ISSUE TWO • 2020
THE VOICE OF THE PRECAST CONCRETE INDUSTRY
PRODUCT CERTIFICATION – YOUR KEY TO QUALITY ASSURANCE
• Successful project delivery • Meeting post-lockdown demand • RDP housing project uses precast
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25 NORTH WEST TAXI RANK GETS PRECAST MAKEOVER
2 QUALIT Y AND STANDARDS, PRODUCT CERTIFICATION AND SUCCESSFUL PROJECT DELIVERY
INDUSTRY NEWS 5
PRECAST TO SOLVE HOUSING CRISIS HIGHLIGHTED BY COVID-19
THE PICP COMPENDIUM – INFORMATION REQUIRED
16 18 MANAGING STORMWATER WITH PERMEABLE PAVING
28 EXPOSED AGGREGATE PAVERS TRANSFORM HISTORIC CAPE TOURIST DESTINATION 30 RETAINING WALL REPAIR: A STITCH IN TIME
10 POST-VIRUS UNIT Y IS REQUIRED 11 WOMEN BREAKING BARRIERS IN CONSTRUCTION 12 REVELSTONE COMMITS TO JOB CREATION AND LOCAL PRODUCTION
15 PRECAST is the mouthpiece for the Concrete Manufacturers’ Association - CMA Concrete Manufacturers’ Association Physical Address: Office 0400, Standard Plaza Building, 440 Hilda St, Hatfield, Pretoria Postal Address: Post Net Suite 334 Private Bag X 15, Menlo Park, 0102 Tel: (+27 11) 805 6742 Fax: (+27) 86 524 9216 E-mail: email@example.com Website: www.cma.org.za Publishers: Isikhova Media Address: 10th Floor, Metalbox, 25 Owl Street, Milpark, South Africa Tel: (+27 11) 883 4627 Fax: (+27 11) 783 2677 Website: www.isikhova.co.za Publisher: Imraan Mahomed Tel: (+27 11) 883 4627 E-mail: firstname.lastname@example.org Consulting editor: Raymond Campling Tel: 076 297 2775 E-mail: email@example.com
PRECAST | ISSUE TWO | 2020
21 TECHNICAL 22 BATTERY-MOULDED SOLID WALLS AND FLOOR SLABS
32 33 PERMEABLE PAVERS FOR A GREENER MOSSEL BAY 34 PRECAST CONCRETE SPEEDS UP CONSTRUCTION OF HIGHWAY FOOTBRIDGES
Coastal editorial: David Beer Tel: 082 880 6726 E-mail: firstname.lastname@example.org
ISSUE TWO • 2020
THE VOICE OF THE PRECAST CONCRETE INDUSTRY
Subscriptions/Accounts/ Advertising: Thuli Majola Tel: (+27 11) 883 4627 E-mail: email@example.com Design and layout: Joanne Brook 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© 2020. All rights reserved. No part of this magazine may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage retrieval system, without prior written permission from the publishers. Endorsed by:
ON THE COVER The quest to im-
PRODUCT CERTIFICATION – YOUR KEY TO QUALITY ASSURANCE
prove product quality and delivery to clients has existed for as long as we
• Successful project delivery • Meeting post-lockdown demand • RDP housing project uses precast
have been trading. To achieve this objective, businesses implement quality management systems and standards. It comes as no surprise that the very first lines in ISO 9001:2015 read: “The adoption of a quality management system is a strategic decision for an organisation that can help to improve its overall performance and provide a sound basis for sustainable development initiatives".
QUALITY AND STANDARDS, PRODUCT CERTIFICATION AND SUCCESSFUL PROJECT DELIVERY
T h e q u e s t t o im -
• define and control internal
products have reached a predetermined
prove product qual-
level of quality. For a precast concrete
ity and delivery to
• meet environmental objectives.
producer, this certification would mean
clients has existed
Businesses committed to implement-
f or as long as we
ing and following quality management
• the producer knows the specifications
have been trading.
systems and standards are more often
To achieve this ob-
• the producer has implemented a
• increase their profits;
system to monitor the achievement
implemen t quali t y
• reduce losses or costs across
of the specification or standard;
• during production, this is evaluated
management systems and standards. It comes as no surprise that the very first lines in ISO 9001:2015 read: “The
the following: or the product standard;
• improve their competitiveness; and
• increase consumer loyalty.
• records regarding all the facets
adoption of a quality management system
Should a company successfully imple-
is a strategic decision for an organisation
ment a quality management system, the
• through this, the producer can “guar-
that can help to improve its overall
next obvious step would be to apply for
performance and provide a sound basis
product certification according to a
Fresh information on the subject
for sustainable development initiatives.”
national standard. Of importance here
matter is rare. As a result, the powers
Businesses use standards to:
is understanding the definition of cer-
that be and office-bearers gain their
• satisfy customers’ quality
tification which, according to Google,
k n o w le dge f r om p e er s, c olle ague s
“is the action or process of providing
and personal interpretations. In many
• ensure safety;
someone or something with an official
instances, this leads to the content of
• ensure reliability;
document attesting to a status or a
the subject matter being misconstrued
• ensure consistency in service offering;
level of achievement”. In the precast
– a case of “broken telephone”!
• comply with regulations – eg the
concrete industry, product certifica-
How often have we heard in the cor-
tion thus means that the cer tified
ridors of production facilities and tender
Occupational Health & Safety Act;
involved in production are maintained; antee” product consistency and quality.
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• Once the comments have been in-
• a product having accreditation;
specifications SANS 1058:2012.”
• a product being accredited; or
and be certified to a standard, it is also
• a production manager boasting about
• T he f inal do cumen t is appr o v e d
important to request that the product
the accreditation of the products
and formatted by the SABS to SANS
certification certificates accompany the
response. Special attention should be
Hence, we again consult Google, which
• The standard is submitted to the DTI
paid to product certification expiry dates.
defines accreditation as: “The action or
This will be indicated on the certificate.
process of officially recognising someone
• The standard is gazetted and becomes
Consult the website of the certification
as having a particular status or being
vestigated, the draft is aligned and
When specifying products to adhere
official and legal.
body to verify the validity of certification.
qualified to perform a particular activity”.
Product certification according to
A letter accompanying an expired product
Our key phrase in terms of accredita-
SANS specifications in the precast
certification certificate, stating that a
tion and product certification would read
concrete industry can be issued by
certification audit is in process, does not
as follows: “an institution, accredited to
two accredited entities: the Concrete
guarantee product certification.
do so, will issue product certification”.
Manufacturers Association Certification
There is thus a definite relationship
No product in the world is accredited
Services (CMACS) or the SABS. Both
between the correct specification of
to do anything. Products, however, can
these entities are South African National
products (with valid product certification,
be certified to adhere to a particular
Accreditation System (SANAS) product
according to the national standard) and
specification by someone who is ac-
successful project delivery.
credited to do so. We need to empha-
It is important to specif y quality
It is important to design correctly,
sise the accreditation of institutions
precast products correctly. The first
specif y correctly, draw the correct
which issue product certification. This
indication that a manufacturer might
supplier, verify the supplier and quality
is important because it contributes to
be manufacturing products consistent
standards, verify the supply product
proving that the product certification
in quality would be the implementation
and verify the contractor. Your ally in
is done according to an international
of a quality management system. This
these matters would be the industry
standard (ISO/IEC 17065:2012), that
could be a system recognised in terms
association. In terms of precast
it is legal and that it is recognised by
of ISO 9001 or an in-house system.
concrete, this would be the Concrete
Another important aspect to investigate
Manufacturers Association. In terms
To understand certification, it is
is whether manufacturers subscribe
of product certification, it would be
important to look at the origin of product
to their industry body or association.
the CMACS. Through these industry
specifications and standards. Strictly
Association membership, in the case of
association memberships, the industry
speaking, these were devised, written
precast concrete, is synonymous with
has access to and influence in important
and brought to life through industry.
quality, honesty, professionalism and
matters, such as national standards
The South African National Standards
adherence to a proper code of conduct.
relating to its businesses
(SANS) belongs to the Department of
Ultimately, the client would require
Trade & Industry (DTI). The South African
product certification from the supplier.
effectiveness are advanced through:
Bureau of Standards (SABS) is a service
Product certification should be issued by
• The elimination of remedial activities:
provider of the DTI. No standard was
an accredited certification body.
rebuilding, re-installing, re-excavating,
etc – all of which are very costly!
As a final word, project success and
ever designed by or belongs to the SABS.
It is essential that the call f or
We often hear it said that a product
product certification is done correctly
• T h e e limin a ti o n o f p r e v en t a ti v e
“must adhere to SABS standards” – an
in official requests for pricing and tender
ill-informed statement carrying specific
documents. Consider the following:
activities: propping, reinforcing and
• … The client calls for the supply of
• Product consistency, which elimi-
Simplifying the structure, national
products accredited to specifications
standards and specifications is done and
number “xyz”. Wrong : A product
• Quality products contributing to the
published in the following way:
cannot be accredited.
• The SABS, as the DTI service provider,
• ... The product should carry SANAS
• Quality products influencing delivery
nates failures. ease and speed of installation.
hosts, manages and fulfils the process.
accreditation to the South African
• Committees, sub-committees and
national standard. Wrong: SANAS
• Quality products contributing to
work groups concerned with a stan-
does not accredit products.
dard will contribute to its content.
• ... The tender calls for the supply of
Improve project delivery and reduce le-
Representatives would include engi-
a product according to SABS
gal liability by knowing what you purchase,
neers, architects, specifiers, con-
standard 1058. Wrong: SABS does
knowing how to specify it and knowing
t r a c t o r s, p r o d u c e r s a n d o t h e r
not have standards or specifications.
the resources available to investigate
T he corr ect way of specif y ing a
product consistency and quality.
industry or product experts.
• A draft of a specification or amendment
product would read as follows: “This
to site positively. positive project time-frames.
is created and approved internally.
document (RFI, RFP, tender) calls for
• The draft is circulated to the industry
the supply of products conforming to
the South African National Standards
Director: CMA Certification Services
PRECAST | ISSUE TWO | 2020
offices references to the following?
PRECAST TO SOLVE HOUSING CRISIS HIGHLIGHTED BY COVID-19 Difficulty containing the COVID-19 virus, particularly in informal housing settlements, has highlighted the urgent need for permanent, decent housing that allows some form of social distancing
bricks or blocks and mortar construction methods, only precast concrete construction techniques can fulfil this requirement. And the larger the unit, panel or entire wall made from precast concrete, the quicker and easier it becomes to erect a wall,” says Cockcroft. “Imagine each town, province or government department concentrating on this type of construction and
In this time of rebuilding and rethinking
ships with the various housing delivery
encouraging existing and new precast
our social structures, precast concrete
instruments of all levels of government,
manufacturers to deliver precast units
holds many of the answers government
including the relevant departments,
for the rapid erection of houses and
and society have been seeking. After
municipalities and state-owned enter-
buildings to replace informal housing
all, precast units and panels of precast
prises tasked with delivering housing
shanties. While the industry only has two
concrete offer solid, factory-made quality
and infrastructure to the nation.
or three role-players, we can rapidly add
materials for the rapid construction
moulds and facilities to precast walling,
of housing, clinics, hospitals and other
wet-cast cladding and many other types
“Traditionally, South Af ricans have
of established manufacturing plants.
CMA general manager Henry Cock-
rejected alternative construction tech-
croft says that now is the time for
niques such as wood, expanded polysty-
innovation and for companies, as well
rene and thin fibre cement panels as
“Community upliftment projects can also
as the association, to seek partner-
cheap, unsafe and insecure. These simply
be launched to manufacture panels and
fail the ‘knock test’ – when a knock’s
columns, as well as bricks and blocks. In
made on a structure and there’s a hollow,
addition, large-scale manufacturers who
resounding echo. Such units are usually
traditionally serve the infrastructural
rejected by the entire community as
needs of the country with concrete
cheap, inferior or even demeaning.
pipes, bridge beams, masts, etc can
“Given SA’s political past, housing is
launch advanced, new automated lines
a sensitive subject and promised hous-
using the latest panel walling equipment
ing allocations often need to be of high
to turn entire house walls quickly and
standards, solid and durable. Therefore,
efficiently,” says Cockcroft.
apart from the industry’s traditional
PRECAST | ISSUE TWO | 2020
He adds that rapid upscaling of the
“Precast concrete is the only viable and feasible solution to provide decent and durable housing for all South Africans more cost-effectively, rapidly and sustainably.”
industry will require commitment from
for windows, doors, plumbing and electrical
government and role-players. Perhaps
fittings in this type of housing may enable
banks and financial institutions can
would-be home-owners to buy kit form
throw their collective weight behind such
houses and erect them themselves,
initiatives by approving precast products
according to prescribed requirements.
and methods and making finance available to establish such plants.
The house, clinic or building could then be upgraded or expanded as funds become
With a little imagination and pooled
available. Most importantly, if erected
technical input of the industry, existing
correctly, this type of housing would
precast walling companies could relatively
pass the “knock test”, is attractive,
easily redesign more suitable products
safe, secure and could be passed on from
that work in much the same manner as
generation to generation.
Once production is ramped up, factories
current walling solutions. At the bottom
As far as RDP-type housing and
end of the industry, products could be pro-
affordable housing developments are
duced fairly inexpensively to compete with
concerned, large wall panels provide an
corrugated iron, but with the advantage
easy solution that is factory-perfect
of providing a solid and durable solution.
and can be pre-manufactured with all
“This will not only serve the purpose of
fittings in place. After a slab has been
finally ending the housing backlog, but
laid, either in-situ or hollow core-type
will also stimulate the building industry,
Flush-fitting columns, longer spans,
floating foundations are installed and the
as well as its downstream supply chain,
decorative finishes and standard fittings
house can be erected in a day or two.
including road manufacturers, plumbers,
can literally produce the walls as fast as builders can install them.
electricians, flooring, roofing and various fittings, etc,” says Cockcroft. “With the ravages of COVID-19 still working through our communities and the urgent need for social distancing in future, it’s about time that government, our industry and communities got serious about solving housing issues in SA. “Upon closer examination, I’m sure we’ll find that precast concrete is the only viable and feasible solution to provide decent and durable housing for all South Africans more cost-effectively, rapidly and sustainably than any other material available.”
THE PICP COMPENDIUM – INFORMATION REQUIRED Neil Armitage, deputy director: Future
via email: Neil.Armitage@uct.ac.za.
During the Mar ch workshop, he
Water and a professor in the Department
A list of PICP suppliers and contractors
welcomed Prof Anne Fitchett from the
of Civil Engineering at the University of
is also being assembled and details should
University of the Witwatersrand’s School
Cape Town (UC T ), has initiated the
be sent to Prof Armitage as well.
of Civil & Environmental Engineering.
compilation of a compendium of all South
As Precast readers know, Armitage
Fitchett will be conducting research into
African permeable interlocking concrete
heads a PICP working group comprised
PICP performance in Gauteng and, to this
pavement (PICP) installations.
of professionals and civil engineering
end, she has recruited two fourth-year
The intention is to record details
students who are conducting research
civil engineering students. They will follow
such as location, date of installation,
into how to improve the performance
the same general approach taken by UCT
design and designer, paving supplier,
of permeable paving systems and the
civil engineering student Cole Barnard,
PICP installer and performance criteria
quality of stormwater in a South African
while researching for his thesis. This
so that these details are readily to hand
context. The workshop convenes monthly
will involve carrying out both ASTM and
from a single source for ongoing research
and in March, it met via Skype for obvious
modified SWIFT infiltration tests to help
into local PICP performance.
reasons. Future meetings will be held on
verify or improve the equation describing
If you, dear reader, are aware of or
Zoom and anyone involved with PICP –
the link between the notional wetted area
have been involved in a PICP installation
for example, stormwater managers and
(m²) and the infiltration rate (mm/hr), as
at any point since 2007, Armitage would
landscape architects – and wishing to
well as determining the condition of the
like to hear from you. He can be reached
participate in these monthly workshops
pavements and the link between this and
on tel: (021) 650-2569 or, preferably,
should contact Armitage.
various design parameters.
PRECAST | ISSUE TWO | 2020
A NAME TRULY CAST IN CONCRETE
GAUTENG | KZN | WESTERN CAPE
PRECAST CONSTRUCTION SOLUTIONS
HEAD OFFICE: (011) 589 8800 WWW.ECHO.CO.ZA
essentially closed for business due to COVID-19 restrictions, it is critical that
MEETING POST-COVID-19 DEMAND
precast manufacturers plan for re-
essential maintenance throughout the
opening and the potential surge of demand
lockdown should have been carried out to
that may occur immediately afterwards.
enable factories to start up rapidly and
Construction must go on and materi-
enter production. “The quickest way to
als must be made available to rebuild the
recover from the effects of the shutdown
livelihoods of everyone in SA. This will take
is to work together and boost production
a concerted effort and require meticu-
to recoup losses.”
lous planning of smart building material suppliers to find ways of returning to production and profitability quickly.
With the construction industry still
He suggests seven interventions to boost production post-COVID-19: 1. Allocate resources and manpower
goals and yardsticks to: a) ensuring
This is according to Concrete Manu-
to the manufacture of products that
the company’s survival, b) recouping
facturers Association (CMA) general
will be in short supply due to low
lost pr oduction, c) r eturning to
manager Henry Cockcroft, who says that
stockpiles or high demand.
profitability and d) stretching targets.
2. Survey customers in order to forecast
6. Ensure that care is taken to prevent
their requirements upon re-opening.
the further spread of the disease.
3. Prepare concise instruction for
7. Monitor trade news, national and
managers, section leaders, supervisors
local media, as well as social media to
and staff to ensure the workforce gets
gain information that will assist in the
behind the plans.
4. Consider pr oduc tion incentives
response to actual requirements. “We wan t to con tr ibu te to the
to boost production and allow staff
country’s economic recovery and help
to claw back financial losses they
rebuild SA after this disaster. What
may have incurred.
better way to rebuild our livelihoods and
5. Implement a communication strategy
contribute to the country’s economy than
by being successful?” asks Cockcroft.
that motivates and provides simple
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POST-VIRUS UNITY IS REQUIRED With precast manufacturing businesses across the country entering uncertain times amid the COVID-19 pandemic, it is vital that the entire industry supply chain stands together and rebuilds in a structured and sustainable way. Work is already in progress as the construction industry seeks ways of rebuilding capacity in order to support the delivery of much-needed infrastructure, houses and related projects that need to be completed as quickly as possible after the pandemic has run its course. As a result, the Concrete Manufacturers Association (CMA) stands ready to support the industry in every way possible to ensure that the industry springs back more quickly. This includes the supply of information, networking, sharing best practices or any of the services offered through the association and its certification services. CMA general manager Henry Cockcrof t says the association has established communication networks reaching all areas of the industry, from grass-roots to managements and all stakeholders. “We’re going to have to stand shoulder-to-shoulder and rebuild our nation together. That’s why we want all concrete manufacturers, as well as their supply chains, to become members and strengthen our response,” says Cockcroft. He adds that a combined effort will be required to deal with future supply, manpower and resources of the industry, as well as with service providers. “Industry associations will play a more important role than ever before and we’re ready for the challenge.” (Above): CMA general manager Henry Cockcroft.
PRECAST | ISSUE TWO | 2020
“Lassen is as tough as any business-owner, with a firm, but fair approach which ensures all employees are treated equally and with respect.”
WOMEN BREAKING BARRIERS IN CONSTRUCTION For some time, Lascocrete in Cape
ticularly in traditionally male-dominated
is far from the truth. She is as tough
Town has been causing waves with its
industries like construction. Aiming to
as any male business-owner, with a
supply of all types of precast concrete
help change the status quo, Lassen is in
firm, but fair approach which ensures
products and standing by its motto of
the top bracket of women who make up
all employees are treated equally and
“impossible is nothing”.
14% of construction industry profession-
with respect. Her emphasis is on the
als and she hopes this number will rise as
importance of listening to employees
more females enter the sector.
and using that feedback to create bet-
The women-led company has become a leading manufacturer and installer of quality concrete products in and around
ter training methods and keep relation-
Cape Town. Leveraging 45 years of ex-
pertise, owner Theresa Lassen is proud
“The construction industry has been
ships healthy. The company produces specially de-
of its track record of delivering solutions
known for its male dominance in its po-
signed, lightweight precast Vibracrete
during troubling times.
sitions of power. Lascocrete’s success
panels for perimeters which provide
Women empowerment is a topic which
shows that the women of this era are
security and are aesthetically pleasing.
has generated substantial traction, par-
resilient and dominant and can achieve
Recently, it also introduced Lascokerbs
greatness. As a company, we pride our-
to the industry, which ties in with its
selves on women empowerment.
growth strategy of producing multiple
“We hope that our achievements will
complementary products. The kerb busi-
encourage all the women in our country
ness falls under the Lascokerbs banner
to speak up and fight for their success,”
and supplies civil contractors, develop-
ers and builders.
She adds that the company takes
Lascocrete has managed to stay
great pride in employee investment to
relevant for over 45 years, producing
ensure the highest standards are main-
high-quality products and building solid
tained. This is evident in the developmen-
customer relationships. The importance
tal strides made in the 10 years she’s
of role models to young South African
been at the helm, during which she’s
women cannot be underestimated and
created a structure that promotes in-
the strides taken by females such as Las-
clusivity, discipline and respect and aims
sen will contribute to their progression
to provide quality concrete products to
up the construction industry ladder.
satisfied customers. (Top): Theresa Lassen of Lascocrete.
Progressive style Overseeing a team of over 65 men and women, Lassen says the assumption that a female leader is soft and easy
PRECAST | ISSUE TWO | 2020
(Top left): Some of the products produced by Lascocrete. (Left, from top): The women-led manufacturing plant in Cape Town and a truck delivering products produced by Lascocrete.
INDUSTRY NEWS 12
REVELSTONE COMMITS TO JOB CREATION AND LOCAL PRODUCTION A s one of SA’s leading cast-stone producers of pavers and walling cladding pr oduc ts, Revelstone has always supported job creation and local production. “Re-igniting SA’s economy, job creation and the support of local businesses are more important than ever during the current pandemic,” says Revelstone director Alex Cyprianos. “We’re totally committed to alleviating unemployment and have always opted for increased labour over mechanisation. All the products in our extensive range are 100% locally designed, manufactured and delivered from our Cape Town factory, where we employ over 100 people. “In addition to creating employment, we’ve consistently upskilled and trained our own staff to grow into positions of greater responsibility. This, in turn, creates personal growth and long-term employment. “All South African manufacturers need the local economy to specif y
1993 by Cyprianos’s father, Andrew,
Revelstone into the market leader it
and use their products. Not only does
when he identified a niche in both the
this create employment, but it spurs
domestic and commercial markets for
investment in new products that equal
customised cast-stone products.
“We’re proud of what we’ve achieved. Through continual in-depth research into
or better global trends in designs and
Alex joined the company in 1997.
the art of stone masonry and design,
technology. For example, we’ve recently
By fusing their talents, substantial
we’ve been able to consistently introduce
created custom-made products for
concrete experience and their passion
exciting products to the market.”
several commercial projects in the
for the business, Andrew and Alex grew
Western Cape,” says Cyprianos. Made o f concr e te, Revelstone’s cast-stone products are an attractive alternative to natural stone products which are not only more expensive, but are less environmentally friendly and usually imported. “We only source the very best local materials for our cast-stone range. Ninety-five percent of our raw materials are sourced within a 100km radius of our factory. In addition, all our moulds are 100% recyclable, making our products environmentally friendly,” he adds. Revelstone was founded in August
“All the products in our extensive range are 100% locally designed, manufactured and delivered from our Cape Town factory, where we employ over 100 people.”
The company is still 100% familyowned and run, which guarantees that its founding principles of custom-made designs and high quality are not only maintained, bu t r einv ented as the business grows and develops. In this way, the ethos of Revelstone and what it has become is not compromised, but enhanced. “Knowledge gained from our research means all our products are indistinguishable from natural stone. Attention to detail, subtle variations in colour, variety of surface textures and the shape of the stone are essential in creating a worthy, genuine replica,” says Cyprianos.
PRECAST | ISSUE TWO | 2020
PRECAST | ISSUE TWO | 2020
BUILDING A POSITIVE AFRICAN FUTURE With evidence of the longevity and potential of its products on display in infrastructure across southern Africa, AfriSam’s presence is widespread. With a legacy that goes back 85 years, this construction materials supplier has contributed to many iconic projects. These include the Carlton Centre in the Johannesburg CBD, the Nelson Mandela Bridge, the Lesotho Highlands Water Project, numerous new developments in Sandton (including the tallest building on the continent, the Leonardo) and the Zeitz MOCAA in the V&A Waterfront in Cape Town. Although the CMA member has undergone changes in shareholding and names during its existence, AfriSam has remained true to its formula, according to Rob Wessels, acting CEO and Richard Tomes, sales and marketing executive. Tough times This, they concur, has been pivotal to AfriSam’s success, despite economic cycles experienced by the construction industry. The past five to six years have been particularly difficult for the construction industry (a key customer segment for AfriSam) and companies operating in that sector. Wessels says AfriSam has had to “right-size the business” and adapt where necessary to remain competitive, as well as continue to be the supplier of choice. “Business performance in tough times comes through shifting and broadening our customer base and by continuing to focus on the quality of our product, technical advice and the relationships we have with our customers. “AfriSam has a reputation for expertise and getting things right, and we’re determined to maintain this,” he says. Quality control Among the initiatives AfriSam undertakes to promote quality within the industry is its anchor sponsor of the Concrete Society of Southern Africa’s Fulton Awards. This, says Tomes, is in line with the company’s mission of “creating concrete possibilities by pushing the boundaries of concrete products, both in terms of sustainability and technical performance”. AfriSam is also the co-founder of the AfriSam-SAIA Award for Sustainable Architecture + Innovation, which recognises the importance of “green” building and acknowledges the contributions made by forward-thinking industry players towards bringing sustainable innovation to human living environments.
PRECAST | ISSUE TWO | 2020
PRECAST CONCRETE SLABS
SPEED UP HOUSING DELIVERY
MANUFACTURERS AND SUPPLIERS OF: Civil Engineering Pipes – Man Holes – Storm Water Channels Road Kerbs & Channels – Culverts Lighting & Transmission Poles Precasting, Poststressing & Prestressing to specification – Toilet Cubicles & Bus Shelters – Earth Retaining Systems
SA’s massive backlog in af f or dable
the norm,” says Elematic SA director
housing is likely to see continued demand
Craig Webber. “This makes the use of
for precast hollow core concrete slabs
pre-stressed concrete slabs an efficient
from Elematic SA, given the high-quality
and affordable solution, streamlining the
finish and the time that this technology
pace of construction work while enhancing
saves in the construction process.
building quality and lifespan.”
“With rapid urbanisation and the in-
The four-storey walk-up design, for
creased premium on land in urban areas,
instance, lends itself well to a repetitive
multi-storey residential designs are now
construction methodology where precast comes into its own. Webber emphasises that the precast option eliminates the need for back-propping and allows other trades to start working under the slabs immediately, significantly accelerating the project schedule.
Building Industry Hollowcore Decking Slabs – Beams Columns – Staircases – Walling Panels & Multi Story Precast Elements
Ready solution Moreover, the high-quality finish on the soffit – or underside – of the slabs makes an additional false ceiling unnecessary and eliminates this potential cost. The company’s precast staircases also lend themselves well to the fast-track approach to many modern housing projects. Using the traditional rib-and-block method of slab construction, contractors can wait about three weeks for concrete to cure fully before props can be removed and work can commence. “By comparison, we install our precast
Cape Concrete Works 021 9051200 firstname.lastname@example.org www.capeconcrete.com
“We install our precast slabs on one day and grout the next, allowing building to start on the third day.”
slabs on one day and grout the next, allowing building to start on the third day without any further delay in the project timeline,” says Webber. Factory conditions Manufacturing these advanced precast products under controlled conditions in E l em a ti c S A’s s t a t e - o f-th e - ar t production facilities on Gauteng’s East
PRECAST | ISSUE TWO | 2020
Hard product in the 52,5R strength
T his allows the manufactured
that is tested and fit for purpose. As the
class – to Elematic SA’s factories near
concrete product to be released from
largest producer of pre-stressed hollow
Benoni. AfriSam Rapid Hard cement is
the mould sooner, speeding up the
core slabs in the Johannesburg area, the
very fine, giving it a larger surface area
production cycle and making factories
company’s two factories include 16 beds
to react with water, which increases
as efficient as possible. It also provides
for a variety of slab sizes.
the rate of hydration and gives it higher
consistent strength performance, so
that production processes can be timed
“In operation since 2005, we received ISO 9001 certification in 2009 and
with precision and without any danger of
our products are approved by the SA
breakage due to weakness when removing
Bureau of Standards,” he says. “These
products from moulds. The high early
quality standards underpin our products’
strength makes this cement brand ideal
standing as among the most advanced
for pre-stressed members.
in the industry, backed by the extensive
The company has been using AfriSam
knowledge and experience behind the
cement since 2007, r elying on the
product’s consistency and quality, and
Originally established in Finland in 1959,
on AfriSam’s high level of customer
Elematic has precast production plants in
service. Like AfriSam, Elematic SA has
more than 70 countries worldwide. It is part of the Consolis Group, which focuses on research and development in cement and precast concrete products. Fast-setting Helping the business sustain its quality standards is construction material leader AfriSam, which provides a reliable supply of specialised cement – the Rapid
its own ISO-accredited laboratories and (Above left): In operation since 2005, Elematic SA received ISO 9001 certification in 2009 and its products are approved by the SA Bureau of Standards. (Below left): Controlled conditions under Elematic SA’s state-of-the-art production facilities ensures a constantly high standard that is tested and fit for purpose. (Above): Elematic SA has been using AfriSam cement since 2007, relying on the product’s consistency and quality, and on AfriSam’s high level of customer service.
WATERTIGHT CONCRETE SIKA® WT-200P
The crystalline admixture enables concrete cracks to self-heal and therefore block water, even when under extreme hydrostatic pressure. It will continue to reactivate whenever water is present. Benefits of using Sika® WT-200P in waterproof concrete: ■ Increase in service life of the construction ■ Significantly improved durability and sustainability of the hardened concrete ■ Ensured watertightness without other expensive measures ■ Reduced maintenance costs ■ Enhances the self-healing properties of concrete and promotes the ability to heal concrete cracks Call us for more info: 010 823 8688 www.sika.co.za
testing equipment to ensure consistent quality. Calibration of its test equipment is conducted regularly in line with SANAS standards. Moving with the times to conserve energy costs, this year the Elematic SA facility installed photovoltaic cells that will generate some 40% of its factories’ power demand.
Rand ensures a constantly high standard
The ef fective management and subsequent attenuation or storage of stormwater is critical in SA, as most municipalities now require the submission of stormwater management with all proposals for new commercial and residential developments.
Municipalities and engineers alike are trying to reduce the load on existing, traditional stormwater networks, as these are falling behind in their effectiveness due to massively increased volumes of water caused by the developmental impact of replacing grassland with hardstand. Sustainable urban drainage systems (SUDS) and subsequent engineering
MANAGING STORMWATER WITH
their pre-development state by virtue of
the majority of stormwater not running
instances, the impervious membrane is
off the site, but rather infiltrating into the
required to restrict water from entering
ground and thereby replenishing critical
the subgrade and thereby preserve
below-grade water tables and aquifers.
structural integrity of this layer. This
The goal is to manage stormwater on site
could be an important factor where clay
and have as little of it as possible passing
subgrades are encountered, in dolomitic
into municipal systems.
areas or where soils/stormwater are
designs start with the intention of creating newly-developed sites that mimic
expected to be contaminated. Viable solution
system over time. Accordingly, a heavy
An additional advantage of permeable
CMA member Technicrete’s “Aqua” range
rainfall event can be designed so that
pavement design is the element of
of blocks, manufactured to national
the entire volume of water is maintained
contaminant treatment. Studies have
standard: SANS 1058-2012, subscribes
and managed within the site boundaries.
shown that heav y metals, including
to a form of SUDS known as permeable
A secondary consideration at this
cadmium, copper, lead, nickel and zinc,
paving whereby vertical “slots” between
stage of design is whether to capture
are partly removed from the water
adjacent pavers provide drainage channels
this water only for attenuation (slow
through percolation in the stone layer
which allow stormwater to flow from the
release) or retention and re-use, both of
works so that water flowing out of these
surface, through the paving layer, into
which offer a myriad of further options.
systems is within potable requirements
suitably designed layer works below.
As such, three basic design philosophies
for these metals. Hydrocarbons (oil)
The premise behind a permeable paving
prevail, namely a full infiltration system,
have also been seen to be broken down
system is such that voids, inherently
a partial-infiltration, partial-discharge
by micro-organisms that grow in the
present between stones (19-63mm)
system or a “tanked” storage system.
geofabric and other layers that are
making up the structural layer works of
A full infiltration system is underlaid
generally kept moist.
the pavement, can accommodate water
with a pervious geotextile and is suitable
Technicrete’s permeable paving sys-
capacity up to 25% of the volume of
for use where it is feasible to infiltrate
tems have been successfully applied in
stormwater directly into a suitable
various developments, including major
A general design consideration for
subgrade. A par t-infiltration, par t-
industrial factories and large campus
the paving block is to allow water to
discharge system enables attenuation
parking facilities, and should be both the
flow through this layer at a rate of
into the municipal network at the rate
client’s and designer’s preferred system
approximately 9 000 litres (9 000mm)
prescribed for the site, as well as
for prevention of run-off and flooding.
per square metre per hour. A geotextile
infiltration into the ground below.
These systems are ideally suited for in-
placed between the bedding and storage
stallation in car parks, industrial estates,
layers will have the effect of throttling
retail centres, pedestrian areas, domes-
this flow-through rate to approximately
The third option is that of a tanked
tic estate drives, freeway services, ga-
half, or 4 500 litres (4 500mm) per
system which is lined with either LDPE or
rages, truck stops, container terminals
square metre per hour, although at
HDPE impervious membranes to create
and other heavy-duty applications and
design stage of the overall system, one
a “tank” and thereby capture and store
can be installed at almost any installation
generally uses a rate of 10% of the
the water for re-use in grey water and
where traditional segmental concrete
maximum, namely 900 litres (900mm)
irrigation systems. With additional
block paving has been specified.
per square metre per hour, as this allows
treatment, this stored water could be
for up to 90% potential blocking up of the
made available for potable use. In some
(Above): Successful stormwater retention can be achieved with permeable paving.
PRECAST | ISSUE TWO | 2020
, ,Y INFRASET
HOME WITHOUT HARM
Aveng lnfraset produces a diverse range of precast concrete products to world-class quality standards and actively contributes to SADC infrastructure development. Our range includes concrete pipes, culverts, manholes, special precast products, various types of pre-stressed railway sleepers, turnouts, maintenance-free railway electrification masts and poles, paving blocks, retaining wall systems and roof tiles.
Aveng lnfraset's admired heritage is founded on innovation, technical and service excellence.
Aveng Infraset Head Office Tel: +27 (0)11 876 5500 Fax: +27 (0)11 872 1713 email: email@example.com www.infraset.com
Pipes• Culverts• Manholes: Gauteng Tel: +27 (0)11 876 5100 Cape Town Tel: +27 (0)21 908 1156 Kwazulu Natal (Pietermaritzburg) Tel: +27 (0)33 387 2236
Railway Sleepers• Poles & Masts National Tel: +27 (0)11 813 2340
Paving• Retaining Walls• Roof Tiles Rossway (Midrand) Tel: +27 (0)12 652 0000
International Branches Swaziland Tel: +2682 518 4236
Kwazulu Natal (Effingham) Tel: +27 (0)31 569 6900
Zambia Tel: +260 21 131 1838
NEW CONCRETE PRODUCT SEALING SYSTEM
IMPROVES PRODUCT MARKETABILITY
Home-grown concrete manufacturing
edge of the concrete products or pallets.
and concise information. It allows for
solution provider, PMSA, has introduced
The spraying system may be used on the
easy input of data, as well as application
an advanced sealing solution to protect
wet side (prior to curing) and on the dry
recipes which can be created via the
pavers, slabs and blocks, as well as
side (after curing). All the nozzles also
touch-screen panel for various products
precast and wet-cast products from
have specially designed mechanisms
and then stored.
the effects of weathering, staining and
that prevent clogging and resultant
Besides relevant parameters, such
downtime. In addition, the Finke system
as applied quantity, pallet speed rate
The equipment supplier’s imported
has an integrated sensor that monitors
and pallet length, the recipes also store
range of ProSeal and ProSeal Plus
the temperature of the product, as it
the positioning of the spray nozzles, eg
sealants, as well as its intelligent low-
shouldn’t be applied at temperatures
for different product heights. When a
pressure spraying system, allow seam-
below 10°C,” says Booysen.
particular recipe is uploaded, the spray
less sealing of concrete products while still in the production plant in a rapid and cost-effective manner. The film-forming sealants reduce the penetration of external impurities, as well as the formation of efflorescence. In addition, the new water-based sealants are 100% solvent-free and environmentally friendly. According to PMSA marketing and sales manager Quintin Booysen, the automated application of sealants is less
“The precise coverage of each product on the pallet significantly improves the marketability of concrete products.”
system automatically moves into the pre-programmed position. The control system is also equipped with a LAN port, making it possible to access via the Internet at any time.
Benefits of the PMSA-Finke SPA system • Easy integration into the pallet
• Precisely adjustable
labour-intensive and the precise coverage
He explains that speed, pallet and prod-
of each product on the pallet significantly
uct size, temperature variances and other
improves the marketability of concrete
factors are pre-programmed into the unit,
• Short installation time.
products due to their improved appear-
as well as a measurement of the exact
• Adaptable to various
ance, colour intensity and long-lasting
amount of ProSeal sealant to be applied.
• Uniform sealer application.
repellent and strength characteristics. Easy controls
• Sturdy and reliably built.
These measurements are then used in
• Low maintenance.
“The sealants are best applied with our
accordance with the program, which
• When used on dry side, infra-red
precision SPA spraying system from
means that even if the pallet feed rate
Finke Solutions, which ensures exact
changes, the spray system automati-
• Clogging of nozzles is prevented.
measurement of sealants for complete
cally adapts to such changes. The pallet
• Application quantity is approxi-
coverage of each unit on pallet – with
feed rate can be entered manually or the
mately 70-200g/m², depending
almost no wastage.
control panel of the spray system can be
on surface texture and
“It’s a low-pressure system that
linked via a “Profibus” with the control
applies the sealants in an exceptionally
panel of the production machine, which
uniform manner, avoiding excessive spray
then specifies speed and applied quantity.
mist. It has two outer nozzles which ex-
The SPA spraying system is operated
tend the coverage to exactly the outer
via a touch-screen panel, giving clear
PRECAST | ISSUE TWO | 2020
heaters are required.
(Above): PMSA’s ProSeal and ProSeal Plus sealants being applied with its PMSA-Finke SPA spraying system.
BATTERY-MOULDED SOLID WALLS AND FLOOR SLABS T he manufacture of solid walls and
space on its site. The two-sided version,
of a traditional battery mould into two
floors can benefit from battery moulds
in p ar ticular, o f f er s the f lex ibili t y
separate cells, it allows production of
which greatly assist in increasing the
of both sides being able to be used
two products, instead of one.”
production of these products, despite
independently. These machines are also
restricted space in the precast plant.
easily customised for the number and size
They also ensure that a smooth and
of the manufacturer’s casting cells, while
Elematic’s cold shuttering system also
ready-to-paint finish is achieved on
the mould furnishing can be chosen to
doubles the capacity of a traditional
both sides of the panel. Solid walls are
meet the individual needs of the factory.
battery mould. The system allows two
similar to solid floors in that they are
It is also possible to add more casting
castings per day. A cold shuttering
constructed from concrete and can
cells to an existing mould, if needed, or
system means that a casting cell of a
be manufactured in any structurally
to upgrade a traditional mould into a cold
traditional battery mould is divided into
required thicknesses. The solid wall is
two separate cells with a partition plate.
cast at the factory and then delivered
“The most common wall panel size
The partition plate – a shutter plate –
to site, completely ready for installation.
produced is 3m x 8m and such a panel
moves most of the process steps outside
Solid walls are used as façades or
can be cast in every casting cell. All the
the actual battery mould, therefore
functional walls. They are well suited to
furnishing – eg door and window openings
significantly speeding up the production.
structural load-bearing applications.
and electrical wall sockets – also happens
Furnishing of the 20mm-thick cold
Technologies such as the Elematic
vertically,” says Elematic’s product
shutter plates takes place outside the
battery mould can be game-changers for
director: Wall Technologies, Toni Koitmaa.
mould. After casting and pre-curing,
precasters to produce more products
“With a cold shuttering version, you can
the slabs attached to the cold shutter
more quickly, even in limited spaces. For
also double the output and increase the
pla tes ar e mo v ed to special r ack-
example, the machines offer high produc-
holders for final curing and de-moulding.
tion capacity in a very compact format,
“Normally, it takes eight to 10 hours
Once the mould is empty and clean,
with all handling done in a vertical position.
for a slab cast in a battery mould to
another casting round can be started
It is also fast to install and movable.
cure, but the cold shuttering version is
immediately by placing new, already
available for a new casting round after a
furnished cold shutter plates to the
four-hour pre-curing process. Because
With one- or two-sided versions available
the mould is equipped wi th pla tes
in SA, the manufacturer can maximise
which basically divide the casting cell
(Top): Elematic’s cold shuttering system.
PRECAST | ISSUE TWO | 2020
NORTH WEST TAXI RANK
GETS PRECAST MAKEOVER The JB Marx taxi rank in North West
vandal-proof. They offer shelter from
P r o v in c e h a s b e e n u p g r a d e d w i t h
heat and rain, besides providing seating
new precast concrete shelters and
for waiting commuters,â&#x20AC;? comments Dillon
supporting infrastructure designed to
Carter, sales consultant for Rocla in
make commutersâ&#x20AC;&#x2122; trips more comfortable.
North West Province.
T he R12 million upgrade centres
He adds that the durability of the
around the precast concrete shelters
precast concrete products of fers a
and provides commuters with access
relatively maintenance-free lifespan â&#x20AC;&#x201C; an
t o w ashing b a y s, ha w ker s t alls,
important factor for local municipalities
ablution facilities and a complete waste
wanting to ensure budgets for street
management building. The structures for
furniture are well spent. And, with the
the rank in Ikageng Extension 7, which
flexibility of the Rocla bus shelter, which
borders Potchefstroom, were supplied
can be supplied in various configurations
by CMA members Rocla, with interlocking
and colours, the new shelters now
pavers supplied by Technicrete.
also provide an easily painted surface
According to contractor ALS Civil Projectsâ&#x20AC;&#x2122; project manager, Chris Nel, the
for advertising, roadside markings and community notice purposes.
company required high-quality products from a trusted supplier in order to
get the job done professionally and
Technicr e te 60mm Double Zig-Z ag
on time. Having worked with the two
(DZZ) CL40/2.6 (40mpa) interlocking
precast manufacturers on numerous
pavers were selected for the entire
projects since 2010, the company knew
road surface of the rank, as well as
it could expect a high standard from the
for the walkways, with a total area of
suppliers. â&#x20AC;&#x153;Theyâ&#x20AC;&#x2122;ve never let us down and
7 000mÂ˛. The pavers were ideal for
we find their cost-competitiveness is in
installation in the taxi rank, where heavy
the quality of their product,â&#x20AC;? says Nel.
traffic footprints are anticipated. The interlocking pavers form a continuous
surface overlay, while still providing a
â&#x20AC;&#x153;The precast concrete bus shelters are
good-quality, attractive finish.
a specialised product from Rocla. We
â&#x20AC;&#x153;Space on site became one of the
needed 148 units for the JB Marx taxi
projectâ&#x20AC;&#x2122;s challenges, but was overcome
rank and due to the variety of dimensions
by fine-tuning our delivery scheduling.
required for the project, different moulds
The feedback on the product quality from
had to be used in the manufacturing
ALS Civil Projects was very positive. Our
process. This meant the moulds had to
efforts to ensure that the DZZs were
be numbered at the Rocla factory and
cured appropriately â&#x20AC;&#x201C; longer than usual,
delivered to site in the correct order
due to the paver strength requirements
for installation, This was seamlessly
â&#x20AC;&#x201C; and that our production and delivery
executed by Rocla.â&#x20AC;?
planning dovetailed with deadlines also
â&#x20AC;&#x153;Some of the bus shelters were also
contributed to the successful installation
converted into hawker stalls and, as a
of the taxi rank project,â&#x20AC;? says Technicrete
result, are virtually indestructible and
civil technician James Honibal.
PRECAST | ISSUE TWO | 2020
1907 Tel: 021 465
Find a supplier www.terraforce.com
RDP HOUSING PROJECT Precast concrete masonry blocks and
390 x 190 x 140mm and 390 x 190 x
hollow-core slabs are being used for
90mm. In addition. BluBlok is supplying
the construction of Lourensia Park, a
its 140mm U block, which is being used
City of Cape Town RDP housing project
in place of lintels, as well as the kerbing
situated in Somerset West. Comprising
for Lourensia Park’s roads, which were
86 double-storey 40m² units and 62 single-storey 40m² units, Lourensia Park was designed and is being built by housing specialist ASLA Construction. Concrete blocks are being supplied by precast concrete manufacturer BluBlok in three sizes: 190 x 190 x 190mm,
(Top, from left): Some of the single-storey houses at Lourensia Park and BluBlok production manager Kevin Coetzee and Wayne Nieuwoudt, ASLA site manager at Lourensia Park. (Left): Partially completed double-storey houses at Lourensia Park. (Right, from top): The interior of a single-storey unit and a double-storey unit under construction.
Since 1958 we have been developing and producing world-class products for YOU USE ONLY QUALITY PROVEN PRODUCTS FOR THE BEST RESULTS: • • • • • • • •
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Reap the benefits with OUR products: • Tel: + 27 11 822 2320 • Fax: + 27 11 822 2354 • e-mail: firstname.lastname@example.org 6091 A.Shak Constrctn PRECAST 1/2PG july’20
BUILT WITH PRECAST CONCRETE built as part of the civil works by ASLA
Eastern Cape Housing Depar tment
inspected the site in December. One of
the time it is completed. Each house comprises a living area,
BluBlok’s140mm block is being used
the contract conditions was that local
a bathroom and two bedrooms, and
for the exterior walls of the double-
labour be used for the construction
the ceilings are insulated with 135ml
storey units and the 190mm block for
work and at least 60 local labourers
Isotherm. The window frames are in alu-
the inner walls. The exterior walls of
will have been used on the project by
minium and the roofing is IRB sheeting.
the single units are being built with the 190mm block and the interior walls with the 90mm block. Trusted supplier ASLA site manager Wayne Nieuwoudt says BluBlok blocks were chosen for this pr ojec t because o f their high quality. “It’s vital to use a good-quality building material to ensure there are no comebacks and we know we can rely on BluBlok. We’ve never had any problems with its output,” he says. Both the single- and double-storey units are being built in f our-unit structures and pre-stressed hollow-core slabs, manufactured by CMA member, Cape Concrete, were used for the upperlevel flooring of the double-storey units. Nieuwoudt says using precast slabs makes for considerable time-saving. “No propping or shuttering are required and the slabs can be installed in a matter of hours, as opposed to the weeks it would take to build the upper flooring with insitu concrete. Moreover, we’re able to start building the upper-level walls as soon as the slab installation has been inspected.” Completion near Building began in October last year and the houses will be ready for occupancy in June/July 2020. A delegation for the
PRECAST | ISSUE TWO | 2020
“It’s vital to use a good-quality building material to ensure there are no comebacks.”
EXPOSED AGGREGATE PAVERS TRANSFORM
HISTORIC CAPE TOURIST DESTINATION One of Cape Town’s well-known tourist
infrastructure for the sewerage, storm-
Inca director of operations Schalk van
destinations, the historic Imhoff Farm
water, water, fire network and electrical
Wyk says the tan exposed aggregate
in the gr ea ter K omme tjie ar ea, is
reticulation,” says Burger & Wallace
paver conforms to SANS 1058:2015
undergoing a regeneration project. An
director Colin Budge. “The stormwater
Class 2.0 paver specifications. It is
important aspect of the project has
pipes feed into an attenuation pond which
tested on a regular basis for tensile
been the paving of the existing entrance,
will alleviate any over-burdening of the
splitting, abrasion-resistance and water
driveway and parking areas with an
area’s existing stormwater drainage.”
absorption at Inca’s in-house laboratory.
exposed aggregate paver supplied by
“Our tan exposed aggregate material
CMA member Inca Concrete Products.
through-mix is specifically designed to
The project was initiated and is being
achieve a uniform, natural look that
managed by Imhoff Farm owner Red Cliff
mimics and blends in with the natural
Property. According to Red Cliff MD
Gerhard van der Horst, the paving serves
“The advantage of an interlocking
the dual purpose of providing a durable
paver is that once laid, it doesn’t move
surface for cars and trucks and adding
and forms an integrated whole. It’s also
greater aesthetic appeal at the front
extremely strong, which is why it’s so
end of the farm.
popular across the world. Furthermore,
“T he paving formed par t of a
sections of paving can be removed for re-
landscaping plan, which was drawn up by
medial work or new below-ground installa-
landscape architect, Planning Partners.
tions and then replaced without patches
The result is an integration of the paving
or visible evidence,” says Van Wyk.
w i th se v er al indigenous r ocker ies, the latter having been established to
add colour and natural variety to the
Van der Horst says the architectural
landscape. The rockeries were built using
language of the new building plans is
rock excavated during the installation
a contemporary and complementary
o f below-gr ound inf r astr uc tur e. In
response to the farm’s existing historical
introducing paving to the farm, we
felt it was important to retain a rural
The layer works of the paved area
“In addition to the landscaping, other
look and feel by choosing a paver with
comprise 150mm G5 sub-base aggregate
regeneration aspects include a vineyard,
rustic appeal – and Inca’s tan exposed
and the pavers are bedded in 20mm of
an office pavilion, a stable, farm stores
aggregate interlocking paver fulfils this
sand. “One of the advantages of using
and a market/pedestrian avenue. The
objective perfectly,” says Van der Horst.
ex posed aggr ega te pa v er s is tha t
project has resulted in the creation of
they’re less prone to show tyre marks.
local jobs in the broader Kommetjie area,
Inca’s tan exposed aggregate pavers
which will also benefit from increased
Laid by Burger & Wallace Construction
are cast with aggregate throughout
tourism to the area,” he says.
in November 2019, the paved area cov-
the whole paver, which means that if
ers 3 200m². “Before we could begin
there’s any wear, they’ll retain the same
laying the pavers, we had to install the
appearance,” says Budge.
(Top and above left): Imhoff Farm with recentlyinstalled Inca tan exposed aggregate pavers.
PRECAST | ISSUE TWO | 2020
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When Anat Yukel, owner of a home on the slopes of Table Mountain, noticed some sections of her existing retaining wall collapsing and leaning over dangerously in others, she turned to her trusted builder, Zane Samuels of Zane Samuels Construction, for help.
After examining the wall, Samuels recommended replacing it with the Terraforce retaining wall system. “I suggested Terraforce because of the system’s ability to handle tight working spaces and varied inclines and, most importantly, because of its attractive aesthetics,” he says.
RETAINING WALL REPAIR:
A STITCH IN TIME
“We began by carefully removing the
cludes a new curved feature that hides
needs to do what it was designed for
old retaining walls. This also involved
a bulky section of the previous retaining
– stabilising the embankment. Overall,
propping them up in some sections to
wall, while simultaneously adding visual
this worked out very well, as the two
handle the surcharge loading of the prop-
character to the backyard area.
block textures complement each other,”
erty directly above. L11 retaining blocks,
Samuels opted to install the L11’s
supplied by licensed Terraforce manu-
rock face on the curved section facing
“I’m beyond happy with the result of
facturer Klapmuts Concrete, were then
onto the garden and the flat-faced
this repair,” says Yukel. “My backyard
placed on a solid concrete foundation.”
block for the wall immediately behind
looks much better than before and the
wall’s also very pleasing to the eye. I
The wall was designed by Fred Laker
of ICOS Engineers, who has extensive
“The curved wall needed to form
plan to plant creepers at the top that
experience with the Terraforce system.
part of an attractive space because an
will gently trail down the wall. That will
Working with the existing contours of
office window opens onto this area, while
add some greenery and soften the look
the property boundary, the design in-
the wall behind the main home simply
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PERMEABLE STABILISATION BLOCKS LINE STORMWATER CHANNELS Permeable concrete stabilising blocks
erosion control before the Earthlock
have been used to line three stormwater
blocks were laid.
channels which drain a section of Sanral’s
A single row of blocks was placed
widened and upgraded portion of the N7
at the base of the channel and two
highway just north of Malmesbury in the
rows of blocks were laid on its sloping
sides. The blocks were laced with steel
Supplied by CMA member CEL Paving
wire to provide a flexible structure and
Products to the main contractor, Triamic
reinforced concrete edge beams were
Construction, hollow G8 Earthlock blocks
installed between the blocks at 20m
were laid to stabilise the channels,
intervals as a further stability measure.
preventing soil erosion and ensuring
“The edge beams ensure that should a
a controlled discharge of stormwater
section be damaged, the whole channel
during heavy downpours.
won’t be affected – only that particular
According to Sanral project manager
20m section,” says Marius Matthee,
E lma L our ens, the E ar thlo ck-line d
the site agent for Triamic Construction.
channels ar e f ed by concr ete-lined
Two further soil-covered rows of
trapezoidal drains which run parallel to
blocks were laid on either side of all three
the highway. “They drain into concrete
channels to ensure that stormwater
The side slopes of these two channels
drop inlets or gabion side overflow weir
flows into and not under them, which
were kept flatter than the first channel
boxes and then drain down the Earthlock-
it would have done had these additional
to allow farmers to drive over them in
lined channels into gabion stilling basins
rows not been installed. These buried
their tractors and bakkies.
lined with reno aprons at the outlets.
r o w s w er e an ch o r e d w i th w o o d en
Matthee notes that G8 Earthlocks
The stilling basins drastically reduce the
pegs to keep them in position while
are easy to work with, especially on
water velocity and facilitate a controlled,
backfilling and soil covering took place.
sites which are inaccessible to readymix
non-erosive discharge into adjacent
Further anchorage was achieved by
fields,” says Lourens.
driving 1,4m-long Y-standards into the
“They have an additional advantage in
holes in the blocks at a spacing of one
that the hollows in the blocks are filled
with soil. This facilitates the growth of
grass, which only takes a year or two,
The combined length of the three channels amounts to approximately 700m along
depending on rainfall. Besides looking
sloping ground that varies from 1:10-1:7.
The second and third channels were built
good, the grass further slows down the
The first channel was built on a 12% slope
to handle greater volumes of water and
velocity of water.”
(1:8) after stormwater had cut a deep
are more than double the width of the
donga in the soil. It began by repairing
first. They were lined with three rows of
the er oded section with impor ted,
blocks at the base, three rows on each
compacted material and then placing a
of the sides and, as with the first, two
layer of geotextile for additional subsoil
earth-covered flanking rows for stability.
(Top): The first channel, with one of the stabilising concrete edge beams in the foreground. (Above, from top): The top section of the second channel before the finishing-off work was completed and the bottom end of the second channel under construction.
PRECAST | ISSUE TWO | 2020
PERMEABLE PAVERS FOR A GREENER MOSSEL BAY Between 2016 and 2019, the Mossel
(tapestry) of blocks for extra stability.
B a y M u n i c i p a l i t y h a d 6 5 8 7m ² o f
However, Holger Rust, member and
Terracrete Eco-surfacing installed using
owner of Terraforce, believes it was not
the Terracrete® paving block system to
necessary to add the horizontal holes.
line stormwater channels and create
“According to the American National
country road strips. This multi-purpose
Concrete Masonry Association, cabled
and cost-effective eco-surfacing system
articulating concrete mats, for design
was supplied by CMA member Mobicast,
purposes, offer no additional hydraulic
which manufactures the Terracrete®
stability or structural value to the
block for the Southern Cape region
articulating concrete block mat or block
under licence to another well-known
system [NCMA T EK 11-9B, revised
CMA member, Terraforce.
2014]. Where it can be justified is in
According to Altus Eitner, Streets
the prevention of vandalism. It’s up to
& S t o r m w a t e r / P r oj e c t P l anning &
each client to decide whether they wish
Management, Mossel Bay Municipality,
to pursue this option, but it does make
the Terracrete® paving block system was
the manufacture and laying of the blocks
fit for purpose thanks to the blocks’ large
much more time-consuming and labour-
holes and unique interlocking mechanism.
intensive,” says Rust.
“Moreover, they’re fully permeable
Nickey le Rou x, communications
and plantable. This enables them to easily
officer: Mossel Bay Municipality, says:
integrate with any environment to which
“We strive for a green municipality and
they’re introduced. Plant roots anchor
in being less expensive than the normal
the blocks and help strengthen them,
interlocking paving systems, Terracrete®
especially against flooding and the holes
Eco-surfacing has allowed us to do more
also provide passage through the blocks
with the funds at hand. In other words,
for worms and bugs,” says Eitner.
we’re getting more value for money.”
“Another beneficial aspect of the blocks is their size. T hey’re larger, wider and thicker than normal paving,
and are better at spreading the load.
Engineer: Municipal Official,
In addition, maintenance is easy, as the
Altus Eitner Pr.Eng
blocks provide a stable platform for the
Main contractors: Benver Civils,
mowing of grass, if needed, and when
New Adventure Plant Hire, Move
block strength is increased to 30Mpa,
they’re suitable for low-volume country
Municipal OHS Officer:
roads, such as our Stasiekop Road
installation, where the gradient was
Mobicast has also developed a method to add horizontal holes to the blocks during manufacture, allowing the threading of 3,1mm galvanised fencing wire through each block, so that they form a tight unit
PRECAST | ISSUE TWO | 2020
(Above): A water channel in Mossel Bay lined with the Terracrete® paving block system and a Terracrete® paving block system in a Mossel Bay water channel partially covered with grass and other plants.
Precast concrete beams and slabs manufactured by Cape Concrete have been used for the construction of two footbridges on either side of an existing road bridge on the R44 which carries traffic over the N2 highway in Somerset West. Spanning approximately 35m across each of the N2 lanes and 3m wide, the f ootbridges were required because the lef t-hand pedestrian/cycle lanes on either side of the road bridge were appropriated to accommodate a third traffic lane in both directions. Begun in April and completed in March 2020, the footbridges were designed by HHO Consulting Engineers and were constructed by Martin & East. The use of precast concrete greatly reduced the disruption to traffic which would have ensued had in-situ construction been used for the construction of the bridge decking. Each bridge required eight pre-stressed beams which were arched for material efficiency and aesthetic appeal. Further, a variable recess was introduced to the outer beam profile, creating additional visual interest. Four beams extend 22,5m x 1,53m (maximum
PRECAST CONCRETE SPEEDS UP CONSTRUCTION
OF HIGHWAY FOOTBRIDGES height) x 800mm (width) and four meas-
removed from the soffit formwork, the
ure 12,5m x 1,2m (maximum height) x
pre-tensioned steel strands were de-
800m (width). The 68 reinforced precast
tensioned/cut, thereby transferring the
concrete slabs measure 2m x 3,1m x
load from the strands to the beams,”
support on either side of each bridge,
Cape Concrete factory manager Johan
the beams also act as parapet walling
Nel says the longer beams weighed 34
and provide support for steel handrails
tonnes and the shorter beams 17 tonnes
which were interlaced with steel ropes
apiece. “We used an approved W50 con-
for the additional safety of bridge-users.
crete mix design to achieve the required
The beams were cast with anchor bolts
concrete strength and quality, a formula
to accommodate the handrails, a pro-
we’ve used successfully on numerous
cess which required a high degree of
other precast bridge beam contracts.
casting accuracy at Cape Concrete’s
Besides providing structural decking
“The beams were cast at our 1 000T,
38m pre-stressing facility and were individually stressed with a single-strand jack. Using overnight steam-curing, we achieved the required 35Mpa strength after 18 hours. Before the beams were
(Above): A deck expansion gap prior to the expansion joint installation. (Left, from top): Concrete panels loaded for delivery and some of the arched concrete beams prior to delivery at Cape Concrete’s production yard.
PRECAST | ISSUE TWO | 2020
tween Saturday night and Sunday morning and the other between Sunday night and Monday morning. During this process, the N2 traffic was diverted over the existing interchange on- and off-ramps. The beams rest under their own dead weight on 80mm bearing pads and. once in position, were temporarily anchored to the existing bridge and then cross-braced with push-pull props until the slabs had been inserted. Cast with protruding steel stirrups, the slabs were installed at a later stage using a truck-mounted crane parked on the road bridge. Once the slabs were in place, the steel stirrups meshed with the protruding rebar of the beams and, together with additional lacing, were then filled with in-situ concrete to form
“One bridge was completed between Saturday night and Sunday morning.”
an integrated structure. Finishing touches Once all the construction work had been completed a 30mm layer of asphalt was laid as the final wearing surface. HHO director Andrew Rowan says the
considerable attention to detail in the
The decking is supported by three cast-
design phase transformed a conventional
in-situ concrete piers and two abut-
beam and slab bridge concept into a
ments at either end of each bridge. Each
visually pleasing upgrade to the existing
abutment was founded on two 14m x
200mm diameter micro-piles, installed
“T he ex tensi ve use of pr ecast
through the existing bridge embank-
concrete for the bridge superstructure
ments, mitigating the need for large
and careful planning during the
excavations. Piling was not required for
construction phase have delivered a
the piers thanks to the bridges’ light
footbridge that takes full advantage of
loading requirement and good-quality
prefabricated concrete construction’s
positive benefits,” he says.
Due to the high traffic volumes at this intersection, the installation of the beams took place at night using a 150-tonne mobile crane. One bridge was completed be-
PRECAST | ISSUE TWO | 2020
(Above): A mobile crane offloads and places one of the beams into position. (Below): One of the three piers with bearing pads in position.
MEMBER LIST 36
PRODUCER MEMBERS A FICK SEMENTWERKE BK TEL: (022) 913 1921 PROVINCE/COUNTRY: WC PILLAR: PB AGW TRADING T/A KOLBE BLOCKS TEL: (041) 406 7900 PROVINCE/COUNTRY: EC PILLAR: PB AVENG INFRASET (PTY) LTD TEL: (011) 876 5500/872 1713 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BETA TILES (PVT) LTD TEL: (263) 4333735 PROVINCE/COUNTRY: ZIM PILLAR: PB C.E.L. PAVING PRODUCTS (PTY) LTD TEL: (021) 905 5998 PROVINCE/COUNTRY: WC PILLAR: PI CEMBLOCKS (PTY) LTD TEL: (014) 538 0311 PROVINCE/COUNTRY: NW PILLAR: PB/PI CEM BRICK MANUFACTURERS (PT Y) LTD TEL: (051) 433 4479 PROVINCE/COUNTRY: F/STATE PILLAR: PB/PI CONCRETE UNITS (PT Y) LTD TEL: (021) 386 1923/ (016) 362 2236 PROVINCE/COUNTRY: WC/GAUT PILLAR: PB/PI CONFRAMAT (PTY) LTD TEL: (0861) 33 5599 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CORESLAB (PTY) LTD TEL: (087) 232 2462 PROVINCE/COUNTRY: LIMPOPO PILLAR: PB/PI COROBRIK (PTY) LTD TEL: (031) 560 3252 PROVINCE/COUNTRY: KZN PILLAR: PI DERANCO PRECAST (PTY) LTD TEL: (041) 463 3338 PROVINCE/COUNTRY: EC PILLAR: PB/PI EAGLE ROOF TILES (PTY) LTD TEL: (044) 874 0290 PROVINCE/COUNTRY: WC PILLAR: PB HORIZON BRICK & CONCRETE TEL: (012) 943 3701 PROVINCE/COUNTRY: N/W PILLAR: PB INCA CONCRETE PRODUCTS (PT Y) LTD TEL: 072 646 4916
PROVINCE/COUNTRY: WC PILLAR: PB/PI LATEGAN CEMENT WORKS (PT Y) LTD TEL: (021) 873 1154 PROVINCE/COUNTRY: WC PILLAR: PB/PI MANHOLES 4 AFRICA (PT Y) LTD TEL: (011) 903 7023 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI MOBICAST (PT Y) LTD TEL: 086 111 2346 PROVINCE/COUNTRY: WC PILLAR: PB/PI MONIER COVERLAND (PT Y) LTD TEL: (011) 222 7300/7334 PROVINCE/COUNTRY: GAUT PILLAR: PB MVA BRICKS CC TEL: (012) 386 0050 PROVINCE/COUNTRY: GAUT PILLAR: PI PAVECON MANUFACTURING (PT Y) LTD TEL: 087 940 3631 PROVINCE/COUNTRY: LIMPOPO PILLAR: PI PORTLAND HOLLOWCORE SLABS (PT Y) LTD TEL: (021) 972 1111 PROVINCE/COUNTRY: WC PILLAR: PI REMACON PRODUCTS CC TEL: (011) 393 5504 PROVINCE/COUNTRY: GAUT PILLAR: PI REVELSTONE (CAPE) (PT Y) LTD TEL: (0861) 173 835/ (021) 761 9737 PROVINCE/COUNTRY WC PILLAR: PI ROCLA (PT Y) LTD TEL: (011) 670 7600 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI SHUKUMA BRICKS (PT Y) LTD TEL: (041) 372 1013 PROVINCE/COUNTRY: EC PILLAR: PB SHUKUMA FLOORING SYSTEMS T/A ZITTLAU EIENDOMME (PT Y) LTD TEL: (041) 372 1933 PROVINCE/COUNTRY: EC PILLAR: PB SOLID PAVE BRICKS (PT Y) LTD (CONTICRETE) TEL: (041) 365 7676 PROVINCE/COUNTRY: EC PILLAR: PB TECHNICRETE (PT Y) LTD TEL: (011) 672 1425/670 7600 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI
VANSTONE PRECAST (PTY) LTD TEL: (012) 541 2056/1808 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI VIBRO BRICKS & PAVING (PTY) LTD TEL: (012) 374 5533 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI WEST END CEMENT BRICKS (PTY) LTD TEL: (011) 851 1005 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI WZ BETONWERKE (PTY) LTD TEL: (057) 733 1626 PROVINCE/COUNTRY: FREE STATE PILLAR: PB NON-PRODUCER MEMBERS ABEL EQUIPMENT CC TEL: (044) 874 1876 PROVINCE/COUNTRY: EC BIRKENMAYER H (PT Y) LTD TEL: (011) 970 3880 PROVINCE/COUNTRY: GAUT CHRYSO SOUTHERN AFRICA (PT Y) LTD TEL: (011) 395 9700/ (031) 564 0325/(021) 928 1660 PROVINCE/COUNTRY: GAUT/ KZN/ WC
ASSOCIATE MEMBERS AF CONSULTING ENGINEERS & ASSOCIATES (PT Y) LTD PROVINCE/COUNTRY: JHB ASPASA TEL: (011) 791 3327 PROVINCE/COUNTRY: JHB BRITISH PRECAST CONCRETE FEDERATION TEL: +(44) 116 232 5170 PROVINCE/COUNTRY: UK CONCRETE SOCIET Y OF SOUTHERN AFRICA TEL: (012) 348 5305 PROVINCE/COUNTRY: PTA CPI CONCRETE PLANT INTERNATIONAL TEL: (02236) 962390 PROVINCE/COUNTRY: GERMANY JC PAVING CONSULTING TEL: (011) 431 0727 PROVINCE/COUNTRY: JHB SEKHUKHUNE & ASSOCIATES TEL: (012) 346 1945 PROVINCE/COUNTRY: PTA STEFANUTTI STOCKS TEL (011) 571 4300 PROVINCE/COUNTRY: GAUTENG
DICK KING LAB SUPPLIES (PT Y) LTD TEL: (011) 499 9400/ (031) 700 2551 PROVINCE/COUNTRY: GAUT/DBN
TACO VOOGT CONSULTING ENGINEER TEL: (012) 669 0125 PROVINCE/COUNTRY: PTA
HAWKEYEPEDERSHAAB TEL: 00 459645 4193 PROVINCE/COUNTRY: DENMARK
YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS TEL: (031) 207 7252 PROVINCE/COUNTRY: KZN
KERNEOS SOUTH AFRICA (PT Y) LTD TEL: (011) 444 3090 PROVINCE/COUNTRY: GAUT KOBRA MOULDS B.V. TEL: 003111 356 2460 PROVINCE/COUNTRY: NETHERLANDS MANITOU SA (PT Y) LTD TEL: (011) 975 7770 PROVINCE/COUNTRY: JHB PAN MIXERS SA (PT Y) LTD TEL: (011) 578 8700/8600 PROVINCE/COUNTRY: JHB QUANGONG MACHINES CO LTD TEL: +865 958 679 9557 PROVINCE/COUNTRY: CHINA
CONTRACTOR MEMBERS DECORTON RETAINING SYSTEMS (PT Y) LTD TEL: (021) 875 5155 PROVINCE/COUNTRY: WC FRICTION RETAINING STRUCTURES (PT Y) LTD TEL: (011) 608 4321 PROVINCE/COUNTRY: GAUT POWERGATE CONSTRUCTION CC TEL: 071 603 5070 PROVINCE/COUNTRY: GAUT VALCAL INTERNATIONAL EXPORT CC TEL: (011) 867 2471 PROVINCE/COUNTRY: GAUT CEMENT MEMBERS
REVARO CONCRETE EQUIPMENT TEL: (011) 794 827 PROVINCE/COUNTRY: JHB SIKA SOUTH AFRICA (PT Y) LTD TEL: (031) 792 6500 PROVINCE/COUNTRY: KZN TERRAFORCE (PT Y) LTD TEL: (021) 465 1907 PROVINCE/COUNTRY: WC
AFRISAM SOUTH AFRICA (PT Y) LTD TEL: (011) 670 5500/5752 PROVINCE/COUNTRY: GAUT
PI – Precast Infrastructure PB – Precast Building
PLEASE NOTE: The above member list was correct at the time of going to print. If your details have changed, please contact Rita at the CMA offices on tel: (011) 805 6742.
PRECAST | ISSUE TWO | 2020
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