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ISSUE TWO • 2020

R49,00

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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PROJECTS

PRODUCTS

25 NORTH WEST TAXI RANK GETS PRECAST MAKEOVER

2 QUALIT Y AND STANDARDS, PRODUCT CERTIFICATION AND SUCCESSFUL PROJECT DELIVERY

INDUSTRY NEWS 5

9 6

26

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: admin@cma.org.za Website: www.cma.org.za Publishers: Isikhova Media Address: 10th Floor, Metalbox, 25 Owl Street, Milpark, South Africa Tel: (+27 11) 883 4627 Fax: (+27 11) 783 2677 Website: www.isikhova.co.za Publisher: Imraan Mahomed Tel: (+27 11) 883 4627 E-mail: imraanm@isikhova.co.za Consulting editor: Raymond Campling Tel: 076 297 2775 E-mail: media@mediasavvy.biz

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: david.bigsky@gmail.com

ISSUE TWO • 2020

R49,00

THE VOICE OF THE PRECAST CONCRETE INDUSTRY

Subscriptions/Accounts/ Advertising: Thuli Majola Tel: (+27 11) 883 4627 E-mail: thuli@isikhova.co.za Design and layout: Joanne Brook E-mail: joanne@isikhova.co.za 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".

CONTENTS

GM’S NOTE

1


GM’S NOTE

QUALITY AND STANDARDS, PRODUCT CERTIFICATION AND SUCCESSFUL PROJECT DELIVERY

2

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.

processes; and

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-

able to:

• the producer has implemented a

jective, businesses

• 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 organisation;

the following: or the product standard;

• improve their competitiveness; and

constantly;

• 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

requirements;

“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

recirculated.

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

being manufactured.

document specifications.

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

for approval.

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-

certification bodies.

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

authorities.

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:

redesigning.

legal liability.

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

Henry Cockcroft

• The draft is circulated to the industry

the supply of products conforming to

GM: CMA

the South African National Standards

Director: CMA Certification Services

for comment.

PRECAST | ISSUE TWO | 2020

GM'S NOTE

offices references to the following?

3


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

Knock test

wet-cast cladding and many other types

critical infrastructure.

“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-

Rapid deployment

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

INDUSTRY NEWS

“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.”

5


INDUSTRY NEWS

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.

6

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

Permanent fix

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

Attractive solution

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.

INDUSTRY NEWS

With the construction industry still

9

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


INDUSTRY NEWS

“Lassen is as tough as any business-owner, with a firm, but fair approach which ensures all employees are treated equally and with respect.”

11

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-

New ground

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-

says Lassen

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

is today.

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


EST. 1932

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 info@capeconcrete.com 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

early strength.

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

Elematic brand.”

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.

EXCELLENCE IN

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.

PRODUCTS

Rand ensures a constantly high standard

17


PRODUCTS

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.

18

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

PERMEABLE PAVING

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

these layers.

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

Geological conditions

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


A,IAVENG

, ,Y INFRASET

HOME WITHOUT HARM

TECHNICAL

EVERYONE EVERYDAY

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: lnfrasetinfo@infraset.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

0


PRODUCTS 21

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

efflorescence.

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

transport system.

• 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.

application quantity.

pallet sizes.

• Uniform sealer application.

repellent and strength characteristics. Easy controls

• Sturdy and reliably built.

Spraying system

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

absorbency.

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.


TECHNICAL 22

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

Efficient operation

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

shuttering version.

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-

casting sequence.

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

Large spans

four-hour pre-curing process. Because

casting cells.

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,� comments Dillon

supporting infrastructure designed to

Carter, sales consultant for Rocla in

make commuters’ 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 – 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 Projects’ 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

Tough paving

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. “They’ve never let us down and

7 000m². The pavers were ideal for

we find their cost-competitiveness is in

installation in the taxi rank, where heavy

the quality of their product,� says Nel.

traffic footprints are anticipated. The interlocking pavers form a continuous

Durable concrete

surface overlay, while still providing a

“The precast concrete bus shelters are

good-quality, attractive finish.

a specialised product from Rocla. We

“Space on site became one of the

needed 148 units for the JB Marx taxi

project’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 – longer than usual,

delivered to site in the correct order

due to the paver strength requirements

for installation, This was seamlessly

– and that our production and delivery

executed by Rocla.�

planning dovetailed with deadlines also

“Some of the bus shelters were also

contributed to the successful installation

converted into hawker stalls and, as a

of the taxi rank project,� 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

PROJECTS

 



25


PROJECTS 26

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.

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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: cindy@ashak.co.za 6091 A.Shak Constrctn PRECAST 1/2PG july’20


PROJECTS 27

BUILT WITH PRECAST CONCRETE built as part of the civil works by ASLA

Eastern Cape Housing Depar tment

in 2019.

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.”


PROJECTS 28

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

environment.

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

Maintaining appearance

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

structures.

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,

Stormwater management

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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PROJECTS

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.

30

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

the house.

wall’s also very pleasing to the eye. I

The wall was designed by Fred Laker

says Samuels.

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

further.”

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for our nationwide branches


PRODUCTS 32

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

Western Cape.

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

concrete trucks.

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

standard/2m2.

with soil. This facilitates the growth of

Natural gradients

grass, which only takes a year or two,

The combined length of the three channels amounts to approximately 700m along

High discharge

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,

Project participants

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,

It Civils

they’re suitable for low-volume country

Municipal OHS Officer:

roads, such as our Stasiekop Road

Craig Moster

installation, where the gradient was

Terraforce/Terracrete licensed

approximately 17%.”

manufacturer: Mobicast

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.


PROJECTS 34

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,”

230mm (thickness).

he explains.

Heavy 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,

production facility.

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

Minimal disruption

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

interchange.

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

founding material.

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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Precast • Issue 2 • 2020  

Precast • Issue 2 • 2020  

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