Precast • Issue 3 • 2018

ISSUE THREE • 2018

R49.00

THE VOICE OF THE PRECAST CONCRETE INDUSTRY

• New path for CMA • SABS board fired • Precasters work smarter

2

PALLETS CAN MAKE OR BREAK AN OPERATION

19

INDUSTRY NEWS 5

NEW PATH FOR THE CMA

7

CMA AGM

8

GROWTH IN INSURED CONSTRUCTION ACTIVIT Y: 2017 VS 2016

11 TECHNICRETE TURNS 50 13 CMA CONCERNED OVER FIRING OF SABS BOARD 14 USE BUILDING SLUMPS TO TRAIN STAFF

28 GUIDELINES ON USING CEMENT AND CONCRETE SAFELY AND SENSIBLY 29 CONCRETE ROADS SAVE FUEL 30 PREVENTATIVE MAINTENANCE ENSURES DURABILIT Y

20 CHEMICAL SOLUTIONS FOR DIFFERENT CONCRETE NEEDS

32 WATER CONSERVATION AND PERMEABLE PAVING: LOCAL GOVERNMENT MUST LEAD THE WAY

21 PRECASTER OFFERS MODERN FORMING SOLUTIONS

35 RESEARCH TO BENEFIT PRECASTERS

1

COMPANY NEWS 22 WESTERN CAPE BRICK AND BLOCK PRODUCER GEARED FOR GROWTH

36

23 NEW OWNERS FOR OCON BRICKS

PROJECTS

15

38 EARTHFORM: THE PERFECT SOLUTION 39 SA’S CONSTRUCTION INDUSTRY TILTS UP

25

GLOBAL VIEW 16 ADJUSTABLE EXTRUDER SOLVES MAJOR CHALLENGE OF AMERICAN PRECASTERS

40 CONCRETE ROOF TILES ON THE RISE AT SATARI COUNTRY ESTATE 41 PRECAST CONCRETE PAVING SPURS ECONOMIC GROWTH IN SALDANHA

PRODUCTS

AROUND & ABOUT

42 PRECAST CONCRETE PAVILION SEATING FOR SA’S OLDEST SCHOOL

18 NEW HIGH-CAPACIT Y POWERED PALLET TRUCK

26 CONCRETE CONFERENCE UNITES THE INDUSTRY

43 N2 SECURITY WALL CONSTRUCTED WITH PRECAST CONCRETE

PRECAST is the mouthpiece for the Concrete Manufacturers’ Association - CMA Concrete Manufacturers’ Association Physical Address: Office 0400, Standard Plaza Building, 440 Hilda St, Hatfield, Pretoria Postal Address: Post Net Suite 334 Private Bag X 15, Menlo Park, 0102 Tel: (+27 11) 805 6742 Fax: (+27) 86 524 9216 E-mail: admin@cma.org.za Website: www.cma.org.za Publishers: Isikhova 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 E-mail: andrewm@isikhova.co.za Consulting editor: Raymond Campling Tel: 076 297 2775 E-mail: media@mediasavvy.co.za

PRECAST | ISSUE THREE | 2018

Coastal editorial: David Beer Tel: 082 880 6726 E-mail: david.bigsky@gmail.com

ISSUE THREE • 2018

R49.00

THE VOICE OF THE PRECAST CONCRETE INDUSTRY

Advertising: Linda Meyer Cell: 083 626 8814 E-mail: linda.precast@gmail.com Subscriptions/Accounts/ Advertising Admin: Thuli Majola Tel: (+27 11) 883 4627 E-mail: subscriptions@isikhova.co.za • New path for CMA • SABS board fired

Design and layout: Joanne Brook 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© 2018. All rights reserved. No part of this magazine may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage retrieval system, without prior written permission from the publishers.

Endorsed by:

• Precasters work smarter

ON THE COVER PMSA offer the widest range of production boards for brick, block and paver machinery while ensuring they are high-quality and fit for purpose.

Recent supplies include GMT pallets to Van Dyk Stene, resulting in cement reduction of over 20% and Composite UP Advanced boards at Cape Brick for vapour-curing chambers.

CONTENTS

TECHNICAL

COVER STORY

COVER STORY 2

PALLETS CAN MAKE OR BREAK

AN OPERATION Optimisation of pallets in the manufacturing process is one of the most cost-effective and easiest ways to boost output and improve the quality of products made with the existing machinery.

has focused a great deal of attention on

materials transmit vibration better

studying the characteristics and per-

for faster mould-filling and settling.

formance of different types of pallets on

This means production speeds can be

local production lines. This has also led to

increased on machinery using the right

the company stocking and selling a wide

pallet for the job at hand.

This often-overlooked element in the manufacturing process is, in fact, one of

are one of the most basic parts of

the most important, as the pallet serves

the production cycle, yet they hold

as the foundation of any production

an important key to achieving better

process and requires a perfect match

efficiency and savings on cement and

between the equipment used, the mix

materials. Drawing on recent studies, he

design and the type of product being

also reveals some of the criteria which

produced. Unsurprisingly, a well-matched

make a pallet good and the different

pallet will produce better-quality products

requirements for varying types of plants.

range of pallets suitable for most produc-

“However, lightweight products or

tion lines and manufacturing conditions.

shallow moulds may require different

Quintin Booysen, sales and marketing

vibration transmission and may benefit

manager of PMSA, explains that pallets

more from smoother surface finishes

more quickly than less suitable types.

One company that understands the

Different requirements

importance of pallet selection is local

“When considering which pallets to use,

equipment manufacturer PMSA (non-

it’s important to start with the most

producer member of the CMA), which

important factor: production efficiency.

Here one needs to consider factors such

(Top): UPplus Pallets with pavers during production process.

as the rigidity and density of the material

(Right, from top): UPadvanced Pallets up close; GMT Pallet up close.

pallets and understand that denser

used in the manufacturing of different

PRECAST | ISSUE THREE | 2018

COVER STORY

or the use of ultra-durable polymers that provide benefits in demoulding and surface finishes. Next, one needs to consider the environment in which the products are being manufactured and cured as it may be corrosive, acidic, hot, cold, humid or have other issues that require considerations over and above pure production-related issues,” says Booysen.

“Temperature, mould depth, special mechanical requirements and a host of other factors may also play a role and need to be identified before making the final decision. Lastly, the price needs to be weighed up against the

“It’s not always the price that determines the quality or suitability of the pallet: rather, it’s the application.”

3

produced, as well as being sealed and impervious to moisture ingress from the steam-curing chamber.

per formance and durability of each

Wide range

Problem solved

pallet being considered. Although an

“A s a r e sul t, P MS A h a s c ar e f ull y

Another manufacturer, Van Dyk Stene,

individual price tag may sway close

selected a range of pallets for nearly

has opted for PMSA Glass Mat Thermo-

decisions, it should never be used as

all applic a tions and r equir emen ts.

plastic (GMT) pallets for its outdoor

the only determinant, as it’s far more

These include cost-effective MyWood

plant. These proved to be better than

important to consider the total cost of

A d v an c e d C omp o si t e an d M y Wo o d

wet off-sawn pallets, with no treatment

ownership and production requirements

UP Plus pallets, which are made from

required for moisture and fungus. In this

in the long term.

European pine, lar ch or spruce, or

application, the GMT pallets proved to be

the hybrid MyWood Advanced option,

the perfect balance between low-cost,

Different applications

which are coated with a durable plastic

wet off-sawn wooden pallets and pricier

“With pallets ranging from R2 800

composite outer layer. Due to higher

laminated ones.

for European composite plastic types,

density on European-grown timber,

Van Dyk also found that the smoother

to just R280 for locally grown, wet,

these imported pallets provide better

surface of the GMT pallets reduced

off-sawn pallets (for a typical 1 400

transmission of vibration than local pine

damage and ongoing maintenance to the

x 840 x 42mm pallet), and everything

ones and are longer-lasting, all-round

pallet feeder, compared with wet off-sawn

else in between, it’s easy to see how

performers for general use.”

pallets. The higher density of the PMSA

manufacturers can get confused about

Customers like West End Bricks

GMT pallets transmits vibration better,

the better option. Suffice to say that

(producer member of the CMA) have used

translating to a better compaction

neither the price nor the perceived

them with great success, adds Booysen.

with less voids and, ultimately, better

quality are the crucial deciding factors:

“The MyWood UP Plus boards have been

strengths. This has allowed the company

rather, the application is.

perfect for us and lasted more than

to reduce cement mix ratios by at least

“For example, heavy products may re-

10 years on our plant,” says plant

20%, compared with the previously used

quire a denser wood with less deflection

manager Denver Rambaross. T hese

wet off-sawn pallets.

and lighter product with high abrasion

pallets are easily maintained for internal

“There are so many factors to consid-

characteristics may benefit through

curing rack plants and are not subjected

er when buying a pallet that it really does

polymer types such as PVC that have

to excessive mechanical or varying

pay to rather speak to our Sales Techni-

better wear-resistance. Alternatively,

environmental factors, whereas other

cal Division, which will be able to advise

wet off-sawn pallets may be an alterna-

manufacturers may have to opt for

on the best solutions for specific plant

tive in low-wear environments with dry

hardwood or solid plastic composite

types and conditions,” adds Booysen.

climates that don’t need ongoing fungus

alternatives, or the top-per forming

and moisture treatments.

hybrid Advanced option from MyWood.

“Buyers also need to know whether

The UP Advanced hybrid pallets are an

the pallets are going to be handled

economical solution that incorporates

manally or mechanically, as this also

the rigidity of wooden pallets into an

plays a role in determining their required

encapsulated plastic bonder upper and

strength and weight. So do temperature

lower production surface. These are also

ratings, as curing treatments or even

manufactured with individual planks and

climate extremes may require differ-

have growth rings orientated vertically,

ent characteristics. Surface finishes,

which add strength and rigidity to the

thickness tolerance and other factors

pallet. They are proving to be a success

can also lead to end product variances

at Cape Bricks, where the pallets’

and therefore need to be monitored,”

extra rigidity and high wear-resistance

says Booysen.

are ideal for the heavy products being

PRECAST | ISSUE THREE | 2018

(Top): UPplus Pallets up close.

(Above): PMSA GMT Pallets – Van Dyk Stene (Western Cape).

INDUSTRY NEWS 5

NEW PATH FOR THE CMA Henry Cockcroft, newly-appointed general

That doesn’t mean

manager of the Concrete Manufacturers

we’ll be relaxing our

Association, is determined to give the

standards, though:

association a louder voice than ever

rather, we’ll be communicating with

before and fulfil its mission of making

small businesses and educating them

precast concrete the building material of

on the need to adopt national standards

choice in every town and city throughout

when it comes to making products and

southern Africa.

the importance of being affiliated with

Over the past five years, the as-

associations like the CMA.

sociation has been in a period of flux,

“There’ll also be a focus on growing

constantly adapting to changing and

membership among medium and large

e v er -toughening economic cir cum-

corporates and listening to the require-

stances. Having been ably steered by his

ments and concerns of both our members

predecessors, Cockcroft feels the time

and non-members, in order to learn and

is right to complete the transformation

adapt accordingly. With a broad base of

of the association into a fully self-sus-

members in all regions and supplying a

taining entity with a broad membership

wide variety of products, our other focus

representing every precast concrete

will be on making consumers aware that

manufacturer in the sub-region.

there’s an association looking out for the

“As part of the bigger picture, we have our sights set on representing the

industry which can assist with finding quality producers,” says Cockcroft.

(Above): Henry Cockroft, CMA general manager.

We’ll also be making these publications available through various retail channels,

entire industry, upholding standards and the good name of our industry, as well as

Industry manuals

as w ell as t o e duc a tion f acili tie s,

influencing users and specifiers to make

“ To assist member s, we’ll also be

specifiers, engineers and architects.

precast concrete products the materials

resurrecting the use of CMA publications

“I feel that a lot of work needs to be

of choice for all their construction

which will either be updated and refreshed

done for our industry to re-ignite a love

requirements. And these aren’t just pipe-

or simply r eprinted, if they’r e still

for precast concrete. As the new GM of

dreams: we’ve formulated a marketing

relevant. These are among the most

the CMA, I can assure our members that

plan that will help us achieve these and

valuable reference sources in the entire

achieving these goals is my passion and

other goals that we’ve identified and set

industry, whether it be for structural

that our team will strive to make this an

at board level,” he says.

concrete masonry, manufacturing units

association for everyone.

or precast of all shapes and descriptions.

“In the months to come, our members

Growing support

will also see that we’re embarking on a

“In future, it’s going to be all about

marketing strategy designed to offer

working together to find ways of pro-

maximum benefit to members, while

moting the use of concrete, specifically

maintaining much lower-key branding for

precast concrete in industry. Moreover,

the CMA. We hope this will indirectly

we want to promote our members and

increase the popularity of the CMA as

grow the reputation of the CMA so that

an industry association.

professional bodies, users and end users

“S im ul t a n e o u sl y, w e’ll c o n t in u e

specify CMA membership before buying

ser ving on various panels and work

precast concrete products.

groups to ensure that the CMA and its

“In order to grow our appeal, we’ll

producer members influence standards

also begin reaching out to SMMEs which

and ensure the delivery of consistent,

haven’t traditionally had the resources

high-quality precast concrete solutions

or inclination to become members.

to the industry.”

PRECAST | ISSUE THREE | 2018

CMA AGM The CMA AGM which was held in Germiston recently gave the new general manager, Henry Cockroft, the opportunity to share past successes and cast light on the future vision of the association with its board members.

Topics of discussion included another clean audit for the association, funding challenges in the year ahead, ideas to grow the association’s membership and funding base, as well as revenue-generating opportunities, including sponsors, CMA CS and training.

It also offered the opportunity to bid retiring executive director, Frans Minnaar, farewell and congratulate him on his achievements. Special mention was made of his steadying the ship at the CMA during his two-year tenure, as well as his efforts to reach out to all sectors of the industry in order to specify CMA members’ precast concrete as the building material of choice.

Perhaps the biggest “thank you” was for his efforts in launching the CMA CS, which – since its establishment – has provided the industry with a much-needed means of certifying products where traditional means were failing. CMA CS also provides the association with a means of funding its existence and relying less on donations and sponsorships.

PRECAST | ISSUE THREE | 2018

INDUSTRY NEWS 8

GROWTH IN INSURED CONSTRUCTION ACTIVITY: 2017 VS 2016 Statistics showing insured project values

health of the country. With so many

recorded from 2006-2008 – a period

can offer construction professionals in-

sectors and industries dependent on

dur ing which inf r astr uc tur e spend

sights into the industry and provide useful

the construction sector for their ad-

was markedly higher in preparation

information when planning for the future.

vancement, this monitor recognises that

for the 2010 Fifa World Cup in SA.

Some of the latest data available

inherent value and aims to interrogate

Projects included power generation

from Bryte Insurance on the trends for

some of the trends noted,” says Juan-

projects, upgrades of airports, roads and

major construction projects shows an

Pierre Holmes, head of the specialised

stadiums, as well as the construction of

increase in projects from 2016-2017,

property division at Bryte.

new stadiums.

but a tapering trend towards 2018.

“We launched our inaugural monitor

T he Bry te Construction Activity

in October last year and this is an

High activity

Monitor analyses long-term insured

updated version which provides a much

Looking specifically at 2017, a major

construction projects data within the

mor e concise v iew. I t anal y ses an

spike in construction activity is reflected

South African market and provides a

expanded time-frame, but also includes

in Q1, followed by a tapering in activity

high-level overview of activity within the

reformulated parameters to look at the

over successi ve quar ter s. O verall,

country’s construction sector. It also

sector more closely, rather than the

2017 activity during each quarter was

measures the change, on a quarterly

extended value chain. Going forward,

greater than the corresponding periods

basis, in insured construction projects

we aim to release the monitor annually.”

in 2016. Increases of 50%, 45% and

undertaken by small, medium and large

T he Br y te Construction Activity

61% are noted in Q1, Q2 and Q4 2017

Monitor, expressed in rand value terms,

respectively, compared with the same

shows that the value of 2017 projects

periods in 2016.

construction entities.

Financial health

is estimated at R61 billion, while in

In addition to general heightened

“As one of the economic engines of the

2016, this figure was R42 billion. This

constr uc tion ac ti v i t y ( p ar ticular l y

country, SA’s construction sector is an

is, however, substantially lower than

within the mining sector), the growth

important gauge of the general financial

the insured construction activity values

in 2017 may have been supported by

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INDUSTRY NEWS

rising inflation, which translated into increases in labour and constructionrelated costs. Other factors that may have impacted increases include the heightened awareness of risks after the Southern Cape fires and multiple extreme weather-related flooding incidents.

Within the broader South African con-

9

text, a contradictory trend is noted, with a slow-down in construction activity in 2017 compared with 2016. Unfortunately, 2018 is not expected to fare much better in terms of the number of projects, but actual costs will continue to climb due to currency fluctuations, high rates of borrowing and an all-time high petrol price, among

(Above): Graph 1 depicts gross value insured, expressed in annual frequency from January 2001-December 2017. The series on the graph highlights changes over the 17-year period to provide a view of trends.

other factors. Already, Johannesburg has

technologies should also be re-evaluated.

continues to constrain the construction

experienced the highest construction cost

“Overall efforts by government to

sector and indicates a need for greater

inflation (which increased by 6%) on the

stabilise the national economy also augur

private-sector investment. The muted

continent in 2018.

well for the progress across key sectors,

construction activity is also depicted by

including construction. The proposed

the challenges facing construction com-

Tough times

budget of more than R800 billion for

panies, with many increasingly seeking

“We’r e seeing a tough 2018, with

public infrastructure development, which

consolidation within the sector.

decreased government spending, low

may not be as major as those seen

W i t h f o u r o f t h e t o p si x l a r g e

business confidence (exacerbated by

before, will continue to be vital in igniting

construction companies losing 50-75%

corruption, policy uncertainty, labour

sustainable growth within the sector.”

of their share price in 2017, and some losing in excess of 90% of their value as

challenges, etc) and decreased foreign di r e c t in v e s tm e n t . W h il e a m aj o r

Long drop

at June 2018, these alarming losses are

turnaround for the construction sector

In relation to GDP, the National Trea-

likely to have caused irreversible change,

may not be on the cards, sustained

sury’s public-sector infrastructure spend

as it may be too late for some key players.

growth is expected in successive years,

– which is the greatest funder of con-

Another trend is the diversifying focus

which will be spurred by a continued,

struction activity in the country – shows

of some medium to large construction

prudent focus on cost,” says Holmes.

a declining trend since 2009. This trend

sector players who are exploring op-

“The need to proactively manage the construction business’s risk portfolio becomes increasingly important and insurers and brokers will maintain a vital role in this process. A review of current and future risks, together with mitigation measures, must be scrutinised and solutions reassessed.

Equally, the business’s capacity to seamlessly and successfully incorporate innovative processes, practices and

“We’re likely to see an increase in the number of smallervalue construction projects over the coming years.”

portunities that can supplement growth outside SA’s borders. However, this comes with its own challenges, including the tightening of import and export of services, stronger regulatory governance in certain neighbouring countries and a shortage of technical skills.

Tread carefully Elaborating on opportunities for the construction sector, Holmes adds: “Investors will remain very circumspect.

However, we’re likely to see an increase in the number of smaller-value construction projects over the coming years. This could potentially be due to government/ businesses looking to break down largescale, complex construction projects into smaller undertakings that are less challenging to finance and manage. It could also be spurred by the need to better manage project delays (from approvals to execution) and facilitate shorter turnarounds.

(Above): Graph 2 depicts gross value insured, expressed in quarterly frequency from January 2016December 2017. The series on the graph shows changes thereof.

PRECAST | ISSUE THREE | 2018

“Government’s investment in renewable energy projects as part of the REIPPP

INDUSTRY NEWS 10

programme and the ongoing focus on

Revolution) is crucial and can be

pr ic e -sensi ti v e, bu t the danger

housing are some examples. The residen-

valuable across multiple functions

of seeking the lowest cost could be

tial property construction market will also

within the constr uction sector.

contending with costs which are many

need to continue growing substantially

Adopting enabling technologies for

times higher for uninsured or under-

over the next decade to address the de-

operational and cost-efficiencies could

insured projects – in the event of a

mands of a growing urban South African

also be a key ingredient in aiding

claim – as well as the knock-on effects

population, which is estimated to rise to

growth – regardless of how small the

70% of the total population tally.”

project may be.

of the loss.

• Empowering the youth to address the

Despite the anticipated decrease in

• Seek ing the ex per tise o f a r isk

increasingly apparent skills gap within

large-scale insured activities, project

management professional to

the sector must also be a priority.

values are expected to be higher (as

thoroughly map out exposures, and

On-the-job training and other skills

outlined above), as well as the number

present holistic solutions to plug

development opportunities need to

o f smaller -scale pr ojec ts. Gr adual

them, can have substantial long-term

become more widely available to the

incr eases in conf idence within the

benefits. Some businesses are highly

future leaders of our country.”

sector (following a 17-year low in 2017), a stronger-performing rand and greater investments in advanced technologies that drive process and cost-efficiencies will contribute towards this trend.

Skills gap Holmes of fers tips for construction businesses to support business and economic progression. “Businesses within the sector must focus on: • Meaningfully integrating physical and digital technologies (which are the basis of the Fourth Industrial

(Above): Graph 4: Public-sector infrastructure spend.

Graphic source: National Treasury

INDUSTRY NEWS 11

TECHNICRETE TURNS 50 Technicrete, long-time CMA member

change to simply Technicrete, an iconic

and one of the leading manufacturers of

brand which has stood the test of time.

precast concrete products in SA, turns 50 this year.

In 2013, the Infrastructure Specialist Group (ISG) was formed after Murray &

It was originally part of the Concor

Roberts unbundled Technicrete, Rocla

Group launched in 1948 by Jurgen

and Ocon Brick, which joined the ISG

fers a complete range of precast con-

Schultz, who in 1968 saw a gap in the

Group. A new executive team for ISG

crete pavers, kerbs, erosion protection

market for the manufacture and applica-

was established, led by Albert Weber,

systems, drainage, retaining walls and

tion of precast concrete products. The

the current chief executive officer (CEO).

concrete masonry solutions which have

group launched Concor Technicrete as

“The Technicrete brand is iconic

applications for both commercial and

a new division that would focus totally

in SA and southern Africa. It’s known

on this new range of precast offerings.

for quality products that have been

“Our people are at the core of our

So strong was Schultz’s belief in the

manufactured using the latest available

success. Without their commitment to

precast market that he obtained exclu-

technologies, backed up by a superior

our brand and customers we wouldn’t be

sive rights to manufacture Deckwerk

plant workforce and sales team,” says

here 50 years later. It’s our people who

blocks in SA. They were used in the suc-

Weber. “Celebrating Technicrete’s 50th

live our core values of care, respect, in-

cessful construction of the Magoebas-

birthday is a major milestone in our his-

tegrity, accountability and commitment

kloof, Fanie Botha and Bloemhof Dams, all

tory as a company and in my role as its

to the delivery of quality products and

of which were lined with these purpose-

CEO. I’m extremely proud that it’s still

services,” says Weber.

design blocks from Technicrete. The suc-

considered a preferred supplier to most

“We’re committed not only to the

cess of Concor Technicrete products on

commercial and residential projects of all

continued upskilling of our own staff, but

these projects is what established the

dimensions and that it’s grown to meet

also to the upliftment of local workforces

division as a major industry player.

the often stringent requirements of our

through knowledge transfer in areas

ever-changing times.”

where we supply or manufacture our

As a result, it received a contract to

residential developments.

products. We wish to make a meaningful

line a canal from the Kukane River in then Ovamboland (now Northern Namibia) to

Still growing

contribution to the infrastructure and

Oshakati. Fifty years and thousands of

Over the past five decades, Techni-

people of this country.”

projects later, the rest, as they say, is

crete has grown both operationally and

Technicrete history.

product-wise. From small beginnings

CMA member

to the construction of the company’s

Technicrete is a fervent member of the

Past and present

first major plant at Randfontein, the

Concrete Manufacturers Association

In 2006, Concor was acquired by Mur-

establishment of nine other country-wide

(CMA) in SA and adheres to the ISO

ray & Roberts and Concor Technicrete

manufacturing facilities followed.

9001:2015 Quality Management System.

became an independent company within

The product range has also expanded

Despite congestion within the precast

the group. This resulted in the name

from Deckwerk to a catalogue that of-

concrete product market, the company

PRECAST | ISSUE THREE | 2018

INSTALL

CERTIFIED

PRECAST CONCRETE

PRODUCTS

TO OBTAIN A LIST OF CERTIFIED SUPPLIERS, CONTACT CMA CERTIFICATION SERVICES OR VISIT WWW.CMA.ORG.ZA.

Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Tel: (011) 805 6742 • Email: admin@cma.org.za

IF YOU THINK PRECAST CONCRETE, THINK CMA

A

N

UF

ACTURER

S A OCI

NCRETE

SS

M

PRODUCER MEMBERS.

CO

AT I O N

al

t

e

Q

u

it

y c nc a s t in c o

re

Address: Office 0400, Standard Plaza Building, 440 Hilda Street, Hatfield, Pretoria, 0083 Tel: (011) 805 6742 • Email: admin@cma.org.za • Website: www.cma.org.za

– based on its history – has always had the edge. Its unique attributes include: • A strong historical foundation which allows it to build on its trust marks of heritage and credibility.

• Delivery on key promises of quality and product service, for

A strong foundation for infrastructure success

which it is highly respected.

• A depth of knowledge based on the experience it brings to the business environment and customer base.

Technicrete’s involvement in initiatives around SA and southern Africa includes major civils projects, medical facilities and universities, residential upgrades, upmarket residential estates, motor vehicle dealerships, large commercial buildings, shopping complexes, infrastructural projects and health clubs.

Durable solution “In 1978, the Aggeneys mining township was established in the Northern Cape. The Technicrete Zig-Zag Block Pavers are still there in good working order, nearly 40 years later – that’s a good-quality product for you!” says Weber.

“We’ll continue playing a major role in the supply of precast concrete products as infrastructure around the country continues to be upgraded. Private-sector commercial and residential property developments still reflect as a growth industry and I believe our service, competitive pricing and product quality will continue giving us the edge, making us a preferred supplier for at least the next 50 years.”

CMA CONCERNED OVER FIRING OF SABS BOARD The Concrete Manufacturers Association stands ready to assist the precast concrete industry with required certification of products in the event that the SABS will not be able to do so.

This is the word of CMA general manager Henry Cockroft in response to the dismissal of the entire South African Bureau of Standards (SABS) board of directors due to its failure to exercise its fiduciary duties in terms of the Standards Act and the Public Finance Management Act. The decision was made by the Minister of Trade & Industry, Rob Davies, recently, after he had received numerous complaints regarding a lack of service delivery by the SABS. “This may have a ripple effect through the SABS and could affect service delivery throughout its different business units, including concrete manufacturing and products. It’s our fear that members who still make use of the SABS for certification of products may once again find themselves in a position where these are delayed or mislaid, which is exactly why we launched our own certification service nearly two years ago.

“For those producers that are concerned or who are still struggling to obtain new permits or renewals from the SABS, we’re happy to inform them that the CMA CS is available to issue certificates with the SANAS Accreditation number and logo on it, like any other accredited certification body. With this comes the added assurance that we’ll always maintain the high-

ROCLA is South Africa’s leading manufacturer of pre-cast concrete products. Surpassing 100 years of product excellence, including pipes, culverts, manholes, poles, retaining walls, roadside furniture, sanitation and other related products within infrastructure development and related industries.

est standards for our certification services,” says Cockcroft.

“The CMA CS Mark of Approval is the mark you can trust for genuine compliance with SANS specifications.”

PRECAST | ISSUE THREE | 2018

Visit us on www.rocla.co.za for our nationwide branches

INDUSTRY NEWS 14

USE BUILDING SLUMPS TO TRAIN STAFF

and necessity for repairs and damage

tor, to name just a few potential careers.

to reputations. There’s no doubt that

“The SCT has structured a progres-

trained staff make construction compa-

sion of course levels that will allow

nies more competitive,” says Roxburgh.

prospective students to join at a level which matches personal competency.

Competency required

There can be no short-cuts to becoming

He also points out for that small build-

a good concrete technology practitioner

ers and emerging contractors who

and the school has all the educational

The construction industry should use

lack substantial concrete technology

requirements to help trainees meet

slumps to train staff in order to gain

competency, there is very

a competitive edge when work volumes

little chance of their com-

increase again, urges John Roxburgh,

panies performing to speci-

Courses available

lecturer at The Concrete Institute’s

fications and establishing a

T he SC T 2019 education

School of Concrete Technology (SCT).

sound business foundation.

programme offers 16 differ-

He says the volatility of the South

“Spending money now on

ent courses, all developed to

African construction industry is virtu-

training by the SCT – SA’s

meet the various needs of

ally unmatched, with slumps and booms

oldest and most internation-

the concrete and concrete-

always the norm. “Right now, the in-

ally respected facility for

related industries.

dustry’s decidedly struggling, with work

education in concrete – is

The prestigious Advanced

scarce and many experienced employees

an investment in the future

Concrete Technology diploma

being retrenched to make ends meet.

of any company.

course (SCT50) will be pre-

their specific goals.”

The SCT firmly believes that employers

“The slump in the con-

should first consider using the current

struction industry shouldn’t

sented in the first half of

lean order book period to upskill their

deter those seeking a career in concrete

is globally recognised as the leading

staff in concrete technology.

2019. This diploma course

technology, as there are still many oppor-

qualification in concrete technology and

“Concrete work on site is usually a

tunities available. SA urgently requires

examined by the UK-based Institute of

major cost component in building con-

competent concrete practitioners and

Concrete Technology. Roxburgh urges

tracts. With trained staf f who are

sales specialists in admixtures, con-

those with the required experience to

competent in all relevant aspects of

struction chemicals, ready-mix concrete,

tackle this career-boosting course and

concrete practice, contracts could

precast concrete, concrete repairs, ce-

register for it as soon as possible.

be carried out more economically and

ment production, aggregate production,

quickly, with fewer costly site errors

testing laboratories and the mining sec-

(Above): John Roxburgh, lecturer at The Concrete Institute’s School of Concrete Technology.

PRECAST | ISSUE THREE | 2018

INDUSTRY NEWS

Building contract administrators should take note: more than half of disputes relate to late, partial or non-payment, warns Uwe Putlitz, CEO of the Joint Building Contracts Committee (JBCC).

The JBCC is a non-profit company which represents building-owners and developers, professional consultants

15

and general and specialist contractors, who all provide input for the compilation of JBCC agreements (contracts) that por tray the consensus view of the committee’s constituent members.

Putlitz says many potential site disputes could be avoided by the administrator following the “notice” procedures within defined timelines in the contract. “This includes the employer paying the contractor a certified amount in full by the due date so that the contractor can timeously pay subcontractors and suppliers. Without a signed standard form contract, it’s very difficult to deal with disputes. Contrary to common belief, there’s no need to repeat legal principles in every standard form contract – but it’s important to clearly define the rights and obligations of the parties.”

The contract administrator’s role is

ADMINISTRATOR PLAYS VITAL ROLE IN AVOIDING BUILDING CONTRACT DISPUTES

vital for the smooth running of building

procedures to be followed. “Standard

projects. “For standard form contracts

form contracts generally assume that

used in the building industry, a neutral

the parties will act in good faith and deal

party is usually appointed to administer

with their respective obligations fairly to

a contract on behalf of the parties. This

build a specified facility within a defined

neutral party – traditionally paid by the

time for an agreed amount of money.

employer – is usually referred to as the

“However, that only happens in a

principal agent, engineer, employer’s

perfect world. In modern times, such a

agent or contract administrator.”

predictable scenario is only likely when buying shares through a broker on the

Putlitz says the contract administrator must:

stock exchange, where the scope and

• Administer the contract and regularly

value of the transaction are known and

report to and liaise with all parties

execution occurs immediately on receipt

involved.

of payment – all done electronically –

• Be proactive to anticipate events

leaving no room for disputes.

that may delay the works and/or

“But in most building contracts,

attract additional costs.

there are many unpredictable elements,

• Attend and record all proceedings.

whether climatic or logistical – such as

“I f ther e ar e no r e c or ds, w hen

“The contract administrator must also

late delivery of materials and goods – to

timelines are missed it’s almost im-

be able to interpret all this information to

complicate matters and spark disputes.

p o s si b l e t o d e a l w i t h d i sp u t e s

gauge its significance in future. He or she

Where disputes arise within the para-

promptly and fairly without incurring

should determine whether the information

meters of a contract, they should be

significant legal costs,” says Putlitz.

may become ‘evidence’, should a dispute

resolved in terms of the dispute resolu-

• The significant volumes of information

arise later. If so, this information must be

tion provisions of that contract. Litiga-

continuously generated by all involved

protected against loss, fire or vandalism

tion should be avoided, if possible, as it’s

must be read, understood and dealt

for future reference.”

very expensive and time-consuming, with

with promptly. The information should also be systematically filed so that it can reliably and speedily be retrieved in hard- or soft-copy format.

PRECAST | ISSUE THREE | 2018

So what happens if the scope, time and value of a contract change?

no guarantee of an equitable settlement,” cautions Putlitz.

Putlitz says standard form contracts provide for this by describing specific

(Above): JBCC CEO Uwe Putlitz.

GLOBAL VIEW 16

ADJUSTABLE EXTRUDER

SOLVES MAJOR CHALLENGE OF AMERICAN PRECASTERS Mid-States Concrete Industries in Illinois, USA, saves up to $20 000 (approximately R244 000) a week at its hollow-core production plant. The new adjustable extruder of E9 series from Elematic enabled simultaneous manufacturing of non-standard narrow hollow-core slabs on the same production line. No more saw-cutting, dust, noise and injury risks.

Mid-States Concrete Industries was

of narrow slabs or, as they are called

faced with a problem, which is actually

there, filler pieces of non-standard width.

very common all over the USA. Besides the fact that the design of the hollow-

Residential projects

core slabs has its own specifics in that

Narrow slabs are also very useful in

country, the erection of slabs on the

small residential housing sites and in

construction site is also done in a differ-

tight areas of a hollow-core construc-

ent way from, for example, the way it is

tion site like mezzanine. The largest cost

done in Europe. It is common practice for

for the hollow-core contractor on such a

some narrow space to be left at the end

site is the crane. Downgrading the size

of the floor slab system, when finishing the slab run with standard pieces.

(Top and above): The Elematic extruder in action.

of the crane and narrow, smaller slabs for smaller jobs saves both the contrac-

In Europe, longitudinally cut slabs are

a precast manufacturer to rip standard

used as well, but not very narrow pieces

slabs into narrow pieces and deliver them

tor and the customer money.

Traditionally, manufacturing of non-

as cast-in-situ is used to close such

for erection to the site. That is why Mid-

standard widths of hollow-core concrete

gaps. In the USA, the contractor expects

States constantly needs a large number

slabs means a huge amount of rip-saw

PRECAST | ISSUE THREE | 2018

sible to cast two slabs of different width simultaneously on the same production line. It is possible to divide the standard slab in two identical or two asymmetrical slabs.

Hollow-core slabs of various dimensions can be profitably produced with less time and effort. With a basic setup, one can produce slabs with widths of 600-2 400mm, thicknesses of 1606 500mm and lengths of up to 24m.

Mid-States received the adjustable extruder in June 2017 and started production right away. “The filler machine not only responded to the specific needs of Mid-States, but also to specific needs that every hollow-core producer has in the USA,” says Wolff.

The benefits of the E9 extruder include: • Reduction in scrap.

• Huge cost-savings.

• Increased efficiency on the plant floor.

• Quality of the surface and edges of the filler pieces.

• Less camber differential.

• No time-consuming, noisy and dustysaw cutting required.

• Improved workplace safety and lower injury risks.

The South African context cutting, which is a time-consuming,

Elematic’s area sales director Mika

noisy and dusty operation. The result is

Reunanen, who regularly visits SA,

a slab with saw-cut edges which do not

says: “While our extruders are already

look as good as machine-finished edges.

operational in SA, the benefits – besides

Furthermore, noise and dust cause

solving the problems experienced by

workplace safety and health issues.

Mid-States Concrete Industries – have

“This is a very common problem. When

enabled the hollow-core factories to

you cut a piece off a four-feet section, it

cast at a faster speed and across two

creates a lot of scrap, because you have

lanes, thereby increasing production and

to throw the other piece away. A company

output. Feedback verifies that Elematic

carries the costs from this operation of

extruders exceed expectations, both re-

approximately $10 000-$20 000 [approx-

garding the quantity of metres of slabs

imately R122 000-R244 000) per week],”

produced per minute and their quality.”

says Mike Wolff, vice-president of safety and plant operations at Mid-States.

Hollow-core slabs are generally used for flooring of both commercial buildings and homes. Using an adjustable extruder

Problem solved

for their production is an economical

Elematic’s new filler machine, the modi-

solution for meeting the varying dimen-

fied version of the E9 series extruder,

sional needs of concrete slabs. It speeds

solves this problem perfectly. A special

up production and increases profitabil-

nozzle and a few more parts added to

ity, while eliminating the laborious and

the standard E9 extruder make it pos-

dusty sawing process.

“It enables the hollow-core factories to cast at a faster speed and across two lanes, thereby increasing production and output.”

PRECAST | ISSUE THREE | 2018

PRODUCTS 18

NEW HIGH-CAPACITY POWERED PALLET TRUCK Material handling solutions provider

ibility of even the bulkiest loads and

ers and/or employees are in the vicinity

Combilift has launched a new high-

their surroundings. The operator’s

of operating forklifts. It’s our intention

capacity powered pallet truck

position also eliminates any pos-

to significantly expand our pedestrian

for the South African market.

sibility of crush risk when working

forklift range, as can be seen with the

in confined areas and prevents

launch of the Combi-PPT. This forklift of-

product damage.

fers safer operation, maximum operator

The truck is suitable for use in the precast concrete manufacturing industry and comes with stand-

“W i th th e in tr o du c -

visibility and narrow aisle performance.”

tion of the Combi-PPT,

The Combi-PPT’s automatic folding

ard lift capacities of 3 000kg and

very heavy loads can

platform is an added benefit for operators

6 000kg, with higher capacity models

us now be handled us-

when large distances have to be covered

from 7 000-16 000kg avail-

ing these walk-behind

in a warehouse or production plant. The

able on request. It is a fur--

machines, ensuring

power steering, dual rear-wheel drive and

ther addition to the Irish

high levels of safety

AC motor technology make it effortless

while guaranteeing efficient

and stress-free for operators: it “glides”

procedures even in confined spaces,”

across the floor, even when moving very

operator’s platform enabling

according to Martin McVicar, managing

heavy loads and its manoeuverability

stand-on or walk-behind operation.

director of Combilift.

enables tight corners to be negotiated

company’s growing pedestrian range, with the optional

The Combi-PPT includes a feature com-

“Combilift developed its first pedes-

safely and easily. A range of optional

mon to all Combilift’s pedestrian models:

trian models (the Combi-WR, Combi-WR4

fork lengths, widths and configurations

its unique, patented multi-position tiller

and the Combi-CS) in response to an

is available, in line with Combilift’s policy

arm. This enables the operator to stand

industry demand to move away from ride-

of supplying customised solutions for

at the side of the unit, rather than at the

on forklifts. As a company, we’re seeing

individual customer requirements.

rear (as is the case with other walk-behind

a growing demand for pedestrian trucks,

brands), giving operators excellent vis-

driven by safety concerns where custom-

(Left): The new Combi-PPT pallet truck.

The thin line between success and failure of forklifting operations can most often be traced back to the quality of advice

PRODUCTS

CHOOSING A FORKLIFT FOR PRECAST YARDS offered by the equipment supplier at the time of the original purchase.

19

With a bewildering number of types of machines for mixed and varied applications and with diesel, gas or electric options, the decision to buy a forklift is not necessarily a straightforward one. In reality, it requires considerable thought and technical knowledge to make the right choices based on current and future requirements. This is particularly true of the precast industry, where a simple product change or pallet size can have a big impact on the type of forklift required.

It is therefore not surprising that SA’s best-known forklift brand, Linde M a t e r i a l s H a n d l i n g S A ( L M H S A ), continues to invest heavily in training its front-line sales and service staff to help

types, to ensure the right selections

its customers make informed decisions

can be made for each new customer,”

when buying forklifts and remain well-

says Klerck.

informed throughout the life-cycle of the equipment procured.

(Above): Linde Materials Handling SA is investing heavily in staff training to ensure customers get the best advice possible when buying forklifts.

offer products and solutions that improve Future-proofing

the efficiency and cost-effectiveness of

He adds that in addition, the training

the customer’s operations has become

International training

helped the sales sta f f under stand

a critical success factor in our industry,

LMHSA sales director Deon Klerck says

modern new solutions that are available

as companies ar e looking f or ways

the most recent training initiative was

to customers, including the company’s

to improve their cost base and gain

aimed at the company’s sales force,

latest Linde Connected Solutions, a

competitive advantages,” says Klerck.

who underwent intensive training from

sophisticated communications and data

“It also enables us to build better

two of the German company’s overseas

tracking system deployed for the purpose

long-term partnerships with clients and

training professionals. “In order to have

of increasing the efficiency, safety and

help them increase the profitability of

a substantial advantage in today’s mar-

profitability of warehouse operations.

their operations.”

ketplace, we have to give the right advice

Lithium ion batteries will also be

quickly and in such a manner that our

introduced in SA in the near future

customers understand all the require-

and although they cost mor e than

ments to make a successful purchase.

conventional lead acid ones, they last

“That’s why this training was geared to

much longer and charge very quickly. As a

help our sales professionals understand

result, their life-cycle cost is significantly

the precast concrete industry and dif-

less than that of conventional batteries

ferent market types, as well as storage

and they provide big opportunities for

and warehousing practicalities and a host

customers in terms of productivity and

of intricacies, to further build upon their

value for money.

knowledge base. Through our overseas

Practical workshops were also held,

trainers, we also want to expose them

giving the sales force the opportunity

to worldwide best practices and solutions

to drive the warehouse trucks. This

that can be applied locally as well.

helped translate theory into practice by

“The course comprehensively covered matching storage requirements to dif-

physically demonstrating the features and benefits of the equipment.

ferent forklift ranges from very narrow aisle trucks to order pickers, reach

Long-term commitment

trucks, stackers and even powered pallet

“Equipping our sales force with in-depth

trucks. It also examined appropriate uses

knowledge to recommend the right

for reach trucks, stackers and other

product for a particular application and

PRECAST | ISSUE THREE | 2018

(Left): Elematic’s new Plotter E9.

PRODUCTS 20

The concrete manufacturing sector faces a plethora of different demands daily for concrete applications. Chemical company Chryso Southern Africa applies solutions to ensure that these needs

CHEMICAL SOLUTIONS FOR DIFFERENT CONCRETE NEEDS modify concrete rheology to provide the

include fibres for cohesive mix to limit

Common issues such as durability of

required lubrication within the pump line,

rebound and shotcrete accelerators to

concrete due to shrinkage cracking can

reducing pump pressures and improved

improve build-up.

be addressed with a range of products

concrete flowability and providing better

Fibre-reinforced concrete is ideal

that reduce early and long-term drying

workability retention for long pumping

for limiting the formation of cracks and

shrinkage, while the company’s fluid

distances.

for improving surface quality; it can

are met.

Optima range combats the effect which

For concrete mortars, Chryso admix-

even provide an alternative to mesh

shrinkage-reduced admixture may have

tures can improve plasticity, cohesion

reinforcement. Super-plasticisers are

on the strength of the concrete.

and adherence, and prevent infiltration of

part of the offering, as fibres tend to

Pumping concrete over long horizontal

water, plastic shrinkage cracking, as well

reduce the workability of fresh concrete.

or vertical distances causes the danger

as the segregation of fine cement and

Impermeable concrete for waterproof

of concrete stiffening in the line, which

sand particles. Shotcreting is another

or under water applications can be

can disrupt the pumping operation. The

common application that can be enhanced

achieved to r educe water content

company’s product ranges, however, can

by the right concrete; available solutions

and water-cement ratios, as well as admixtures that block pores in concrete.

In situations where vibration is not possible to compact concrete, selfcompacting concrete is the answer and the correct product will allow high fluidity, ease of placing and finishing, with extended slump retention, if required.

Chryso’s extensive range of solutions is based on leading-edge research and can be produced in 26 facilities worldwide, each equipped with sophisticated technology for precision manufacturing.

(Above, from left): Chryso admixtures are used in concrete pumping applications; Chryso’s range of admixtures has changed the face of construction by broadening ready-mix options for designers and contractors.

(Left): Increased concrete workability is easily achieved using Chryso admixtures.

PRECAST | ISSUE THREE | 2018

Two years after introducing its Spartan precast concrete formwork system to the local market, local distributor RMCS

PRODUCTS

PRECASTER OFFERS MODERN FORMING SOLUTIONS has established a growing customer base of precasters who are making use

21

of the system to manufacture a wide range of products.

The Spartan system provides a faster solution for the precast manufacturing and tilt-up construction industry with its lightweight, magnet-connec ted formwork which can be easily rebuilt af ter use to cast dif ferent shapes and sizes. with the addition of various lengths and profiles.

According to Louis Aylward, managing director of Rebar Mesh & Construction Supplies (RMCS), the snap-together system is steadily finding favour, as it

(Above): Good finishes on the 2Ten Hotel add a quality feel of the exterior.

saves a considerable amount of time on

(Left, from top): Precast lifting anchors provided ease of placement of heavy precast units at Lanseria Airport; a tilt-up anchor and clutch.

set-up. This enables users to redeploy manpower and efforts to other parts of the process, which considerably improves productivity. It is also valuable

“T he system’s user -f riendly and

on projects where units vary in size and

we ultimately manuf actur ed 365

shape, such as decorative cladding.

balustrade panels which are decorative and functional. We also used form-liners

2Ten Hotel

to create semi-circular grooves on the

O n e o f t h e l a t e s t p r oj e c t s t o b e

face, which is towards the airport. We

completed with the Spartan system

used eight different sizes, starting with

was by CMA member CoreSlab, where it

the widest ones and going down to the

was used to cast a series of slabs and

smaller sizes, and cut the form-liner

cladding in large 2,7m x 5m and 150mm-

to fit.

thick sizes for the newly-constructed

“Through the use of the system, we

2 Ten Hotel in T hohoyondou. Wher e

saved about 50% on labour and 30% on

necessary, the panel sizes also had to

enabled the casting crew to redeploy

mould costs. Time and labour go hand in

vary to allow for perfect fitting and it is

the other workers into more productive

hand and savings of both are significant.

here that the Spartan System proved

areas, as required.

More importantly, you don’t need skilled

This combination translated to a

labourers to do the resetting each day.

According to Jaco de Bruin, managing

considerable cost-saving on the project

Demoulding is very simply achieved by

dir e c t o r o f C o r e Sl ab, th e sy s t em

and, in addition to these benefits, the

removing the magnets and then removing

accounted for significant time-savings

company will be able to clean and re-use

the panels. It’s a developed-world solution

on the project. Due to the lightweight

the moulds on future projects.

and, in the right application, is a game-

invaluable.

changer,” says Wesley Sevenster, Allasso

aluminium construction and easy-to-

Construction general manager.

assemble, magnetised jointing system,

Lanseria Airport

the moulds could be prepared by one

Another interesting project undertaken

person instead of the usual three. This

by Allasso Construction was the supply

Flexible solution

of concrete elements for the extension

“We’re pleased with the results being

of Lanseria Airport parking garages.

achieved by customer s using our

Here the manufacturer made extensive

system and it’s easy to see why,” says

use of the RMCS Spartan system, as

Aylward. “It enables higher volumes to be

well as its unique lifting anchors to more

produced from relatively small casting

safely transport the heavy fresh-cast

yards. It also requires less, meaning

concrete units throughout the curing

that workers can be used elsewhere

period, as well as for the transportation

to boost productivity. But the most

and placement of the units on site.

decisive benefit is its flexibility.”

“Through the use of the system, we saved about 50% on labour and 30% on mould costs.”

PRECAST | ISSUE THREE | 2018

COMPANY NEWS

WESTERN CAPE BRICK AND BLOCK PRODUCER GEARED FOR GROWTH Based in Piketberg, midway between Cape Town and Clanwilliam, CMA member,

22

Fick Sementwerke produces a diverse range of concrete blocks, bricks, pavers and retaining wall blocks. Founded in 1995 by the current owner and managing director, Anton Fick, the company recently invested in new plant and equipment to increase production capacity.

Demand for the company’s products began to outstrip supply from 2007 and a decision was taken to halt the production of pavers so that the demand for bricks and blocks could be met. At

(Above): Fick Sementwerke financial manager Felecia Paulissen, seen here with the company’s founder and managing director, Anton Fick.

(Right): The new plant at Fick Sementwerke.

one stage, the company was working extended hours and over weekends.

Good decision

“Seventy percent of our range goes to

“When the market was still rampant

the farming community and the remain-

– demand doubled between 2007 and

der is supplied to independent retailers

2017 – we decided to re-introduce

which operate in towns within a 100km

paving blocks. Last year, we installed

radius of our plant and sell to the resi-

impor ted high-qualit y block-mak ing

dential market. However, we sometimes

equipment,” he added.

supply as far afield as Springbok, some 450km away,” says Fick.

“The new plant has tripled our overall production capacity and paving block

I started by making blocks and over the

(Below): CRB blocks prior to delivery.

years, the business has grown to the extent that it now occupies six adjacent

also supply an imperial brick in several

properties in Piketberg.

MPa ratings.

“Our Concrete Retaining Block [CRB]

High standard

for retaining walls comprises the stand-

“We currently manufacture to the SANS

ard L12, which we make under licence

standard, but we’re not accredited. We

to Terraforce in smooth and rock face

operate on a philosophy of continuous

finishes and in tans and greys. Retaining

quality improvement and I spend much

walls built with CRBs are in their infancy

of my time in the plant, ensuring that

in this area – most people still prefer

our products are made to the highest

brick walls. Notwithstanding, we’ve

possible standards.

supplied blocks to rooibos tea farmers

“Our measurement deviations either

in Clanwilliam who used them for building

equal or better SANS’ standard de-

level platforms for the construction of

viations and we’re seriously considering

production began in January this year.

storage sheds and we are currently sup-

implementing the CMA’s Certification

Due to unforeseen circumstances such

plying farmers in the Calvinia area. We’re

and Mark of Approval system. We also

as the drought in the Western Cape

even supplying CRBs to a private house

aim to set up our own testing laboratory

and a general downturn in construction,

in Constantia, Cape Town.”

as soon as possible and we’re currently

product of f take has fallen, so we’re

in the process of installing a semi-auto-

currently not working to full capacity.

Long history

Nevertheless, we believe the downturn

A fifth-generation Piketberger, Fick says

will be short-lived and that it won’t

his family has been producing bricks and

b e long b e f or e demand incr e ase s.

blocks in the town for the past 60 years.

Dam levels are rising and farmers are

“My father owned a transport company

benefiting from this year’s better rains.

and during the quiet winter months, he

“O ur p a v ing r ang e c omp r ise s a

kept his staff busy by producing bricks

bevelled 50mm rectangular block and

and blocks as a sideline. I used to work

two interlockers, a 60mm and a heavy-

in the yard driving the front-end loader

duty 80mm, both available in a variety of

and forklift trucks in my school holidays

colours. We supply four masonry blocks,

and I learnt a lot about brick production

all of them 390mm long and 190mm high,

from the people working in the plant. My

in varying widths of 90mm, two in 140mm

father closed the plant in 1993 to focus

and one in 190mm, and we produce a

solely on the transport business.

maxi brick in varying strengths. Our maxi

“While his transpor t business

bricks are cast with cylindrical voids,

continued to demand his full attention in

which are popular in the Western Cape

1995, I founded Fick Sementwerke as a

and are used for building cavity walls. We

means of attaining financial independence.

mated palletising system,” says Fick.

NEW OWNERS FOR OCON BRICKS CMA member, the Infrastructure Spe-

group, and therefore decided to sell

cialist Group (ISG), has announced the

Ocon Brick.

sale of clay brick manufacturer Ocon

“On behalf of the IS Group, I’d like to thank management and the entire team

“With the strong demand for Tech-

at Ocon Brick for their dedicated con-

Brick to Willem Pienaar and

nicrete- and Rocla-manu-

tribution to its success during the past

his partner, Mike Koch.

f actur ed pr oducts in the

five years that they’ve been part of it.”

A lb er t Web er, C E O o f

industry and with govern-

Rocla and Technicrete are key manu-

ISG, says: “ISG r egularly

ment’s commi t ted spend

facturers and suppliers of precast

evaluates and reviews its

on infrastructure, we see a

concrete products that service the in-

op er a tional ac ti v i tie s t o

bright future for the busi-

frastructure building and mining sectors

ensure that our long-term

nesses. Both brands ar e

nationally and in neighbouring countries.

strategies and objectives

well-established industr y

Rocla celebrated its 100th birthday

remain on track . Af ter a

leaders and our long-term

in 2017 and Technicrete celebrates

careful analysis, the board

s tr a t eg y is t o gr o w and

50 years of operation this year.

decided to focus on the core business

further enhance our service offering to

that Rocla and Technicrete afford the

the industry,” he adds.

PRECAST | ISSUE THREE | 2018

(Left): Albert Weber, CEO of ISG.

COMPANY NEWS

(Left): Freshly cast masonry blocks.

23

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(Below): CRB walls under construction at the Phase 2 Courier Guy distribution centre project in Kya Sands, Gauteng.

COMPANY NEWS

(Left): The 3 700m² CRB wall at the new Cummins Southern Africa Regional Distribution Centre site at Waterfall Park, Midrand, MVA Bricks’ first major CRB project.

25

MVA INJECTS NEW LIFE INTO CRB WALL MARKET Pretoria-based concrete block paving

a rounded half-moon face and is designed

and precast concrete kerb producer and

for upmarket commercial walls in closed-

CMA member, MVA Bricks, has taken the

faced designs. A heavier block, it has a

concrete retaining block (CRB) wall mar-

much greater load-bearing capacity and

ket by storm. Since launching two block

can be deployed in walls with wall face

types, the MVA-7 and the MVA-13, the

angles which vary from 60-90˚.

company has won at least half a dozen

“The MVA-7 has a locking mechanism

major CRB wall projects in Gauteng and

which restricts its usage to wall faces

Mpumalanga. It has also supplied numer-

of 60-75˚. However, it can be modified,

Founded in 1995, MVA Bricks also

ous smaller projects.

as it was for the Cummins project,

produces a range of concrete block pav-

high loadings and pressures,” he says.

“Production began in June last year,”

where one section of the wall was built

ers which are available in various sizes,

says MVA general manager Brennan

at an angle of 85˚. This was necessary

shapes and colours. The production of

Small, “and our first major order followed

because of space constraints and to

kerbs began in 2005 using pressed cast-

shortly thereafter, when we supplied the

accommodate an attenuation pond at

ing to achieve exacting and highly durable

new Cummins Southern Africa Regional

the footing of the wall.”

quality standards.

Distribution Centre & Filtration Plant

Small adds that a third block, LokBlok,

MVA has a fully accredited SANS

development in Waterfall Park, Midrand,

was launched in July and two orders have

standard for its pavers and kerbs and is

with 26 000 MVA-7 blocks. These were

been delivered.

producing the CRB blocks to SANS stand-

used in the construction of a CRB fill-wall facing on a large building platform.

ards while it awaits SABS accreditation.

Product range

“We maintain an in-house laboratory

“Since then, we’ve delivered MVA-7

“The LokBlok comes with a tongue-and-

and we test our products on a daily

blocks to several other major retaining

groove configuration, which allows the

basis. Our results are at hand within

wall projects: the Courier Guys Phase

blocks to interlock positively. This means

24 hours and form the basis of our on-

2 distribution centre development in

they’re well suited for high walls up to

going quality analysis. This means we’re

Kya Sands (24 000); a new Builders

90˚. LokBloks come into their own on

able to tell very early on whether our

Warehouse in Midrand (19 000); a new

walls in excess of 8m – heights which

products meet our required strength

industrial park on the R21 near Oliver

require a very specific block because of

ratings,” says Small.

Tambo International Airport (12 000); a new industrial park in Nelspruit (8 000); and Thulamahashe Plaza, some 200km from Nelspruit (3 400).”

Economical construction Small says the MVA-7 has a flat face and was designed for economical, open-faced wall construction. As its name suggests, it is generally used on the basis of seven blocks per square metre, although this can be increased to a 10-block configuration when required.

“The MVA-13 is quite different. It has

PRECAST | ISSUE THREE | 2018

(Above): MVA Bricks’ general manager, Brennan Small, stands next to one of the CRB walls at the site of the new Cummins Southern Africa Regional Distribution Centre.

AROUND & ABOUT 26

CONCRETE CONFERENCE UNITES TH A united industry is a stronger one that

our concrete professional bodies.”

is better able to represent its members

SARMA’s Johan van Wyk agreed,

through periods of high growth, while

adding that associations have to move

maintaining its solid structure in times

with the times and become more relevant,

of adversity.

with added benefits for members and a

This was the overriding message of

louder voice within policy and economic

The Concrete Conference 2018, which

frameworks. By combining the strengths

was held in Boksburg recently as the first

of the industry bodies, it will be possible

of its kind to fully involve representative

to provide more value for members.

or ganisations o f the concr ete and

“What excites us unites us!” he said.

cement industries. The events therefore gave local and international speakers the

Long road

ability to address a combined audience of

Adding to the discussion, TCI’s Bryan

members of The Concrete Institute (TCI),

Perrie said the pooled resources of the

the Concrete Society of Southern Africa

five organisations will make for a robust

(CSSA), the Concrete Manufacturers

organisation which will have different

Association (CMA), the Southern Africa

agendas for different disciplines, but the

Readymix Association (SARMA) and the

same end-goal of making concrete the

Association of Cementitious Material Producers (ACMP).

Opening the conference, Richard Tomes of AfriSam, the main sponsor,

building material of choice. on board. We need to support industry

“At present, the individual industry

associations such as these here today

bodies draw funding from the same major

and obtain funding to keep them going.

stakeholders and these can’t continue

said that a unified industry is essential

“For example, Afrisam is the only

funding them, as they have in the past.

for the industry to make headway. “The

cement producer which is a member of

A single co-ordinated body would be more

entire construction industry needs to

SARMA right now and, in my opinion,

agile and eliminate duplicated costs. It

plan for the future and map a way forward

it’s simply not right that it funds this

could also continue providing the key

that involves all professional bodies. It’s

association by itself. It’s time other

activities that were previously provided,

therefore extremely important that the

role-players and suppliers to these

and more.”

concrete industry finds its unified voice

industries star ted contributing. If

In closing, Perrie said that a lot of

to help shape construction in future and

not, we’ll also eventually be forced to

work still needs to be done to unify the

address challenges that face this end of

withdraw our funding and the industry’s

concrete associations and consultations

the sector,” he said.

own association may be faced with

with members and business studies are

closure as a result. It’s time for other

still being conducted to work out the

role-players to step up and support all

finer details.

Strong voice “If we don’t get our act together soon, our infrastructure will collapse: this has already started happening at some levels within our municipalities and state-owned enterprises. However, in order to make positive changes, we need everyone to be

“The entire construction industry needs to plan for the future and map a way forward that involves all professional bodies.”

PRECAST | ISSUE THREE | 2018

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TECHNICAL 28

John Roxburgh, lecturer at The Concrete Institute’s School of Concrete Technology, provides some guidelines on mixing and using concrete in a safe manner: The composition of portland cement is such that when dry cement is exposed to water, a chemical reaction called hydra-

GUIDELINES ON USING CEMENT AND CONCRETE

tion takes place, resulting in an alkaline mixture that can be caustic. This could cause alkali burns on the skin, so safety measures should be observed to prevent fresh concrete or its bleed water from coming into contact with the skin.

Roughness and dryness of the hands are a typical result of exposure to cement, so to safeguard against accidental skin exposure, appropriate protective equipment is strongly recommended. This

SAFELY AND SENSIBLY Concrete is the world’s most widely used building material. Workers in every sector of the construction and precasting industries, as well as DIY enthusiasts, handle portland cement and wet concrete every day.

However, as with most materials, there are potential risks involved in working with portland cement or mixes made using it.

includes wearing impermeable, gauntlet-

in the working area and is inhaled by

if this is not possible, the use of suitable

type rubber gloves and high-length rubber

every person on site, potentially causing

respiratory protective equipment such

boots. Trousers should overlap the boots,

irritation of the nose, throat and eyes.

as dust masks is recommended.

rather than be tucked into them.

For this reason, every attempt should be

Particular care should be taken to

It is also recommended that hydro-

made to keep airborne cement dust to a

ensure that:

phobic, alkali-resistant barrier creams

minimum. If this is impracticable, the use

• Normal and protective clothing does

be applied to hands and any other areas

of goggles and dust masks is strongly

not become soaked with wet concrete

of skin likely to come into contact with

recommended.

or concrete fluids, as this could result

fresh concrete. Ordinary barrier creams

Many of the aggregates used in con-

in exposure over an extended period,

are unlikely to offer adequate protection,

crete have high silica contents. The fine

resulting in tissue damage that can be

especially if the skin itself is not clean

silica dusts created when crushing or

particularly severe and even disfiguring.

and free of concrete residue. Even a tiny

handling these aggregates could cause

• Workers do not kneel on fresh con-

trace of cement dust remaining in con-

lung problems and precautions should be

crete during placing, compacting and

tact with wet skin could burn it. For this

taken to avoid breathing in such dusts.

finishing operations. If kneeling is

reason, some authorities recommend

Dust from demolishing or cutting

unavoidable, thick, waterproof knee-

the use of disposable gloves, rather than

hardened concrete may contain unhy-

pads should be worn and a kneeling

re-usable ones.

drated cement and could cause respira-

board used to prevent the pads from sinking into the fresh concrete.

Other organic tissue (for example,

tory problems. In addition, if the coarse

mucus membrane) can also be attacked

or fine aggregate used in making the

• Protective clothing should also be

by strong alkalis, leading to burns that

concrete contains crystalline silica, the

regularly and properly washed to keep

can sometimes be severe.

inhalation of these fine silica particles

it clean and free of concrete. Any

The use of cement inevitably creates

could expose workers to the risk of de-

areas that have been accidentally

dust, particularly in operations such as

veloping the occupational lung disease,

splashed with wet concrete should

handling aggregates or cutting concrete.

silicosis. A concerted effort should be

be rinsed clean with water as soon

The dust becomes suspended in the air

made to avoid generating such dusts, but

as possible.

PRECAST | ISSUE THREE | 2018

CONCRETE ROADS SAVE FUEL With the fuel price constantly rising, the lower fuel consumption offered by concrete pavements should be an important factor in future road transport planning, says Bryan Perrie, MD of The Concrete Institute.

and full tractor-trailer unit – ranged from

Because of the social and ecological impor-

lifetime of a busy freeway.

0,8-3,9% in four out of five periods in the year. This was found in results with a field of reliability of 95%.”

Perrie adds that an average fuel-saving of 2,35% would represent an immense difference in overall fuel consumption and emissions of greenhouse gases over the

tance of reducing fossil fuel consumption,

Laboratory research by the Transport

several studies and research projects con-

Research Laboratories in the UK, commis-

cerning the effect of pavement type on the

sioned by the Highways Agency, was carried

fuel consumption of industrial goods vehicles

out to determine the effect of the rigidity

and cars have already been carried out. The

of the pavement on fuel consumption. The

best-known study is that of the National

reduced deflection of concrete pavement

Research Council (NRC) of Canada.

led to a 5,7% reduction in rolling resistance,

“The Canadian NRC did a series of four

also resulting in fuel-savings. Similar results

investigations. These were progressively

have been obtained from extensive research

extended with additional test phases on

done in Sweden, Japan and the American

various types of pavements and vehicles

states of Texas and Massachusetts.

in different seasons and using a variety of

“Apart from the type of pavement, even-

statistical models. Reduced fuel consump-

ness and surface texture are also important

tion in heavy goods vehicles was seen in all

factors influencing fuel consumption. The

phases for concrete pavements, compared

quality of the finished concrete surface

with asphalt pavements,” says Perrie.

plays a crucial role: a good-quality and

“The final phase – which was also the

evenly-laid concrete pavement retains these

most complete and evaluated a range of

qualities for decades. A concrete pavement

pavements with various degrees of even-

with undulations or uneven patches will

ness and included observations made in

require difficult and expensive treatment

all seasons – revealed the smallest differ-

to obtain the desired ride quality,” explains

ences, but still showed that the fuel-saving

Perrie.

on concrete pavements compared with asphalt pavements – both for an empty

PRECAST | ISSUE THREE | 2018

(Below): Work in progress on concrete pavement construction in KwaZulu-Natal.

TECHNICAL

PREVENTATIVE MAINTENANCE ENS The durability of concrete structures, including precast, can be greatly increased by a proper preventative maintenance and repair programme, says

30

Warren Trew, Gauteng sales manager: General Construction of a.b.e. Construction Chemicals.

Trew says many key South African building and civil structures have eroded with age or due to neglect, misuse, wea ther f ac tor s, r ebar cor r osion, extraneous loading and natural disasters. “Neglecting the need to introduce proper repair and maintenance systems for these structures results in reduced capital value and wastage of resources, which could lead to poor quality of life for communities. With large parts of SA currently experiencing devastating drought, the need for adequate maintenance of water reservoirs and dams, particularly, comes to mind.

(Left): Repairing deteriorated concrete and restoring its structural integrity should form part of the initial design, says a.b.e.’s Warren Trew.

SURES DURABILITY “In a sustainable built environment,

“Experience is vital for this diagnosis

structural maintenance is non-negotia-

and for planning concrete repairs. While

ble. As soon as a concrete structure is

there’s a high level of expertise that

completed, the need for a maintenance

goes into concrete construction, the

programme must start. Maintenance

skills, understanding and experience

shouldn’t be driven simply by the need to

required to repair damaged or deterio-

correct defects that occur over time,

rated structures are decidedly differ-

but should be undertaken early enough

ent from those required to build new

to avoid them,” he states.

structures. That’s why it’s important to consult reputable suppliers of con-

Dire need

crete repair products – companies that

Crew says that concrete is a durable,

can offer not just the product, but also

but not eternal material and will de-

provide advice on its suitability, as well

teriorate over time, requiring repair

as the system and procedures to be

or replacement, especially in zones

followed for concrete repair projects.

where chloride ingress or carbonation are a reality. Repairing deteriorated

Crack repairs

concrete and restoring its structural

“Among the most common challenges

integrity should consequently f orm

of concrete rehabilitation are crack

part of the initial design – but these

repairs, patching, using strengthening

measures are frequently only resorted

methods (instead of repairs) such as

to once emergencies arise.

carbon fibre plate or wrap, and generally

“ T he f ir s t s t ep in a suc c ess f ul

choosing the most appropriate repair

repair project involves early damage

materials for an ef fective long-term

assessment and arriving at a proper

solution. A decision should also be taken

diagnosis. The owners shouldn’t wait

on whether strengthening methods

until the concrete shows obvious signs

should be opted for, instead of repair.

of distress. The most crucial aspect

Fortunately, the range of concrete re-

of the repair process is the evaluation

pair products available today has made

stage. To properly repair any damage,

it possible to economically refurbish

it’s impor tant to understand what

structures that just a few decades ago

caused the problem and then determine

would have had to be demolished and

the correct method of repair.

rebuilt. The input from specialists in concrete rehabilitation – and the selection of the correct products – will avoid common pitfalls of concrete repairs,” observes Trew.

He says a.b.e. Construction Chemicals’ range of concrete repair products is based on epoxies, synthetic resins, silanes and cementitious materials.

Applications include flexible slurries and coatings for protecting and waterproofing the concrete parts of bridges, silos, building and water containment structures against attack from their en v ir o nm en t . “a .b .e . c an sup p l y a wide range of products – as well as professional advice – on projects such as concrete crack injection, fairing, reprofiling, priming, mortar repair and the rehabilitation of spalled concrete surfaces, to name just a few requirements of concrete repair procedure

(Above): Warren Trew, a.b.e Construction Chemicals Gauteng sales manager: General Construction.

PRECAST | ISSUE THREE | 2018

which could save the owners thousands, if not millions, of rands.”

TECHNICAL

By John Cairns, independent paving consultant SA is one of the world’s water-scarce regions. Prey to recurring droughts, there is rarely a period in which one or more of the country’s provinces is not in

32

the grip of an extended dry period. Cape Town’s recent disastrous drought is just one such example. Being a global destination, the city’s critical water shortage drew international interest, but it was the entire Western Cape region and not just Cape Town which was declared a disaster area in 2017.

The drought in the Western Cape should act as a wake-up call for SA, underscoring the need for water to be treated as a precious and vulnerable resource. Cape Town came perilously close to Day Zero and the same set of conditions could easily prevail in other regions. Rather than wait for a disaster to occur, regional and local governments should lead the way through mandating a broad swathe of water conservation measures, including permeable paving. By way of example, the German government takes permeable paving so seriously that

WATER CONSERVATION AND PER

LOCAL GOVERNMENT MUST

any impervious, hard-standing surface

Reducing costs

characterised by a higher frequency

attracts additional rates and taxes.

Permeable paving also offers economic

of storms and a longer rainy season.

Besides water conservation, the main

advantages by minimising the costs of

T he stud y r ecommended tha t new

benefit of permeable paving is that it

surface drainage works and reducing the

proper ty developments be carefully

reduces the negative impact of imper-

demands on stormwater sewerage. In

designed to ensure that run-off from

meable surfaces on aquatic ecosystems

addition, it is suitable for flat areas with

new developments is maintained at pre-

through stormwater management and

limited falls, such as container terminals

development levels. Correctly designed

pollution control. With the exception of

and roof decks. And, unlike other water

and installed, permeable paving meets this

Cape Town, which has legislated its use

conservation systems such as swales

objective and is particularly effective when

along with other water conservation

and attenuation ponds, it allows full

existing stormwater drainage systems

measures, the rest of SA pays scant

land usage.

are operating near or at capacity.

heed to the system: permeable paving

A study by the Johannesburg

Although this was only a recommenda-

installations in other provinces number

City Council f ound that the city is

tion, some permeable paving projects have

no more than a dozen.

experiencing an increase in annual rainfall,

been undertaken in Johannesburg. In some of the city’s first installations, the designers appeared to lose sight of the fact that the materials used in the construction of permeable paving are vastly different from conventional paving, particularly the bedding material beneath the pavers and the jointing material between the pavers (see Figure 1). In at least two installations, conventional bedding and jointing sands, rather than small aggregate, was used.

(Top): The voids between permeable paving blocks are clearly visible at the 45 000m² Blue Route Mall parking area in Cape Town.

(Left): A permeable paving system takes shape on a parking lot on the West Campus of the University of the Witwatersrand. The system comprises layers of stone, membrane and paving block.

PRECAST | ISSUE THREE | 2018

procedures which assess impacts on

the aggregate used to fill the joints or

water quality.

drainage apertures. Polluted material

Permeable paving should be consid-

can therefore be easily and economically

ered when:

removed and replaced. Several European

• Stormwater and sewer systems are

installations – such as car and bus parking areas at the Prater Football Stadium in Vienna – have been in service for 15 years and more, with only routine maintenance.

In Australia, a permeable paving system has been developed for domestic driveways. Rainwater collected from

close to capacity.

• There are limitations on the extent of impermeable cover.

• There is insufficient space for both vehicle use and attenuation ponds.

• Water quality and pollution control are primary design objectives.

the driveway and the roofs of adjacent

For these reasons, permeable paving

houses is channelled onto the driveway’s

provides an option especially relevant to

permeable surface and stored in a tank

urban roads. However, it has also been

under the paving. By means of an im-

successful in heavily trafficked applica-

mersible pump, this water is used for all

tions, such as container yards.

non-potable applications in the houses and for watering the gardens.

Design of permeable paving Several distinct engineering require-

RMEABLE PAVING:

LEAD THE WAY

Typical regulations for new urban paving

ments must be addressed in design-

developments

ing p e r m e ab l e p a v ing . I d e all y, th e

These include:

methodology should embrace the

• Limits on the extent of

following objectives:

impermeable areas.

• On-site retention of rainwater.

• Control of the discharge rate.

• Flood mitigation by r etention or detention, ie water quantity.

• Water quality improvement by

• Control of the discharged water quality.

filtration or retention, ie water quality.

• Measures to reduce sedimentation

• Water conservation by collection and

and/or pollution.

• Increasingly, measures for harvesting and re-using rainfall.

re-use, ie water harvesting.

• The ability to carry traffic.

An overview of permeable paving de-

To meet such requirements, best

sign is given in figure 2. This figure shows

management practices include controls

that, in contrast to conventional paving,

for reducing or managing pollutants,

permeable paving involves two parallel

procedures for the proper disposal of

design requirements, structural design

waste and the use of flood management

and stormwater management, each of

Figure 1 Bedding sand is not the best material, as it limits the flow rate of water through the pavement and leads to surface flooding during heavy storms.

Offshore research Studies in the UK have shown that permeable paving yields significantly lower initial and whole-of-life costs than asphalt or cast-in-place concrete surfaces.

Moreover, initial concerns about the long-term maintenance costs of permeable paving due to clogging have largely been allayed by tests in Europe, North America and Australia.

These tests indicate that permeable paving can achieve a service life in excess of 25 years without maintenance and, more importantly, that pollutants mainly

PRECAST | ISSUE THREE | 2018

TECHNICAL

accumulate in the upper 25-50mm of

Figure 2: Methodology of permeable pavement design.

33

TECHNICAL

which is likely to require different paving

3. No infiltration: Where there are

thicknesses. Clearly, the designer must

contaminated flows or issues of

The range of water management outputs

opt for the greater thickness.

soil salinity. Here an impermeable liner

should include:

needs to be placed between the per-

1. Storage size requirement to achieve

The principal design questions are: 1. What is the design life of the pavement?

2. How fast can the pavement accept

34

meable pavement and the sub-grade, and drainage pipes are required to remove infiltration. (See figure 3.)

rainfall? This depends on the paver Water infiltration and treatment

drainage materials, and the type of

Three issues must be considered in the

base and sub-base.

design of pavements:

3. How fast will the pavement drain?

1. Stormwater management: How much

This is related to the type of base and

water can infiltrate the pavement over

the position of the water table.

specified performance targets.

2. Peak flow rate for selected storm events at the site.

3. Site-critical storm duration.

type, the cross-fall, the bedding and

sub-base, the type of sub-grade and

Water management outputs

a given time and where will it go?

4. Average annual reduction in pollutant load.

5. Average annual harvesting/ re-use capability.

Structural design

2. Pollution control: What is the quality

As mentioned above, the pavement

4. How much water can the pavement

of the effluent leaving the pavement?

thicknesses required for stormwater

retain and for how long? This will de-

3. Water harvesting: How much water

management normally differ from those

pend on the thickness and permeabil-

can be stored and re-used?

ity of the pavement layers.

5. How thick should the pavement be to

needed to carry traf fic. This means that, in addition to water manage-

Water quality, harvesting and re-use

ment, traffic flows and loading must

carry traf fic? Here the resilient

There are two approaches in controlling

be considered in the structural design.

properties of the permeable pavement

water quality. The first of these is to

Worldwide, permeable paving has already

materials are paramount.

filter the stormwater and then release

been successf ully used in pr ojects

it into the local government drainage

ranging from car parks to roads, ports

Cross-section selection

system. The second is to filter and re-

and container yards. Accordingly, any

As shown in figure 2, the first step in

tain the stormwater on site, allowing it

structural design procedure should

permeable paving design is to determine

to slowly percolate into the underlying

be capable of handling a wide range of

how the water will be controlled and man-

soil. Factors that must be considered

traffic conditions, while utilising the full

aged within the pavement system. This

here include:

range of new materials which are avail-

entails choosing the right cross-section

• Pollutant input concentration

able for the construction of permeable

and pavement materials. Broadly, three scenarios need to be considered: 1. Total infiltration: Where the water is

characteristics.

• Pollutant removal efficiency characteristics.

paving surfaces. It is also important to note that in any new development, only part of the paved surface needs to be

allowed to flow into the sub-grade and

• Historical rainfall data.

permeable. Engineers must structure

water table. Although sub-surface

• “First flush” pollutant characteristics.

their designs based on an appropriate

drains can sometimes be omitted,

• Build-up/wash-off of pollutants.

ratio of permeable to non-permeable in

they are only feasible on permeable sandy soils.

2. Partial infiltration: Where the permeable paving is founded on impermeable clay, sub-grade provision must be made to drain the water from the site using drainage pipes. Moreover, a filter fabric must be used to prevent clay fines from contaminating the base and sub-base.

Monthly demand characteristics are

order to ensure that all stormwater is

the main consideration for water har-

channelled to and drains into the perme-

vesting (re-use).

able surface.

“The drought in the Western Cape should act as a wakeup call for SA.”

Conclusion P er me able p a v ing is an imp or t an t technique for achieving water-sensitive urban design and should be mandated

by SA’s provincial and local authorities.

There is now sufficient data to allow permeable paving designs for all types of applications. The design engineer needs to identify retention and detention requirements, predict outflows to the surrounding catchment, integrate the project as a node in existing catchment management procedures and design software, and ensure it is compatible with water quality monitoring programmes. All these factors should be rated as very important by municipal engineers for

Figure 3

whom water-sensitive urban design is a basic requirement.

PRECAST | ISSUE THREE | 2018

A joint initiative of the City of Cape Town and the Southern Africa Readymix Association (SARMA) is underway Until now, no specific standards have

irrigation and isn’t disallowed, according

facturing, which relies heavily on a reliable

existed to allow the use of anything but

to national standards, nor is provision

supply of it. Water shortages can result

“potable” water in the process. How-

made for it in SANS 51008 water for

in either the closure of concrete manu-

ever, the recent drought in the Cape

making concrete because, until now, no

facturing plants or in manufacturers

Town region has spurred concerned

specific testing’s been done.

seeking alternative methods of obtaining

SARMA members to join forces with the

“As a result, we’re currently compiling

water. In the Cape, the drought even led

Cape Town Municipality in using effluent

a testing which will enable us to run an

to manufacturers sinking hundreds of

water instead.

eight-week study and collate results, in-

boreholes throughout the region. This

According to SARMA director Johan

cluding chemistry and all the parameters

could eventually lead to the concentra-

van Wyk, if a suitable solution can be

surrounding the water. We can then

tion of salts which can render the water

found, it will not only have a positive effect

monitor its effect on the mixing, setting,

unusable to future generations for drink-

on water supplies and the environment,

curing and strengths of the concrete.

ing or agricultural purposes.

but will also reduce the cost of water for construction by as much as 75%.

“This will then be compared with

“As the guardians of future genera-

current concrete standards and data

tions, we feel it’s our responsibility to

to make a finding. Our preliminary find-

find sustainable, alternative means of

Safe usage

ings have been positive and offer hope

manufacturing concrete,” says Van Wyk.

“In this instance, effluent water doesn’t

for a major evolution in the way we make

refer to sewage, but rather to water from

concrete in dry climatic regions.”

sewerage plants that’s gone through all

TECHNICAL

RESEARCH TO BENEFIT PRECASTERS

35

“The finding we make on effluent water will be made available on completion of the research and best practices will be

cycles of treatment except naturalisa-

Seeking alternatives

shared with all concrete manufacturers

tion in a maturation pond,” explains Van

The construction industry is a major

via internal communications, as well as all

Wyk. “This type of water is often used for

water-user, particularly concrete manu-

forms of media at our disposal.”

We are there when you need support

Need help with your concrete? We offer a free advisory service for general concrete queries. Perfect concrete with us.

www.theconcreteinstitute.org.za +27 11 315 0300

TECHNICAL 36

CONCRETE OFFERS UNMATCHED

STRUCTURAL INTEGRITY S construction offers for the creation of infrastructure, says Bryan Perrie, MD of The Concrete Institute (TCI).

He says the strength of concrete ele-

concrete. In the case of reinforced con-

Ensuring concrete integrity and du-

ments in buildings is well understood

crete, the quality of the cover concrete

rability is essential in using the equity

by structural engineers, architects

is extremely important in protecting the

already in the existing structure. It also

and contractors. This includes in-situ

steel reinforcement against aggressive

prevents the need to re-invest in materi-

reinforced concrete, precast concrete,

agents and fire. This zone of concrete is

als and energy prematurely.

tilt-up, hybrid construction and post-

intended to act as the barrier between

tensioned concrete elements.

the reinforcing steel and external ag-

Sustainable solution

“South African design and construc-

Concrete’s energy-efficiency is shown

tion codes regulate the structural re-

in many ways. The use of local materi-

quirements of concrete buildings, which

als in production of concrete minimises

ensure that concrete structures are

fuel costs for handling and transporta-

safe and have the capacity to cope with

tion and, once in place, concrete offers

any permanent, imposed, wind and earth-

significant energy-savings over the

quake actions. For common spans, the

lifetime of the structure. Most of the

relatively high mass of concrete floors

primary materials used in concrete are

leads to natural damping and low vibra-

produced locally. Cement extenders and

tion. For more stringent criteria, such

slag aggregates used are secondary in-

as for laboratories or hospital operating

dustrial products that would otherwise

theatres, the additional cost to meet

have required dumping. While cement

stricter vibration criteria is negligible,”

factories are generally located close to

adds Perrie.

the location of the necessary raw materials, sources of aggregates and ready-mix

More durable

plants can be placed close to the areas

Concrete is renowned as one of the most

of demand, thereby reducing the energy

durable materials on earth, ensuring lon-

required for transport.

gevity in any structure. This not only low-

“The materials used in concrete also

ers the expenditure of energy in building

gressive environments and its quality is

make efficient use of natural resources

new infrastructure or housing, but also

of primary importance in durability con-

and, again, the potential for recycling

reduces maintenance and the impact on

siderations. Good material choice, mix

at life-end saves quarrying of finite re-

the use of finite resources.

proportioning and sound construction

sources. Concrete mixes for ready-mix

practice are essential to ensure durable

plants and precast yards are designed

concrete,” stresses Perrie.

specifically to use aggregates sourced

“The first line of defence against deterioration is good-quality, impermeable

PRECAST | ISSUE THREE | 2018

buckling or yielding,” says Perrie.

(Left and below): The flexibility of concrete as a building material – both externally and in interiors – has inspired designers the world over.

largely maintains a building’s strength

major impact on the energy usage over

smoke damage also reduce the magnitude

the lifetime of a busy highway. A major

of insurance claims. Concrete structures

Canadian study showed a 2,35% fuel-

generally remain intact after a blaze,

saving by using concrete roads, with a

allowing for relatively quick repair and

subsequent reduction in the emission of

re-occupation, saving time and costs,

polluting gases.”

as well as finite resources.

Fire-resistant

Good-looking

Perrie says another benefit of concrete

“Fire-damaged concrete buildings usually

is that it does not burn or emit any

don’t require demolishing or rebuilding,

toxic substances during a fire. It will not

so concrete structures protect life and

produce smoke or drip molten particles,

preserve property, contributing to en-

from local quarries – and, more recently,

which means it is fire-resistant. Unlike

hanced social and economic performance

also from recycled concrete – which re-

other construction materials, therefore,

of the built environment – an important

duces fuel costs for transporting these

its use in structures means they do not

consideration for all property-owners,

materials,” explains Perrie.

require fire-proofing or additional pro-

such as municipalities,” adds Perrie.

“The embodied energy in the construction of a structure is usually minimal,

tection, provided they are appropriately designed.

Concrete’s inherent fire-resistance restricts smoke from spreading and during a fire. After a fire, the continuing structural strength and reduction in

TECHNICAL

(Far left): The structural strength of concrete elements such as precast concrete (pictured) is well-known to all in the South African construction industry.

37

“When aesthetic qualities such as design flexibility and variety of finishes

compared with the energy likely to be

“This eliminates the time, cost, ad-

are added to the sustainability benefits

consumed during the life or use phase

ditional materials and labour required to

of concrete, it’s easy to understand why

of a structure. In the case of roads and

provide separate fire protection mea-

it’s the preferred building material among

transport infrastructure, any aspect

sures. During a fire, the concrete cover

property-owners, developers, designers

reducing fuel consumption will have a

will protect the steel reinforcement from

and contractors.”

ENDING EROSION Technicrete Armorflex erosion control system provides an alternative for a wide variety of erosion control and drainage projects. When your project calls for protection that can withstand severe applications and climatic conditions, with quick installation with no in-situ concrete or even under water, Armorflex from Technicrete is the engineered solution.

Suitable for:

Specially designed:

•

•

• • • •

Rivers, Estuaries, Dams, Reservoirs Areas subject to wave action Access roads Parking areas Stormwater drift crossings

• • •

Compressed concrete blocks (solid or vertical holes

or horizontal cable ducts)

Interlocking system Partial taper of each block Various sizes of blocks available

paving | mining | masonry | kerbs erosion protection | retaining walls | drainage www.technicrete.co.za Technicrete is a subsidiary of ISG, a leading supplier of innovative infrastructure products to the construction and mining markets in Southern Africa.

Tel: 011 674 6900 Maxi call: 0861 266 267

RPOJECTS 38

EARTHFORM: THE PERFECT SOLUTION When a couple in Thohoyandou, Limpopo,

“I knew that Manie Troskie from En-

the embankment be cut back and the soil

decided to build their dream retirement

gineered Interlock Solutions [EIS] was a

stockpiled to provide space for the geo-

home, they were faced with an unex-

specialist concrete block retaining wall

synthetic reinforcement and drainage.

pected challenge – soil erosion due to the

contractor with many years of experience

high-lying area of their land.

in the design and building of concrete block

Good result

A Google search highlighted CMA

retaining walls, as he’s a regular customer

“This is the biggest residential retaining

member Technicrete’s Earthform re-

of ours. Due to the massive size of the

wall project we’ve undertaken to date,”

taining wall blocks as a solution. Meet-

project and the challenging terrain, I re-

adds Troskie. “Over 20 000 grey Earth-

ing Technicrete at its Polokwane office

ferred the couple to him for the retaining

form blocks were needed to complete

offered the couple the erosion solution

wall installation and design.”

the Thohoyandou project. The house

they required.

“Our Earthform retaining wall blocks

was situated off the main tarred road Economical design

– and this is where the expertise of the

are ideal for the kind of challenges the

“EIS designed and constructed the

Technicrete drivers came to the fore,

couple was facing. The longevity of the

retaining wall in various stages. The

as they battled dirt roads, sometimes

product has stood the test of time on

critical area was in front of the house,

in rainy weather, and still delivered on

many projects where soil erosion has

where 80mm-wide tension cracks had

time, without breakages.

been vast due to flooding,” says Peter

already developed. There was a risk of

“The access to stock as required and

Hilton, sales consultant for Technicrete

this embankment collapsing. A total slip

competitive pricing were other factors

in Polokwane.

failure would have had a major impact on

that made working with Technicrete a

the structural integrity of the house.

win-win situation during the eight months

Soil erosion

The in-situ embankment was cut back

it took to complete this project. The

Due to the magnitude of the project, Hil-

to the required design distance for the

couple involved were very happy with the

ton travelled to Thohoyandou to assess

geosynthetic reinforcement and drainage

end result in terms of erosion control and

the site and take the required measure-

to be installed. The soil was stockpiled for

final appearance.”

ments, which took over two hours. The

re-use,” says Troskie.

Earthform retaining wall blocks can

house, large enough to accommodate

“The fill wall was constructed in two

be stacked up to 7m high, provided that

four children and extended family, was

terraces, each 3m high. The terraces

sufficient geosynthetic reinforcement,

built high up in the magnificent, hilly area

were of a more economical design so-

erosion control layers and drainage are

of the region, affording the property

lution and provided a softer look for

installed in the reinforced fill section

exquisite views, but heavy rains were

landscaping. There were various smaller

directly behind the blocks.

causing massive soil erosion on the

terraced walls constructed on both sides

Plants or vegetation suited to the

chosen site.

of the house. One wall was constructed

style of the Earthform retaining wall

as a 7m-high continuous wall that flared

blocks should be planted facing outward

out into three smaller terraces.

of the front face of the wall and require

“Earthform gives embankments a natural support, while protecting the land from collapsing due to erosion,”

“The wall behind the house in the cut

says Hilton. “Additionally, it provides an

section was also designed as a two-

attractive and practical finish in steep

terrace wall. The bottom section was 5m

areas that are dif ficult to maintain

high and the second wall 3m high. There’s

through the creation of plantable retain-

an access road to the neighbour’s prop-

ing walls.

erty on top of the wall. This required that

little maintenance. The blocks are available in Autumn, grey and plum.

(Above): The Thohoyandou family house with Earthform erosion blocks to prevent erosion of the relatively steep property.

Ten years ago, tilt-up construction could only claim fewer than 10 proE years back, its use was random and T ±50 for the current year heralds a big leap in the right direction.

a European construction design which

panels were erected without columns

called for precast columns and precast

for support. In this instance, they are

column foundations. Bedrock suggested

held in place by the roof, while the panels,

its in-situ foundation system, which

in turn, support the roof structure. In

involves casting columns with protrud-

other instances, panels were erected in

ing rebar, as an alternative. Once the

combination with columns, both of which

columns have been lifted into position and

support the roof.

The reason for the upsurge isn’t hard to find. Property designers and developers

precast foundation and rather than

the panels against the inner-facing sur-

are always on the look-out for improve-

convert to a foreign methodology, we

face of the columns, with two panels

ments in quality, accuracy and, above all,

suggested an in-situ foundation,” says

abutting at the middle of each column.

speed – and tilt-up ticks all these boxes.

Bedrock manager David Kitching. “The

We did this at the request of the ar-

vertically aligned, concrete is poured into

“In sections where columns and panels

the foundation cavity around their base.

were combined, the panels weren’t posi-

“This is the way we’ve always done

tioned on the outside of the columns, as

it, as it eliminates the transport of the

they normally are. Instead, we mounted

Tilt-up construction, which involves

chitects, who wanted smooth surfaces

casting large panels or columns horizon-

on the inside of the building. Moreover,

tally on site, did not gain wide traction

we cast the roof mounting plates inside

until the advent of the mobile crane after

the panels to give a nice, flush finish and

World War II, which allowed builders to lift

we cast the roof brackets above ceiling

the massive panels into position. It was

level so that they were also concealed,”

also then that ready-mix concrete was

explains Kitching.

introduced, making tilt-up an even more

“In another section, we integrated an

viable proposition.

in-situ mezzanine level into our concrete

Over the years, industry experts

panels. This was achieved by casting our

have refined the tilt-up process and in

panels with rebar protruding at right

1986, the Tilt-up Concrete Association

angles from the top of the panels. Then,

(TCA) was founded in the USA to create

when the mezzanine formwork was as-

processes and standards for the indus-

sembled, it was linked longitudinally into

try. Today tilt-up accounts for as much

our rebar.”

as 75% of new one-storey commercial

These variations in design and con-

building construction in the USA.

struction demonstrate the flexibility of

SA’s first tilt-up project is said to

tilt-up and how easily it can be adapted

have taken place in 1984 and involved

to the requirements of numerous design

the construction of Myrther House, an

options.

office building in Pinetown which is now

T he Isipingo Retail Development

occupied by the Department of Labour.

project is being constructed above a (Above): Tilt-up panels mounted flush to create a smooth finish at Junction Mall. The panels are mounted against the inner surface of concrete columns, rendering the columns invisible from the inside of the building.

fully functional railway line and could not

in the greater Durban area. Today SA’s

European engineers had no problem with

and erected by Bedrock as a complete

largest tilt-up practitioner is the Bedrock

our alternative proposal and it sailed

structural concrete frame.

Group. Also Durban-based, it entered the

through their approval process.

And the first company actively involved in this precast building method was Durban-based Tilt-Up Technologies, an outfit which focused on industrial parks

market in 2013 and now commands 65%

have been executed without the use of precast concrete in the form of columns, beams and panels, all designed, supplied

Kitching advises that erecting a wall

“The Atlantis project was unusually

with tilt-up is faster than traditional

complex because the columns had to be

construction techniques, thereby accel-

As of mid-July 2018, 28 tilt-up pro-

cast with corbels in different positions

erating the overall building process and,

jects had been completed in the coun-

and heights. They also required steel

at the same time, providing exceptional

try’s three major cities. Bedrock’s tally

brackets, which were cast into the

levels of strength and quality.

numbered 18: seven in Cape Town, six in

columns at precise positions for roof

Durban and five in Johannesburg. Other

frame support.”

of the market.

“The other trades can begin work earlier on a tilt-up project, which allows

suppliers accounted for three projects

The construction of Junction Mall,

greater overlapping of project phases.

in Cape Town, five in Johannesburg and

a new shopping centre in Philippi, is a

And, being reinforced, a tilt-up wall is

two in Durban.

good example of the alternate use of col-

better able to withstand the battering

Pegas, a R1,3 billion fabrics manufac-

umns and panels for roof support at the

from forklift trucks and delivery vehicles,”

turing facility in Atlantis, was based on

external elevations. In some sections,

says Kitching.

PRECAST | ISSUE THREE | 2018

PROJECTS

SA’S CONSTRUCTION INDUSTRY TILTS UP

39

CONCRETE ROOF TILES ON THE RISE AT SATARI COUNTRY ESTATE Increasing numbers of concrete tiles are being used to roof private houses and apartment blocks at Satari Country Estate. Located on the outskirts of Somerset West, just off the N2 highway, Satari offers a tranquil countryside setting with schools, shops and other communal conveniences within easy reach.

At the time of going to press, CMA member Monier Coverland had supplied its black Elite concrete roof tile for the roofing of approximately 60 houses and four apartment blocks.

The houses are being built by UVest in two-to-four bedroom designs and the apartments in one-to-three bedroom layouts.

The Elite tiles were installed in combination with doublesided Radiant Shield, yielding a combined R-value of R1,59.

Over 90% of the Satari houses built with concrete roof tiles have exposed trusses, a feature in keeping with the rustic environment of this tranquil estate.

Danie Hattingh, regional manager of Monier Coverland Cape Town, says that besides their obvious aesthetic attributes, concrete roof tiles offer several other advantages. “They’re one of the most cost-effective roofing materials and are largely maintenance-free. They don’t need painting, nor do they rust.

They also have good thermal properties and don’t require as much insulation material as steel roofs do to meet legal thermal roofing requirements.”

Monier Coverland has been manufacturing concrete roof tiles for the past 69 years and is part of the BMI Group, the largest manufacturer of flat and pitched roofing systems in Europe.

(Top and above): Pitch-perfect: Monier Coverland’s black Elite concrete roof tiles complement these houses at Satari Country Estate; an apartment block at Satari Country Estate attractively roofed with Monier Coverland’s black Elite concrete roof tiles.

PRECAST | ISSUE THREE | 2018

In one of the largest paving projects to date, the roads in the country’s fourth Industrial Development Zone, Saldanha IDZ, have been surfaced with Concrete Block Paving (CBP).

41

Eight metres wide and 4,3km long, the roads and adjacent sidewalks were paved with 2,2 million concrete block pavers manufactured by Vredenburg-based precast concrete manufacturer, Van Dyk Stene and 11 000m of kerbing produced by associate company, Vredenburg-based Van Dyk Precast.

The rationale behind the choice of CBP for this project was that it supports the main driver of the Special Economic Zone (SEZ) programme, namely job creation.

“By contrast, laying CBP required no machinery and could be done by small

(Above): One of the CBP roads at the Saldanha IDZ, which generated jobs and commercial opportunities for the local community.

contractors using local labour. Moreover, Local benefit

all the paving blocks, kerbing and other

responsibility and technical perspective,

“The SEZ aims to stimulate the local

materials required for the construction

and we’re very pleased that the whole

economy through international invest-

of the roads were available locally, includ-

project was contracted locally. The roads

ment. However, the Saldanha IDZ made

ing the materials for the manufacture of

were paved with 80mm interlocking

a strategic decision not to wait for job

the CBP. This meant that the total value

blocks and the pavements with a 50mm

creation through investment alone, but

of the project could be earned by the

rectangular block. These and the kerbing

to kick-start the process during the

local economy, which resulted in a mas-

were manufactured by Van Dyk Precast.

infrastructural development of the es-

sive multiplier effect.

tate,” says Hannes Marais, Executive: Infrastructure & Environmental Planning of the Saldanha IDZ. “We followed an approach which would create as many jobs and local contracting opportunities as possible during the development phase and paving our roads

“Laying CBP required no machinery and could be done by small contractors.”

with CBP was one of the ways we could achieve that objective.”

“We employed two small contractors to do the laying of the pavers. One was a sole provider on this project and today he owns a registered company.”

Roadworks “Power Group was the main contractor responsible for the main excavations and the laying of the stormwater and sewer

Maintenance-free

pipes, but was obliged to sub-contract

Marais says he and his colleagues

“The other benefit was that, if laid prop-

certain portions of the work to local small

worked through some design scenarios

erly, CBP is largely maintenance-free and

businesses, including the CBP contrac-

with engineers and using CBP presented

has a longer lifespan than its asphalt

tors. Power built the roads to upper sub-

several advantages.

equivalent. It also offers the opportunity

base level and thereafter smaller local

“Although CBP was only slightly more

of running pipes and cabling under the

contractors handled the side drainage,

expensive initially, our projected lifespan

paved surface post-construction of the

the kerbs, the sidewalks and, of course,

costs were very positive. And in terms

paved surface. This is done by simply

the paving of the roads. It would have

of job creation, asphalt had several dis-

lifting the pavers before digging and then

been easier to give Power the whole

advantages. For starters, only the big

re-laying them, with no visible evidence of

job, but we wanted to create as many

contractors are equipped to handle this

their removal. Asphalt, by contrast, must

opportunities as possible for the local

type of project, which requires very ex-

be dug up and replaced with fresh mate-

community and economy,” says Marais.

pensive plant and equipment. Moreover,

rial – a wasteful process which leaves an

Saldanha was over 120km away from

ugly scar on the road.

the nearest asphalt plant in Contermans Kloof near Cape Town.

PRECAST | ISSUE THREE | 2018

PROJECTS

PRECAST CONCRETE PAVING SPURS ECONOMIC GROWTH IN SALDANHA

“The roads were designed with open V-drains and single cross-fall drainage,

“We believe we took the right deci-

because the area’s very hard calcrete

sion in opting for CBP, both from a social

sub-strata meant we weren’t able to

PROJECTS

justify the installation of sub-surface

vided our lower sub-base construction

drainage. Stormwater runs across the

matched the upper sub-base, our surface

roads and drains into open channels.

tolerances were more than adequate to

“That hard calcrete sub-strata of the Western Cape gave us a unique

42

support the upper layer of bedding sand and paving blocks.

road-building advantage. It meant we

“In the end, our sub-base comprised

didn’t require two sub-grade layers and

two 125mm layers of G5 material im-

three sub-base layers. Rather, we only

ported from one of the local quarries.

needed two supporting layers, a selected

Had we used asphalt, we would have

sub-grade layer and a sub-base layer,

required an additional base of G2 or G1

which saved us a lot. In fact, we were

material, not to mention losing out on

able to dispense with a whole 300mm

numerous job creation opportunities,”

layer of sub-grade. We found that pro-

says Marais.

Precast concrete seating, manufactured and installed by CMA member Concrete Units, has been used in the construction of a new rugby pavilion at the country’s oldest school, Cape Town-based South African College High School (SACS). The school also happens to be the alma mater of Concrete Units manager, Brian Cook.

PRECAST CONCRETE PAVILION SEATING FOR SA’S OLDEST SCHOOL Situated in arguably the country’s most

were challenging and the seats had to

scenic school campus at the foot of Table

be delivered around the perimeter of the

damage to the field,” says Cook.

“We also had to take particular care

Mountain and Devil’s Peak, the pavilion

field and then placed from there. This

to get our storage dimensions correct

was designed by Vivid Architects and

situation wasn’t made easier by a wet

in order to minimise any creep that

built by main contractor Brice Construc-

Cape winter and we did our best to man-

might have occurred immediately after

tion. The pavilion houses VIP seating on

age the soggy conditions and minimise

lifting. If the storage positions had been

the upper level and stepped concrete

too wide, the seats would have sagged.

seating below.

Conversely, if they’d been too narrow,

The concrete seating comprises 54

they would have hogged. Each seating

of f-white bench-style units with the

unit was also provided with weep holes

seating and foot support elements cast

for drainage purposes.

as a single unit. Apart from six units

“And given that the seats are on

which were 3,5m long, all the seats

public display, it was important that

measured 5m and weighed 1,6 tonnes

we achieve exceptionally high-quality

each. Actual seating sections were

smooth finishes without any blemishes

100mm thick and had recessed upstands

and we achieved that objective.”

for greater comfort.

The seats were installed on an embankment by the Concrete Units instal-

T he s t adium w as r e ad y f or the SACS/Paarl Boys’ High School match in late July.

lation team using a crane mounted on the delivery truck and were attached to in-situ concrete footings built by Brice Construction.

“As there was no access from behind the pavilion, offloading and installation

(Above): The Table Mountain plateau and Devil’s Peak (right) form the perfect backdrop for the new rugby pavilion at SACS. (Left, from top): Off-white precast concrete seating benches were used in the construction of a new rugby pavilion at SACS in Cape Town; the seating has high-quality, smooth finishes without blemishes.

PRECAST | ISSUE THREE | 2018

PROJECTS 43

“Parts of the fence were stolen,” says Concrete Units manager Brian Cook, “leaving gaps through which taxis and other vehicles could access Borcherds Quarry Rd illegally, directly off the N2.

Moreover, the security of the area was severely compromised and it was these two factors which motivated the Borcherds Quarry CID to invest in a precast concrete security wall.

“After various types of wall systems had been explored and priced, we were appointed by the CID to provide a turnkey wall installation. This involved designing the wall, casting its component parts and doing the assembly work ourselves.

“The wall comprises a combination of solid pre-stressed panels [5 860mm x 2 400mm x 100mm) mounted between reinforced precast concrete H-section poles that are 3,2m high. We began construction in June at a rate of two slabs and three poles a day and the wall was completed by the end of September.

“The panels were pre-stressed and we had to take particular care to ensure that the pre-stressed steel wire was precisely positioned dead-centre to avoid

N2 SECURITY WALL CONSTRUCTED WITH PRECAST CONCRETE A solid precast concrete wall has been constructed by CMA member, Concrete Units, for the Borcherds Quarry Community Improvement District (CID) close to Cape Town International Airport and a stone’s throw from various informal townships across the N2. Six hundred and

any ‘banana’ bending of the panels. Our production schedule meant that panels had to be removed from the moulds every

barrier between the Borcherds Quarry industrial area and the N2 highway.

second day, and this required a concrete

upright position until they were mounted

The poles were then plumbed with a spirit

which delivered high early strengths and

as part of the wall.

level and we used a long bar to measure

“The concrete poles were normally

the correct distance between the con-

reinforced and mounted in a square me-

crete footing and the top of the poles,”

“Before the panels were removed

tre concrete footing 850mm deep. All

says Cook.

from the moulds, the latter were tilted

the holes were dug by hand and we gave

to a vertical position. This was done

the foundation a 50mm blinding layer to

(Top left): A recently completed section of the wall.

because the panels weren’t thick enough

provide a working surface. Wooden planks

to sustain horizontal lif ting. Af ter

were used to align the flat face and give

demoulding, the panels were kept in an

us a centre line for mounting purposes.

(Above, from top): A precast panel is lowered into position by a mobile crane during construction of the wall; members of the Concrete Units wall construction team during preparation of a pole foundation.

a final strength of 55-60MPa to prevent wire slippage.

PRECAST | ISSUE THREE | 2018

MEMBER LIST 44

PRODUCER MEMBERS A FICK SEMENT WERKE BK TEL: (022) 913 1921 PROVINCE/COUNTRY: WC PILLAR: PB AVENG INFRASET (PTY) LTD TEL: (011) 876 5100/872 1713/ (012) 652 0000 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BANZI TRADE 31 (PTY) LTD T/A BRICKIT TEL: (011) 023 6708 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BETA TILES (PVT) LTD TEL: (263) 433 3735 PROVINCE/COUNTRY: ZIM PILLAR: PB BOSUN BRICK BRITS (PTY) LTD TEL: (012) 250 1711 PROVINCE/COUNTRY: NW PILLAR: PB/PI BOSUN BRICK MIDRAND (PTY) LTD TEL: (011) 310 1176 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI BOSUN BRICK PORT ELIZABETH (PTY) LTD TEL: (041) 405 0100 PROVINCE/COUNTRY: EC PILLAR: PB/PI C.E.L. PAVING PRODUCTS (PTY) LTD TEL: (021) 905 5998 PROVINCE/COUNTRY: WC PILLAR: PI CEM BRICK MANUFACTURERS (PTY) LTD TEL: (051) 433 4479 PROVINCE/COUNTRY: FREE STATE PILLAR: PB/PI CEMBLOCKS (PTY) LTD TEL: (014) 538 0311 PROVINCE/COUNTRY: NW PILLAR: PB/PI CIVILWORKS (PTY) LTD REAL TIME INVESTMENTS TEL: (011) 903 7023 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CONCRETE UNITS (PTY) LTD TEL: (021) 386 1923 PROVINCE/COUNTRY: WC PILLAR: PB/PI CONCRETE UNITS (PTY) LTD TEL: (016) 362 2236 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CONFRAMAT (PTY) LTD TEL: (0861) 33 5599 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI CORESLAB (PTY) LTD TEL: (087) 232 2462 PROVINCE/COUNTRY: LIMPOPO PILLAR: PB/PI COROBRIK (PTY) LTD TEL: (031) 560 3111 PROVINCE/COUNTRY: KZN PILLAR: PI DERANCO PRECAST (PTY) LTD TEL: (041) 463 3338 PROVINCE/COUNTRY: EC PILLAR: PB/PI EAGLE ROOF TILES (PTY) LTD TEL: (044) 874 0290 PROVINCE/COUNTRY: WC PILLAR: PB ECHO FLOORS (PTY) LTD TEL: (011) 668 1900

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TECHNICRETE (PTY) LTD TEL: (011) 672 1425/670 7600 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI TOPFLOOR CONCRETE (PTY) LTD TEL: (021) 951 7700 PROVINCE/COUNTRY: WC PILLAR: PB VANSTONE PRECAST (PTY) LTD TEL: (012) 541 2056/1808 PROVINCE/COUNTRY: GAUT PILLAR: PB/PI

CIVILPRO ENGINEERING SOLUTIONS (PT Y) LTD TEL: 083 226 2567 PROVINCE/COUNTRY: JHB

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BIRKENMAYER H (PT Y) LTD TEL: (011) 970 3880 PROVINCE/COUNTRY: GAUT

MVA BRICKS CC TEL: (012) 386 0050 PROVINCE/COUNTRY: GAUT PILLAR: PI

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ASSOCIATE MEMBERS

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CONCRETE SOCIET Y OF SOUTHERN AFRICA TEL: (012) 348 5305 PROVINCE/COUNTRY: PTA CPI CONCRETE PLANT INTERNATIONAL TEL: (02236) 962390 PROVINCE/COUNTRY: GERMANY ILIFA AFRICA ENGINEERS (PT Y) LTD TEL: (012) 362 1473 PROVINCE/COUNTRY: PTA JC PAVING CONSULTING TEL: (011) 431 0727 PROVINCE/COUNTRY: JHB SARMA TEL: (011) 315 0300 PROVINCE/COUNTRY: JHB SEKHUKHUNE & ASSOCIATES TEL: (012) 346 1945 PROVINCE/COUNTRY: PTA TACO VOOGT CONSULTING ENGINEER TEL: (012) 669 0125 PROVINCE/COUNTRY: PTA YOUNG & SATHARIA CONSULTING CIVIL ENGINEERS TEL: (031) 207 7252 PROVINCE/COUNTRY: KZN CONTRACTOR MEMBERS BUFFALO RETAINING WALLS CC TEL: (016) 366 1801 PROVINCE/COUNTRY: GAUT DECORTON RETAINING SYSTEMS (PT Y) LTD TEL: (021) 875 5155 PROVINCE/COUNTRY: WC FRICTION RETAINING STRUCTURES (PT Y) LTD TEL: (011) 608 4321 PROVINCE/COUNTRY: GAUT POWERGATE CONSTRUCTION CC TEL: 071 603 5070 PROVINCE/COUNTRY: GAUT VALCAL INTERNATIONAL EXPORT CC TEL: (011) 867 2471 PROVINCE/COUNTRY: GAUT CEMENT MEMBERS

QUANGONG MACHINES CO LTD TEL: +865 958 679 9557 PROVINCE/COUNTRY: CHINA

AFRISAM SOUTH AFRICA (PT Y) LTD TEL: (011) 670 5500/5752/5972 PROVINCE/COUNTRY: GAUT

SIKA SOUTH AFRICA (PT Y) LTD TEL: (031) 792 6500 PROVINCE/COUNTRY: KZN

PPC LTD TEL: (011) 386 9000/9091/626 3150 PROVINCE/COUNTRY: GAUT

TECHMATIK S.A. TEL: (0048) 608 422 300 PROVINCE/COUNTRY: POLAND

SEPHAKU CEMENT (PT Y) LTD TEL: (012) 684 6300 PROVINCE/COUNTRY: GAUT

PLEASE NOTE: The above member list was correct at the time of going to print.

If your details have changed, please contact Rita at the CMA offices on tel: (011) 805 6742.

PI – Precast Infrastructure PB – Precast Building

PRECAST | ISSUE THREE | 2018