speci cally designed for all your concrete, mortar and plaster needs. This versatile, locally-produced cement ensures consistent strength, workability and durability. Each bag re ects our unwavering commitment to superior quality. Cement Your Legacy and Ask for AfriSam.
MBA North members continue their winning streak 12 MBA KZN celebrates excellence at annual awards SKILLS AND TRAINING
Zimile calls for collaboration as SA invests in infrastructure INDUSTRY NEWS 17 Prominent hotel to undergo refurbishment with REHAU solutions 18 Rural road infrastructure needs more attention
Premium, professional after-market service
Suspension trauma management
INNOVATION
25 Zutari’s young engineering talent commended
BUSINESS
27 Harvey Roofing’s new robotics solution
PRODUCTS
29 Fireproof aggregate for screeds, walls and floors
31 Mobile jetting unit simplifies inner-city plumbing maintenance
PROJECT MANAGEMENT
32 Cracks and carbonation: What’s your corrosion mitigation plan?
GLOBAL VIEW
39 The science of sheen
CAPTAINS OF CONSTRUCTION
40 Meet Heinrich Schroder, business development manager: Gravity
PUBLISHER
Jet Demolition helps mining houses meet their ESG commitments
Isikhova Media (Pty) Ltd 10th Floor, Metal Box, 25 Owl Street, Milpark, Johannesburg, South Africa
Severe weather conditions have caused havoc in many parts of South Africa. There are also reports of very old drainage systems in many municipalities. We have members who are willing and able to help sort out the backlogs in the crumbling infrastructure.
Despite good efforts from the Security Cluster, the crime rate continues in the country. We encourage members to support the efforts of Business Against Crime SA groups in their respective areas and to report crime. It was encouraging to read National Police Commissioner Fannie Masemola’s statement: “We’re cracking the whip and fetching each of these extortionists, one by one.” I hope the same vigour can be used to beef up the intelligence units so that the police become more proactive.
We live in a very challenging business environment where good technical skills and business management acumen are no longer the only recipes for a competitive edge. Visionary and supportive leadership embraces diversity, equity and inclusion, along with potential and intelligence.
Since its establishment, this federation has
EDITOR' S NOTE
offered many training programmes and bursaries. Due to natural attrition, retrenchments and general unemployment, we have witnessed the migration of critical skills to other industries in the country and offshore. The need for impactful training cannot be over-emphasised. I believe that real training is anchored to practical, on-the-job mentorship. Quality of work should always be uppermost in our minds. Those who cut corners and do shoddy work should be reminded of John Ruskin’s words in The Seven Lamps of Architecture: “Therefore, when we build, let us think that we build forever… Let us think as we lay stone on stone that a time will come when those stones will be held sacred because our hands have touched them, and that men will say when they see them: ‘See! This our fathers did for us!’”
Sam Ngcongo: President: MBSA
As 2024 draws to a close, the construction industry is both licking its wounds and looking hopefully to the new year. The much-needed kick-start of the sector has been long in coming, despite repeated promises from government about investment, development and addressing the country’s many infrastructural problems, as well as providing housing for scores of desperate communities.
Yet there is certainly cause for optimism. Projects have continued apace, interest rates have lowered and new entrants to the industry indicate that activity is ongoing.
By the time this issue appears, the American election results will be known. Their effects on the global industry will soon be felt, and – like the spin-offs of the conflicts being waged around the world – will have particular bearing on the prices of oil and other essentials.
We wish our all readers a safe and happy festive season and a well-deserved break after a challenging year. We look forward to a 2025 in which our industry is restored to its rightful place as a crucial sector in our beloved country.
swartland.co.za
Swartland, a leading supplier to the building trade since 1951, offers a diverse range of quality products. From wooden windows and doors to aluminium windows, doors and showers, garage doors and automation, XPS insulation board, cornices, awnings and manufactured
products, we have it all. ‘Experience Quality’ is not just a slogan. It’s our commitment to maintaining the highest standards, ensuring that every interaction with us is a testament to quality. Call us on 086 110 2425 or visit swartland.co.za to discover our extensive product range.
CONCOR: GOING FROM GOOD TO GREAT
Continued dedication to quality management allows Concor to raise the performance bar, thereby streamlining projects for customers and ensuring the highest levels of workmanship.
According to David Akinnusi, senior quality assurance and quality control (QA/QC) manager at Concor Construction, the quality journey has led to significant advances in the company’s key performance indicators (KPIs). For instance, there has been a 30% improvement in its pass rate for first-time inspections in recent years.
“Our continuous attention to quality is taking us from good to great,” explains Akinnusi. “An important factor driving this process has been our ‘Build to Last’ quality initiative, which we launched two years ago.”
This commitment, he explains, means creating an enabling environment for high performance by all Concor employees – to build long-lasting structures that satisfy clients. The quality philosophy drives this performance through excellent workmanship, delivered consistently in every project.
“By carefully managing our work
processes, we ensure the quality of our outputs or end-results,” he says. “Our quality system also benchmarks these processes against world-class standards; the system itself complies with ISO 9001:2015, while our workmanship meets both SA National Standards and each project’s specifications.”
Concor’s quality assurance is therefore closely tied to established standards and procedures, which undergo internal auditing. This is followed by the quality control function, in which the necessary measures are applied through work area inspections and material testing, for example.
“What’s important is that we allocate designated QA/QC personnel to each project,” says Akinnusi. “They’re dedicated
to monitoring and ensuring compliance with both internal and external procedures and specifications.”
He notes that Concor’s quality philosophy extends beyond the physical structures that the company erects to the people who build them. This relates to creating a culture of excellence where everyone feels proud, valued, respected and empowered to do their best work.
“We believe the work done by every individual connects us as a team,” says Akinnusi. “This makes training and development paramount to our operations. It’s vital that our employees are well equipped to champion excellence on every site.”
This staff development is done through a range of ongoing programmes designed to bring the latest knowledge and skills into each field of work. Among Concor’s development initiatives for employees are its study assistance
programme, its engineer-toproject-manager programme for graduate engineers, its performance enhancement programme and its career path and succession planning for key functions.
Combining its systems with its depth of experience and skills, the company is able to manage its quality at every stage of the project life-cycle. At planning stage, for instance, detailed tender reviews are undertaken by the project contract director and the estimating team. This helps to understand the detailed project requirements in relation to resourcing, scheduling and costing of projects.
“When we get to the design stage, we use only professionally registered engineers to produce drawings for construction,” says Akinnusi. “Collaborative efforts are made to identify constructability concerns with the designers, both at the design and construction phases of a project.”
“WE ALSO ALLOCATE SUFFICIENT SUPERVISION TO THESE SPECIFIC HIGHRISK TRADES AND ENSURE THAT THE PERSONNEL INVOLVED ARE COMPETENT AND TRAINED.”
During execution, strict quality control plans are compiled and agreed on between Concor and the client. These outline the specific testing and inspection requirements for different activity trades in the project.
“The handover of works is done progressively through trade data book reviews,” he says. “Clients are contractually allowed to snag the works, ensuring that the handover’s done to their satisfaction.”
There is also a post-handover stage, when a contractual defects liability period is applied. Depending on the latent root cause of a defect, Concor remedies any that arise during this period. Akinnusi notes that concreting, brickwork and waterproofing are fields in which contractors commonly experience quality challenges. Overcoming them demands proactive mitigation, with Concor using robust root cause analysis and lessons learnt to apply preventive measures.
“We also allocate sufficient supervision to these specific high-risk trades and ensure that the personnel involved are
competent and trained,” he says. “Our success in doing this is reflected in our nonconformance reporting [NCR] – another of our KPIs – and has direct cost benefits. In recent years, we’ve trimmed our NCR rates by 20%.”
A crucial outcome of all these quality efforts is the strengthening of relationships with clients, says Akinnusi, so Concor’s KPIs include regular feedback surveys to measure client satisfaction. An intensive 20-item questionnaire is
conducted with clients each year to gauge this important factor, so any issues can be quickly identified, discussed and resolved.
“This level of customer engagement helps to underpin the excellence we deliver, which leads to repeat business,” he says.
“In the Oxford Parks Precinct developments, for instance, we’ve been engaged in five separate contracts over the years – a good sign of client trust in our ability.”
With standards this high and service of this calibre, there is no doubt that Concor is claiming a uniquely elevated niche for itself in the industry. Good to great, indeed.
“AN IMPORTANT FACTOR DRIVING THIS PROCESS HAS BEEN OUR ‘BUILD TO LAST’ QUALITY INITIATIVE, WHICH WE LAUNCHED TWO YEARS AGO.”
CHANGES TO NHBRC REGISTRATION AND RENEWAL POLICY
The National Home Builders Registration Council (NHBRC) is making important changes to its Registration and Renewal policy, effective December 2024.
These changes are aimed at ensuring that all registered homebuilders maintain the highest technical standards, thereby enhancing the quality and reliability of home building services.
All registered homebuilders are advised to read the following new requirements carefully and ensure compliance to avoid any disruptions to your registration status:
Homebuilders and technical managers: Rules of engagement
• Homebuilders must demonstrate appropriate financial, technical, construction and management capacity during registration, relevant to the specific
nature of their business.
• Registered homebuilders are required to have active technical managers.
• A homebuilder may nominate more than one technical manager to take the NHBRC technical assessment.
• During the renewal of NHBRC membership, registered homebuilders must update the details of their technical managers.
• For every enrolled project, the homebuilder must inform the NHBRC of the appointed technical manager.
• Any technical manager who fails the technical assessment more than twice will undergo a three-month cooling-off period to receive preparatory training from the NHBRC. During this period, the homebuilder may appoint a new technical manager to take the assessment.
• A technical manager may represent more than one homebuilder, subject to
approval by the provincial manager.
• Homebuilders with multiple active sites are encouraged to appoint residential technical managers, who will also be subject to the NHBRC technical assessment.
• If a technical manager resigns from the company, the homebuilder must appoint a replacement within 21 calendar days.
• Homebuilders operating without an NHBRCassessed technical manager may face suspension.
• All changes regarding the technical manager must be promptly communicated to the NHBRC, as the company’s technical competency relies on their skills and knowledge.
Should you have any questions or require further clarification, contact any NHBRC provincial office or visit: www.nhbrc.org.za.
Visit: www.nhbrc.org.za
ANNUAL “SAFETEMBER” CONFERENCE
Federated Employers Mutual (FEM) held its annual “Safetember” conference and national awards in Johannesburg on 3 September 2024. Major focus areas were motor vehicle safety, the George building collapse and mental health in the construction industry.
Milly Ruiters, chief inspector of the Department of Employment & Labour, pointed out that the construction industry is one of the high-risk sectors in the country and, indeed, around the world. She noted that the recent round of blitz inspections countrywide had indicated 33% non-compliance with health and safety regulations.
It was also noted that motor vehicle accidents are the single biggest contributor to fatalities in our industry.
FEM chief business development manager, Dr Sanjay Munnoo, highlighted some of the innovative initiatives on the cards at FEM and FEM health and safety coordinators Loria Malindzisa reported that there were 105 fatalities as a result of motor vehicle accidents over the five-year period to 2023, 43% of which were single-vehicle accidents and 28% head-on collisions. The East Cape also recorded the highest number of motor vehicle fatalities. This is certainly an area that our health and safety team will have to focus on, going forward. Motor vehicle accidents – like fatal accidents on construction sites – are avoidable, provided the importance of observing safety precautions becomes nonnegotiable for all concerned.
One of FEM’s pensioner beneficiaries, Abel Ntshabele, who was severely injured in a head-on collision, gave an inspiring testimony to both FEM and his employer, Ruwacon, which had stood by him through his long trial and recovery. He strongly emphasised that his employer’s WCA with FEM had ensured that he did not become another fatality, but was still alive to tell the tale. His words made a strong impact on the audience.
The “Safetember” conference was an informative and important event which reminded us that while construction is a key industry in the future of our country, its central concern must always remain the lives and safety of its people.
MBA NORTH MEMBERS CONTINUE THEIR MULTIYEAR WINNING STREAK
MBA North members have continued their multi-year winning streak by being placed in the top four of every category in the 2024 MBSA National Safety Competition (NSC) – the flagship event for health and safety in the building industry.
Gerhard Roets, health and safety manager at MBA North, says the competition was particularly fierce at this year’s NSC, which pits members from seven MBA districts against each other. The competition aims to encourage and reward
health and safety best practice in construction, which is – by its nature – a dangerous sector to work in.
The 2024 MBSA NSC received 44 entries and three voluntary withdrawals. Audits were
conducted at 42 construction sites, including plant yards and manufacturing premises, across various categories over six weeks from 18 June-31 July 2024. During this time, the two auditors travelled a total of 10 403km by road and air.
“MBA members who take part in the regional competition and progress to the national competition are committed to best practice in occupational health and safety. The fact that so many of them are top performers year after year is encouraging and sets a good example to others in the industry. This year, the competition at the national level was tough, with an exceptionally high average compliance rate of 98%. This meant that a mere 0,01% could be the difference between taking first and second place in the competition,” says Roets.
MBA North members – most of whom have won several safety awards – took one first place, two second places, four third places and two fourth places in the 2024 competition.
WBHO Construction Signage Manufacturing was placed first in Category B2 for manufacturers. This is the third time WBHO has been a top achiever in the National Safety Awards, finishing in the top three of every category from 2021-2024.
Form-Scaff Nelspruit finished second in Category B1 for allied trades and GVK-Siya Zama Building Contractors took second
place in Category F for the Bertrams Multi-Purpose Centre. Form-Scaff is a multi-award-winner in the National Safety Awards, having won twice before.
Third places were taken by Tiber Construction Village Deep Yard in Category A, Washirika 3 Oaks for a Bedfordview residential development in Category D, TriStar Construction for the China City Shopping Centre Crown City in Category E, and a joint venture between WBHO and Trencon for Barlow Park Residential Phase 2 in Category G. Tiber Construction has won four National Safety Awards, while Washirika 3 Oaks has two to its credit and WBHO has six.
Fourth places were awarded to WBHO Construction for Teraco JB5 in Category H and GVK-Siya Zama Building Contractors for the Soshanguve Plaza Redevelopment in Category I.
Roets congratulates the MBA members, noting that participation in the regional and national safety competitions is voluntary and that only companies committed to health and safety and seeking to benchmark themselves against industry best practice participate.
“With a 2% improvement in average compliance rates, the compliance rate this year was one of the highest ever,” he says. “This may be due in part to the fact that the construction industry’s better regulated than many others. In addition, industry bodies and
stakeholders like MBA North and the Federated Employers’ Mutual Assurance Company (FEM) play an active role in improving health and safety in construction.”
MBA North and FEM collaborate on a range of initiatives to improve workplace health and safety on site, as well as working to enhance awareness of the importance of other factors that influence workplace safety, such as nutritional status and HIV/Aids management.
MBA NORTH
MBA KZN CELEBRATES EXCELLENCE AT ANNUAL AWARDS
The MBA KZN Annual Awards honour exceptional achievements in construction and occupational health and safety. Held on 25 October 2024 at the Radisson Blu Hotel in Umhlanga, under the theme “Future-Proofing Sustainable Construction”, this high-profile gathering brought together construction companies and key industry stakeholders to acknowledge those who have attained excellence in their
respective disciplines.
Public Works & Infrastructure
Minister Dean Macpherson delivered the keynote address via a recorded video speech, in which he announced key priorities that resonated with the audience. He expressed commitment to helping rebuild the nation’s economy and address social challenges by transforming South Africa
into a hub of construction and opportunity. He added that there was an agenda to create thousands of jobs by expanding the construction sector and to vigorously address corruption and criminal activity plaguing construction sites.
Emphasis was placed on collaborating with the sector to unlock its full potential and one of the priorities was transforming SA
The team of WBHO Construction KZN, which was the Overall Winner of the awards.
into a construction site by fasttracking catalytic infrastructure projects, which means ensuring that such projects are completed on time and within budget. Macpherson called on MBSA to partner with government in this regard.
Marcus Peter Gonzalves, the president of MBA KZN, opened the gala event and stated: “These awards aren’t just about recognising outstanding projects, but are a tribute to the resilience, innovation and dedication that our industry embodies, even in the toughest times.”
Vikashnee Harbhajan, executive director of MBA KZN, unveiled the recipients of the awards for excellence in construction and health and safety, stating that by honouring these accomplishments, the association
aimed to promote best practice, inspire continuous improvement and elevate the overall standards of the construction sector.
Special awards were bestowed to recognise outstanding contributions to the construction sector. MBA KZN congratulates the following distinguished recipients:
• Award of Merit: Barry Livsey, Watertite Projects CC
• Supplier of the Year: Thekweni Reinforcing (Pty) Ltd
• Woman in Construction: Indrani Govender, Ricinz Construction
• Health and Safety Person of the Year: Viresh Rajkumar, Enza Construction
• Supreme Award for Health and
Safety: Patcon Building and Civil Engineering Contractors (Pty) Ltd
• Supreme Award for Excellence in Construction: CHA Construction CC
• Overall Winner: WBHO Construction KZN
The MBA KZN Annual Awards remain a beacon of excellence, encouraging construction companies to strive for the highest standards in construction and health and safety.
“THESE AWARDS AREN’T JUST ABOUT RECOGNISING OUTSTANDING PROJECTS, BUT ARE A TRIBUTE TO THEIR RESILIENCE, INNOVATION AND DEDICATION.”
Health and Safety Person of the Year Viresh Rajkumar of Enza Construction receiving his award.
The Supreme Award for Excellence in Construction went to CHA Construction CC.
ZIMILE CALLS FOR COLLABORATION AS SA INVESTS IN INFRASTRUCTURE
As South Africa continues to navigate its economic recovery, Zimile Consulting Engineers welcomes the recent MediumTerm Budget Policy Speech delivered by Finance Minister Enoch Godongwana.
With government planning to invest more in infrastructure over the next three years, Zimile Consulting Engineers CEO Shawn Gama is optimistic about the growth trajectory towards which the country is heading.
“Godongwana’s announcement emphasises the importance of relationships between the private sector and government, both from a financing and technical expertise perspective, to enhance publicsector capabilities. This approach is essential for bridging significant funding gaps and ensuring that infrastructure projects are executed efficiently,” he notes.
He says it is also encouraging that, according to Godongwana, private-public partnership (PPP) regulations are being simplified to
undertake these projects. “The proposed amendments should attract more private-sector investment, which is crucial, as public funding alone is insufficient to meet our growing infrastructure needs.”
INFRASTRUCTURE
DEVELOPMENT – A SHARED RESPONSIBILITY
However, Gama emphasises the role businesses play in providing opportunities for young people to assist in boosting the economy. “Government’s focus on infrastructure investment presents an excellent opportunity for companies in the built environment to contribute meaningfully to skills development while addressing critical infrastructure gaps.”
Through collaboration with public institutions and leveraging programmes offered by institutions, such as the Sector Education and Training Authority, businesses can help equip young South Africans with the competencies necessary for
future employment.
“As investor sentiment improves in SA, I’d like to encourage businessowners in the country to facilitate access and provide unemployed youth with the opportunity to gain experience and skills. As business leaders, we can open the doors to the youth and enable them to build their careers while building our businesses,” says Gama.
BUILDING A SUSTAINABLE FUTURE
The 2024 MTBPS sets a clear direction for enhancing infrastructure investment in SA. Zimile Consulting Engineers is committed to being part of this transformation by participating in infrastructure projects and fostering an inclusive approach that prioritises skills development and job creation.
“As we move forward, it’s imperative that private-sector players actively engage with government initiatives to unlock new opportunities and drive economic recovery,” says Gama.
Shawn Gama, CEO of Zimile Consulting Engineers.
PRODUCTS
Storm Water
Electrical
Markers
Water Reticulation
Outdoor & Building
Polymer Products
Mining Solutions
Kerb Inlet & Road Products Custom Products
SERVICES Moulds
Drawings
PROMINENT HOTEL TO UNDERGO REFURBISHMENT WITH REHAU SOLUTIONS
Platinum Hospitality Holdings chose REHAU partner, New Look Window Systems, to implement a three-phase project to refresh the windows and doors of the guest rooms at the Protea Hotel by Marriot Sea Point. Phase 1 (67 rooms) is complete, with Phase 2 in progress.
“The hotel already had uPVC window and door frames, but they wanted a more sophisticated
iteration that would improve thermal efficiency even more and block out ambient sound,” says Jörn Jünger, sales director of New Look Window Systems. “Having had uPVC frames in place for at least 20 years, the owners knew the benefits of the material from a low maintenance point of view, but wanted to take advantage of REHAU’s sophisticated design parameters to meet more
stringent goals, such as better noise and temperature control.”
New Look Window Systems is a long-established Cape Townbased firm which custom-makes window and door frames using uPVC lengths imported from REHAU.
The new REHAU frames are made out of a special highweather formula uPVC in order
REHAU’s formulation means that the hotel can withstand not only ultraviolet rays, but also the corrosive effects of the sea air.
SOUTH
to cope with the harsh African climate. Cape Town’s long, dry summers mean that all materials have to cope with a high amount of ultraviolet radiation, which can reduce the lifespan of weaker materials and cause colour to fade. REHAU’s formulation means that the hotel can withstand not only ultraviolet rays, but also the corrosive effects of the sea air – and without the extra maintenance that timber and aluminium frames require.
The hotel’s owner, Platinum Hospitality Holdings, chose REHAU’s ECOTEC range with double glazing to enhance thermal efficiency in both the hot summers and cold winters of the city, as well as sound-deadening. Since the establishment occupies a prime site in vibrant Sea Point, the latter was a major requirement to ensure guests’ comfort.
“Experience showed us that uPVC was the right choice of material from many points of view, so it was an easy choice to make,” says Jünger. “Our team and REHAU ensured that the new windows and doors lived up to expectations. Once Phase 1 of the installation was complete, it was immediately obvious that the acoustic safety glass has made an enormous difference when it comes to outside noise. Once all three phases are complete, we expect the whole hotel to start realising the benefits of
greater thermal efficiency too.” In addition, a highly secure six-point locking system was installed on all the balcony doors to enhance security, a key consideration for South Africans. Phase 2 will cover 36 rooms, as well as windows and doors in passages and common-area bathrooms.
Standard colours for REHAU uPVC are white, bronze, black and two shades of grey. Other colours can be provided by using specially formulated paint.
Jünger says that, for best results, REHAU and its local partners
“NEW LOOK WINDOW SYSTEMS IS A LONGESTABLISHED CAPE TOWNBASED FIRM WHICH CUSTOM-MAKES WINDOW AND DOOR FRAMES USING UPVC LENGTHS IMPORTED FROM REHAU.”
should be involved at the design stage of any project to ensure that the technical specifications, as well as aesthetics, are properly integrated.
“More South Africans have been recognising that uPVC has an unbeatable value proposition, offering greater security, low maintenance and considerable thermal efficiency and noisereduction – which is why it has become the material of choice in Europe and the USA, where climatic conditions are much more severe,” says Stephan van Niekerk, CEO at REHAU Industries. “It’s significant that PVC was chosen again for the hotel’s window and door frames when developing the specifications for this major upgrade.
“The fact that REHAU’s local fabricators can offer a range of standard and bespoke colours also means that architects and owners can get the look they want.”.
REHAU’s acoustic safety glass has made an enormous difference when it comes to outside noise.
Routine and periodic maintenance of rural road infrastructure requires more attention.
RURAL ROAD INFRASTRUCTURE NEEDS MORE ATTENTION
With South Africa’s road network playing a pivotal role in the country’s economic recovery and growth, proper planning and scheduled road maintenance in rural areas also need to be prioritised, says Ntsika Mhlanga, route manager at Zimile Consulting Engineers.
He adds that routine and periodic maintenance of the rural road infrastructure requires more attention, as a significant portion of the country’s roads are gravel, isolated in rural areas with little or no oversight. These roads are often in poor condition,
which makes mobility difficult. The knock-on effect is the obstruction of transportation of agricultural produce to urban centres, labourers and rural communities (including school pupils) being unable to reach their workplaces and schools, and periodic rains exacerbating the problem by creating mudlogged roads which are impassable and develop dongas.
The Department of Public Works’ National Infrastructure Plan 2050 alludes to this by highlighting that more than
80% of the country’s provincial roads are gravel, with only 1% being regravelled every year. This means that for every 100km of the total gravel network, only 1km is regravelled.
“We know there’s a commitment from various stakeholders, such as SANRAL and national, provincial and local government, who drive new projects, maintaining and rehabilitating existing road infrastructure. These investments remain critical and need to be executed to have safe roads for the benefit of the public,” says Mhlanga.
More than 80% of the country’s rural roads are gravel.
PREMIUM, PROFESSIONAL AFTER-MARKET SERVICE
Plant optimisation and, ultimately, business profitability depend on high machine and equipment performance, reliability and availability. These, in turn, depend on the strict implementation of well-orchestrated service and maintenance strategies – something Atlas Copco has perfected.
“Maintenance procedures, while comprising a vast range of topics, are in fact a very simple concept,” says Douw van Schalkwyk, business line manager for Power Technique’s Service Division. “It all comes down to adhering to the maintenance schedules and service intervals of each machine or piece of equipment. When
a customer invests in an Atlas Copco machine, they get the performance and reliability they expect from the brand. However, to ensure they get this consistently from their machines, good maintenance practices are critical, including after-market service quality. It’s really no different from servicing one’s car at an original equipment manufacturer [OEM] dealer.”
Van Schalkwyk strongly advises customers to appoint only OEMs to service and repair their machines. As an OEM, Atlas Copco must follow global requirements and adhere to international rules and standards. “This compels us to create a pool
of highly trained, highly skilled product specialists who know the Atlas Copco products inside out,” he says.
Atlas Copco identifies and develops stand-out talent among all employees and also fosters an apprenticeship initiative, creating an internal pool of top performers. Power Technique provides hands-on training in-house, while theoretical training is managed by Atlas Copco’s HR department in collaboration with an outside Merceta-approved company. “This enables us to offer customers best-in-class service and support provided by highly trained, skilled technicians,” says Van Schalkwyk. “Using the correct tooling and
An Atlas Copco Power Technique specialist servicing a PAS 150MF pump.
genuine original equipment parts, our technicians perform service, maintenance and repair work in the shortest possible time, helping to get customers up and running as soon as possible.”
He also points out that in the event of a warranty issue, the customer – having followed the OEM’s recommended service intervals – can rely on the OEM for an immediate response.
“Moreover, fully serviced units fetch a better selling price, similar to a car with a full service history).
“We, as the OEM, will carry the consequential damages resulting from the failed part. On the contrary, failure to follow OEM requirements will result in claims being declined, leaving the customer with downtime and repair-related costs. Customers must also bear in mind that sub-standard parts are known to fail, driving up operational costs
through downtime, production losses and parts replacement.”
Van Schalkwyk highlights the importance of following the OEM’s recommended service intervals. “A preventive maintenance culture will help reduce the risk of component failure and resultant unplanned, costly stoppages, subsequently increasing machine availability and extending life-cycles, delivering an uptick in production and lowering the total cost of operation and ownership.”
Besides servicing and repairing Atlas Copco’s comprehensive mobile equipment range, the Power Technique after-market team also completely and/ or partially rebuilds portable equipment components.
Power Technique’s range of mobile equipment, including air compressors, generators,
“ATLAS COPCO IDENTIFIES AND DEVELOPS STANDOUT TALENT AMONG ALL EMPLOYEES AND ALSO FOSTERS AN APPRENTICESHIP INITIATIVE, CREATING AN INTERNAL POOL OF TOP PERFORMERS.”
light towers and pumps, is used for a wide variety of applications, such as water well and exploration drilling, mining, quarrying and construction.
Atlas Copco Power Technique has created a strategic dealer network that stretches across SA and into neighbouring countries to bring products, qualified technicians and original equipment parts closer to customers who operate equipment on remote job sites.
“Because our dealers are at the coalface, they’re able to deliver rapid turn-around times, helping to maximise customer uptime,” says area sales manager Roelf van Niekerk.
Further adding value to the supply chain, Power Technique has invested substantially in digitalised systems, developing several user-friendly online platforms that enable customers to conveniently remain connected to with their machines and equipment, access vital product information and purchase parts online 24/7/365 – all at the click of a button.
A service kit for PAS pumps from Atlas Copco Power Technique.
SUSPENSION TRAUMA MANAGEMENT
On 11 February 2011, a rock climber was found dead, suspended in his harness 60m above ground in San Diego county, USA. The autopsy revealed that the man’s death, while accidental, was the result of mechanical asphyxia. Essentially, he had succumbed to a respiratory and systemic collapse from hanging motionless for a prolonged period in his rock-climbing harness.
potentially fatal condition affecting individuals engaged in occupations or activities that require the wearing of a pelvic harness, such as powerline workers, cellphone tower installers, rock climbers, parachutists and caving and rope rescue technicians.
As the brain becomes more ischaemic (lacking in blood supply, which leads to oxygen deprivation), fainting occurs to force the body into a horizontal state and return venous volume to the heart and brain. If the suspended person faints without achieving a horizontal position, the head and neck may pitch forward, causing a potential airway obstruction. The person with an obstructed airway and hypotension has only minutes before cardiac arrest occurs. HEALTH AND
hypovolaemia (loss of blood pressure/volume in the body), leading to cerebral hypoperfusion (reduced blood flow to the brain) and low cardiac stroke volume (the heart not pumping enough blood per beat).
Suspension trauma is also referred to as mechanical asphyxia, harness-induced pathology, orthostatic shock while suspended, harness suspension, suspension trauma cascade and orthostatic intolerance. It is a rare, but
Injury and death from suspension trauma is a rapid cascade of events taking place over 10-60 minutes. When a person is suspended vertically, it decreases venous circulation in the lower extremities, which causes sluggish blood return to the body’s core. Lack of contraction of the leg muscles, due to confinement or fatigue, worsens venous pooling. The core then suffers from
HEALTH AND SAFETY
PRE-SYNCOPAL PHASE
Early warning signs of suspension trauma – usually occurring within 10 minutes of being suspended, but typically after an hour – may include hot flushes, sweating, diaphoresis (excessive sweating), numbness in the legs, bradycardia (an unnaturally slow heartbeat) or other changes in heart rate such as arrhythmia, low blood pressure, nausea, dizziness and confusion secondary to cerebral hypoperfusion (irregular blood flow to the brain, which can result in a stroke).
The earliest known example of suspension trauma occurred in the Roman era when the execution method of crucifixion was practised. The above symptoms
describe what a person being crucified would have experienced.
This warning stage presents an opportunity, however , to call for help, deploy and use a suspension trauma relief strap or get out of the harness and lie supine (flat on one’s back). The patient may sense a need to be horizontal to mitigate the symptoms, but be unable to stand or sit up because of an injury or a technical issue involving the rope/harness/ climbing gear.
When the patient experiences syncope (fainting), they cannot protect their airway and can succumb to mechanical
asphyxia. This is especially relevant in the case of harnesses with a rear rope attachment, which encourages neck flexion in an unconscious patient.
NB: The best way to prevent suspension trauma is not to become suspended in the first place (ie, loss of balance and then falling, so that the fall arrest system catches and suspends them). This can be prevented through proper risk management and a welldeveloped and communicated fall protection plan.
For construction workers working at heights and wearing harnesses, the risk of suspension trauma is always present unless the above precautions are taken.
A demonstration of how to treat a patient suffering from asphyxiation trauma.
Reprinted with permission from Gravity.
JET DEMOLITION HELPS MINING HOUSES MEET THEIR ESG COMMITMENTS
The demolition of aged and redundant infrastructure, and undertaking assessments and studies of current infrastructure to determine appropriate and industry-specific cost provisions for future demolition activities, are just two of the ways that Jet Demolition supports mining houses to achieve their environmental, social and governance (ESG) commitments.
The proactive removal of redundant infrastructure allows the footprint to become available for new construction, thereby further limiting the direct impact of infrastructure on undisturbed land. The removal of redundant infrastructure, especially during ongoing operations, also allows for the removal of unsafe structures, thus lessening the burden on ongoing maintenance, further conserving resources. Large mining houses generally have a long-standing working relationship with environmental specialists who offer guidance regarding the legislative and social responsibilities of the mine. “We support these relationships by offering demolition services and solutions tailored to sitespecific requirements, with a
focus on removing redundant infrastructure without impacting ongoing operations,” explains Kate Bester, contracts and project manager at Jet Demolition.
The company is equipped and experienced in delivering turnkey demolition services, with final rehabilitation of the impacted footprint included in the scope of services. This means that redundant infrastructure can be removed, and any land affected by process spillages or hydrocarbon spills can be rehabilitated immediately thereafter by a single service provider. “This has both a cost benefit to the client in terms of a turnkey solution, but also a risk benefit, in line with the widely adopted progressive rehabilitation approach,” notes Bester.
Jet Demolition’s onsite management team is supplemented by its own full-time safety personnel, who ensure that the team can work safely in a dynamic environment. Judicious method selection, efficient resourcing and detailed planning all contribute to the safety profile.
If operations are ongoing, methods and approaches must be tailored for operational
environments, with due care for working around live services, for example. In fully redundant operations, the primary focus might be speed in order to deliver a cleared footprint for redevelopment in the shortest possible time. “Accordingly, it’s essential that the client and contractor collectively determine the most suitable approach to the works, aligned to the ESG commitments and objectives of the mine,” says Bester.
Careful method selection allows Jet Demolition to reduce its impact on the environments in which it operates. This includes exploring novel ways of reducing waste generated by demolition activities, as well as optimising ways of working to preserve valuable resources. “We’re able to help clients proactively seek alternative solutions and uses for materials and resources that would otherwise have been deemed waste, with a focus on achieving as much of a circular economy as possible,” says Bester.
Kate Bester, contracts and project manager: Jet Demolitions.
ZUTARI’S YOUNG ENGINEERING TALENT COMMENDED
Istiaan Lubbe received a commendation in the Young Engineer of the Year category of leading consulting engineering and infrastructure advisory practice Zutari’s 2024 CESA Aon Engineering Excellence Awards.
The impact of Lubbe’s eightyear experience in the industry sets him on a pedestal among South Africa’s brightest
young engineers, reshaping the industry to not only innovate ways of working, but also reinforce presentday capabilities to build a sustainable future.
Having graduated with a BEng in mechanical engineering from the University of Pretoria in 2017, he became an Engineering Council of SA Certified Professional Engineer
in 2023. He is also a member of both the SA Institution of Mechanical Engineering and the Consulting Engineers SA (CESA) Young Professionals Forum. In addition, he holds an ASSE 6005 Medical Gas Generalist Certification, making him the youngest medical gas specialist within Zutari and possibly in the country.
With his accreditation as a
INNOVATION
medical gas specialist, Lubbe conducted a thorough study in 2019, comparing international medical gas design standards with those practised in SA – a contribution he regards as his most significant to the medical gas field.
The study aimed to ensure that medical gas systems were designed to the highest standards of reliability and patient safety, and to establish uniformity among all designers. His findings were presented to a panel of industry leaders and subsequently adopted as the formal standard for all medical gas system designs within the Netcare Hospital Group. Lubbe’s contribution proved invaluable in supporting healthcare facilities when the demand for oxygen and other medical gases surged during the Covid-19 pandemic.
Beyond medical gas systems, he has showcased his versatility as an engineer by excelling in a range of projects spanning various market sectors, industries and clients. His experience extends the design of specialised HVAC systems, vertical transportation and clean rooms. He has served as lead engineer on more than 28 successfully completed projects and is currently leading 15 ongoing and in-process projects.
Lubbe has acted as a technical integrator and MEPF project manager on several multidisciplinary mega and giga projects in the Middle East.
“About 90% of our projects, especially on a mega-scale, reassure clients that everything’s handled in-house. This results in a well-co-ordinated, integrated service delivery and product,” he says.
He explains that the role of a young engineer has changed significantly over the past decade. Apart from technical skills, soft skills – such as giving presentations in meetings and interacting with different cultures on site – are becoming more important than purely technical knowledge. Leadership and adaptability have become crucial in integrating complex professional teams.
Lubbe credits his mentors and employers, who helped him harness his potential early on as he began showing enormous growth potential. This resulted in his exposure to an array of projects. At just 30 years old, he has proven himself to be a highly innovative individual, an agile project leader, a dynamic co-ordinator and an exemplary lead engineer who takes great pride not only in his work, but in being part of a collaboration.
Zutari’s emerging talent ecosystem offers a range of programmes to nurture and develop emerging
talent in the engineering field. From mentorship to training programmes, it provides practical experience and growth opportunities. This starts from grassroots level with Grades 11 and 12 pupils through its job-shadowing initiative in partnership with CESA, supporting young scholars with an interest in engineering from an early age.
The consultancy offers engineering students comprehensive course funding and support, including academic assistance, career guidance and development, which ultimately help them succeed in their studies. Its Work-Integrated Learning programme partners with educational institutions to give students industry exposure and technical experience. Graduates and interns are afforded the opportunity to work alongside industry leaders and experts, gaining the knowledge, skills and confidence needed to become recognised professionals.
The 2024 CESA Aon Engineering Excellence Awards took place on 14 August at Vodacom World in Midrand, Johannesburg, organised by CESA in partnership with Aon SA.
“THE STUDY AIMED TO ENSURE THAT MEDICAL GAS SYSTEMS WERE DESIGNED TO THE HIGHEST STANDARDS OF RELIABILITY AND PATIENT SAFETY, AND TO ESTABLISH UNIFORMITY AMONG ALL DESIGNERS.”
TWO-STAGE TENDERING NEEDS A COLLABORATIVE APPROACH
Construction projects in South Africa are often concluded in a single stage. Designs (usually incomplete) are used by the main contractor to provide tenders for constructing the project. Twostage contracting is a growing trend, where engineers work in concert with the preferred contractor to finalise the design, typically from an early stage in the project life-cycle, according to construction and mining law specialists MDA Attorneys.
“The combined effort upfront allows for quicker finalisation of the design and ultimately results in an improved construction process. Instead of dictating
to the contractor, who must then execute the project works, two-stage tendering allows for practical and realistic prequalification based on the contractor’s preferred method of working. Any changes can be ironed out early, reducing the likelihood of variations during project execution,” says Euan Massey, MDA Attorneys director.
He unpacks the benefits and drawbacks of both single- and two-stage tendering:
TWO-STAGE PROCUREMENT
IN SA’S PUBLIC SECTOR
The concept of two-stage procurement has been in place
in SA for some time. An example is the two-envelope system used in public-sector projects. This system involves an initial technical proposal without costs, aimed at establishing that tendering companies have the necessary skills and capacity to undertake the project. Once the bidders have been narrowed down to those with the skills and capacity, the second “envelope” containing costs is considered, providing the ability to rule out contractors who are not proficient.
However, two-stage procurement has wider application and several broader benefits when used outside of public-sector procurement.
Experienced contractors can make suggestions to improve designs that will suit constructability, saving money and time, which is always attractive in building projects.
Euan Massey, director of MDA Attorneys.
“ANY CHANGES CAN BE IRONED OUT EARLY, REDUCING THE LIKELIHOOD OF VARIATIONS DURING PROJECT EXECUTION.”
Another benefit particular to South Africa is that contractors have developed relationships with local communities and sub-contractors. Two-stage procurement can enable the adjudication and negotiation of contracts based on the contractor’s track record in uplifting these local communities. Although engaging contractors upfront may incur initial costs for mining houses procuring the works, this can avert serious delays and costs later on.
SPEED, ACCURACY AND PRICE CERTAINTY
In single-stage contracting, a main contractor bids on the work based on plans which have been drawn up by the client’s team. This traditional method gives clients a quick route to starting their project, but all too often, these designs are incomplete and require finalisation.
Any steps that can be taken to firm up the scope of work and allow for accurate pricing before the primary construction contract is awarded is an advantage to clients, who will pay a premium for that certainty as soon as possible. It also appeals to contractors who want assurances that a simple,
well-defined project is going to proceed quickly.
BETTER SCOPING, LOWER RISKS
On a two-stage contract, a contractor or group of contractors is brought on board to determine and cost works while carrying out preliminary activities (usually confined to the client’s design team). They do this while collaborating with the client and supply chain. The same contractor is not guaranteed to win the second stage, but it is usually in the best interests of both parties for it to continue with the contract.
Two-stage contracts allow the contractor to properly understand the scope, raise questions regarding constructability and other risks such as ground conditions, and to price the work before it starts on site.
Under two-stage contracts, clients will pay more upfront before appointing a main contractor. However, this additional cost should be seen in context – without the early contractor involvement, tendering contractors will include contingency in their prices for the perceived risks in the project, resulting in additional costs to the client. Even if the contractors do not include these contingencies due to work scarcity, for instance, they will pursue variations and claims when changes and risks do materialise. This will again result in higher costs for the client.
Thus, advocates of twostage contracts believe it is in
everyone’s interests to work closely together, citing the fundamental principle that planning ahead can usually save costs later on.
This applies to construction more than most industries, because the costs of delay are so high. As with all relationships, it will yield greater rewards if the parties work in a genuinely collaborative and trusting way.
NARROW MARGINS, HIGHER RISKS
Depending on the nature , contractors on a single-stage tender are unlikely to get more accurate pricing than about 10% of the final price. Overheads and profit will be priced at 5-10%, making this a high-risk strategy. Companies will be delighted if they get it right, but if they get it wrong, it is potentially disastrous.
With two-stage contracting, clients run the risk of contractors being unrealistic in their initial pitch during the first stage to get into the second stage and then hike up their prices.
“MDA Attorneys has always advocated a collaborative approach to contracting and this is crucial in two-stage contracting. Contractors operate in a really challenging market with high risk, but if the client, consultant and contractor are working collaboratively from the start, there should be fewer surprises, as their risk assessments should already have factored in higher prices,” says Massey.
Harvey Roofing, a division of Macsteel (Pty) Ltd and a leading provider of roofing solutions, has reached a significant milestone in its commitment to innovation and advancement in the industry. Through a strategic partnership with renowned industrial robotics manufacturer Yaskawa, the company is set to revolutionise its roof tile production process, leveraging a unique prototype product and cutting-edge robotics solutions to enhance efficiency, quality and sustainability.
As the demand for high-quality roofing materials continues to grow, Harvey Roofing recognised the need for an innovative approach to upgrade its current manufacturing process. “After the successful roll-out of our prototype product and funding for our business case, we had to approach various suppliers to make this a reality,” says Frikkie Erasmus, business unit executive at the company. “Our choice
HARVEY ROOFING’S NEW ROBOTICS SOLUTION
for robotics boiled down to addressing safety concerns, increased efficiency and accuracy, as well as the extended lifespan of the robots.”
Harvey Roofing’s relationship with Yaskawa pre-dates this project, having previously implemented feeding robots for its roofing products, resulting in high efficiency and reduced scrap. Now the roofing company aims to upgrade the production line of one of its most innovative products: Harvey EcoTile. Constructed from a mineral polymer composite, the EcoTile is a sustainable answer to an industry which has seen minimal improvement in centuries. Harvey EcoTiles are lightweight, strong, weather-proof, paintable and maintenance-free.
“Yaskawa sealed the deal with its innovative solutions, prompt response, reputation and positive existing relationship with Harvey Roofing”, explains Erasmus. “We
wanted to make the necessary changes to be competitive on the world stage in terms of cost per unit.” Following the successful extrusion of composite slabs, Yaskawa would then handle the downstream elements, automating the production process from start to finish.
Overseeing the installation and set-up were two technicians and one project leader from Yaskawa, working alongside Harvey Roofing’s own project leader and specialist. The relationship between the roof tile leader and robotics experts is at an exciting stage, with both invested in improving efficiency and plenty of room for further development to match demand. For now, Harvey Roofing is poised to meet its automation goals with innovative industrial robots from Yaskawa while delivering superior sustainable products like the Harvey EcoTile to its valued customers.
Maintaining stormwater systems in inner-city Johannesburg can be tricky. There is often no space to manoeuvre a truck-mounted jetting vehicle and sometimes jetting needs to take place in extremely-hard-to-reach places –such as the rooftop of a high-rise building.
These are the challenges which Brett Ross, owner of Modular Plumbing, was seeking to overcome by procuring a trolleymounted jetting unit from Werner Pumps.
For over 30 years, Werner SA Pumps & Equipment (Pty) Ltd has been designing, manufacturing, supplying and maintaining specialist high-pressure jetting equipment. The company has built a reputation as a local industry leader through its focus on delivering high-quality, lowmaintenance, 100% South African-
MOBILE JETTING UNIT SIMPLIFIES INNER-CITY PLUMBING MAINTENANCE
manufactured products that last, all while considering clients’ budgets.
Aside from its in-house manufacturing capabilities, Werner Pumps specialises in the supply and maintenance of high-pressure jetting equipment, German high-pressure pumps, high-pressure sewer cleaning hoses, Swiss-engineered nozzles by ENZ and high-pressure guns, lances and cleaning equipment.
“Modular Plumbing actually started out as a manufacturing company, selling products into city settings, but our maintenance business grew out of that and has become our main focus,” says Ross. “We predominantly service developers with large-scale housing units in the CBD. Getting to some of their stormwater drains to clean them out is a major challenge, but they need regular maintenance to avoid issues like flooding.”
Initially, Ross rented a trolleymounted jetting unit from a supplier, but ultimately decided to invest in one for the company. He approached the supplier about buying a unit, but the response was lacklustre, at best.
Frustrated with the service he had received after several weeks, Ross
searched for a unit online and came across Werner Pumps. “I got in touch and quickly heard back from George Jolly, the sales manager. He set up a meeting, got me the information I was looking for and said they could manufacture a unit for me. Once I’d paid the deposit and placed the order, he sent me regular updates with photos and exact timeframes. The service was incredible, compared with the opposition, who didn’t seem interested.”
Ross received his unit – a trolleymounted jetting unit with a 13,5 horsepower Honda petrol engine, which can operate at 200 bar and pump 21 litres per minute. It includes a 50m jetting hose with hose reel and a 10m high-pressure hose with lance.
He says that while the unit will predominantly be used for jetting to clean out stormwater drains, it also offers a useful high-pressure spray function for water cleaning. “We’ve used it a few times and it’s working perfectly, while its manoeuverability means we can get it where we need it to be, even if that means taking it up to a roof in a lift,” he says. “We’ve used it more over winter, which is the dry season in Johannesburg and the perfect time to do stormwater maintenance before the next rains.”
The trolley-mounted jetting unit from Werner Pumps.
CRACKS AND CARBONATION: WHAT’S YOUR CORROSION MITIGATION PLAN?
By Julie Holmquist
Corrosion is the Achilles’ heel of reinforced concrete, an otherwise extremely durable, widely used building material. Once corrosion starts, it introduces a vicious cycle: corrosion products expand and put pressure on the overlying concrete, eventually causing it to crack and spall, allowing more corrosive materials to enter and continue the process until a repair is made to preserve structural integrity. While concrete initially offers a pristine protective environment, sooner or later
cracks and carbonation will allow corrosion to initiate at the level of the rebar. It is therefore important for engineers and builders to incorporate corrosion mitigation into the design phase of a reinforced concrete structure.
BENEFITS OF CORROSION
PROTECTION: LONGER SERVICE
LIFE = RESOURCES SAVED
One may ask: why worry about how long a structure will last, since repairs and replacements are a normal part of structural
maintenance and may not be needed for years? Aside from the fact that construction plans typically call for a specific design life that engineers must figure out how to meet, extending service life equals resources saved for the party who owns the structure. Nowadays, when “sustainable construction” is a key watchword, being able to conserve resources is highly relevant. Furthermore, those concerned about the environment may note that concrete production is a huge
Artist’s conception of how MCI forms a molecular layer on the surface of metallic reinforcement, protecting it from interaction with water, oxygen and chlorides. (Image courtesy of Cortec Middle East)
contributor to greenhouse gas emissions. Therefore, something that can help concrete last longer and eliminate the need for replacement concrete will theoretically reduce carbon output. Even from a practical standpoint, greater durability of a structure can save the buildingowner time and money that might otherwise be needed for repairs or rebuilding.
NATURAL PROTECTIVE ENVIRONMENT EXPIRATION DATE
Yet what about the natural protective environment that new concrete creates for embedded rebar? New concrete has a high pH that initially protects rebar from corrosion. Unfortunately, concrete does not stay alkaline forever. As it reacts with CO2 from the air, it forms calcium carbonates, reducing concrete pH. This carbonation can make its way through concrete at a rate of approximately 1mm per year, depending on the quality and porosity of the concrete and other factors (eg industrial, metropolitan areas tend to have more CO2 in the air from burning fossil fuels for heat or industrial use). What may occur even sooner is cracking. Shrinkage on new concrete, expansion and absorption from freeze-thaw cycles, heavy loads and structural shifting can all lead to crack formation, giving corrosive materials – moisture, chlorides, oxygen and carbon –easier access to the concrete and rebar. Unless the concrete is in a very dry, non-corrosive environment, corrosion is likely at some point in its lifespan. Most
builders and engineers should therefore at least consider whether their project warrants special corrosion mitigation measures before proceeding.
WHAT ARE YOUR ENVIRONMENTAL RISK FACTORS?
One of the first things to ask when considering corrosion mitigation is what special environmental risk factors will be present. Some regions are naturally more corrosive than others, whether directly or indirectly. For instance, concrete structures located near the sea will be exposed to higher levels of moisture and chlorides from the seawater. Tropical climates can accelerate corrosion due to high temperatures and humidity. Some regions also deal with high water tables or highmineral sabkha soil that can bring moisture and chlorides into contact with the building’s sub-structure. Another serious corrosive factor in some climates is the use of de-icing salts. Regions with cold winters, snow and ice use de-icers generously on roads and bridges for commuter safety. These de-icing salts attack the surfaces to which they are applied and are also carried by vehicles into parking ramps. Service life prediction models take elements like these into account when calculating a projected service life and are an excellent tool for evaluating the expected benefits of admixtures and some other protective strategies.
BUDGET CONSTRAINTS
In addition to looking at service
PROJECT MANAGEMENT
“TROPICAL CLIMATES CAN ACCELERATE CORROSION DUE TO HIGH TEMPERATURES AND HUMIDITY. SOME REGIONS ALSO DEAL WITH HIGH WATER TABLES OR HIGHMINERAL SABKHA SOIL THAT CAN BRING MOISTURE AND CHLORIDES INTO CONTACT WITH THE BUILDING’S SUBSTRUCTURE.”
life predictions, engineers must consider time and budget constraints for each project. Strategies like a thicker concrete cover, epoxy-coated rebar and cathodic protection may add years to the service life of the structure, but introduce prohibitive costs that take the project out of budget.
WHAT ARE YOUR APPLICATION CONCERNS?
Yet another factor to consider in selecting a corrosion mitigation strategy is application practicality. For example, the use of sacrificial anodes can be time- and labourintensive. Moreover, the use of corrosion-inhibiting admixtures, which may be less expensive than other protection methods, can affect properties of the concrete mix and should be carefully considered before selection. Sometimes the impact depends
on the time of year that the job will be done. Calcium nitrite (CNI) admixtures tend to accelerate set time and, while this may not be a bad feature in winter, it can raise serious issues in the heat of summer, giving the contractor workability issues and even causing structural concerns such as cold joints. Still other admixtures can decelerate set time, which may be great for hot climates, but are not the best choice for winter construction, when cold temperatures slow drying and curing time. Practically speaking, these characteristics are very relevant to project success because the easier an admixture is to work with in the field, the better the quality of the finished product (and structure) is likely to be.
CORROSION PROTECTION WITHIN EVERYONE’S REACH
When considering all these factors, migrating corrosion
inhibitor (MCI) admixtures based on amine carboxylate chemistry stand out as an excellent option in terms of price and performance. According to the MCI handbook, amine carboxylate formulations can double or triple time to corrosion onset and reduce corrosion rates by five to 15 times thereafter. They can often be added to the concrete mix at a very small fraction of the total construction cost, while significantly increasing service life predictions. For example, the use of an amine carboxylate admixture in the foundation of the Princess Tower in Dubai more than doubled service life expectancy at 0,07% of the total construction cost. In another project, an engineer saved six figures and added years to the service life prediction by recommending an amine carboxylate admixture as an
alternative to epoxy-coated rebar.
Other benefits of the admixture used in the aforementioned projects are that it contains 67% US Department of Agriculture-certified biobased content and does not negatively impact concrete properties under ASTM C1582. The chemistry works by forming a protective molecular layer on the surface of the metal via an alkyl polar functional group that adsorbs to the metal and a non-polar hydrophobic tail which interacts with other MCI tails to form a film that microscopically repels corrosive fluids. This so-called “mixed” or ambiodic protection (inhibiting both anodic and cathodic reactions) at the rebar level offers advantages other methods of corrosion mitigation do not
Artist’s conception of corrosion products expanding the volume of the rebar, putting pressure on the concrete overlay and creating cracks that will allow the ingress of more corrosives. (Image courtesy of Cortec Middle East)
have. It is not dependent on maintaining a crack-free, highalkaline environment in the concrete cover and may even keep pH in an optimal range on the rebar surface. If used in combination with epoxy-coated rebar, which can be damaged during transport and installation, it can help protect areas of the rebar where the coating has been compromised. Unlike CNI, which raises the chloride threshold by competing with chloride ions to passivate the rebar surface, MCI admixtures are dosed
independently of expected chloride levels. Furthermore, several MCI admixtures have been certified to meet approved standards for use in drinking water components, enhancing their user-friendly profile.
PLAN YOUR DEFENCE NOW
Reinforced concrete will continue to be a widely used structural material for the foreseeable future. Due to the subtle, but steady threat of corrosion, it is important for engineers to consider corrosion mitigation
techniques in the design stage to maximise building service life and continue protection in the presence of cracks and carbonation. Due to their lower relative cost and advantages, amine carboxylate admixtures are an important option to consider – alone or in conjunction with other methods of corrosion mitigation – when choosing a strategy for structural longevity.
Cracks and carbonation are inevitable, so be sure to have a line of defence ready!
Reprinted with permission of Cortec and Building Enclosure magazine: https://www.buildingenclosureonline.com/articles/92714-cracksand-carbonation-are-inevitable-whats-your-corrosion-mitigation-plan
THE SCIENCE OF SHEEN
By Karine Gallia
By definition, “sheen” refers to the shiny or reflective quality of a surface, determined by the amount of light it reflects, and is most commonly related to paints or coatings. Glossy finishes have a higher sheen and therefore reflect more light, while flat or matte finishes have virtually no sheen at all and reflect less light. The higher the sheen, the more protective the finish – or so we have been told.
Innovation is challenging these simplistic definitions. New coatings and sheens do not always live and perform by the old rules. What is driving this innovation and what are some examples of these new rule-breaking coatings? We will get to that, but first, let us talk about the origin of coatings and sheens.
A history of coatings and sheen
Since the dawn of man, humans
have expressed themselves through art and painting. The earliest evidence of paint-making is from South Africa and dates back over 100 000 years. The paint was made from red iron oxide and charcoal, and bone marrow was used as a binder, providing the sheen. From there, our desire for more pigments and different sheens drove innovation. Ancient Greeks, Egyptians and Romans
The Kaleideum Museum showcases vibrant, creative shapes finished with StoColor® Acryl Plus in an eggshell sheen. This exterior insulation and finish system (EIFS) not only enhances the bold, eyecatching appearance, but ensures long-lasting colour retention and minimal maintenance to the façade.
(Photo courtesy of Sto Corp.)
made coatings by mixing lead with wine and vinegar. Beeswax, egg yolk and milk were used as binders. (Egyptians loved the high gloss.) In the late 19th century, enamel wall paint was introduced to European and American homes and was considered the ultimate in high gloss. As the science of coatings evolved, linseed oil became the go-to for creating a glossy finish. The more linseed oil was used, the higher the gloss. However, there was no gloss meter: painters determined the gloss level with the naked eye and achieved the sheen they were after by trial and error.
Today, the gloss meter measures how much light is reflected from a particular finish – and the finish you want is achieved through a modernised process that involves little guesswork.
TODAY’S PROCESS FOR CREATING SHEEN
While there will always be some trial and error in innovation, for the most part, modern research and development (R&D) has everything dialled in, even with the linseed oil, which is still used in oil-based coatings. The components in most coatings are essentially the same: pigments, binders, liquids and additives. Each element in the coating has a particular role. Pigments provide the colour. Binders bind the pigments together. Liquids suspend and carry the pigments to the desired surface. Additives provide specific coating properties, such as mouldand mildew-resistance.
The more binder used in the coating’s formulation, the higher
the sheen; conversely, there is a lower sheen with less binder. Why? With less binder, more pigment grains become exposed at the coating’s surface, scattering the light and creating a matte effect. Of course, flat or matte finishes are a little more challenging to clean, but they hide imperfections. That is important when the surface faces the scrutiny of critical lighting.
THE SOURCE OF THE SHEEN
The sheen of a coating is primarily influenced by several key factors: light interaction, surface texture, material composition and environmental conditions. The fundamental principle behind sheen is the reflection and absorption of light. When light hits a surface, some of it is reflected, while some is absorbed, which determines the appearance of the sheen. Glossy surfaces reflect more light, creating a shiny appearance, whereas matte surfaces absorb more light, resulting in a dull finish.
Surface roughness and texture also play a crucial role in the perception of sheen. Smooth surfaces tend to reflect light more uniformly, enhancing the gloss effect, while rough or textured surfaces scatter light in multiple directions, reducing the gloss and creating a matte appearance. The formulation of the coating itself is another vital factor. The composition of binders, pigments and additives in the coating affects how light interacts with the surface. Higher binder content typically results
in a glossier finish, while higher pigment concentration can create a more matte effect by scattering light.
The angle of incidence, or the angle at which light strikes the surface, can change the perceived sheen. For instance, a surface may appear glossier when viewed from a certain angle compared with its appearance when viewed headon. Environmental factors, such as humidity and temperature, can also impact the final appearance of the sheen. These conditions can affect the drying process and the final texture of the coating, thereby influencing its reflective properties.
CRITICAL LIGHTING REVEALS A WALL’S SECRETS
9Wood, a specialty wood ceilings company based in Oregon, USA, defines critical lighting as “specularly [like a mirror] reflected light at an acute or glancing angle. Critical lighting related to architecture occurs when light from fixtures or windows reflects onto a surface and highlights imperfections.”
Evaluating critical lighting helps you identify where light will expose your walls for what they really are: imperfect and sometimes downright ugly. You can then select the right sheen for that area, so no-one has to know the truth. Will innovation help walls stand up to critical light? If so, where are these innovative products and what is driving the innovation?
THE DRIVERS OF INNOVATION
There are a range of factors that drive innovation: design and colour trends, a changing climate, sustainability, raw material reliability
GLOBAL VIEW
and stability and the biggie: environmental regulations. Not long ago, oil-based coatings were preferred. However, oil-based coatings require chemicals like acetone and mineral spirits to clean up, emitting heavy fumes. Regulations have led to the development of acrylic coatings, which are more environmentally friendly and require only soap and water for cleaning.
In a recent CoatingTech survey, Sjaak Griffioen, director of innovation, strategy and sustainability at DSM Coating Resins & Functional Materials, sums up his take on innovation: “[There’s a] focus on alternative raw materials creating the highestperforming coatings partially made from waste or renewable raw materials. It’s now all about coatings and coatings with higher performance than is currently available without any negative environmental or indoor air quality impact.
“Higher performance, in combination with a reduction of VOC to zero, as well as the reduction or even deletion of substances of high concern, give companies like DSM fantastic opportunities in new polymer design.”
Sheen plays a crucial role in these innovations, as the desire to create sustainable coatings does not come at the cost of aesthetic qualities. Advances in raw material science and formulation technologies have enabled the production of environmentally friendly coatings that can achieve
the same, if not better, levels of sheen and durability as their traditional counterparts.
There are many drivers of inspiration – certainly, more than we have covered here. However, in addition to the market driving innovation, the coatings industry is always searching for inspiration.
NANOTECHNOLOGY DELIVERS BIG RESULTS
While the first paints made by man used charcoal and bone marrow, the future of coating and its high-tech properties lies in nanotechnology. Nanoparticles can be engineered to absorb or scatter light in different ways. They also give us the ability to manipulate the chemical makeup of the coating. Using different nanoparticle sizes and shapes, we can tailor the reflective properties to achieve the exact sheen we want. Nanotechnology gives us greater control over every part of the coating, which means we can manipulate the formula to achieve things that were never possible before. However, right now, the price of nanotechnology is high, which means the cost of the coatings developed using nanotechnology is expensive. Yet that cost will surely come down as the industry moves toward greater use.
THE FUTURE OF SHEEN
Initially, paint was used for expression. The art of painting, as it was, relied heavily upon what was abundant in the environment. Today, R&D and nanotechnology are making the impossible possible. New products
will continue challenging the traditional rules of a matte finish versus a gloss one. Yet, even if coatings become so smart that you can choose any coating for any environment and eliminate the concerns of critical light, you will have the freedom to select the finish you desire for purely aesthetic reasons. Which means that the future of coatings and sheen is most definitely bright.
SHEEN IN ACTION:
HOUSTON HOUSE
Houston House, located in New York City’s East Village, is an excellent example of how sheen can be used to achieve a modern, stylish look while maintaining practicality. The project utilised innovative techniques to replicate the appearance of sleek metal panels, driven by the need for a high-end, contemporary aesthetic that resonates with the vibrant neighbourhood.
The building’s finish is designed to mimic the sheen and texture of metal panels. This finish provides a smooth, reflective surface that captures light beautifully, creating an eye-catching façade. The ability to reflect light in a controlled manner gives the building a polished, upscale look, enhancing its visual appeal in the bustling urban environment.
The application process was crucial in achieving the desired metallike sheen. Skilled applicators meticulously applied the finish in multiple coats, sanding each layer to perfection. The final coat was trowelled to create deep grooves, imitating the joints of metal panels.
This attention to detail ensured a uniform, glossy finish that convincingly replicates the look of metal.
One of the significant advantages of using a specialised finish over actual metal panels is its superior thermal performance. The system provides continuous insulation, which helps regulate the building’s temperature and reduces energy consumption. Additionally, the finish offers excellent durability and weather-resistance, crucial for withstanding New York City’s harsh winters and hot summers.
Moreover, this innovative finish is more cost-effective than traditional metal panels. It delivers the same high-end appearance without the associated expenses, making it a practical choice for developers seeking to balance aesthetics and budget. This approach not only enhances the building’s exterior, but contributes to its overall sustainability and energyefficiency.
In conclusion, the Houston House project demonstrates how modern coating technologies can effectively use sheen to
achieve a sophisticated, metallike appearance. The finish provides a durable, energyefficient solution that meets both aesthetic and practical requirements, setting a new standard for urban residential design.
Printed with permission of BNP Media, Fall 2024: https://digitaledition. buildingenclosureonline.com/ fall-2024/coatings-sheen/?utm_ medium=emailsend&utm_source=DGBE-Building+Enclosure&utm_ content=BNPCD241007035_01&oly_enc_ id=5433H6645390C4J
Houston House is an excellent example of how sheen can give a modern, stylish look.
CAPTAINS OF CONSTRUCTION
CAPTAINS OF CONSTRUCTION
MBA REGIONAL LISTING AND AFFILIATE MEMBERS
Master Builders Association
Boland
Contact: Daniel Uys info@mbaboland.org.za 021 863 3330
North Contact: Mohau Mphomela info@mbanorth.co.za 011 805 6611
Master Builders Association Northern Cape
Contact: Graham Andrews info@mbanc.org.za 053 832 1762
Master Builders Association Western Cape
Master Builders Association
Contact: Petra Devereux petra@mbawc.org.za 021 685 2625
Contact: Mark Fugard info@mbawc.org.za 021 685 2625
Association of Architectural Aluminium Manufacturers of SA
Contact: Johan Heyneke reception@aaamsa.co.za 011 805 5002
CAPTAINS OF CONSTRUCTION
REACHING NEW HEIGHTS IN SAFETY
Roy Mnisi, Executive Director: Master Builders South Africa (MBSA)
Mnisi is an admitted attorney of the High Court of SA, with more than 15 years postadmission experience. He started his law career in 2002 at Madelein Nel Attorneys and practised at law firm Johan Jacobs & Malcolm Moodie (JJMM) Inc until 2005.
Heinrich Schroder, business development manager: Gravity
Schroder’s career began in tourism, but his passion for teaching and rock-climbing drew him to join Gravity Training as a work-at-height trainer in 2008. “Finding solutions for people to work safely in various fall risk positions and training them in those procedures has been my core business ever since,” he says.
He has worked for the revenue department of the City of Johannesburg Metropolitan Municipality and as the CEO of the Institute of Municipal Finance Officers. He has also served on the boards of the Playhouse Company, the Independent Regulatory Board for Auditors, the Water Research Commission, Freedom
Mnisi is a member of the Institute of Directors and of the Legal Practice Council. He currently serves on the boards of the National Home Builders Registration Council, the Joint Building Contracts Committee and the Construction Education and Training Authority.
While the South African construction industry faces various challenges, including socio-economic and political instability, what is unchanging is the need for safety across the sector. This is paramount to Schroder.
When asked about the most challenging part of his job, he said “Challenges facing the construction industry have a way of becoming our challenges as industry leaders. When I see companies closing their businesses due to lack of work opportunities and other inhibitors, I feel the pain. When I see employees losing their jobs and livelihoods, I feel challenged at both professional and personal level. You kind of feel you should have done something to help the situation. Dealing with industry challenges such as violence on construction side, non-payment of contractors, declining construction sector are some of the challenges associated with the job.”
“When it comes to safety – particularly work-at-height safety – I can confidently say that SA’s far ahead of many other countries worldwide. The requirements set by the Construction Regulations have created a mature safety market in the country. However, many still follow these regulations simply to meet compliance, rather than from a genuine desire to ensure worker safety. Fortunately, I’ve noticed a gradual positive shift in this culture. Safety’s increasingly becoming a boardroom topic and top management is giving safety managers greater freedom to implement necessary controls. I hope to see this trend continue to grow in the coming years,” he says.
“The best part of my job is when a client has a challenging access requirement and we’re able to provide a solution, train them and equip them with the appropriate PPE to complete the task safely and efficiently. The most frustrating part is when a client fails to see the value of proper training and equipment, despite our consultations and advice – often compromising both worker safety and operational efficiency.”
In relation to what is the most rewarding part of his job, he reflected on the role of the construction sector and the impact it has on people. He said “Whenever construction work happens, it’s not about the structure, it’s about dreams, hopes and aspirations. I remember when I was a little boy and my parents were planning and eventually built out house, it had some positive impact on me. It brought with it a lot of inspiration. So, whenever a house, school, library nor a road is built, it has a lot of impact on people, and we often don’t pay attention to that part. Being part of an industry body that deals with building industry matters at a national level is a fulfilment of a kind. Dealing with all things aimed at promotion and protecting the industry is the most rewarding part of my job.”
BRAND
A SHAK CONSTRUCTION
www.ashak.co.za
sales@ashak.co.za 011 822 2320
EVA LASTING
www.eva-last.co.za
sales@eva-last.com 010 593 9220
MBA NORTH www.mbanorth.co.za reception@mbanorth.co.za 011 805 6611
NATIONAL HOME BUILDERS REGISTRATION COUNCIL www.nhbrc.org.za digitalservices@nhbrc.org.za 0800 200 824
