Precast Issue 2 2024

Twinstar's 10 years of inspiring achievements – and counting! From wheels to floors: Rubber reinvents itself

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In this issue

Like the rest of the country, PRECAST noted with horror the collapse of an apartment block in George early in May, which claimed several lives and severely injured many others. The event highlighted the urgency with which the industry needs to review its safety standards and the credibility, skills and qualifications of those tasked with contracting, supervising and performing the work. The regulations governing these areas, and those responsible for enforcing them, as well as the quality of materials used, may also require attention, along with the timelines applied to the construction of projects. The state of the industry’s vulnerability to criminals such as the “construction mafia” is further cause for concern.

However, in this feature, we highlight some of the positive – indeed, inspiring – achievements of companies such as Twinstar Precast, which is celebrating its 10th anniversary. This milestone marks its very proud legacy of superb service, design and manufacturing, which have made it a leader in its field.

We also feature the Mathe Group’s Hammarsdale facility, which recycles approximately 1 000 radial truck tyres per day to produce 45 tons of rubber crumb. The organisation’s innovative rubber flooring solutions which helped establish it in the first place continue to highlight its global reach and position it as a local leader in green building solutions.

By the time this issue reaches our readers, the results of the national elections will be known. It is to be hoped that whoever emerges from them triumphant will ensure that a morally robust, accountable and dedicated government addresses the many urgent problems which plague our industry and country, and help it realise its overwhelming potential as a powerhouse not just in Africa, but globally.

AfriSam’s

ON THE COVER

ON THE COVER

Twinstar Precast is celebrating its 10th anniversary, marking a proud decade of excellent service, uncompromising quality, custom designs and a solution for every client’s needs

supply for about 40 years and will need to deliver around two million tons of limestone to Ulco each year. The supply of readymix will include AfriSam cement.

capable of providing security of supply for about 40 years and will need to deliver around two million tons of limestone to Ulco each year. The supply of readymix will include AfriSam cement.

PRECAST is independently

by Isikhova Media (Pty) Ltd

PRECAST is independently published by Isikhova Media (Pty) Ltd Tel: +27 (11) 883 4627 www.isikhova.co.za

PRECAST is independently published by Isikhova Media (Pty) Ltd Tel: +27 (11) 883 4627 www.isikhova.co.za

Operations director: Thuli Majola

Thuli Majola

E-mail: thuli@isikhova.co.za

Operations director: Thuli Majola E-mail: thuli@isikhova.co.za

E-mail: thuli@isikhova.co.za

Design and layout: Yoland Crator

Design and layout: Yoland Crator

E-mail: yoland@edgehosting.co.za

Sales Director: Ruwayda Mahomed E-mail: ruwayda@isikhova.co.za

E-mail: yoland@edgehosting.co.za

Managing director: Imraan Mahomed

Design and layout: Phumi Vilakazi E-mail: newjak87@gmail.com

Managing director: Imraan Mahomed

E-mail: imraan@isikhova.co.za

E-mail: imraan@isikhova.co.za

Copy editor: Anne Phillips

Managing director: Imraan Mahomed E-mail: imraan@isikhova.co.za

Media sales: Tel: +27 (11) 883 4627 / 083 450 6052

Copy editor: Anne Phillips Media sales: Tel: +27 (11) 883 4627 / 083 450 6052

Media sales: Tel: +27 (11) 883 4627 / 083 450 6052

TEN YEARS OF INSPIRING ACHIEVEMENTS – AND COUNTING!

On 16 June this year, it will be 10 years since Twinstar Precast opened its doors and began manufacturing custom precast products for the civil engineering and building sectors.

With a casting area of 150m², an office area which had been converted from a horse stable, only one order, a concrete mixer, two wheelbarrows and six staff members, the company took a giant leap of faith in pursuing a passion for precast concrete, specifically custom designs. Its determination more than paid off, as the next decade of success has shown. Today, the company is acknowledged as a respected and trusted industry leader, with a reputation for expertise and excellence in both its service and products. It now has 1 150m² of casting

area, an office adjacent to its factory with interlinking doors between them, four Silla concrete mixers, 18 factory staff members, one office assistant, two managers and its founder and MD Annemerie Coetzee.

From the complex

Twinstar Precast solves the difficult, onceoff jobs as well as those on complicated sites that can make civil engineering and construction challenging.

Not all building contractors have the necessary expertise, manpower or facilities to manufacture such products on site. For that reason, it is Twinstar’s express aim to assist both civil engineers and civil engineering contractors dealing with difficult worksites and situations in which using currently available precast concrete

products will simply not work.

The company has specifically geared itself to undertake these types of once-off jobs, which are typically avoided by many precasters due to their complexity, size and

A custom-precast vent slab by Twinstar, which specialises in solving construction problems of any size or complexity.

A concrete bicycle stand –another example of Twinstar’s meticulous custom designs.

“Some of these enclosures or bunkers have been designed by the clients and brought to us to cast and test their durability. Others have been designed by us, after a client has approached us with a problem and asked us for a solution.”

resource-intensive nature. Customised precast products require additional effort and time to design with their once-off moulds. They can also disrupt normal production lines, due to their need for additional skills and supervision.

The company manufactures products ranging in weight from 2kg up to 6 tons. As a result of the complexity of this type of work, it remains the only company in the country specialising exclusively in custommade and one-off, unconventional precast concrete products.

Any other sizes can be manufactured on request, as Twinstar specialises in custom sizes and once-off items. Its products are known and respected throughout the construction industry for their durability, versatility, costeffectiveness and visual appeal. They are manufactured using advanced techniques and undergo stringent quality checks before being made available to clients. The products are supplied with meticulous manufacturer’s guidelines for installation which ensure correct positioning, proper alignment and stability.

The company’s success is the result of its strong relationships within the industry, ranging from civil engineering contractors – its direct customers – to architects and specifying engineers who conceptualise requirements. It enjoys a unique relationship with mainstream precast concrete companies who pass on referrals and use Twinstar to supply

certain non-standard products to keep their clients happy.

...To the conventional Twinstar also always keeps a few fastmoving products in stock which are standard specifications in tenders and drawings. Companies which previously manufactured them have either stopped or have closed down. This is another reason for Twinstar’s singular positioning in the industry as a manufacturer of products for both conventional and customised requirements of all types.

“Solving a client’s problem is what we do, no matter how big or small,” says Coetzee.

“With theft of all types of equipment rising every day in SA and the current situation, in which law enforcement is failing to curb this, we’ve been approached by numerous clients to come up with a solution to protect equipment with concrete enclosures. In response, we’ve designed and manufactured different types of enclosures to safeguard various types of equipment, such as electrical components,

solar equipment and batteries.

“Some of these enclosures or bunkers have been designed by the clients and brought to us to cast and test their durability. Others have been designed by us, after a client has approached us with a problem and asked us for a solution. Still others have been designed, cast and eventually perfected by us after a client has explained a problem and requested our help. In every case, however, we’ve ensured that we’ve provided the correct product for the job and kept the client happy.”

With this type of service ethic and legacy behind it, Twinstar Precast can celebrate its 10th birthday secure in the knowledge that there will be many more decades of excellence ahead.

TWINSTAR: Unit 21, Hunky Dory, Business Park, 9 Goedehoop Avenue, Olifantsfontein, Gauteng Tel: 012 670 9083 E-mail: info@twinstar.co.za. Website: www.twinstar.co.za.

(Above): Custom pole supports – a specialised concrete design, cast to perfection by Twinstar.

CCSA CLOSES DOWN

In a sad development for the construction sector, Cement & Concrete SA (CCSA) – which, for more than eight decades since its establishment as the (then) Concrete Association of SA, has advanced world-class quality and the use of environmentally friendly cement and concrete products for the South African industry – wound down its operations as of 1 April this year. In accordance with its Memorandum of Incorporation, CCSA has now been deregistered from the Companies and Intellectual Property Commission.

Having first been established more than eight decades ago as the Concrete Association of SA, this non-profit organisation’s decision to wind down

was prompted by its operational costs, which had become unaffordable as a result of the many challenges facing the broader construction industry, primarily the sizeable reduction in infrastructure investment in the country and the Covid-19 lockdowns in 2020, which hamstrung almost all of SA’s industries and caused profound damage to its economy.

Although CCSA was formed the following year by consolidating various concrete industry bodies into one entity in order to strengthen them, continued lack of investment in SA’s infrastructure (prompted by corruption, neglect and poor governance) exerted further pressure on the cement industry, making

“In line with its closure, CCSA has cancelled the Fulton Awards 2024 and has committed to refunding any participation fees paid to it by entrants.”

it unsustainable to continue operating.

A new cement industry body will continue handling important issues to ensure the sustainability of the sector. These include imports, carbon tax, quality standards, electricity and rail infrastructure, among others.

In line with its closure, CCSA has cancelled the Fulton Awards 2024 and has committed to refunding any participation fees paid to it by entrants. However, it commends the excellence and innovation of the projects which were submitted for consideration.

Further intakes for new courses at the School of Concrete Technology have also been frozen, but the CCSA is considering a number of options to retain accessibility to that institution in the future, especially for students needing to conclude their courses and write their examinations. Further information in this regard will be released as soon as possible.

The World Day for Safety and Health at Work 2024 was commemorated by the International Labour Organisation on 28 April under the theme: “Climate Change and Safety and Health at Work”. The risks involved in construction were highlighted, particularly regarding climate change, with its extreme temperatures, electrical storms and changing weather patterns around the globe, including South Africa.

In line with this, the Department of Construction Management at Nelson Mandela University in Gqeberha reminds the industry that it currently offers a number of courses in construction health and safety (H&S).

BSc (Honours) (Construction Health and Safety Management)

This one-year programme has been accredited by the SA Council for the Project and Construction Management Professions (SACPCMP).

It includes eight semester modules and a year-long treatise research project addressing a construction H&S subject area.

The purpose of the programme is to develop the necessary knowledge, understanding, abilities and skills required to practise as a construction H&S manager and/or a construction H&S agent. Graduates will be able to practise as construction H&S officers by default.

MSc (Built Environment) Construction Health and Safety Management Specialisation

This 18-month programme – which has also been accredited by the SACPCMP – includes 10 modules delivered on a block basis and a year treatise research project addressing a construction H&S subject area.

The purpose of the programme is to develop the necessary knowledge, understanding, abilities and skills required to practise as a construction H&S agent or a construction H&S consultant.

MSc (Construction Management) and PhD (Construction Management)

Students can register for these research degrees on a full- or part-time basis. Although potential students are welcome to address any of a range of construction

CONSTRUCTION HEALTH AND SAFETY

POST-GRADUATE STUDY OPPORTUNITIES

management subject areas, construction H&S-orientated studies are encouraged.

The purpose of the MSc by research programme is to develop research skills and address an area of interest, either as a practitioner and/or a potential academic, and contribute to the related body of knowledge.

The purpose of the PhD programme is to conduct an in-depth study relative to an area of interest, either as a practitioner, an academic or a potential academic, and make a significant contribution to the related body of knowledge through the development of a validated model.

For further information about these courses, contact the NMU on tel: 041 504 1111 or visit: www.mandela.ac.za.

NORDEX ENERGY EXPANDS ITS HORIZONS IN THE SA RENEWABLE ENERGY MARKET

One quarter into 2024 and the South African private off-taker market is already delivering investment, jobs and commercial agreements. This is reflected in the wind power sector, with a leading turbine manufacturer announcing a 75% increase in its current generation capacity in operations, as well as plans to locally manufacture concrete tower sections in the Eastern Cape, ushering in the creation of up to 300 jobs within the region.

Nordex Energy SA (NESA) announced that this additional 830MW of operational capacity will start feeding into the country’s energy grid by mid-2025, delivering thousands of GWh per annum to the private market to help drive industry and economic recovery.

“Our increased commitment in SA, including a significant addition to our order book and growing market share, demonstrates our confidence in the renewable energy sector here. We’re focused on adding valuable energy resources to the country’s grid and supporting the broader shift towards sustainable energy and delivering jobs,” says David Moncasi Hortet, head of sales: Africa at NESA.

This follows closely on the heels of the financial closure of EDF Renewables’ Korosun 2 cluster, consisting of the Umsobomvu and Hartebeesthoek projects, in the Eastern and Western Cape, which comprises 50 Nordex 5,9MW turbines with a total capacity of 295MW.

NESA has similarly confirmed its role in supplying 57 Nordex WTG Delta4000 series turbines for a R9 billion cluster of three wind farms in the Eastern Cape, with a combined capacity of 336MW, which will make for the largest purely private renewable energy facility in the country.

Approximately 1 400 keystones conforming the 57 towers for this cluster

“Our increased commitment in SA, including a significant addition to our order book and growing market share, demonstrates our confidence in the renewable energy sector here.”

of IPPs will be produced locally at a newly established manufacturing facility in Humansdorp, about a 1,5-hour drive from the Port of Ngqura. This facility, dedicated to fabricating the 120m-high towers, is expected to begin operations by June 2024, with the initial turbine installations scheduled for the second half of the year. The subsequent energy delivery to the grid, anticipated in the second half of 2025, will contribute significantly to mitigating the country’s energy shortages.

NESA is tasked with the operations and maintenance of these wind farms throughout their 20-year lifespan, underscoring the demand for skilled personnel in the sector. “To address the skills gap and meet market demands, we’ve introduced new-generation technology

that enhances unitary power. We’ve also initiated an internship programme to build a pipeline of future technicians. We’re committed to ongoing dialogue and collaboration with key stakeholders to further skills development within the industry,” says Zelrese Brair, head of people and culture at NESA.

To ensure the successful implementation of these projects, NESA’s local construction operations team has undergone comprehensive training in Spain on the company’s latest wind turbine technology platform. This preparation is essential for meeting the anticipated growth of SA’s wind sector and underscores NESA’s commitment to providing robust construction expertise and support for the country’s renewable energy ambitions.

The Delta4000 wind turbine from NESA.

The Refratechnik Group is one of the world’s top 10 manufacturers of refractory products and the largest family-owned global company in its sector.

TWO NEW MEMBERS FOR WCA

The World Cement Association (WCA) has welcomed Refratechnik Asia, a market leader in the field of refractory materials based in Hong Kong, as an associate corporate member.

Refratechnik Asia supplies high-quality refractory materials to the cement and lime industries in China, South-East Asia and Oceania. Operating across five sites and plants in China and Hong Kong, the firm annually manufactures approximately 120 000 tons of refractory materials.

In the cement industry, refractory engineering plays a key role, impacting product quality, combustion system longevity, energy-efficiency and emission control. Refratechnik handles aspects from raw meal pre-heating to clinker cooling and provides comprehensive refractory training and tutorials to enhance furnace performance, operational safety and sustainability for its customers.

The company is part of the Refratechnik Group, one of the world’s top 10 manufacturers of refractory products and the largest family-owned global company in its sector. As a result, it aims to follow a value-orientated corporate culture and regards sustainability as integral to its operations.

With more than 3 000 cement kilns worldwide equipped with Refratechnik products totalling 350 000 tons of material annually, the Refratechnik Group team – comprising more than 2 100 employees worldwide – specialises in developing, manufacturing and handling the development of specific components for cement kilns.

“As the world’s largest family-owned refractory business, we’re keen to see Refratechnik Asia promote its value-orientated culture within our organisation and its commitment to driving greener practices in the cement and wider construction industry. All

our members have the opportunity to take part in professional committees, various activities tailored to their needs and member forums, to which we eagerly anticipate the team’s contributions,” says Ian Riley, WCA’s CEO.

“We’re pleased to become part of WCA and look forward to exchanging ideas, sharing our research and introducing innovative operational approaches to the network. Additionally, we hope to enhance technical and economic efficiency within the organisation, while upholding our sustainability-driven company ethos,” says Christof Kilb, MD of Refratechnik Asia.

The Seventh WCA annual conference and exhibition will take place from 18-19 October 2024 at the Hilton Nanjing Niushoushan in Nanjing, China.

For any questions or sponsorship information, please email: events@worldcementassociation.org.

Our range of locally produced superior quality cement is designed for specialised applications demanding high early strength, enhanced durability and superior concrete. Supported by our dedicated expertise, our superior products are the ultimate choice when compromise is not an option and time is of the essence. Cement Your Legacy and Ask for AfriSam.

ANOTHER CONSTRUCTION DISASTER

On the afternoon of 6 May, the five-storey Neo Victoria apartment block – where construction was nearing completion –collapsed in Victoria Street, George. At the time, there were 81 workers on site performing various tasks. At least 32 of them were killed, others rescued (some seriously injured) and – at the time of writing – about 20 were still unaccounted for, with little hope of finding them alive. The development had promised twobedroomed apartments priced at R1,7 millioin, with occupation from 1 August.

Emergency personnel rushed to the scene from as far away as Worcester and the City of Cape Town, while the Gift of the Givers also arrived with sniffer dogs to help locate the missing workers.

By 8 May, the rescue operations were using smaller machinery in order to break through the concrete of the rubble faster.

Government responds

A full investigation into the tragedy has been called for by President Cyril Ramaphosa, while the Department of Employment and Labour stated that it could not launch its own investigation until formally tasked with doing so by the relevant parties. The National Home Builders Registration Council also anticipated a forensic investigation to determine the cause of the collapse, but declined to comment

on the registration of contractors or the building regulations relating to residential developments. Minister of Employment and Labour Thulas Nxesi said that the event was “a sobering reminder of the critical importance of prioritising safety in the workplace”.

While engineers and experts were attempting to draw preliminary conclusions about the cause of the building collapse, the landowner of the site (Neo Victoria Developments) expressed its shock and horror at the event. “Buildings aren’t built with the purpose of collapsing. The project team of specialists are appointed to execute the planning and design, and manage the construction process and quality of work,” it stated, adding that it was committed to working with the investigating teams to analyse the disaster and evaluate what was needed.

This was not the first construction disaster experienced in urban South Africa. In October 2015, 120 tons of steel crashed onto the M1 highway as the bridge over the highway on Grayston Drive, Johannesburg, collapsed. Investigations later revealed that the disaster could have been prevented, had more stringent safety measures been taken. The omission of a pylon, mass scaffolding, bolts and a pier, as well as improvised or insufficient supports, were found to have led to the bridge collapsing.

While the weeks and months ahead will no doubt reveal what factors led to the George tragedy, what is certain is that it has highlighted the need for an overhaul of the safety standards governing the construction industry. A plethora of factors could be contributing to this, including the use of inferior materials, insufficient supervision, stet poor workmanship and teams attempting to complete projects in haste, in order to achieve deadlines, thus overlooking crucial steps in ensuring the stability of constructions. Greater transparency in the awarding of construction tenders may also need urgent attention.

(Above): Emergency workers at the scene of the George disaster. PHOTO: Herman Pieters/ George Herald.

Creating Quality Concrete Solutions

VOLVO TRUCKS SA APPOINTS NEW SALES DIRECTOR

Volvo Trucks SA has announced the appointment of Anders Friberg as the company’s new director of new truck sales, based at the Volvo Group Southern Africa headquarters in Johannesburg.

With extensive experience across the commercial vehicle industry and various international brands, Friberg most recently served as the director of private importer development within Volvo Trucks International, where he further proved his skill at driving sales and implementing effective business development strategies.

His career has also spanned pivotal roles within other premium truck brands, including serving as area sales manager, senior sales manager and business development manager in Turkey, as

MD in Tanzania and as sales director for Scania SA and Export from 2016-2020.

Friberg says he is excited to be back in SA. “The local transport industry has unique challenges in terms of operating conditions and logistical pressures. At Volvo Trucks, we’re committed to helping our customers overcome these challenges by providing the best products for the job at hand, as well as unrelenting support and quality services. I look forward to serving our customers and driving success, together,” he says.

This year, Volvo Trucks SA is celebrating its 24th anniversary in the country. The company has an assembly plant in Durban and currently employs around 900 people at various sites across the country.

Anders Friberg, Volvo Trucks SA’s new director of new truck sales.

READYMIX

SOUTH SUDAN ENERGY SUMMIT

The South Sudan Oil & Power (SSOP) 2024 conference and exhibition takes place in Juba from June 25-28. It will be attended by Ethiopian Minister of Water & Energy Habtamu Itefa Geleta, who will share his country’s experiences in developing clean energy capacity and call for more power infrastructure investments.

Ethiopia is Africa’s largest hydropower market and has embarked on a strategic diversification of its energy mix. As such, the minister’s attendance at this year’s summit will showcase an efficient, secure, affordable and sustainable power sector as vital to Africa’s economic growth and transformation.

Organised by Energy Capital & Power, SSOP 2024 positions South Sudan at the centre of investments and partnerships in the East African energy landscape. The conference and exhibition will invite investors to explore and take advantage of opportunities across the hydrocarbons, renewable energy and power sectors.

In April 2024, the Ethiopian government and the World Bank signed loan

agreements worth $1,72 billion to enhance the country’s electricity and water supply. In terms of the agreement, $523 million will be allocated to expand the country’s electricity network and boost renewable energy generation, while $500 million will be directed towards facilitating the movement of food to markets.

Meanwhile, the African Development Bank approved a $104 million grant to finance a transmission project to improve Ethiopia’s electricity supply. The project will involve the construction of 157km of transmission lines and will include associated substations near the cities of Harar, Jijiga and Farem.

Ethiopia, along with Zimbabwe, signed intergovernmental agreements with Russia in July 2023 to establish a legal framework for the development of nuclear energy in those countries. During the same month, Ethiopia’s government signed a grant agreement with Denmark which will see the mobilisation of $10 million towards developing the Danish-Ethiopian Energy Partnership

“Ethiopia is Africa’s largest hydropower market and has embarked on a strategic diversification of its energy mix.”

and phase one of the Ethiopian Danish Water Sector Co-operation.

At SSOP 2024, Geleta is expected to discuss the Ethiopian government’s plans to diversify its energy mix, while delivering a consistent supply of power and unlocking opportunities that will stimulate publicand private-sector participation in the East African energy landscape.

Those wishing to participate in SSOP 2024 as delegates should e-mail: sales@energycapitalpower.com for further information.

INFRASTRUCTURE DEVELOPMENT MUST REMAIN UNAFFECTED BY POLITICAL TRANSITION

In the aftermath of the national elections in South Africa, Chris Campbell, CEO of Consulting Engineers SA (CESA), highlights the critical importance of ensuring that infrastructure development and service delivery remains uninterrupted. He stresses that regardless of the political landscape, the nation’s progress and well-being depend on the continuous improvement and maintenance of its infrastructure.

“Infrastructure development and service delivery are the backbone of any thriving society,” says Campbell. “It impacts every facet of our lives, from transportation and communication to healthcare and education. Having just had the national elections, it’s imperative that we prioritise the continuation of infrastructure projects to sustain the momentum of growth and development in SA.”

He acknowledges that periods of political transition can often lead to uncertainties and delays in infrastructure projects. However, he emphasises that the incoming government should not allow such transitions to derail the progress already achieved in infrastructure development.

The strategy for service delivery needs to be inclusive, he adds, catering to all segments of society. “This is where we must re-strategise as a country. The operational arm responsible for service delivery within local and provincial government entities should operate independently of political affiliations.

The political landscape shouldn’t impede the function of service delivery, which is paramount.”

CESA, representing over 500 member firms in the consulting engineering sector, plays a pivotal role in advocating sustainable infrastructure development and

ensuring the highest standards of service delivery. Campbell underscores the importance of collaboration between the public and private sectors in driving infrastructure initiatives forward.

“Our industry stands ready to work hand-in-hand with government to overcome any challenges and ensure the successful implementation of infrastructure projects,” he says. “By fostering strong partnerships and maintaining a steadfast commitment to excellence, we can build a resilient infrastructure network that will benefit generations to come.”

“This is where we must re-strategise as a country. The operational arm responsible for service delivery within local and provincial government entities should operate independently of political affiliations. The political landscape shouldn’t impede the function of service delivery, which is paramount.”

Chris Campbell, CEO of CESA.

BIG 5 CONSTRUCT SA

Big 5 Construct South Africa, taking place from 4-6 June 2024 in Halls 2 and 3 at the Gallagher Convention Centre in Johannesburg, offers contractors, engineers, architects, quantity surveyors, designers and property-owners a onestop shop to identify viable opportunities and materials to complete projects efficiently.

This year, it is going above and beyond to deliver an experience that encompasses the entire spectrum of the construction industry, from cutting-edge exhibits to insightful, free-to-attend CPD-certified workshops aimed at

enriching your skills.

This is your chance to witness the latest trends and breakthroughs in the construction industry, discover innovative products and services from more than 200 exhibiting companies and gain insights into future developments at Big 5 talks, the Stakeholders’ Engagement Forum and the African Smart Cities Summit. Do not miss this event, which celebrates the impact of construction on our country! You can also celebrate the impact of construction at Big 5 South Africa Impact Awards.

STEPS TO REGISTER FOR BIG 5 CONSTRUCT SA

There are two ways to register: Register for your free pass online. Visit: https://bit.ly/3WuV4qV OR Register at the door when you arrive at the Gallagher Convention Centre.

For further information, visit: Facebook: www.facebook.com/Big5SouthAfrica. LinkedIn: www.linkedin.com/company/ big5southafrica. X: https://twitter.com/Big5SouthAfrica. Tel: 021 137 5963.

FROM WHEELS TO FLOORS: RUBBER REINVENTS ITSELF

Mathe Group’s Hammarsdale facility, which recycles approximately 1 000 radial truck tyres per day to produce 45 tons of rubber crumb, is a pivotal export hub. Although many of its products are distributed internationally, the innovative rubber flooring solutions which helped establish this growing company in the first place continue to highlight its global reach and position it as a local leader in green building solutions.

Dr Mehran Zarrebini, CEO of the Mathe Group, points out that strategic partnerships have helped the company spread its wings, while also helping reduce South Africa’s hazardous buildup of used tyres.

He explains how, in 2013, sister company Van Dyck embarked on a strategic initiative to enhance the sustainability of its product range by incorporating recycled content. However, the availability of rubber crumb – a key component offering significant benefits – was limited.

Initially, Van Dyck resorted to importing. “This was paradoxical, given the abundance of local waste tyre material. This prompted us to engage with the Mathe Group, a firm based in New Germany with a nascent operation constrained by its waste management licence’s capacity. Our growing demand soon outstripped the group’s supply capabilities, compelling us to invest in the development of a new facility. This not only secured Van Dyck’s supply chain, but also presented an opportunity to cultivate the local market for rubber crumb,” he explains.

To date, Zarrebini has been instrumental not only in increasing the Mathe Group’s production capacity six times, but in developing new products.

The collaboration with The Flooring Connection (TFC) – which brings together Instafloor SA,

Instafloor UK and Van Dyck – now spans several years. Van Dyck manufactures the acoustic products at its Hammarsdale production facility.

“Our initial engagement involved providing acoustic underlay products. Through our partnership with Instafloor SA, it’s also procured advanced acoustic solutions. Given the specialised nature of these products, TFC plays a critical role in liaising closely with end clients and offering essential technical support,” he explains.

Jonathan Bodley, head of TFC, says the organisation is dedicated to helping transform the African construction industry, promoting flooring products that align with the circular economy for renovations and new building projects.

“Partnering with Dr Zarrebini of the Mathe Group and Van Dyck (PFE) was a natural choice. Our partnership’s grounded in our shared goal of greening the flooring industry,” he says.

Bodley adds that because all Van

InstaCradles are loose-laid and timber battens are laid between the grooves. This creates a lightweight, raised sub-floor system which is ready for various flooring covers.

Dyck’s products are tested to international specifications, his company can market and export products made locally that can compete against less sustainable alternatives on both quality and cost.

He points out that product development is a key shared goal. “TFC has seen progression in our offerings in terms of innovative uses of our products and new developments. We take pride in the way the versatility of these products showcases African creativity and innovation.”

InstaCradle rubber crumb subflooring cradles were initially used for raised acoustic flooring in the sports and office environment to absorb impact force and sound. Decking applications

“Importing was paradoxical, given the abundance of local waste tyre material. This prompted us to engage with the Mathe Group, a firm based in New Germany with a nascent operation constrained by its waste management licence’s capacity. Our growing demand soon outstripped the group’s supply capabilities, compelling us to invest in the development of a new facility. This not only secured Van Dyck’s supply chain, but also presented an opportunity to cultivate the local market for rubber crumb.”

followed, specifically in situations where waterproofing needed to be protected.

With support from PFE, the EcoPaver Cradle was developed for external, permeable paving, allowing for easy water run-off and the creation of water reticulation systems. This has since been used in several water-wise buildings.

“Our rubber crumb underlays, long used in the flooring industry, are now being used as acoustic barriers under standard cement screeds and as low-profile solutions for self-levelling screeds,” says Bodley.

“These products have proven remarkably versatile, with contractors finding unexpected ways to utilise them. For example, InstaCradles are now used in acoustic recording studios, to install wall cladding and even support roofing joists. In addition to rooftop decks, the cradles are used to hold the feet of solar geysers.”

Zarrebini adds that ongoing research and development continue to yield innovative products that are nearing completion, including acoustic solutions for high-performance gymnasiums and adhesive-free flooring systems.

Bodley and Zarrebini believe that, although SA is still relatively new to the modern green building wave, demand for and awareness of green building products such as these are growing.

“The South African market exhibits a promising trajectory for the adoption of our products, particularly within the built environment, where there’s a noticeable shift towards sustainable

building solutions. However, the pace of adoption in SA typically lags behind markets like the UK, where legislation and regulatory frameworks more actively drive sustainable innovation,” explains Zarrebini.

He is nevertheless confident that integrating recycled rubber into flooring solutions offers multi-faceted benefits, including a significant reduction in the dependence on imported raw materials like virgin rubber which, ultimately, contributes to a more sustainable manufacturing ecosystem.

This sustainability goal is prized by both parties.

“Our future expansion plans will accommodate the dual objectives of supplying rubber crumb to external customers and leveraging it for valorisation in our locally manufactured acoustic products. This strategy aligns with our commitment to sustainability and the optimisation of resource use within our production processes,” says Zarrebini.

“The recycled rubber crumb product range attains the highest acoustic performance standards, while having a positive environmental impact. Looking ahead, sustained collaborations with PFE are anticipated. We’ve seen much potential in the SA sports flooring market. Above all, we aim to increase demand for recycled rubber crumb products, stimulate government support for recycling efforts and foster a sustainable solution to environmental challenges,” says Bodley.

Pratliperl® has been developed by Pratley to promote sustainability in the construction industry. “We’ve always been committed to sustainability and energy-efficiency, especially in terms of infrastructure development and energy-savings,” says Pratley MD Eldon Kruger.

Pratliperl® is a naturally occurring mineral aggregate for plaster and screeds that can help contractors and developers meet standards such as SANS 204, which specifies the design requirements for energy-efficiency in buildings. The product is a perlite-based, lightweight, cement aggregate used instead of ordinary building sand.

Unlike ordinary perlites which are brittle and friable, Pratliperl® has a stronger surface structure and can be used in conjunction with cement. “The end result is a unique, eco-friendly and lightweight building material that’s both fireproof and thermally-insulating,” notes Eldon. A major benefit is a reduced requirement for air-conditioning, as structures can be kept naturally cool in summer and warm in winter.

Applications for Pratliperl® range from plaster (internal and external thermal insulation) to lightweight floors for high-rise buildings, roof decks, fire barriers, precast mouldings, fireproofing for tunnels in mines, screeds, bathtubs, underfloor heating, tile adhesive

SUSTAINABILITY PRATLEY PROMOTES

Pratliperl® is an eco-friendly and lightweight building material which is both fireproof and thermally-insulating and can be used in conjunction with cement.

filler, bricks and boards, pizza ovens, cryogenic tanks, loose fill, a paint texturing agent, aggregate for refractory cements and as an insulating surface for molten metal.

A mere 16mm of Pratliperl® plaster on each side of a wall provides the same thermal insulation as a double-brick (220mm-thick) wall, which essentially means that the wall’s thermal insulation is doubled. “This incredible insulation value translates into significant energyand cost-savings in support of sustainability,” says Eldon.

“The use of a product such as Pratliperl® is the ideal simple step to reduce costs, save energy and ultimately unify our collective commitment to help protect the planet.”

(Above): Pratliperl® is derived from a volcanic glass called perlite.

AFRISAM ALL PURPOSE CEMENT: STILL A

BUILDING ESSENTIAL

AfriSam All Purpose Cement is recognised as a fundamental component in various construction applications, embodying versatility, reliability, quality and affordability. This premium product is designed to meet the needs of a wide range of construction projects, from large-scale commercial and infrastructure developments to smaller residential and DIY projects.

Ease of use and the ability to produce consistently excellent results make AfriSam All Purpose Cement a preferred choice among construction professionals. Manufactured in the company’s state-ofthe-art facilities, where quality management systems of the highest standard are a priority, the cement complies fully with the SANS 50197 specification for common cements. Its constant monitoring and maintenance of composition ensure it delivers high-quality performance within the 42,5N MPa strength class.

The unique composition of AfriSam All Purpose Cement addresses the industry’s need for a cement that reduces heat hydration in mass concrete works and enhances concrete’s resistance to chemical

attacks, including sulphate, chloride and exposure to soft water.

“Ease of use and the ability to produce consistently excellent results make AfriSam All Purpose Cement a preferred choice among construction professionals.”

The use of AfriSam All Purpose Cement in projects also significantly improves resistance to alkali-aggregate reactions and decreases the permeability of concrete in water-retaining structures, contributing to the sustainability and longevity of these projects.

AfriSam All Purpose Cement is suitable for a wide range of applications, from structural concrete and residential projects to brick- and block-making, as well as plaster mortar and shotcrete.

The addition of fly-ash and slag, where indicated, to this specially developed cement improves the overall workability of concrete, as fly-ash introduces microscopic spheres that effectively reduce the water demand of mortars and plasters. This not only makes the mix more cohesive, but enhances its ease of application. The improvement in texture and consistency ensures a superior bond in plaster applications, attributed to the increased stickiness of the mix. Consequently, this leads to a more efficient application process and results in smoother, more durable finishes in construction projects.

AfriSam All Purpose Cement remains a preferred choice among construction professionals.

BEWARE OF HIRING AN UNREGISTERED BUILDING CONTRACTOR

While addressing South Africa’s dire unemployment rate is critical, building industry role-players recommend that businesses and members of the public tread carefully when securing the services of unregistered contractors.

From a company-owner’s perspective, being a registered entity means that they are obliged to meet quality standards, construction regulations and customer expectations, all of which promote higher standards of workmanship, safety and project delivery.

However, findings by the Building Industry Bargaining Council (BIBC) indicate that businesses not registered with the organisation do not have the basic infrastructure in place to deliver on quality outcomes. In addition, they often

miss deadlines and budget targets.

The BIBC’s spokesperson for business, Danie Hattingh, says the council has seen many examples of work having to be redone to address these quality concerns.

“The direct result of this is that the contractor responsible has narrower profit margins or has eroded margins due to the penalties imposed by the ‘giver of work’. The delays that result from having to redo work have financial implications for all parties caught up in this unfortunate scenario,” he says.

The impact on unregistered employees is equally severe.

While unregistered employment accounts for 38% of all jobs in SA’s construction sector, of which the building industry forms a large part, these workers

are not typically protected by labour laws that govern minimum wage requirements, overtime pay and workplace safety regulations.

Unregistered employers also frequently exploit labour to undercut competitors.

Unregistered labourers may not receive the negotiated minimum benefits applicable in the industry and receive whatever the non-compliant employer arbitrarily decides. These arrangements also often lack stability and security, with workers facing uncertainty about future income and job prospects.

The BIBC’s spokesperson for labour, Luyanda Mgqamqo, points out that these employees often experience irregular working hours, fluctuating income and the need to rely on temporary work.

“Of particular concern to the BIBC is that these employees and their dependants also aren’t protected in the event of death and disability,” he says.

Conversely, employees registered with compliant employers receive daily contributions towards their annual (holiday) leave, sick leave, retirement fund and bonus.

By way of example, the BIBC collected and paid out more than R200 million in leave pay and bonuses at the end of 2023 – funds that went directly into the pockets of employees whose registered employers had contributed on their behalf throughout the year.

Another positive spin-off was that contributions were made towards more than 28 000 registered building industry employees for future funeral, death and

“Unregistered labourers may not receive the negotiated minimum benefits applicable in the industry and receive whatever the non-compliant employer arbitrarily decides.”

disability benefits.

It has become evident that employees registered with the BIBC are usually part of stable teams in which skills are transferable and complementary in nature. This generally results in a higher standard of work, as individuals who operate within these teams are more responsible and accountable.

Hattingh emphasises that failure to address the gaps that exist between registered and unregistered parties can be detrimental to both the industry and the economy.

Unregistered labour can compete unfairly with registered contractors by circumventing regulations and standards. This may hinder government tax collection, infrastructure development and efforts to promote sustainable housing solutions.

“Where both the ‘giver of work’ and the contractor have a culture of noncompliance, the impact on sustainable and decent employment is even more pronounced,” he adds.

There are positive developments, however.

Collective bargaining, for example, is ensuring that all employers in the industry compete on unique selling points such as excellent work and quick turnaround times stemming from skilled and stable teams.

Here, the BIBC has been instrumental in driving the transition from unregistered to registered employment by establishing standards, negotiating agreements, managing compliance, offering support services and promoting dialogue and collaboration among stakeholders.

Hattingh says that when engaging with a building contractor as a “giver of work”, it is important that the firm is properly registered with the BIBC, as this provides assurance that a business is not enabling labour exploitation.

““Givers of work’ can visit the BIBC website to see whether the contractor’s registered with the council and is compliant. Our experience is that when employers are compliant with the BIBC, there’s a higher likelihood that they’re also compliant in other areas, such as adherence to health and safety and unemployment insurance regulations, he says.

IS THE NEW NATIONAL MINIMUM WAGE A SUSTAINABILITY CONCERN?

On 1 March 2024, the national minimum wage increased by 8,5% from R25,42 to R27,58 per ordinary hour worked. But is it enough?

“It’s definitely a step in the right direction, but it still doesn’t allow workers to live a dignified existence,” says Prof Ines Meyer from the University of Cape Town, who also chairs the Living Wage South Africa Network. “8,5% might sound like a lot, but it translates to just R2 per hour.”

Meyer is a staunch promoter of the Living Wage concept which is gaining popularity in many countries. She recently returned from India, where she attended meetings with living wage proponents from around the globe. Among these were members of the International Labour Organisation (ILO), whose governing body has just endorsed living wages as central to economic and social development. This means that ILO employer, government and worker representatives agree that living wages need to be part of labour standards in ILO member countries – among them South Africa.

Living wage vs minimum wage

Meyer says a living wage is remuneration that is sufficient for an individual to provide their family with the basic necessities, while also allowing them to save and thus cover unexpected emergencies. The required amount should be based on evidence.

While legislated minimum wages compel companies to pay workers not less than the prescribed amount, they seldom satisfy Living Wage criteria. “A person labouring at the minimum wage for nine hours a day over the typical 22 working days per month stands to earn less than R5 500,” says Meyer. She notes that this is hardly enough to survive and affords

little chance of a decent, healthy or happy lifestyle. “A job paying the minimum wage keeps people in poverty. As an employer, I need to be aware that I actively prevent people from living a dignified life.”

A sustainability concern

Over the past decade, corporate sustainability reporting has been gaining

momentum. The core focus is typically on environmental, social and governance (ESG) concerns.

Such reporting allows organisations to be transparent with the public about their impact on people, the planet and prosperity within their operational ecosystem, as well as their integrity as a going concern.

ESG frameworks assume that prosperity not only refers to the profit a company makes, but also to whether it improves or degrades the economic conditions of the community within which it operates. This includes the financial well-being of its workers.

While some have decried the latest minimum wage increase as too costly and likely to raise unemployment, paying employees humanely attracts investment.

In a world where tempers run high on social concerns, a good report can work in an organisation’s favour, while a bad report can adversely affect its share price and investors.

“A company can’t be earnest about good ESG while its workers remain living in poverty, even though they’re employed,” explains Meyer.

Scaling up to a living wage

Unlike the legally enforced minimum wage, a living wage is meant to be adopted voluntarily by employers as an act of human decency.

“It demonstrates that the employer’s genuinely concerned about their workers’ constitutional right to dignity, rather than simply checking a compliance box,” says Meyer. “Pay isn’t just an amount – it also communicates to the employee how they’re seen and valued as human beings by their employer.”

She says this demands a mindset shift from profits at all costs to profits resulting from recognising workers as fellow human beings whose personal economic enrichment contributes to the national economy’s sustainability. Living wages increase buying power and thus create a stronger market. Research suggests that offering decent working conditions, including decent pay, leads to economic growth. “Contrary to popular belief, we don’t require economic growth first to create jobs,” says Meyer.

Living Wages have been successfully implemented in other countries, such as the UK and New Zealand, with little impact on profits or employment opportunities.

Meyer started conducting independent research to determine a living wage range in SA. For the past two years, she asked workers across the country about their current income and the degree of choice they experienced in a variety of life domains. Through this, her research group has estimated an ideal living wage for South Africa at R12 000-R15 000 per month. She emphasises that this is the cash amount required, exclusive of potential non-monetary contributions made by an employer.

“We realise that this is quite a leap and that organisations need time to gradually implement it, but when approached as a strategic imperative, it’s as possible as any other business endeavour,” says Meyer. “And there are companies in SA which have started doing so.”

Reprinted with courtesy of the Living Wage South Africa Network.

“A person labouring at the minimum wage for nine hours a day over the typical 22 working days per month stands to earn less than R5 500.”

Meet Wilson Tan, service and training manager at Lintec & Linnhoff, who has been keeping customers happy for more than three decades –and is still going strong.

Wilson Tan is no stranger to the global asphalt and construction industries. He spent 25 years of his 30-year career in China managing client services, the warehouse, after-sales support and quality control.

A stickler for professionalism and perfection, he will do whatever is necessary to keep a customer happy. “My job is to ensure that our customers are satisfied by solving critical issues whenever they happen. Most of the time, this involves engaging in conversations with the engineers on site and determining the best way to solve the problem quickly. I also manage the installation of new plants, which comprises a broad range of tasks, such

A DEDICATED DOYEN

as checking that the specifications of the foundation drawing are correct before the plant installation,” he says.

“In practice, this involves a number of tasks before we start plant work, including discussions about safety measures, such as the roles of the electrical and mechanical individuals in charge. I also provide advice on how and where to start the plant installation.”

While dealing with diverse – and often pressurised – customers is never easy, Tan has a simple, but foolproof approach. “I treat all customers as partners. This means resolving issues by listening and understanding to their pain points. Every customer interaction presents its unique challenges, which

helps me to continuously learn and adapt. From handling difficult situations to finding creative solutions, working in after-sales service constantly pushes me to improve my problem-solving and communication skills when handling different customers,” he says.

“To me, the most important part of customer support is solving the problem, regardless of when and where it’s happening. Machine or plant downtime is expensive for our customers, so I do everything I can to minimise this. I like to build a relationship based on trust, keep communication channels open and solve a customer’s specific issues as quickly and efficiently as possible.”

With a wide range of diverse projects

Wilson Tan, service and training manager at Lintec & Linnhoff.

with Lintec & Linnhoff in SA to his credit, Tan regards some of his earlier experiences as among the most instructive and rewarding ones.

“I’m proud of the work I completed on the Shandong Dongyin Road and Bridge project in China, as well as the Hong Kong-Zhuhai-Macau bridge project. Both projects presented unique challenges, which required me being on site for the project duration of about two months each. For both projects, we were working on a tight deadline for the delivery and installation of the plants. The projects were highly complex and required customised solutions. However, we managed to complete them in good time and even sold another plant, as the customers were very satisfied with our presence and the plant’s performance,” he recalls.

Lintec & Linhoff has a proud track record in both Asia and Europe, having worked on some of the world’s most prominent construction achievements, including the Yas Marina Circuit in Abu Dhabi, the Palm Island in Dubai, the

“I treat all customers as partners. This means resolving issues by listening and understanding to their pain points.”

Storebaelt Bridge in Denmark, the Merdeka 118 Tower in Malaysia and the First Polder Project in Singapore. The company’s key technologies include its containerised asphalt and concrete batching plants built in 100% certified ISO sea containers and its screen drum technology.

Tan’s experience has also included work in Africa. “I worked on a memorable project in Ethiopia, which was the construction of a highway connecting the capital city, Addis Ababa, to other cities and towns in the country. This project improved the national transport network for cargo movements, and that helped improve the country’s economy,” he says.

Regarding his future at Lintec & Linnhoff, whose products include asphalt mixing plants, concrete batching plants, pavement-related technologies

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and specialist concrete cooling solutions, Tan is upbeat. “I’m very excited because there’ll be a new scope to my job role this year, which will involve training the organisation’s service engineers so that they’re fully prepared to go out into the field and provide valuable service to our customers on the installation of new plants. I’m happy to pass on my 30 years of experience to the next generation,” he says.

Away from his hard hat and desk, Tan – who has construction in his blood – loves nothing more than dabbling with Lego. However, downtime is also family time, especially when he has a chance to spend it with his two sons. “My elder son’s in the Singapore Navy and the younger one’s studying at a polytechnic. During the weekend, we enjoy visiting places such as the Singapore Zoo, Marina Bay and the Sembawang Hot Spring Park,” he says.

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DURABLE, ATTRACTIVE GRANDSTANDS

Municipal sports and recreational centres are essential basic services infrastructure that can play a key role in uplifting communities. However, there are still many low-income communities in the country that do not have suitable spaces where township youth can participate in sports.

Taking the form of the Municipal Infrastructure Grant and Neighbourhood Partnership Grant, funding for these projects is often under-utilised. Many municipalities simply lack the capacity to administer the funding or the ability to implement planned projects. There have also been instances where funds provided by the National Treasury for these projects have been used by municipalities for other seemingly more important purposes. In extenuating circumstances, there have even been instances where communities have received sub-standard facilities that were also vastly over-priced.

Yet there are enterprising municipalities that are delivering quality sports and recreational facilities

to their constituents and ensuring that these projects already begin benefiting many community members during the construction phase. This while also working closely with their professional teams to find more effective ways of executing such projects. Harnessing innovative building technologies and methods, attractive infrastructure is being built in a very short timeframe and in a cost-effective manner. The exponentially high standard to which the infrastructure has been built also reduces operating costs over the long service life of the structures.

Durable, high-quality stadiums

A case in point are the many sports and recreational centres which Corestruc has helped to deliver while working alongside principal builders who are determined to scale the ranks of the Construction Industry Development Board’s Register of Contractors. This will enable them to take on even larger and more complex projects.

By harnessing Corestruc’s extensive

precast concrete knowledge, these contractors are making light work of the projects, while also providing infrastructure of an unrivalled quality, both in terms of durability and aesthetics.

The most complex aspect of municipal sports and recreational centres is the grandstands. Building a high-quality, cast-in-situ concrete structure requires specialist skills and capacity that have not yet been developed by the contractors appointed to work on these projects. Note that these projects also serve as an important catalyst for black-owned construction of small, medium and microenterprise developments. As principal contractors, they are responsible for constructing the other important components of these facilities, such as the pitch, the changing rooms and administration building. They are also tasked with creating employment, as well as skills development and training opportunities for communities residing within the operational footprint. These meet the requirements of government’s Expanded Public Works Programme.

Even so, in-situ concrete grandstands take an extraordinarily long time to build. These structures also carry a hefty price which is beyond the reach of many municipalities.

Rather than building structures with construction materials that do not provide the same durability and aesthetics as concrete, enterprising municipalities and their professional

teams are specifying Corestruc’s unique prefabricated concrete grandstands for their projects.

Designed specifically for such projects, this standardised system can be deployed quickly, with only minor modifications needed in order to cater to varying number of spectators from one facility to the next. Having finalised these details during the very early design stages of the project, Corestruc can commence with the manufacture of the system as early as possible. In this way, the various precast concrete elements that make up the system are ready to be integrated immediately after the earthworks, site terracing and in-situ foundations have been completed by the principal contractor.

Throughout these early phases, Corestruc maintains close contact with the main contractor. This ensures that no errors will delay the project.

Once the foundations have been completed, Corestruc mobilises to site to complete the integration of the system quickly and efficiently.

Cost-effectiveness

More recently, the company constructed a large grandstand consisting of more than 800 precast concrete elements

“The precast concrete elements are cast in forms manufactured from steel that has been precisely cut to purpose with lasers.”

and 22 grids in only four months. Measuring 14,9m in height at the back columns and 121m in length, this is one of the largest grandstands that Corestruc has built to date. It was also up to 40% more cost-effective than in-situ construction, since it eliminated the need to manufacture bespoke shutters and operate a tower crane for almost 12 months on site, among other preliminary and general costs associated with such a project. Furthermore, by standardising the system, Corestruc can fix construction costs. This facilitates accurate budgeting and avoids cost overruns. Precast concrete also addresses the delicate cost concerns associated with scheduling a typical cast-in-place construction project. By eliminating logistical concerns, scheduling

“The most complex aspect of municipal sports and recreational centres is the grandstands. Building a high-quality, cast-insitu concrete structure requires specialist skills and capacity that have not yet been developed by the contractors appointed to work on these projects.”

becomes easier – which, in turn, helps to ensure that unexpected expenses do not arise.

Meanwhile, smaller precast concrete grandstands have been constructed in a matter of weeks and have also proved to be a cost-effective method of constructing an aesthetically appealing, durable structure to seat spectators.

Corestruc has perfected the design of its system over many years to enable rapid integration of the components on site.

The number of precast concrete elements required to construct a grandstand have been minimised and standardised. Moreover, curved columns and rakers, benches and side panels facilitate efficient installation.

Putting it together

The manner in which the various precast concrete elements are connected has also been simplified. The columns are connected to the in-situ bases by components that have been cast into

the precast concrete elements. They are then easily secured using holddown bolts. The raker beams, seating benches and side panels are held with strategically positioned dowels. They fit seamlessly into the sleeves that have been cast into the various precast concrete elements and into which the grout is then poured.

Notably, Corestruc’s riggers achieve tolerances of 5mm when connecting the columns to the foundations and 5mm when integrating the other components of the system. This is made possible by the high level of accuracy achieved in the design of the system and manufacture of each individual precast concrete element that makes up the grandstand. Of course, this also contributes to the very high durability of the structures.

Digital ingenuity

Corestruc’s engineers use sophisticated commercial software for structural analysis and design. Building information management (BIM) systems are deployed to model the structures and each precast concrete element. BIM improves quality control by enabling seamless tracking and tracing of every precast concrete element, from their design phase through to integration on site. It also facilitates quick and efficient communication between all stakeholders. This includes clients and their implementing agents, consulting engineers, principal contractors and the specialist precast concrete subcontractor, as well as its own engineers, who provide additional technical support.

The precast concrete elements are cast in forms manufactured from steel that has been precisely cut to purpose with lasers. They have also been designed to facilitate the accurate placement of the various cast-in components. Moreover, computerised batching plants facilitate optimised curing processes to further reduce lead time.

In addition to those deployed in the

precast concrete factories, quality control checks are conducted after the transportation of the prefabricated concrete elements to site. This is another important component of the precast concrete value chain over which Corestruc has complete control. The precast concrete elements are carefully loaded onto and affixed to the company’s tri-axle flatbed trailers. Although they have had enough time to harden fully, extreme caution must still be exercised to avoid damaging them.

The order of work

The middle columns are the first to be placed. They are set out with co-ordinates to confirm the plumb and position. The front raker beams are then aligned with the top and bottom bolts of the columns and fastened in place. Corestruc then places the rear columns and braces them with structural steel. This provides the necessary stability at this stage of construction, considering the slenderness of the columns. The top raker beams are then installed in the same way as the front elements are placed. Afterwards, they are braced horizontally in a similar sequence to that used for the back columns. This is followed by the installation of the seating benches. They are lined up with the raker beams and then grouted into position, thus forming a single monolithic structure. Thereafter, the side panels and steps are installed. The roofs of the structures vary from one sports and recreational centre to the next, but are predominantly constructed using structural steel with sheet metal as the cover.

“Our grandstands are just one example of the potential that precast concrete can play in addressing many of the challenges facing our country. We’ll continue taking the lead by using the technology as a basis for faster, more efficient and more cost-effective municipal infrastructure delivery,” says Willie de Jager, Corestruc MD.

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CHRYSO

www.za.chryso.com

CONCRETE MOUL dS www.concretemoulds.co.za

CONCRETE MOUL dS www.concretemoulds.co.za nigelbrown@mweb.co.za 082 774 4657

AVOID CONCRETE STRENGTH DELAYS. As winter approaches, the colder ambient temperatures

hannelie@chrysosa.co.za 011 395 9700

nigelbrown@mweb.co.za 082 774 4657

ONCRETE MOUL dS www.concretemoulds.co.za nigelbrown@mweb.co.za 082 774 4657

M ASTER BUIL dERS SOUTH AFRICA www.masterbuilders.org.za info@masterbuilders.org.za 011 205 9000

www.masterbuilders.org.za info@masterbuilders.org.za 011 205 9000

AVOID CONCRETE STRENGTH DELAYS. As winter approaches, the colder ambient temperatures can cause delays in concrete strength development as well as finishing aspects. Rest assured, this challenge can be easily overcome using CHRYSO’s Premia Range of admixtures and demoulding agents.

TECHNICRETE

www.technicrete.co.za info@technicrete.co.za

T WINSTAR www.twinstar.co.za

Annemerie@Twinstar.co.za 012 670 9083

www.twinstar.co.za

Annemerie@Twinstar.co.za 012 670 9083

CHRYSO Winte

Sika’s solution for WATERTIGHT CONCRETE

Sika® WT-200 P

High performance crystalline waterproofing admixture that 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.

KEEPING WATER OUT:

■ Basements

■ Habitable basements

■ Parking garages

■ Utility/plant rooms

■ Tunnels

www.sika.co.za

KEEPING WATER IN:

■ Swimming pools

■ Water retaining structures

■ Dams

■ Water structures

■ Waste water treatment structures