ISSUE TWO • 2016
THE CMA – QUALITY CAST IN CONCRETE
• CMA CS undertakes first audits • Creating safer workplaces • Seawall protects Strand
MEMBER ASSISTS THE NEEDY
NEW LEADERSHIP FOR EQUIPMENT MANFACTURER
ANIMAL RESCUE FUNDS RAISED
2 COVER STORY 2
RUSTENBURG PLANT GETS ADVANCED EQUIPMENT
PPC EARNINGS UP
AROUND & ABOUT 28
TOTALLY CONCRETE IN PICTURES
SPECTACULAR TERRACED GARDEN
CREATING SAFER WORKPLACES
GLOBAL VIEW 22
ESTABLISHING AN ENVIABLE REPUTATION
INDUSTRY NEWS 5
CMA IS ON TRACK
TAKING THE CMA TO THE WORLD
CMA CS FIRST AUDITS UNDERTAKEN
RETAINING WALL SECURES PROPERTY
BROADER APPEAL FOR READYMIX CONFERENCE
GEARING FOR NEXT YEAR’S FULTONS
WELCOME NEW PRESIDENT
USES FOR THE YFEL
ENTRIES OPEN FOR IMAGINARIUM AWARDS
FASTER FORMWORK WITH MAGNETS
PRECAST is the official journal of the Concrete Manufacturers Association NPC (CMA)
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33 PROJECTS 34
STRAND WATERFRONT PROTECTED
SMART NEW PAVING FOR CLINIC
WITS’ SMART MASONRY DECISION
CENTURY CIT Y DEVELOPMENT
NAVAL SECURIT Y WALL
ISSUE TWO • 2016
THE CMA – QUALITY CAST IN CONCRETE
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 Publisher: Andrew Meyer Tel: +(+27 11) 883 4627 Cell: 082 456 5175 E-mail: firstname.lastname@example.org Consulting editor: Raymond Campling Tel: 076 297 2775 Email: email@example.com
PRECAST | ISSUE TWO | 2016
Design and layout: Joanne Brook Tel: (+27 11) 883 4627 E-mail: firstname.lastname@example.org The views and statements expressed in this publication are not necessarily those of the editor or the publishers and neither the publishers nor the CMA accept responsibility for them. No person connected with the publication of this journal will be liable for any loss or damage sustained as a result of action following any statements or opinions expressed herein. The same applies to all advertising. Precast© 2015. All rights reserved. No part of this magazine may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage retrieval system, without prior written permission from the publishers.
• CMA CS undertakes first audits • Creating safer workplaces • Seawall protects Strand
ON THE COVER In a short space of time newcomer Enviro-Cast has built up an enviable reputation for its ability to deliver good quality products on time and to specification. Its lean manufacturing principals combined with efficient transport systems enables the company to reach out and deliver costeffective products to a wide geographical area. As a result, the company’s products are becom-
ing sought after on a growing number of construction site across the country.
COVER STORY 2
Specialist precast concrete manufacturer Enviro-Cast is rapidly establishing itself as a trusted supplier of both volume-based as well as technically challenging products. In the two years since opening its factory, the CMA member has focused on developing smar t manufacturing techniques that deliver high-quality
and the company is currently enjoying
unprecedented growth of revenue, as
developing and improving processes in
port costs, so we can sell our products
well as expanding its customer base
order to make the best possible products
to distant customers at prices that are
across the country.
without wastage or unnecessary costs.
still competitive, compared with local
products to its clients on time and to specification. While initially cumbersome to implement, these efforts are now clearly paying dividends in terms of quality
Simultaneously, Enviro-Cast’s invest-
“We run a lean manufacturing plant
ment in developing technical skills has also
using the right equipment and materials in
suppliers in the area,” says Metzer.
enabled it to take on techni-
the right applications. Likewise,
cally challenging projects with
we build good relationships with
In addition, the company owns its own
confidence. In fact, in its short
our core suppliers in order to
fleet of delivery vehicles which further
existence, the company has
get the best value and qual-
drives down expenses, compared with
already successfully completed
ity raw materials to suit our
outsourced freighting costs. Another
many custom projects which
cost-cutting factor is Enviro-Cast’s
have considerably bolstered
“In doing so, we’re able to
investment in high-tech peripheral
its resumé and supported its
significantly reduce the cost
machinery in order to support its two
of manufacturing products and
large-scale. semi-automated brick manu-
bring a technically superior,
facturing machines, as well as its wet and
high-quality product to market
semi-dry manufacturing plants.
Reducing costs Company CEO, Craig Metzer,
(Above): Craig Metzer, the CEO of Enviro-Cast.
at a far more competitive price
attributes the success of the company
than our competitors. Another positive
to the fact that there are no shortcuts
benefit of this type of manufacturing is
at Enviro-Cast and a lot of money is spent
that savings can be offset against trans-
(Top, from left): Enviro-Cast manufactures highquality wet and semi-dry products, in addition to concrete pavers; specialised manufacturing of customised products.
PRECAST | ISSUE TWO | 2016
pack 42 x 13 brick pallets in minutes, rather than hours when done manually. Other purpose-built weighing, dosing and batching equipment also speeds up the process and ensures that the plant runs like clockwork – even at full production. Enviro-Cast’s brick-making machines
T his includes the use of a highspeed Abel packaging machine that can
“We have a young and innovative company that takes pride in the products we make and deliver.”
are able to produce 2 400m² of concrete
our manufacturing process to get each
pavers per day, while semi-automated
of our products optimal,” says Metzer.
and manual processes for other types of
“Between me, our production man-
products ensure a healthy daily output of
ager, Malcolm Armstrong and our tech-
a wide variety of products. These include
nical and production teams, we have a
kerbs, pavers, semi-dry-cast pavers,
long history and good experience in the
wet-cast pavers, copings, cladding and
business of making precast concrete.
special orders for clients. Engineered or
Ensuring quality and consistency in our
custom products manufactured thus far
products is part of Enviro-Cast’s culture
include high-strength reinforced kerbs,
and is upheld throughout the organisa-
raised barrier kerbs for BRT in Ekurhuleni
tion’s various departments.”
He adds that Enviro-Cast’s products
quality and strength. “That’s why we’re
are highly sought after, as it guaran-
so highly regarded and why we’re credited
tees its products’ compliane with client
with making some of the best pavers
specifications. Test are done on site
and blocks in the business, according to
“We’re a young and innovative company
in the company’s fully-fitted, in-house
industry insiders,” says Metzer.
that takes pride in the products we make
laboratory to ensure concrete mixes and
and deliver. Through our process of ongo-
products are manufactured within speci-
ing improvement, we constantly refine
fied parameters to ensure consistent
and Rustenburg, electrical plinths and bollards for traffic control.
(Above): At full production, Enviro-Cast’s brick-making machines can produce 2 400m² of concrete pavers per day.
THE CMA IS ON TRACK The Concrete Manufacturers’ Association (CMA) NPC recently conducted a number of well-attended member feedback sessions and quality assurance workshops around the country.
The meetings were presented by CMA executive director Frans Minnaar and Christo van Zyl, general manager of the newly-formed precast concrete quality assurance certification company, CMA Certification Services. In introducing Van Zyl, Minnaar said there was huge interest in CMA Certification Services, and although the company has only begun operating, he mentioned that several applications for the CMA product certification had already been received and that he anticipated rapid growth as soon as the new company was officially launched. New company CMA Certification Services will be run as an entirely separate entity, focusing solely on certification audits. The CMA’s normal promotion of precast concrete will not be affected in any way. Apart from informing members about the CMA Certification Services of fering, the workshops were held to answer questions and address members’ concerns. Minnaar advised that the CMA mark is not exclusive to CMA members, which means any precast concrete manufacturer can ap-
and the revision of existing
has applied to the South African National
standards in close collabora-
Standards Authority (SANAS) for SANS
tion with associations such as
17065 accreditation. Although SANS
the CMA. SABS also provides its
17065 accreditation is only required by
own certification services.
certification entities which audit regulated products such as cement, the fact
ply for certification. However, CMA Certification Services activities will
that CMA Certification Services will be
be restricted to the precast concrete
In providing an alternative certification
SANS 17065-accredited lends consider-
industry and CMA members will qualify
service, CMA Certification Services will
able weight to its auditing competency
for fee discounts.
comply with SANS 17065, the national
Van Zyl explained that all national
standard for certification bodies and it
Moreover, tender requirements will
specifications belong to SA and are re-
not be affected by the new CMA Product
ferred to as SANS specifications, as op-
Certification Mark, as it will comply with
posed to the period prior to 1994, when
all the requirements for a certification
all specifications were owned by the SA
body. There will be no difference between
Bureau of Standards and were referred
the CMA Mark of Approval and those of
to as SABS specifications. However, the
other certification providers and it will
bureau is still used by the Department of
enjoy the same level of competence as
Trade & Industry as a publisher of SANS
any other certification body.
specifications and a service provider.
Van Zyl advised that CMA Certifi-
For example, although it no longer owns
cation Services will be conducting an
the standards, SABS is still very much involved in the drafting of new standards
PRECAST | ISSUE TWO | 2016
(Above): CMA executive director Frans Minnaar during his feedback presentation in Cape Town.
extensive marketing strategy to alert all precast concrete role-players and
associated professionals about the entry of a new certification provider to the market. He also explained in considerable detail what the CMA certification process entailed. Creating competition Van Zyl wrapped up his presentation by
saying that it is not the CMA’s intention to change the status quo or to challenge the certification business for the sake of it. Rather, by introducing another service provider into the precast concrete certification arena – and, with it, competition – service providers will be more alert and creative, which will be to the benefit of all precast concrete producers and the public at large. Minnaar added that once CMA Cer-
standard on which the SABS standards
tification Services is well established,
were originally based is no longer valid.
it will also investigate the possibility of
The new standard SANS 50771-3:2015
providing an ISO certification service.
will be based on the European standard
Furthermore, it is well placed to handle
and SANS 1215 is being withdrawn. The
an increase in demand for its existing
new standard is imminent.
certification services and it has a list of
Minor changes and administrative re-
additional auditors waiting in the wings.
visions were made to SANS 542:2015 for
Before being appointed, new auditors will
concrete roofing tiles. SANS 541:2012
undergo a strict assessment procedure
precast concrete slabs was also scruti-
to ensure they comply with all the SANAS
nised and contradictory wear and abra-
sion requirements were amended after
Once product manufacturers obtain
the specification was changed. It was
the CMA Mark of Approval, they will be
also found that the necessary testing
posted on the CMA’s website, together
equipment was not available in the coun-
with a list of all the other product manu-
try. A request for the complete overhaul
facturers. Certification will be valid for
of the SANS 541 has been submitted to
three years and after the initial assess-
the SABS. SANS 937:2013 concrete
ment follow-up, audits will take place
kerbs, edgings and channels has also
been revised. SABS’ Auditing Division has recently
undertook to initiate the drafting of an
clamped down on CMA members’ inter-
All the standards on requirement for
installation manual for wetcast products.
pretation of the standards on aggregates and water. The CMA is working on
precast concrete raw materials are up for review. Taco Voogt heads the CMA’s
changing the specifications for water,
Technical Committee and represents the
A workgroup was created for SANS
but the ratification process of workgroup
CMA on SABS technical committees and
1058: 2012 on concrete paving blocks.
members is still underway. This has led to
workgroups. He serves on TC 0081– the
Concrete aggregate requirements as
certifications being withheld on products
Cement Lime & Concrete Committee – as
per SANS 1083 were reviewed and the
that were previously deemed to conform.
well as several sub-committees under TC
water absorption requirement was taken
0081 on materials, products and test
out of the main body of SANS 1058 and
The past year
methods. Sub-committee workgroups
moved to the annex as a recommendation
Besides the initiatives described above,
include members from the precast in-
only. Greater clarity on measuring the
the association enjoyed a productive
dustry who assist with the initiation of
length of pavers for the tensile splitting
2015. Membership-drive roadshows
new specifications and the revision of
test was achieved and the K factor was
were held in Durban and the KZN Mid-
removed. The amendments are awaiting
lands, as well as in Limpopo’s Polokwane
ratification by the SABS.
and Tzaneen. This was the first time that
In the past all standards were reviewed every two years, but at different
A SANS 1215: 2008 concrete ma-
Limpopo had been visited by the CMA and
times. From now on, all specifications will
sonry units workgroup was created at the
the response was very positive. As a
be reviewed jointly. During the feedback
request of the CMA and the joint struc-
result, a Polokwane producer has already
meeting in Cape Town, the CMA also
tural division of SAICE because the British
joined the association.
PRECAST | ISSUE TWO | 2016
Western Cape and KZN. Paving seminars
programs will be held after the updates
are planned for the same centres, as are
are completed at the end of 2016.
to inform members of changes to the
seminars on paving software. The paving
The collection of industry statistics
standard. Seminars on Hybricem, which
seminar will take the form of a workshop
has been resumed and is being controlled
examines the combination of in-situ con-
presented by local and overseas experts;
by the CMA chartered accountants.
crete with precast, were held in Cape
its main focus will be the manner in which
The accounting and auditing functions
Town, Port Elizabeth and Midrand.
paving should be properly installed and
have been separated and new auditor
the workshop will involve some actual
Strachan & Crouse has been appointed.
paving installation work.
The newly-appointed bookkeeping firm is
The CMA participated in Totally Concrete, together with CMA members, in May 2015 on a 27m² stand. This ini-
tiative spurred renewed interest in the
Upcoming technical publications in-
activities of the association. Demand for
clude a substantially revised roof tile
Precast, the CMA’s official mouthpiece,
manual and this project has progressed
is growing and has reached a circulation
to its second revision stage. In addition,
of 5 000+. In future, the magazine will
the CMA’s paving manual is to be reviewed
include one or two technical articles.
and a wetcast manual is being considered.
New CMA publications released during
Three issues of Precast are being pub-
2015 included a manhole manual and a
lished during 2016 and emphasis is being
quality management system manual. The manhole manual has been placed on the
placed on making the magazine increasingly An upgraded and user-friendlier web-
relevant to the precast concrete indus-
site was launched in January 2016 and
try. Totally Concrete was staged again in
the site is being continually reviewed and
May, this time at Gallagher Estate, which
updated. The site is currently averaging
was more accessible than the Sandton
2016 promises to be an exciting period
43 visits per day. Paving design soft-
Convention Centre. Once again the CMA
for the CMA. Roadshows on the CMA
ware, Permpave and Lockpave, which is
took a 27m² stand with 15 panels. The
mark were held in Cape Town, Port
marketed by the CMA, is currently being
association is also due to participate in
Elizabeth, KZN and Gauteng and roof
revised by Dr Beechham on behalf of the
the Cape Construction Expo at the Cape
tile seminars will be held in Gauteng, the
CMAA in Australia. A seminar on the two
Town International Convention Centre.
PRECAST | ISSUE TWO | 2016
A seminar on ISO 9001:2015 was presented by Advantage ACT in Midrand
TAKING THE CMA TO THE WORLD The appointment of a new marketing manager marks a new phase of expansion for the CMA, as it reaches out to an increasingly wide member base and engages the industry to highlight the benefits of sourcing products from CMA members. Simultaneously, new campaigns to introduce and market CMA Certification Services and the CMA Mark of Approval have necessitated the appointment of an experienced campaigner with a passion for marketing and deep-rooted experience in the industry. A tough ask, but one met by Henry Cockcroft, who is a wellknown figure in the industry. He is also a stalwart with experience in both the contracting and manufacturing of bricks and blocks. This gives him a unique understanding of the requirements throughout the precast concrete value chain and provides the crucial link to service those needs. All-round campaigner Cockcroft’s background in sales and marketing will also stand him in good stead as he takes on the role of communicating the available services and benefits on offer to existing members and potential members. At the same time, his teaching and training experience will be used to raise awareness of the CMA and its members, as well as popularise the CMA Mark of Approval among professionals in the construction industry. “I have a long history in the construction industry as a civil lecturer for various technical colleges, as well as private-sector training facilities. Most recently, I was a training and business development manager for one of our member companies before finally taking on this new challenge with the association. “It’s important that our members know what we do so that they can get the maximum benefits from their membership. I also want to address other contact points so that we’re in constant communication with our members and the industry at large. We want to continue working with other industry bodies in order to build meaningful relationships with specification writers, who need to know the benefits of specifying CMA members’ products,” says Cockcroft. Setting goals Although he is still learning the ropes, he has big plans, but adds that his immediate goal is to develop a marketing strategy for the CMA NPC, as well as for the CMA CS. He is already working on ways to make contact between members and the association easier. His longer-term plan is to unlock more value to members, grow the overall membership base and work towards achieving the CMA’s goal of becoming a fully independent and self-funding body while maintaining the inclusive fundamentals of the association. “Through our marketing efforts, we want to establish the value and proposition of our association to stakeholders everywhere so that they know the value of the CMA, its certification services and the importance of dealing with its members whenever they procure precast concrete products,” says Cockcroft.
PRECAST | ISSUE TWO | 2016
FIRST AUDITS UNDERTAKEN BY CMA CS CMA Certification Services (CMACS) has hit the ground running in its first month of operation, having completed its first certification audits (Above): General Manager of the new CMA Certification Services, Christo van Zyl.
at the end of June. According to general manager, Christo van Zyl, the company kicked
off its audit services with an audit of Bosun Bricks Brits and Midrand. These will be followed by another eight companies which have already added their names to the list with applications for at least 20 permits. Full schedule “Bosun Bricks Brits and Midrand will be followed by a host of others and at this rate, after one-and-a-half months we’ll have reached half of our annual target. So clearly we underestimated the demand for our services and we’re pleased that our members finally have an alternative to the existing certification services,” says Van Zyl. Garth McMillan, divisional general manager of Bosun Bricks, says the process has been smooth and seamless. “The audits were handled in a professional manner and were comparable with other certifications we’ve undergone in the past. Technically, the audits are comprehensive and dealt with all aspects, including viewing procedures such as our quality management and testing, etc. “In addition, the process was far more personal, taking a one-on-one approach, rather than the impersonal one we’re used to. Christo was approachable and even took the time to meet us to iron out the process and the requirements upfront in order to avoid confusion at the time of the audits,” says McMillan. Long process While the first audits are already underway, CMACS is still feverishly completing all the formalities of its own certification with the SA National Accreditation System (SANAS). “The process has required a mountain of documents to be submitted and once this has been vetted, we’ll be audited on our own audit process, whereafter we’ll become SANASaccredited. This will be the last step to establishing CMACS as a world-class certification service,” says Van Zyl.
(Above): The CMA Mark of approval.
PRECAST | ISSUE TWO | 2016
RETAINING WALL SECURES PROPERTY Some split Face L12 Terraforce retaining blocks manufactured by CMA member, Klapmuts Concrete, have been used to construct two closed-faced retaining walls, es(Above): The lower concrete block retaining wall at House Joubert.
sential structural landscaping elements for a new upmarket private
residence in Cape Town’s northern suburb of Welgemoed. Situated on steeply sloping ground, the luxurious House Joubert development comprises a 500m² double storey private dwelling at the lower end of the slope, and above it, outbuildings which house six garages and extensive staff quarters. The lower of the two retaining walls is situated between the house and the outbuildings, while the upper wall has been built above the latter. Designed by consulting engineer, Fred Laker, the walls were constructed by retaining wall specialist company, Surewall, in close collaboration with the main contractor, PB Construction. Both walls slope at an angle of 65˚ and were built with attractive convex and concave curves which the L12 block handles with ease. The lower wall, which covers an area of 180m², rises to four metres for most of its 55m length and the 200m² upper wall, which is 60m long, reaches a maximum height of three metres. According to site manager, Conrad Steyn of PB Construction, a full geotechnical report was undertaken before construction
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use as backfill material. Surewall owner, Hannes Mostert, said that both walls were built with reinforced foundations 900mm wide and 350mm deep and the first six layers of blocks were filled with concrete for additional stability. “We also stabilised the ground between the foundation of the house and the lower retaining wall with cement. “As with all concrete block retaining walls, drainage was a crucial design element. To this end we placed 110mm slotted pipes covered with Bidim and 90mm aggregate at both cut faces and we installed weep holes at every two metres. Drainage was further enhanced by the introduction of 300mm of clean sand as alternative backfill material which we placed immediately behind both walls from bottom to top,” advised Mostert.
began and the ground was found to be sufficiently stable for
20 year s
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s ed ethic oval nown of -re pr de rld Ap wo w co k of for • Ne A Mar idge br • CM ast ec • Pr
• New home for CMA • Pus hing producti • Pion on with eering self-com prestres pacting sed slab concrete manufac turer celebrat es
Contact Wally Armstrong for more information
t in concret
• CMA CS undertakes first audits • Creati ng safer workplaces • Seawa ll protec ts Strand
THE CMA – QUALITY CAST IN CONCRETE
(Above): An architect’s impression of House Joubert.
PRECAST | ISSUE TWO | 2016
BROADER APPEAL FOR READYMIX CONFERENCE
professional members of our association
T hose invol ved in the manuf actur e of
enable them to make better decisions,” says
concrete products or who use and specify
Johan van Wyk, GM of Sarma.
who are eager to work with delegates to find solutions to their construction challenges. “This year the conference will also look at strategic, up-to-date information related to the economy and the industry that can help decision-makers develop strategies that will
the use of concrete on construction sites are being specially invited to attend this
year’s readymix conference.
He adds that the many technical talks
This is being done in order to stimulate
delivered at the show will appeal to the
discussion and foster innovation in the
widest possible audience and will be centred
industry, which is based on the changing
on providing solutions to real-life technical
needs of the construction industry. By
challenges, case studies, best practices,
working together, the industry may be able to
changes in standards relating to the way
change the way concrete is manufactured,
concrete is manufactured and used, as well
delivered and received on site and could give
as new technologies aimed at better, faster
rise to smarter and better construction
and more efficient construction techniques.
F u r t h e r m o r e, t h e c o n f e r e n c e w ill
The Southern Africa Readymix Associa-
highlight opportunities for the industry and
tion (SARMA) has therefore invited the CMA,
look at ways of utilising resources more
as well as other organisations involved in
effectively. This will include a technical
the concrete industry to participate in the
discussion on the use of Eskom-generated
conference. Together the industry associa-
fly ash, which has the potential to be used as
tions are inviting industry professionals to
an admixture/extender in the manufacture
attend the conference in order to be part of
of concrete, with potential benefits for
a new way of thinking in order to overcome
certain types of mixed concrete.
challenges in both the concrete industry, as well as the overall construction industry.
These and many more topics will be discussed at our Readymix by SARMA Conference and we invite all stakeholders
in the construction industry to be part
“We want this year’s conference to be
of this groundbreaking forum. For further
about using concrete wisely in order to get
information, contact the Sarma office on
the most out of its properties, about part-
tel: (011) 791-3327, e-mail: johan@sarma.
nering with like-minded organisations and
co.za or register online as soon as possible
companies and about forging co-operation
on: www.sarma.co.za to benefit from our
between suppliers to the industry, produc-
early-bird booking promotions.
ers of concrete and the users and specifiers of concrete products.
“Therefore we want architects, en-
Delegate bookings are currently being made
gineer s, quantit y sur veyor s, pr ecast
on a first-come, first-served basis. The
concrete manufacturers and contractors
conference and exhibition will be held at the
to attend in order to find out more about
Misty Hills Conference & Exhibition Centre
exciting developments within the readymix
in Muldersdrift from 26-27 August 2016.
concrete industry. We also want to share ideas and forge relationships with the many
PRECAST | ISSUE TWO | 2016
(Top): Last year’s readymix conference was bigger than ever.
INDUSTRY NEWS 14
GEARING FOR NEXT YEAR’S FULTONS The Concrete Society of Southern Africa
The awards continue to celebrate
NPC is calling for nominations for its
the legacy of scientific and technologi-
prestigious biennial Fulton Awards, which
cal advances in concrete within the built
recognise excellence and innovation in the
environment, as well as the late Dr
design and use of concrete.
“Sandy” Fulton’s life and achievements in the industry. The 2017 awards will include both new categories and a new approach to judging and the society is
• Overall aesthetic impact of the concrete aspects of the structure. • Rationale behind the chosen concrete finish. • Standard of workmanship of the concrete. • Effect of the concrete on the architectural landscape and environment.
proud to announce that PPC is once again the Anchor Sponsor for them. According to John Sheath, CEO and director of the Concrete Society, after more than 30 years of the awards’
Some unique criteria will apply to the Innovation in Concrete category: • Significance of the use/application of the innovation.
existence, some serious updating was
• The industry’s need for this innovation.
required in terms of both the criteria for
• Does it address or contribute to
adjudication of the entries and the entry categories themselves.
sustainability issues? • Will it make concrete more competitive and therefore grow the market?
(Above): John Sheath, CEO of the Concrete Society.
also changed. These can be made online
all that was special and exceptional in
through the society’s website and will
the concrete,” says Sheath, “and in the
require a short motivation explaining why
opinion of the Fulton Awards Committee,
the nomination deserves an award. The
we were focusing too much on the total
judges will assess these nominations and
project, considering aspects that had
a short-list of entries will be drawn up for
little to do with the material.”
subsequent adjudication on site.
So, irrespective of category, the
T he de adline f or nomina tions is
adjudication criteria that the judges will
31 August 2016, while the completed
be using are:
entry packs must be submitted by 30
• Quality of concrete – focusing on finish.
November 2016. The award-winners will
• Sustainability – green building initiatives.
be announced at a special gala week-
• Inventiveness/innovation in the
end to be held in the Drakensberg from
application of concrete technology. • Innovation in concrete (Above): Fairscape Precinct Office Tower, Botswana – a 2015 Fulton Award-winner.
The procedure for nominations has
“We had drifted away from identifying
construction methods. • Innovative geotechnical use of concrete.
2-4 June 2017. Full details of the 2017 awards are available on the Concrete Society website at: www.concretesociety.co.za.
The new categories for 2017 are: CATEGORY TITLE
Buildings up to three storeys
Residential, schools, commercial, factories, warehousing, industrial, etc
Buildings of more than three storeys
Office buildings, multi-family housing, etc
Slabs, paving, hardscape, etc
Bridges, roads, water resources, marine structures, power, transportation, etc
Innovation in concrete
Initiatives where totally new materials, techniques, technologies, applications, designs, and/or concepts using concrete as the principal material have been developed or utilised
Use of concrete as the principal construction material, demonstrating a unique and exceptional structure, surface finishes or particular detail in an aesthetic manner
Special or unusual concrete applications within the mining sector, both above and below ground
PRECAST | ISSUE TWO | 2016
SOCIETY WELCOMES NEW PRESIDENT Well-known concrete industry personality,
“It’s a task I won’t take lightly, as I cher-
Hanlie Turner, was recently inaugurated
ish what the Concrete Society stands for
as the Concrete Society’s new national
and its sense of belonging”, she continued.
president for 2016/17.
“The Concrete Society ticks all the boxes
As a technical information specialist
of what a professional interest group is all
with cement company PPC, Turner has
about, the real value-add being the network-
been a member of the Concrete Society for
ing opportunities created at both branch
many years and has held several voluntary
and national level.”
positions in the organisation, including
“Members’ personal level of involvement
chairperson of the Inland Branch and, more
with the Concrete Society will determine
recently, national vice-president.
the value they can add to their jobs, their
Outgoing president, Tseli Maliehe of Ibhayi Contracting in Port Elizabeth, told
personal and professional development and the strategic insights they can gather.”
members attending the meeting that he was confident the society would be in good hands under Turner’s leadership, guidance and enthusiasm for all things concrete. Proud moment In accepting the chain of office, Turner said she was honoured to assume the responsibilities that came with it and thrilled to be part of the industry that shapes our skylines and in many aspects defines our civilisation.
(Above): Hanlie Turner with outgoing president of the Concrete Society of Southern Africa, Tseli Maliehe.
ENTRIES OPEN FOR IMAGINARIUM AWARDS Following hot on the heels of the success-
Concrete Sculptor Awards, the PPC Im-
ful PPC Imaginarium 2015/16 Awards, the
aginarium encourages artists and designers
organisers have sounded the official call for
to create and express their abilities using
entries for the next edition, with registra-
Portland cement-based concrete as a pri-
tions accepted online via the official website.
mary base or material.
Unestablished artists and designers
The competition will feature six disci-
stand a chance of changing their careers
plines in the arts and design fields. These
through financial support, recognition,
disciplines are sculpture, jewellery, archi-
mentorship and guidance by entering the
tecture, film, industrial and fashion design.
PPC Imaginarium Awards 2016/17. Having
Boasting prize money to the value of R500
evolved from the long-standing PPC Young
000, each category winner stands a chance of winning R50 000, while runner-up contestants receive R15 000. The overall competition winner will receive the grand prize of R100 000 at the winners’ exhibition in 2017. Entries close on Friday, 30 September 2016. The winners in each competition category will be announced in March 2017 and their work will be on display at the University of Johannesburg in Auckland Park. The overall competition winner announcement will take place in April 2017. To enter the PPC Imaginarium Awards, visit: www.ppcimaginarium.co.za.
PRECAST | ISSUE TWO | 2016
INDUSTRY NEWS 16
CONCRETE CONVERSATION PIECES For its participation in National Library
concrete and also to demonstrate the
School of Concrete Technology, provided
Week, The Concrete Institute (TCI) Infor-
material’s renowned versatility. “At the
the staff with expert guidelines on creat-
mation Centre invited staff to enter a
same time, our fun competition’s educa-
ing the conversation pieces, which now
special competition to see who could cre-
tion element was in line with the Library
have pride of place at their workstations
ate the most innovative small concrete
& Information Association of SA [LIASA] ‘
in the TCI offices in Midrand.
“conversation pieces” for their desks.
#libraries4lifelonglearning’ theme for 2016
Guest judge for the competition was
Susan Battison, the institute’s infor-
and endorsed the LIASA viewpoint that
Michelle Fick, Chryso SA’s executive re-
mation specialist, says the motive behind
libraries have a major role to play in the
lationship and projects manager. Three
the “First Impressions” competition was
development of a knowledgeable nation.”
prizes were awarded, plus another for
to showcase how easy it is to work with
John Roxburgh, lecturer at the TCI
the entry with the best title.
PRECASTER ASSISTS THE NEEDY CMA member, Technicrete ISG, has
1 122m of concrete palisade fencing
donated more than 1 000m of concrete
for two Viva properties: 286m at the
palisade fencing to impoverished commu-
Mamelodi East Viva Village and 836m at
nities in the Mamelodi and Cullinan areas.
the Refilwe, Cullinan Viva Sharehouse.
According to the group’s marketing and communications manager, Guinevere
Thomas, the South African impoverished
“Projects such as the Viva Villages pro-
community faces many challenges, not
vide a lot of hope for those living in these
least the increasing development of
informal settlements, particularly the
informal settlements and the related
children, whom we at Technicrete ISG
problems that create an environment
wanted to assist in securing facilities
and equipment – hence our donation of
The Viva Foundation, a non-profit organisation which strives to turn these
concrete palisade fencing and its installation,” says Thomas.
informal settlements into stable and safe
“Both of these Viva facilities offer
Meleney Berry-Kriel. “Obviously, at site
neighbourhoods, relies heavily on support
crucial activities such as education,
we have valuable training and computer
from the industrial and business sectors
sport and recreation, employment, social
equipment, as well as hardware and tools
for funding and donations of materials
awareness support and developmental
for the farming activities. The donation of
that assist in the establishment of safe
programmes, accommodation, farming
the concrete fencing by Technicrete ISG
havens, known as “Viva Villages”. In or-
and fresh vegetable projects,” says chief
has been most welcome and affords our
der to assist, Technicrete ISG donated
executive officer of the Viva Foundation,
village community some security in this poverty-stricken area.” “Hav ing the perimeter concr ete palisade fencing also ensures that we can keep the children and other Viva employees safe while conducting our daily activities and classes.” (Left and above): The Technicrete ISG steelreinforced concrete palisade fence acts as a deterrent to intruders, since it renders them clearly visible.
PRECAST | ISSUE TWO | 2016
NEW LEADERSHIP FOR EQUIPMENT MANUFACTURER
usz will complement our strong team of lead-
Techmatik SA has appointed Mariusz Gil as
Techmatik and the entire Columbia Group.”
president of the well-known global equipment supply company.
ers who’ve built Techmatik over the years. “His experience as a leader of companies in similar industries to ours, as well as his high energy and proactive, customer-focused personality, will fit in well with our team at Rick Goode, CEO of Columbia Machine, says: “Dariusz will be working closely with
Gil comes to Techmatik with extensive
Mariusz over the coming months to bring
experience in the construction materials
him up to speed on the many opportunities
industry, where he was previously focused
Techmatik’s currently pursuing. These will
on paving stones, slabs and bagged prod-
help continue the significant growth our
ucts. He had formerly held the positions of
company has experienced over the past few
managing director and CEO of Quick-Mix,
years. Dariusz will remain as an advisor to
sales and marketing director of Semmel-
Techmatik for the foreseeable future.”
rock Stein + Design (Wienerberger Group) and various sales positions at Henkel. “We’re happy to have Mariusz join Techmatik. He brings a strong level of industry experience to it,” says Dariusz Kupidura, founder and current president of the company. “We’re a family company, with extensive experience in the markets we target. Mari-
YOUTUBE MARKETING CMA member Revelstone is a company
YouTube videos to entertain and inform
which has positioned itself at the de-
visitors of its products, as well as shed
fining edge of concrete marketing and
light on the ability of the manufacturer
design, with modern and exotic products
to make superb and “unusual” architec-
that often go beyond the “norm” of con-
crete manufacture. Likewise, its marketing has recently gone high-tech with the introduction of
Search Revelstone on YouTube to see what the company is up to on the digital stage.
FUNDS RAISED FOR ANIMAL RESCUE
company manufactured and donated 320
Revelstone, manufacturer of cast-stone
delightful art concrete bunnies for the fundraising drive. The bunnies were sold for R50 each and the target was reached within the
products, recently raised a grand “paw-
DARG is a pro-life, non-profit organisa-
some” total of R16 000 for the Domestic
tion that rescues, cares for, sterilises and
Animal Rescue Group (DARG) with the sale
re-homes previously abused, neglected
of specially cast concrete bunnies.
and abandoned cats and dogs. DARG pro-
The fundraiser was held over a period of
vides a crucial role for the communities of
six weeks from 1 March-5 April 2016. The
Imizamo Yethu, Hangberg and the greater Hout Bay area. Andrew Cyprianos, CEO and founder of Revelstone, says: “We were overwhelmed by the response we got from our clients and the general public. We’d like to thank everyone who contributed towards this fantastic fundraiser. It’s been a huge success.” The funds raised will go towards assisting DARG with continue its work in the Western Cape.
PRECAST | ISSUE TWO | 2016
COMPANY NEWS 19
ADVANCED EQUIPMENT FOR RUSTENBURG PLANT Precast manufacturer Mighty Cement
these machines, we’re easily able to
Products recently installed a set of four
produce quality bricks using a 7% cement
T10 brick-making machines to boost
to aggregate ratio. As a result, our maxi
production at its Rustenburg factory.
brick has an average 20MPA strength
The equipment, supplied and installed by CMA non-producer member QuanGong
after 10 days and we can change this to meet customers’ needs,” says Lin.
(Clockwise from top right): Some of the high-quality bricks produced; quality control; Mighty Cement Products’ batching plant and yard; one of the QGM T10 fully automated brick machines that was recently installed at Mighty Cement Products in Rustenburg. (Below): Fresh off the production line, a forklift removes pallets of bricks produced on the T10 machine.
Machinery (QGM), will enable Mighty Ce-
He adds that due to the advanced
ment Products to produce quality bricks
nature of the four T10 machines, the
Maschinenfabrik Gmbh, a manufacturer
for the Rustenburg area, as well as pro-
supplier has a full-time engineer on site
of fully automatic mobile and stationary
viding cost-effective units to customers
who oversees the equipment and ensures
multi-layer machines, as well as Zenith
in areas as far afield as Johannesburg,
that the four machines maintain their
Formen Produktions, a well-known mould
Dundee, Stanger, Pinetown, Newcastle,
maximum output of 260 000pcs per
production company in Austria. As a re-
Cato Ridge and East London.
sult of this acquired expertise, GQM is
According to the owner of Mighty
making a name for itself in the brick and
Cement Products, Mr Lin, the company
is aiming to become one of the biggest
Established in 1979, QGM is the biggest
and most reliable suppliers of concrete
block-making equipment manufacturer in
products in North West Province, with a
China. In recent years it has acquired and
range of quality approved products that
partnered with a number of international-
meet all the relevant SANS specifications.
ly renowned companies in the equipment
“We chose the QGM T10 brick machine
manufacturing industry and has become
due to its German-designed functionality,
a force to be reckoned with globally.
as well as the fact that it’s manufactured
Recent acquisitions and partnerships
according to European standards. With
include German manufacturer Zenith
PRECAST | ISSUE TWO | 2016
block machinery market.
PP C announced an inter esting set
pleased with the cost savings achieved
independently owned readymix concrete
of results, with a number of ups and
across the business during this period.
supplier in southern Africa.
downs following approval of its board to
We ha v e a deliber a te appr oach to
“PPC is fundamentally strong and
change the financial year-end from 30
navigating the current economic
profitable, with a solid operating base.
September 2016 to 31 March 2016.
landscape by driving cost-efficiencies
In the long term, [we aim to get] the
According to a statement from the
and leveraging our capabilities to achieve
company future-ready to partner with
cement producer, the group EBITDA
operational excellence,” says Darryll
and enable economies across Africa
was up 2% to R1,1 billion, largely due
Castle, CEO of PPC.
to achieve their growth imperatives,”
to impr oved ef f iciencies and cost-
“Our strategy to expand into a di-
sav ings which r esulted in r educed
verse pan-African player is starting to
administration and other operating
bear fruit, as evidenced by CIMERWA’s
expenditure. The Profit Improvement
positive contribution to group revenue.
PPC seeks to raise R3 billion-R4 billion by
Programme (PIP), which aimed to deliver
The three African expansion projects to
way of a proposed rights issue to improve
R400 million by 2017, generated R178
be commissioned in the next 12 months
liquidity and alleviate constraints. The
million for the period after
will provide us with the
capital raised will mainly be used to
providing R212 million by
necessary headroom to
repay debt funders for a guarantee
cushion us against macro-
extended to PPC bond-holders and an
PPC’s total cement
economic movements and
existing term facility that redeemed a
sales volumes for the six-
operational risks, including
PPC bond in March 2016, as well as for
month reporting period
the redemption of BEE 1 debt maturing
were 1% below those of
in December 2016.
last year. In SA, cement
volumes were up by 1%,
According to the state-
capital in the latter half of 2015 and
al though lower selling
ment, in order to enable
were far advanced with an orderly capital
prices reduced revenue.
PPC to effectively execute
raise process which was interrupted by
While revenue in the lime
its new strategy, a few
the sudden and severe ratings action
changes have been made
taken by S&P two weeks ago. The ratings
aggregates and readymix operations
to the group’s operating architecture.
downgrade meant that we needed to
contributed positively to group revenue.
PPC Aggregates, Pronto Readymix, Ulula
accelerate the capital raise and increase
CIMERWA, PP C’s new oper ation in
Ash and PPC Lime have been consolidated
the quantum to ensure that we can pay
Rwanda, achieved sales volumes of
into a materials business and a new com-
down the required debt and strengthen
124 000 tons at the expected EBITDA
mercial division with a dedicated project
the balance sheet,” explains Castle.
margin, adding nearly R200 million to
management office has been introduced.
“A de-gear ed balance sheet will
group revenue for the reporting period
The materials business division –
give us greater flexibility to absorb
which is focused on expanding PPC’s
any further weakness in the operating
product range and service offering in
environment, as well as the ability to
aggregates, readymix, fly ash, lime and
pursue our corporate strategy, which is
Group cost of sales were only 2% higher,
related businesses – has made good
to be a world-class provider of materials
following the inclusion of CIMERWA in
progress, including the imminent acquisi-
and solutions, with a view to doubling the
Rwanda, with cost increases particularly
tion of 3Q Mahuma Concrete, the largest
business every 10 years.”
business declined 12%,
(Above): Darryll Castle, CEO of PPC.
to 31 March 2016.
well managed in the South African and Botswana cement businesses, as well as in the lime division. Cost of sales in the South African cement business was down 3%, on a per-ton basis, while administration and overhead costs fell 12% for the period. PPC’s expansion strategy, embarked on in 2010 to extract value from highgrowth economies, is progressing well. Projects in the DRC, Zimbabwe and Ethiopia are all over 70% complete and due to be commissioned in the next 12 months. with ramp-up to the required production capacity to take appr oximately thr ee year s. “We’r e
PRECAST | ISSUE TWO | 2016
“We identified the need to raise
PPC EARNINGS UP, DESPITE TOUGH ECONOMY
GLOBAL VIEW 22
COOLS CITIES Concrete’s relatively light colour has several important environmental
ment. In contrast, dark materials, such as new asphalt, can have an albedo or reflectance capacity as low as 0,05,” says Perrie. Concrete is cooler “The incorporation of high albedo con-
This principle also applies to urban areas
crete products in exposed surfaces
and car parks.
such as roads and parking areas can significantly reduce the heat island ef-
fect and lead to cooler urban areas. In
The two primary benefits of concrete’s
Bryan Perrie, MD of The Concrete In-
Arizona, USA, for example, the summer
light colour are reduced lighting energy
stitute, says that on hot summer days,
temperatures of adjacent concrete and
consumption and a decrease of the
ambient conditions in urban
asphalt roads were measured:
“heat island” effect in cities and built-
areas can be 2-6˚C warmer
concrete was a staggering
up areas, both of which help to combat
than the adjacent countryside,
11˚C cooler,” he adds.
thus making the built-up areas
In the first instance, the light col-
He says using concrete with its high heat reflectance abil-
our of concrete provides a safer en-
These urban heat islands
ity can lower average summer
vironment and also enables lighting
can influence rainfall patterns,
afternoon temperatures in sur-
requirements in a town or city to be
with higher rainfall downwind of
rounding buildings by as much
reduced, both internally and externally.
cities compared with upwind
as 3˚C, cutting air-conditioning
For concrete roads or parking areas,
areas. The reflectance ratio,
research in the USA has shown that
or “albedo effect”, of reflected solar
“The potential increase in cost during
surface reflection readings on concrete
radiation to the amount that falls on the
the design and construction phases in
pavements and other surfaces are four
surface rates from 0 (when no incoming
providing a green structure will generally
to five times higher than other road
radiation is reflected) to 1 (when all in-
be more than offset by the savings from
coming radiation is reflected). The light-
reduced energy usage when concrete
This means increased visibility for
er the surface colour, the more solar
structures are used. Life-cycle cost
drivers and increased security in urban
radiation it will reflect and the less heat
analyses have shown that, because of
areas. Similar research has shown that
it will absorb. The solar reflectance of
concrete’s durability, the whole life cost
the increased reflectance of concrete
concrete varies from 0,2-0,4, compared
of many projects is lower when concrete
roads calls for fewer lighting masts and
with asphalt’s much lower reflectance,
is used as the major construction ma-
up to 24% lower energy requirements.
which ranges from 0,05-0,2.
terials,” Perrie concludes.
usage by as much as 18%.
“Exposed building materials with a
“The light colour of concrete provides a safer environment.”
high albedo reflect more heat and lead to cooler cities. The average albedo of normal concrete is about 0,35, with reflectance values as high as 0,7-0,8 for white concrete made with white ce-
(Top): Exposed concrete areas such as expansive parking lots reflect more heat and help produce cooler cities, according to The Concrete Institute. (Above): Concrete’s relatively light colour has several environmental benefits, says Bryan Perrie, MD of The Concrete Institute.
PRECAST | ISSUE TWO | 2016
AVOIDING BOTTLENECKS ON SITE While achieving a dense, cohesive con-
crete mix with sufficient paste volume
CMA member, Chryso, has also developed
will enable the correct level of workability
“Fill Free” technology which helps manufac-
of concrete, concrete manufacturers
turers produce concrete that is cohesive,
must also avoid practices that result in
yet still has a moderate viscosity. This
risky segregation during concrete pump-
modified PCE technology was developed to
ing on sites.
have non-thixotropic properties and makes
site workability is attained so that the
use of Chryso superplasticisers.
concrete can be pushed or transported
“Where material segregates and the
water separates out of the mix – in other
Correia explains that other factors
words, where water washes out of the
which could contribute to segregation
through this channel,” he says.
paste – there’s a strong possibility of
are pumping pressure and material grad-
Getting it right
blockages occurring in the pipeline,” says
ing. If the pumping pressure used is too
Chryso Fill Free technology facilitates a
Eddie Correia, executive vice-president
high, excessive pressure is placed on the
cohesive concrete paste which is less
at Chryso Southern Africa, a producer
mix and this could force segregation of
sticky. This is important, as stickiness
the concrete during pumping. Likewise,
can produce lower cleaning efforts in
These water-reducing agents enable
if the grading of the aggregates is in-
the pipeline and also increase the resist-
good aggregate coating by dispersing
correct, they will be pushed out during
ance of the flow of the concrete there.
the cement grains, thereby minimising
pumping and this will result in blockages
Moreover, a paste that is too sticky will
agglomeration of the mix and increasing
in the pump and/or pipeline.
make it difficult to maintain a constant rate of pumping.
plasticity and therefore workability of
“When being pumped, concrete moves
the concrete. Superplasticisers from
in the form of a cylinder and is separated
Again, this is where superplasticisers
the Chryso Fluid range will assist in
from the pipeline wall by a lubricating
are invaluable in achieving the plasticity
creating a favourable water/cement
layer made up of water, cement and
and workability needed for the concrete
ratio by reducing the amount of water.
fine aggregate or sand. It’s essential
paste to pass easily through reducers
This also prevents shrinking, cracking
that this lubricating film is achieved on
and move through bends in the pump and
and porous concrete.
all sides of the pipe and that the requi-
pipeline without causing blockages.
Wet Cast & Precast Production line
RER TU Comprehensive range of equipment for custom-made C FA NU the Concrete Industry Manufacturer of Equipment Afor plant definition M H NC FRE
High technology Turnkey Plant INNOVATIVE CONCRETE SOLUTIONS QUADRA 40 route de Findrol - 74130 Contamine-sur-Arve (France) Tel. +33 4 50 03 92 21 - Fax. +33 4 50 03 69 97 www.quadra-concrete.com
Block & Paving stone machine State of the art handling system
QUADRA - 40 route de Findrol - 74130 Contamine-sur-Arve - France Tel. +33 4 50 03 92 21 - Fax. +33 4 50 03 69 97
AN AWFUL LOT OF USES FOR THE YFEL
A range of versatile precast concrete barriers, inspired by the Eiffel Tower, is finding favour across industries as a rapid-to-erect and effective means of separating areas for different land uses. The Yfel barrier, designed and manufactured by CMA member Remacon, is an ingenious barrier that can easily be transported and erected on sites as an alternative to permanent immovable structures. Whether it be in a stockyard to prevent material contamination, a security barrier with an anti-climb curve or even as a traffic or noise barrier, the Yfel has few peers when it comes to sturdiness and versatility. According to Silvio Ferraris of Remacon, the idea of the Yfel is to provide easy-up barriers that provide sufficient sturdiness to be used in heavy-duty or even permanent applications. Should the need arise, however, they can simply be uploaded with a forklift and their positions changed, or they can be transported to a new area. Whatâ€™s more, the barriers are available in a number of other configurations with additions to the mould that can produce security, noise barriers and more. (Left): Silvio Ferraris of Remacon shows the bolt on noise barriers allow the Yfel to fulfil multiple roles as a physical security wall as well as noise barrier.
(Above, far right and below): Remacon provides a wide range of solutions for all industries requiring material bunkering, noise attenuation and security walling.
the construction industry, so I started
â€œI wanted to reduce our dependency on to look at potential new products that cut across all industries. Having just
PRECAST | ISSUE TWO | 2016
YFEL Storage solutions for different types of dry bulk materials noises, although they can also be used to dampen noise at construction and industrial sites, or even playgrounds. When combined with the Yfel barrier system, they provide an all-in-one noise and perimeter barrier par excellence. As can be expected, the Yfel barriers have been well received across a number of industries and are already in use in industrial applications such as chemical plants, aggregate stores and building suppliers’ yards, where they are used as bunkers to prevent cross-contamination returned from Paris, the Eiffel Tower
of products. The curved anti-climb bar-
was still fresh in my memory and the
rier types have further been used to
strength of the shape came to mind. I
deflect wind to prevent fine particles
used this basic shape to model a new
being blown away in these yards.
creation that has enough strength
“Yfel barriers can be used in security,
and stability to withstand considerable
agriculture, roads and construction,
forces and enough height to be effective.
retail and a number of other industries.
“So the Yfel was born and we’ve sub-
They can also be used for architectural
sequently worked on a number of types
purposes in prisons, stadiums, ports
that harness the basic principle for use
and harbours, airports and a myriad of
in a wide range of applications. Where
other locations,” says Ferraris.
the original concept has an Eiffel Towershaped side cross-section, others have been adapted to either curve over at the top to create an anti-climb or windblocking shape. Still others have bolt-on precast noise dampers or adjustments for different heights, etc. “Units are interlocking and, if desired, they can be secured at the base, as well as with locking pins on either side to fasten them to units on either side. The nature of the moulds also allows us to manufacture the Yfels with ready-made fittings or conduits to house electric fencing, lights or other fittings, if neces-
Road fixtures Remacon is well known for manufacturing the patented Deltabloc highway barrier systems from Austria. Designed to withstand and divert the forces of speeding vehicles, the Deltabloc is a modern, high-quality fixture on highways across the globe. A derivative of the original concept, the Citibloc, aimed at providing barriers for suburban, retail and office park roads, has recently
sary,” says Ferraris.
been introduced to the South
to its smaller size (600mm high)
Regarding the manufacturing process, he explains that the moulds are standard steel ones sized in accordance with the standard product line-up. Additional fitments can be bolted on to produce anti-climb curves or other shapes, as required by the customer. Reinforcing and concrete strengths are done in accordance with the original design, but can be modified in to make allowance for special requirements. Bolt-on noise barrier mouldings are separately moulded and make use of noise-dispersing and absorbing patterns, as well as more porous types of concrete finishes. They are particularly effective in blocking road and railway
PRECAST | ISSUE TWO | 2016
African market by Remacon. Due and lighter weight, the Citibloc is easier to move and transport, so it is ideal for use in traffic-calming situations where it can be erected during certain times of day and moved as the need arises. It is has also been earmarked as a solution for taxi ranks, where
Dry bulk materials such as: • Sand and stone
lanes need to be created for dif-
• Waste, fertilisers and compost
ferent routes and where marshals
• Coal and mineral ores
need to maintain order within the
• Scrap metal
rank to prevent lane-skipping. This newly-released “mini-road barrier”
• Silage etc, require separation using YFEL
is also expected to find favour with municipalities for traffic control purposes.
ReMaCon Products Tel: 011 393 5504 • Fax: 011 393 5502 E-mail: email@example.com/ firstname.lastname@example.org Website: www.remacon.co.za
FASTER FORMWORK WITH MAGNETS L ong-standing r ebar and f ormwork
The Spartan Precast Concrete Sys-
without problems. It is fully configurable,
supplier RMCS has acquired the rights
tem is faster and more cost-effective
with fully adjustable sideform/edgeform
to distribute an innovative formwork
than traditional alternatives, with solu-
moulds that allow height adjustment in
system that allows quick and easy set-
tions for the precast manufacturing and
5mm increments, as well as providing the
up of moulds to produce a wide variety
tilt-up construction industry. Its light-
ability to change the edge fillet chamfer.
of different cast products.
weight, magnet-connected construction
Precast System include:
reshaped after use to cast different
• Magnet clamps, which provide out-
shapes and sizes, with the addition of
standing pull-down strengths in a fully
various lengths and profiles.
sealed housing that protects it from dirt
According to Louis Aylward, managing
and foreign metallic magnetic matter.
director of RMCS, the high-tech system
The magnet’s structural polymer housing
is light and easy to move, requiring less
is designed to minimise concrete adhe-
manpower and effort to reconfigure. In
sion, which allows easier cleaning and
addition, its snap-together magnet joints
maintenance, while the handle operation
do not need to be bolted and secured,
is easy to engage and disengage and
which dramatically cuts down set-up
provides a semi-engage setting for fine-
time. This ensures that more time is
positioning. The magnet is also designed
spent casting products and less time wasted on building and rebuilding forms. Hard-wearing He adds that despite its light weight, it is fully as robust as traditional systems (Above): Magnet makes for easy operation.
T he components of the Spar tan
means that the formwork can easily be
and can be used for thousands of cycles
“The Spartan Precast System requires fewer man-hours to be spent on set-up.”
A name truly cast in concrete
HOLLOW-CORE CONCRETE FLOORING ECHO PRESTRESS (Pty) Ltd. (Prestressed Hollow-Core Floors) Private Bag 1, Edleen 1625 Tel: 011 589 8800 Fax: 011 589 8955 Email: email@example.com www.echo.co.za
ECHO PRESTRESS DURBAN (Pty) Ltd. (Prestressed Hollow-Core Floors) P.O. Box 40726, Red Hill, 4071 Tel: 031 569 6950 Fax: 031 569 6974 Email: firstname.lastname@example.org www.echo.co.za
ECHO FLOORS (Pty) Ltd. (Reinforced Hollow-Core Floors) P O Box 706, Muldersdrift, 1747 Tel: 011 662 4600 / 083 602 0966 Fax: 086 667 2037 Email: email@example.com www.echo.co.za
TOPFLOOR (Prestressed Hollow-Core Floors) P O Box 124, Sanlamhof, 7532 Tel: 021 951 7700 Fax: 021 951 7790 Email: firstname.lastname@example.org www.topfloor.co.za
to absorb production vibration from vibrating beds and tables. â€˘ Composite sideforms are specifically designed for magnetic clamp precast application for support onto the steel casting bed table. They have ball lock rail strip at the rear, which allows for quick and simple engagement and dis-
engagement of the magnet clamp. They are lightweight and easy to handle, with no bolts, screws or any complicated and tim-consuming fixing required. Shapes and sizes Sideforms come in 5,8m lengths with joiner plates available to allow them to be joined together for very large panels. Available in 100mm, 125mm, 150mm, 175mm, 200mm, 225mm, 250mm, 275mm and 300mm heights, they can be lapped to make different size panels.
(Above): The layout of the Spartan Precast System shows the sideforms held in place with magnets.
Sideform caps are used to vary the
that there is a watertight seal between
Precast System requires fewer man-
size of the panel in 5mm increments. They
the sides and the casting bed, and prevent
hours to be spent on set-up, which means
are available to clip onto the top of the
bleeding at bottom of sideforms.
that labour can be redeployed in other
sideform with ease and are available with
â€œThis is a system that enables high vol-
revenue-earning roles. This is especially
straight or chamfered edges. Bottom
umes to be produced from relatively small
true wherever manufacturers produce
caps are available with a straight edge or
casting yards. Thanks to its ease of use
a lot of custom products that require
a chamfered edge rubber seal to ensure
and time-saving features, the Spartan
regular mould changes,â€? says Aylward.
AROUND & ABOUT
TOTALLY CONCRETE ROUND-UP The Concrete Manufacturersâ€™ Association and its members were well represented at this yearâ€™s instalment of the Totally Concrete Expo. Once again the
CMA commandeered a large stand in the middle of the exhibition, with a number of CMA members choosing to share space with the association and highlight the services and products they offer. Others were represented in their own stands where they had more room to show their wares.
PRECAST | ISSUE TWO | 2016
The reason why concrete block retaining walls are used so widely is that they offer much more than the stabilisation of earthen embankments. They also give full reign to the creative talents of landscape architects and retaining wall builders. The Grove Mall, an upmarket shopping precinct developed by Resilient Africa and si tua t e d o f f Ly nw o o d R o ad in eastern Pretoria, illustrates this point in spectacular fashion. Its 420m long multi-faceted retaining wall structure on its southern and western boundaries has transformed a six-metre-high erosionpr one ear then emb ank men t in to a terraced wall garden, comprising three, and in one section four layers, of retaining walls interspersed and overhung with abundant plant and flower life. Despite their eye-catching attributes, public safety rather than aesthetics was the prime motivator for shoring the embankment with terraced walls which were designed, built and engineered by Engineered Interlock Solutions to provide many years of trouble-free service.
PRECAST | ISSUE TWO | 2016
(Above): Public safety and natural beauty combine at The Grove Mall in Pretoria in a multi-terraced wall garden, built with over 46 000 of Aveng Infrasetâ€™s Infrablokâ„˘ 350 retaining wall blocks.
SPECTACULAR TERRACED GARDEN FOR UPMARKET RETAIL CENTRE
Right solution According to Engineered Interlock Solutions, owner, Manie Troskie, before the retaining wall option was considered, gabions were the front-running reinforcement solution. “We wer e appr oached by A x iom Consulting Engineers to provide an
alternative terraced concrete block retaining wall design using a cut-and fill construction technique. We submitted our design, which was based on Aveng Infraset’s very attractive and natural looking split-face retaining block, the Infrablok 350, to BJV Quantity Surveyors. “This solution not only proved less expensive to build than the gabion-based alternative, but offered the opportunity of creating a wall garden. Over 46 000 block were supplied by Aveng Infraset to cover a total wall-face area of 2 570m². We incorporated terracing for two reasons. It was a far more attractive option than a single wall and it provided the parking basement with more natural light. The individual walls were built in S
and unimpeded access for building the
shapes with varying wall heights to lend
lower wall. Provisional alternative drain-
Drainage was a very important facet
further aesthetic appeal,” said Troskie.
age was installed in this section during
of the project, given the large volume of
on all the walls for erosion protection.
construction. Dust was another problem
water on site. Sub-soil pipes were placed
and the on-site water was used to damp
at the bottom of the cut face and outlet
Actual construction was complicated
down the soil.
pipes were run from the cut faces to the bottom of the walls. Sausage drains
because it commenced while the centre was fully functional. “This meant we had to work in a public space and this restricted our available working area. In addition, a section of the parking basement adjacent to the embankment had to be used for temporary storage of the excavated soil. Moreover, although
“We had to work in a public space and this restricted our available working area.”
the soil was suf ficiently stable for
were placed against the cut faces of the upper walls and the outlet pipes drained onto the flower beds of the lower terraces. Kaytech’s M100 Geopipe was used for drainage where the water flow was at its heaviest. Easy access
backfill purposes, there was so much
Troskie said that one of the reasons
water in one section of the embankment
In order to ensure that the walls were
why Aveng infraset’s Infrablok 350 was
that it ran continuously, and we had to
structurally sound and well drained, En-
specified is that it allows for the crea-
pay particular attention to drainage”
gineered Interlock Solutions was obliged
tion of concave and curves which were
to use low-fines concrete as the backfill
deployed at The Grove. Aveng Infraset
The walls were completed at the end
material for the first wall. This wall varied
landscape products sales manager,
of 2014 and took six months to build. The
in height between one and three metres
Brennan Small, commented further, say-
bulk of the structure comprised three
and in one three metre section the wall
ing that the Infrablok 350 also allows the
walls, apart from the south western
was built around a substantial quantity
construction of staircases and two were
corner where a fourth wall was added.
of rock. The upper walls ran between one
built at The Grove to provide access to
and two metres in height.
Detailed logistical planning was required to counter the restricted working
All the walls were built with concrete
“Furthermore, the blocks can be
space and a ramp, which provided access
foundations and the excavated soil was
filled with concrete for the placing of
to the upper wall sections, had to be
used as backfill material for the upper
handrails, light posts and fences,” ad-
built. Besides excavating and stockpiling
terraces. All the walls were built at
the soil, an existing precast concrete
an angle of 80˚ with Maccaferri WG4
drainage channel, which ran along the
geosynthetic reinf orcement. In ad-
bottom of the embankment, had to be
dition, a layer of bidem was installed
temporarily filled in to provide adequate
under the second to last layer of blocks
PRECAST | ISSUE TWO | 2016
(Above): Public safety and natural beauty combine at The Grove Mall in Pretoria in a multi-terraced wall garden, built with over 46 000 of Aveng Infraset’s Infrablok™ 350 retaining wall blocks.
CREATING SAFER WORKPLACES I I of chemicals or explosives on site may only
O O S some of the main causes of accidents/incidents on our sites.
be done by suitably qualified people with the right training and equipment, using the information available in the Material
“By far and away the biggest preventable
ensure workers are protected against
cause of injuries on site is not using the
the hazardous work they’re doing.
correct safety gear, like lock-out proce-
Safety Data Sheet. Legal-wise
dures or personal protective equipment
“Other areas of concern I’ve noted in
[PPE]. Harm is caused to a person that’s
“Next is dust suppression and prevent-
my years of doing assessments in the
ing respiratory ailments caused
concrete manufacturing industry are
by breathing in cement or
lock out procedures that are either in-
entirely preventable when wearing the desired PPE. “ T her e’s also no ex-
dust generated from sands
adequate or non-existent.
cuse for not wearing PPE
and aggregates, etc. In-
“Equipment guarding needs to be cor-
because the nature of
halation of this dust can
rect and in place. Also, vehicles/forklifts/
the work we do is inher-
cause silicosis, a debili-
cranes on site must be managed correct-
ently dangerous and it’s
tating disease that can
ly and competency training and checks
therefore reasonable to
considerably decrease the
for operators’/drivers’ should always be
life expectancy of sufferers
done. Clearly demarcated areas where
assume that everybody on site should be using some form of PPE or another. Also, if you don’t
by many years.
equipment may and may not operate also
“As a result, the au-
need to be established.
know what the appropriate PPE equip-
thorities are clamping down on
“These are just some of
ment is for a task, do some research,
industries where dust is emit-
the issues we encounter on
as there’s a lot of information available
ted. Companies found guilty of
site, which we’ll be looking at in
through the CMA, online or through OHS
generating dust and not tak-
more detail in future articles.
consultants. Remember, prevention is
ing the necessary precautions
To begin with, it’s essential
better than cure, so try to avoid inci-
to prevent people’s exposure
that companies assess these
dents in the first place. If you can’t, then
to silicosis are liable to receive extremely heavy fines.
“Probably the biggest cause of serious injuries on site is falling from heights.”
“Equally dangerous, and probably the biggest cause
and other risks on their sites. (Above): Oom Callie Calitz is an experienced health and safety practitioner.
of serious injuries on site, is falling from
Once they’ve established, it’s critical to follow the letter of the law and ensure that all
stipulated requirements are met.
heights. Working at heights requires the
“The next step is to implement man-
correct training, medical fitness certifi-
agement systems to manage and mitigate
cates and fall arrest equipment, other-
risks, and this will also be the topic of a
wise lives are at stake. Similarly, handling
future article. Until then, stay safe!”
PRECAST | ISSUE TWO | 2016
Without well-managed quarries the cost of construction will become unaffordable for home-owners and ture such as roads and hospitals.
Quarries are essential for the legal extraction of sands and aggregates used in the manufacture of concrete structures, as well as base and top courses of roads and ballast for railways. If for any reason the materials for these construction projects need to be sourced from too far away (more than 100km), the cost of transport can become prohibitive and dramatically increase the price of building products.
LOCAL LEGAL QUARRIES CURB
HIGH BUILDING COSTS
Research has shown that the average
population growth, a strong demand for
South African citizen accounts for over
infrastructure development has arisen
three tons of aggregates, which is
and needs to be supported by legal quarry
calculated using the house they live in, as
operations in every town and city
well as streets and other infrastructure
However, residents should remain
they use during this period. This means
vigilant and report quarries that are not
that even if a person is not actively
being responsible, as they may be illegal
involved in the construction industry,
operations which operate outside all laws
they still require that amount of material
of the country. These operators some-
just to go about their daily lives.
times operate “quarries” and borrow pits that cause severe damage to the sur-
rounds. Rather than creating sustainable
In order to raise awareness of the im-
work for residents, they often exploit
portance of well-managed legal quarries
workers and scar the environment.
nearby our towns, the Aggregate & Sand
“If residents suspect that quarrying
Producers’ Association of Southern
is being carried out in a manner that’s
Africa (ASPASA) has embarked on an in-
and water pollution, among others. An
harmful or if they suspect that a quarry
formation campaign to educate residents
additional benefit is the creation of direct
(or borrow pit) is being illegally operated,
of our towns and cities about the many
and indirect jobs that are sustainable
we strongly encourage them to contact
uses of materials being taken from their
o v er a long per iod,” say s A SPA S A
ASPASA, as well as their local police and
director Nico Pienaar.
Department of Mineral Resources offices.
“All too often residents only see the
“ASPASA members also get involved
negative side of quarrying, such as the
in a host of community projects that are
use of heavy equipment on site, blasting
specially identified to benefit and uplift
“Rather than single-mindedly oppos-
or increased heavy vehicle traffic and
residents of surrounding communities.
ing quarrying in our towns and cities,
get upset at the mere thought of having
They usually encourage residents to get
ASPASA encourages residents to work
a ‘big, dirty quarry’ nearby. Few people
involved and to make use of areas that
with our legal quarry operators to ensure
realise that formal, registered quarries
are suitable for activities such as bird
they’re operated in a way that’s accept-
belonging to the association are far from
watching, cycling etc in order to also
able to them. They should also provide
being bad neighbours.
make meaningful contributions to the
active input on how the quarry is reha-
bilitated and possibly look at using the
“These legal quarries have to obtain mining, water usage and environmental
quarry as a dam, park, shopping mall or
permits and must abide by extreme
other type of land use when the quarrying
str ic t r egula tions simpl y to b egin
Pienaar explains that the aggregates
operations cease,” advises Pienaar.
quarrying operations. Once in operation,
and sand quarry industry has never been
they are heavily regulated (in terms of
more responsible and committed to the
the impact on surrounding communities)
communities in which they operate.
and have to comply with very stringent
With the government’s commitment
r egulations r elating to noise, dust
to building new homes and the rising
PRECAST | ISSUE TWO | 2016
(Top): Quarries should provide safe and sustainable employment for surrounding communities. (Above, left): Aggregates and sands make up more than 75% of the contents of concrete and are the main ingredients in road and railway construction.
PRECAST CONCRETE SEAWALL
PROTECTS STRAND WATERFRONT O
mouth of the Eerste River. Sections of a seawall adjacent to Beach
(CCT), which included replacing a broken
Road in Strand were breached between
seawall with a temporary revetment on
April 2006 and June 2007, causing dam-
the eastern beach, the seawall to the
age to pavements and streetlights, and
west at the Sarel Cilliers intersection
threatening to flood basements in some
continued to be overtopped.
of the side-streets. Despite remedial
This ongoing damage to the Strand
measures taken by the City of Cape Town
seawall and other structures prompted CCT to appoint PDNA (later acquired
(Left and Top): L-shaped units are lowered onto the mass foundation. (Below): Concrete is poured into a section of the Phase 1 mass foundation.
by Mott MacDonald) to undertake a detailed coastal study from Gordonâ€™s Bay to the mouth of the Zeekoevlei canal outlet in 2011. The study had a threefold objective: to realise a better understanding of coastal zone dynamics in a context of rising sea levels; to assess the condition of coastal structures along the 38km of coastline to Zeekoevlei, especially their performance in relation to wind-blown sand and beach-wall overtopping; and to propose solutions for the Strand beachfront.
PRECAST | ISSUE TWO | 2016
dif ferent coastal defences were assessed against the allowable overtopping rates. Key factors in the elevation of the seawall also included future climate changes and line-of-sight for the public enjoyment of the beachfront.” Unimpeded views The amounts of water and wind-blown sand which could overtop the walls were crucial research elements. Given that this is a holiday destination, aesthetic considerations also played a significant role in the design brief. “For instance, we had to restrict the height of the walls, as measured from the promenade surface to the top of the walls, to give promenade strollers an unimpeded view of the beach and the sea. And even though Beach Road slopes gradually from the west to the east, the elevation of the top of the wall will remain constant, “The great bulk of the wall is buried below ground and the portion visible from the beach will vary constantly, depending on the vagaries of shifting beach sands. All our calculations, based on both our Technical team
numerical and physical models, indicated
Mott MacDonald assembled a team of
that 3,5m above zero land levelling datum
coastal research specialists, including
was our optimum height. This, and the
Geoff Toms, head of ports and coastal
horizontal alignment of the wall in relation
engineering at the University of Stellen-
to the coastline, was arrived at after
bosch, and Piet Badenhorst, a special-
extensive debate with environmental
ist in dune management. This two-year
advisers and City Parks,” says Cooksey.
research programme led to a decision to replace the existing Strand seawall with a 3km precast concrete seawall in a triple-phased construction programme. “The choice of precast concrete units for building the seawall was an engineering decision based on the need to build quickly and achieve high standards in durability and finish qualities,” comments Mott MacDonald specialist consultant
“Another quality requirement was the absence of blemishes and blow holes on the surfaces of the units.”
Tony Cooksey. “Manufacturing precast elements in a factory away from the marine environment made it easier to achieve the high specifications on a consistent basis. It was also more cost-effective. “The height of the precast wall was calculated through the numerical modelling of deep-sea wave conditions close to the near-shore and by physical modelling of the design wave (significant wave) against allowable overtopping rates. The physical modelling included flume experimentation at Stellenbosch University’s Coastal Engineering Laboratory, where
PRECAST | ISSUE TWO | 2016
(Above): A section of the Phase 1 seawall and the reno mattress.
Effective solution Construction of Phase 1, which is 1,1km long and runs from the Strand Pavilion to a point between Burnard and Da Gama Streets, began in January 2016 and is due for completion at the end of July 2017. Phase 2 will begin where Phase
1 ends and will provide protection up to a point near the Strand Surf LifeSaving Club. Phase 3 will cover the area from the Strand Pavilion to Greenways. Phases 2 and 3 should begin shortly after the completion of Phase 1 and will run concurrently. As Mott MacDonald marine coastal engineer Brenton Heron says, an Lshaped gravity wall is an attractive op-
(Above): An engineer’s cross-section of the completed wall.
tion for a number of reasons. “It’s a highly flexible solution, as it can be integrated
beach nourishment. It can also be eas-
with various other coastal protection
ily integrated with a promenade, as in
measures, such as rock revetment or
the case of Strand, as well as other beachfront amenities. However, varying founding conditions at the Strand beachfront, and the placement of the L-shaped units in a challenging environment, made achieving a uniform vertical and smooth horizontal alignment one of our main
“The choice of precast concrete units for building the seawall was an engineering decision.”
construction-related challenges. Dur-
are: an in-situ concrete mass-concrete
ing the design stage, it was envisaged
foundation which, depending on the
that achieving a tight tolerance on the
bedrock, was laid on varying founding
works would be challenging. Therefore
conditions; L-shaped precast concrete
the coping’s been designed to take in
units which weigh 14-16 tonnes and
the differences in tolerances and deliver
measure 3,5m (length), 2,65m (height)
a smooth wall alignment, both vertically
and 2,4m (width); and curved 1,5-tonne
precast concrete coping units, 835mm
The walls contain three main structural
high and 795mm wide. On certain sections
elements. Starting from the bottom, they
there is a fourth element, namely rockbased reno mattresses which are 4m
(Left): Recently-installed coping units prior to grouting.
long and 300mm deep. They are placed at
(Below): A completed section of the Phase 1 wall.
the toe of all L-shaped units not founded on bedrock and provide scour protection. Strong foundations “Without de-watering, much of the sand is water-logged and during construction, de-watering has to be continuous,” says Brenton. “Where sandy saturated conditions persist, a 350mm pioneer layer of rock, wrapped in geotextile fabric, provides a stable surface for casting the concrete foundation. In drier sections, the mass concrete foundation is cast directly onto sand or rock, or a combination of the two.” The coping units are lowered into position onto galvanised rebar which are cast into the L-shaped units. They have vertical corrugated sleeves 80mm in diameter which run the full depth. CMA
PRECAST | ISSUE TWO | 2016
on the surfaces of the units and we
winner, Concrete Units, is casting 494
changed our casting methodology to
L-shaped units and 1 600 coping units.
ensure this. Moreover, instead of self-
Approximately 100 L-shape units are
compacting concrete, we opted for a
being cast with curves to accommodate
high slump alternative.
the curvatures of the walls and there are
“Initially we batched the concrete
30 different types. Some 200 curved
ourselves, using a 26mm aggregate
coping units are being cast in eight
and pulverised fly ash from Gauteng and
different shapes. These were optimised
achieved a strength rating above the
by using innovative variable moulds.
required 40MPa. We’ve subsequently
Commenting on the casting process,
given our mix designs to Megamix, which
Concrete Units manager, Brian Cook,
is supplying us with the concrete. An
says a very high standard of concrete
exposed aggregate finish was considered
was a project specification. “The quality
as an option for the coping units, but
rating of the concrete centred around
ultimately of f-shutter finishes were
four durability indices and we submitted
chosen for both units. This simplified
our concrete mix design to the concrete
matters and gave matching finishes on
laboratory at the University of Cape
both units,” says Cook.
member and Awards for Excellence 2016
(Above): A section of the Phase 1 seawall and the reno mattress.
Town for verification. The results were
“This project also calls for 75mm
extremely satisfactory and were higher
cover to the rebar. We had to have
than what’s normally associated with a
the cover blocks cast locally because a
Concrete Units also designed and
marine environment. For instance, we
weak rand made the imported units too
built lifting systems for the loading and
were working on a permeability index of
expensive. They’re very heavy-duty units
offloading of the units. At the time of
9,6 and achieved 10,24.
with very low absorption properties and
writing, the construction of Phase 1 was
have the same durability properties as
only 25% complete and the final placing
the concrete used on the L-shaped and
of coping units was being done. The client
“Another quality requirement was the
coping units. We’re using pulverised fly
and engineers are satisfied with the
absence of blemishes and blow holes
ash and many other special materials to
appearances of finished work to date.
achieve a cover-block strength rating of over 50MPa.”
Market leader in Hollowcore – Western Cape
Multi Story Buildings, High Strength Security Walls, Retaining Walls
A Corner Fabriek & Oop Street, Bellville South T
021 951 7700
E info@topﬂoor.co.za W www.topﬂoor.co.za
Part of the
CLINIC GETS SMART NEW PAVING Technicrete Stilfontein manufacturing
200 of the exterior of the building provides a reassuring and professional welcome for patients and visitors alike.
plant, and still met all delivery deadlines,”
The project team chose Double Zig-Zag
DZZ (Grey) 2 360m², 60mm DZZ (Slate)
crucial to Technicrete ISG and it’s critical
(DZZ), Trojan Square paving and kerbs
65m², 60mm DZZ (Tan) 65m², 60mm
that all walkways and kerbing are profes-
from CMA member, Technicrete, to
Trojan Square, as well as Fig7 semi-
sionally installed with a flawless and evenly
achieve the desired aesthetics, as well
mountable kerbs 96 x 1m.
laid finish.” added Steenkamp.
as provide the clinic with a long-lasting and durable solution for its traffic areas.
This included paving and kerbs around
“The scheduling on this project was
walkways, parking and emergency drop-
extremely tight and we were pleased to
off zones where the installation needed
be able to meet all deadlines presented
to be professionally managed in order to
to us by the developer and building
provide a safe and attractive finish.
contr ac tor. We o v er came pr oduc t
The clinic required an area of 2 550m²
availability challenges and sourced the
to be paved. Technicrete supplied 80mm
correct quantities required from our
says Hendrik Steenkamp, Technicrete ISG sales consultant in Polokwane. “The safety of people who utilise parking and visitor areas at medical facilities is
created a visually impactful and rustic element to the faculty construction” says spokesperson Guinevere Thomas, group marketing and communications manager for the IS Group. She adds that the Wits faculty used 380 194 concrete masonry face-bricks which enhanced the look and feel of the building through the distinctive choice of paint colours, rustic concrete slabs and rhythmic patterns of glass for an architectural impact. Grey masonry was chosen for its aesthetic finish, as well as to increase the durability of the building, while the irregular pattern of the Technicrete Rockface brick illustrated the shadow lines of the building.
WITS MAKES INTELLIGENT
Concrete masonry face-brick was selected for the recently completed S the West Campus of the UniverW W Johannesburg.
The use of the Technicrete masonry product also eliminated the need for exterior walls to be painted, thereby reducing building maintenance costs. Technicrete ISG’s masonry products were required to meet manufacturing standards and building regulation requirements and have undergone testing for water absorption, as well as vigorous strength factor testing. Wide range T he Technicr ete Rock f ace masonr y brick comes in two thicknesses: 73mm and 70mm, with lengths and widths of 222mm x 103mm and 220mm x 100mm respectively. Standard colours available are “autumn”, terracotta, grey, plum,
A two phase re-build was commissioned in
slate and tan, although special colours
2013, in order to meet functionality and
can be made upon request.
standards pertaining to student accom-
Guinevere says the masonry bricks
modation and faculty requirements. The
used at for the university project are
buildings comprise lecture venues, stu-
an increasingly popular choice among
dent seminar rooms and staff offices, and
architects and contractors seeking
were completed towards the end of 2014.
a hard-wearing, durable solution that
The university chose masonry bricks
is highly attractive for high-impact
from CMA member Technicrete ISG due
structures. As a result, the company has
to its aesthetically pleasing appearance
made them available from a wide range of
and maintenance-free features. They
Technicrete ISG factories in Carletonville,
represent a durable form of construction
Stilfontein, Olifantsfontein, Polokwane,
and are commonly used for retaining and
Welkom and Witbank.
building walls for both residential and commercial building applications. Architectural impact “T he Technicrete masonr y range is used to create an appealing edge as a face-brick boundary wall solution. It’s a cost-ef ficient, high-end brick that delivers an aesthetically pleasing finish, and in the case of the new Wits faculty building, the Technicrete masonry range
PRECAST | ISSUE TWO | 2016
“The Wits faculty used 380 194 concrete masonry face-bricks which enhanced the look and feel of the building.”
(Left): One of the elevated courtyards where Revelstone’s Ravine and Random Edge pavers were used to delineate and embellish gravel sections.
tial block, and retaining walls were built around the perimeters. “We felt that dropping the courtyard to the same level as the parking basement would have meant locating it in a
sea of parking. Moreover, the value of the courtyards would have been lost to the home-owners because the gardens would have been situated 2m lower than the patio levels of the ground-floor units. “Raising the courtyards allowed direct visual interaction with the ground-floor units and gave us the elevation needed
MEMBERS CONTRIBUTE TO
to create natural water features comprising ponds, waterfalls and streams.
CENTURY CITY DEVELOPMENT
Rabie prefers its landscaped areas to
and Revelstone pavers.
be quite soft, using lawn and indigenous plant life. However, the back ends of the courtyards at The Mayfair are shaded and this prevented us from grassing these areas. So we decided to create a hard landscaping experience using gravel
Adding dimensions “We used Revelstone’s Ravine and Kent
Random Edge pavers to create linear bandings to contain and delineate the gravel sections and to provide stepping stones in some of the soft landscapes. We
Construction was the main contractor.
chose Revelstone pavers because of their
Revelstone supplied a selection of paving,
pavers were loosely packed on a layer of
tiling and cladding products, specified
Bidim, rather than on a concrete haunch,
by the professional team to enhance
the extra weight of the Revelstone pavers
external building façades and provide
was an added advantage. Over time the
linear aesthetic expression to two gar-
courtyards will be fully hedged and this
den courtyards which form part of the
will add a further linear dimension to the
development’s residential component.
courtyards,” explains Dohse.
consistent quality. Moreover, because the
Topfloor provided a range of pre-
A combination of Revelstone products
stressed hollow-core floor slabs and
was used to beautify the residential
precast beams for the first floors and
blocks’ external staircases. Ravine tiling
roofs of six double-storey office blocks,
was employed to finish off the top of the
while Terraforce supplied precast retain-
concrete balustrade and Worcester split
ing wall blocks for the construction of
cladding gave the balustrade walls a rock-
retaining walls in the courtyards.
like façade. The actual stairs were paved with Ravine Bullnose pavers. Another
smaller external staircase was tiled with
“Rabie was concerned about how the de-
velopment would affect the long boundary between the residential and commercial
Precast solution Commenting on the use of prestressed
buildings, so we placed a green buffer zone between them,” says Tim Hughes. Dohse says both residential courtyards were raised 700mm to 1m below the finished patio level of the first residen-
(Above, from top): Kent Random Edge pavers interspersed between lawn and flowerbeds create an attractive and durable path; a combination of Revelstone paving, tiling and cladding products makes for an imposing staircase.
slabs for the construction of the office buildings, Hughes says the original design called for in-situ columns and support beams.
PRECAST | ISSUE TWO | 2016
PRESTRESSED SLABS FOR
NAVAL SECURITY WALL Some 3 400 prestressed hollow-core concrete slabs are being used to construct a 5km security wall for the Department of Public Works S S
result, nothing short of mechanised dem-
Designed by Delta Built Environment
country,” says Prinsloo.
olition equipment or high explosives would make any sort of destructive impression
on the wall. This is why prestressed slabs are being used on an increasing basis to safeguard property of strategic importance or high value in other parts of the
Consultants in close collaboration with leading prestressed hollow-core con-
Simple by design
crete slab manufacturer, CMA member
The wall is being built to a simple, yet
Topfloor, the wall is being erected by
effective design which uses galvanised
KP Construction, the project’s main
steel H-sections to support the 6m-
contractor. According to Topfloor direc-
long slabs. The H-sections are bolted
tor, Wessel Prinsloo, the slabs are being
onto six threaded bars cast into the
precast at Topfloor’s Cape Town factory,
reinforced concrete foundations. These
where they are prestressed with steel
ex tra-heav y-duty f oundations wer e
reinforcement before being delivered on
specified by Delta to ensure that the
and rises 3,2m and 4,2m above ground
flatbed trucks to Saldanha.
wall can withstand the frequent and
level; a section of approximately 400mm
sometimes gale-force winds prevalent
is buried below ground. Construction,
on this stretch of coastline.
which began in December 2015 and is
“Prestressing provides hollow-core slabs with additional strength and the
(Above, from top): Topfloor contracts manager, Norlando Nomdoe, stands on one of the concrete foundations; a section of completed security wall built with Topfloor prestressed hollow-core slabs at the Saldanha naval base.
slabs being used for the Saldanha wall
The wall follows the natural contours
due for completion by the end of 2016,
boast a strength rating of 50MPa+. As a
of the undulating fynbos-strewn land
is effected by hoisting the slabs using
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a truck-mounted crane. A special grab mechanism had to be designed by Topfloor to lift and install the slabs. The crane has sufficient reach to service three wall bays from one location. Once installed, the slabs are caulked into the H-sections with a plaster sand and cement mix.
“Nothing short of mechanised demolition equipment or high explosives would make any sort of destructive impression on the wall.” A conventional masonry wall, which isn’t
Part of the contract involves the
nearly as strong or durable, would have
planting of a line of various types of
taken twice or three times as long to
trees on the outer perimeter of the wall
build. The cost of constructing a security
to add a green and aesthetic element to
wall using prestressed hollow-core slabs
what would otherwise have been a stark
is considerably less than an in-situ wall
monolith. Additional aesthetic appeal is
offering the same properties. Moreover,
achieved by mounting the panels so that
precast walling requires no shuttering
the slabs’ smooth soffit sides are posi-
or propping, on-site curing, formwork
tioned on the outer (public) side of the
wall. Moreover, the slabs have been cast
“A s w i th o ther w alls buil t w i th
with bevelled edges which form V-shaped
pr estr essed hollow-cor e panelling,
channels where the slabs meet to further
the Saldanha wall will have a very long
enhance the appearance of the walls.
lifespan. It’s maintenance-free, and other than occasional cleaning, no other
servicing is required. The slabs can also
Prinsloo says there are several advan-
be dismantled and re-used elsewhere,”
tages to this type of walling, speed of
construction and the superior strength of the wall being major considerations. “Eight to 10 bays or 48-60 linear metres are completed daily (eight hours).
(Left, from top): A Topfloor wall slab is offloaded prior to installation between the steel H-sections; an inner section of the Saldanha wall in which the attractive V-shaped indentations between the slabs are clearly visible.
ARCHITECTURAL INFRASTRUCTURE CONSTRUCTION STRUCTURAL EROSION PROTECTION SANITATION ENERGY ROADS WATER SECURIT Y RAILWAY OCEAN MINING MISCELLANEOUS
safeguarding excellence in precast concrete
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PI – Precast Infrastructure PB – Precast Building
PRECAST | ISSUE TWO | 2016