Precast • Issue 1 • 2022 by Isikhova Media

CONCRETE MANUFACTURING & CONSTRUCTION ISSUE 1 2022

R49,00

PRECAST

IN THIS ISSUE: Twinstar Precast: a look inside SANRAL Projects' Opportunities The source of your cement

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A LOT OF INNOVATION. EVEN MORE DEDICATION. QUALITY CEMENT. WHAT GOES INTO IT MATTERS.

Our range of high quality cement is designed for specialised applications where early strength is required. The fine-particle mineral components mean our cement offers improved durability and a superior quality concrete. When you’re putting everything into delivering a quality product, you need quality cement that delivers every time. Ask for AfriSam.

www.afrisam.com

Creating Concrete Possibilities

FROM THE PUBLISHERS OF PRECAST MAGAZINE

COMING IN THE

APRIL ISSUE Heavy equipment Renovations and restorations: focus on concrete Modular housing systems Bricks and paving Heavy equipment: excavators, bulldozers, backhoes Walls and floors Occupational Health & Safety: Covid 19/infectious diseases MBA North

@SouthAfricanBuilder

For all brand marketing and advertising contact Jenny Justus on 083 450 6052 / 011 883 4627 or jenny@isikhova.co.za

| CONTENTS |

Editor’s NOTE The impact of burning fossil fuels has officially reached deadly levels and a massive iceberg from Antarctica was making news for its release of 152 billion tonnes of water into our oceans over the last weeks of January. It joins the now 15 million cubic tonnes of water released into our oceans every single day. So it really is hats off to PPC for its construction of alternative power generators now underway in Zimbabwe. It began construction in January, with15MW going towards powering the clinker establishment, and the rest will be fed into the national grid. Precast will keep you updated on all developments and possible alternatives for your procurement and production needs, as the truly the race is now truly on. No looking back. Precast has been a good solution for a long while and will continue along this path as it transform into a zero emissions industry.

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| CONTENTS |

COVER STORY Twinstar Precast – a look behind the curtain

PRECAST R49,00

CONCRETE MANUFACTURING & CONSTRUCTION ISSUE 1 2022

INDUSTRY NEWS 6

The people of WSP SA

Home builders’ course

Local winners with surprising designs

10 2Roads acquires stake in AWT

IN THIS ISSUE:

11 Eskom generates interest for the next generation

Twinstar Precast; a look inside SANRAL Projects' Opportunities

12 Musina project benefits from new plasticiser

PRODUCTS

The source of your cement

ON THE COVER

14 Concrete roads – from kerbs to surface 16 The essence of your product starts at source

GLOBAL INNOVATION

Twinstar Precast is truly a one-of-a kind company. Quality, bespoke precast concrete pieces, elements and parts have all taken on a life of their own, through development, planning, creation, delivery and assembly. PRECAST is independently published

18 Building the future – driven by Covid-19

by Isikhova Media (Pty) Ltd 10th Floor, Metal Box, 25 Owl Street, Milpark, South Africa Tel: +27 (11) 883 4627 www.isikhova.co.za

PROJECTS

Pubishing director/Editor-in-chief: Jason Aarons

20 A mix of concrete for MeerKAT extension 22 National project updates

Tel: +27 (11) 883 4627 E-mail: jason@isikhova.co.za Editor: Nicholas McDiarmid

26 State-of-the-art concrete repair 28 Corobrik Student Architect Awards

Tel: 067 672 2503 E-mail: nicholas@isikhova.co.za Director of brand strategy: Jenny Justus

TECHNICAL

Tel: +27 (11) 883 4627 E-mail: jenny@isikhova.co.za

31 Five crucial factors for cost-efficient developments The views and statements expressed in this publication are not necessarily those of the editor or the publishers and neither the publishers nor the editor 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© 2022. 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.

Operations director: Thuli Majola Tel: +27 (11) 883 4627 E-mail: thuli@isikhova.co.za Creative director: Joanne Brook E-mail: joanne@isikhova.co.za Managing director: Imraan Mahomed Tel: +27 (11) 883 4627 E-mail: imraan@isikhova.co.za

Find us online

@precastmag

Copy Editor: Anne Phillips savvy thinkers smart doers together people

Media sales: Tel: +27 (11) 883 4627 / 083 450 6052 / 072 383 3203

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| COVER STORY |

TWINSTAR PRECAST – Twinstar Precast is without doubt the first choice for all seeking custom designs or bespoke concrete projects. Established 26 years ago, Annemerie Coetzee has achieved, along with her committed team, a rare success in a tough market. Twinstar Precast is relied upon

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not only for custom projects, but the company’s imprinting and mass production capabilities, making it the only choice for many local councils and municipalities. It is fair to say that if you have enjoyed the benefits of local infrastructure, you have had a Twinstar moment. From kerb-inlets to manhole covers, wind farm infrastructure and bicycle racks, the company does it all… and to an unfailingly high standard. Precast magazine shares a very proud partnership with Twinstar Precast and it is a privilege to take you, our readers, behind the scenes, for a rare view of the company – behind the curtain.

(Left): It starts with a mix. Getting the precise mix for each project is based purely on the necessary outcomes. Twinstar is expert at precast mixes, from light products to heavy industrial slabs, and has a network of suppliers second to none.

| COVER STORY |

A LOOK BEHIND THE CURTAIN (Below): Twinstar Precast is equally adept at producing bulk precast products, from slabs to manhole covers and kerb-inlets. The company is based in Olifantsfontein and takes orders nationwide. Owner and director Coetzee says she will continue to resist enlarging Twinstar’s campus in order to maintain the necessary controls over quality and output. “No piece moves from my yard without my say-so,” she says, with a smile.

(Left): The craft of mould-building – in this case, a wooden one – is at the heart of precast manufacturing. For the kind of bespoke products in which Twinstar uniquely specialises, it takes a highly experienced set of eyes to know just the right corners to cut, as well as the shapes and perspectives needed to produce the perfect mould for a project.

These moulds are not replicable and the craftsmanship of Twinstar Precast represents an incalculable investment in time, money, trial and error. Developing a bespoke precast manufacturing business is not for the faint-hearted, yet Twinstar provides an almost unique service in the South African precast concrete industry.

(Right): Twinstar Precast has the personnel and skills to assist with local deliveries and assembly. One of the company’s fundamental aims is to offer value. By creating bespoke products in pieces for later assembly, the company can shave thousands of rands off the cost an overall project. These savings are made at the planning stage and are factored in across the project, from first consultation to delivery.

Twinstar Precast (Pty) Ltd

Twinstar Precast is truly a one-of-a kind company. Quality, bespoke precast concrete pieces, elements and parts have all taken on a life of their own, from development to planning, creation, delivery and assembly. Whatever your needs, contact Twinstar Precast first.

Tel: +27 (12) 670 9083 or 082 552 1915 E-mail: info@twinstar.co.za Website: www.twinstar.co.za

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| INDUSTRY NEWS |

THE PEOPLE OF WSP SA – IN IT FOR THE INFRASTRUCTURE WSP has announced the appointment of Paul Grota as its new MD for SA. Grota joined WSP in November 2014, as part of the Parsons Brinckerhoff acquisition, where he was head of operations for Africa. After the acquisition, he led the integration of WSP and Parsons Brinckerhoff in Africa and has, until recently, been the COO for the Power, Industry and Property business units. “I’m very excited to be taking over from Mathieu du Plooy, who’s moved to the UK to take up the role of COO for the UK and SA, after leading our African business for 12 years,” he says.

(Above, from top): Paul Grota, Michelle Jackson and Mathieu du Plooy.

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Creating sustainable solutions Grota believes WSP is moving into a new phase of growth in Africa. “We ended last year on a high, with some significant new projects and the news that both WSP Group Africa and Golder Associates Africa had achieved Level 1 BBBEE status, solidifying our position as a preferential partner to local clients and partners,” he says. “This is an exciting time to be taking on this role and I’m confident that we can continue developing creative, comprehensive and sustainable engineering solutions for a future in which society can thrive.” “Paul's understanding of our clients and passion for developing our people and culture will help WSP capitalise on the many opportunities that exist within the African market,” says Du Plooy. “I look forward to working with him through the strong relationship between our UK and African businesses.” As Grota moves into his new role, Michelle Jackson joined the organisation from Turner & Townsend as MD for Property and Buildings on 1 February 2022. Most recent ly, she led Turner & Townsend’s Data Centre business, having also led a variety of projects and business units across sectors, including Property, Infrastructure, Oil and Gas and Mining. Jackson also supported the development and management of Turner &

Townsend’s regional West African business, as well as successfully managing projects in Mozambique, Nigeria and Ghana. Infrastructure, community and environment With this new leadership in place, WSP remains focused on playing its part in Africa’s sustainable development. “There’s no denying the massive infrastructure needs in Africa,” says Grota. “To keep up with the demands of rapid population growth and urbanisation, and to support existing industries while helping to establish new ones, infrastructure remains a key contributor to economic activity and social development needs. “We see ourselves as having an important role to play in delivering much-needed infrastructure projects. Our purpose of preparing our communities and environment for the future is underpinned by how we see ourselves as a link between, and providing support for, the effective delivery of these aspirations, policies and project.” WSP also remains committed to helping its clients take up opportunities to leapfrog into more sustainable technology – such as renewable energy – and keep environmental, sustainability and governance (ESG) matters top of mind, as these are adopted. “We’ve always worked with our clients to remain future-focused, even as we design in the now, and bring our expertise in environmental and sustainability matters to bear when we advise our clients on how to ensure that their projects are future-ready and sustainable,” says Grota. Promoting STEM throughout the continent In support of these aspirations and projects, WSP remains a proud STEM employer and advocate for advancing upcoming generations of talented engineers, scientists and ESG experts. With acknowledgement to Rod Sweet, Global Construction Review

| INDUSTRY NEWS |

“If there’s an area still commonly neglected by the home builders, it’s curing.”

SCT’S HOME BUILDERS’ COURSE As the construction industry gradually gains post-pandemic momentum, there has been steady support for the Mortars, Plasters, Screeds and Masonry – SCT 12 online training course for home builders offered by the School of Concrete Technology (SCT). Matthews Magwaza, lecturer at the school – which is part of Cement & Concrete SA – says the SCT 12 course was originally developed to assist National Home Builders’ Registration Council (NHBRC) inspectors interpret and assess the requirements of the NHBRC Home Builders’ Manual. South African builders must enrol new homes with the council before construction starts to protect housing consumers’ rights. Magwaza says builders from diverse parts of SA, including the Eastern Cape and KZN, have recently completed the one-day course, which included a laboratory session in the form of a virtual presentation, video recording and description. The course is currently presented only online, but should lockdown regulations allow, there are plans to resume live classes in Midrand, Cape Town and Durban later this year. The syllabus for Mortars, Plasters, Screeds and Masonry – SCT 12 includes: • Factors that affect the strength of concrete.

• The role and selection of cement, sand, stone and water in the production of concrete. • Mix proportions for concrete for foundations and floors. • Floor screeds. • Properties of mortar and plaster. • Sand-cement mixes. • Slump and cube tests for concrete. • The vital role of proper curing. • Concrete and clay masonry: expansion and shrinkage. • Cavity and block walls. • The importance of movement joints. • Common causes of cracking. • Receiving and storage of materials. Magwaza says the SCT has generally been impressed by the students’ enthusiasm to learn more about concrete and provide satisfactory, sustainable homes. “If there’s an area still commonly neglected by the home builders, it’s curing. There still seems to be a great deal of ignorance about proper curing’s major inf luence on concrete durability, strength, wearresistance and stability. Even concrete that’s been specified, matched, mixed, placed and finished could still fail if the project isn’t completed with proper curing,” he says.

The SCT will present several SCT 12 courses this year. The first three (which are likely to be held online) will be on 24 Februar y, 31 March and 19 May. Live classes are provisionally planned for Durban and Cape Town in June and August, respectively, should lockdown regulations be relaxed. (Above): Matthews Magwaza, lecturer at the School of Concrete Technolog y (SCT).

For further information about locations and modes of instruction, e-mail Rennisha Sewnarain at: rennisha.sewnarain@cemson-sa.org.za.

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| INDUSTRY NEWS |

Electrocomponents plc (LSE: ECM), a global omni-channel provider of product and service solutions, has announced the winners of the People.Planet.Product student design challenge launched early last year in collaboration with the company’s first global social enterprise partner, The Washing Machine Project, a humanitarian initiative dedicated to alleviating the burden of hand-washing in low-income and displaced communities through innovative product design and distribution. The three winning designs, which were selected from six global f inalists, were Kai Goodall, Team Scentury and Joseph Baker, who came first, second and third respectively. The challenge tasked student members of the DesignSpark engineering community to apply original thinking and practical skills to the ongoing development of The Washing Machine Project’s f irst water-sav ing, of f-g r id manual crank-handle washing machine, the Divya. Entries were invited in three different focus areas: People (empowering people to use the Divya by improving the technology or implementation of the design); Planet (filtering out greywater or microplastics) and Product (encouraging better posture through changes in weight – eg, portability). South African winner Kai Goodall’s “Pedal ’n Spin” design is a foot-cranked washing machine that rotates easily using a combination of the principle of a treadle system and pedal system. It is a pedalpowered, connected, rod-driven rotating drum washing machine system which is purely mechanical in nature. It improves the user’s posture, ease of use and sustainability of the current Divya washing machine, allowing longer-term adoption, improved hygiene and increased rotation efficiency with a huge mechanical advantage. Goodall, currently a Master’s student in electrical engineering at the University of Cape Town (UCT), mentioned that it was moving to see his sustainable and userfriendly washing machine design selected as one of the winners of the global contest.

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PEOPLE.PLANET.PRODUCT – LOCAL WINNERS WITH SURPRISING DESIGNS Innovative winning solutions will enhance the design and accessibility of the Divya manual crank washing machine developed by The Washing Machine Project, helping to improve lives “My UCT supervisor and chairperson of the Institute of Electrical & Electronics Eng ineers SA, Dr Dav id Oyedokun, i n s pi red me to compete i n t he R S Components Student Design Challenge. Being the sole finalist from Africa in the competition and winning first prize was a special recognition of my invention and motivated me to take my passion to new frontiers and hopefully inspire more young people to use engineering as a tool for their progression,” he said. All six finalists, including Team Oro ( Product), Team Neolithic ( Product)

and Ketki Dave (Planet), pitched their designs at a live virtual event to a panel of judges from leading industrial and humanitarian organisations which share the goal of helping to improve lives. Mike England, chief operating off icer of Electrocomponents, opened the finals w it h a speech about t he compa ny’s c om m it ment to “ M a k i n g A m a z i n g Things Happen for a Better World” t hrough socia l impact par t ners and education programmes. Yewande Akinola MBE, Ambassador for Clean Growth and Infrastructure, UK, delivered a

keynote address at the event, emphasising the importance of sustainability and innovation for the world. Panel judge Navjot Sawhney, founder of The Washing Machine Project, commented: “With the Electrocomponents Grassroots team, The Washing Machine Project devised the People.Planet.Product student design challenge to inspire students with STEM backgrounds to get involved in our humanitarian initiative. These are the scientists, engineers and mathematicians of tomorrow and the amazing quality of designs we’ve seen through this challenge is really heartwarming and proof that the younger generation are fully engaged in playing their part in a sustainable future.” Fellow judge Mike Bray, VP: innovation and DesignSpark at Electrocomponents, which hosted the challenge, said: “The Washing Machine Project is a great engineering initiative to help improve people’s lives and combining it with the inspirational ideas of student engineers through our DesignSpark community, we have the ability to work together to truly make a massive difference to people around the world.” Providing active support for the People.Planet.Product challenge and completing the line-up of distinguished judges were Bjoern Klaas, CEO: EMEA region, Protolabs, Clare Larkspur, head of product management: Elvie, Simon Wells, VP: engineering, Shark Ninja and Eleonora Gatti, innovation portfolio manager (WASH + Climate Change), Unicef. Each of the three winners received £1 000 in RS products or a cash equivalent to support their prototype development, plus access to a business mentor and a knowledge session with Sawhney. Goodall recently joined forces with Forest Creations, a sustainable woodworking company, to create four more improved Pedal ’n Spin units for donation and field testing in Cape Town townships, with a view to more sustained manufacturing and distribution. “I welcome collaboration and financial support in my bid to roll out many more of these units, to provide a healthy and sustainable innovation to those in need,” he said.

“We have the ability to work together to truly make a massive difference to people around the world.” For more information, collaboration or updates on Goodall's Pedal ’n Spin washing machine innovation, e-mail: kaigoodall@gmail.com, connect on LinkedIn: Kai Goodall or follow him on Instagram: @kaigoodall.

| INDUSTRY NEWS |

2Roads has expanded its ownership and participation in the process f low value chain by acquiring a 51% stake in Applied Welding Technology (AWT), a specialist welding and machining company capable of welding and machining a wide variety of metals, including basic carbon steels, low-a l loy steels, sta in less steels and aluminium. The official announcement was made at the 2Roads head of f ice in Illovo, Johannesburg, on 13 January this year. AWT is a natural fit into the 2Roads Group’s portfolio, as it expands its current ser vice of fering to the industr y. The acquisition is also in line with the group’s strategy of investing in businesses that deliver superior earnings and dividend growth over the long term. “AWT is a bolt-on acquisition in line with 2Roads’ process f low value chain approach. T he acqu isit ion ex pa nd s the service offering to various clients, especially within the high-pressure and high-temperature sector. It also positions 2Roads as one of the largest specialised welding and engineering f irms in the country,” says Kagisho Bapela, executive for strategy, mergers and acquisitions at the 2Roads Group. Bapela adds that the end goal is to offer a comprehensive asset integrity management of products and services to target clients. AWT adds to the current service offering and

2ROADS ACQUIRES STAKE IN APPLIED WELDING TECHNOLOGY complements existing products and services. In addition, the acquisition enables the group to establish a fully-fledged training centre that will offer skills development and vocational training, as the welding techniques performed by AWT are unique and in high demand.

Founded in 1987 by Johnny Hattingh and subsequently bought in 2005 by Ross and June Tudhope, AWT is an essential services provider, offering specialised welding for turbine valve components and rebuilding parts machined to tight tolerances. Only a handful of companies in SA have this capability. “The fit of AWT in the structure of 2Roads is an exciting development for the future growth of the company. The combination of the 2Roads Group of companies with the markets AWT serves, is a powerful one and will substantially extend the capabilities of the group, as well as providing synergies within it,” says Ross Tudhope, CEO of AWT.

(Above): Specialised technologies and techniques at work on specialised steel equipment. (Left): 2Roads conducts training from its premises, ensuring the handing on of specialised welding techniques.

“The acquisition enables the group to establish a fully-fledged training centre that will offer skills development and vocational training, as the welding techniques performed by AWT are unique and in high demand.” 10

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| INDUSTRY NEWS |

ESKOM GENERATES INTEREST FOR THE NEXT GENERATION “Winning the Simama-Ranta competition will enable us to invest in much-needed resources, create jobs and continue giving back to our community, something the club holds very dear,” said Enett Mokoena, educator at Lethulwazi Comprehensive School, upon its announcement as Gauteng’s provincial winner of Eskom’s 2021 SimamaRanta High School Entrepreneurship Competition. The competition has been running since 2010, promoting entrepreneurship among high school pupils throughout South Africa with enterprise clubs. Lethulwazi Comprehensive School’s Vosloorus-based enterprise club, Lethulwazi Pioneers, comprises 53 pupils from Grades 8 -11 and has operated since 2019. Although it did not meet the competition’s criteria to participate in 2019, the club was inspired to participate in the 2021 leg of the competition, after attending the 2019 awards ceremony and went on to win at its first attempt. It grows its own vegetable garden, does beadwork, sewing, nail and hair-grooming, as well as providing ice and laundry services. The prize money will be used to purchase beading equipment, for tuckshop operations and for a vegetable garden project. “The club’s vision and approach resonate with us. Eskom applauds the club’s efforts to promote an entrepreneurial mindset among pupils, such as the Entrepreneurship Day it hosted in 2019. Such efforts are aligned to what we endeavour to achieve through the Simama-Ranta programme,” said Eskom Development Foundation CEO Cecil Ramonotsi. Rutasetjhaba Secondary School from Evaton was the first runner-up. Its fiveyear-old Risk-Takers Yes Club specialises in manufacturing school bags, repairing tables and creating beadwork. “The club started off with two pupils providing a gift-wrapping service, designing book covers using recycled paper and doing beadwork. Over the years we’ve grown to 60 members, coming second in the 2017 provincial Simama-Ranta competition and being the provincial winner of the SAGE

SA competition,” said club leader and teacher Victries Radebe. The school plans to use the prize money to install wall heaters in classrooms and to support a local home housing children with disabilities. Lakeside Secondar y School’s The Lakers Enterprise Club from Palm Springs came third in Gauteng. The club uses recycled material to produce functional decorative pieces, grow vegetables, sell snacks and design bookmarks. Kholosa Plaatjie, educator and club co-ordinator at the school, said: “Our community’s underprivileged and some households barely manage two meals a day. This programme has empowered pupils to use their talents to become financially independent and improve the lives of their families and community. “For a country to grow its economy, it needs as many successful small businesses in as wide a range of activities as possible. This is where Eskom’s Simama-Ranta competition is so important, reaching far and wide across our country into schools and opening doors for many to better their own lives and the lives of those around them. “To all our young people in Gauteng who seized the opportunity to participate in the 2020 Simama-Ranta High School E nt repreneu r sh ip C ompet it ion, we congratulate you,” said Nthato Minyuku, Eskom’s group executive for government and regulatory affairs.

(Above): Lethulwazi Pioneers club member Sebenzile Ntuli.

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| INDUSTRY NEWS |

MUSINA BRIDGE PROJECT GETS BENEFITS OF NEW PLASTICISER A n advanced new-generation waterreducing plasticiser – CHRYSO® Plast Omega 174 – has notched up another successful application. The product has been used in the concrete mixes for the new Nancefield Bridge, which forms part of Sanral’s Musina Ring Road Project in Limpopo Province. The R640 million project, which allows the N1 to by pass Musina, is due for completion in the second quarter of 2022. Less water in the palms of your hands The N1 will pass under the 77m-long br idge. Sanra l wanted v isitors from Zimbabwe and SA travelling on the N1 to experience a feeling of being welcomed, so the bridge features a prominent pair of 13m-high “hands” – which are essentially extensions of the centre piers – expressing this message. The deck is supported by the columns of the hands and the bridge is aesthetically held on their palms. One of the main reasons CHRYSO® Plast Omega 174 plasticiser was selected for the project was that it countered the problem of slump loss. Due to the

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available aggregate, ambient temperature and distance from site, the plasticiser was tested and found to be the most suitable admixture. Mix designs were conducted by Matthew Barker, general manager at CHRYSO for technical, mining and export at the company’s Centre of Excellence.

(Above, from top): The deck is supported by the columns of the hands; the specially designed balustrades follow the angle of the fingers and the prominent pair of 13m-high hands was designed to give visitors a welcoming experience.

Temperature control Another challenge was presented by the hot temperatures – up to 45°C – typical of Musina in summer. The concrete temperature needed to be kept under 30°C to prevent thermal cracking. This was achieved by a combination of measures, including ensuring that the concrete was under shade and cooling it with sprayers, for which a cooling tower was installed to keep the water cool. CHRYSO® Plast Omega 174 allowed the mix designs to be optimised, affording more open time on the fresh-mix concrete. CHRYSO® Plast Omega 174 was the primary product supplied for the Nancefield bridge and was used for the bridge decks, balustrades and piers with hands. Just over 3 000m 3 was required for the concrete of the bridge. The use of

| INDUSTRY NEWS |

CHRYSO admixtures for the mix design was implemented by Jacques Marais, senior plant foreman for the production of concrete at OMV, part of the Raubex Group. The consulting engineers for the project were KBK Engineers. C H RY S O S o u t h e r n A f r i c a’s personalised technical service offering and logistics were the deciding factor in OMV using CHRYSO as the main admixture supplier for the project. Extended workability According to Ben Myburg, technical c on s u lt a nt at C H RY S O S out her n Africa: “CHRYSO® Plast Omega 174 is a multi-dose admixture which allows concrete to exhibit extended workability characteristics. It improves the cohesion and lowers the viscosity of a concrete mix, which results in improved homogeneity and compaction, allowing for superior off-shutter finishes that eliminate the risk of repairs. By reducing the need for extra water, it increases the durability of concrete by lessening permeability.”

CHRYSO® Plast Omega 174 is part of the wider CHRYSO Plast Omega range. Products in the range are ideal for applications such as underwater concrete, pumped concrete, large pours and flowing concrete. (Above): The Nancefield Bridge project in progress. (Right): CHRYSO® Plast Omega 174 allowed the mix designs to be optimised, affording more open time on the fresh-mix concrete.

| PRODUCTS |

FROM KERBS TO SURFACE,

IT’S ALL CONCRETE With gravel roads causing horrific accidents, Bryan Perrie, CEO of Cement & Concrete SA, says there is substantial scope for more low-volume concrete roads to increase road safety in the country. Joined in-situ (poured into place) concrete can be used to construct economical and durable rural low-traff ic volume roads which can be used as access roads or farmto-market pavements, designed to handle speeds of up to 90km/h in unpopulated areas and up to 65km/h speeds as low-volume city roads. Protections and maintenance “ I n joi nted low-volume roads, load transfer by aggregate interlock is generally adequate. When close-joint spacings are used, reinforcing steel isn’t needed, but reinforcing mesh should be used in oddshaped panels and for those with manholes and other openings,” says Perrie. Moreover, concrete roads have a relatively maintenance-free life of up to and (Above right): Cutting concrete requires machinery, skill and patience. (Above from top): Manhole covers are a safety feature which require highly skilled, mass-production capabilities and concrete. Kerbs are in high demand.

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beyond 30 years, depending on the traffic load. Maintenance of concrete roads mostly involves re-sealing joints and carrying out minor repairs every 10-15 years. Joi nt s a r e pr ov ide d i n c onc r et e pavements to limit stresses and control cr ac k i ng resu lt i ng f rom rest r a i ned contraction and the effects of restrained warping and traff ic loads, to facilitate construction and level control and to accommodate movements. Joints must provide adequate load transfer to ensure adequate performance of the pavement. This can be achieved by the use of sawn construction joints at relatively close spacings and keyways at construction joints. Materials, materials, materials Perrie says the correct choice of materials is vital for the construction of durable lowvolume concrete roads. Cement should be CEM I, CEM Il A 42.5 or higher, complying with the requirements of SANS 50197. Where extenders (ground granulated blast furnace slag or fly ash) are used, these should comply with the requirements of SANS 50450 and SANS 55167. When extenders are used, allowances should be made in the concrete mix design,

“Concrete roads have a relatively maintenancefree life of up to and beyond, 30 years, depending on the traffic load.” particularly with regard to early strength under field conditions to ensure timeous cutting of joints. Curing methods and regimes may also have to be improved, especially in inclement weather. “Satisfactory aggregates for use in low-volume concrete roads and streets are those that comply generally with SANS 1083 Aggregates for Concrete. In addition, the fine aggregate should possess an acid insolubility of at least 40% for skidresistance. This requirement is satisfied when quartzose sand is used. Calcareous sands, such as dolomite, are acceptable if blended with at least 40% of a suitable quartzose sand,” explains Perrie. He adds that the mixing agent should be clean, potable water or other water free of substances that may impair the strength,

| PRODUCTS |

setting time or durability of the concrete, or of any reinforcement. “In certain circumstances, the properties of the concrete may be improved by the proper use of chemical admixtures, such as water-reducing admixtures. Its use should be based on an evaluation of its effects on specif ic materials and combinations of materials, including strength development, particularly within the first 24 hours after concrete placing,” says Perrie. This is because certain admixtures may retard the setting and strength development of the concrete, thereby delaying joint-sawing and increasing the risk of random cracking. “The concrete should be strong enough to ensure a hard, durable, skid-resistant surface and to accommodate the tensile stresses resulting from shrinkage, warping and loading. This requirement is satisfied by specifying a flexural strength or modulus of rupture (third-point loading, determined in accordance with SANS 8 64) of not less than 4,5MPa at 28 days,” he explains. Drainage Proper drainage is also essential to prolong the life-span of low-volume concrete pavements. Experience has shown that inadequate drainage is probably responsible for more pavement distress in southern Africa than inadequate structural or material design. The design philosophy is to provide effective drainage so that the pavement structure is prevented from becoming saturated.

Both the discharge of surface run-off and the control of sub-surface water need to be considered. Consequently, effective drainage is essential for good pavement performance and is assumed in structural design. “ Su r face r u n- of f c a n be controlled in the rural environment by constructing suf f icient ly w ide side drains, which discharge at sufficiently frequent intervals into the adjacent land, or into culverts that carry the water to suitable discharge points,” says Perrie. “In the urban environment, it can be controlled with the use of kerb and channel systems discharging into inlets into a stormwater pipe system. To reduce costs for low-volume roads, consideration should be given to dishing the road surface and carrying the stormwater on it to suitable discharge points.” (Above): Brian Perrie, CEO of Cement & Concrete SA.

| PRODUCTS |

THE ESSENCE OF YOUR PRODUCT

STARTS AT SOURCE

With long-standing over-supply conditions in the cement sector, it is vital that South African cement producers, consumers and government alike continue to support responsible manufacturing practices. AfriSam cementitious executive Hannes Meyer highlights that the sector brings far more than just cementitious products to the market. As SA endures some of its most difficult economic times yet, the country should

recognise the importance of supporting responsible manufacturing practice in its cement sector. Meyer emphasises the strategic value – both economic and social – in an industry that generates this vital commodity. Benefits of beneficiation “A s t he ba c k b one of ou r n at ion a l infrastructure, cement’s also a product that represents our highest aspirations

of mineral benef iciation,” says Meyer. “To produce this valuable resource, we must start with mining our own deposits. We should then process the ingredients through complex technologies that demand considerable f inancial investment and expertise.” The range of products that result must form part of an intricate supply chain before arriving where it must be used, he says. Almost the entire value chain, however, is local – creating market demand and local job opportunities along the way. “In addition to the basic requirements of the cement business, SA’s cement producers are mineral rights-holders who must comply with mining regulations, which include social and labour plans,” he says. “Besides normal business legislation, we must go the extra mile to promote development in and around the communities where we operate.” Compliance for everyone Meyer points out that this is currently more difficult for cement producers than for miners of higher-value commodities, who are currently benefiting from buoyant prices set by global markets. In contrast, cement prices are determined by demand in the country’s building and construction sectors, where performance remains lacklustre. “Despite the challenges, local cement producers like AfriSam continue to meet compliance requirements, as these align with our underlying corporate commitment to the future of Africa and the planet,” says Meyer. Added to the industry’s responsibilities, he notes, is the growing pressure on all South African businesses to reduce carbon emissions in the interests of a low-carbon

(Left): An important part of local cement producers’ contribution is the skills and technolog y development which they continue to generate for the South African economy. (Above): Hannes Meyer, AfriSam cementitious executive.

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| PRODUCTS |

(Above): AfriSam promotes development in and around the communities where it operates.

future that responds to the growing dangers of climate change. As an energy-intensive sector, cement production is researching and applying various innovations to reduce its carbon footprint. The government’s recent carbon tax – which is payable by local producers – has created a further imbalance in the market that disadvantages local players, he points out. Strengthening a market under siege “With the wholesale import of cement from countries unencumbered by a carbon tax, there’s no level playing field for responsible local manufacturers who’re often undercut by imports not governed by our rules,” says Meyer. The danger of further weakening the South African base of responsible All South African businesses are under pressure to reduce their carbon emissions.

manufacturers, he adds, is that the country will need to rely mainly on its own internal capacity if it wants to generate inclusive and sustainable economic growth in future. With the government hoping to raise infrastructure expenditure, there must be strong local construction expertise and products to implement these projects. “An important part of local cement producers’ contribution is the skills and technology development which we continue to generate for the South African economy,” says Meyer. “We develop skills in local communities and opportunities for small black-owned businesses, as well as for women and youth in our supply chain. This is a core pillar of responsible manufacturing that the country should support and reward.”

| GLOBAL INNOVATION |

BUILDING THE FUTURE – DRIVEN BY COVID-19 By Monica Bennett, director of Thought Leadership, GI HUB The GI Hub recently launched its newest resource, Transfor mat ive Outcomes Through Infrastructure. Its purpose is to uncover the G20 priorities that underlie the US$3,2 trillion (ZAR48,66 trillion) of infrastructure investments announced postCovid-19 and to help direct future spending into areas that could yield the greatest possible benefits for people and the planet. With this resource, we are making available data that we collected collaboratively with G20 governments and sharing insights on how those governments are using infrastructure to achieve transformative outcomes after the pandemic. This information will help governments, investors, multilateral development banks and project directors across the public and private sectors to develop future infra-

structure packages with transformative outcomes in mind. The initiative has revealed itself to be even more timely and relevant than expected, especially in the context of the various national pledges to net zero and the ever-growing attention on digitalisation, connectivity, circularity and affordability in infrastructure. An unprecedented scale of opportunity Why did we need this resource? Because the scale of opportunity after Covid-19 is almost unprecedented – and so is the need. The infrastructure landscape changed rapidly after the virus f irst struck and governments needed an immediate reference point to enable better decision-making. An unprecedented level of fiscal stimulus was deployed after Covid-19 started: indeed, in April 2021, the International Fund’s Fiscal Monitor reported a total of US$17 trillion of key fiscal measures for the G20

“Between February 2020 and August 2021, G20 governments announced US$3,2 trillion in infrastructure as a stimulus, the equivalent of 3,2% of GDP across G20 member and guest economies.” 18

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(including member and guest economies) since Januar y 2020. This represents approximately 20% of the G20 GDP and has resulted in a reduced fiscal space which has forced governments to divert their budgets into urgent areas such as healthcare and social protection. As a result, infrastructure as a stimulus was slow to emerge in the early days of the pandemic. However, an analysis of the G20’s stimulus packages over the past 18 months has demonstrated substantial commitment by G20 governments to infrastructure investments for Covid-19 recovery. Global stimulus Bet ween Februar y 2020 and Aug ust 2021, G20 gover nment s a nnounced US$3,2 trillion in infrastructure as a stimulus, the equivalent of 3,2% of GDP across G20 member and guest economies. This is substantial compared with the total stimulus deployed during the global financial crisis of 2007/8, which was US$2 trillion (roughly 1,4% of GDP). If this infrastructure as a stimulus is spent in the next two years, it would be a 45% increase in yearly infrastructure investment compared with 2019 levels. The boost to infrastructure investment is sorely needed. The pandemic increased inequalities among vulnerable people and

highlighted gaps in access to financing and services in every country. Simultaneously, the climate crisis is still at “code red”. It remains urgent for the sector to confront its contributions to climate change and embrace the positive impact by adopting more green and circular infrastructure. However, investment alone is an incomplete solution. Governments cannot afford to continually increase spending. In April 2021, public debt levels across G20 economies were 50-100% higher than they were following the global financial crisis. In thinking about transformative outcomes through infrastructure, governments can leverage the private sector demand for environmental, social and governance outcomes to mobilise private investment in infrastructure. In this context, innovative financing and delivery models start to play a role in achieving transformation. From every vantage point, it is clear that we need to get as much as possible out of the unprecedented level of infrastructure as a stimulus. Getting the most from infrastructure The infrastructure sector needs to make a fundamental shift from built solutions that address singular problems to those that address multiple transformative outcomes. Transformative outcomes are those that have the greatest impacts on our most pressing global challenges, including the climate crisis, social inequality, adaptability and resilience. All infrastructure as a stimulus can create jobs and economic growth. A 2020 GI Hub study found that the economic multiplier for public investment (including infrastructure) was 1,5 times greater than the initial investment in two to five years – much higher than other forms of public spending. Targeting of transformative outcomes should, in addition to creating better social and environmental outcomes, result in an even greater economic multiplier and help close the infrastructure gap. For example, recent GI Hub analysis found that technological innovation could fill 60% of the infrastructure investment gap, if rolled out at scale. Transformative outcomes are achievable Achieving transformative outcomes is possible. Our Transformative Outcomes Through Infrastructure resource contains examples of infrastructure as stimulus packages in G20 countries that are targeting transformative outcomes, which can be used as templates to create stimulus packages or structure projects for transformative outcomes. We have also curated a library of reference documents that are full of ideas and guidance for targeted transformative outcomes through national and local infrastructure. All of these are underpinned by the InfraTracker, which shows data on how stimulus is being applied by country, sector, sub-sector and targeted outcomes. We encourage readers to explore the resource and contact us with questions or feedback, or to contribute or collaborate. We are also inviting collaboration with public- and privatesector organisations and individuals to extend our work and advance transformative outcomes through infrastructure. We welcome your ideas.

| PROJECTS |

The precursor to the trailblazing Square Kilometre Array (SKA) mid-frequency radio telescope project, the MeerKAT radio telescope is being further expanded with another 20 dishes. Concor was awarded the project to provide the civil engineering elements for the extension earlier this year and is now on site and busy with the construction of roads, dish foundations and other infrastructure.

Each dish foundation will have eight piles that are 7-11m deep.

An astronomical project C o n c or, t he l e a d i n g b l a c k- ow n e d construction company, in partnership with OptiPower, is building the foundations and infrastructure for 20 more dishes for the pioneering MeerKAT radio telescope. The SKA will be the world’s largest radio telescope and the MeerKAT project has already allowed astronomers to deliver unprecedented results. Its remote location in an arid area about 90km from the town of Carnarvon is ideal for its purpose, providing a “radio-controlled” backdrop for the mid-frequency array that enables the SKA’s work. According to Concor contracts manager Stephan Venter, the team commenced with the construction work on site in September 2021. Piling it on “With the piling rig on site, October saw our first piles drilled and concrete poured,” says Venter. “Soft soil and sandy conditions require that the 20 foundations are based on piles with a concrete cap. Each of these foundations has eight piles of 750mm diameter and 7-11m depth.” He highlights that precision is critical to the foundation construction, particularly the positioning of the bolt cage onto which each antenna pedestal is secured. These have to be accurate within fractions of a millimetre to avoid any deflection when the dish “looks” millions of light years into space. “In addition to the accuracy, the foundations must ensure that the antennae are able to resist the force of winds, especially as the dish has a wide surface area,” says Venter. “There’s also no room for any vibration of the dish.” The 1,7m-tall galvanised bolt cages – constructed to specifications locally – are carefully positioned on the blinding of the foundation cap before the rebar armature is

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A mix of concrete

FOR THE MEERKAT EXTENSION PROJECT

assembled, the shuttering installed and the concrete poured. After the pour, the top of the bolt cage extends from the foundation for securing the dish pedestal or tower. Pre-tests and modifications Among the specif ic challenges of this project is the strict requirement to limit any radio frequency interference (RFI) in the vicinity of the MeerKAT telescope array. The highly sensitive radio telescopic equipment is designed to detect extremely weak radio signals from astrophysical sources and can easily be damaged by RFI from vehicle electronics, cellular phones and a wide range of other tools

| PROJECTS |

(Above): Pre-fixed pile steel in the laydown area. (Right): Concor, in partnership with OptiPower, is building the foundations and infrastructure for 20 more dishes for the pioneering MeerKAT radio telescope.

and equipment. For this reason, Concor’s offices, workshops and laboratory are in Carnarvon and personnel must commute to and from the site each day. “We’ve tested and modif ied all our on-site equipment to comply with the RFI limitations,” says Venter. “This includes excavators, trucks, graders, compactors, telehandlers, water bowsers, tractor-loaderbackhoes and our specialised concrete batching truck.” Self-batching concrete trucks The Reimer concrete truck is a selfbatching unit chosen to do the work of a conventional batching plant, which in this instance was not justified by the relatively small volumes of concrete required. With 19mm aggregate and crusher dust transported from De Aar, cement from PPC and tested water from local boreholes, concrete can be mixed in the truck on each foundation platform. The 20 smaller, piled foundations each take 60m³ of concrete,

while the larger four foundations each consume 144m³. “We’re also employing a recycler on this project to prepare the wearing course layer for much of the 40km of gravel access roads,” says Venter. “This allows us to save water in this dry area, as the recycler introduces water into the layer and then closes it up – keeping the moisture in for longer.” The machine can cover long, straight sections of road efficiently, preparing the way for the grader to level the surface before final compaction. Concor will also excavate and fill 70km of trenching, for electrical and data cables to run from the antennae to the Karoo Array Processor Building. The project is due for completion by September 2022. (Above): The MeerKAT project is situated about 90km from Carnarvon, with its remote location in an arid area. (Photograph courtesy of the SA Radio Astronomy Observatory) (Above): Clearing for borrow pit 2 underway at the MeerKAT project.

“Among the specific challenges of this project is the strict requirement to limit any radio frequency interference (RFI) in the vicinity of the MeerKAT telescope array.” PRECAST | ISSUE ONE | 2022

| PROJECTS |

National project As Sanral unlocks its f low of projects, precast concrete suppliers have a host of new opportunities to explore. N3 national road upgrade projects are set to bring significant benefits to KwaZulu-Natal’s economy and road-users. Infrastructure Investment Plan The Infrastructure Investment Plan is a credible pipeline of projects from all three spheres of government, state-owned entities and the private sector. The plan is also an integral part of the Economic Reconstruction and Recovery Plan (ERRP) announced by President Cyril Ramaphosa in October 2020, in which infrastructure development was identified as the flywheel to economic growth. N3 upgrade The N3 National Road upgrade has been gazetted as a strategic integrated

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UPDATES

project and is being implemented by the Department of Transport and the SA National Roads Agency (Sanral) and its contractors. The N3 programme, which comprises two projects, spans the next six to eight years and includes 14 packages estimated to be in excess of R20 billion. The two sections of the road being upgraded are divided into two contracts and are already bringing signif icant benefits through SMME empowerment and job creation. Project 1: Scope The first section of the N3 upgrade spans 6km of the N3. The road upgrade project extends from north of the Cato Ridge interchange to south of the Dardanelles interchange and includes the Camperdown interchange and the north-facing ramps of the Cato Ridge interchange. The project falls within the uMgungundlovu District

Mun icipa l it y, M k ha mbat h in i L oca l Municipality and eThekwini Metropolitan Municipality. This project’s contribution to the ERRP is substantial, as the N3 is integral to the economic growth of SA. The country’s growing population has placed this strategic corridor under severe pressure, requiring substantial upgrading to portions of it. The N3 upgrade forms an integral part of government’s strategic integrated projects as part of the Durban-Free State-Gauteng logistics and industrial corridor. It aims to strengthen and raise efficiency of this corridor between SA’s main industrial hubs, while improving access to Durban’s export and import facilities. It is the busiest road freight corridor in SA, with over 70 million tons of freight per annum transported by road. The upgrade to the N3 should alleviate congestion on roads around the port and on the crucial

| PROJECTS |

N3 corridor linking the port of Durban and Gauteng. It should shorten turnaround times for freight-carrying vehicles, reduce accidents, increase prof itabilit y and contribute to economic growth. The need for the project arose from increased traffic volumes, declining levels of service on the freeway and the pavement of the existing road reaching a terminal state. The investment in this project demonstrates Sanral’s understanding of the need for quality roads to ensure the safe and efficient movement of people and goods through proper infrastructure to support economic activity and growth. Project details The project entails upgrading the existing four-lane dual carriageway to an eight-lane dual carriageway by widening the road to the median and outer shoulders over a distance of 6,4km. The upgrade will increase safety and also signif icantly improve the level of service for years to come. In terms of the priority interventions of the ERRP, this project is aimed at aggressive infrastructure investment which will assist in reviving the construction industry and contribute to employment creation. The Sanral board approved the award of the construction contract in November 2020 and work commenced on site in April 2021. The contract period is 51 months and is scheduled for completion on 12 April 2025. Apart from widening the N3 median, the current work includes piling in the med ian for the future Camperdown interchange pier, temporary pavement maintenance on the N3 and local roads, installation of temporary concrete barriers to protect the works and earthworks for the fill widenings. Project 1: Economic benefits T he project va lue is approx imately R1,4 billion, of which R82,5 million has been spent to date. The project has already created a substantial number of jobs. There are currently 237 persons employed on the site, 200 of whom were the contractor’s and sub-contractor’s staff. It is estimated that the maximum number of persons employed on this project over its duration will be in excess of 450.

Currently 12 local sub-contractors have been appointed on the contract, with R3,74 million spent to date. It is estimated that 50 local sub-contractors will be employed on this project over its duration. In line with Sanral’s transformation objectives, a minimum of R430 million will be subcontracted to black-owned SMMEs, while just over R115 million will be spent on local labour. The main contract was awarded to Raubex Construction, which has a Level 1 B-BBEE Contributor status. The direct economic benefits of the upgrades are reductions in travel times, vehicle operating costs and accident costs. Offshoots: Early Childhood Development Centre There are also indirect economic benefits that will accrue to the local areas. In addition, through Sanral’s community development strategy, local projects in the surrounding areas will be identified through the local municipality where improvements can be made. One of these is the construction of an Early Childhood Development Centre in the Mkhambathini Municipality. The upgrade of the N3 will ensure ease of traffic movement and the continual maintenance will reduce fatalities on the roads. Project 2: Scope The second project of upgrades to the N3 between Dardanelles and Lynnfield Park

(Above): The Cato Ridge service area off the N3.

is also being done by Raubex Construction. The project is worth R1,48 billion, with R126 million spent to date. The need for the project arose from increased traffic volumes, declining levels of service on the freeway and the pavement of the existing road reaching a terminal state. The project entails upgrading of 4km of the N3 from four lanes to eight lanes by widening to the median and outer shoulders, as well as the upgrade of the Dardanelles interchange and connecting roads to improve traffic movement. Work on this project commenced on 21 January 2021, with completion scheduled for September 2024. The initial maintenance of the R103 that will serve as an alternative route in the event of incidents on the N3, as well as initial maintenance of the N3 road surface, are complete. Work on the upgrade of the access roads to the Dardanelles interchange is progressing well. Project 2: Economic benefits Job creation: Currently, 248 people are employed on site, 148 of whom are from the Mkhambathini and Msunduzi local municipal areas. The number of employees is expected to increase to 450 in 2022, with a total of R103 million to be spent on local labour. Empowerment/Sub-contracting: Nineteen black-owned SMME sub-contractors and suppliers have been appointed through

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an open tender process to date. A total of R385 million is anticipated to be spent on black-owned enterprises over the contract duration. Training: Training in the form of structured workplace learning, work-integrated training and training courses to a value of R3,2 million will be provided. Economy: This project aims to strengthen the logistics and transport corridor and reduce turnaround times for freightcarrying vehicles, while opening up economic activity along the N3. Safety: The project aims to provide additional capacity on the road, reducing delays and accidents. The provision of area lighting along the N3 will also improve night travelling safety. Socio-economic: The project will create direct employment through the construction contract, as well as indirect employment through economic growth in the area. A minimum of 30% of contract value is spent on black-owned companies. Local municipality: The project includes the construction of a Youth Skills Centre within Mkhambathini Municipality in the KwaNyavu Traditional Authority. Dr Kgosientsho Ramokgopa, Head of Investment and Structure in the presidency, says: “We’re incredibly proud of the good work done by Sanral and the National Department of Transport in implementing the N3 Cato Ridge development, which will bring much-needed relief to the traffic congestion on this national road. The N3 carries the country's logistics economy and is an essential economic driver in Kwa-Zulu Natal.” Minister of Public Works Patricia de Lille says: “The importance of decent roads and infrastructure can’t be over-emphasised and I was pleased to see the progress on site first-hand. Our roads are important carriers, ensuring that people can get to work safely and that economic goods can be transported safely and efficiently.” This project is one of many which demonstrate the Infrastructure Investment Plan in action and brings to life the objectives of the ERRP to reignite our economy, assist the struggling construction sector and provide much-needed jobs for our people.

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(Above): The N3 through KwaZulu-Natal is one of SAs busiest transport hubs, with sections of concrete road and precast concrete elements throughout.

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| PROJECTS |

State-of-the-art

CONCRETE REPAIR

C ut t i n g- e d g e S pr ay l o c k C o n c r e t e P r o t e c t i o n’s S C P t e c h n o l o g y w a s deployed in the successful repair of five concrete silos at Rio Tinto’s Richards Bay Minerals (RBM) operation, SA’s largest minerals sands producer. SCP 743 was specif ied as part of the repair design by LNW Consulting Engineers, a leading provider of multidisciplinar y eng ineering and project m a n a gement ser v ices to t he heav y industrial engineering and commercial sectors. On t he company’s prev ious projects, SCP 743 enhanced concrete remediation practices. It fills the concrete capillaries and pores to waterproof the construction material. Tests have shown that concrete treated with SCP 743 can withstand 100m of negative head pressure. Depending on the mix designs, SCP 743 purges and/or encapsulates contaminants within the concrete capillary and pore structure, eliminating their contribution to reinforced concrete distress. Enhanced concrete remediation LNW Consulting Engineers also supervised the repairs, which were undertaken by Rodcol Contracts, a concrete repair specialist

with a solid track record providing quality services to all industries in the Zululand area, Swaziland, the Natal Midlands, Mozambique and the Eastern Cape. Walter Muhl, CEO of Rodcol Contracts, says a total of 4 725m 2 of concrete was treated with SCP. “SCP is an extremely effective product, in terms of its ability to purge concrete of contaminants and provide permanent protection. While initially costlier than other available products on the market, it significantly reduces the maintenance of reinforced concrete structures, saving time and money over the long term,” he says. Rodcol Contracts mobilised to site at the end of 2019. The repairs to the five structures, including Char Silo 1 and 2, Ore Silo 4, Magnetite Silo and Lime Silo, were successfully completed at the end of 2020.

Monstrous and time-consuming Considering the sheer size of the silos, it was an extensive undertaking. Ore Silo 4 is 20m in diameter and 34m high; the Char Silos are 12m in diameter and 25m high, and the Lime and Magnetite Silos are each 7m in diameter and 17m high. The most onerous and time-consuming

“The most onerous and time-consuming process entailed first erecting scaffolding inside and outside the structures to provide access to the work areas.” process entailed first erecting scaffolding inside and outside the structures to provide access to the work areas, the largest of which was Ore Silo 4, where SCP was applied over 2 095m2. The external repairs f irst entailed removing the spalled and cracked concrete and then cleaning and treating the exposed reinforcing bar with an epoxy coating. SCP 743 was then applied to the opened concrete area to neutralise the concrete and bring it back to an acceptable level. Once the repair was completed, SCP 743 was applied to the repaired concrete and the surrounding areas. A Sika repair system and protective coating was then applied to complete the repairs. (Top): SCP 743 was specified for the repair of five concrete silos at Rio Tinto’s Richards Bay Minerals Operation by LNW Consulting Engineers.

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| PROJECTS |

A first for Africa Considering that this was the first time Rodcol Contracts had used SCP technologies, the company received training in the correct application of the technology from Spraylock Africa, the exclusive African distributor for Spraylock Concrete Protection based in Chattanooga, Tennessee, USA. A total of 0,25L of SCP 743 is applied to a square metre of concrete using an airless spray machine. SCP 743 penetrates deeply into the capillaries and pores of the concrete, conditioning it and improving the pH levels to help protect the embedded reinforcing steel. In addition to contamination, the technology successfully addresses de-icing salts and freeze-thaw damage, as well as moisture migration, while also addressing concrete permeability and carbonation. Moreover, SCP 743 locks in free alkali to mitigate efflorescence.

Inside the structures, Rodcol Contracts repaired the cracked and spalling concrete and provided a new 50mm gunite layer. “Spraylock A fr ica is proud to be associated with LNW Consulting and

Rodcol Contracts, both of which are reputable experts in concrete repairs. We look forward to working with these companies on future projects,” says Carl White, MD of Spraylock Africa.

(Right): The petrochemical sector depends on fastacting, effective concrete repair.

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| PROJECTS |

Lúnell Greyling from the University of the Free State was declared a Regional Winner in the 2022 Corobrik Student Architecture Awards, with her entry project: to develop a Shipwreck Interpretation Centre at Cape Agulhas, to preserve largely forgotten shipwreck tragedies. Greyling receives a R10 000 prize and the opportunity to compete in the national awards. “It's a privilege and extreme honour to be a regional winner. It's also a wonderful feeling to know that all the hard work and passion I put into the thesis paid off,” she says. Showcasing talent, creativity, innovation and inspiration, the Corobrik Student Architecture Awards are all about jumpstarting careers, building the industry and designing tomorrow. Regional winners are selected from eight major universities, based on the students’ final theses. These regional winners then go through to the national round, where the top title is awarded, plus a R70 000 grand prize.

Ode to tragedies lost between land and sea site perspective.

Mysteries at sea star at this year's

COROBRIK STUDENT ARCHITECTU Inspiration at sea Greyling explains that she was inspired by the wreck of the Japanese fishing vessel Meisho Maru No 38, which ran aground off the Cape Agulhas coastline on 16 November 1982. Visiting the area in the first year of her architectural studies, she recalls: “We never think twice about the tragedies of those lost at sea. Preserving these memories is therefore important, which inspired me to write about architectural spaces that act as a stage which interprets and retells shipwreck events.” The Shipwreck Interpretation Centre The proposed Shipwreck Interpretation Centre, which will tap into funding from South African National Parks, will be located right next to the Meisho Maru No 38 and the Agulhas National Park. “The strong filmic quality of the setting inspires an intervention that builds on the experiential cinematic elements, creating architecture that tells a story,” highlights Greyling. The centre “proposes sequences of architectural mises-en-scène that articulate both the dualities between

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and interconnectedness within human experiences as visitors move through places and times.” She add s: “ For me, a rch itect ure becomes more than just buildings. It can inspire, educate and bring people together, bridging differences through

shared spaces. Architecture that roots itself in a specific place, when it combines local and traditional craft and materials with contemporary building methods, can be meaningful and sensitive to the place and past, but bearing the future in mind. Using local skills, materials, craftsmanship and

(Above): Altus le Roux's second-hand book market won the prize for Best Use of Clay Masonry.

| PROJECTS |

“Architecture that roots itself in a specific place, when it combines local and traditional craft and materials with contemporary building methods, can be meaningful and sensitive to the place and past, but bearing the future in mind.”

URE AWARDS labour empowers local communities, which contributes to socio-economic development and transformation.” In addition, Altus le Roux clinched a R6 000 prize for Best Use of Clay Masonry for his concept of the “Litterateur’s Citadel”, a place specifically for the appreciation of literature in the Cape Town city centre that includes a variety of literary functions such as bookshops, a library and writing spaces.

(Above): Ode to tragedies lost between land and sea site plan.

The dual benefits of the awards By hosting and sponsoring such awards, a great platform is created for students to receive exposure after their studies. The Corobrik Student Architecture Awards also has a dual benef it by challenging students to use materials such as brick in ingenious ways, while also promoting and exhibiting the company’s products. This year the national awards will again be a hybrid event held in May, following a similar format to that used in 2021. The 2019 awards ceremony was postponed due to Covid-19, with Corobrik instead announcing the 2019 and 2020

winners at a combined event last year. “We're very excited to celebrate the 35th edition of the awards. It's been an incredibly exciting and richly fulfilling journey,” highlights Corobrik marketing support manager Thilo Sidambaram, who herself has been involved with the awards for two decades. “Our relationship with the awards goes back some 35 years and has proved very enlightening for Corobrik. It's added a lot of depth and enriched the architectural profession by allowing young up-andcoming architects to express themselves and show the kinds of directions they

believe architecture should be going in,” comments Corobrik CEO Nick Booth. Since 1986, the awards have placed 34 winners on the architectural map, both in leading practices as well as their own firms. This year’s achievements The 35th Corobrik Architectural Student of the Year Awards: University of the Free State Winner – Lúnell Greyling (R10 000) First runner-up – Chrizelle Loots (R8 000) Second runner-up – Amirah Patel (R6 000) Best Use of Clay Masonry – Altus le Roux (R6 000)

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| TECHNICAL |

FIVE CRUCIAL FACTORS FOR BUILDING COST-EFFICIENT DEVELOPMENTS By Shaun Roos, MD: Longitude Developments The biggest risk for prospective property developers is delivery, especially in current times, with the property sector having become substantially more cost-driven. Even though diminished returns are predicted over the next five to 10 years, the need for property remains – people are still buying houses and apartments. In fact, the trends (in urban areas) show that consumers are searching for an upmarket aesthetic even when they do not necessarily have the means to purchase at that level. The challenge (and opportunity), then,

is for developers to bring the desired aesthetics to market, while still keeping their offering budget-friendly. Here are a handful of ways in which we got it right at our new residential development, 73 on Grosvenor, 36 two-bedroom, two-bathroom residential development in the upmarket suburb of Bryanston, Johannesburg. Build for the future While cost and timeous delivery will always remain top of mind for us, building with sustainability in mind is a critical philosophy that must be applied from the design and planning stage right through to construction and delivery. We have chosen to embrace sustainability, longevity and efficiency in every aspect. This is nonnegotiable for us when bringing any new development to market. With our roots on the costing side of the equation and a firm handle on what works in terms of design functionality and visual impact, we feel we are poised to thrive in the new construction climate. Regardless of how much we expand over the years, our plan is to remain true (Above left): Shaun Roos, managing director of Longitude Developments.

to this “efficiency” philosophy so that we can deliver on each deadline. If you miss a deadline, credibility and trust are lost and once that happens in our game, you are done. Identify the need Coming from a quantity surveying background, we are often regarded with mild derision as the proverbial “bean-counters” of the construction industry, but it is the basic economics of supply and demand where everything starts – and ends. My years in the commercial construction sector have allowed me to ref ine cost models and resource output requirements in a way that makes the company not only price-efficient, but programme-efficient as well. We identified this particular property and really liked it in terms of the location in Bryanston, with a demand from the middle class and its proximity to amenities. Our

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aim was to bring a product to market that would give consumers real “bang for their buck”, offering them a beautiful, well-finished, modern apartment at a great price point.

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Property developers are really “ just” big project managers, so we are heavily reliant on suppliers and sub-contractors. In mitigating the risk of timeous delivery, it is crucial to pick the 522 sub-contractors and specialists 523 524 right in various fields. In this 525 527 regard, we would rather pay526 a premium to A-grade sub-contractors than take the chance of a sub-contractor not delivering and creating a bottleneck for everyone else, which will end up costing overtime and possibly irate customers down the line.

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Precast • Issue 1 • 2022

Articles inside

The essence of your product starts at source

State-of-the-art concrete repair

National project updates

Five crucial factors for cost-efficient developments

Building the future – driven by Covid-19

A mix of concrete for MeerKAT extension

Local winners with surprising designs

2Roads acquires stake in AWT

Musina project benefits from new plasticiser

Concrete roads – from kerbs to surface

Eskom generates interest for the next generation

Twinstar Precast – a look behind the curtain

The people of WSP SA

Home builders’ course