Precast November 2014

PRECAST VOLUME EIGHT ISSUE 3 • 2014

the cma – QUALITY CAST IN CONCRETE

• Wind farm opts for precast concrete • Masonry standards - the case for Eurocodes • The totally concrete road

CONTENTS

1

precast contents NEWS 2

CONCRETE STANDARDS SET TO CHANGE

2

TECHMATIK CELEBRATES 10TH ANNIVERSARY

4

EASTERN CAPE SEMINAR THROWS FRESH LIGHT ON PRECAST CONCRETE

4

Sephaku Cement supports provincial job creation priority

6

LAFARGE TRUSTS’ FIRST FIVE YEARS: CELEBRATING THE JOURNEY

7

KAY TECH WORKSHOPS INTRODUCE NEW ROAD DESIGN SOFTWARE

8

PORTLAND HOLLOWCORE EXPANDS PRODUCTION

Member details 33 MEMBERS’ LIST

PRECAST VOLUME EIGHT ISSUE 3 • 2014

ON THE COVER

A giant mobile crane lifts a precast concrete tower segment into position at Gouda Wind Farm near Tulbach in the Western Cape. The segments are being used in the assembly of 100m towers which support wind-powered turbines. Full story on page 11. the cma – QUaLItY caSt IN cONcRete

• Wind farm opts for precast concrete

• Masonry standards - the case for Eurocodes • The totally concrete road

Precast is the official journal of the Concrete Manufacturers Association NPC (CMA) 16 Horn Street, Chloorkop, Kempton Park, 1620

COVER STORY 11 WIND FARM OPTS FOR GIANT PRECAST

CONCRETE TOWERS

PostNet Suite 8612, Private Bag X32, Kempton Park, 1620 Tel: +27 11 805 6742, Fax: +27 86 524 9216 E-mail: admin@cma.org.za, Website: www.cma.org.za Publishers Isikhova Publishing & Communications PO Box 651793, Benmore, 2010, South Africa

ARTICLES 14 MASONRY STANDARDS –

THE CASE FOR EUROCODES

Tel: +27 11 883 4627, Fax: +27 11 783 2677 Website: www.isikhova.co.za Publisher: Andrew Meyer Tel: +27 11 883 4627, Cell 082 456 5175

17 STEENBERG SOCIAL HOUSING PROJECT BUILT WITH PRECAST, BUILT WITH PRIDE

E-mail: andrewm@isikhova.co.za

20 the totally Concrete road

E-mail: david.bigsky@gmail.com

22 THE BEAUT Y OF PRECAST CONCRETE

Tel: +27 11 883 4627

25 MOTLHABE VILLAGE ROAD PAVED WITH

CONCRETE BLOCK PAVING 26 MAMMOTH CULVERTS USED for

STORMWATER CHANNEL REHABILITATION 28 CMA ADDS THREE NEW MEMBERS 29 FOUR PRECAST CONCRETE STANDARDS UNDER REVIEW

Editor: David Beer Tel: +27 11 478 0239, Fax: +27 11 678 0254 Advertising: Charlene Pillay E-mail: communications@isikhova.co.za Design, layout and production: Chantelle Johnston Tel: +27 11 883 4627 E-mail: chantelle.studio@isikhova.co.za The views and statements expressed in this publication are not necessarily those of the editor or the publishers and neither he, 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.

APPLICATIONS 30 SIKA LAUNCHES NEW FLOORING RANGE 31 PPC takes information sharing and concrete innovation to next level 32 REVELSTONE LAUNCHES off SHUTTER CLADDING 33 PMSA SECURES CONTROLLED CURING

EQUIPMENT AGENCY 34 innovative thinking generates new retaining wall concept

building construction standards for south africa Available from the CMA or 086 1234 888 www.architective.co.za

PRECAST VOLUME 8 • ISSUE 3 • 2014

2

NEWS

CONCRETE STANDARDS SET TO CHANGE

most of the good local information contained

Changes are afoot in concrete’s design

prescriptive and included some performance

cess is fairly advanced.

codes, standards, material specifica-

requirements. Recently specifications were

Once these two documents have been

tions and test methods, says Concrete

amended to control covercrete and to spec-

issued, the SANS 2001 concrete series

Institute MD, Bryan Perrie.

ify properties which prevent deterioration.

will have to be revised.

“South Africa’s concrete codes, speci-

in SANS 10100-2 and will indicate how they should be applied in South Africa. This pro-

The new philosophy in the EN docu-

fications and test methods have generally

ments includes:

Material standards

been based on similar documents in the UK.

1. Determining the environment and re-

In 1996, SA adopted the EN standards for

With the advent of the European Union, all

cement: “SANS 50197 Common Cements”

countries in Europe, including the UK, had

2. Determining the required durability in

and “SANS 50413 Masonry Cements”. Ma-

to adopt European Standards (EN). This

sonry cements are not permitted to be used

means that SA is no longer able to rely on

3. Choosing an approach to achieve durability

in concrete. Since then a number of other

UK standards as reference documents.

4. Determining the structural design.

EN standards have been adopted including:

quired longevity that environment

As a result the local concrete industry

• SANS 51008 Mixing water for concrete

is in the process of adopting or adapting

Design codes

• SANS 50450 Fly ash for concrete to

to European standards and several SABS

South Africa has adapted the EN “Basis for

working groups have been established to

Structural Design” or loading code which is

• SANS 55167 Ground granulated blast

ensure that it is professionally and respon-

referred to as SANS 10160.

furnace slag for use in concrete, mortar

and grout to replace SANS 1491-1

sibly executed”, says Perrie.

T he EN wa ter -r e taining code has

replace SANS 1491-2

EN design codes, which vary significantly

been adopted but cannot be issued until

• SANS 53263 Silica fume for concrete

from current local codes, ensure durability

the structural design code EN 1992 is

and sustainability by designing buildings which

adopted to replace SANS 10100-1. This

• SANS 50934 1-6 Admixtures of con-

are more energy-efficient, last

is almost complete.

to replace SANS 1491-3 crete, mortar and grout.

longer and use less material.

Previously, concrete struc-

Construction specifications

Test methods

tures were designed to be

A decision has been taken to

All construction test methods are cur-

structurally stable and then

adopt two EN codes namely

rently being revised and reviewed. In the

detailed or specified for dura-

“EN 206-1 Concrete” and “EN

case of concrete, they are being compared

bility. Specifications covered

13670-1 Execution of concrete

to EN methods for obvious reasons. In

the properties of aggregates,

structures” to replace SANS

future all construction test methods will

the concrete, the construction

10100-2. The intention is to

form part of the SANS 3001 series with

process and quality control

create complementary SANS

a prefix to indicate the material type.

documents. These will retain

www.theconcreteinstitute.org.za.

(strength). They were largely

Bryan Perrie

TECHMATIK CELEBRATES 10TH ANNIVERSARY CMA member, Techmatik celebrated its

manufacture of precast concrete products.

dom’s R&D facility before being handed over

10th anniversary in Random, central Poland

Guaranteeing high performance, consisten-

to the customer. And thanks to a contract

on 24 October. Guests from more than

cy, and the highest quality, every machine is

with the America’s Columbia Machines, Inc.,

50 countries attended the event in which

automated and controlled by an integrated

Columbia-Techmatik moulds are distributed

the latest generation of textured moulds

computer system. Moreover, machines and

to vibropress manufacturers throughout the

and heating systems, as well as other

moulds manufactured by the company are

world. www.techmatik.pl.

innovative equipment was on display.

adapted for steel pallets and thus achieve

Visitors were able to view the HP

the highest possible compaction rates and

3000 and SHP 5000 Pro C concrete

low production costs through decreased

block machines working simultaneously

cement usage.

and saw the Multi 200 ‘egg-layer’ machine

Techmatik works closely with leading man-

which produces concrete blocks with

ufacturers of pavers in Poland and abroad

polystyrene inserts.

and constantly modernises its offering

Techmatik specialises in high-perfor-

through the introduction of new products. All

mance machines and moulds f or the

equipment undergoes rigorous testing at Ra-

PRECAST VOLUME 8 • ISSUE 3 • 2014

Techmatik’s plant in Random, Poland.

4

NEWS

EASTERN CAPE SEMINAR THROWS FRESH LIGHT ON PRECAST CONCRETE

tations on modern cement production and

The Concrete Manufacturers Association

and construction standards for concrete

manager. The presentation on release

NPC (CMA), staged a two-day seminar on

block paving (CBP).

agents and concrete additives was de-

current trends in the precast concrete

Day two included: practical aspects of

industry in East London on 27/28 August.

concrete retaining blocks; the causes and

The seminar was presented by some of

prevention of failures in CBP; special CBP

the country’s leading precast-concrete

applications; basic masonry units; and the

experts and was sponsored by cement

construction of multi-storey buildings using

producer, AfriSam Cement.

load-bearing masonry.

Delegates, who numbered approximately

The seminars were chaired by CMA

30, qualified for CPD points, and subject

executive director, Wally Armstrong, who

matter included recent developments in

opened the event with an overview of the

precast concrete raw materials and finished

CMA. Precast concrete roads and all

products, as well as some recent initiatives

paving-related subject matter were covered

in the overhaul of industry standards.

by independent paving consultant, John

Day one covered: the extensive roll

Cairns. Masonry matters and multi-storey

that precast concrete plays in modern

buildings were presented by consulting

r o a d c o n s t r u c t i o n; a n o v e r v i e w o f

engineer and masonry expert, Fred Crofts

modern cement production; concrete

of FSC Consulting Engineers.

r elease agents and admi x tur es; the

Structural engineer, Dennis Walters

design of concr ete r etaining blocks;

of Walters and Associates, lectured on

Eurocode 6 in relation to the revision of

some of the applications and advantages

SA’s masonry standards; and product

of concrete retaining blocks, and presen-

application were made by Mike McDonald, manager of AfriSam’s centre of product excellence, and Amit Dawneerangen, AfriSam’s national multi-products solution

livered by Chryso Eastern Cape sales manager, Patrick Flannigan.

Wally Armstrong, CMA executive director, opens the CMA’s Eastern Cape precast concrete seminar.

Sephaku Cement supports provincial job creation priority

ment’s project contractor spent approxi-

Sephaku Cement chief executive, Pieter

and Mpumalanga to make a real difference

to developing skills through trade and

Fourie, has affirmed the company’s support

to their lives,” said Fourie.

artisan training.

mately R500m with local sub-contractors, mostly from the North West Province.

Both premiers made firm commitments

for regional job-creation targets and

To date, Sephaku Cement has recruited

“Development of trade skills is critical

initiatives as outlined in two state-of-

more than half the employees at its flagship

to the two provinces,” commented Fourie.

the-province addresses delivered in June

plant, Aganang from local communities.

by North West Province Premier, Supra

Most had never been employed or were

“During the three-year construction of our

Mahumapelo and Mpumalanga Premier,

unemployed prior to the commencement

David Mabuza.

of the project.

Premier Mahumapelo aims to create

“As we move into the operational phase

7 407 job opportunities through infrastruc-

of the Aganang plant, our employment num-

cement plants, we invested extensively in artisan development. We trained 10 fitters and electricians, seven of whom have been employed as artisans and artisan assistants at Aganang.”

ture development, the green

bers will reach 170 people at

economy and social economy

the cement factory and an

Sephaku Cement will also focus on

during the 2014/15 financial

additional 300 employment

sour cing youth f r om FE T colleges in

year while in Mpumalanga,

opportunities will be created

the target is 78 000 new

through sub-contractors,”

the two regions for its artisan recruit-

jobs per year over the next

added Fourie. T he major -

five years.

ity of semi-skilled employees

ment programme.

“We are committed to supporting the communities in which we operate by of-

“As our business grows,

will be recruited from the

we will do what is in our

adjacent communities.

During the company’s con-

fering skills development opportunities to

struction phase, Sephaku Ce-

backgrounds,” concluded Fourie.

power to support the people of the North West Province

PRECAST VOLUME 8 • ISSUE 3 • 2014

Peter Fourie

young people from previously disadvantaged

6

NEWS

LAFARGE TRUSTS’ FIRST FIVE YEARS – CELEBRATING THE JOURNEY Lafarge South Africa Trusts, comprising the Lafarge Education Trust, the Lafarge Community Trust and empowerment partner Sinako, was created five years ago.

The trusts contribute to community empowerment through education and social development. The Lafarge Education Trust supports education for historically disadvantaged South Africans and the Lafarge Community Trust aims to mobilise communities with an emphasis on empowering women and providing support for the visually impaired.

To celebrate the work and achievements of the trusts over the past five years, Lafarge Trusts has published a book: “Celebrating the Journey: The First Five Years of Creating Change”, which recognises the efforts of those who went out of their way to make transformation a reality.

The book’s foreword is written by outgoing Lafarge Country CEO, Thierry Legrand, who says a core policy of the Lafarge Group is to help facilitate the improvement of communities in which it operates.

“The success of South Africa and our success as a local company which employs over 2 000 South Africans is intrinsically linked to the provision of sustainable quality education for the country’s children.”

The trusts’ successes can readily be seen in the improved performance of learners involved in various initiatives, something credited to the very hands-on approach of the trusts’ leadership and partners.

Launched at the end of July with Cheryl Carolus, the chairperson of the Trusts, the book highlights the trusts’ pioneering commitment to education upliftment; its bursary programme achievements; its investment in science facilities; and what the trusts and their recipients can look forward to.

Change is very evident in the Bodibe community where the trusts implemented a flagship school development project with 11 schools. The Bodibe Village community has a long-standing association with the Lafarge Lichtenburg cement plant in North West Province. The project was a culmination of consultations with government, business, tribal councils, local non-profit organisations and other community structures.

“The trusts took on the daunting challenge of contributing to the improvement of education for the children in South Africa’s impoverished communities,” said Cheryl Carolus. “We have built relationships with selected partners, including government agencies, who can combine their special skills and resources with those of the trusts. Consequently I confidently look forward to the trusts’ future. I am proud of our positive results and the unique corporate support the trusts receive from Lafarge SA and Sinako Holdings.

The best part is that we created replicable models – pioneering support for the visually impaired and implementing whole school development projects. This inspires me and I am honoured to be part of these efforts to make a long-lasting difference.”

PRECAST VOLUME 8 • ISSUE 3 • 2014

NEWS

7

KAYTECH WORKSHOPS INTRODUCE NEW ROAD DESIGN SOFTWARE CMA member, Kaytech recently held CPD-accredited design workshops on the Spectra Pavement Optimisation System, road and pavement design software which optimises base-layer designs using multi-directional hexagonal geogrids. The workshops were held in Johannesburg, Cape Town and Durban and were aimed at design engineers involved in infrastructure and structural design, as well as those looking for better road-design alternatives. It was attended by more than 180 professional engineers and technologists in civil, geotechnical, structural, environmental, municipal, transport and mining fields.

Craig Andrews, technology manager, pavement optimisation for UK-based Tensar International (Eastern Hemisphere), presented the two-and-half-hour technical workshop during which he described how Tensar’s TriAx geogrid offered optimal mechanical stabilisation due to its isometric design and efficiency approach.

“TriAx employs the improved performance properties of mechanically stabilised layers to provide designers with an innovative way of reducing both aggregate and paving costs on asphalt and various types of concrete surfaces including concrete paving blocks. Alternatively, better durability and life cycles can be achieved when material quantities are not reduced. The system follows AASHTO 1993 design methodology and incorporates a multi-directional, hexagonal geogrid, for total road design,” he explained.

“The software provides engineers with various design options such as layer thicknesses, pavement life, and optimised cost and carbon savings. Roads built using the software in the United Kingdom have been put through extensive traffic trials at a transport research laboratory,” said Andrews.

All attendees received CPD certificates on pavement optimisation. www.kaytech.co.za.

Tony Roe (left), Tensar’s international sales manager; Craig Andrews, Tensar International technology manager, pavement optimisation; and Kaytech technical director, Garth James.

PRECAST VOLUME 8 • ISSUE 3 • 2014

8

NEWS

PORTLAND HOLLOWCORE EXPANDS PRODUCTION CMA member, Portland Hollowcore, which

with two cassettes (one for walling and

manufactures hollow-core slabs for the

one for decking), as well as a cutting

precast decking and walling market in the

saw, casting beds and new overhead

Western Cape, has completed a four-month

cranes. The latter are being installed in

expansion project at its Durbanville factory

an extended stock yard adjacent to the

which saw slab production capacity increase

existing factory.

by 75% from mid-October.

“We are also in the process of installing

Nico Hey ns, managing dir ector of

a concrete recycling plant at our batching

Portland Hollowcore, says that besides

facility which adds a green dimension to

increasing production, the project will yield

our production output. Moreover, the

better turnaround times, improved material

expansion means that we are creating new

handling and better management controls.

jobs across the board,” says Heyns.

“Until this expansion project we made

Portland is handling all aspects of the

exclusive use of slab machinery imported

expansion itself including the installation

Portland Hollowcore’s extended stock yard where overhead cranes were mounted on these concrete columns.

from Elematic in Finland. However, we

of the new plant and equipment.

also encourage them to visit our factory

conducted extensive research as to who

“Feedback from our customer base has

our new equipment suppliers would be and in

helped us with the expansion. We have

In addition to the hollow-core decking

the end we decided on Weiler after several

learnt what they want and how to give

and walling markets, Portland Hollowcore

factory visits in Germany,” said Heyns.

them what they expect, namely excellent

also serves the stone and readymix markets

customer service and quality products. We

from its Durbanville and Paarl plants.

Weiler is supplying a new slab extruder

and view our manufacturing process.”

COVER STORY

A tower segment is loaded onto a low-bed truck for delivery to a tower site.

T5 tower sections are prepared for supporting the turbines.

11

One of the in-situ concrete foundations at Gouda.

WIND FARM OPTS FOR GIANT PRECAST CONCRETE TOWERS Forty six precast concrete towers are being deployed for the construction of one of South Africa’s largest wind farms to date, situated on farmland in the Gouda district of the Western Cape. The towers stand at 100m and support wind-powered turbines, each with a maximum generating capacity of 3MW. The wind farm is jointly owned by Spain’s

other local company, civil engineering con-

Acciona Energy and South Africa’s Aveng

sultancy, Concrete Growth, was appointed

Group and when completed in 2015, will

by Acciona Wind Power as an external

feed up to 138MW into the national grid

quality auditing agency, responsible for the

daily. An agreement between the JV and

implementation of quality management in

Eskom will see ownership of the entire

the manufacturing process.

operation being transferred to the utility giant after 20 years.

According to Concrete Units Cape Town manager, Brian Cook, each completed tower

Part of the assembly process which sees a tower segment being offloaded and swung into position.

The precast concrete tower segments

comprises five 20m tapered concrete

tower sites where individual segments are

were manufactured by Cape Town-based

sections, each section being assembled

lifted off the trucks and then lowered verti-

precast concrete producer and Concrete

with individual precast concrete segments.

cally onto circular concrete bases by a giant

Manufacturers Association NPC (CMA)

“The base section, T1, comprises four

mobile crane. They are then joined to match-

member, Concrete Units, in a joint venture

segments and is mounted on an in-situ

ing segments using ‘bowtie’ connections.

with another Spanish company, Windtech-

concrete foundation. T2 which is mounted

This is achieved by inserting reinforcing into

nix. The latter has extensive experience in

on T1, and T3, which is mounted on T2,

hollow slots formed by the segments’ two

the manufacture of precast concrete wind

are also assembled using four precast

opposing vertical channels. A proprietary

towers and is providing engineering input.

concrete segments each, whereas T4

high-strength grout is then pumped into the

Once the overall project is completed some

is constructed with three parts and T5

joint to create a permanent seal.

16 500m³ of concrete, 2 800 tons of rein-

requires only two.

forcing steel and 160 000m² of shuttering will have been used.

“The 20m sections are attached to each

“T5 sections are assembled at Gouda’s

other in a horizontal plane using male starter

storage yard where they are made ready for

bars at the bottom end and female ducting at

The on-site assembly of the towers and

supporting the turbines. Turbines consist of

the top end and these joints are sealed with

manufacture and installation of the tur-

a nacelle and hub which weigh 140 tons, and

grout. The flawless execution of this process

bines is being handled by Acciona Energy’s

three blades, each weighing 10 tons. Sec-

requires extremely accurate casting and

sister company, Acciona Wind Power. An-

tions T1 – T4 are assembled at the actual

very tight tolerances,” says Cook.

PRECAST VOLUME 8 • ISSUE 3 • 2014

12

COVER STORY

The Gouda towers have been designed

being manufactured to 75MPa which is the

“SCC was supplied by Megamix, which has

to bend with the wind and can move up

strength required to handle the loading

a batching plant close to Concrete Units.

to 700mm at their apexes during strong

of the turbines and the wind. This high

The SCC mix was one of the critical compo-

winds. This flexibility was facilitated by

characteristic strength allowed Acciona’s

nents of the whole manufacturing process

the use of steel reinforcing inside the

engineers to opt for lighter concrete

and one member of the Concrete Growth

tower walls. The lateral movement was

sections which has added a further eco-

team was permanently based at Megamix to

counterbalanced by the installation of

friendly dimension to the project through

monitor the batching process. Wet weather

six 90mm steel cables, which attach

lower material usage and transport costs.

can affect the mix because the amount of

the inner walls of T5s to the concrete

“Secondly, the tower segments were

water used is critical. Even a slight water

bases and provide additional strength to

being manufactured with self-compacting

overdose can cause segregation and a loss

the overall structures. Once installed,

concrete (SCC). SCC is comparatively new

of strength. Our system ensured that we

they are post-tensioned by Acciona Wind

to this country and besides being the larg-

had very few problems with the mixes. Need-

Power’s engineers.

est wind farm to date, Gouda is also the

less to say the slump flow of every batch

The segments, 782 in all, were cast at

country’s largest SCC project thus far.

was tested at Concrete Units before being

Concrete Units’ factory using five moulds

In fact it is using approximately half the

pumped into the moulds.

which were shipped to South Africa from

amount of concrete used for the precast

Poland and Brazil by Acciona Wind Power.

segments of the Gautrain project.

Each mould section was two metres long and

“Without SCC, the project would have

the sections were attached to each other

been much more complex, involving external

using precision-based laser technology.

vibration and more expensive moulds.

Gouws added that turbine towers generally amount to approximately 15 to 20% of a wind farm’s capital cost, a figure which does not include the foundations.

In most instances, the higher one

Moreover, to ensure the accurate layout of

goes, the better the wind, and for heights

the steel reinforcing, Concrete Units used

above 80m, concrete towers tend to

special reinforcing jigs.

be less expensive than imported steel

A maximum of five segments were

towers, thus impacting on the cost of the

cast daily. Various types of inserts and

electricity generated positively. To date,

sockets were cast into specific positions

most wind turbines in South Africa have

to locate the mechanical (ladders, lifts and

been mounted on steel towers, which have

landings) and electrical equipment (cable

the disadvantage of being imported and

trays etc)

a comparatively low local labour and job-

required inside the towers.

creation component.’

Spaces for doors were cast into every fourth T1 segment. Mould stripping took

“By contrast, concrete wind towers

place either late into the night shift or

come with high local-content inputs and by default carry a much higher job generating

first thing every morning by which time the segments had reached a compressive strength of 25MPa.

The Concrete Units yard where a T5 wind tower segment is prepared for delivery to Gouda.

capacity. For example, over 95% of the raw materials for Gouda’s concrete towers including the reinf orcing steel, were

Af ter three days the moulds were

sourced locally.

given a light post-tensioning prior to being transported to Gouda on extra heavy-duty

“Moreover, wind power forms part

low-bed trucks. Segment T1 which is 5,5m

of the Government’s renewable energy

wide and T2, which spans 4,8m, required

strategy which was formulated by the

police escourts. The smaller segments,

Departments of Energy and of Trade and

using normal escourts, were generally

Industry in 2011. The CSIR was tasked

shipped first which allowed the trucks to

with researching its job creation and economic development potential, and it

return for a second load.

Santie Gouws, managing director of Concrete Growth, says that in terms of

All the concrete used on the Gouda Wind Farm project is measured for slump prior to casting.

was on the basis of the CSIR’s report that the DTI increased the local-content wind-

concrete manufacture, the Gouda Wind

farm requirement for Round Three of its

Farm project is cutting-edge.

Renewable Energy Programme, of which Gouda forms a part,” concluded Gouws.”

“For example, the tower segments were designed according to Euopean as

Alternative energy is scheduled to add

opposed to SANS codes. This allowed us

9 000MW (equivalent to two coal-fired

to design up to 115MPa cube strength

power stations) by 2030, and it seems a

rather than the 60MPa which forms part

safe bet that precast concrete towers will play a major role in Rounds Four and

of the SANS structural concrete code.

The Gouda tower concrete segments were

PRECAST VOLUME 8 • ISSUE 3 • 2014

One of the five moulds used on the Gouda project.

Five of the programme.

14

article

MASONRY STANDARDS –T The current South African National Standards covering the design, materials and construction of masonry standards were introduced some 30 years ago and need updating. In this interview with the country’s leading masonry expert, Fred Crofts of FSC Consulting Engineers, Precast examines the advantages of adopting Eurocode 6 for the country’s masonry standards requirements.

Precast: South Africa has traditionally

at best fragmentary and

FC: T he manuf acturing

based its masonry standards on those of

need reviewing. In addition,

industry in South Africa

the United Kingdom. Why should we now

supporting standards such

will have to adopt the new

adopt the Euro standards?

as SANS 523 (limes for use

supp or ting s t andar ds.

in building) and SANS 1090

In f act, some of these

FC: The British Standards Institution (BSI),

(sand for plaster and mor-

EN

which is a sub-section of the European

tar) require some editing.

alr ead y been accep ted

Standards Authority, has itself discarded

Eurocode 6 will address all

by the SABS/ TC 081/ 01

its old masonry codes in favour of Eurocode

these requirements by in-

c ommi t t e e ( m a t er ials,

6. The South African Bureau of Standards

troducing a comprehensive

products

(SABS) has an agreement with BSI which,

set of manufacturing and

methods

if we choose to, will enable us to adopt

auxiliary testing methods.

lime and concrete).

Eurocde 6. If we opt not to we are liable to

It’s there for us to use and

find ourselves in a standards vacuum and will

only has to be modified as

no longer have ready access to the latest

a two-to-three page annex to reflect local

and configurations will be introduced

standards, research and development

environmental and climatic conditions.

based on the proportion and direction of

taking place in Europe and the UK.

standards

and –

have

test

cement,

Furthermore, a wide range Fred Crofts.

of masonry materials

In addition, Eurocode 6 will provide

holes or perforations, web thicknesses,

Eurocode 6 covers buildings and other

a wealth of research support, arising

etc, in masonry units. Moreover, the

ci v il engineer ing wor ks and includes

as it does from a much larger first-

characteristic compressive strength of

reinforced, prestressed and confined

world environment where research into

masonry will be presented in the form of an

masonry. There are four documents which

numerous aspects of masonry performance

equation, using the normalised strength of

make up the current British masonry

is widespread and ongoing. T his vast

the masonry and the strength of mortar.

standard BS EN 1966. First published in

knowledge pool can only be of benefit to us.

Normalised str eng th r ela tes to the

2005 and 2006, they include the rules

For example, r esear ch is being

compressive strength of a masonry unit

for reinforced and unreinforced masonry,

c u r r e n t l y c o n d u c t e d in t o t h e r m a l l y

which involves testing to a standardised

structural fire design and detailed rules

ef ficient aerated autoclaved concrete

shape and moisture content.

for lateral loading. Eurocode 6 comprises

masonry (AAC). If we adopt Eurocode 6

Structural reliability and safety indices

the following parts and each part has a

we will have a ready-made standard for

will have to be revisited and the designa-

corresponding national annex:

AAC when the technology is introduced to

tion of mortars may change based on

BS EN 1966-1-1: Rules for reinforced and

this country, as it surely will be.

performance as opposed to prescriptive

unreinforced masonry

Over the years research has continually

specifications. The compressive strength

BS EN 1966-1-1-2: Structural fire design

improved the performance of masonry

used for masonry units will be the nor-

BS EN 1966-1-2: Selection of materials

walls and European standards have been

malised compressive strength which will

and execution of masonry

updated to reflect that. For instance,

either be declared by the manufacturer

BS EN 1966-1-3: Simplified calculation meth-

we now have a better understanding

or obtained by using the EN 771 series.

ods for unreinforced masonry structures.

of the eccentricities of masonry walls

The manner in which eccentricities

In South Africa, the manufacture of vari-

such as the interface between slabs and

on walls are analysed using Eurocode 6

ous types of masonry units is essentially cov-

load-bearing masonry, and this has been

now includes an initial eccentricity to

ered by three standards, SANS 227 (burnt

adopted into the European standard.

allow for inaccuracies in the construction

clay masonry units), SANS 1215 (concrete

of the masonry and the same will apply

masonry units) and SANS 285 (calcium sili-

Precast: How will the introduction of

locally. Concentrated loads ar e also

cate masonry units). The testing procedures

Eurocode 6 impact on local masonr y

handled dif ferently in Eurocode 6.

in the design and materials standards are

manufacturers?

Lateral load design, however, will remain

PRECAST VOLUME 8 • ISSUE 3 • 2014

ARTICLE

15

THE CASE FOR EUROCODES unchanged. Ancillary components will be

South Africa has over 20 million people

Pr ecas t: How long would it take to

dealt with in a more coherent way and

living in shacks with no standards and

implement Eurocode 6 in this country and

suitable values of material partial safety

in many instances RDP (Reconstruction

who would be responsible for making the

will be introduced.

and Development Project) houses are

local amendments?

F ir e de sign w ill lar gel y r em ain in

not even built to minimum standards.

the f or m o f t ables similar to those

Poor construction and the deviation from

FC: Approximately six months. The technical

contained in BS 5628 Part 3 (Code of

acceptable building standards were the

committee SABS/TC 098/SC 05 (Structural

practice for the use of masonry – Part

reasons for the failure of approximately

and geotechnical design standards - design

3: materials and components, design

600 houses in Khuma after the earth

of masonry structures) would be responsi-

and workmanship). The fire resistance

tremor in Klerksdorp on 5 August 2014.

ble for writing the local annex. The SABS/TC

of load-bearing walls will comprise two

The walls were not even bonded and if they

098/SC 05 is one of six tiers of materials

values, depending on how a wall is loaded

had been built properly there would have

standards committees operating under the

and if it is plastered.

been little or no damage.

auspices of the structural and geotechni-

We should b e ge t ting the b asic s

cal design standards SABS/TC98 advisory

Precast: If, as seems likely, we adopt

right such as building RDP houses using

group which was created to manage the

Eurocode 6, how will it be affected by the

modular masonry before even considering

approval process in the adoption of new

new energy regulations in the National

expensive energy construction legislation.

or revised masonry standards. The overall

Building Regulations Act (NBR)?

Someone needs to come to their senses

standards authority for masonry ie, SABC/

and revisit the NBR energy legislation

TC 098/SC 05 which, together with the sec-

FC: T he Eur o standar d cover s the

because it’s simply not affordable given

ond and third tier technical committees, ie

manufacturing of masonry units and the

the fragile state of our economy.

building and construction standards SABS/

design and construction of masonry walls.

TC059 and material standards SABS/ TC

And although it covers thermal and energy

Precast: What are the advantages of

081/SC 01, handle all construction material

aspects, the NBR’s 10400K (application

masonry for affordable and other types

standards besides masonry, such as steel,

of the NBR, Part K: Walls) and 10400XA

of housing?

timber and composite materials, among

(the application of the NBR, Part X A:

others. The material working groups over-

E ner g y usage in Buildings ) w ill t ake

FC: There is no economical alternative to

seeing the manufacturing of masonry units

precedence over whatever standards

a masonry envelope for normal housing

comprise stakeholders who essentially are

we adopt.

over its intended service life. It is a simple

the masonry manufacturers.

form of construction and masonry units Precast: So in other words if the NBR

can be manufactured on site. Moreover,

Precast: What is the main stumbling

has a higher thermal/energy requirement,

because there are so many masonry fac-

block in the approval process?

which it does, it will prevail?

tories countrywide, transport costs are relatively low. Masonry also offers great

FC: A lack of stakeholder interest. I am

design flexibility. However, the level of

getting very little support. For example,

masonry expertise in this country, both

I know that when we get to the stage of

Precast: Isn’t this like trying to run

in its design aspects and in the laying of

circulating the Eurocodes for comment, to

before we can walk?

actual bricks, has dropped alarmingly and

say, 20 respondents, we’ll be lucky if we

this is a contributing factor to why we

get one response from the professional

FC: Again, yes, it is. In my opinion the

experience so many defects and building

fraternity. People are either too busy or

thermal/energy requirement in Eurocode

failures, especially in RDP housing.

just apathetic and don’t respond the way

FC: Yes.

6 is more than sufficient for our needs

I believe the masonry industry, that

one thinks they ought to. I’m seen as the

and the implementation of the NBR will

is both concrete and clay producers,

champion for Eurocode 6 but no one is

severely impinge on the cost of construc-

need to work together to promote the

willing to get involved. So basically I have

tion in this country. Although at first

advantages of masonry. Precast concrete

to rely on the Joint Structural Division of

glance the NBR’s energy requirement may

masonry producers should be promoting

the Institution of Civil Engineering. But it

appear to make sense, the consumer will

modular masonr y, which i f execu ted

would be far preferable if I could get some

have to bear the brunt of the ensuing and

properly, creates durable housing very

back-up from professionals residing in the

unnecessary cost escalations.

cost-effectively.

large consulting companies.

PRECAST VOLUME 8 • ISSUE 3 • 2014

ARTICLE

A completed double-storey unit at the Steenberg Social Housing project.

17

One of the precast staircases supplied by CMA member, Topfloor.

STEENBERG SOCIAL HOUSING PROJECT - BUILT WITH PRECAST, BUILT WITH PRIDE

addition, solar heating units, with backing elements supplied by Sunlight Solar, were fitted throughout.

Concrete Manufacturers Association

Concrete masonry blocks, prestressed hollow-core slabs, staircases and concrete beams are some of the precast concrete elements which have been used in the construction of the Steenberg Social Housing project in Cape Town. Others include paving blocks, windows, door frames and precast concrete balustrades.

NPC (CMA) member, Topfloor, supplied

When completed during the first quarter of

three sizes which included a 21m² studio

in combination with in-situ concrete to

2014, 700 housing units had been erected

and two two-bedroom units in either 36m²

support in-situ cantilevers. The columns

in three phases by the main contractor,

or 42m² . Studios comprise a living room

were cast with castor bars to which the

Remey Construction, on behalf of Sohco

with kitchenette, a separate bathroom and

beams were attached.

Amalinda, the company contracted by the

a bedroom on a mezzanine floor. The two-

The walls were built using modular ma-

City of Cape Town to build the houses for

bedroomed units were built either as ground

sonry Super Maxi blocks in combination with

the rental market.

the prestressed hollow-core slabs which varied in length from three-and-a-half to seven metres, for the upper level flooring during Phase 2 of the project. It also supplied the precast stairs and the precast beams. The beams were used

floor or first floor units but all come with

half blocks and corner blocks to avoid the

The apartments are housed in double

an upper level bedroom and precast stairs.

wasteful chopping of full blocks. The blocks

and triple storey buildings. Phase 1 be-

The finishes include granite work tops

were laid by sub-contractors and local

gan in 2008 when 450 apartments were

in the kitchenettes, tiled f loor s and

labour was used for excavation and in-situ

constructed and a further 150 units were

tiled bathrooms with specially moulded

concrete work. Moreover, over 80% of the

erected in 2012 during Phase 2A. The re-

sit-baths. The kitchenettes also have

bricklayers were recruited from local com-

maining 100 units were built in four sections

larger than normal sinks for washing

munities in Steenberg, Retreat and Laven-

during Phase 2B, which was begun in July

clothes and linen. The window frames,

der Hill. The outer walls were plastered and

2013 and was completed in March 2014.

door frames, balustrades and the kitchen

the inner walls bag-finished.

The apartments were all built with

cupboard frames were all made from

The paving comprised a combination of

quality finishes and were constructed in

a r e sin -b ase d p o l y m er c o n cr e t e . In

permeable and non-permeable surfaces in

PRECAST VOLUME 8 • ISSUE 3 • 2014

18

ARTICLE

a ratio of two-and-a-half non-permeable to

the last phase will be completed in tandem

The paver used for the permeable paving

one permeable. All the parking areas were

with Phase 2B.

was the Aquaflow bond paver which is rated

covered with permeable paving whereas

“Our design was based on the Aquaflow

at 45MPa. And a mix of clay and concrete

the roads, verges and building surrounds

Permeable Paving System. The sub-base

pavers were used for the non-permeable

were all non-permeable. The permeable

comprised 250mm of single-sized 53mm

paved sections.

paving section covered 8 400m² and

crushed rock which was laid on selected

“The water drains into the subgrade

was designed by project engineer, Peter

subgrade (min CBR of 15%, permeability of

and the underground Cape Flats Aquifer

Wium, in collaboration with De Villiers

1 x 10-4m/s). It was overlain with 100mm

and any overflows are channelled into the

Sheard Consulting Engineers, the civil and

of single-sized 19mm crushed rock, and

external stormwater system,” says Wium.

structural consultants on the project.

included two layers of Inbetex geofabric, one

The apartments are being rented for

Wium says that this was the second

placed below the 53mm stone and the other

between R700 and R2 500 a month and

permeable paving project ever to have

above the 19mm stone. The 80mm pavers

tenants must qualify on the basis of their

been undertaken in Cape Town. The original

were laid on 50mm of 6mm bedding stone,

monthly income. Most residents commute

tender was issued in October 2008 and

and a 3mm grit was used for the grouting.

with public transport and the Steenberg station is within easy walking distance of the development.

Members of the professional team comprised: architects, Servaas Crowther; electrical consortium, B2A Consulting Engineers; earthworks and civil contractor, Lancer Civils; main contractor, Remey Construction; project managers, Delta Built Environment Consultants; and paving project

A section of permeable paving at the Steenberg Social Housing project.

A completed unit showing some of the high quality finishes.

engineer, Peter Wium, in collaboration with De Villiers Sheard Consulting Engineers.

20

article

The precast concrete panelling on this Gautrain bridge serves the dual purpose of a safety wall and an aesthetically pleasing façade.

One of several roads which were paved with concrete block paving in Thembalihle, Phumelela (Vrede).

A typical precast concre

the totally Concret Most people associate roads and road building with asphalt as this is what they see when driving or walking. However, those involved with road design know that precast concrete plays an indispensable role in road construction.

environments where SABS standards and ISO 9000 management systems ensure a consistently high quality.

Furthermore, the sourcing and production of raw materials for the manufacture

Any road, be it a suburban by-way or a

Perhaps the biggest benefit of precast

of precast concrete as well as the instal-

national freeway, can be built entirely with

concrete is it is much faster to use than its

lation of precast concrete products is

concrete and suburban roads and often are

in-situ equivalent. Imagine the time it would

labour intensive, and this is very important

completely built with precast concrete.

take if water-management systems were

in South Africa. There is also an abundance

There are six product categories in which

cast on site rather than being built with

of the raw materials available in southern

precast concrete is used:

products such as precast pipes, culverts

Africa for the manufacture of precast

• Paving and kerbs

and kerb inlets. Instead of taking months

concrete products as well as more than

• Water management products such

the process would take years. Moreover,

enough installed manufacturing capacity

as pipes, culverts, kerb inlets, grating,

precast concrete has the added advantage

to meet the demands of any accelerated

manholes, and embankment down drains

of being manufactured in controlled factory

infrastructure programme.

• Columns, beams, slabs and barriers for

Precast concrete played a substantial

bridges over roads

role in the upgrade of the GFIP (Gauteng

• Retaining walls, security walls, sound-

Freeway Improvement Project). During con-

struction SANRAL’s project manager, Hennie

proofing walls and barriers

• Poles and masts for electricity re-

Kotze, said that the space for staging and

shuttering support was often extremely lim-

ticulation and lighting

• And a general category for products

ited and this meant that the use of precast

such as bus shelters, bollards, concrete

concrete elements such as beams on bridges

furniture, lay-bys, signage, security

boxes and toilets.

Precast concrete façade panelling on the N1 freeway.

was indispensable to the upgrading process.

In addition, stormwater pipes and box

Unlike other materials which deterio-

culverts had to be extended under the

rate with age, concrete gains strength,

freeways, and in instances where new

requires little if any maintenance, and has

interchanges were built, new culver t

a life expectancy in excess of 50 years. And

and stormwater systems using precast

unlike asphalt, which is an imported mate-

concrete pipes and precast concrete

rial subject to periodic shortages and rising

rectangular culverts were installed. And it

costs, the elements which constitute concrete such as cement, aggregate, flyash, sand and water, can all be locally sourced.

PRECAST VOLUME 8 • ISSUE 3 • 2014

Storm water concrete piping, 1 350mm in diameter, is installed under a section of the N12 west-bound freeway in Gauteng.

was the first time that precast concrete highway barriers were used extensively, replacing ‘W’ section crash barriers.

ARTICLE

ete roadside manhole.

21

A beany block stormwater drain.

te road Precast concrete paneling was used for embankment reinforcing and facades, and

have benefitted from CBP projects. The income earned has a multiplier effect, stimulating economic activity in other sectors of local communities. Moreover, it imbues residents with homes facing onto CBP roads with a new-found pride in their communities and this is reflected in cleaner streets and better-maintained houses.

precast beams, which varied from small

Road safety is high on the Government’s

I-beams to huge U beams, were also used

agenda and CBP contributes significantly

on the project.

in this r egar d. Fir st, the chance o f

Although municipal engineers still tend

aquaplaning on wet surfaces is greatly

to favour asphalt as their default paving

reduced. The two-to-three millimetre

material, an increasing number of roads,

water sheet o f ten f ound on asphalt

be they in former townships or upmarket

roads during heavy downpours is virtually

suburbs, are being paved with concrete

non-existent, especially when the pavers

block paving (CBP), sustainability, poverty

are bevelled. One may find an isolated

alleviation and safety being the main drivers.

water channel crossing a CBP road but

CBP was first introduced to this country 50

not water sheeting over an extended

years ago when it was used to pave roads

area. Permeable paving installations,

in the Durban township of Chatsworth.

which are specifically designed to soak

However, it was only with the advent of the

up stormwater, are even more effective

new millennium that CBP was taken seriously

at dispersing surface water and can be

as a suburban road paving alternative.

installed on sections of road where water

As the Chatsworth roads have demon-

channels are likely to form.

strated, CBP is essentially maintenance-free

Secondly, CBP also offers better brak-

provided it is laid in compliance with best

ing owing to its rough texture and broken

practice standards and this is one of the

(channelled) surface. In addition, it provides

main reasons why it is finding favour with

better road marking with coloured and lumi-

local governments. What’s more, the initial

nous concrete pavers. They offer constant

capital outlay on CBP roads is only marginally

and maintenance-free signage, unlike painted

greater than the asphalt equivalent while the

surfaces which require regular maintenance.

saving on maintenance is huge and quickly offsets any higher capital spend.

Laying roads with CBP is labour-intensive

Also, one seldom finds the dreaded pothole on CBP surfaces, which is destructive, dangerous and expensive to repair.

and offers the unemployed an opportunity

Today’s roads can all be ef fectively

of acquiring marketable skills and earning

constructed utilising locally manufactured

capacity. The process also lends itself

precast concrete products from start to

to Government’s Expanded Public Works

finish with no material shortages or the

Programme. Over the years thousands

need for expensive imports.

PRECAST VOLUME 8 • ISSUE 3 • 2014

22

ARTICLE

THE BEAUTY OF PRECAST CONC Precast concrete is one of the most innovative sectors of the construction industry, offering high quality, cost efficiency, eco-friendly solutions and almost limitless architectural variety. Certainly, no other construction material can match its versatility and durability, with new techniques being constantly developed to increase the range of choices available to the client and architect. Facade surfaces can be retarded, polished, acid etched, or sand-blasted, with colour achieved by judicious use of white cement, pigments and coloured aggregates. And as well as being beautiful and practical, precast concrete is safe, since factory manufacture reduces the need for site labour and cuts construction time.

To demonstrate its visual appeal, here a few

Block GN15, Athletes Village, London

from the powerful circular form of the un-

examples of European architectural precast

A further example of what can be achieved is

derground well and reflects the functional

concrete at its best.

Thorp Precast’s involvement in block GN15

aspects of the engineering. The pigmented

in the Athletes Village, one of the first ac-

concrete walls of the building and perimeter

Van der Meij College, Netherlands

commodation units to be completed for the

were cast with a relief pattern based on the

When the Van der Meij College, Alkmaar,

2012 London Olympic Games. Designed by

Victorian engineering drawings of Sir Joseph

Netherlands, required an artistic facade

architects Piercy & Company, the building

Bazalgette. They celebrate the engineering

for a new school building, Decomo took on

is clad with a combination of smooth white

achievements of sewer networks old and

the challenge. The snow-white colour was

Portland precast concrete and white clay

new, and contribute to a sense of civic pride

achieved by using white cement and a snow-

brick panels, the facade being inlaid with an

engendered by this key infrastructure build-

white additive. The surface was polished and

abstract pattern of a running figure, refer-

ing. A detailed design brief was supported

protected with a water-repellent coating

encing the pioneering photographic work of

by a comprehensive set of implementation

after installation. From a distance, the

Eadweard Muybridge.

guidance documents for the Olympic Park

facade looks like marble, but closer inspec-

that included requirements for sustainabil-

tion reveals a tree-like relief structure with

ity, biodiversity, inclusive access, materials

3 046 leaves, 1523 branches, 391 birds and

and security. Precast concrete cladding

117 nests. The tree is a symbol of life and of

was chosen for its long-lasting robust finish

growth and the nests reflect the fact that

and fast erection time and Thorp’s ability

the students will spread their wings and

to mould graphic representations into the

enter the wide world.

concrete surface enabled the architects (John Lyall Architects) to make the building a subtle homage to Sir Joseph.

The precast concrete façade of the GN15 Athletes Village in London was inlaid with an abstract pattern of a runner, referencing the pioneering photographic work of Eadweard Muybridge (1830-1904).

Pudding Mill Lane Pumping Station, London An historical figure also featured in Thorp’s involvement in the Pudding Mill Lane Pumping Station – an Olympic ‘Legacy’ project – the first operational building on the Olympic Van der Meij College, Alkmaar, Netherlands.

PRECAST VOLUME 8 • ISSUE 3 • 2014

Park. The shape of the building is generated

Pudding Mill Lane Pumping Station, Olympic Park, London.

ARTICLE

CONCRETE

23

Block N15 Athletes Village, London Another Techrete project involved six mansion blocks at the 2012 Olympics Athletes Village, each consisting of six to eight multi-storey residential buildings.

Cladding panels, SouthGate, Bath, UK

The total facade area was 84,500m2,

On a larger scale, Techrete was appointed

requiring more than 8 000 single- and

to design, manufacture and install some

two-storey panels with punched window

19,000m² of precast architectural clad-

openings. Each mansion block has its own

ding panels to the facades of the six

identity with contrasting colours and

buildings of a £360m retail-led, mixed-

textures. Deep vertical ribbing and flut-

use development at SouthGate in Bath.

ing were widely adopted with brick-faced

In the main, natural Bath Stone was cast

cladding panels to add to the variety of

onto precast units but some elevations

finishes. On block N15, the reconstructed

are of reconstructed stone developed

stone panels include replicas of the Elgin

to give the same colour. Mined locally,

Marbles at the British Museum, while

the Bath Stone was manufactured for

those on N3 accurately replicate Roach

the project by Techrete. To produce a

Bed Portland stone. New techniques of

development with a traditional solid look

fixing panels were developed and tested in

and feel, window reveal and building cor-

Trinity College Dublin, and new methods of

ner details, which often betray panelised

casting dual-colour panels were developed

construction because of visible seams,

to accommodate the requirements of the

were designed to give the impression of

seven architectural practices.

solid stone. And to disguise panel seams on the facades, neo-classical devices such as string courses, columns and pilasters were used so that the panels are not evident.

Precast concrete replicas of the British Museum’s Elgin Marbles were used on Block N15 at the 2012 Olympics Athletes Village in London.

Maison de la Petite Enfance in Clichy sous Bois, France and Sint-Lukas School for Arts and Architecture in Belgium More recently, Decomo has been involved in two very attractive projects in Europe – a reception space for a day-nursery at the Maison de la Petite Enfance in Clichy sous Bois, France, and the Sint-Lukas school for Arts and Architecture in Brussels, One of six mixed-use buildings at SouthGate, Bath, UK, where precast cladding panels were used as decorative facades.

Belgium – both of which were inspired by everyday life. The skin of the Maison

PRECAST VOLUME 8 • ISSUE 3 • 2014

24

ARTICLE

de la Petite Enfance is a very protective

the panels at the front elevation – which

tor Balfour Beatty. The pale cream pre-

cocoon made from grey precast elements

houses the reception and offices – are the

cast walls feature surface finishes includ-

cast in an elastomer matrix mould. The

most interesting, with an attractive relief

ing exposed aggregate , smooth and lightly

pattern sprouts from the imagination of

pattern simulating the appearance of books

etched within the same units to further

architect Gaëtan le Penhuel and refers

stored on bookshelves.

enhance the overall visual appeal. Topped off with a large overhanging bulbous cap-

to pixellated digital images which create, on the whole, a contemporary feel.

Dover Seafront, UK

ping, which was cast independently, the

Joints are discreetly hidden within the

While architectural concrete is of ten

coping element was set face down in the

randomly created shadows, while the

thought of and indeed seen in the form of

mould with projecting reinforcement as

white translucent glazed finish lends this

vertical panels, it is certainly not limited

permanent formwork before being cast

grey concrete a moiré-look which gives

to that direction. At Dover’s seafront,

integrally with the main decorative verti-

the appealing softness needed in such a

for example, white architectural precast

cal wall face.

reception space.

concrete manufactured by Thorp Precast

As part of a commitment to working

form a ‘Lifting wave’ and ‘Resting wave’

in partnership with communities to find

together with a series of 70 sculptural

ways of enhancing the local landscape

ramps and stairs that rise and fall to

while reducing flood risk, the Environment

connect the beach to the esplanade.

Agency ran an artwork design competition

‘Resting wave’ is a sculptural retaining

for the project that was won by Latchford

wall comprising 124 units running the

St James’s CE Primary School pupils Jack

length of esplanade. Driven by a strict

Arrowsmith and Zac Singleton. Their eye-

budget and fast-track programme, solid

catching designs – featuring fish, reeds

modelling software was exploited in both

and kingfishers – were imprinted by Thorp

the design and the manufacture. The

on the precast units. To do this, the

layered steps, like a spun pack of cards,

company had to draw on its experience

express how the mould for the ramps is

and expertise with water-jet cutting and

made and the use of fibre-reinforced and

3D mould technology to create ceramic

self-compacting concrete technology

forms that were cast integrally into the

ensured fast economic manufacture with

wall units to reflect the vibrant colours

a high-quality finish.

and flowing shapes of the winning design.

Maison de la Petite Enfance in Clichy sous Bois, France.

Bodleian Library, Oxford Back in the UK, the new storage facility for

As a result, these creative youngsters will

Oxford University’s ever-expanding Bodleian

be able to see their handiwork live on as

Library, which dates from 1602, involved

part of the flood defence legacy for many

stringent demands, starting with a minimum

years to come.

four-hour fire protection. Here Decomo sup-

Most of the wall units are supported

plied architectural-grade precast sandwich

and restrained to the sheet-piled walls be-

panels with a grit-blasted finish to the ex-

hind: others are designed as free-standing

ternal faces. Typical dimensions were 7.5m

vertical cantilevers, with rebar at the base

long × 3m high, each weighing 12.5 tons:

projecting into a trough foundation and

some were larger, the biggest closer to

temporarily propped before a stitched in-

18.5 tons. From the aesthetic point of view,

situ concrete connection was made and the props removed after curing. The project Dover’s sea front where white architectural precast concrete was used to form a sculptural retaining wall.

has not only already proved its worth by protecting around 1 500 local homes and businesses during one of the biggest tidal

Bodleian Library, Oxford, where architectural-grade precast sandwich panels with a grit-blasted finish clad the building’s external faces.

PRECAST VOLUME 8 • ISSUE 3 • 2014

River Mersey Warrington Flood Risk Man-

surges on the River Mersey since 1990 but

agement Scheme, UK

in addition has been crowned Project of the

That aesthetic appeal can be combined

Year at the recent North West Construc-

with strength and durability can be seen

tion Awards for 2014.

in flood defence wall units that form part

W h a t all th e s e e x amp l e s d em o n -

of phase 1 of the River Mersey Warrington

strate is the increasing sophistication

Flood Risk Management Scheme along a

of architectural precast concrete and

1.5km stretch of the river bank in Latch-

the growing confidence among clients

ford. Here Thorp designed, manufactured

and architects that if they can visualise

and erected more than 400 architectural

something in the material then it is in-

precast concrete units for main contrac-

deed possible.

ARTICLE

25

MOTLHABE VILLAGE ROAD PAVED WITH CONCRETE BLOCK PAVING A 2.5km gravel road which links two provincial roads has been paved with concrete block paving in Motlhabe Village, North West Province. Situated ±90km north west of Rustenburg, Motlhabe Village falls under the Moses Kotane Local Municipality which in turn forms part of the Bojanala Platinum District Municipality.

This turnkey project was awarded to TN

“Another major advantage of CBP is

Molefe Construction Engineers, which han-

its low maintenance requirement. Unlike

dled the design, construction and project

asphalt roads which generally require resur-

management elements. The work, which

facing every seven to 10 years, CBP roads

also entailed the widening of a bridge on the

require very little maintenance and are sav-

road, was begun in June and completed in

ing local authorities R-millions every year.

December 2013.

“For example, the Royal Bafokeng Admin-

The road is 6.2m wide and was paved

istration is saving approximately R13 million

with heavy-duty 80mm interlocking paver

a year or R42 000 per kilometre in main-

supplied by CMA member, Bosun Brick and

tenance cost on 28 villages in North West

another CMA member, Technicrete, sup-

province where some 300km of CBP roads

plied 5 000m of precast concrete kerbing.

have been built since 1996. Some paved

Rated at 35MPa, the pavers were laid

roads have been in operation with very little

on 50mm of bedding sand. The base com-

maintenance for close on 50 years such as

prised 150 G5 stabilised with 3% cement

those found in Chatsworth, Durban.

compacted to 97% MOD AASHTO. The

“Moreover, the initial capital outlay on

sub-base consisted of a 150mm G5 (natu-

CBP roads is only marginally greater than the

ral gravel) layer, compacted to 95% MOD

asphalt equivalent,” concluded Armstrong.

AASHTO and the in-situ road preparation entailed a 150mm G5 (natural gravel) compacted to 93% MOD AASHTO. According to TN Molefe regional manager, Kenanao Mogawane, one of the reasons for using concrete block pavers (CBP) rather than asphalt was job creation, empowerment of local SMMEs and poverty alleviation.

“L ay ing r oads with CBP is labour intensive and of fers the unskilled and unemployed an opportunity of acquiring a marketable skill and earning income. We used 50 unemployed members of the local community to do the actual laying, and they underwent two weeks of SETA-approved training which we outsourced.”

CMA executive director, Wally Armstrong, adds that each job created in a local community has a multiplier effect, stimulating economic activity in other areas.

The Motlhabe Village shortly after the laying of CBP.

PRECAST VOLUME 8 • ISSUE 3 • 2014

26

ARTICLE

The collapsed road above a stormwatwer channel on Andre Greyvenstein Road.

One of the mammoth culverts is lowered into position.

The entrance to the channel showing the wing walls.

MAMMOTH CULVERTS USED for STORMWATER CHANNEL REHABILITATION Mammoth precast concrete culverts, manufactured by CMA member, Aveng Manufacturing Infraset, have been used for the rehabilitation of a stormwater channel which collapsed under Andre Greyvenstein Rd near Gauteng’s Oliver Tambo Airport in November last year.

Excavation work began in March after wayleaves had been granted by Sasol, Eskom, Telkom and Neotel. A total of 32 culverts were delivered by flatbed trucks and lowered into position by a mobile crane onto a concrete platform measuring 35m

T he channel, which comprised a cor-

solution made more sense. In fact one-and-

x 6m. The platform was constructed with

rugated metal pipe, had been gradually

a-half months construction time was saved

500mm of dump rock, two 150mm layers

eroded over decades by chemical and

by using the mammoth culverts, which were

of G7, a 50mm layer of blinding, and 350mm

other industrial effluent and the whole

supplied from our Brakpan factory.”

of reinforce concrete.

section collapsed during some particularly heavy rainfall during November.

Ndodana Consulting Engineers was

Weighing 12,8 tons apiece and reinforced

Concrete wing walls were attached to

with 600kg of rebar, the culverts stand 3.5m

the first culvert using in-situ concrete and

tall, are 5.3m wide and one metre deep.”

the culverts were waterproofed using a

appointed by Ekurhuleni Metropolitan Mu-

normal concrete grout. Sub-soil drainage

nicipality to design the new culvert and a

pipes were installed on the outside of the

decision was taken to widen and deepen

two culvert walls to prevent water build up

the stormwater channel to cope with an

under the road.

anticipated increase in flooding incidents.

Once the concrete work was completed

According to Coenraad Groenewald, tech-

the culverts were covered with G7 material

nical marketing manager of the construction

and then compacted. Some areas were too

products division of Aveng Manufacturing

narrow for the compacting equipment and

Infraset, one design option had been to con-

in these instances soilcrete was used as

struct the culvert using in-situ concrete and

an alternative filling material.

this route would have been chosen had the

Groenewald says that the Andre Greyven-

mammoth culverts not existed.

stein rehabilitation project has opened up

“However, given that this was a public

new opportunities for faster and more eco-

road which needed to be re-opened as soon as possible, opting for a precast concrete

PRECAST VOLUME 8 • ISSUE 3 • 2014

nomical construction of large stormwater An internal view of the culvert channel.

culverts. www.avengman.com.

28

ARTICLE

Precast concrete bridge beam for Exxaro’s Grootgeluk Coal Mine.

CMA ADDS THREE NEW MEMBERS

Three new members have joined the CMA since July and new member enrolment since November 2012 now stands at 37. The new members include cement giant, Lafarge and Italian paving machinery manufacturer, OCEM. The third company is a local lintel and concrete beam manufacturer, Silverton Precast.

Outlined below are brief profiles on some of the new members:

OCEM SRL OCEM SRL was established in 1926 by the Giannelli family, which remains the sole owner. Since 1953, the company has specialised in manufacturing machines for the production of concrete tiles as well as slabs and decorative pavers. Single layer and double layer technologies have been developed and are used widely.

OCEM is a world leader in the sector, in both market share and technology. With around 70 employees, an engineering department, traditional and CNC machines, mechanical, electrical and electronic technicians, and an automated spares warehouse, OCEM operates out of two factories located in Florence.

OCEM technical and commercial services or its local agents are located globally.

Lafarge

www.ocemflorence.com.

Lafarge is the leading global cement brand and a world leader in building materials. Em-

SILVERTON PRECAST

ploying 64 000 people in 62 countries, the

Silverton Precast was founded in 1998 in

Group has top-ranking positions in its ce-

Silverton, Pretoria.

ment, aggregates and concr-ete businesses.

Initially a dedicated concrete lintel

In South Africa, the company manufac-

manufacturer with a production capacity

tures and supplies cement, aggregates,

of 300m per day, Silverton Precast has

ready mixed concrete, gypsum plaster-

grown to be the largest lintel manufacturer

board and interior building fittings.

in Pretoria, producing 4 000m per day.

Lafarge applies its unparalleled techni-

Since 2008 Silverton Precast has ex-

cal strength to continually develop inno-

panded its operations and product range.

vative building material solutions for the

Manufactured precast elements now in-

construction industry, while reducing the

clude bridge beams, median barriers, man-

environmental footprint of its products and

hole covers and palisade fencing. Recent

manufacturing processes.

projects include median barriers for the

The Lafarge brand symbolises integrity, openness, respect for people and the enviLafarge’s Lichtenburg plant.

PRECAST VOLUME 8 • ISSUE 3 • 2014

ronment. www.lafarge.co.za .

Zambezi Interchange on the N1 and bridge beams for Grootgeluk Coal Mine. www.silvertonprecast.co.za.

ARTICLE

29

FOUR PRECAST CONCRETE STANDARDS UNDER REVIEW The CMA’s technical committee under the chairmanship of Taco Voogt has formed a working group to revise four precast concrete standards: SANS 1058 (Concrete Paving Blocks) SANS 1215 (Concrete Masonry Units) SANS 677 (Interlocking Concrete Pipes) and SANS 542 (Concrete Roof Tiles). SANS 1215 needs major revision whereas the other three require only minor changes. Once completed and agreed to by various interested parties, the revised standards will be published by the South African Bureau of Standards (SABS).

The proposed regulations will make South African buildings among the most thermally efficient in the world, but at what cost?

New buildings, especially in the affordable and low-cost housing sectors will become anything but affordable and double-skin cavity walls will become the norm,” says Voogt.

South Africa’s paving standard SANS 1058 was extensively revised in 2010 when a test based on compressive strength was

SANS 1215 was first intro-

standard will be adopted

replaced with tensile splitting, abrasion

duced in 1984 and there

under the auspices of the

resistance and water absorption. The cur-

have been six subsequent

South African Bureau of

rent initiative seeks to remove all reference

amendments. The last two

Standards (SABS) with

to compressive strength as it is deemed

were drafted in 2013 and

a South African annex to

irrelevant to paver performance and to

are currently being circu-

reflect local requirements.

place the standrd’s water absorption re-

l a t e d f o r c omm e n t . T h e

This is not only a simpler

quirement into an annex.

masonry standard includes

option which saves time

Some concrete pipe manufacturers

testing procedures for di-

and money, but the South

have requested an annex on jacked pipes

mensions, squareness, com-

African masonry fraternity

to be inserted in SANS 677 and a working

pressive strength, drying

can draw on the experience

group has been convened by Rocla’s Ger-

shrinkage, expansion and re-wetting and

and research of its European counterparts.

soundness/consistency.

hard Rossouw for that purpose.

“There is a complication, however, and

No changes ar e pr oposed f or the

The CMA’s SANS 1215 working group is

that is the revision of the National Building

roof tile standard, SANS 542, apar t

faced with two options, the first being to re-

Regulations through the addition of SANS

f r om r ectif ying a minor omission f or

vise and update the existing standard which

10400XA, which deals with energy effi-

on-site testing which simply entails the

was historically based on the British masonry

ciency and sustainability. Its introduction

insertion of a missing zero on one of the

standard, (which no longer applies in the UK)

means that concrete masonry manufac-

test schedules. The CMA is monitoring

or to adopt the European standard BS EN

turers must comply with stringent energy

the effect that the revision of the Na-

771-3 which is a supporting standard for

requirements and right now there is no con-

tional Building Regulations through SANS

Eurocode 6 – Design of Masonry Structures.

crete masonry manufacturer which meets

10400L-Roofs may have on the applica-

At this stage it appears likely the European

the standard especially in single-skin walls.

tion of concrete roof tiles.

Please fill out the form below and fax it to +27 11 783 2677 Name:________________________________________________________________

PREC AST VOLU

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1 • 2014

the

cma

– QUa

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Postal address:_______________________________________________________ ______________________________________________________________________

IN cON

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______________________________________________________________________ Telephone: (H)_________________________________________________________ • Build

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concret

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s

ing pract • Preca ice antiq st trans uated • Recor forms facto d retai ry into ning wall show heigh room t

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the cma – QUALITY CAST IN CONCRETE

Telephone: (W)________________________________________________________ Mobile:_______________________________________________________________ Email:_________________________________________________________________

30

APPLICATIONS

SIKA LAUNCHES NEW FLOORING RANGE CMA member, Sika South Africa has launched two flooring epoxies, Sikafloor®- 263SL and Sikafloor®-264 Econo Line. Both products are Clean-room suitable and certified as low VOC (Volatile Organic Compound) emission.

Sikafloor-263 SL is a two-part epoxy self-levelling, broadcast and screeding system. It is highly fillable and economical, offers good chemical and mechanical resistance, easy application, a gloss finish, is liquid-proof, and a slip resistant surface is possible. The self-smoothing and broadcast systems are suitable for concrete and cement screeds with normal to medium/ heavy wear, such as storage and assembly halls, maintenance workshops, garages and loading ramps. The broadcast system is recommended for multi-storey and underground car parks, maintenance hangars and for wet process areas, as found in the food and beverage industry.

Sikafloor-264 is a two-par t epox y roller and seal coat resin. The roller coat product is suitable for concrete and ce-

ment screeds with normal to medium/ heavy wear such as storage and assembly halls, maintenance workshops, garages and loading ramps. The seal coat is suitable for broadcast systems such as multi-storey and underground car parks, maintenance hangars and for wet process areas.

Both new flooring systems can be used with a complete range of different surface finishes, textures and profiles using Sikafloor Decorative systems, namely, SikaDecoFiller, Sika-DecoFlakes and broadcast aggregates, Sika-DecoQuartz.

All the Sikafloor Decorative systems,

Sika-DecoQuartz flooring.

as well as the transparent matt sealer coating, are based on the same low emission, UV resistant, high-per formance epoxy resin that is tested in accordance with Germany’s stringent AgBB minimum outgassing procedure.

TYPICAL AREAS OF USE: Sika-DecoFiller • Life Sciences/ Health Care (Pharmaceu tical industries) • Education (Schools and universities) • Leisure and Culture (Museums and stadiums) • Retail (Shopping malls) Sika-DecoFlake • Life Sciences/ Health Care (Pharmaceu tical industries) • Education (Schools and universities) • Leisure and Culture (Museums and stadiums) Sika-DecoQuartz • Retail (Shopping malls) • Industrial (Manufacturing) • Transportation (Airports) www.sika.co.za.

APPLICATION

PPC takes information sharing and concrete innovation to next level Concrete is the most widely used man-made

C3 will make information for improved

material in the world and is a cornerstone of

efficiency and productivity more accessible.

civilization. The leading supplier of cement in

The streamlined interaction with experts

southern Africa, PPC Ltd, has launched the

also facilitates the flow of information and

Cement & Concrete Cube (C3), a dynamic in-

knowledge transfer. The site is powered by

formation sharing and collaboration platform.

an intelligent search engine which suggests

C3 will facilitate interaction and informa-

content and connects the browser con-

tion sharing between cement and concrete

nections to people with similar interests.

users, designers, academics, industry

31

“The platform will not only enable public access to the information database but allows connections between PPC’s own team members. We believe that experts and thought leaders will be able to inform and influence the industry through this platform, and in doing so, take Africa’s concrete and construction industry to the next level,” says Turner.

C3 also incorporates paid-for-content by providing users with access to the latest international r esear ch in the field of cement and concrete through academic and industrial journals, and

experts and enthusiasts. Participants will

book subscriptions.

find information and contribute to interest

“Our newsdesk feed for South Africa and

groups through blogs, wikis, documents,

Africa is also available on the C3.

graphics and comments in private or public

“C3 will include all material relevant

groups on this platform.

to our industry in the widest sense. As

“This is certainly a first-of-its-kind in the

a dynamic platform, we envisage that its

cement and concrete industry. C3 is more

content and scope will grow and reinforce

than a professional directory, pin-board or

PPC’s strength beyond the bag ethos,”

social chat page - the facility to upload and

concluded Turner.

share information in all formats sets C3 apart,” said Hanlie Turner, PPC’s specialist of technical information services.

PPC staff look on as Monique Eggebeen, MD of the Echo Group of Companies registers on the Cement & Concrete Cube.

The PPC Cement & Concrete Cube will be available to all stakeholders. To access the platform, register at http://c3.ppc.co.za/.

32

application

REVELSTONE LAUNCHES OFF SHUTTER CLADDING CMA member, Revelstone, has expanded

ble and hard wearing which makes it a great

which will reduce its weight by more than

its range of engineered concrete products

option for both commercial and residential

50% and make it even easier to apply.

by launching Off Shutter, a wall cladding

structures. It is currently available in our

“We launched the product at the Cape

block which can be used for enhancing un-

standard concrete and weighs approxi-

Homemakers Expo in September and were

plastered brick and other types of walling.

mately 56 kg per square metre. However,

overwhelmed with the interest and positive

Available in four sizes, it has been de-

we are also launching light-weight version

feedback. The market has been waiting for

signed to simulate the look of in-situ off

an alternative to in-situ off shutter concrete

shutter concrete. Different sizes can be

for some time now and Off Shutter provides

combined to create realistic and attrac-

the answer, especially when one considers its

tive wall finishes for internal and external

refined appearance and multi-colour options.

applications and, using Tylon WB114, Off

The four Off Shutter sizes are:

Shutter is very easy and cost-effective

• 1000mm x 500mm x 25mm

to apply.

• 500mm x 500mm x 25mm

Revelstone director, Alex Cyprianos,

• 1000mm x 300mm x 25mm

says Of f Shutter has a more refined

• 500mm x 300mm x 25mm.

texture than in-situ concrete and being a

Off Shutter is currently available in any

wetcast product, it can be manufactured

of Revelstone’s standard 16 colour range,

in almost any colour, consistently and in

making it a very versatile and attractive al-

any quantity, large or small.

“Off Shutter cladding is extremely dura-

Off Shutter’s launch at the Cape Homemakers Expo in September.

ternative for designers looking for a cleancut, modern finish. www.revelstone.co.za.

APPLICATION

33

PMSA SECURES CONTROLLED CURING EQUIPMENT AGENCY CMA member, Pan Mixers South Africa (PMSA), the largest supplier of concrete brick, block and paving making machinery in Africa, has secured the Sub-Saharan African marketing rights for German-controlled curing equipment supplier, Kraft Curing Solutions.

Kraft produces customised thermal-dynamic and accelerated concrete curing equipment which results in precast concrete products with higher strengths, less efflorescence, and brighter colours. The company has designed and installed over 650 concrete curing systems in 56 countries since it was founded in 1991.

Kraft and PMSA have struck an agreement whereby curing equipment can be imported from Germany in kit form to be assembled by PMSA appointed sub-contractors using local insulation and ducting materials. This will not only make the equipment more affordable for local precast concrete producers but will create jobs and stimulate the local economy.

According to Kraft Curing Solutions, managing director, Michael Kraft, controlled curing makes for a more durable concrete product and can result in reduced cement usage of up to 10% and a decrease in pigment content.

“Cement hydrates naturally, but what we are doing is controlling that process to take advantage of characteristics that benefit the producer. Controlled curing results in concrete with a higher resistance to abrasion and chloride penetration. Moreover, less chipping occurs on the corners and edges of precast concrete products,” says Kraft.

PMSA has already delivered Africa’s first Kraft Curing Solutions plant to brick-maker, Van Dyk Stene in the Western Cape.

One of the most advanced curing systems in the country, the plant comprises fully insulated racking and curing chambers, and includes circulation of the precast products.

Kraft and his colleagues have accumulated vast and in-depth knowledge in precast concrete curing and during September they shared some of this expertise with South African professionals in two seminars held in Johannesburg and Cape Town. The principles of curing as well as the difference between racking and curing systems were discussed, and products covered included: bricks; blocks; pavers; roof tiles; prestressed slabs; concrete piping and other types of infrastructural concrete.

PMSA sales and marketing manager, Quintin Booysen, says the South African market is ready for this evolution in precast concrete manufacture.

“By installing curing systems manufacturers will find it easier to maintain consistent quality,” comments Booysen.

A Kraft Curing Solutions vapour generator used for curing precast concrete.

PRECAST VOLUME 8 • ISSUE 3 • 2014

34

APPLICATION

INNOVATIVE THINKING GENERATES NEW RETAINING WALL CONCEPT

combination with geotextile membrane.

The design offered substantial savings in reinforced concrete and formwork, not to mention considerably faster construction times,” said Echo technical director,

A new concept in retaining wall systems,

construct an in-situ retaining wall. Echo’s

Echo Gravity Retaining Walling (EGRW),

engineers, however, believed that a pre-

“When the decision to opt for the EGRW

which utilises precast concrete hollow-core

cast concrete wall would offer a more

route was taken an in-situ wall foundation

slabs in combination with geotextile mem-

cost-effective option and submitted an

and steel starter bars were already in place

brane, has been introduced by South Africa’s

alternative design proposal based on the

and to minimise costs, we incorporated

leading hollow-core slab producer, and CMA

use of prestressed hollow-core slabs in

these elements into the EGRW design,”

member, the Echo Group of Companies.

Daniel Petrov.

said Petrov.

The first EGRW system was built at

The top of the wall was finished with

the recently constructed Green Cross

precast concrete coping to add further

Medical Centre, one of the first property

aesthetic appeal.

developments to have been completed

Petrov says that precast retaining walls

at the newly pr oclaimed L or ds V iew

are generally built considerably faster than

Industrial Park, situated in Chloorkop,

in-situ walling.

Kempton Park.

“Moreover, because our hollow-core

The idea behind the Green Cross EGRW

slabs are manufactured in a factory envi-

wall, which is 135m long and varies between

ronment in compliance with Echo’s strin-

2,5m to 5,7m high, was the brainchild of

gent quality control measures, we are able

Echo’s engineering team.

“The original intention had been to

to provide a top-quality end product on a The completed Green Cross EGRW wall.

consistent basis.” www.echo.co.za.

36

MEMBERS’ LIST

Producer members telephone

PROVINCE/ country

Pillar

A Fick Sementwerke Bk

022 913 2370

Western Cape

PB

Aveng Manufacturing Infraset

011 876 5500

Gauteng

PB/PI

Bass Beams

031 784 1920

Kwa-Zulu Natal

Bay Brick

035 792 5218

Boland Concrete

telephone

PROVINCE/ country

Pillar

Rocla

011 670 7600

Gauteng

PB/PI

Shukuma Flooring

041 372 1933

Eastern Cape

PB

PB

Silverton Precast Pty Ltd

012 804 4525

Gauteng

PB

Kwa-Zulu Natal

PB

Smartstone

011 310 1161

Gauteng

PB

021 875 5365

Western Cape

PB

Southern Pipeline Contractors

011 914 8500

Gauteng

PB/PI

Bosun Brick Midrand

011 310 1176

Gauteng

PB

Style Décor Pty Ltd

012 376 2454

Gauteng

PB

Brickbuild t/a Panda

00267 244 2107/8

Botswana

PB/PI

00264 6446 3717

Namibia

PB

Brickcast Industries cc

031 507 5525

Kwa-Zulu Natal

PI

Technicrete

011 674 6900

Gauteng

PB/PI

C.E.L. Paving Products

021 905 5998

Western Cape

PI

Topfloor Concrete

021 951 7700

Western Cape

PB

Cast Industries

011 316 2375

Gauteng

PB/PI

Vanstone Precast Pty Ltd

012 541 2056/1808

Gauteng

PI

Civil Works

011 903 7023

Gauteng

PI

West End Cement Bricks Pty Ltd

011 851 1005/1063

Gauteng

PI

Concrete Units

016 362 2236 021 386 1923

Western Cape/Gauteng

PB/PI

Conframat

0861 33 5599

Gauteng

PB/PI

Corobrik Pty Ltd

031 560 3111

Kwa-Zulu Natal

PI

Deranco Precast

041 933 2755

Eastern Cape

PB/PI

Eagle Roof Tiles Pty Ltd

044 874 0290

Western Cape

011 589 8800/8899

company name

company name

Swakop Tiles cc t/a Namib Roof Tile Company

PI - Precast Infrastructure PB - Precast Building

Associate Members telephone

PROVINCE/ country

Aspasa

011 791 3327

Gauteng

PB

ARQ Consulting Engineers Pty Ltd

012 348 6668

Gauteng

Gauteng

PB

British Precast Concrete Federation

044 116 253 6161

United Kingdom

002677 1321528

Botswana

PB

Concrete Society

012 348 5305

Gauteng

Inca Masonry Products

043 745 1215

Eastern Cape

PB/PI

ILIFA Africa Engineers Pty Ltd

012 362 1473

Gauteng

Keystone Walling

082 850 3512

Gauteng

PB/PI

JC Paving Consulting

011 431 0727

Gauteng

Lategan Cement Works

021 873 1154

Western Cape

PB

Sekhukhune & Associates

012 993 4776

Gauteng

Mobicast (Pty) Ltd

044 874 2268

Western Cape

PB

SNA Civil & Structural Eng

012 842 000

Gauteng

Monier Roofing South Africa

011 222 7300

Gauteng

PB

SARMA

011 791 3327

Gauteng

MVA Bricks

012 386 0050

Gauteng

PI

The Job Club

012 661 1099

Gauteng

Portland Hollowcore Slabs Pty Ltd

021 972 1111

Western Cape

PB

Terraforce Pty Ltd

021 465 1907

Western Cape

ReMaCon Products cc

011 393 5504

Gauteng

PI

Tjeka Training Matters

011 665 2777

Gauteng

Revelstone (Cape) Pty Ltd

021 761 9734

Western Cape

PB

Young & Satharia Consulting Civil Engineers

031 207 7252

Kwa-Zulu Natal

Echo Group

Fastdeck Pty Ltd

PRECAST VOLUME 8 • ISSUE 3 • 2014

company name

MEMBERS’ LIST

37

non-producer members telephone

PROVINCE/ country

Abel Equipment

044 874 1876

Western Cape

Ash Resources (Pty) Ltd

011 657 0230

Gauteng

H Birkenmayer (Pty) Ltd

011 970 3880

Gauteng

Chryso Southern Africa Pty Ltd

011 395 9700

Gauteng

Doubell Brick Machines

041 585 9060

Eastern Cape

Delta Bloc South Africa (Pty) Ltd

011 024-4604

Gauteng

Dick King Lab Supplies

011 499 9400

Gauteng

Envirotan

011 452 7906

Gauteng

00 45 9645 4040

Denmark

Kaytech

031 717 2300

Kwa-Zulu Natal

Kerenos Southern Africa Pty Ltd

011 444 3090

Gauteng

003111 356 2460

Netherlands

011 975 7770

Gauteng

Ocem

0039 055 658 0120

Italy

Pan Mixers SA Ltd

011 578 8600/8701

Gauteng

00865 958 679 9299

China

0082542607722

Korea

company name

HawkeyePedershaab

Kobra Moulds B.V. Manitou SA (Pty) Ltd

Quangong Machinery Co. Ltd SamJung Industries Ltd Schlüsselbauer Technology GmbH & Co KG Sika South Africa Pty Ltd Techmatik S.A.

004377357144 201

Austria

031 792 6500

Kwa-Zulu Natal

00484 803 690 811

Poland

cement members telephone

PROVINCE/ country

AfriSam South Africa

011 670 5500

Gauteng

Lafarge Industries South Africa Pty Ltd

011 657 0000

Gauteng

PPC Ltd

011 386 9000

Gauteng

Sephaku Cement

012 684 6300

Gauteng

company name

CONTRACTOR members telephone

PROVINCE/ country

Decorton Retaining Systems

021 875 5155

Western Cape

Friction Retaining Structures Pty Ltd

011 608 4321

Gauteng

Powergate Construction

071 603 5070

Gauteng

PYW Paving

031 903 1736

Kwa-Zulu Natal

Valcal International Export

011 867 2471

Gauteng

company name

PRECAST VOLUME 8 • ISSUE 2 • 2014