlay, which

smart” says Meyer.

MODERN PIPE PLANT FOR ZIMBABWE CM A memb er e quipmen t supplier HawkeyePedershaab recently supplied and commissioned a state-of-the-art (Above): Chairman of Hume Pipe Co Ltd Wilson Manase.

new pipe manufacturing plant for the Hume Pipe Co Ltd in Harare.

Plans for the new plant were conceived in 2010 when the company reached a crossroads with demand for its concrete pipes far outstripping the production capacity of its two plants in Harare and Bulawayo. After extensive research and travels, the company’s management team decided to invest in a completely new pipe factory based on VIHY production technology for the manufacture of regular concrete pipes, as well as HDPE lined concrete pipes.

The plant was commissioned in 2013 and Hume Pipe Co Ltd is running at high capacity, delivering state-of-the-art concrete pipes to the Zimbabwean market.

Plant description The initial scope of supply of HawkeyePedershaab included a double station VIHY Multicast SCC 250, mould equipment for 450-2300mm diameter pipes, equipment for lining the pipes with HDPE sheets, pipe handling equipment, automatic concrete batching and mixing plant, cage welding machinery and concrete laboratory equipment.

The co-operation between Hume Pipe Co Ltd and HawkeyePedershaab was based on a turnkey concept, meaning that HawkeyePedershaab supplied everything directly and handled all project management, shipping and commissioning.

“HawkeyePedershaab are experts within the field of building pipe plants, so I was very comfortable letting them handle the entire project. Throughout the whole project period, we worked with a single contact person and this made everything much easier for us. And now after the commissioning, they have completed everything to our full satisfaction,” says Chairman of Hume Pipe Co Ltd Wilson Manase.

(Above): VIHY Multicast SCC 250 installed at Hume Pipe Co Ltd in Harare, Zimbabwe.

PRECAST | ISSUE TWO | 2015

AROUND & ABOUT 42

AFRISAM CATERS TO PRECAST MANUFACTURERS CMA member AfriSam’s offering to con-

“In the CPM market we focus on as-

crete precast manufacturers (CPMs)

sisting our customers to operate as

operating in today’s highly competitive

efficiently as possible,” Mike McDonald,

marketplace incorporates several value-

manager of AfriSam’s Centre of Product

adds designed to improve the perfor-

Excellence, says. “This involves evaluat-

mance of their products and help to

ing their existing mix designs and helping

contain costs.

them to reduce unnecessarily costly

Underpinning the primary

components without compro-

products supplied to this mar-

mising the quality of the end

ket, Rapid Hard Cement in the

product. For example, certain

52.5R strength class, High

customers have successfully

Strength Cement in the 42.5R

switched to our SlagCem

strength class in the northern

42.5N product available from

market and a 52.5N prod-

our Vanderbijlpark plant, a

uct in the southern market,

cost-effective alternative

AfriSam’s value-adds include

to High Strength Cement in

on-site technical services

this market.

to determine the ideal mix designs for

“ T her e is no a one -siz e -f i t s- all

customers’ specific applications and

approach in the CPM market, so we

propose aggregates that meet these re-

draw from all the alternatives available

quirements. SANS-accredited laboratory

to provide the most cost-ef fective

services are also available to verify and

solution for each customer. We value

test the efficiency of mixes and product

our CPMs and we’re committed to

deliveries can be specifically scheduled

building relationships that will give them

to suit customers’ individual activities.

a competitive edge.”

(Left): AfriSam’s Rapid Hard Cement has been developed for specialist concrete product manufacturers.

(Above, from top): AfriSam’s value-add to concrete precast manufacturers includes on-site technical service, SANS-accredited laboratory services and product deliveries to suit customers’ requirements; AfriSam is the only company that manufactures 52.5 Rapid Hard Cement, ideal for applications such as highway barriers, roof tiles, retaining wall systems, culverts and concrete pipes, as a standard product.

AROUND & ABOUT 43

WATERPROOFING RETAINING WALLS AND ROOFS Mapei South Africa recently launched

able for all types of concrete and cellular

that the membrane was not coping on a

Plastimul 2K Reactive, a solvent-free, eco-

concrete surface, limestone, pumice,

roof that was cluttered with pipes, vents

compatible, bitumen waterproofing emul-

lightweight brick and breeze-block ma-

and skylights.

sion that extends its range of well-proven

sonry, render and screeds.

solutions for waterproofing challenges.

Plastimul 2K Reactive provided a

An example of the performance char-

tough, fully-cured membrane with a high

Another technology innovation from

acteristics of Plastimul 2K Reactive

elasticity and crack-bridging capacity

the Mapei group, Plastimul 2K Reactive is

was its use to solve a long-standing

that prevented ingress of water even

a two-component emulsion that is applied

problem in the concrete roof of a sec-

at high positive pressures. “This is an

by airless spray to give immediate wa-

ondary school in Danville Park, Durban.

exciting new product for our waterproof-

terproofing of structures below ground

Mapei South Africa-approved applica-

ing industry,” says Mapei South Africa’s

such as the outside of foundations and

tor, Stonehaven Projects, was asked to

product manager, Paul Nieuwoudt.

retaining walls, as well as virtually any

find a solution for the continual leakage

horizontal and vertical surfaces that are

being experienced through the existing

not exposed to UV. The product is suit-

torch-on membrane. The situation was

(Above, from left): Plastimul 2K is ideal for retaining walls and concrete roofs; Mapei’s Plastimul 2K offers spray-on application.

A GOOD YEAR FOR ISG “The Infrastructure Specialist Group [ISG], as a new entity, has delivered a stable, yet optimistic performance in a tough economic environment in its first year,” says chief executive officer, Albert Weber.

“We have managed our revenue and improved our operational efficiencies in our three well-branded entities, namely, Technicrete, Ocon Brick and Rocla. The biggest challenge faced by the group was (Above): Albert Weber, CEO of ISG.

introducing ISG as the new holding company for these iconic brands. I believe we

have made positive inroads in this regard.”

The three businesses, which operate in markets where overcapacity is the order of the day, still made a steady contribution to ISG’s financial results. CMA member Technicrete’s improved performance can be attributed to greater efficiencies at its factories and capacity expansion at its North West and Mpumalanga facilities.

The high demand by the private sector for clay stock bricks enhanced Ocon Bricks’ already established market footprint, while CMA member Rocla sought new opportunities through the manufacture of 128 unique concrete containers destined for the renewable energy sector in the Northern Cape.

“Our short-term strategies were to manage costs, increase competitiveness and increase market share in a shrinking market and as a management team we are satisfied with the outcome, but we will not rest on our laurels – there is more to focus on going forward.

“The South African governments’ spend on infrastructure has not reached levels anticipated, but we are confident that it will increase in order for the government to fulfill promises of service delivery to the South African population. The future is not without its challenges, but we have the products, technology, technical support and, above all, the people to continue on this positive growth paths,” says Weber.

PRECAST | ISSUE TWO | 2015

All grEAT ThingS WErE crEATED WiTh concrETE Ø Ø 300 bc

PRECAST PRODUCTS FOR AFRICA Rocla and Technicrete were among the members who joined forces with the Concrete Manufacturers Association (CMA) to co-sponsor an information stand at the Totally Concrete Exhibition & Conference held in Sandton recently.

The theme of the CMA stand was “Precast Concrete Solutions”, which afforded both Rocla and Technicrete the opportunity to promote their key technologies and product offerings. Group marketing and communications manager, Guinevere Thomas says:

Ø Ø 2014

“As members of the CMA, it made sense to join hands with the CMA on a co-sponsored exhibition stand. Jointly we attracted many visitors, enabling us to engage not only with our current customers, but also to also explain our services, manufacturing operations and range of precast products to new contacts.”

Rocla, well known for its infrastructure products, showcased its spun concrete poles; concrete cabins; rainwater harvesting options; pressure pipes; stormwater culverts; precast walling and concrete oil separators. Recently, Rocla had manufactured and supplied 128 concrete cabins that had been specifically commissioned for local photo-voltaic farms.

Beany Blocks, retaining walls and precast palisade fencing, as well as paving options that included Double Zig-Zag (DZZ), Armorflex and Cobble Bond products, were highlighted by sister company Technicrete. Many of the Technicrete paving options offer customers a durable and economic solution to walling and paving requirements.

Technicrete and Rocla are two of South Africa’s iconic brands in the construction and building sectors and are part of the Infrastructure Specialists Group, which also includes Ocon Brick, manufacturer of clay stock bricks and clay semi-face bricks.

(Above): Technicrete DZZ interlocking pavers.

Designed in South Africa for South African conditions Tel: 011 393 5504 | Fax: 011 393 5502 E-mail: remacon@telkomsa.net | Website: www.remacon.co.za (Above): A Rocla cabin comes off the manufacturing line.

Visit our website for more information: www.yfel.co.za

PRECAST | ISSUE TWO | 2015

A slow and steady recovery in the con-

government’s R800 billion infrastructure

more positive sentiment to the market.

struction industry is being predicted over

investment plans for the period up to

Simultaneously, the increasing demand

the next five years, with gradually re-

2020, and its promise to build 1,5 million

is also leading to a large number of new

turning business confidence driving new

RDP houses by the same period (at a cost

operators establishing themselves in the

investments in the industry

of over R30 billion per annum),

sector, which is effectively absorbing any

and its key suppliers.

is proving to be a big incentive

real growth that the established players

for investment in the building

would otherwise have enjoyed.

As the largest supplier of materials for construc-

materials industry.

tion projects, the readymix concrete industry is seeing

Investment returning

increasing investment in the

According to a recent report

market in anticipation of more

compiled by BMI on behalf of

buoyant and profitable times in future. Large cement sup-

(Above): Nico Pienaar.

the Southern Africa Readymix Association and the closely

pliers have already made acquisitions of

allied Aggregate & Sand Producers

some of the major readymix companies

Association of Southern Africa, tough

and talks are apparently afoot for more

market conditions since the worldwide

acquisitions and mergers at the top end

recession have led to under-utilisation

of the market.

of manufacturers’ capacity. In addi-

The reasons for the shift in optimism

tion, they have stifled investment in the

are based on a number of positive fac-

construction and related industries and

tors that are seeping into the market

led to some stagnation of the readymix

in the form of a rising number of plans

concrete industry.

being passed and far easier access to

Positive growth signs and returning

mortgage bonds. In addition, the allure of

investment, however, are bringing back a

(Above): Readymix concrete allows for some innovative precast building techniques to be used

AROUND & ABOUT

PREDICTING GROWTH BEYOND 2020

47

MEMBER LIST 48

PRODUCER MEMBERS A FICK SEMENTWERKE BK Tel: 022 913 2370 Province/Country: Western Cape Pillar: PB AVENG MANUFACTURING INFRASET (12) Tel: 011 876 5500 Province/Country: Gauteng Pillar: PB/PI

Province/Country: Western Cape Pillar: PB MONIER ROOFING SOUTH AFRICA (10) Tel: 011 222 7300 Province/Country: Gauteng Pillar: PB MVA BRICKS Tel: 012 386 0050 Province/Country: Gauteng Pillar: PI

BAY BRICK Tel: 035 792 5218 Province/Country: KwaZulu-Natal Pillar: PB

PANDA GROUP (2) Tel: 00267 244 2107 Province/Country: Botswana Pillar: PB/PI

BOSUN BRICK (2) Tel: 011 310 1176 Province/Country: Gauteng Pillar: PI

PORTLAND HOLLOWCORE SLABS (PTY) LTD Tel: 021 972 1111 Province/Country: Western Cape Pillar: PB

BRICKCAST INDUSTRIES CC Tel: 031 507 5525 Province/Country: KwaZulu-Natal Pillar: PI C.E.L PAVING PRODUCTS Tel: 021 905 5998 Privince/Country: Western Cape Pillar: PI CIVIL WORKS Tel: 011 903 7023 Province/Country: Gauteng Pillar: PI CONCRETE UNITS (2) Tel: 016 362 2236/021 386 1923 Province/Country: Western Cape/ Gauteng Pillar: PB/PI

REMACON PRODUCTS CC Tel: 011 393 5504 Province/Country: Gauteng Pillar: PI REVELSTONE (CAPE) (PTY) LTD Tel: 021 761 9739 Province/Country: Western Cape Pillar: PB ROCLA (12) Tel: 011 670 7600 Province/Country: Gauteng Pillar: PB/PI

ARQ CONSULTING ENGINEERS (PTY) LTD Tel: 012 348 6668 Province/Country: Gauteng BRITISH PRECAST CONCRETE FEDERATION Tel: 044 116 253 6161 Province/Country: United Kingdom CONCRETE PLANT INTERNATIONAL Province/ Country: Germany CONCRETE SOCIETY OF SOUTH AFRICA Tel: 012 348 5305 Province/Country: Gauteng ILIFA AFRICA ENGINEERS (PTY) LTD Tel: 012 362 1473 Province/Country: Gauteng JC PAVING CONSULTING Tel: 011 431 0727 Province/Country: Gauteng SEKHUKHUNE & ASSOCIATES Tel: 012 993 4776 Province/Country: Gauteng SNA CIVIL & STRUCTURAL ENG Tel: 012 842 000 Province/Country: Gauteng SARMA Tel: 011 791 3327 Province/Country: Gauteng

SHUKUMA BRICKS Tel: 041 372 1013 Province/Country: Eastern Cape Pillar: PB

TACO VOOGT CONSULTING ENGINEERS Tel: 079 505 7840 Province/Country: Gauteng

CONFRAMAT Tel: 0861 33 5599 Province/Country: Gauteng Pillar: PB/PI

SILVERTON PRECAST (PTY) LTD Tel: 012 804 4525 Province/Country: Gauteng Pillar: PB

THE JOB CLUB Tel: 012 661 1099 Province/Country: Gauteng

COROBRIK (PTY) LTD Tel: 031 560 3111 Province/Country: KwaZulu-Natal Pillar: PI

SIMSTONE (PTY) LTD (2) Tel: 016 362 2181 Province/Country: Gauteng/ Eastern Cape Pillar: PB/PI

DERANCO PRECAST Tel: 041 933 2755 Province/Country: Eastern Cape Pillar: PB/PI EAGLE ROOF TILES (PTY) LTD (4) Tel: 044 874 0290 Province/Country: Western Cape Pillar: PB ECHO GROUP (3) Tel: 011 589 8800/8899 Province/Country: Gauteng Pillar: PB ENVIRO–CAST (PTY) LTD Tel: 016 004 0018 Province/Country: Gauteng Pillar: PI FASTDECK (PTY) LTD Tel: 002677 3971974 Province/Country: Botswana Pillar: PB INCA MASONRY PRODUCTS (2) Tel: 043 745 1215 Province/Country: Eastern Cape Pillar: PB/PI KEYSTONE WALLING Tel: 082 850 3512 Province/Country: Gauteng Pillar: PB/PI LATEGAN CEMENT WORKS Tel: 021 873 1154 Province/Country: Western Cape Pillar: PB MARLEY ROOFING (6) Tel: 011 316 2121 Province/Country: Gauteng Pillar: PB MOBICAST (PTY) LTD Tel: 044 874 2268

SMARTSTONE (13) Tel: 011 310 1161 Province/Country: Gauteng Pillar: PB SOUTHERN PIPELINE CONTRACTORS Tel: 011 914 8500 Province/Country: Gauteng Pillar: PB/PI SWAKOP TILES CC T/A NAMIB ROOF TILE COMPANY Tel: 00264 6446 3717 Province/Country: Namibia Pillar: PB TECHNICRETE (6) Tel: 011 674 6900 Province/Country: Gauteng Pillar: PB/PI TOPFLOOR CONCRETE (2) Tel: 021 951 7700 Province/Country: Western Cape Pillar: PB VAKA CONCRETE (PTY) LTD (2) Tel: +263 864 4088 100 Province/Country: Zimbabwe Pillar: PI VANSTONE PRECAST (PTY) LTD Tel: 012 541 2056/1808 Province/Country: Gauteng Pillar: PI WEST END CEMENT BRICKS (PTY) LTD Tel: 011 851 1005/1063 Province/Country: Gauteng Pillar: PI ASSOCIATE MEMBERS ASPASA Tel: 011 791 3327 Province/Country: Gauteng

TERRAFORCE (PTY) LTD Tel: 021 465 1907 Province/Country: Western Cape TJEKA TRAINING MATTERS Tel: 011 665 2777 Province/Country: Gauteng YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS Tel: 031 207 7252 Province/Country: KwaZulu-Natal NON-PRODUCER MEMBERS ABEL EQUIPMENT Tel: 044 874 1876 Province/Country: Western Cape ASH RESOURCES (PTY) LTD Tel: 011 657 0230 Province/Country: Gauteng H BIRKENMAYER (PTY) LTD Tel: 011 970 3880 Province/Country: Gauteng CHRYSO SOUTHERN AFRICA (PTY) LTD Tel: 011 395 9700 Province/Country: Gauteng DOUBELL BRICK MACHINES Tel: 041 585 9060 Province/Country: Eastern Cape DELTA BLOC SOUTH AFRICA (PTY) LTD Tel: 011 024 4604 Province/Country: Gauteng DICK KING LAB SUPPLIES Tel: 011 499 9400 Province/Country: Gauteng HAWKEYEPEDERSHAAB Tel: 00 45 9645 4040 Province/Country: Denmark HYDRAFORM INTERNATIONAL (PTY) LTD Tel: 011 913 1449 Province/Country: Gauteng

KAYTECH Tel: 031 717 2300 Province/Country: KwaZulu-Natal KERNEOS SOUTHERN AFRICA (PTY) LTD Tel: 011 444 3090 Province/Country: Gauteng KOBRA MOULDS BV Tel: 003111 356 2460 Province/Country: Netherlands MANITOU SA (PTY) LTD Tel: 011 975 7770 Province/Country: Gauteng OCEM Tel: 0039 055 658 0120 Province/Country: Italy PAN MIXERS SA LTD Tel: 011 578 8600/8701 Province/Country: Gauteng PEGASO STAMPI SRI Tel: +39 0577 992635 Province/Country: Italy QUADRA Tel: 0033 67941 2644 Province/Country: France QUANGONG MACHINERY CO LTD Tel: 00865 958 679 9299 Province/Country: China SAMJUNG INDUSTRIES LTD Tel: 0082542607722 Province/Country: Korea SCHLÜSSELBAUER TECHNOLOGY GMBH & CO KG Tel: 004377357144 201 Province/Country: Austria SIKA SOUTH AFRICA (PTY) LTD Tel: 031 792 6500 Province/Country: KwaZulu-Natal TECHMATIK SA Tel: 00484 803 690 811 Province/Country: Poland CEMENT MEMBERS AFRISAM SOUTH AFRICA 011 670 5500 Province/Country: Gauteng LAFARGE INDUSTRIES South Africa (PTY) Ltd 011 657 0000 Province/Country: Gauteng PPC LTD Tel: 011 386 9000 Province/Country: Gauteng SEPHAKU CEMENT Tel: 012 684 6300 Province/Country: Gauteng CONTRACTOR MEMBERS DECORTON RETAINING SYSTEMS Tel: 021 875 5155 Province/Country: Western Cape FRICTION RETAINING STRUCTURES (PTY) LTD Tel: 011 608 4321 Province/Country: Gauteng POWERGATE CONSTRUCTION Tel: 071 603 5070 Province/Country: Gauteng PYW PAVING Tel: 031 903 1736 Province/Country: KwaZulu-Natal VALCAL INTERNATIONAL EXPORT Tel: 011 867 2471 Province/Country: Gauteng

PI - Precast Infrastructure PB - Precast Building (...) - Number of branches

PRECAST | ISSUE TWO | 2015