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• New code of ethics • CMA Mark of Approval • Precast bridge for world-renowned race track











































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

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

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

Subscriptions/Accounts: Thuli Majola Tel: +27 11 883 4627 E-mail: subscriptions@isikhova.co.za





Publishers: Isikhova Publishing & Communications Postal Address: PO Box 651793, Benmore, 2010, South Africa Tel: +27 11 883 4627 Fax: +27 11 783 2677 Website: www.isikhova.co.za Publisher: Andrew Meyer Tel: +27 11 883 4627 Cell: 082 456 5175 E-mail: andrewm@isikhova.co.za Consulting editor: Raymond Campling Tel: 076 297 2775 Email: media@mediasavvy.biz


cast bridge beams have shaved weeks off construction time of a high speed flyover bridge on

Design and layout: Joanne Brook Tel: +27 11 883 4627 E-mail: joanne.studio@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© 2015. All rights reserved. No part of this magazine may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage retrieval system, without prior written permission from the publishers.

Specially manufactured pre-

the revamped Kyalami Race Track. The bridge was required • New code of ethics • CMA Mark of Approval • Precast bridge for world-renowned race track

to be constructed quickly to keep up with the rest of the construction work. Precasting was the obvious choice as this meant that there

were few or no disruptions on site. To achieve this the beams were pre-stressed with up to 500 tons of pressure to conform to National Highway Regulations, which is necessary to allow the heavy weight of the road structure as well as the heavy construction equipment to move over the bridge with

Endorsed by:

no effect on the overall integrity of the structure.






Specially manufactured precast bridge beams have shaved weeks off construction time of a highspeed flyover bridge on the revamped Kyalami Race Track. Manufactured by CMA member, Silverton Precast in Pretoria, the 13m precast T-beams reduced construction time by at least six weeks on site and allowed a far simpler and more cost-effective system to be developed for the worldclass race track. After initially weighing up the options, lead engineers WSP Group Africa (Pty) Ltd designed the structure to be carried on top of reinforced earth embankments spanned with 40 precast beams. These would act as both the backbone of the bridge and as a permanent formwork for an in situ concrete deck, as well as road surface layers. Technical detail In order to ensure the smooth progress of the project, Silverton Precast owner, George Ellinas, invested a considerable amount of time and infrastructure to ensure the 40 oversize beams were deli ver ed on time and to the tight specifications of the engineer. He ex plains: “We wer e awar ded the tender to produce 40 T Y 5 prestressed beams weighing 10 tons each and measuring approximately 13m by 700mm wide and 600mm high. This required us to prepare casting beds with the capacity to produce two beams per bed at a time. We also had to install tensioning equipment to ensure that


and increasing the strength of our


concrete mix, we were then able to

to cure the concrete to at least 40MPa

the Kyalami Race Track, which entails

remove the shutters within just five days

to ensure the shutters for the concrete

lengthening and upgrading the surface of

to ensure the strand could be removed in

could be safely removed.

the track, as well as providing improved

pre-stressed cables were correctly tensioned on each beam. “By putting in two sets of shutters

time. While the sides were removed, the

George explains that the pre-stress-

soffits were designed to be left in place

ing process required up to 500 tons of

to speed up the process.”

pressure to conform to National Highway

access to the inside perimeter via the underpass bridge.

Regulations, which is necessary to allow

Need for speed

Stringent regulations

the heavy weight of the road structure as

“We had to design a bridge that could

With final preparations in place, the first

well as the heavy construction equipment

be constructed quickly to keep up with

pour started early on 21 May this year

to move over the bridge with no effect

the rest of the construction work.

and the entire project was completed

on the overall integrity of the structure.

Precasting was the obvious choice as

just six weeks later on 2 July. This was

Bridge designer, Hugo Louw of WSP

this meant that there were few or no

a remarkable achievement considering

Group Africa, says the bridge project

disruptions on site (as would have been

that the team at Silverton Precast had

forms part of the massive upgrade of

the case with in situ construction). It also


About Silverton Precast

machines, as well as several road base

The company was started in 1998 by

layers and the special bitumen running

George’s father, Costa. Together the

c o ur s e . A s an a d d e d b e n e f i t, th e

f ather -and-son team established a

reinforced earth panels as well as the

concrete yard to manufacture lintels

exposed beams at the bottom of the

for the Pretoria building market. From

bridge provide a more attractive and

humble beginnings manuf acturing

smooth face,” explains Louw.

approximately 300m of lintels per day,

He adds tha t the end r esul t is

the company has expanded to become

satisfying as it met all the criteria for

one of the largest lintel manufacturers

speed, cost and aesthetics. “We are

in the capital, producing 4 000m per day

proud of the rapid deployment of the

and seven days per week.

bridge as well as the overall look, which

In 15 years the company has manu-

fits in with the sophisticated nature of

factured enough lintels to go end-to-end

the track. This is a job we can truly be

from Cape Town to London. It has also

proud of and all sub-contractors involved

expanded into the fields of civil and infra-

in the job need to be commended.”

structure work manufacturing a range of products that range from light mast


bases to road barriers, stormwater

• Manufactured in six weeks

channels, grids and a variety of road-

• Weight per beam 10 tons

related infrastructure.

• Measuring approximately 13m

we know shutters. If you give us a plan and

x 600mm high

a steel bending schedule, we will manage

• Overall bridge span 9m

everything else from there. By adhering

• Bearing-to-bearing span 11m

to all quality management specifications,

• Overall span 13m

the end result will be a product that

• Beam is tensioned

conforms to all specifications and criteria

and prestressed

and that is exactly what we aim to

• Readymix concrete used due

achieve,” concludes George.

to time constraints • Readymix ensured consistent strength and workability • Mix designed by Frank Cutugno of Pronto Readymix • Truck Conveyor Mounted pouring of concrete which allowed concrete to enter gave us the option to be innovative and

300mm space

opt for reinforced earth walls which not

• End strength of beams after

only speeded up the project considerably,

28 days approximately 70MPa

but also significantly reduced the overall cost of the project. “The project relied on sub-contractor, Reinforced Earth, to prepare the walls with steel strap mesh and specially designed panels made from 140mm of reinforced concrete. Once completed a concrete strip was cast in situ at the abutment to form a solid footing for the beams. Elastomeric bearings were then installed with a spacing of 765mm between beams. The upside-down Tshape beams were then lowered into place and spaces were grouted to form permanent formwork that was then filled in with a deck of in situ concrete. “This provided a strong base for construction work to proceed and carry


“We know concrete, we know steel and

• Dimensions 700mm wide

(Clockwise, from left): The bridge under construction at Kyalami Race Track; Silverton Precast manufactures specialised products for roadways; David Shabangu, George Ellinas, Sybert Seshoka and Mpho Mampana.


the weight of the heavy road surfacing


The CMA recently teamed up with the

concrete to be used between the walls.

selves to the technique, especially in

Concrete Society of Southern Africa to

This provides a speedier construction

light of skills shortages in the building and

host the Hybricem 2015 Hybrid Con-

time as well as improved material costs.

construction industries. Tilt-up provides:

crete Construction Seminar at venues

Daniel Petrov of Echo Prestress (a

across the country to highlight the

CMA member) showed how hollow core

• Speed of construction

method of integrating precast con-

flooring (and beams) provided new lev-

• Durability of the end product

crete and in situ cast concrete to build

els of flexibility. This is largely thanks

• Cost-effective designs


to improved speed on site as a result

• Efficient utilisation of available labour

Among the speakers were Prof Jan

of the slabs’ integration with other

• Improved safety, as most work is done

Wium of Stellenbosch University, who

structures. He cautioned, however, that

examined the finding of a study that

hybrid construction projects should be

looked at the various pros and cons of

planned for upfront.

• High-quality finishes

at ground level Technical specialist Daniel Petrov

of Echo Prestress also examined con-

using this technique. The consensus

Charles van Eck of Tilt Up Systems

crete joints and looked at connections

among consultants and contractors was

said that tilt-up is the way of the future

to assist in joining in situ and precast

that precast is favoured for quality and

where suitable structures lend them-

concrete components.

speed, but in situ for cost-competitiveness. Hybrid Construction can deliver the best of both worlds, it seems. Vincent Teissier, of LafargeHolcim Centre of Research, added that a number of technical options are already available and discussed some innovative hybrid approaches, including precast twin wall designs that provide structural strength, as well as formwork for in situ



(Above, from left): Prof Jan Wium, Vincent Teissier, Daniel Petrov and Charles van Eck.


SARMA BEST YEAR EVER Expect more from the readymix industry

minimum standards are maintained that

in future as years of hard work and plan-

will put an end to building collapses and

ning culminate in the professionalisation of

ramshackle houses as a result of inferior

the industry and the widespread adoption

products being used,” says Sarma Chair-

of certified readymix as the construction

man, Deon Fourie.

material of choice by the country’s most

Speaking at the association’s annual general meeting recently, he said that

influential construction bodies. 2015 will go down as the most ground-

these developments mark a watershed as

breaking year since the establishment of

the construction industry embraces nec-

the Southern Africa Readymix Association

essary quality over price. Sarma-certified

(Sarma) more than a decade ago, as indus-

members cannot cut corners and have

try organisations representing engineers,

sometimes been undercut by non-compli-

contractors and building pro-

ant readymix suppliers. This not

fessionals accept Sarma cer-

only jeopardises the integrity of

tification as the criteria for

the structure, but also lends to

all readymix supplied to their

unfair competition.

members’ construction sites. Simultaneously, the coun-

Ongoing initiative

try’s main contracting firms,

“ T h ank s t o th e e f f or t s o f

as well as parastatal organi-

General Manager Johan van Wyk’s role-players across the

sations including the South African National Roads Agency Ltd (Sanral) and other govern-

(Above): Sarma chairman, Deon Fourie.

country, an increasing number of organisations are seeing

ment entities, have also specified that only

the benefits of using only accredited

Sarma-certified readymix concrete may be

readymix and he is slowly winning the fight

used on their sites.

to professionalise readymix concrete in South Africa.

Growing support

“Under his leadership, the association

“This had the knock-on effect of attracting

is also throwing its weight behind the set-

a growing number of non-member readymix

ting up and adoption of new modern-day

suppliers who have begun working tire-

standards for readymix, as well as pushing

lessly to meet membership requirements

for higher standards of testing from the

and become part of the association. As a

country’s laboratories when it comes to

result, membership has grown in leaps and

dealing with concrete.

bounds, with growth of 11% in accredited member numbers during 2015.

“In addition, there are moves afoot to start a clean-up squad to remove concrete

“This is good news for the local con-

spills from our roadways, as well as new

struction industry as it ensures our

training initiatives to improve the skills

construction projects have world-class

of concrete workers and professionals,”

concrete. It also ensures that acceptable

said Fourie.


School of Concrete Technology lecturer,

to enjoy their work and earn a living from

conducted in English or Afrikaans, and a

Matthews Magwaza, has one important

even just basic concrete technology.”

large percentage of black people thirsty

attribute that helps teach hundreds of

Another training obstacle many of

for concrete knowledge could not properly

South Africans how to correctly and

these budding concrete business people

understand the lecturers. In cases where

profitably use concrete: he can speak

face is language. “For many years, South

they were illiterate, this was even more of

five South African languages.

African concrete training was mainly

a problem. The school’s training is done in

Matthews, who has been associated

English, but I am fortunate to be able to

with the Concrete Institute and its

elaborate and answer students’ queries in

Midrand predecessors, the Cement &

Afrikaans, isiZulu, isiXhosa and the Sotho

Concrete Institute (C&CI) and Portland

languages, if required.”

C ement Institute (P CI) f or a total

“Some of my students have become

many previously

successful business people, running

disadvantaged South Africans are keen

concrete brick and block production

to pursue a concrete-related career.

yards. Some are even erecting structural

“Bu t the pr oblem is tha t most o f

elements, and others have rapidly been

these people acquired all their concrete

promoted within their companies. Their

knowledge by watching friends or other

backgrounds vary: most came from

people doing building work, so they end up

impoverished family backgrounds, but

being enthusiastic self-taught individuals,

I have even taught a qualified medical

without the vital technical knowledge of

female doctor how to use concrete. She

how to use concrete correctly to create

quit her job and opted for a career in

durable structures, or make quality

concrete. That’s concrete for you – it

job so much, teaching these people how

(Above): Matthews Magwaza, lecturer at the Concrete Institute’s School of Concrete Technology.

can change your life. It certainly changed mine,” he adds.



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






• 2015














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• 2015






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• New

home for CMA • Push ing prod • Pion uction eerin with g pres tres









20 year s


Tel: 083 701 3278



self-com pacting sed slab concrete manufac turer celebrat es


Contact Wally Armstrong for more information


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E-mail: legweak@mweb.co.za ck










pipe to the test


• CMA’s new Execut ive Directo • Concre r te masonr y pitfalls and solutio Bluff project ns puts watert ight jacking

• Durban


s ed ethic oval nown of -re pr de rld Ap wo w co rk of e for • Ne A Ma bridg • CM ast ec • Pr

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bricks and blocks. This is why I enjoy my


of 18 years, says





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ANNUAL GENERAL MEETING This year’s CMA AGM was held at Emper-

CMA to initiate its own project to ac-

ors Palace, where a number of important

credit its own members. Also discussed

issues were raised and debated. Among

were a new code of ethics, new BEE ac-

them were potentially industry-debilitat-

creditation criteria, technical issues, as

ing delays at the SABS for the issuing of

well as administrative and marketing plans

marks of approval which prompted the

for the new year.

CONCRETE PROTECTION FOR EGGS Engineering students were recently given

mix ratios can be changed and teams have

the opportunity to test their technical

a free hand to come up with designs that

skills and compete against one another

they think will take the most punishment.

to build the best concrete device able to

Students from the University of Johan-

protect a raw egg from multiple blows from

nesburg’s (UJ) Auckland Park and Doorn-

a specially developed weight.

fontein campuses took place entering a

For more than two decades CMA mem-

total of 34 devices. In the end, the honours

ber, the Concrete Society of Southern Afri-

went to the team of Nkosinathi Mngadi,

ca, has hosted the Concrete Egg Protection

Sibusiso Shabangu, Keorapetse Kwele,

Device Competition throughout its branch

Morasoe Bernard, Bongiwe Dlamini, Lebo-

network to test the skills of engineering

hang Mosebi, Ziphiwo Kunene, Dzivhuluwani

students and highlight the strengths of

Nagana, Ore Mpye and Neo Modikeng.

concrete in structural applications. This year entries for the Inland Branch were of a high standard, with a number of structures able to take several blows from the heavy weight before failure and cracking of the egg. Concrete Society CEO, John Sheath, said the event is held annually to raise awareness of concrete among young engineers and highlight the importance of design to overcome challenges. Although all structures need to be designed with the same materials, weight and dimensions, the

(Above): Students from the UJ compete in the Concrete Society’s Annual Concrete Egg Protection Device Competition to see which design is best able to protect a fragile egg from the forces of a falling weight.

NEW MEMBER The CMA’s newest member, Ndlongho Civil & Construction, is a construction and consulting engineering company that provides services to both government and private-sector businesses. It also provides unique services to assist graduates and newcomers to the industry to develop their careers and later to add value in their chosen occupations. Ndlongho Civil & Construction is a fully black-owned company which holds a level 1 BBBEE Certificate.


OUT AND ABOUT AT BAUMA A number of CMA members participated at this year’s Bauma Conexpo Africa trade show to showcase building material manufacturing equipment and techniques. The show is one of the biggest of its type on the African continent and provides an opportunity to showcase products and company services.


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Significant updates to the International

pave the way for easier implementation of

be more transparent and not as easy

Standards Organisation (ISO) ISO 9001

integrated SHEQ management systems.

to fudge. Quality will have to become a

quality management standard this year

As a result, the implementation and

way of life.”

will have a major ef fect on the way

auditing of management systems will be

quality is measured and managed within

run on a similar template, which will make

Summary of changes

companies across the globe.

it easier and faster to implement the

All those involved in quality assurance

Although changes are designed to

different standards without duplication.

within an organisation should make

streamline and simplify the system, it

Although the streamlining will benefit

themselves familiar with the upcoming

will nonetheless need to be implemented

companies in future, companies with ex-

changes and start to prepare and imple-

carefully and changes will need to be made

isting management systems will be faced

ment adjustments as soon as possible

within companies over a period of three

with a number of challenges, according

in order to be ready for ISO 9001: 2015

years to comply with the new ISO 9001:

to Fouché. “Firstly, the system will rely

accreditation in three years.

2015 standard.

on input from senior management and

A short summary of changes follows

Addressing members of the Concrete

auditors will have to be comfortable com-

and needs to be verified and imple-

Manufacturers’ Association (CMA) in

municating at that level. With the cor-

mented by quality personnel and senior

Midrand recently, standards expert

rect questions and information requests,


Christel Fouché, CEO of Advantage

however, CEOs and the management

• The system has changed to a higher

ACT and AGO Certification, said that

team should be able to show compliance.

among the most significant changes

“Another challenge for companies

will be a shift of responsibility to senior

who think tha t they can r un their

is now in line with environmental,

management rather than being the

quality management system as a ‘paper

health, safety and all other standards

domain of companies’ quality management

exercise’ is that the new system will

• Several new clauses have been added


need to be managed 365 days a year

and not just the week before an audit.

• The system will follow a process

New quality management systems will


Necessary for trade

level of management

• Core structure of quality standards

and need to be studied

“In fact, quality management representa-

• Mention of preventative action has

tives are no longer an explicit requirement

been removed, as the system should

of the new standards, nor the require-

automatically take care of issues

ment for compulsory procedures. Rather,

• The term “product” is replaced by

businesses will be required to walk the talk

and be able to prove the steps that are in

• The term “continuous improvement”

place to ensure quality.

“Auditors will also have to adapt

“product or services” has been changed to “improvement”

• T he term “purchasing” has been

and will be required to interview senior

replaced by “externally provided pro-

management at CEO and similar levels

ducts and services”

in order to ensure that standards are

• References to quality manual, docu-

being upheld. While this may seem an

mented procedure and records have

onerous task, it is an absolute necessity

been removed – specific reference to

for businesses as it is very difficult to do

documented information is now done

business without ISO 9001 certification”

• N u m e r o u s w o r d c h a n g e s h a v e

Fouché said.

been made in order to make it easier

to interpret

She explained that the penalty for not maintaining proper quality standards can

• Three new informative annexes have

be severe, with damage to brands and

been included.

reputations being far more costly than

Although no longer a requirement, Fou-

any financial losses that may be incurred.

ché still recommends that quality management representatives be maintained and

Faster to implement

work hand-in-hand with senior manage-

The new ISO 9001: 2015 standard has

ment to implement quality requirements.

been developed on the foundation of the

Likewise, she recommends that quality manuals also not be thrown out, even

new Annex SL document. This document will set the new quality standard in line with ISO 14001 environmental and OHSAS 18001 health and safety standards and


(Above, from top): Delegates and members of the CMA attended a talk on changes that have been made to ISO 9001; Christel Fouché of AGO Certification.

though this is no longer a requirement. “Remember, when you are out of quality, you are out of business,” she concluded.




AWARDS ARE WELL SUPPORTED The Concrete Manufacturers’ Association’s (CMA) NPC 2016 Awards for Excellence competition is being supported by an impressive array of sponsors. PPC is the anchor sponsor and its contribution has underpinned the event’s organisational cost from the earliest planning stages. Other sponsors include Afrisam, Lafarge, BASF and Chryso. In addition to being the anchor sponsor, PPC is also sponsoring the table settings. Afrisam is covering the pre-dinner drinks and dinner wines and Lafarge is taking care of the ladies’ gifts. BASF is sponsoring the production of a short film on precast decorative concrete, which will be shown at the gala dinner ceremony to be held at Summer Place in Johannesburg on 23 April. Chryso’s contribution will cover the cost of producing miniature trophies which will be presented to members of the winning teams during the ceremony. “We are extremely grateful to our sponsors. Thanks to them, the 2016 Awards for Excellence competition will be a memorable event and one which makes a worthwhile contribution to the promotion of precast concrete and its numerous applications,” says CMA Awards Committee Chairperson and Echo Prestress MD, Monique Eggebeen. Entries will be judged on the contribution precast concrete elements make in one or more of the competition categories. Six floating trophies will be presented to the manufacturers of the precast concrete elements in the nominated categories. In addition, commendation awards will be made to three runners-up per category, provided these entries meet the standards of the judges.

CONCRETE INSTITUTE INFO CENTRE GROWS Kizzy Shipalana has joined the Concrete Institute’s Information Centre team as Information Specialist. A qualified librarian with more than 10 years’ experience in the field, Shipalana started her career at the South African National Biodiversity Institute (SANBI) as a library student in 2001. In 2003, she was appointed there permanently as a librarian. She worked for Ditsong Museums of South Africa from 2007, also as a librarian, prior to joining the Concrete Institute. Shipalana holds a BA (Hons) Library and Information Science degree, obtained at UNISA.

(Above): Kizzy Shipalana (right) with Information Centre colleagues Susan Battison (left) and Bongani Methula.

Due to requests from Concrete Manu-

Approval or have no national specifi-

mark holder will provide the names of

facturers’ Association (CMA) members,

cation for their products, as well as

sites where products are delivered or

as well as non-members in the precast

non-producers who would want to be

installed and the auditor will randomly

concrete industry, the CMA has decided

accredited by the CMA. The CMA will

select a site to audit. The final approval

to investigate the possibility of starting

still keep Associate-, Non-producer and

and recommendation for accreditation

an Accreditation/Mark Scheme for its

Contractor- and Cement Producer mem-

and the mark will be done by an inde-


bers. (These members are also allowed

pendent Approvals Board. Accredita-

to be accredited if they comply with the

tion and Mark-holders will be listed on

requirements of the Scheme.)

the CMA website.

Af ter car ef ul consideration, the decision was made to pursue this opportunity and so add more value to its services to the members of the CMA.

“The CMA Mark scheme requirements

The CMA will be the custodian of

will include basic compliance with the

this Accreditation/Mark Scheme and

According to CMA Executive Direc-

Occupational, Health &

will issue and suspend

tor, Frans Minnaar, the CMA Accredita-

Safety Act, the Com-

(if necessary) the ac-

tion/Mark Scheme is a voluntary scheme,

pany’s implemented Qual-

creditation or the mark

so any member can apply for participa-

ity Management System

of members with a rec-

tion in it. With application, the member

and an applicable product

ommendation from the

accepts the scheme’s rules and regula-

specification. (Products

Approvals Board.

tions and will have to comply with it in

will be tested on site

“We will need to mar-

order to obtain the CMA Accreditation

with the manufacturer’s

ket the scheme very well

or the Mark of Approval.

calibrated equipment.

to ensure we have the

Independent testing at

buy-in of the professional

Proving compliance

accredited laboratories

bodies involved in specify-

“In essence, there are two legs for this

will also be allowed.)

ing products and show

scheme, namely Accreditation and the

“Complying members

them that the CMA Ac-

Mark of Approval. Firstly, the Accredi-

will be issued with a cer tificate of

creditation/Mark Scheme proves the

tation scheme requirements will include

compliance and will be allowed to use a

credentials of the products, as well as

basic compliance with the Occupational

‘special’ CMA logo on documentation and

any other mark available in the industry.

Health & Safety Act and an implemented

products,” says Minnaar.

After all, the SABS is an accreditation

operational Quality Management Sys-

agency and we will merely be testing

tem. In addition, the company will be

Keeping it tight

the same standards through a different

audited on an annual basis to determine

He adds that Accreditation audits will

verification agency,” concludes Minnaar.

compliance with CMA requirements.

be once per annum and Mark scheme

“The Accreditation scheme is for

audits will be twice per annum (possibly

producers who do not need a Mark of

one per site visit). For site audits, the

(Above): Frans Minnaar discussed the CMA’s new Accreditation Mark Scheme at the association’s AGM recently.

CHANGES COMING TO BEE CODES Companies in the precast and related

scorecard, as would enterprise and

may very well lose their status and find

industries should be aware that sweep-

supplier development.

their scores only qualify them as a Level

ing changes to BEE codes of

In compiling a BEE score-

7 supplier or worse. For this reason,

practice which will come into

card according to the new

companies need to become familiar

effect next year will have a

r equir ements the scor es

with the new codes as required by the

dramatic influence on compa-

have changed for a number

Department of Trade & Industry.

nies’ overall rating and may

of criteria and it is advisable

“A compliant BEE scorecard can

affect procurement decisions

to become familiar with the

assist companies to retain business,

of their clients.

new requirements, in order to

as well as obtain new business from

This is according to CMA

either try to comply or make

government and the private sector.

member, PPC’s Justin Meth,

allowance f or the change

Compliance also contributes to the

who was speak ing at the

in customer procurement

transformation of the broader society.

association’s recent annual

requirements that may put

My advice is to embrace the codes or

general meeting in Kempton

non-compliant companies

they will become a major stumbling block

Park. He said that company

further down the list in terms

in future,” said Meth.

ownership, management control and

of procurement preference.

skills development would play an increas-

“Companies that may pr ev iously

ingly important part in the overall BEE

have been certified as a Level 4 supplier


(Left): Justin Meth of PPC delivered an insightful talk on the new BEE codes at the CMA AGM held in Kempton Park recently.






Precast hollow-core slabs are to the construction industry what cellphones are to modern communications – fast, flexible, multifunctional and cost-effective. ECHO PRESTRESS (PTY) LTD - GAUTENG | ECHO FLOORS (PTY) LTD - GAUTENG ECHO PRESTRESS DURBAN (PTY) LTD - KZN | TOPFLOOR LTD - WESTERN CAPE



A NEW LEADER FOR A NEW WORLD: LAFARGEHOLCIM On 15 July 2015 LafargeHolcim officially launched the new group around the world and announced key elements of its ambitions for the future. This followed the successful completion of the merger between Lafarge and Holcim and the listing of the new LafargeHolcim shares in Zurich and Paris. LafargeHolcim’s ambition supported by five key focus areas The company is initiating a strategic transformation by building on the best of both Lafarge and Holcim. Key facts and figures about LafargeHolcim • 90 countries • 115 000 employees • CHF32,6 bn in net sales • 386,5mt of installed capacity worldwide • More than 2 500 plants (including over 1 600 in readymix

concrete, over 600 in aggregates, over 180 in cement and

70 grinding plants)

• Our solutions and services: cement, concrete and aggregate

solutions for the following businesses: buildings, infrastruc-

ture, distribution, oil and gas, affordable housing and con-

struction systems

• CEO: Eric Olsen • Founded in 2015 following the merger of Lafarge and Holcim About LafargeHolcim With a well-balanced presence in 90 countries and a focus on cement, aggregates and concrete, LafargeHolcim (SIX Swiss Exchange, Euronext Paris: LHN) is the world leader in the building materials industry. The group has 115 000 employees around the world and combined net sales of CHF33 billion (€27 billion) in 2014. More information is available at www.lafargeholcim.com. About Lafarge South Africa Lafarge South Africa is a member of the LafargeHolcim group. The group applies its technical strength to continually develop innovative products and solutions that contribute to building better cities and communities, while reducing the environmental footprint of its products and manufacturing processes. Lafarge South Africa is one of the major building material manufacturers in southern Africa, with a strong presence in all of its business lines of cement, aggregates, readymixed concrete and fly ash. This places the company in a unique position to help the sustainable development of better communities that are the heart of our cities, rural towns and villages.

(Above): A new company, a new logo and new strategies to make the company a leader throughout the world.



CMA MEMBERS TO BE BOUND BY CODE In future, members of the Concrete

as the integrity of the individuals, we

4. To accept responsibility for our ac-

Manufacturers’ Association (CMA) will

as members should accept a personal

tions, admit mistakes and correct

be bound by a code of ethics in a move

obligation to commit ourselves to the

them promptly.

to uphold professionalism and ensure in-

highest ethical and professional con-

5. To avoid real or perceived conflicts of

tegrity and honesty in their dealings with

duct,” said Minnaar.

interest whenever possible and to

disclose them promptly to affected

forward for comment:

parties when they exist.

general meeting in Pretoria recently, Ex-

1. Members shall strive to comply with

6. All members of the CMA shall do all

ecutive Director Frans Minnaar outlined

these guidelines, uphold, maintain

the importance of introducing a code

and improve the integrity, reputation


of ethics and added that rather than

and practice of the precast concrete

7. All members are urged to guide each

introducing detailed rules and regula-


tions, the association will encourage all

2. All members of this associa-

its members to abide by the codes in the

interests of uplifting the reputation of

• To practise acceptable

the entire industry.

customers, suppliers and competitors. Speaking at the association’s annual

“It is the mission of the CMA NPC to

The following guidelines were put

within their power to protect the

other in carrying out the intent of

these guidelines and are further charged with the responsibility

tion shall strive:

to advise the Directors of this association without

safety standards;

delay of any violation of

• To comply with the

enhance the image of the precast con-

legal and regulatory

these guidelines brought

crete industry. We recognise that integ-

requirements of the

to their attention.

rity is the cornerstone of trust and that


trust itself is something that can only be

• To manufacture good-

earned or built through perseverance and

quality products at all

persistent adherence to responsibilities

times; and

and obligations.

• To comply with our Code of Conduct,

tions relating to ethical conflicts within

namely the Competition Act, 89 of

the association can be best answered


1998, as amended.

by thoughtful consideration of funda-

“Furthermore, realising that an as-

3. Members shall protect each other’s

mental principles, rather than reliance

sociation is essentially the sum of its

right to privacy and confidentiality

on detailed regulations. “Therefore we

members, and that adherence to a code

with respect to information sought

cannot and do not dictate conduct to

of ethical responsibilities is only as good

or received.

cover particular situations.”

8. Members shall seek peer review in situations not fully comprehended. Minnaar concluded that ques-

THE NEW PRODUCTION PALLET FOR PERFECT QUALITY The industrial production of concrete

particularly high impact and abrasion

• Effective and cost-saving utilisation,

blocks and products demands adherence

resistance and ensures the longevity

due to the low net/self-weight of the

to high standards from the manufactur-

and consistent moisture content of the

PERI Pave pallet, Energy savings are

ing systems that are used. The aim is to

PERI Pave pallets.

achieved during the transportation

of the pallet through the machine

The foremost advantages of the PERI

ensure a constantly high and repeatable concrete quality for many years, coupled

Pave pallets are;

cycle. Cycle times are reduced as

with a high output.

• E xcellent compaction character-

there are no withdrawal plates, thus

The PERI Pave production pallet has

istics. Due to the homogenous con-

increasing efficiency.

been used for many years in countless

struction of the pallet, the bandwidth

• Constant properties for repeatable

businesses very successfully, especially

of compaction tolerances are lim-

concrete quality are maintained with

in Europe. Due to the highest quality and

ited to a minimum, uniform heights

the PERI Pave pallet over a long pe-

dimensional accuracy, it is recognised

and high consistencies. Tests in


worldwide as an important factor in the

Germany have proven that by simply

harsh UV exposed conditions, as well

production of quality concrete products.

replacing an existing pallet with

as in air-conditioned chambers.

With the PERI Pave production pal-

a PERI Pave pallet, average paver

• Suitability for every type of machine.

let, concrete products can be manufac-

strengths increased and the spread

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tured consistently and cost-effectively.

of results decreased, allowing for a

PERI Pave pallet ideal for every cust-

The multiplex core of the pallet is pro-

reduction in cement content of the

omer, resulting in problem-free handling.

duced through the cross-binding of

paver mix.

• No leakage of wood substances,

high-quality hard wood veneers from

• Minimal deflections under highest

which means no discolouration of the

sus t ainabl y manage d f or e s t s. T he

loads are achieved, due to the load-

concrete product, as well as less

patented polypropylene coating offers

bearing core of the pallet.

dust formation in production halls.

also with high humidity and


The devastating drought in many parts

First published in 1984 and revised

of South Africa has increased awareness

three years ago, Farm Reservoirs is a

of the need for effective water storage,

manual dealing with the use of concrete

“The manual has enabled owners of

particularly in rural areas. “It is there-

for water-retaining structures for irriga-

farm dams to build a structure that will

fore important that more rural local

tion, watering stock, farm dams, swim-

be serviceable for many years with the

authorities realise that even relatively

ming pools and household use. “There

ability of retaining considerable water

small concrete water reservoirs, stra-

has been tremendously positive feedback

pressures when full. Concrete farm

tegically placed, can play a vital role in

regarding this publication since it was

reservoirs are also a familiar sight in

sustaining struggling rural communities,”

launched by the Concrete Institute’s

most of South Africa’s major national

says Bryan Perrie, Managing Director of

predecessor, the Cement & Concrete

parks, and sustain wildlife in these game

the Concrete Institute.

Institute, so many years ago. The manual

reserves during the frequent droughts

Perrie says the local authorities

has been widely used as reference book

that strike many of these sanctuaries,”

should follow the example of hundreds of

by farmers and smallholdees in urban

Perrie adds.

South African farmers and smallholders

areas,” Perrie states.

who have for nearly three decades re-

The 52-page, A4 publication deals

ferred to the Concrete Institute’s most

with the construction of circular res-

popular and durable publication, Farm

ervoirs with reinforced concrete walls,

Reservoirs, to build dams on their prop-

as well as those with walls of fired clay

erties. “The Concrete Institute would

bricks, concrete masonry and corru-

be prepared to provide supplementary

gated galvanised steel. Guidelines for

advice to any local authority planning

reservoirs built with travelling moulds

to build farm reservoirs to serve people

are included. Rectangular reservoirs

living in isolated areas without or with

and swimming pools, elliptical swim-

limited, or drought-disrupted municipal

ming pools and drinking troughs are the

services,” he adds.

topics of other chapters, while data for

estimating the quantities of materials required is also provided.

(Above): The Concrete Institute’s informative manual on the construction of farm reservoirs has proved invaluable to the southern African rural community for nearly three decades.





Acclaimed and well-respected economist, Dr Roelof Botha of GOPA Group SA, is predicting that an improvement in the construction industry is around the corner and that the country is very possibly sitting at the beginning of the next housing boom. Addressing construction industry


professionals at the recent Readymix by Sarma conference, Botha added that the road to recovery in the economy is still a bumpy one, with commodity prices at a very low level. This is putting pressure on world economies, including SA. However, on the upside, he says that low commodity prices are due to swing as they follow cyclical movements and have done so throughout history. Despite challenges, our economy still continues to grow modestly and when commodity prices do swing, he predicts that it will flourish. Added to that, he says there are indications that the country’s property market is on the brink of the next property boom and that signs are already showing that the boom has started.


Housing and infrastructure

criteria, efficacy of corporate boards,

“This is evidenced by the uptrend in

soundness of our banks, availability of

Despite this, Botha cautions that

building plans passed, which is an indica-

financial services and efficacy of the

as part of a global economy, we are still

tion that the industry is back on track

South African legal framework.

being hamstrung by low GDP growth.

posable income balance figures,” he says.

to grow faster. Contrary to popular

“Compared with the rest of the

Commodity price declines have lasted five

belief, the construction industry has

emerging and developed markets, we have

years already and nobody really knows

done well in the past decade and has

impressive fiscal stability and impres-

where the bottom of the cycle is. On the

grown by 5%.

sive real GDP figures and will therefore

home front, government expenditure is

“Added to this, there is pressure on

continue to outstrip world

increasing, but is still a mere

existing urban infrastructure and with-

GDP for the next 50 years. In

20% of GDP. He adds that

out doubt the country will need many

addition, the JSE (even in the

the lack of electricity, labour

more roads, railways, schools and hos-

commodity slump) is breaking

reductions and other fac-

pitals in future. This will clearly require

all the records and real retail

tors may continue to retard

government and the private sector to

sales are at an all-time high.

growth in future.

invest in infrastructure in the medium

“Household debt versus

term and this is key to unlocking the

disposable income r a tios

construction spending.

have improved dramatically

“Further good news is that credit

(Left): Economist Dr Roelof Botha predicts that South Africa may be at the start of the next housing boom

and are currently very good.

extensions and mortgages are growing

As a result of these and other factors,

(although still from a low base). Resi-

we also expect the prime lending rate to

Five reasons to be proud of SA

dential values are on their way up again

remain in single-digit figures for several

• SA is the 11th-largest market

and are expected to keep trend with

more years.

in the world

the 12% average year-on-year growth

• We have the third-cleanest

rate in the most popular segments of

Personal wealth

tap water

the market. Added to this, the country

“The employment rate is improving and is

• It is home to the world’s

is well positioned for growth due to its

expected to continue in this positive vein

second-largest brewer

competitive strengths in a number of

in future, while real salaries and house-

• The Eastern Cape is the sole

hold expenditure are still increasing.

producer of Mercedes-Benz

critical areas.

“Also, the country’s gross national

C-Class vehicles

Fiscal stability

income per capita is structurally at a

• It is rated No 2 in the world for

“These include our top-class securities

higher level than ever before and we have

budget transparency

exchange, tight auditing and reporting

record new household net wealth to dis-



DANGER AT THE WORKPLACE The construction industry is one of the

R45 billion every year.” Included in the

most dangerous sectors to work for

indirect consequences of a building

and the industry needs to take more

industry accidents are a company’s

responsibility to control the risks that it

loss of reputation and goodwill, loss

creates for employees, Thelma Pugh, MD

of production and skills, low employee

of the Federated Employers’ Mutual Assurance (FEM), has warned.

morale, delays in completion of work, and loss of equipment.

FEM is the official assurer for

“In 2003, the industry killed 83

the South African building industry.

of its workers. In 2013, it again

Speaking at the Master Builders’

killed 83 – so there has clearly been

Association (MBA) North’s annual

no improvement. The UK building

which now accounted for more than

Construction Health & Safety

industry also killed 83 workers in

half of the total fatalities in the building

2013 out of a workforce of

sector. “South Africa records about

Pugh said the building

2,5 million. South Africa’s

15 000 road deaths every year. We have

industry contributed sig-

building sector killed the

some of the best legislation, but the

Awards function in Midrand,

nificantly to national economic growth and job creation, but was consistently plagued with workplace accidents. “Employers tend to see only the direct

same number, but out of a workforce of only 300 000. That shows the gravity of the situation.” She said research told us that the full cost of a building industry ac-

worst enforcement of road safety. “On a scale of 1 to 10, enforcement of national speed limits stands at 3, enforcement of drunken driving at 2, national motorcy-

costs of accidents such as medical, hos-

cident could represent as much

pital expenses and loss of wages, but the

as 37% of annualised profits

cle helmet law at 6, the

indirect costs are much more dramatic.

of an organisation, 8,5%

Research suggests that indirect costs

of a tender price and

at 1, and enforcement

are 14,2 times those of direct costs.

about 5% of an organi-

to prosecute users of

Severe cases can cost over R1 million, so

sation’s running costs.

the real costs could be as high as R14,2

“In addition to the harm

million for a single severe case.

accidents caused employees,

seat belt law at 1, child passenger restraint

mobile phones while driving also at a dismal 1. “Based on road traffic death rates

there are also the increasing

per 100 000 population, South Africa

A lot to lose

number of widows and orphans resulting

at 31,9% is ranked sixth-highest in the

“If one considers that the direct costs

from loss of lives to consider.”

world compared with, for example, the UK with 3,7% and other African countries

paid by FEM and the Compensation Fund collectively total R3,16 billion

Alarming statistics

like Malawi, Madagascar and Mozam-

per annum (and rising), the costs –

Pugh warned that there had been an

bique, which all lose under 20% of its

including indirect costs – must be about

alarming surge in motor vehicle accidents

population using the same yardstick.”







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


Creating space on steeply sloping ground is always tricky, especially when space is tight. This is where the versatility of CMA member, Terraforce’s precast concrete retaining block (CRB) walls came into play recently, when they were used to provide a small footprint near a vertical retaining wall at a residential property in Camps Bay.



When Camps Bay home owner, Sue Schalit, noticed that her original stone retaining wall was cracking and tilting forward, she was concerned

that it

might collapse and damage her own and neighbouring properties. “Geotechnical consultant Mike van Wieringen not only verified movement, but also observed that the foundations were inadequate. He recommended a CRB wall as it would have the least impact on our garden and would provide an exceptionally durable retaining wall solution,” says Schalit. Covering just over 86m², the new wall was designed by Fred Laker, an engineer with Terrasafe, Terraforce’s CRB wall design company, and it was built by an approved Western Cape installer, Das-

offered extremely limited work space

three months and Schalit was impressed

senberg Retaining, using L12 Terraforce

and all materials had to be carried in

with the Dassenberg team and the re-

wall blocks. Four metres high, the wall’s

bags down three staircases. “In addition,

sulting wall. “Dassenberg was incredible,

bottom section had to be reinforced with

spoils had to be carried up to road level

working in tough circumstances and re-

Y12 steel rebar.

by hand, making the whole process very

moving tons of rocks by hand. The wall is


extremely neat and I am very happy with

Dassenberg Retaining’s estimator, Georg Brand, comments that the site

The wall was completed in less than

the result.”



Brick and Block equipment manufacturer Hydraform has contributed to the construction of 27 affordable homes in the Eastern Cape on behalf of the Department of Rural Development & Land Reform.

Helping development Beyond supplying machinery, Hydraform’s participation in this project has not only helped create shelter for worthy citizens, but has also involved the community in the construction of their own houses.



Radway Green Farm community members have also benefited from being gainfully employed during this process and have also acquired the necessary transferable

As part of the department’s commit-

Hydraform is a CMA member and

ment to development and upliftment,

has been a forerunner in the industry

skills in both block-making using Hydra-

the Radway Green Farm community just

for close to three decades, supplying

“The community members we em-

outside Grahamstown is being provided

interlocking block-making machinery to a

ployed for this project previously had no

with permanent shelter during a process

growing market and offering the neces-

transferable skills other than farming.

that will offer them employment while

sary training and skills development to

Now they have the ability to produce

teaching them invaluable skills.

inform and enhance the user’s experience

blocks and build using Hydraform in-

of the machinery. This existing model fed

terlocking building technology. A key

into the company’s extended offering to

objective of the project was to ensure

deliver turnkey solutions for specialised

that the community members were

housing delivery.

not only beneficiaries of homes, but

form’s technology and construction.

Sales and Marketing Director for

that they were trained in block-making

Hydraform, Nazlie Dickson, notes: “The

and construction as part of their skills

opportunity this initiative gave us was

development. The community produced

to implement our own project and prove

150 000 blocks that went into building

that a community can be transformed

their houses,” she says.

and enabled by participating in local con-

Notes Dickson: “The project itself is in

struction in a short period of time and

a rural setting where there are no formal

enjoy benefits beyond housing delivery.”

water and power facilities or supply.”



Our full range of plywood and panel products For concrete block plants ¡ PERI Pave production pallets For precast plants ¡ Plywood and formwork panels in various qualities and sizes ¡ Standard material available at short notice and package-wise


Concrete Block Paving (CBP) supplied by CMA member, Brickcast, has performed well on a 2 400m² section of Chief Albert Luthuli Street, situated between the City Hall and the Tatham Art Gallery in Pietermaritzburg. Completed in December 2013 to mark Pietermaritzburg’s 175th anniversary, the road formed a crucial element in an urban renewal project which was executed close to the City Hall and other historic structures. Shaun Sewnath, Brickcast Managing Director, says the

For other sectors ¡ Plywood for the furniture making, vehicle construction and packaging industry

road proves once again that CBP is as suited to the tough

For further information please contact Marleen Du Plessis Phone: 082 814 2222 | marleen.duplessis@peri.co.za

has to handle diverted traffic from the N3, including huge

conditions of public and heavily-trafficked roads as it is to private driveways and footpaths. “This section of road often multi-axled trucks and as can be seen in the picture, it shows no visible signs of wear.” Specified by consulting engineers Hatch Goba, the

PERI Plywood Solutions for different end uses

80mm/38MPa Roadliner interlocking pavers were cast with a 5mm red topping. They were manufactured to the latest SANS 1058 standard and, as such, were tested for abrasionresistance and strength to ensure that they met long-term (20-year) performance and endurance criteria. Prior to specifying CBP, Hatch Goba researched various road-surfacing options, including clay pavers and coloured asphalt. According to Project Manager Gaillard Rossouw of Hatch Goba, life-cycle costs, aesthetics and loading were of particular concern, the latter proving a key determinant in the choice of CBP. “Besides their superior load-carrying capacity, concrete pavers were chosen because their life-cycle and replacement costs were not only considerably lower than the other materials surveyed, but were much easier to replace. And because Chief Albert Luthuli Road forms an alternative route

Formwork Scaffolding Engineering ZA PERI 15.200


to the N3 during temporary closure, loading was an important design consideration.” (Above): Chief Albert Luthuli Road, Pietermaritzburg, where Roadlliner interlocking pavers, manufactured by CMA member, Brickcast, show no signs of wear after withstanding two years of heavy traffic usage.





CMA member Technicrete was recently selected to pave and kerb the perimeter of Lord’s View Industrial Park in Chloorkop as well as provide a long-lasting solution for potential erosion issues on the site.

to Lord’s View Industrial Park, which is a project in motion and due for completion in June 2016. In addition to our pavers and kerbs, our Armorflex solution offers installation flexibility as it conforms to ground contours, does not fracture and requires little ground preparation. “It provides a good defence against erosion with an excellent lining for drainage channels. We are pleased with the final appearance of our products around

“Location, location, location” is the

BondBrick grey pavers for the parking

the industrial park, which has used the

property developer’s mantra and the new

and other walkway areas.

grey/terracotta colour scheme combina-

industrial park near Midrand offers just

“It was the product quality, service

that, with access to all the major high-

and price from the company that secured

ways, as well as being in close proximity

the contract, as well as their profes-

The Technicrete DZZ’s are available

to OR Tambo International Airport. When

sionalism. Product demand and supply at

in autumn, grey, terracotta, plum, slate

completed, the development will house

times became a challenge, but it was not

and tan colours with a length/width of

global and national industrial and retail

insurmountable for the suppliers, who did

220mm x 97mm. BondBricks are available

distribution centres and warehouses.

not fail in their delivery of stock.”

in the same colourings with a length/

Power Construction’s site agent,

further sites within the complex.”

width of 200/100mm.

Robert Turner, says “On a project of


this magnitude, aesthetics ar e as

In addition to the industrial park develop-

important as functionality. The kerbs

ment, Technicrete ISG also completed

and double zig-zag [DZZ] paving is a

work within the Greencross building area

quality product that gives the industrial

and will be supplying DZZ’s and Bond-

park a good and pleasing finish. We

Brick for the Foschini and Stuttaford

used Technicrete’s barrier, mountable

warehousing sites that are shortly to be

and semi-mountable kerbs in a variety

developed at Lord’s View Industrial Park.

of dimensions to kerb the 2.5km of

Technicrete ISG Sales Consultant

roads and walkways at the park, while

T ienie Br onk hor st comments: “We

the paving ar ea utilised DZZ’s and

supplied R1,5 million worth of product


tion and are delighted to be involved in

(Above): Lord’s View Industrial Estate in Chloorkop.

“Demand and supply at times became a challenge, but it was not insurmountable for the suppliers.”


MPUMALANGA SHOPPING CENTRE STABILISED Five geosynthetic reinforced retaining walls using precast concrete retaining blocks manufactured by CMA member, Aveng Infraset, have played a crucial role in creating stable terraces for the construction of Emoyeni Mall, a recently completed shopping centre situated on the R538 between Nelspruit and Hazyview in Mpumalanga. The mall was built by one of the coun-

face and built with the Infrablok 350.

try’s leading rural retail centre develop-

The largest wall, some 200m long, was

ment specialists, McCormick Property

built in an open-face configuration at an

Development, a company with a strong

angle of 70˚. It was constructed on the

focus on the emerging markets of South

perimeter of the property to reinforce

Africa. Engineered Interlock Solutions

an embankment which rose to 12m at its

(EIS) in conjunction with TMV Consulting

highest point from a service road below.

(Top): One of the open-face retaining walls at Emoyeni Mall. (Above): One of the open-face retaining walls at Emoyeni Mall.

Engineers designed the geosynthetic

“We only had 5-6m to work with on

varied between 300-450mm in depth, de-

reinforced concrete block retaining

this wall and the installation of extensive

pending on the height of the wall. TB 490

walls. The walls were built by EIS in close

sub-surface drainage was required be-

retaining blocks were used to erect the

collaboration with the main earthworks

fore construction of the wall could begin.

lower section of the perimeter wall and

contractor, Joubert en Seuns.

Sub-soil drains were installed on top of

the upper section was laid with lighter

EIS owner, Manie Troskie, says that

the foundations three to four blocks

TB 300s,” says Troskie.

EIS won the retaining wall tender on the

below kerb level. Fin drains, wrapped in

basis of an alternative and more cost-

A2 bidem which go right back to the cut

Basement work

effective design, which also offered bet-

face, were laid to trap water at the top,

High-tenacity Paragrid reinforcing sup-

ter functionality. “There are substantial

sides and bottom of the embankment.

plied by Maccaferri was used to reinforce

quantities of sub-surface water on this

“We also installed 250mm Kaytech

the wall. The material was specified due

site and our design had to make provision

wick drains which were wrapped with

to its very low elongation properties. It

for extensive drainage. In fact, there

bidem. And in areas with the heaviest wa-

also attains its tensile strength very

were some embankment sections where

ter flows, we positioned 100mm slotted

quickly and has a stretch factor of less

one could actually see water oozing from

pipes covered with stone and Geomesh

than 5%. The Paragrid reaches back to

the ground.

geotextile to trap the water at the cut

the cut face and was laid at a spacing

face. All ground water drains into a pipe

of every second block on the lower half

Drainage requirements

at the bottom of the wall, which runs

of the wall. Macgird WG4 was installed

“Three walls were open-face designs and

parallel to the foundation and feeds into

at every third block on the top half and

were built with Aveng Infraset’s Terrace

the stormwater drainage system.

extends 9m into the fill.

Blok TB490 and TB300 retaining wall

“The foundation of the perimeter wall

The parking basement wall was also

blocks. The other two walls were closed-

was steel-reinforced. One metre wide, it

built as a geosynthetic reinforced wall.


ing’s loading. Maccaferri Paragrid was

ing than the perimeter wall as it has to

used to reinforce this wall to prevent

support a portion of the weight of the

any soil movement under the building’s

building, which was built on a jockey slab,


concrete columns and normal foundations. Because of the heavier loading,

Team effort

the wall was built using the TB490 block

The second closed-face wall was built

only. “Basement walls are normally built

around a water reservoir situated on

with solid concrete retaining walling.

ground above the centre. This wall was

However, retaining block walls are more

constructed with Infrablok™ 350s at

cost-effective,” says Troskie.

a face angle of 75º and Macgrid WG4

Two closed-face walls were built using

was used for geosynthetic reinforcing.

Aveng Infraset attractive Infrablok 350

A combination of Macgrid WG4 and

at an angle of 85˚ due to limited space.

cement-stabilised backfill was deployed

The one wall, which varies in height

in areas where the space between the

between 1-3,4m was built adjacent to

reservoir and the concrete block retain-

a car-park feeder road and supports a

ing wall was limited.

building platform on which a Cashbuild

Other members of the professional

store was built. The walls were built

team included the main consultant,

around the concrete support columns

Endacon Consulting Engineers and the

and reinforced soil, and the retaining wall supports a portion of the build-

(Top): The 200m perimeter wall at its highest point of 12m.

main building contractor, Ikotwe Construction.


Rising to 5,5m, it takes a heavier load-


LARGEDIAMETER PIPELINE PROJECTS CM A member Sout hern Pipeline Contractors (SPC) recently completed a number of large-diameter pipeline projects in and around Gauteng. According to SPC Sales Manager Steve Delport, recent projects include Mohgale Soweto, where a 700 litres (l/m) per minute pipeline required pipes with a 1 800mm internal diameter, and 2 160mm external diameter (Above): Steve Delport of SPC.

with an effective length

o f 2 82 0mm p er pip e . E ach pipe weighs approximately 8,4

tons at the point of transport. Another project was for Diepsloot water purification, where pipes were supplied for a 1 300l/m project requiring pipes with a 1 500mm internal and 1 800mm external diameter with an effective length of 2 960mm and a total weight of 5,9 tons. In Germiston pipes were also supplied for the B5 water feed pipeline and required a 2,5m concrete jacking pipe to be used throughout a busy metropolitan area. Pipes for this project were supplied for jacking as a sleeve for the steel pipeline. The pipes have an external diameter of 3 000mm and 2 500m internal diameter and are 1 600mm long, weighing about 8,8 tons per pipe. According to Delport, the pipes needed to be supplied in a very short time and relied on SPC’s ability to supply the requirements in accordance with contractor’s deadlines. Manufactured at their advanced factory in Boksburg, SCC (self-compacting concrete) was the preferred method of manufacturing, as the company has recorded astonishing results in the past 36 months using this process. “The end result of the re-engineering of our production lines has been the creation of a safer and healthier working environment, improved productivity with the added benefit of producing products of a higher quality with better aesthetics and finishes,” concludes Peter Lycklama, SPC Factory Manager.

CORRECTION: In our July 2015 issue we ran an article on the tilt-up precast concrete construction of a tyre factory in Ladysmith. The report said that the factory was owned by Sumitomo Rubber Industries and that it manufactured Kumho tyres, both of which are incorrect. The factory is owned by Sumitomo Rubber South Africa and it manufactures Dunlop tyres.




which meant that other services could

Echo Group company, Topfloor (a CMA member), has supplied over 16 000m² of prestressed hollow-core concrete flooring slabs for the construction of Lange Formal Township, the Western Cape’s first multi-storey, load-bearing reinforced concrete block-masonry development.

top sides hassle-free. All of these time-

Eighteen low-income-rental apartment

Each block houses 25 35m² apart-

staircase/slab interfaces and pull-up

blocks are being built by main contractor,

m e n t s c o m p r i si n g t w o b e d r o o m s,

bars for the reinforcing of the walkway

the Power Construction Group, which

kitchen/lounge, bathroom and balcony.

balustrades,” says Moore.

formed an integral part of the project’s

Moreover, insulated roofing and solar

architectural and engineering develop-

heating are included to meet conserva-

Many advantages

ment teams. Built for the City of Cape

tion requirements and reduce the cost

The Lange buildings have been designed

Town and situated on the Cape Flats off

of living for the occupants.

to comply with seismic codes and this

the N2, the development’s anticipated completion date is November 2015.

begin work as soon as the slabs were installed. Further time-savers were the smooth soffits and rough finishes on the upper sides of the slabs. This enabled the soffits to be painted without the need for skimming and made screed bonding on the saving advantages meant substantial cost-savings for the client. “Topfloor was involved in the primary as well as secondary planning stages and helped resolve details such as the

meant that Topfloor had to provide preAdditional products

cut openings for seismic-stress con-

In addition to the hollow-core concrete

nections. In addition, Topfloor supplied

flooring slabs, Topfloor also provided the

cut-outs for plumbing ducts. Topfloor

Power Group with precast staircases.

General Manager, Wessel Prinsloo, says

Other precast concrete elements included

another advantage of using hollow-core

high-strength concrete blocks, modular

flooring is its superior thermal and sound

precast concrete doorframes and win-

insulation properties.

dows, as well as poly-fibre balcony railings.

The professional team which initi-

According to Power Group Director

ated Lange’s design concept was led by

Johnny Moore, precast hollow-core slabs

Dieter Boessow of Architect Associ-

were an integral part of the structural

ates. Together with Power Construc-

design criteria and saved months in con-

tion’s project engineers and consulting

struction time. “No shuttering was re-

engineers, Aurecon, they succeeded in

quired nor curing time for wet concrete,

setting a new standard and establishing a new trend in cost-effective economic

(Top, from left): An aerial view of the Lange Formal Township housing development; one of the precast staircases supplied by Topfloor.

housing delivery in the Western Cape.

(Left, from top): Three of the Lange Housing Project’s apartment blocks nearing completion; close-up of some Topfloor hollow-core slabs used at Lange.

gained with this project points the way

Moore says that the fiscal benefits forward in labour-intensive skills development and job creation potential.


Standards, however, always make it easier, safer and more efficient to produce these products,” says Evans. He adds that it is also important to relook at standards on a regular

Standards are essential to assist manufacturers meet the needs of end users and ensure quality, price and the longevity of the product.

basis to ensure they are still relevant

George Evans of PPC is passionate

and technologies change the way

about quality and believes that when established correctly, standards should comprise the distilled wisdom of experts within the industry to do things in a uniform and acceptable manner. “Standards are an agreed way of doing something and can cover a huge range of activities to form an average of normal

“Things have changed and we, as the concrete industry, need to constantly change with the times.”

to current practices. Test methods should also improve as times change construction is undertaken. “Currently the concrete industry is adopting overseas standards and our own local experts are reviewing and modifying them to meet our own specific standards. For example, SANS 3001 test methods need to be modernised and many others are under review at present.

ideas of what is acceptable. National

Certain EN standards have also recently

standards constitute a standard set by

been adopted and are being homogenised

the industry that are in line with the laws

by panels of experts.

of the country or customs of the industry

“Things have changed and we, as the

and that are acceptable to the end user.

concrete industry, need to constantly

“When an entire industry works ac-

change with the times. We need to

cording to set standards to produce

ensure that they do what they are

certain products, they can be used as

supposed to do and make quality, price

a powerful tool to increase the success and productivity of manufacturers.

ef f iciency and unif ormity simple to (Above): George Evans of PPC.



obtain,” says Evans.



BENEFITS OF TECHNOLOGY Plasticisers have advanced in leaps and bounds since the early days with modern super plasticisers able to dramatically improve the workability of concrete and also allow it to achieve a 70% increase of its early 24-hour strength.

f ormwor k r elease time w i th f ewer

and late curing stages.

breakages as a result of the increased

“Plasticisers increase electrostatic

early str ength development of the

inter-particle repulsion, allowing en-

concrete. Depending on the type of

trapped water in the cement particles to

products and quantity required, the

be liberated and thus improving workabil-

time shaved off the concrete

ity. Cement particles are also more uni-

production process can

formly distributed due to electrostatic

easily offset the additional

charge provided by the side chains found

cost of the plasticiser.

on the backbone of the super plasticiser polymer. Super plasticiser polymers can

Less water

now be specifically designed to have

For example, standard Cem

According to admix special-

increased water reduction and shorter

42.5R can reach a strength

ist Craig Handler, Concrete

open time, with faster setting charac-

of 28MPa within just a day

Services Manager of Sika

teristics, making them ideal for precast.

by using a super plasticiser

South Africa, the use of a

“Accelerators use a different mecha-

plasticiser has the added ad-

nism from plasticisers, but also allow

vantage of producing higher

increased early strength, with quicker

early and final strength in

setting times. This directly affects the

lent by the super plasticiser has been

concrete as a result of using less water,

early strength in the first 24 hours,

developed to allow similar workability

which allows the cement crystals to form

whereafter the strength development will

characteristics as standar d mixes

closer together. This allows a denser

be similar to non-accelerated concrete.

despite the use of less water.

structure of crystals to form across

“Accelerators come into their own

the curing cycle, both during the early

in low-temperature scenarios or where

which cuts the water content by 25% of that of the usual mix. The improved workability

(Above): Craig Handler of Sika speaks at the recent CMA AGM at Emperors Palace recently.

T he end r esult will be a quicker

after initial curing. They are also ideal for concrete steam curing as they are able to reduce the amount of steam curing that is needed to achieve the required early strength, thereby reducing concrete production costs,” says Handler. Precast applications He adds that a number of modern methods are par ticularly suited to

“Admixtures allow faster casting times, easier casting in confined areas and allows complex shapes to be cast.”

well as allowing concrete casters the opportunity to make more intricate and complex shapes. Semi-dry concrete has been used for some time to make especially economical concrete products that maintain their shape directly after casting, eliminating the need for expensive moulds. Because this type of concrete has low workability it needs intensive, even vibration to achieve compaction and, once cast,

using plasticisers. These include self-

is sensitive to dehydration, therefore

compacting concrete (SCC) and semi-dry

fluctuations in quality can occur if the

concrete applications, among others

compaction and curing procedure are

that are becoming a popular choice of

not carefully controlled. “Plasticiser for this type of concrete

our precasters. T h e u s e o f p l a s t i c i s e r s in S C C

improves compacting ef ficiency. You

ensures ultra-high workability and flow

achieve better compaction with better

ability. It compacts under its own weight

surface finish, as well as better early

and the use of admixtures allows faster

and final strength development. It also

casting times, easier casting in confined

contributes to an increase in the cement

areas and enabling complex shapes

paste at the concrete surface, increas-

to be cast. Although it costs more in

ing lubrication. This improves the life of

material, the benefits are numerous

machinery. The increase in compacting

and quicker placing is possible with no

efficiency produces a more consistent semi-dry concrete product, ultimately

vibration required. This creates a better working environment with less noise, as

(Above): Improved workability due to steric hindrance.


there is a fast application of load shortly

improving quality,” says Handler.



HOW TO USE RE Mistakes that precast manufacturers make when specifying, ordering and receiving concrete can have far-reaching effects on products built by them and may affect the future strength and performance of the structures.


According to CMA member the Southern

ensure that concrete supplied is fit-for-

Africa Readymix Association General

purpose and complies with Sans 878:

Manager, Johan van Wyk, it is very

2004 for generic readymix concrete.

important that project managers, as

Thereafter your technical requirements

well as everyone involved in ordering

for the concrete can be laid out and you

and buying concrete, learn the right

can agree with the readymix company

processes and procedures to use when

on the type of tests that need to be

working with the most important building

performed on site.

material of them all.

“If you are unsure of the best way,

“There are hundreds of dif ferent

then ask the readymix company – it has

types of readymix available on the market

a lot of experience in the field and it pays

for use in different applica-

to check the details with

tions. But it is important

its technical staff before

to remember that it can be

finalising your specification.

supplied in different forms to make allowance for workabil-

Ordering correctly

ity and many other factors

“When making the final ar-

that can affect the success

rangements and ordering,

of concrete on site. The rela-

always use the specification

tionship between the buyer/

that you have drawn up and

user and the professional

discuss your exact needs on

readymix company therefore needs to be

site. If the project is big or difficult, then

accurate and measured,” he says.

it is a good idea to have the readymix company’s technical staff on site to look

(Above, right): Johan van Wyk of Sarma. (Above, from top): A slump test to check the characteristics of the concrete; agree on methods of receiving concrete on site; workability is must be specified.

Getting concrete right

at the way it should be done and look out

Van Wyk explains: “The most important

for any possible problems.

thing is to make sure you are dealing with

“ Your specif ications need to be

a reputable readymix company upfront.

made very clear and you need to make

The only way you can do this is to make

sure that the strength and working

sure you deal with a Sarma-accredited

characteristics of the concrete are

company. In this way, there can be no

right for the job. You also need to say

confusion about meeting quality stand-

exactly how much is required where

ards and honest business practices are

and when – remember that you can be

ensured. Precast manufacturers and

charged a fee if any of the concrete

specifiers can rest easy knowing that

needs to be disposed of (thrown away)

they are dealing with a professional

if it is not used on site. Workability and


slump (consistency) of concrete must

“It is important to remember that all

be agreed and you need to discuss the

Sarma plants are checked and audited

type of equipment that will be used to

to make sure they have the right staff

receive the concrete.

and processes to make quality products.

“Talk to the technical people about

They look after the environment, as well

how you plan to place the concrete on

as the health and safety of workers and

site and discuss your plan for how the

surrounding communities. In addition

concrete will be moved around the site.

Sarma members also have to comply with

For example, if it is to be moved via

road traffic regulations and rules to make

wheelbarrows, it is important to know

sure they are safe on the road.

that the average mixer carries at least

“When using a Sarma member, you

90 wheelbarrow loads – so it cannot

and your client are also guaranteed that

possibly be of floaded by a couple of

the company has the necessary skills to

labourers with wheelbarrows.


Fresh concrete

truck can get to the point of discharge

of quality requirements and cost-savings.

“When a truck arrives with new, fresh

(Sarma members do assist by visiting

Customers want the reassurance of

concrete, then the time it takes to use

sites beforehand to look out for any

knowing that there are no strength

the concrete is very important. Remem-

potential shortfalls, if required.)

concerns or failures that may ruin the

ber, experts say that you have seven

“Next you have to discuss the how the

project. Also, with readymix there is less

minutes per cubic metre to offload and

concrete will be cured and ensure that you

need for storage and no theft onsite and

place the concrete. If the truck stands

are happy with the testing methods and

customers prefer having a clean site with

for too long, the concrete may begin to

that they are being adhered to. Also, have

no leftover concrete and waste when the

go hard and change its workability char-

a clear procedure to follow if the tests fail

job is done.

acteristics, which may affect the end

at any point in the delivery, placing and

result. Also, if the truck stands too long,

curing of the concrete.”

you may be charged a fee called ‘demur-

“Remember, professional readymix concrete suppliers can supply a wide range of mixes to suit different require-

rage’. A good tip is to first agree with the

Concrete on site

ments and have ready-made design mixes

readymix company on the rate of offload-

Few precast manufacturers realise that

for all the different applications (walls,

ing on your site.

if the planning is done correctly at the

retaining walls, façades, etc). This is far

“Last, but not least, always make

time of specification and ordering, then

easier, as site mixing designs takes a long

sure that your workers are ready and

the job of accepting concrete on site is

time and has to move from design to ap-

that they have the right equipment and

much easier. Van Wyk reminds precast-

proval and testing and this takes 28 days,

tools needed to be able to accept the

ers to follow the right steps to make

if done correctly. Using readymix also

concrete when the truck arrives. Also,

sure that the correct specification and

gives builders the flexibility to use many

make sure that you have organised ac-

handling methods are put in place.

different types of concrete on the same

cess for the truck in terms of permis-

“The reason behind the strong shift

sion, physical space and how close the

towards readymix is most often a result

site at the same time, while site mixing can only deliver one type at a time.”





Speaking at the recent ASAQS seminar, “Building on Sunshine”, held in Johannesburg, Dr Letchmiah, who is CEO of the LDM Group and represents ASAQS on the Green Building Council of SA (GBCSA), said the days of quanitity surveyors’ role in the building environment concentrating


mainly on cost control, are over. “Modern quantity surveyors need to consider the driving forces of the green environment in which they operate. They

GROWING ROLE OF QUANTITY SURVEYORS The increasing emphasis on sustainable construction has placed new and unprecedented responsibilities on the shoulders of the quantity surveying profession, Dr Deen Letchmiah, board member of the Association of South African Quantity Surveyors (ASAQS), has stated.

need to be holistic in thought and execu-

realise that all components of structural

• Procuring goods, services and leases

tion to drive sustainability directives and

development and operations must be re-

• Managing contracts and

viewed to provide sustainable solutions,”


he told the more than 200 delegates

• Understanding building

from all over the country who attended

the first ASAQS annual seminar.

• Integrating information and

management systems management systems.

Core skills

* ASAQS is currently conducting an in-

He also urged quantity surveyors to play a

depth and ongoing research study for the

bigger role in facilities management. Some

Green Building Council of SA on the com-

of the core skills in this category included:

parative costs of “green” and conventional

• Construction, building technology

design and construction, and a progress

and maintenance costs

report and preliminary findings of the study

• Estimating and budgeting

were revealed to the GBCSA during the

• Cost control and reporting

Building on Sunshine seminar.

• Managing building operations • Life-cycle costs • Understanding building components

and functionality

(Left): Dr Deen Letchmiah, board member of ASAQS, has warned that sustainable construction places new responsibilities on the quantity surveying profession.




EXPENSIVE COMMODITY We will never have cheap surplus energy again! That is the word of Andre De Klerk, Senior Advisor: Demand Side Management (DSM) for Gauteng and Ekurhuleni.

supply with possible load-shedding will be

walk-through audits at companies to

with us for at least another two-and-a

help them improve energy-efficiency.

half years. It is therefore advisable to

Management and staff need to be aware

have contingency plans and to adopt

of the need to save energy and therefore

efficient processes, where possible.

need to look at the big consumers of

He says that the country’s electricity

This can reduce the overall load on the

capacity is stretched with an overall

grid significantly. Every little bit helps;

within concrete plants include:

generating capacity of 40 Gigawatts

no matter how insignificant it may seem,

• Pumps

“We also have to look at power-saving on an individual and company-wide basis.

electricity within a company and ways of optimising these for efficiency. Common high consumers of electricity

(GW). However, at any

it can have a big effect

• Compressors

given time, at least 10%

on the overall grid. For

• Fans

of the available units are

example, every kilowatt


shut down for planned

(KW) saved at a company

• Lighting

maintenance, while a fur-

or concrete plant saves

• Water heaters

ther 10% are not available

10K W at the point of

due to unplanned main-


Industrial companies can also look at improving thermal efficiency of pro-

tenance, leaving the grid

“That means by simply

cesses where heat is used. Staff can be

with an effective 32GW

switching of f air-cons

trained and responsible people may be

of available power supply.

or heaters when you go

appointed within organisations to look

The problem is that

out or turning of f the

after energy. Even at home individu-

compr essor or pumps

als can replace lights with low-energy

a peak of about 33GW in summer and

when they are not in use, you are saving

alternatives, install low-flow shower

35GW in winter and needs another 15%

the grid and reducing the risk of load

heads and set pool timers to work

spare capacity to avoid overpowering

shedding,” says De Klerk.

outside of peak times. Solar or other

S o u th A f r i c a r e a ch e s

(Above): Andre De Klerk of Eskom.

the system. While the two large, new

renewable energy sources can be used

coal-fired power stations are being

Saving the day

built, there is little room for Eskom

He advises that Eskom has programmes

“The bad news is that even despite

to manoeuvre and whenever there is

to help companies reduce electricity

these savings, the country needs to

a danger to the grid, it is forced to

consumption and are able to conduct

install more generating capacity and

implement load-shedding. Manufacturers take note “We ther ef or e ad v ise concr ete manufacturers to be aware of the fact that the current restrained electricity


where possible.

this is a costly exercise. The recent 16%

“We will continue to pay higher tariffs for electricity in future.”

tariff increase did not even cover the input costs for fuel and manpower, etc, so we will need to continue hiking tariffs for electricity in future. The days of cheap electricity are over,” says De Klerk.


The human race first started using concrete thousands of years ago in one form or another, but it was only in the 1700s that the materials really rose to prominence once again. Since then it has been seen as a mostly utilitarian building product that is dull in colour and mostly dull in the applications in which it is used. But a growing trend worldwide is to use concrete for decorative purposes and make use of its special characteristics to make eyepopping creations. In most instances, the decorative concrete in question is precast and specially manufactured under specialist factory conditions to meet specific requirements of architects and forward-looking engineers. In this regard, concrete is being used to make anything from façades to furniture and fixtures. Bare concrete Across the globe concrete manufacturers are finding innovative ways of using concrete and equally innovative mixes, additives and aggregates to make “good-

HARNESSING THE BEAUT looking” concrete. But, increasingly,

cement and the concrete can be dazzling.

concrete in its raw and beautiful natural

At the same time, add form and shape

state is also being appreciated and used

and think outside the box, and Voila! The

in its bare state with no paint, polish or

next concrete masterpiece is about to

other niceties.

be born in the form of a basin, a bench,

Then there are those who look deeper

a façade or anything else. As long as it

into concrete and expose its internal

still serves the purpose it was intended

magic through polishing, with the insides

for, there is absolutely no harm in making

of the concrete exposed and ‘shined-up’

it decorative at the same time.

for everyone to see. Even in its raw Portland Cement, plain aggregate and

Local take

building sand mix it is possible to polish

Even though South Africa is far behind

concrete to a highly attractive finish fit

many of the developed countries in de-

for counter-tops and decorations. Add

veloping and using decorative concrete

coloured aggregates and perhaps white

there are proponents of the skill who are making waves in concrete circles locally. One such person is Johan Coetzee of World of Decorative Concrete whose creations have graced the covers of magazines and fill glossy architecture and interior decoration publication pages. “We create concrete with soul. Just because it is made of concrete, that doesn’t mean it must be boring. If you want to create an attractive product,


TY OF CONCRETE you need to plan correctly to have the quality and finish that you require. Or if your product is flat, you can transform it with polishing which is still to reach its full potential here and globally – it is a thing of the future. “Then there is the colour of cement, sand and aggregate that can be changed to give an ever-lasting colour. Other finishes use acid staining, water staining, polymer cement overlays, plaster cementitious vertical plasters and more. Simply

draws attention and transforms an in-

changing the surface of the concrete can

terior to the extent that concrete is the

change the concrete to be highly attrac-

focal point, rather than a simple building

tive and sought-after.

material,” says Coetzee.

“The use of different finishes can be

In a competitive environment it is per-

highly effective – for example, a polished

haps a good time for precast manufac-

surface used with an off-shutter con-

turers to explore the use of techniques

trast and plastered surface suddenly

to manufacture decorative concrete to supplement their existing product

“The use of different finishes can be highly effective.” PRECAST | ISSUE THREE | 2015

ranges. Who knows, perhaps they may stumble upon “the next big thing”. (Above and left): Decorative concrete and finishes produced by Johan Coetzee of World of Decorative Concrete.


NEW FACTORY TO MEET GROWING DEMAND Elematic South Africa (ESA) has constructed an all-new plant to double its output capacity and meet growing demand for its precast hollow core


concrete slabs. The new plant boosts capacity of the initial manufacturing facility by adding a further eight 120m long extruder beds to the existing factory’s equally sized capacity. According to Craig Webber, director at ESA, the expansion was due to high

Rand since 2007, using internationally

tion line experiences minimal delays, it

demand for ESA’s products. “Property

respected precast technology. “The

is important to have as reliable a supply

developers and building contractors

extrusion methods we use are well

of raw materials as possible. To ensure

have seen the benefits of using precast

k n o w n in th e in dus tr y t o p r o du c e

a long term reliable supply of aggregate,

concrete floor slabs over the years and

quality hollow core slabs,” Webber adds.

Elematic’s holding company acquired

demand has been surging,” he says. “The

Elematic itself is a well established

Atoll Mining, a dolomite quarry situated

product is becoming more widely used as

international brand. It was established

about 500 metres from the company’s

it is well known to save time and money

in Finland in 1959 and currently has a

main factory. Apart from ensuring a

during the construction process. Over

presence in over 100 countries on six

reliable aggregate supply, additional

and above that, we have always aimed

continents worldwide. Added to this is

benefits are the high quality and consist-

to provide a good and reliable service to

the fact that Elematic South Africa’s

ency of the aggregates supplied by Atoll

our customers.”

production facility is ISO 9001 certified

Hollow core concrete slabs continue

and all its products carry the SABS

to grow in popularity as construction

mark of quality.

timelines are pressurised and contrac-

ESA has been manufacturing precast hollo w- c or e c oncr e t e slab s a t i t s manufacturing plant on Gauteng’s East

In order to ensure that the produc-

tors require reliable solutions.


DRY MORTAR PRODUCTS LAUNCHED Concrete materials company, AfriSam, has r esponded to demands f or increased convenience by introducing its premium-quality Dry Mortar product to the market.


Amit Dawneerangen, Sales Manager for AfriSam’s Gauteng region, says that immediate access to an already blended dry mortar solution is very attractive to South Africa’s time-pressed and c o s t- c o n s c i o u s c o n t r a c t o r s . T h i s product adds to the CMA members’

Adding value

range of concrete solutions and ensures

The product is supplied in 10- or 20-ton

tha t contr ac tor s ha v e a one-stop

silos. This is a space-saving advantage

solution for all their wet trades, ranging

on a construction or building site as it

f r om r eadymix concr ete of var y ing

effectively eliminates the need to ac-

strengths and specifications to cement,

commodate large stockpiles of sand and

aggregates and dry mortar.

frees up the area normally used to store

“The AfriSam Dry Mortar mix offers

bagged cement. Supplying the product in

contractors a number of benefits in

either 10- or 20-ton silos offers optimum

addition to time- and cost-savings.

flexibility for all customers, who can then

Using a pre-blended mortar mix will

decide on the size required, based on

enable optimum product integrity and

individual project requirements.

(Above, left): By attaching a mixer and water connection to the silo, a ready-to-use product is discharged when the dry mortar comes into contact with the water. (Above): AfriSam has responded to demands for increased convenience by introducing its premium quality dry mortar product to the market.

subsequently quality construction on a

The 10-ton silo is delivered fully loaded

project. Manual blending of mortar or

from the AfriSam facility, while the 20-

plaster requires careful attention to

ton silo is delivered to site empty and

by using the dry mortar silos, theft is

ensure that the correct ratios of sand

filled via bulk tanker. Discharge into the

virtually eradicated and there is a similar

and cement are used and incorrect

silo is conducted using a closed convey-

significant reduction in wastage. There

blending or mixing will affect the quality

ance system, which ensures product

are also other environmental and conveni-

of the final product and may result in

integrity and the elimination of dust dur-

ence benefits, such as fewer vehicles on

cracking of plaster. Our dry mortar

ing the process. Not only does this guar-

the road delivering raw materials to site.

solution alleviates human error and goes a

antee optimum quality of the product,

Instead of having separate deliveries for

long way to ensuring quality workmanship

but the process also complies with all

sand and cement, these now arrive in one

– something contractors have identified

the requisite environmental regulations.

vehicle. Procurement is simplified with the

as one of their greatest concerns these

To add to this, stockpiled building

number of suppliers reduced, as is the

days,” says Dawneerangen.

materials are often pilfered on site and

amount of raw materials on site.


from the company’s library and other

Kaytech, a member of

technical advice is offered, while users

Other useful links are designed to as-

the CM A, has devel-

will also be able to ask technical ques-

sist users with requirements quickly and

oped an application that

tions or even request training.

efficiently, with information on the near-

dations for any geotextile requirements.

gives users access to

As far as precast manufacturers or

est branch just a click away. The app is

wide-ranging geosyn-

their customers, as well as consulting

available for Windows phones, Android and

thetic support at the

engineers are concerned, the applica-

iPhones, as well as desktop applications.

touch of a smartphone

tion also allows design requests to be

screen. The “KayApp”

submitted where users can get help

also allows user s to

with designs on subsoil drainage, ground

connect to the company’s technical

stabilisation, road maintenance, haul

team for advice and support.

roads, mine waste containment, landfill

In addition it allows order requests

linings and cappings, dam linings, sludge

to be made online and allows specifica-

dewatering, erosion control, coastal

tions to be entered for a quotation and

erosion protection and DIY. An expert

delivery date. Data sheet, information

will respond with application recommen-


MANUFACTURER MEETING TIGHT SCHEDULE IN DOHA A double-station VIHY Multicast machine that was recently installed in Doha is helping meet the requirement for pipes in one of the world’s fastest-growing cities. The capital city of Qatar has been undergoing dynamic development in recent years, with a population growth that has risen from less than 400 000 people in 2000 to a staggering 1,8 million inhabitants just 15 years later. With no capable precast pipe manufacturer in the city before 2009, all pipes for sewage and stormwater had to be imported from Saudi Arabia, Kuwait and the UAE. The VIHY Multicast machine was selected for its high production capacity and flexibility to handle a wide range of product types and sizes, making it ideal for companies that offer broad product ranges. This was identified early in the feasibility stages and was installed to complement existing machines and meet rising demand for quality products. Today the company is the only local supplier of drycast concrete pipe products in Doha, with products ranging from 300-2 500mm. In collaboration between Doha Precast Factory (DPF) and CMA member HawkeyePedershaab, a long-term plan for the plant site in the Mesaieed Industrial City was developed not only for a single drycast concrete vibration pipe machine, but for several casting stations to be installed in more stages. Thanks to this close cooperation, the company is now also in a position to meet requirements for jacking pipes in diameters up to 3 600mm. The company upholds international standards including BS, ASTM, ACPA, DIN, ATV and the local standards of Qatar’s Public Works Authority (ASHGHAL). DPF has moreover received a BSI Kitemark and has been awarded membership to the coveted and prestigious American Concrete Pipe Association (ACPA) in 2011 and Jackcontrol, Switzerland in 2012. One of the most advanced up-to-date concrete laboratory and test facilities in the Middle East has been installed and DPF’s unique product registration system ensures its clients receive quality products. Plant description HawkeyePedershaab’s main scope of supply since 2009 has comprised the following: • Two double-station VIHY® Multicast SCC 250 machines • Mould equipment for DN300-2 500mm pipes • Product handling equipment • Pipe coating equipment.

(Above, from left): A HawkeyePedershaab mould installed at the Doha Precast Factory in Qatar; a completed pipe in the pipe clamp.


As part of an extensive modernisation

liquid component for the abe cementi-

and expansion programme, abe Con-

tious product range. The acquisition

struction Chemicals, part of the Chryso

of the tank follows the installation of

Group, has virtually completed work on

new bulk liquid mixers about two years

the installation of new high-

ago during phase one of the

technology equipment at both

Boksburg expansion project.

the company’s Boksburg and

The new 50m3 bulk tank offers

Isipingo factories.

several benefits, including bet-

Mario Marais, GM: Opera-

ter consistency of product due

tions of the Chryso Group, says

to the elimination of multiple

an important benefit of the

batches of raw material.

investment in new equipment

pansion project will be the installation

to sustainability which covers economic,

of an automated packaging unit at the

social and environmental commitments

Ekurhuleni facility, and a second auto-

through increasing its pioneering dust-

mated valve bag-filler is also planned for

less production of powdered cementi-

Boksburg,” Marais explained.

tious products at Boksburg and boosting skills upliftment within the group.


“The third phase of the ex-

is intensifying the group’s commitment

At its Isipingo production plant, abe is currently installing a new automated

He says the first component of the

dispensing line for viscous two-compo-

expansion programme was the recent

nent products. This new production line

installation of a new bulk emulsion

will enhance the company’s epoxy and

tank at the abe plant in Boksburg. This

polysulphide production capability and

towering stainless steel structure is

improve speed-to-market for these key

increasing the production rate of the

abe products.



(Above): The new bulk emulsion tank installed at the abe plant in Boksburg is substantially increasing the production rate of the company’s cementitious product range. (Left): Mario Marais, GM: Operations of the Chryso Group, says an important benefit of the investment in new equipment for the abe plants is raising the group’s commitment to sustainability.

PAVING MANUFACTURER ACQUIRED CMA member Technicrete ISG, part of the Infrastructure Specialist Group (ISG), has acquired concrete and precast manufacturing company Cast Industries. This makes the company one of the leading suppliers of paving and kerbing products within Gauteng. Guinevere Thomas, Group Marketing & Communications Manager for ISG, says: “This acquisition will increase Technicrete’s market share within the paving market, increase our (Above): Guinevere Thomas.

customer base and augment our production capabilities. With the increase in production capacity, we will be able to satisfy

market demands, and service existing and future customer needs.” The acquisition includes the operations, staff and assets currently associated with Cast Industries, whose trading name ceased to exist after 1 July 2015.


Cape-based CMA member and hollow-core slab producer, Portland Hollowcore, has

(Above): The newly extended Portland Hollowcore stockyard.

merged with Bobcrete, supplier of hollow-

streamlined group has greater capacity

core slabs to the Western Cape market

and is more cost-effective. It will provide

for the past 28 years.

all our customers with the numerous

The merger entails the closure of Bob-

advantages of slabs produced with the

crete’s manufacturing facility in Belville

latest in plant and machinery and they can

South. All operations were moved to the

look forward to improved quality, service

recently expanded Portland Hollowcore

and pricing – clearly a win for all.

factory, even though Bobcrete will con-

“Since the merger, both companies

tinue to operate under its own name

have maintained their individual market

until its pre-merger order book has been

shares,a factor which now makes us one

fulfilled. Thereafter, Bobcrete will cease

of the largest hollow-core players in the

to exist as a separate brand and its loyal

Western Cape. Normally winter is a quieter

customer base will be serviced by Port-

period in the industry, but this year output

land Hollowcore.

ran at 100%.

All Bobcrete employees were offered

“The hollow-core market is experienc-

jobs at Portland Hollowcore and one of

ing exceptional growth as it is faster and

Bobcrete’s founders and a former Murray

more cost-effective than in situ equivalent

& Roberts Director, Phil Surridge, has

because it dispenses with scaffolding,

taken on the role the Sales Manager of

shuttering, reinforced steel fixes, the

the hollow-core department.

concrete gang and the carpenters. In addition, legislation is forcing businesses to

Latest technology

move away from labour-intensive in situ

Nico Heyns, Portland Hollowcore MD,


says the merger gives the combined

The merger took place when Portland

group improved economies of scale and

Hollowcore was installing extra casting

will leverage the technical skills of Bob-

and cutting equipment, and this additional

crete’s engineering expertise. “The new

capacity facilitated a smooth transition.


Ongoing investment in technologically

contractors who prefer the quality

advanced block-making equipment sup-

of surface of their stock, as well as

ported by an ever-vigilant eye on quality

the peace of mind that the Standard

has led to the meteoric rise of VakaCon-

Association of Zimbabwe certification

crete as a force to be reckoned with in

offers to users.

the Zimbabwean precast industry.


The focus on quality does more than

Always at the front of the queue to

just increase sales – it also saves the

introduce new technologies, the company

company money, according to Muindisi.

has steadily earned a reputation for the

By carefully controlling quality at every

high quality of its products, as well as the

step of the process from raw material

excellent surface finish and aesthetics of

procurement to manufacturing and de-

its bricks and blocks.

livery of the end product, VakaConcrete

According to Managing Director,

is able to maintain a better than 98%

Tawanda Muindisi, the company pays par-

quality ratio, with minimal scrap and

ticular attention to developing in-house

reworking required.

expertise. He adds that membership

“This is largely because of the care

of the CMA gives the company access

we take to source and procure raw ma-

to the large knowledge base within the

terials and our investment in the best

organisation. In addition, by associating

available technology,” he adds. “Also,

Future plans

with equally ambitious and quality-orien-

in Zimbabwe we now have access to

“We have established two plants in

tated companies across borders within

42,5Mpa cement, which allows us to

Harare and Gweru and plan to roll out

the ranks of the CMA, the company is

improve even further. Our continuous

to all the major centres in order to

able to gain insight into emerging trends

investment in skills development of our

capitalise on high levels of growth in the

and developments that may affect the

people also pays dividends and puts our

construction sector. This is a result of a

business or bring new opportunities.

company in a stronger position with a

sharp increase in mining activity, as well

higher level of qualified staff.

as an uptick in the residential housing

(Above and below): VakaConcrete plant in Harare.

market,” he says.

Technology-driven “We started operations in 2012 and

Zimbabwe currently has an estimated

began with the core business of making

shortfall of 1,5 million houses in the

concrete brick pavers and blocks. From

middle and higher end of the market. As

the outset, we wanted to provide un-

it’s economy stabilises and begins to

matched quality and chose to make use of

grow, the demand for bricks and blocks

the best technology available from Birk-

is also expected to increase dramatically.

enmayer South Africa, one of the largest

Muindisi concludes that support and

and most renowned equipment suppliers

technical assistance from the company’s

in the sub-region. We purchased the top-

South African equipment supplier is

of-the range HB68 machine with a capac-

superb and has enabled it to excel amid

ity of 140 000 bricks per nine-hour shift

fierce competition. In turn, VakaCon-

to launch our operation,” says Muindisi.

crete has also been singled out and

He explains that the company has

complimented by Birkenmayer SA on the

especially found a niche for itself in the

efficient operation and high-quality main-

paving market, with pavers accounting

tenance that the company undertakes,

for approximately 70% of production. These have rapidly found favour with


(Above): Tawanda Muindisi, Managing Director of VakaConcrete, with Frans Minnaar of the CMA.



resulting in lower-than-usual technical problems and high production outputs.


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

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

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

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

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

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

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

REMACON PRODUCTS CC Tel: 011 393 5504 Province/Country: Gauteng Pillar: PI REVELSTONE (CAPE) (PTY) LTD Tel: 021 761 9739 Province/Country: Western Cape Pillar: PB ROCLA (12) Tel: 011 670 7600 Province/Country: Gauteng Pillar: PB/PI SHUKUMA BRICKS Tel: 041 372 1013 Province/Country: Eastern Cape Pillar: PB

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

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

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

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

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

SMARTSTONE (13) Tel: 011 310 1161 Province/Country: Gauteng Pillar: PB SOUTHERN PIPELINE CONTRACTORS Tel: 011 914 8500 Province/Country: Gauteng Pillar: PB/PI TECHNICRETE (6) Tel: 011 674 6900 Province/Country: Gauteng Pillar: PB/PI TOPFLOOR CONCRETE (2) Tel: 021 951 7700 Province/Country: Western Cape Pillar: PB VAKA CONCRETE (PTY) LTD (2) Tel: +263 864 4088 100 Province/Country: Zimbabwe Pillar: PI VANSTONE PRECAST (PTY) LTD Tel: 012 541 2056/1808 Province/Country: Gauteng Pillar: PI WEST END CEMENT BRICKS (PTY) LTD Tel: 011 851 1005/1063 Province/Country: Gauteng Pillar: PI ASSOCIATE MEMBERS ARQ CONSULTING ENGINEERS (PTY) LTD Tel: 012 348 6668 Province/Country: Gauteng ASPASA Tel: 011 791 3327 Province/Country: Gauteng

BRITISH PRECAST CONCRETE FEDERATION Tel: 044 116 253 6161 Province/Country: United Kingdom CONCRETE PLANT INTERNATIONAL Province/ Country: Germany CONCRETE SOCIETY OF SOUTH AFRICA Tel: 012 348 5305 Province/Country: Gauteng ILIFA AFRICA ENGINEERS (PTY) LTD Tel: 012 362 1473 Province/Country: Gauteng JC PAVING CONSULTING Tel: 011 431 0727 Province/Country: Gauteng SARMA Tel: 011 791 3327 Province/Country: Gauteng SEKHUKHUNE & ASSOCIATES Tel: 012 993 4776 Province/Country: Gauteng SNA CIVIL & STRUCTURAL ENG Tel: 012 842 000 Province/Country: Gauteng TACO VOOGT CONSULTING ENGINEERS Tel: 079 505 7840 Province/Country: Gauteng

KAYTECH Tel: 031 717 2300 Province/Country: KwaZulu-Natal KERNEOS SOUTHERN AFRICA (PTY) LTD Tel: 011 444 3090 Province/Country: Gauteng KOBRA MOULDS BV Tel: 003111 356 2460 Province/Country: Netherlands MANITOU SA (PTY) LTD Tel: 011 975 7770 Province/Country: Gauteng OCEM Tel: 0039 055 658 0120 Province/Country: Italy PAN MIXERS SA LTD Tel: 011 578 8600/8701 Province/Country: Gauteng PEGASO STAMPI SRI Tel: +39 0577 992635 Province/Country: Italy QUADRA Tel: 0033 67941 2644 Province/Country: France QUANGONG MACHINERY CO LTD Tel: 00865 958 679 9299 Province/Country: China SIKA SOUTH AFRICA (PTY) LTD Tel: 031 792 6500 Province/Country: KwaZulu-Natal

TERRAFORCE (PTY) LTD Tel: 021 465 1907 Province/Country: Western Cape

TECHMATIK SA Tel: 00484 803 690 811 Province/Country: Poland

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


TJEKA TRAINING MATTERS Tel: 011 665 2777 Province/Country: Gauteng YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS Tel: 031 207 7252 Province/Country: KwaZulu-Natal

AFRISAM SOUTH AFRICA 011 670 5500 Province/Country: Gauteng LAFARGE INDUSTRIES SOUTH AFRICA (PTY) LTD 011 657 0000 Province/Country: Gauteng


PPC LTD Tel: 011 386 9000 Province/Country: Gauteng

ABEL EQUIPMENT Tel: 044 874 1876 Province/Country: Western Cape

SEPHAKU CEMENT Tel: 012 684 6300 Province/Country: Gauteng

ASH RESOURCES (PTY) LTD Tel: 011 657 0230 Province/Country: Gauteng


BUFFALO RETAINING WALLS Tel: 016 366 1801 Province/Country: Gauteng CHRYSO SOUTHERN AFRICA (PTY) LTD Tel: 011 395 9700 Province/Country: Gauteng DELTA BLOC SOUTH AFRICA (PTY) LTD Tel: 011 024 4604 Province/Country: Gauteng DICK KING LAB SUPPLIES Tel: 011 499 9400 Province/Country: Gauteng DOUBELL BRICK MACHINES Tel: 041 585 9060 Province/Country: Eastern Cape HAWKEYEPEDERSHAAB Tel: 00 45 9645 4040 Province/Country: Denmark H BIRKENMAYER (PTY) LTD Tel: 011 970 3880 Province/Country: Gauteng HYDRAFORM INTERNATIONAL (PTY) LTD Tel: 011 913 1449 Province/Country: Gauteng

DECORTON RETAINING SYSTEMS Tel: 021 875 5155 Province/Country: Western Cape FRICTION RETAINING STRUCTURES (PTY) LTD Tel: 011 608 4321 Province/Country: Gauteng NDLONGHO CIVIL AND CONSTRUCTION (PTY) LTD Tel: 011 836 2577 Province/Country: Gauteng POWERGATE CONSTRUCTION Tel: 071 603 5070 Province/Country: Gauteng PYW PAVING Tel: 031 903 1736 Province/Country: KwaZulu-Natal VALCAL INTERNATIONAL EXPORT Tel: 011 867 2471 Province/Country: Gauteng

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


Date: 23 April 2016 Venue: Summerplace, Illovo, Johannesburg Bookings: Contact Rita on tel: (011) 805 6742 to secure your table


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Precast Issue 3 2015  

Precast Issue 3 2015  

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