The official publication of the Concrete Society of Southern Africa NPC

NUMBER 163 . NOVEMBER 2020 . ISSN 1682-6116

Fine Ash Dam 6 – Pump Station:

Secunda
Origins Centre: Rock Art Gallery
UTRC Pavement Trial

PLATINUM MEMBERS
CONTENTS
Editor’s comment................................................................................................................ 4
President’s message............................................................................................................ 6

CONSOLIDATION UPDATE.......................................................................................... 5

FULTON AWARDS 2019 ENTRY

Fine Ash Dam 6 – Pump Station: Secunda........................................................................ 7

FULTON AWARDS 2019 COMMENDATION

The making of the Origins Centre: Rock Art Gallery.................................................... 10

CASE STUDY
Ultra-thin concrete pavement trial shows potential...................................................... 14

INDUSTRY NEWS
Oxford Parks phase 2 – another Concor buildings success story.................................... 18
a.b.e. Concrete products for massive Oxford Parks development.................................. 20
Fly ash research paves way to even greener cement.................................................... 22
AfriSam is WBHO’s concrete partner on brt station...................................................... 23
Chryso Southern Africa in pole position with fibre solutions........................................ 24
Construction sector is critical to SA’s post-COVID economic recovery........................... 26
Trash pumps ideal for dirty water with large solids ..................................................... 27
Increasing the life of concrete for sustainable built environments................................ 28
Giving back in a time of need...................................................................................... 29
PPC and CHC-SA PrimX Jointless Flooring propelling SA construction forward............. 30
One-time waterproofing treatment versus topical solutions......................................... 32
TCI finalises online concrete training programme for next year ................................... 33
Megan Weyers – CSSA Bursary Feedback.................................................................... 33
Tiber Construction and Tjeka Training Matters take training to new heights
for prestigious public-sector development................................................................... 34
Concrete Repair.......................................................................................................... 35
Complexity in design – Capitec Project Ikhaya............................................................. 36
M2 Freeway Rehabilitation.......................................................................................... 37
Concrete trumps on municipal sport and recreational projects..................................... 38
Concrete that works fine – without any sand.............................................................. 40

MEMBERSHIP DETAILS............................................................................................. 41
COVER: Origins Centre – Rock Art Gallery.
Volume through stairwell indicating the
play of geometry.

CONCRETE BETON 3
EDITOR’S COMMENT

2020 IS ALMOST ON ITS BACK AND WHAT A YEAR IT HAS BEEN

The COVID-19 pandemic has brought about its fair share of negatives, but also some positives.
We were forced out of our comfort zone to embrace new, more efficient ways of conducting our
business and interacting with our members. On one hand, we had to “let go” of some of our
traditional approaches, but the flipside is that this is steadily preparing us for the transition into
the consolidated industry body.
The complexity of the consolidation project is astonishing, but great progress has been made
to arrive at a structure, membership categories, membership benefits, budget, job descriptions, a
RACI (responsible, accountable, consulted, and informed) matrix and so much more.
Last year when I compiled the article: A journey through time: the History of the Concrete
Society of Southern Africa 1969-2019 (Concrete Beton, March 2019) for the Society’s Golden
Jubilee, two things became clear: our industry and the CSSA is, and has always been, in constant
flux, and the Society is inextricably linked to the people involved in shaping this organisation.
With the approaching consolidation, we would have come full circle to operate once again
as one unified body and voice for the cement and concrete industry in Southern Africa, as it was
more than 50 years ago.
Despite the current climate of uncertainty and financial instability in our industry and the
world at large, one thing stands firm: the commitment and enthusiasm of many individuals have
brought the Society to this milestone of celebrating half a century of promoting excellence in
This issue of Concrete Beton is concrete. That same commitment and enthusiasm will ensure that the ethos of the Concrete
Society of Southern Africa will be carried forward in the new body….for the love of concrete.
the last one published as the
A special word of thanks to everyone who has supported Concrete Beton with advertising
official journal of the CSSA. and content through the years. We look forward to continued relationships and more rewarding
When next you see Concrete engagement.
I enthusiastically remain committed to excellence in concrete as we charter new territory.
Beton in March 2021, it will be
published under the auspices For the love of concrete
of the consolidated body, with
an updated design and fresh Hanlie
offerings. Hanlie Turner, CEO & Editor

OUR VISION ADMINISTRATOR Postal: P O Box 75364, Lynnwood Ridge, 0040

To be the most relevant forum for those who N L Pols Tel: +27 12 348 5305
have an interest in concrete.
HONORARY LIFE MEMBERS E-mail: [email protected]
OUR MISSION P R A Flower, D P Samson, C J Thompson, Web: www.concretesociety.co.za
To promote excellence and innovation in the M G Alexander (Prof)
use of concrete and to provide a forum for The Concrete Society of Southern Africa NPC
networking and for sharing knowledge and EDITORIAL COMMITTEE (CSSA), its directors, officers, employees,
information on concrete-related matters. Chair: W P Boshoff (Prof), G C Fanourakis (Prof), representatives and agents are not liable for any
G P A G van Zijl (Prof), E P Kearsley (Prof), death, harm or injury caused to any person or
OFFICE BEARERS H D Beushausen (Prof) any loss, destruction or damage caused to any
President: W P Boshoff (Prof), person’s property or possessions arising from
Editor: H Turner
goods supplied, or services rendered by
Vice-President: F le Roux,
the CSSA.
Design, layout and production:
Immediate Past President: M G Alexander (Prof).
DesignWright, Tel: +27 83 448 4264 © COPYRIGHT All editorial material published
ELECTED DIRECTORS in Concrete Beton is reserved to the Concrete
Reproduction and print: Society. Requests for permission to use any of the
R Jacobs, B D Perrie, R Maliehe, J Kanjee,
Jetline Corporate Print Solutions (Pty) Ltd,
R Raghubir material, in part or in full, should be addressed to
Tel: 011 566-0501
the Chief Executive Officer of the CSSA.
CHIEF EXECUTIVE OFFICER OFFICIAL PUBLICATION OF THE Although the CSSA does its best to ensure
H Turner Concrete Society of Southern Africa NPC that information contained herein is accurate,
BRANCH CHAIRS Physical: 275 20th Avenue, Villieria, 0186 no liabilities for negligence are accepted by the
P Flannigan, B Hunt, H van Wijk, T Coetzee. CSSA, its offices, its members, publishers or
agents.

44 NUMBER
NUMBER 163
163 || NOVEMBER
NOVEMBER 2020
2020
 CONSOLIDATION UPDATE

CONCRETE SOCIETY
OF SOUTHERN AFRICA

Cement & Concrete SA

T
he long-awaited cement and concrete industry body consolidation What has been shared here is but a glimpse into the whole value
process is entering the home straight - Cement & Concrete SA will offering of Cement & Concrete SA. We will keep you posted on the
officially be launched in March 2021. details via members’ mailers in the months to come.
As far back as 2013 the CSSA Board with a strong mandate from you, The ethos and goodwill that have been part of CSSA for 51 years,
the Society’s members, started advocating some form of consolidation will be carried forward with a revitalised strategic focus, renewed vigour
and cooperation between the different bodies to eliminate duplication, and greater access to resources. We believe that this will unlock new
to provide better value for industry stakeholders and a platform for opportunities for members, and the industry at large. We look forward
growth. to sharing more information soon and welcoming you to being part of
The planning gained momentum when Lloyd Macfarlane from the only official unified voice of the cement and concrete industry in
GSA Campbell was appointed as independent facilitator to oversee the South Africa. s
consolidation process. Engaging with the various stakeholders to gather
information about the missions, value offerings, structures, operations
and expectations of the bodies, resulted in CSSA, TCI and ACMP
OBJECTIVES
committing to be part of the consolidated Cement & Concrete SA. • Work with industry role players to develop the value
The vision of Cement & Concrete SA (CCSA) is to be the unified propositions of cement and concrete
voice of the cement and concrete industry in South Africa, defending
• Promote the value creation story of the cement and
and promoting the industry, driving growth and delivering shared value.
concrete industry in South Africa.
The traditional strengths of the CSSA find a home in the “Growth”
strategic pillar of the consolidated industry body and we are well • Develop various membership options that are
positioned to leverage the increased resources available to us, to deliver representative all industry segments and stakeholders
real value for members, and for the industry as a whole.
• Grow membership of the CIB in all membership categories
GROWTH • Support research as a means of increasing the ongoing
relevance and efficacy of concrete
Cement and concrete value proposition • Promote industry standards and audit compliance
amongst members and industry role players.
THEMES

Membership and network development • Grow industry skills and build capacity by developing
and offering manuals, courses, seminars and training
Research, standards, training, advisory materials.

• Provide information, research, advisory and on-site

technical consulting services to members, government,
Cement & Concrete SA will have a strong focus on committees and our
standards authorities and the public.
existing Branch committees will remain important for engagement with
members at regional levels.
The good news for CSSA members, is that existing membership
benefits will be extended by two months in the new year to the 28th
February 2021, after which time the revised and updated membership
categories will take effect. The various benefits and fees for these new
membership categories will be finalised by January 2021.

CONCRETE BETON 5
PRESIDENT’S MESSAGE

T
he time has come to say farewell from remain loyal to this new organisation as we
my side as my term as President of the did to the CSSA. The answer lies at loyalty.
Concrete Society of Southern Africa If we stay loyal to the new organisation, it
(CSSA) is coming to an end. It has been a will become a success. But we need to stand
really interesting (you know the old Chinese together.
saying…) but fulfilling year. COVID 19 has Benefits for members will increase, both
changed the way we operate completely, but for individual and company members. This
we came out stronger on the other side. comes with being part of a larger organisation.
It is also time for a new beginning: These details are being sorted out as you read
the consolidation process is about to be this. Please keep an eye open for email(s) from
finalised and early next year we will see the the CSSA about the details of the consolidated
CSSA consolidate with other cement and organisation.
concrete organisations, much as aggregates, I want to thank the CSSA members for your
cement and water (and I dare not forget loyalty and goodwill over the past 51 years. I
the admixtures…) consolidate to become believe this kind of support will continue over
one versatile and durable material, namely the next 51 years, under a new consolidated
concrete. The final product is much stronger organisation.
than what any of the constituents can dream Let me end off by thanking my fellow
to be on its own. The consolidated body will CSSA Board Members, Branch Chairs, and
personify synergy in the real sense of the word. most importantly, Hanlie Turner (CSSA CEO)
I am sure the new consolidated organisa- and Natasja Pols (CSSA Administrator) for all
tion will be a success, but we need to work the support and strategic discussions in my
together as members of the CSSA. The old term as President.
saying goes: it takes 10 years to become an Finally, I wish to thank you, local CSSA
overnight success. The same goes for the members for your support.
new organisation, but we have the advantage
of 51 years of experience in the CSSA. That Yours truly,
experience lies in the hands of the loyal CSSA
members. Prof Billy Boshoff
The question is, what can we do to make President of the Concrete Society of Southern
this new organisation of ours an overnight Africa
success? I say the word “ours” as we should

37 COMMERCE CRESCENT is a renovation

project which forms part of a new retail /
showroom development, comprising four
buildings in Kramerville, Johannesburg and
won a commendation in the 2019 the Fulton
Awards in the ‘Buildings up to 3 storeys
category.

Judges’ Citation
An adaption of an existing but insignificant
industrial building, has transformed the
original building into an unusual retail/
showroom development. A new floor was
added, the existing roof re-used, and a new
concrete façade was wrapped around the
building, transforming it into a new landmark
which contributes positively to the upgrade of
the local precinct. The use of simple volumetric
PROJECT TEAM
forms and in-situ timber shuttered concrete
Architect: Paragon Architects
enhances the appeal of the building. Working
Client: Alchemy Properties
with a tight budget and short construction
Principal Agent: Alchemy Properties
period resulted in simplified details, and the
Main contractor: Astek Property Group (Pty) Ltd
rough concrete finishes allow for a poetic play
Supplier: Instant Readymix (Pty) Ltd; Formacon (Pty) Ltd
of light onto the building surfaces.

6 NUMBER 163 | NOVEMBER 2020

 FULTON AWARDS 2019 ENTRY

Suction Chamber Foundation Curing.

Fine Ash Dam 6 – pump station: Secunda

The Fine Ash Dam 6 (FAD 6) pump station is certainly no ordinary concrete structure and, being built
within an earth dam wall, is the first of its kind in South Africa (and possibly the world).

T
he construction of this unique piece of infrastructure was “heart”, in almost a literal sense, of the dam.
awarded to WBHO. The FAD 6 project in its entirety consists of the Had the dam been constructed in a typical fashion, with pipes going
construction of a ± 4 km2 ash impoundment/dam facility. Jones & through the RWD wall the risk associated with scaling of these pipes
Wagener were appointed by SASOL to complete the basic engineering, would be too high. As such, SASOL requested J&W to investigate the
detailed engineering and construction management of the entire possibility of building the pump station inside the earth dam wall.
facility and associated infrastructure. After developing numerous concepts during the basic engineering
phase, the decision was made to incorporate the pump station inside
PROJECT BACKGROUND the dam wall. Although complex from both a construction and
The operation of the pump station forms part of a larger process, the design perspective, this solution would eliminate the risk of scaling of
steps of which are broadly summarised below: inaccessible buried pipes.
• Fine ash, being a bi-product of the Sasol Secunda process plants,
is mixed with water and pumped via slurry lines into the main dam CHOSEN SOLUTION
mentioned in section 1 above. The geometry of pump station is some 80 m long x 17 m wide and
• Over time, the ash settles out of solution and the surface water is 15 m high. It consists of 4 distinct parts and a basic functional description
decanted via several inlets within the main dam. below.
• These inlets report to buried penstock pipes which gravity feed
the water into the “Return Water Dam” (RWD). The RWD is a INLET
temporary storage facility for the water, now termed Clear Ash This deceptively simple portion of the structure comprises of sloping
Effluent (CAE). retaining walls, in three planes, buttressed by large reinforced concrete
• The pump station pulls CAE out of the Return Water Dam and beams.
pumps this water for reuse in the process plants. The steps from Both the Return Water Dam and FAD 6 are lined facilities, meaning
point “i” above are then repeated. that an impermeable plastic liner is placed over the entire dam basin
and up the dam walls. The purpose of the liner is to prevent leakage of
PROBLEM DESCRIPTION AND SOLUTION DEVELOPMENT polluted water into the environment. The performance of the liner and
Most tailings and ash handling facilities, where water is recirculated, its interface with the pump station are critical.
are constructed in such a way that pumping occurs outside of the dam. A key challenge in the design (and construction) of the pump
In these instances, pipes are constructed that run through the earth station’s inlet were the sloping walls mentioned above.
dam wall and into a pump station located some distance away.
A problem with CAE is that scaling, a build-up of calcium SLOPE 1
carbonate, frequently occurs in pipes and fluid handling systems. The The first slope, and most obvious occurs diagonally along the length
successful operation of the FAD 6 facility is entirely dependent on the of the inlet structure. This is done purely for economising the use of
pump station operating correctly. The pump station is essentially the materials.

CONCRETE BETON 7
FULTON AWARDS 2019 ENTRY

SLOPE 2
The second slope is in the cross-sectional plane of the
walls. This slope is required for 2 reasons. Firstly, to
ensure better compaction of the earth wall because
compacting adjacent to an inclined plane with a roller
compactor is more effective compared to a vertical
plane. The operator is able to “hug” the wall closer.
See figure below.
The second reason for sloping the wall in section
is to increase the frictional resistance of the soil-
structure interface. As a result of this friction, the soil
mass will be less likely to “slide” down the sloping
face of the wall compared to if the wall was vertical.
This is critical in ensuring that no settlement of the soil
occurs which could lead to tearing of the liner along
its line of fixing to the concrete.
Wall Lifts. The liner fixing detail at the top of the concrete
wall required careful thought and consideration.
The second reason for sloping the wall in section
is to increase the frictional resistance of the soil-
structure interface. As a result of this friction, the soil
mass will be less likely to “slide” down the sloping
face of the wall compared to if the wall was vertical.
This is critical in ensuring that no settlement of the soil
occurs which could lead to tearing of the liner along
its line of fixing to the concrete.
The liner fixing detail at the top of the concrete
wall required careful thought and consideration, a
typic The effect of removing the steps resulted in a
curved surface.
Early coordination and “workshop” meetings
were held between the designers and contractors to
discuss this complex geometry and specifically the
correct forming system. This proved hugely beneficial
for the project overall.
In order to reduce bending stresses and reinforcing
requirements, four 350 mm wide by 600 mm deep
reinforced concrete props were placed within the
higher portion of the inlet structure. The position
Inlet Structure Side.
was optimised in such a way as to maximise flexural
benefit.

SCREENING CHAMBER
The screening chamber’s main function is to prevent
particles larger than 40 mm from entering the suction
chamber and pump system. It consists of an upstream
wall with two adjacent openings, over each opening
sits a “trash screen”. These screens are guided via
custom made cast-in rails running up and along the
upstream wall.
The second, downstream wall of the screening
chamber is 1000 mm thick and provides the running
surface for two large 2.5 m by 2.5 m stainless steel
gates. The two gates sit on either side of the wall
and provide redundancy in case of a gate becoming
stuck. The operation of the dam includes emptying
the full storage on a yearly basis for maintenance and
cleaning. By utilising two gates the operators are also
able to shut one and clean seal while the dam is in
Pump Bay 2. operation.

8 NUMBER 163 | NOVEMBER 2020

 FULTON AWARDS 2019 ENTRY

These gates control the flow of CAE from the dam and into the Following the test results, the heat variance and maximum
pump station’s suction chamber. temperatures were found to be within acceptable limits.
As with the inlet structure, 2 large reinforced concrete props,
SUCTION CHAMBER 500 mm wide by 1000 mm deep were created in the well in order
This portion of the pump station is a wet well designed to store to reduce bending stresses within the walls. These beams span an
approximately 2300 m3 of CAE. As with the inlet structure, the walls impressive 15 m.
of the suction chamber are sloping in order to aid soil compaction and The suction chamber’s roof consists of an open grid grating to
frictional resistance. However, the curved surfaces of the inlet were not provide visual access and enable dosing of the CAE before it is pumped
required as the top of the suction chamber walls are all at a constant level. back to the factories. A reinforced concrete stair chosen for its improved
Wall thickness varies from 1750 mm to 500 mm. Due to the massive durability compared with mild steel in contact with CAE and cost
concrete sections thermal cracking from hydration and heat loss was effectiveness compared with stainless steel provides access into the
a real concern. Careful attention to the choice of formwork material well. This can be seen in figure 2 above.
(timber as opposed to steel) and the mix design had to be exercised.
The above was in fact applicable to the entire pump station PUMP AREA / DRY WELL
which had to be designed as a liquid retaining structure and hence Water from the suction chamber is pulled via 3 large centrifugal pumps
minimisation of crack width sizes. A low heat of hydration mix was located in the pump area. In addition to housing the pumps, this area
designed in conjunction with the ready-mix supplier’s (AfriSam’s) contains an overhead crane supported by reinforced concrete corbels
concrete technologists. Furthermore, thermal logging on a test panel and columns. Forming corbels from the walls was seen as a more
2.8 m x 1.4 m x 1.4 m was conducted on site to experimentally ascertain constructible and practical support compared with manufacturing steel
heat variance for the specific mix. supports and post fixing these to the walls.
A key challenge in the design of this section was coordinating the
PROJECT TEAM numerous access requirements around the network of piping, sloping
Client: Sasol Group Technology floors and drainage channels. s
Principal Agent: Jones Wagener
Editor’s note: This project was an entry in the 2019 Futon Awards.
Main contractor: WBHO Construction (Pty) Ltd
Supplier: AfriSam SA (Pty) Ltd

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6192 A.Shak Constrctn Concrete Beton A5 Nov’20
FULTON AWARDS 2019 COMMENDATION

Bold, intersecting presence of form on the book-end site.

The making of the Origins Centre: Rock Art Gallery

The design of the building and experiential use of concrete is informed by a depth of
ethnographic research involving the history and meanings of rock carvings, paintings,
and the inherent forms and symbols used.

T
he Origins Centre Rock Art Gallery housed on the campus of the In considering the building, the Architects referenced literate
University of the Witwatersrand in Johannesburg, facilitates the cultures, wherein a rock relief or rock-cut relief is carved on solid or
experience of the user on a carved-out route through visually “living rock” such as a cliff, rather than a detached piece of stone. This
stimulating insightful rock exhibits. Centuries of archaeological research category of rock art can be found in architecture, termed “rock-cut”.
has gone into the cultural and historic meaning of the art crafted on The architectural reference influenced the primary aesthetic, form and
rocks. The fundamental approach to this unique design was to ensure detail of the structure – which is experienced externally as a seamlessly
that the crafted space which frames the experience of traditional art is punctured skin, and internally through the carved-out shapes and
suitable to its significance. volumes filtering light into the spaces.
Rock art is a cultural art form, it is finite and fragile human-made
markings placed on natural stone resource that tells the story of the DESIGN APPROACH
hunter-gatherer society. In the context of concrete being a composite of The considered rock art collection obtained by the Rock Art Research
elements in the stone and rock families, the structure of the building, Institute (RARI) gave rise to the brief and required design of the space.
being entirely made out of concrete, aligns perfectly with the content In conjunction with these findings, the Origins Centre, an institution
and time being conserved and experienced. Concrete, known for its dedicated to ‘exploring and celebrating the deep history of Africa’ and
flexibility, was pushed and successfully tested to meet design challenges parent organization of RARI, raised concern about the remaining book-
of accommodating required space on the book-end site given, and to end site at the existing building. At this point, Mashabane Rose and
shape these spaces in a cave-like nature. While the man-made art is Associates (MRA) entered discussion to propose that the Origins Centre
being experienced through an exhibition of rocks, the building seeks to considers maximizing on the site coverage by pushing the boundary
offer an example of a contemporary experience of a cave, appropriate to its limit. The client is known for ethos of making meaningful
to the tradition and time being referenced. interventions in spaces that reflect and enhance the lives of people.
The design of the building and experiential use of concrete is With this dual challenge presented by cooperating institutions, the
informed by a depth of ethnographic research involving the history project for a meaningful space was initiated.
and meanings of rock carvings, paintings, and the inherent forms and Research began with the architects taking note of the ethnographic
symbols used. The design was incepted as an extension to the existing recordings that have been produced as a part of the ritual of petroglyphs.
Origins Centre, when the need arose to house indigenous rocks to These are carvings into the rock surface; pictographs – images painted
protect them from the elements. onto the surface; and earth figures formed on the ground in distant

10 NUMBER 163 | NOVEMBER 2020

 FULTON AWARDS 2019 COMMENDATION

Rock display in the context of interior finish.

places. These practices are known for their magical and religious concrete. The sheer wall along Enoch Sontonga Avenue channels
significance. The depth of research was considered as a formation of movement along its edge, pulling back at the book-end street corner.
importance to the indigenous people in various parts of the world who This urban strategy engages the pedestrian with the building and urban
view them as sacred items and significant components of their cultural intervention, either in motion or moments of pause.
patrimony. As such, these design drivers became significant sources The Architects found it natural to place this boulder as a termination
of cultural tourism, which continued to reverberate in the process point to the campus edge, only to recede at the street apex where
of finding a home for the collection that has been displaced. A risk a public reception area invites the passer-by to engage with the
of being lost in varied gardens was an urgent reality that the client intervention.
faced. Indigenous rocks and rock art are often an attraction utilized in
popular culture for their aesthetic qualities. The vision for the Gallery INTERIOR OF THE ‘CAVE’
was therefore established as a response to the requirement that they The austere external boldness is juxtaposed with a subtle playfulness
are conserved and exhibited appropriately. inside. Each level reveals its surprises along both the horizontal and
The making of this intervention was never contemplated as a vertical circulation paths. The building’s structural gymnastics offers
building, but rather a relocation place (safe house) that would ensure experiences of:
the preservation and protection the treasured rock art from various • Floor plates protruding and receding from structural elements,
urban elements. • Columns blasting through slabs to intersect with the beams above,
• Expressive beams, unexpectedly seeming to pass through one
ARRANGEMENT OF EXTERIOR another,
The new structure stands as a bold presence, comprises of intersecting • Structural tension: A slab stopping shy of touching a wall – adding
geometric shapes. The building steps out daringly onto the University’s to the theme of tension between spatial objects.
pavement, rendering it more inviting as a space of interaction and • Voids for unexpected volumetric experiences levels, offering
exploration in comparison to the initial space which was fenced. strategic views between the spaces.
The external off-shutter concrete bears horizontal timber slat
imprints, allowing a play of shadows that shifts throughout the day. The To house the rock collection, the programme divided each of the 90
intention of the palette of the rough texture is to echo of the rugged plus rocks (graded by their size and weight) into groups; the larger the
city surrounding the site and building. rock, the lower it would be housed in the levels of the building. Split
Textured and bold, the tough exterior is pierced by flush-glazed onto three levels, the Rock Gallery was spatially designed to mimic a
windows. Depending on the time of day, the tinted glass offers an cave; a solid enveloping enclosure evoking both gravitas and strength.
interesting changing exhibition to the façade. The glass exposed Controlled natural light permeates into the spaces to add to the
to the light offers a reflection of the city and skies surrounding, experience between light and dark, form and void; and furthermore,
while others remain dark in the materiality contrast of the building’s allows for the controlled, oblique lighting of the rocks on display. This

CONCRETE BETON 11
FULTON AWARDS 2019 COMMENDATION

Contrast of form and finishes – Old vs New. Geometry of beams, balustrades and slab edges through void.

Volumetric naturally lit void. Strategic void offering user and spatial interactions with levels.

PROJECT TEAM form of lighting is recommended to highlight rock engravings in the

Architect: Mashabane Rose & Associates CC (MRA) most effective way. Lighting tracks are proposed to reinforce the strong
Principal Agent: University of Witwatersrand linear design of the interior, deviating from the structural language to
Main contractor: Murray & Dickson Construction (Pty) Ltd create another directional layer. Light is cast only where needed without
Specialist Sub-Contractors: Viva Formwork & Scaffolding (Pty) Ltd hindering the impact of the shadows and shapes inherent in the clean
Supplier: WG Wearne Ltd design of the interior.

12 NUMBER 163 | NOVEMBER 2020

 FULTON AWARDS 2019 COMMENDATION

The new gallery matches the existing floor levels of the existing
Origins Centre – allowing circulation to continue unhindered between
old and new exhibits. The new extension allows the narrative of the
museum to extend comfortably.

The Gallery is an example of an execution in modern minimalism; a

visual symphony of one material, both dynamic and deceptively simple.
Floor Areas
Lower Ground Floor: 218 m2
Ground Floor: 218 m2
First Floor: 195 m2

SIGNIFICANCE IN CHOICE OF CONCRETE

The exterior concrete finish was prepared for with Grade A Steel
shutters, fixed with 152 mm wide timber planks, horizontally laid with
the intention of no joints in between the planks. In the event of a
joint gap, silicone needed to be applied precisely. The timber texture
required uniformity in its lack of pattern. A note was made for no
concrete corners to be chamfered in view to highlight the sharpness
of the arrangement of angles.
The interior concrete finish was prepared for with Grade A steel
shutters, fixed with 2700 x 2700 mm, or 2700 x 1500 mm timber
boards. A note was made for all corners to be built according to the
details provided.
The external off-shutter concrete finish of the building mimicked
the natural contours of rock by bearing the horizontal imprints of
the timber formwork. This formwork, used as our inventive, crafted
approach created crevices to be revealed & concealed throughout the
day by shifting shadows.
The quality of the off-shuttering is successful in giving the building
the crafted, tactile experience. This, however, was not achieved
with ease. In the process of assembly, off-shuttering was damaged
unfortunately; comment was given to ensure the quality of the silicone

A STRONG FOUNDATION FOR

joint was consistent. Due to the determination of the contractors to
achieve this attention to detail, the building stands as a work of art.
The flexibility of concrete depends on the quality of the formwork INFRASTRUCTURE SUCCESS
designed. This understanding was pushed to its limit in scales ranging
from the structural angels to balustrade details: ROCLA is South Africa’s leading
• Coordination with engineers required constant revision to achieve manufacturer of pre-cast
the correlation between floor and wall voids, in terms of their concrete products.
opening, dimension and angles.
• An element of this resulted in ensuring that risers are no higher Surpassing 100 years of
than 170mm to ensure that Top of Concrete levels, and Parapet product excellence.
lines are maintained precisely with interchanging levels and
landings. • Pipes
• The play of light and shadow exists in the size of the void and • Culverts
opening at the structural level, and at the shadow gap detail of the • Manholes
finishing level. This intention for detail in the workmanship of the • Poles
concrete was achieved through the use of timber formwork. • Retaining walls
• Roadside furniture
DETAIL AND USER EXPERIENCE • Sanitation
With the attention to detail, recognition is given to the team who
worked tirelessly and attentively to achieve the vision for this important Including other related products within
space. Referencing a time of tradition, indigenous craft, shelter infrastructure development and related
and primitive inhabitation, a building of contemporary significance industries.
was achieved to transport the user through time with relevance on
reflective importance. s
Visit us on
Editors note: This project received a Commendation in the 2019 www.rocla.co.za
Fulton Awards in the category Architectural Concrete. for our nationwide branches

CONCRETE BETON 13
CASE STUDY

Ultra-thin concrete pavement trial shows potential

Gordon Forrester A.C.T.
Technical Director, Stonerod Technologies (Pty) Ltd, Jet Park, Gauteng.

SYNOPSIS gave an excellent load-bearing performance, lightweight (225g/ sq

Ultra-thin Reinforced Concrete Pavement cracking of the concrete led to moisture m) basalt fibre mesh.
(UTRCP) trials were constructed in 2001 under ingress and the inevitable reinforcement (The normal basalt
the auspices of C&CI, CSIR and University of corrosion followed. Steel reinforcement mesh weighs 450g/
Pretoria. Test panels were laid on the exit road became exposed causing tyre punctures. One sq m). The mesh was
from a quarry in Roodekrans, Gauteng. Later of the concerns in building steel-reinforced placed mid-depth in a
on, an access road was constructed to a quarry UTRC roads is the necessity to keep the conventional 30 MPa Gordon Forrester
in Mthatha and the City of Tshwane paved steel reinforcement in the correct position, ready-mix concrete.
some roads in various townships in Gauteng. to avoid corrosion, and obtain the correct The concrete was purchased from a ready-
The Roodekrans Quarry test pavement was reinforcement. mix plant situated approximately one kilometre
removed after several years due to tyre Interesting papers, provided by the CSSA (1 km) from the section of road selected for
damage resulting from mesh exposure. Editorial Board, containing further background the overlay trial. No special qualities other
In 2016, a new section of UTRC pavement on the “original project” are listed in the than specifying a 19 mm, 30 MPa, 100 mm
was laid as an overlay of an existing asphalt endnotes.[ ][ ][ ] Unlike the “original” trial, the slump concrete, were requested from the
pavement using basalt mesh reinforcement. current trial was not funded by any Research ready-mix plant.
Basalt mesh reinforcement is corrosion free Organisations in any way. The trial had its The engineer estimated that sufficient
and is not stiff enough to damage tyres if roots based on a comment made by Adrian compressive strength would be developed in
exposed. The UTRC trial also proved that Bergh, who said, “I wonder how the mesh will seven (7) days, after which the overlay surface
rehabilitation of roadways could be carried work in UTRC?” could be opened to the heavy traffic. (A traffic
out on sound sub-bases. The original asphalt count was taken over 12 hours on a Thursday.
road had suffered from long term wear but COST COMPARISONS The actual table is given later).
had not rutted or shoved. The overlay was In Africa, many economies and governments To produce a lightweight 50 mm x 50 mm
constructed using untrained labour. The are already looking favourably towards mesh, pieces were hand-cut from the centre
team were residents of an adjoining informal concrete roads. Most countries have under- of each set of four 25 mm x 25 mm apertures
settlement. To date, no maintenance has been utilised cement plants and almost all face rising found in a standard mesh. Price considerations
necessary. oil import costs. The number of tenders now
being requested, around the world, indicates
INTRODUCTION that concrete has become an acceptable
In 1981, CSIR’s Adrian Bergh visited Iowa, alternative. The basalt reinforced UTRC trial
in the USA, to participate in the Second was conducted to compare the basalt mesh
International Conference on Low-volume with a wire mesh reinforced pavement section,
Roads. He and other delegates saw the thin similar to the system investigated for ReCAP
concrete pavement concept in operation. Due and AfCAP.
to Adrian Bergh’s interest, in 2002, the CSIR, It seems incredible that most road-
UP and C&CI worked to lay the first ultra-thin maintenance authorities persist in spending
reinforced concrete pavements. One of the valuable funds to pay for the frequent repair
first projects was a bus route in Soshanguve bills that are part of the asphalt road market.
which was followed by test panels 50 mm, The method using basalt mesh could be used Standard 25 mm x 25 mm basalt
75 mm and 100 mm thick at Roodekrans to replace old asphalt pavement or concrete mesh layout.
quarry where the C&CI, the UP, and the CSIR roads. Concrete overlays, which have become
participated. Further test sites around the highly cost-competitive, should last much
country followed, which included a quarry longer than asphalt pavement.
access road near Mthatha, Eastern Cape.
Ultra-thin Reinforced Concrete Pavement MATERIALS USED
trials were conducted using the CSIR’s heavy In 2016, a “modified” UTRCP test section
vehicle simulator to advance research into using a concrete overlay was placed over a
the relatively new concept. Gautrans and worn section of asphaltic pavement at the
The City of Tshwane built some township access to the Roodekrans Quarry area. The
roads, providing an alternative to asphalt site is approximately 500 metres away from
pavement. These projects received a Fulton the intersection of Hole in One Avenue, on
Commendation in 2009 in the category for Abraham Van Wyk Road, in Ruimsig North,
“Unique Design Aspects.” Gauteng.
Although the “original” test sections at The 50mm thick overlay of concrete was 25 mm x 25 mm mesh modified to
Roodekrans were in use for many years, and reinforced with a “doctored” 50mm x 50mm 50 mm x 50 mm.

14 NUMBER 163 | NOVEMBER 2020

 CASE STUDY

were the reason behind the hand cutting of a PLACING THE OVERLAY With hindsight, the use of 50 MPa
standard 25 mm x 25 mm basalt fibre mesh. After sweeping and cleaning the old asphalt concrete would have provided advantages,
More recently, mesh imported for an industrial surface 100 mm x 100 mm trenches for such as earlier strength development and
floor area, has benefitted from better pricing thickening beams were dug around the improved flexural strength. The higher cost of
agreements, which has made the use of the periphery. 25 mm high screed rails were fitted 50 MPa concrete would be inconsequential
standard mesh more desirable. to the surface of the asphalt road to control when measured against an earlier strength
The use of 450 g/m2 fibre mass is expected the initial concrete thickness. All spoil was development. Since the traffic count is
to provide better crack control, although the removed and the asphalt was thoroughly particularly high, and the tonnages are large,
lightweight mesh has performed beyond washed with clean water. The surface was early opening of the road-strip was important.
expectations. The only crack control measure left until all surface water had evaporated. After laying the first 25 mm of concrete,
taken for the overlay was the use of a The mesh was laid out and cut to fit into the hand tamping and levelling were carried out,
“modified” basalt fibre mesh. overlay area. It was then rolled to one side to using a straight channel iron screeding beam.
prepare for the concrete arrival.

Mesh rolled out over first 25 mm thick concrete layer. Surface in January 2017 (4 months).

Mash pulled flat to remove folds and wrinkles. Surface in July 2018 (21 months).

Mesh ready to receive the second 25 mm thick concrete layer. Surface in January 2020 (40 months).

CONCRETE BETON 15
CASE STUDY

The lightweight basalt mesh was then unrolled

CAR/LDV HEAVY-DUTY VEHICLES
and stretched over the wet concrete. The
second set of 25 mm high screed rails were 2 axle 2 axle 3 axle 4 axle 5 axle 6 axle 7 axle
fixed onto the initial set to ensure a final 50mm 4 wheel 6 wheel 10 wheel 14 wheel 18 wheel 22 wheel 26 wheel
final thickness. Then another 25 mm thickness
VEHICLE
of 30 MPa concrete was laid, and screeded 194 62 70 47 98 34 3
OVER
level, creating a final 50 mm thick UTRCP.
Once sufficient set was obtained, the AXLE
388 124 210 188 490 204 21
OVER
surface was wood-floated to minimise any
screeding defects. The edge formers were VEHICLE
160 52 62 35 71 27 4
removed, and a triangular fillet was hand- RETURN
trowelled to provide an angled edge. No TOTAL
354 114 132 82 169 61 7
tie bars were inserted between the overlay VEHICLES
and the triangular fillet, and the fillet was
TOTAL
unreinforced. The Engineer requested the 708 228 396 328 845 366 49
AXLES
edge thickeners but has subsequently stated
that their inclusion was not really necessary. TOTAL
1416 684 1320 1148 3718 976 182
WHEELS
The concrete was covered with plastic
sheeting to cure the concrete, but no crack
inducement was provided. With such light overlay, reinforcement was minimal. No steel completely exposed to traffic. Loose sand was
reinforcement, it was anticipated that reinforcement or fibres were added. The test displaced, due to the sand-vacuum cleaning
shrinkage cracking would occur. After seven was planned to be a “worst-case” scenario. effect of the vehicles. Only during the last six
(7) days, the plastic sheeting was removed, Although shrinkage cracks did form, the month period had the concrete been subject
the earthen protection bunds that had been lightweight mesh has reinforced the concrete to less abrasion, due to a thin mud layer.
provided to divert traffic were returned to sufficiently to prevent any dislodgement. Inspections have shown that the overlay
the borrow pit, and the concrete overlay was Also, since basalt fibre is lava-rock based, no is whole, with no displacement or spalling
placed in service. corrosion of reinforcement is possible. The of the concrete, during the period since the
transverse cracking, due to drying shrinkage, overlap was placed. The edges of some of the
CRACKING occurred as expected. The crack spacing was a cracks have shown some slight wear but, with
Although normal concrete drying shrinkage typical 4.5 m – 5.0 m apart. the constant traffic of heavily laden vehicles,
and some minor corner-curl and slab-end the wear is not significant. A video taken
cracking have occurred, the performance PERFORMANCE OF THE OVERLAY during the most recent inspection showed
of the test section has far exceeded the Over almost four (4) years, regular monitoring that six (6) heavily laden trucks and a couple
performance of the old asphalt road surface, of the overlay has been conducted. The last of motor cars passed over the test section in
alongside the test patch, which is now severely inspection was carried out in January 2020, one minute. The overlay section is subjected to
potholed. Without the overlay, it could have when a tractor-loader-backhoe (TLB) was heavy traffic and cannot be classed as part of a
been expected that the base asphalt would borrowed from a nearby business and a thin low-volume road.
have become as badly potholed as the mud layer was removed from the overlay
adjoining original asphalt. surface. TRAFFIC LOADS
In thin slabs, warping and corner-curl are The overlay was placed next to an informal Estimations were made of the loads that have
always possible. Laying thin-skinned concrete housing development. Vehicle speeds and been carried by the overlay system. Figures
over an essentially waterproof asphalt surface dust production were relatively unsafe for road were obtained from one of the businesses
would encourage slab curl. During cleaning users. Therefore, the area management group that use the road extensively. Since all the
before laying, there was excess water that decided to place earthen speed restriction material supplied by the company is weighed
had to be swept from the asphalt surface, and humps along the road. One of the speed on a weigh-bridge before delivery, an accurate
minimal penetration was observed. humps was placed at the end of the asphalt minimum quantity was obtained. This is based
Also, providing edge thickeners has road section, abutting the overlay. on weighbridge figures from the most prolific
increased crack potentials as a longitudinal Due to the speed control humps, vehicle user of the road that affirmed 110 000 tons of
crack formed parallel to the edge, in line with speed levels have dropped and the vacuum- material delivered every month.
the longitudinal slab edge thickener. Mesh was cleaning action has been lost. The area When taking the baseline provided by
not used to strengthen the edge-thickeners. management group has provided regular the company, and estimating the output of
Also, there is a longitudinal crack between the watering of the gravel road section, to two other quarrying companies, an annual
overlay and the triangular fillet that was added minimise dust, and sand has been carried onto tonnage of 1.7 million tons of traffic was
to minimise edge impacts. the overlay, which has formed a thin mud estimated. The output of two ready-mix plants
The very light mesh weave may have proved coating. The ease of monitoring has been lost was not used in the estimations. Over the
detrimental to the ultimate performance of the as a TLB unit is now required to expose the current service life, it is estimated that at least
test panel, as no additional crack suppression surface. 6.5 million tons of traffic has been carried.
systems were used. A very light mesh was the Further inspections have been restricted This figure was conservative since the output
only reinforcement medium. Since only 225 g/ due to the COVID pandemic. For the first of a brick and block factory and two ready-mix
sq m of fibre mesh was added to the concrete three (3) years, the concrete had remained concrete plants were not factored in.

16 NUMBER 163 | NOVEMBER 2020

 CASE STUDY

TRAFFIC COUNT would be of concern. In road surfaces, the re-surfacing of pavements requiring
A traffic count was conducted over a 12-hour use of wire or steel reinforcement may, over rejuvenation. Laying experience indicated
continuous period on a normal weekday time, protrude from the pavement and cause that the system could be used to replace
(taken on 05.07.2018). The count identified tyre damage. This concern is eliminated when hot-mix asphalt, in pavement refurbishment.
the main types of vehicles, their axle and basalt mesh is used as reinforcement. Furthermore, future shoving, rutting and
numbers of tyres. The table, recording the The laying procedure does not require potholing, as is expected with asphalt
traffic count is shown in the table. sophisticated paving machines and is an premix pavements could be delayed, or even
Unfortunately, Because of the variability excellent means of providing work opportunities eliminated. The system could be laid over
of the types of vehicles passing the for untrained and unemployed labour. potholed pavements, with the proviso that the
monitoring site, it was not possible to check Concrete overlays, or inlays, using basalt sub-base is sound. s
individual tonnages, nor obtain parameters fibre mesh reinforcement, could provide
necessary for calculating E80 equivalent axle
loads. These calculations would have been
invaluable. REFERENCES:
1 The assessment of the structural characteristics of ultra thin-layer lightly continuously
reinforced concrete through accelerated pavement testing in South Africa. L. du Plessis,
CONCLUSIONS
P.J. Strauss and A. Kilian, 28th Annual Southern African Transport Conference and
The use of lightweight basalt mesh
Exhibition: sustainable transport, 6 to 9 July 2009, CSIR, Pretoria.
reinforcement in concrete overlays seems to
be a viable system. The use of standard basalt 2. Ultra-thin reinforced concrete pavements: experiences encountered during the
mesh could have been a better choice, as the construction of two roads, M.R. Louw, A.O. Bergh and A.H. Mckay, 28th Annual
quantity of actual fibre reinforcement used Southern African Transport Conference and Exhibition: sustainable transport,
in the overlay was extremely low. Also, the 6 to 9 July 2009, CSIR, Pretoria.
use of 50 MPa concrete would have provided
3. Constructability aspects of ultra-thin continuously reinforced concrete pavement,
improved flexural strength
M.W.K.E. Mukandila, T.I. Milne and E. Horak, 28th Annual Southern African Transport
Basalt reinforced concrete could be laid in
Conference and Exhibition: sustainable transport, 6 to 9 July 2009, CSIR, Pretoria.
thin sections where corrosion of reinforcement
INDUSTRY NEWS

OXFORD PARKS PHASE 2 –

another Concor buildings success story
The Oxford Parks Phase 2 project is a testimony to meticulous coordination on the part
of Concor Buildings ensuring the concurrent construction of three different buildings
would run smoothly. Designed to complement each other, the respective footprints of the
buildings fit together in a jigsaw puzzle configuration, proportionately occupying the site
to optimise the land usage of this prime precinct with its generous public environment.

O
xford Parks is an architectural focal This phase includes the simultaneous The buildings, together with Phase 1, 199
point along Oxford Road in Rosebank. construction of 203 Oxford Road – Life Oxford Road, were designed to complement
On completion, this site will house five Healthcare’s new 10 000 m2 head office, 8 each other, and their respective footprints
buildings on a master basement structure. Parks Boulevard – a 4 000 m2 multi-tenanted fit together in a jigsaw puzzle configuration,
Oxford Parks Phase 2 is a testimony to building housing inter alia Metier Private proportionately occupying the site to optimise
meticulous coordination on the part of Equity and G+D Currency Technology, and 6 the usage of this prime pedestrian precinct
Concor Buildings to ensure the concurrent Parks Boulevard – 3 400 m2 offices for Arup, with its generous public environment.
construction of three different buildings Sony Music and Sony Publishing. Through bold yet sensitive design of the
would run smoothly. buildings, together with the hard and soft
landscaping of the outdoor piazza area, a
natural environment was created ensuring a
harmonious blend of business, life and leisure
for the end user. Accommodating all parking
in basements has shaped a precinct that is
pedestrian friendly and offers a safe retail
experience.
Martin Muller, Concor Buildings’ contracts
manager, explains that all the buildings are
constructed to be compliant with Green Star
design requirements. 199 Oxford Road in
Phase 1 achieved a 5-Star Green Star rating.
All specifications on the project are in line with
Green Star requirements and the buildings in
Phase 2 are also designed to achieve 5-Star
Green Star ratings.
A comprehensive Environmental Manage-
ment Plan was adopted that amongst many
criteria, specified the installation of waste
management systems to maximise recycling
Oxford Parks precinct showing the buildings 1 to 5.
from waste generated on the project.
Another environmental intervention was the
installation of state-of-the-art HVAC systems
in all the buildings presenting energy saving,
efficiency and sustainability features including
air-cooled systems to eliminate water usage.
To optimise energy usage during
occupation, different striking façades provide
the respective buildings with both aesthetic
interest and added energy benefits.
Muller emphasises Concor Buildings’
commitment to health and safety on site.
“Creating a strong safety culture is always
a challenge on bigger projects with a large
number of subcontractors but Concor’s pledge
to its Stop.Think.Act initiative has seen active
involvement becoming a trend on site.”

Western façade of building 3.

18 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

“Visible Felt Leadership from the entire Muller adds: “As is the case on all spoiled by contractors fixing incomplete works
production and safety team ensures that the projects we undertake, quality plays a once tenants have taken occupation.”
contractors, subcontractors and tenant major part in the execution of this project. This was a particularly challenging period,
contractors execute work safely at all times. Progressive snagging is implemented to but through Concor Buildings’ commitment to
This is vital as on average there are 350 ensure that works are checked and signed its values, one of which is care, the contractor
workers from 22 different contractors on site off as completed by each trade. This practice is still producing an upmarket and modern
and this will increase as tenants start with their results in a minimised snag list of items to product while demonstrating care towards
fit-out activities,” he says. attend to once the buildings are complete, all parties on site and careful attention to the
The COVID lockdown added a new level ensuring that the end user experience is not various features of this complex project. s
of challenges and anxiety to the construction
industry. According to Muller, through early
preparation and policy implementation,
Concor Buildings ensured it was ready
to start again on site once the lockdown
restriction relaxation allowed construction
to commence on 1 June 2020. Implemented
daily scanning points, wash stations, social
distancing measures, signage and continual
communication led to construction activities
being back on track from day one after the
restrictions were removed.
Risk management became a particularly
important part of this project considering that
the lockdown delayed construction by more
than two months. Concor Buildings has clearly
North east corner showing cladding and glazed façades.
demonstrated its agility value by completing
the buildings in, or close to, the originally
contracted completion dates.
During this period, Concor Buildings ring-
fenced long-lead manufacturing items and key
focus points with the client, subcontractors
and suppliers. These pro-active interventions
ensured all materials were delivered on time
allowing subcontractors to finish off when the
client required the areas for tenants to take
occupation. These measures also ensured
the contractor could mitigate most of the
additional costs due to the COVID lockdown
period, ensuring practical completion (PC)
dates are achieved as per the contract.
Sony Music, Sony Publishing and Arup
have taken occupation of 6 Parks Boulevard,
Eastern façade of building 5.
which was completed on time. The first and
second tenants in 8 Parks Boulevard took
official occupation on 1 September 2020,
a week earlier than the extended practical
completion date of 9 September 2020. Again,
testimony to Concor’s agility and commitment
to meeting project targets.
The Life Healthcare tenant installation in
203 Oxford Road started ground and first floor
handover on 10 August 2020 with all other
floor level handovers on track with overall
building practical completion on 2 November
2020. This date, which was extended due to
lockdown delays, will be achieved through
client and professional team assistance,
identifying risks and dealing with these before
they occur, dedicated resources and time
management on the buildings. Eastern façade of building 3.

CONCRETE BETON 19
INDUSTRY NEWS

An aerial view of what the impressive Oxford Parks project where concrete enhancing and repair products supplied by a.b.e. are being used.

a.b.e. Concrete products for massive

Oxford Parks development
C
oncrete enhancing and repair products durarep FR is a polymer-modified, cement- each other, and their respective footprints
supplied by a.b.e. Construction based mortar widely used to repair voids fit together in a jigsaw puzzle configuration,
Chemicals are being used for the and honeycombed areas of concrete. “The proportionately occupying the site to optimise
construction of the massive Green Star product, which is also chloride-free, provides the usage of this prime precinct.
precinct, Oxford Parks, now being developed high ultimate strength and has high resistance All precinct buildings are constructed
in Rosebank by Intaprop with Concor Buildings to abrasion – in fact, four to six times stronger to be compliant with Green Star design
as the main contractor. than plain rendering. durarep FR does not requirements. “Building 1” in Phase 1 was
a.b.e. Construction Chemicals, part of the shrink and is easy to apply and, as it is pre- Green Star-registered and awarded a 5-Star
Chryso Southern Africa Group, is supplying blended, constant quality and performance Green Star rating. All specifications on the
durarep FC fairing compound to provide are ensured,” Pelser explained. “It can be used project are in line with Green Star requirements
an attractive finish to the concrete works, to repair potable water-retaining structures, and the buildings in Phase 2 will also be Green
and durarep FR fibre-reinforced mortar to cooling towers, and as bedding mortar Star-registered to achieve 5-Star Green Star
deal with concrete imperfections and for for concrete planks at sports stadiums or ratings.
column construction at the multi-million- suspended flooring.”
rand development between Bompas and Oxford Parks is a focal point along Oxford Other noteworthy SA building projects for
Jellicoe roads. Road in Rosebank and when completed will which a.b.e.’s durarep products were used
Rens Pelser, Technical Sales Consultant house five buildings on a master basement include:
for a.b.e., based in Boksburg, says durarep structure. • Impala Platinum cooling tower, Springs;
FC is a single component, polymer-modified Oxfords Parks Phase 2 commenced in • Growthpoint Lakeside offices, Centurion;
cementitious compound that provides a fair- February 2019 after the successful completion • N17 Regents Park highway bridge,
faced finish to concrete and masonry, and can of Phase 1 in 2018 which houses the new Johannesburg;
also close blowholes prior to the application of head office of BP Southern Africa. Phase • Val de Vie River Bridge, Paarl;
protective coatings. “durarep FC only requires 2 of the project includes the simultaneous • Norval Foundation premises, Steenberg;
the addition of a minimal amount of water construction of “Building 2” – Life Healthcare’s and
for mixing. It is easy to apply and requires new 10 000 m2 head office, “Building 3” – • Nuform office block, Margate. s
no priming or curing membranes to ensure a 4 000 m2 multi-tenanted building housing
excellent bonding to concrete and masonry inter alia Metier Private Equity and G+D www.abe.co.za
structures. It contains no chlorides and can be Currency Technology, and “Building 5” –
used for vertical and overhead applications,” 3 400 m2 offices for Arup and S ony Music.
Pelser said. The buildings were designed to complement

20 NUMBER 163 | NOVEMBER 2020

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PPC Readymix concrete simplifies the wet trade requirements of any

site. PPC Readymix has a number of advantages over site-batched
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requirements are reduced.
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INDUSTRY NEWS

Hannes Meyer,
cementitious executive,
AfriSam.

AfriSam has successfully manufactured cement with up to 70% of GGBFS while still
achieving the required strength. A typical 32.5 strength
cement will typically

Fly ash research paves way to comprise up to 31% slag

and 31% fly ash, totally
62% of the total volume

even greener cement of the blend.

South Africa’s pioneering role in the use of fly ash in cement production opens the door for the
country to reduce its carbon emissions while retaining a strong and innovative cement sector.
Hannes Meyer, cementitious executive at South African construction materials leader AfriSam,
who says the local sector has already made great strides in reducing its carbon footprint.

S
outh Africa’s pioneering role in the use says the local sector has already made great “The use of fly ash in clinker production
of fly ash in cement production opens strides in reducing its carbon footprint. By means less carbon dioxide is produced,”
the door for the country to reduce its incorporating fly ash – as well as ground he says. “Usually, calcium carbonate in the
carbon emissions while retaining a strong and granulated blast furnace slag (GGBFS) – in limestone must first be converted to calcium
innovative cement sector. its cements, AfriSam reduced its carbon oxide, and this generates carbon dioxide. The
This is according to Hannes Meyer, emissions per tonne of cement by over 30% calcium in ash, however, has already been
cementitious executive at South African between 2000 and 2018. converted in calcium oxide and silicate form.”
construction materials leader AfriSam, who There are other environmental benefits Meyer highlights the strategic importance
from using more fly ash, including a reduction of this kind of research and development for
in the amount of coal ash that power stations the future of the South African economy. He
must dump on surface. About two-thirds of urges that revenues from the government’s
the ash produced worldwide still ends up in recent carbon tax be carefully channelled into
ash ponds or landfill sites, says Meyer. Fly ash incentivising this kind of innovation in the
comprises the fine particles of coal ash that market.
rise with flue gases from burning coal, and is “The carbon tax needs to play a supportive
usually removed by electrostatic precipitators role in gearing up the economy for a low-
or bag filters. carbon future,” he says. “This is in fact vital
“Fly ash extends the volume of cement to off-set the negative impact that the tax
while adding valuable cementitious qualities could have on the cement sector’s global
to the final product,” Meyer says. “This on its competitiveness and its capacity to retain or
own reduces the amount of energy-intensive create jobs.”
clinker that must be produced – thereby The danger of the tax rising to
economising on the energy our plants must unsustainable levels in future was that local
consume.” clinker manufacturing facilities could be
More than that, he says, the use of fly ash moved offshore to untaxed jurisdictions. The
can also replace the traditional non-renewable cheaper clinker would then be imported,
products in the manufacture of clinker. These and the number of jobs required to produce
include limestone and shale, which have to cement locally would drop significantly. s
The field of blended cements has become
intensely science-driven, with material
be mined at considerable cost. AfriSam has
been researching this area for some time, with Contact information: www.afrisam.com,
such as fly-ash and GGBS contributing
Facebook: @AfriSamSA.Twitter: @AfriSam,
significantly to the performance of cement. exciting results.
LinkedIn : AfriSam

22 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

AfriSam is WBHO’s concrete partner on BRT station

Construction leader AfriSam has conducted two large continuous pours as part
of its readymix supply to WBHO Roads and Earthworks’ contract at Watt Street
Bus Rapid Transport (BRT) station in Wynberg, Johannesburg.
The two pours – conducted in February and concrete tends to be limited – due mainly to only a few concrete suppliers with the capacity
June this year – comprised over 550 m3 each, the high cement content in the mix. to conduct the size of pours required for this
according to AfriSam’s key accounts manager, “This meant that we had to have fresh contract, within the timeframe required.
Randal Chetty. The concrete work on the BRT concrete on site all the time, with no queueing “This was also a highly-specified project
project included piles, pile-caps and bridge of trucks,” says Naidoo. “The laboratory in terms of concrete mix designs, requiring
structures including precast concrete beams. at our Jukskei plant – close to the project – considerable upfront collaboration with the
Daniel Kwele, construc-tion manager also assisted with checking the quality of our engineers to approve the designs within the
at WBHO Roads and Earthworks, says the 150-slump mix.” SANRAL specifications,” he says. s
contract involved extensive earthworks to Readymix was supplied from AfriSam’s
Contact information: www.afrisam.com,
excavate the underground station, and almost Wynberg plant, with 14 to 17 trucks dedicated
Facebook: @AfriSamSA.Twitter: @AfriSam,
9,000 m3 of readymix for concrete works. to supply WBHO’s concrete pumps during the LinkedIn : AfriSam
“The southern portion of the main large pours. Chetty says that AfriSam is one of
bridge over Pretoria Main Road included the
installation of 342 lateral support piles and
pile caps to carry about 244 precast concrete
beams,” says Kwele. “To the north of the
bus station, the most notable structures are
the twin viaduct bridges, resting on 220 end-
bearing piles and over 70 footings.”
He notes that the close collaboration
with AfriSam and detailed planning for the
continuous pours helped to foresee and
mitigate any challenges. “The pours became
a smooth process, thanks to the commitment
from AfriSam’s senior management,” he says.
Kevin Naidoo, operations manager for
AfriSam’s central plants, notes that in large
pours for this kind of application, the window
period for pumping and placing the high-spec AfriSam dedicated between 14 to 17 trucks to the job of servicing WBHO’s concrete
pumps during the large continuous pours of around 550 m3 each.

Contractor WBHO Roads and Earthworks is making good progress on the Bus Rapid Transport (BRT) station at Watt Street in Wynberg.

CONCRETE BETON 23
INDUSTRY NEWS

Chryso Southern Africa in pole

position with fibre solutions
CHRYSO Southern Africa has made its mark in the construction
industry as a supplier of value-added solutions with an extensive
range of products and services. The shift towards the use of
fibres over conventional steel mesh reinforcement in concrete
mixes prompted CHRYSO Southern Africa to include fibres in
the company’s portfolio of products. Through the company’s
partnership with Oxyfibre, this offering is underpinned by an
in-depth understanding of fibre technology facilitating access to
best practice solutions using fibres.

T
he partnership formed with Oxyfibre uses, as well as steel fibres for use on projects
Fibrin XT polypropylene fibre serves as an
created a dynamic enterprise to the where these fibres are specified. alternative to crack control mesh.
advantage of both companies, and CHRYSO® EasyFinish is shaped to create
provides the construction sector with ready a smooth concrete surface finish. These fibres loadbearing capacity of the structure to advise
access to product as well as technical expertise. are engineered to replace steel mesh or steel on the ideal solution,” Louw says.
Izak Louw, general manager at Oxyfibre, fibres in precast and sprayed concrete, ground For micro fibre applications, CHRYSO®
explains that when Oxyfibre became the supported internal slabs and external hard Fibrin XT serves as an alternative to crack
agent for Adfil fibres in Africa during standings. control mesh. The use of micro fibres in
2016, CHRYSO’s presence and established Louw says the main benefit is to optimise concrete product manufacturing has proved to
infrastructure in Southern Africa made them speed of construction by eliminating the need enhance the surface properties and durability,
the partner of choice. CHRYSO Southern for costly placement of rebar and ensuring significantly reducing the occurrence of plastic
Africa takes care of the pricing, stock, supply adequate cover to reinforcement. Added shrinkage and plastic settlement cracking.
and marketing of the product and services, benefits include maximum bond within The application of fibre technology has led
with Oxyfibre continuing in its role as fibre concrete, greater tensile strength per fibre to the execution of many successful projects
technology developer and consultant. for enhanced residual flexural strength and in Southern Africa.
The Durus range of synthetic macro fibre toughness in the concrete. In a recent project, the thickness of the
replaces steel mesh for effective and cost “When the project calls for the use of designed surface beds made the use of
efficient reinforcement of readymix, precast a structural fibre, the Oxyfibre team will traditional reinforcement impractical. A high-
or sprayed concrete. This range includes assess the ground conditions, the structural dosage fibre addition to the mix resulted
polypropylene fibres tailored to specific end- element design and particularly the specified in 7000 m2 of concrete being placed with

Fibre technology is used extensively in readymix concrete, easily pumped on site without the
use of steel mesh.

24 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

Several large warehouse floors have been constructed maximising the benefits of fibres over Durus S400 macro fibres supplied for the
conventional reinforcement. floor slabs readymix for offices.

noticeable cost and time savings. Similarly, Louw adds that ongoing research in “Since 2016 the use of our fibres has
several large warehouse floors have been collaboration with both local and European doubled. The partnership between CHRYSO
constructed maximising the benefits of fibres universities has resulted in the expansion of Southern Africa and Oxyfibre created a
over conventional reinforcement. the Adfil product range. Newer developments win-win solution for all the stakeholders.
In the Western Cape, the use of fibres in include Ignis, a micro fibre specifically Together we provide concrete reinforcement
coastal defence structures and shotcrete for designed for its fire protection benefits and a solutions for construction projects that
water channel linings are examples where this macro fibre that will address problem areas in can be undertaken safely and rapidly with
technology specifically serves this aggressive the precast industry. reduced waste and reduced impact on the
environment. Fibre technology is used extensively in environment,” Louw concludes. s
Fibres have also been used successfully readymix concrete, but the ease of transport,
in the construction of floors in the farming, storage and handling of these fibres also Contact: https://za.chryso.com
food processing and industrial industries makes it ideal for smaller projects. This is
where harsh chemicals and other deleterious because the contractor can usually follow
substances could potentially affect the a prescribed dosage rate of 600g per cubic
concrete. Fibre reinforcement in concrete metre of concrete and mix instructions to do
used in power stations eliminates the risk of concrete mixing on-site.
electrical current being conducted by the steel.

There has been a shift in the use of fibres EasyFinish is shaped to create a smooth Tailor mixed concrete design containing
over conventional steel mesh reinforcement concrete surface finish. EasyFinish fibres used for a project in
in concrete mixes. Spartan.

CONCRETE BETON 25
INDUSTRY NEWS

Construction sector is critical to

SA’s post-COVID economic recovery
T
raditionally, the development of risk severe that contractors are either forced
management plans is tailored to address to comply at huge cost, or in some
assessed and quantified risks. There is instances, abandon the projects entirely as
however always the ‘the unknown factor’. the situation becomes untenable and not
Enter the COVID-19 pandemic. Of course, we worth the risk. It’s a serious and growing
have faced localised pandemics before, but threat to the construction industry and the
never one on such a globally synchronous scale, much-needed infrastructure development
thanks to global travel and trade. It propelled in SA – law enforcement, local authorities
the entire world into unchartered territory as and construction bodies need to find
mass economic and travel lockdowns were common ground to resolve this issue and
implemented, and contingency plans were regulate the practice – the practice is likely
hurriedly rolled out. For many industry sectors to worsen as South Africa shed a further
and businesses already teetering on the brink, two million jobs in the last quarter alone.
it has been a crisis of unprecedented scale • Pricing – With work and projects in short
- a black swan event that simply cannot be supply, pricing wars are leaving contractors
Michael Viterenwa
quantified or dealt with, without the benefit exposed to the risk of unexpected costs or
of hindsight. delays, that are often met with penalties from-home trend took hold. As a result,
According to Michael Viterenwa, Senior that contractors will simply not be able to many companies are not spending on
Broker in Aon South Africa’s Construction meet. Cutting corners and costs inevitably building new offices or renovating existing
& Engineering Broking Centre, Government means cutting skills, quality and safety. office space. It’s likely to be a long-term
is the biggest spender on infrastructure in • Currency – The Rand’s declining value trend as many corporates realise that
SA’s construction industry. “With the onset against the US Dollar (26% in the last five staff can successfully work from home,
of our national lockdown, government years) has severe financial implications for and that prime floorspace might not be
diverted infrastructure spending to alleviate an industry that relies on the import of as necessary as once thought. Shopping
the economic and social crisis facing the machinery and specialised materials. centres and malls are also under severe
country, cutting traditional expenditure by • Supply Chain - Given the global nature pressure with many large retailers having
80%. This brought a large portion of the of this crisis, supply chains across all to cull stores and jobs as a result of the
country’s economy, including the construction geographies have been disrupted with lockdown and depressed consumer
industry, to a grinding halt. At the same time, extended and costly delays on key spending.
restrictions on construction activity under components and materials, not to mention
lockdown regulations added further pain. skills. To say that times are incredibly tough and
Projects were left standing, deadlines were • Credit Risk – The failure of businesses uncertain would be a gross understatement.
missed – the consequences of which are across the spectrum is bringing capital In a bid to cope, many construction companies
enormous.” availability problems into sharp focus. have cut capex by 50% – 60%, jobs have
Viterenwa goes on to detail some of the Accounts receivable is often the largest been cut, work hours have been reduced and
emerging and concerning trends impacting uninsured asset on a company’s balance property rentals in industrial and commercial
the construction industry – and while many sheet, constraining cash flows and properties are likely to never return to pre-
existed prior to Covid-19 – they are now having huge implications for creditors COVID levels as remote working becomes part
exponentially amplified: when debtors go into business rescue or of the new normal.
• Community Forums – Better known in the liquidation. “Construction companies, landlords, deve-
industry as the ‘construction mafia’, local • Skills Shortages – Uncertainty and volatility lopers and contractors will need to explore
‘community forums’ have been springing around politics and economics are likely ways of managing the impact and complexity
up around virtually every construction to widen SA’s growing skills shortage as of a radically changed environment. It is vital to
project – from a commercial project an exodus of skilled people takes place. engage with all relevant parties to renegotiate
to the roll-out of fibre in the suburbs. Companies are under pressure to afford contracts and clauses. These may include
Members demand their cut of the ‘work’ and retain top talent. Increasing crime authorities, owners, lenders, contractors,
pie by applying pressure to contractors to rates and growing social unrest as a direct subcontractors, suppliers, clients, and so on.
employ local ‘community’ members, many result of the Covid-19 fallout are likely to Aon Global Risk Consulting (AGRC) has been
who do not have the experience or skills further push skilled people into the arms working with organisations to identify, assess
required to perform the job. If contractors of emigration to seemingly safer shores and quantify the short- and long-term impact
don’t comply, they are typically threatened and better social structures. of Covid19 on construction projects which can
with disruptions and even the safety of • Property Portfolios – During lockdown, then be used as a basis for negotiation with
their employees and projects – some many companies gave up their office external stakeholders and help communicate
of these disruptions and threats are so space in a bid to cut costs as the work- the situation internally,” Michael explains.

26 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

To this extent, the approach consists of: could be catastrophic if anything should go with a professional broker that specialises in
• Identifying construction project compo- wrong,” Viterenwa urges. construction risk is crucial in order to anticipate
nents which can generate high financial “The industry will pick up in the any changes in policy wording, terms and
impacts, from a cost and delay perspective. coming months and we are already seeing conditions, pricing and potential exclusions
• Preparing a register listing and justifying a commitment from Government to to maintain a workable and affordable level
each high financial impact and grouped infrastructure spending, and positive signs of cover during these trying times, and to
by generating component. on the energy front with a determination avoid the potential for costly and potentially
• Quantify the overall financial losses by mineral resources & energy minister uninsurable liabilities,” says Michael.
associated with each impact and creating Gwede Mantashe to procure 11.8GW of As a key driver of South Africa’s economy,
multiple impact scenarios from a cost and additional electricity in the coming years from and a key pivot in the country’s post-COVID
delay perspective. Independent Power Producers. Government recovery, more than ever the industry sector
• Comparing the results of impacts quanti- has also committed to expedite the needs to maintain and grow its resilience and
fication to the contingency plans in place implementation of at least 50 infrastructure embrace change to emerge leaner, focused,
and existing insurance policies. projects with a total investment value of more having mastered new technologies and a
than R340 billion in the coming months as new world of work in a very different new
Insurance matters related to projects that part of South Africa’s economic recovery plan. normal. Suitably scoped insurance and risk
are still on the go remains a concern. “Many “It is crucial that construction companies management practices remain fundamental
companies are opting not to renew their maintain their covers and conditions of cover to being able to embrace risks for the
insurance policies due to cost-cutting, which as far as possible. As reinsurers and insurers opportunities they present in the coming
could be detrimental to their operations on prepare for their major renewal season in months. s
projects that are still in progress. Companies January 2021, they may find that they will
Contact: https://aon.co.za
have a legal obligation to ensure that cover is not have access to the same type of cover,
maintained up to the conclusion of a project, pricing and terms and conditions from
as the financial and liability repercussions insurers that they have now. A conversation

Trash pumps ideal for dirty water with large solids

Contractors often find themselves having to pump water that
contains hard and soft solids such as trash, gravel, stones, leaves
and twigs. Integrated Pump Rental says its customised trash pump
set are a popular and reliable option.

D
ewatering activities on large construction en end-user’s specifications we can ensure the
and infrastructure project sites is not pump dewatering solution is fit-for-purpose.”
always a simple task. In fact, pumping The trash pump sets provided by the
dirty water containing large amounts of debris company are usually trailer-mounted with a
calls for a ‘trash pump’, according to Henru diesel engine for optimal mobility, but Strydom
Strydom, operations manager at Integrated says these can also be static units driven by
Pump Rental. electric motors.
“Contractors often find themselves having Ensuring proper pump selection means
to pump water that contains hard and soft understanding basic requirements like the Trash pumps can typically handle solids up
to 76 mm in size with flow rates of up to
solids such as trash, gravel, stones, leaves and head height to be pumped, the quantity and
110 litres per second at a maximum head
twigs,” Strydom says. “In many instances, the flow rate required, and the distance over of 32 metres.
construction site needs dewatering to be done which the water will be transferred. Trash
at a consistent rate and needs to reduce the pumps can typically handle solids up to 76
them to avoid the use of cranes to move and
chance of a pump clogging with this kind of mm in size with flow rates of up to about 110
place large single pumping units.
material. This is why a trash pump is a popular litres per second and a maximum head of 32
Strydom highlights that Integrated Pump
and reliable option, and it offers versatility in metres.
Rental’s in-house experience in designing and
terms of its configuration.” “Our self-priming, tried-and-tested trash
assembling trash pump sets also allows it to
Integrated Pump Rental, with its capacity pumps are often considered as the real
offer customised service level agreements,
to design and assembly pump sets in-house, workhorses of the construction pump market,”
based on customers’ preferences and specific
can customise these for the user’s specific site Strydom notes. “Apart from dewatering sites,
conditions. The company’s expertise and
conditions. these can also be easily moved into place
service capability mean units can be constantly
“Our comprehensive pump rental fleet where large pipelines have to be temporarily
supported with maintenance, repairs and
has included trash pumps for some time, and bypassed, for instance, moving large volumes
replacement parts. s
more recently we have been tailor making of water quickly and dependably.”
trash pump sets for customers on request,” Contractors even use multiple units in Contact: Integrated Pump Rental
Strydom says “By configuring the pump set to remote sites where access is difficult, allowing www.pumprental.co.za

CONCRETE BETON 27
INDUSTRY NEWS

Increasing the life of concrete for

sustainable built environments
O
ver the years, built-environment pro-fessionals have increasingly SprayLock Africa is the African distributor of United States-based
turned their efforts towards improving the durability traits of Spray-Lock Concrete Protection’s (SCP’s) cutting-edge technologies,
concrete to construct longer lasting structures for sustainable which have been designed and developed to provide enhanced concrete
built environments. durability, protection and performance.
Fire resistant and durable, concrete enables the construction of Factors that influence concrete durability include water to
buildings and infrastructure that can sometimes last for about 100 cementitious ratio; aggregate packing; reinforcement and type; curing
years. Increasing its durability will, therefore, further reduce the amount methods; the environment in which it is placed; and finishing practices.
of energy, time and resources that would otherwise have been required All concrete is susceptible to contaminant ingress, considering
for maintenance, repair or rebuilding. its porous nature and bleed-water channel. This is especially true
“The global ‘green’ building movement has transcended merely for reinforced concrete, where the corrosion potential of reinforcing
using recycled materials to construct sustainable structures. Built steel is directly related to the water, oxygen and chloride movement
environment professionals are taking a longer-term view of sustainability into the building material. It disrupts the protective layer around the
by, importantly, also focusing on raising the expected lifecycle of service- reinforcement which leads to corrosion/rusting of the rebar.
delivery infrastructure and buildings. By building concrete structures White says that SCP helps reduce the corrosion potential of concrete
that last two to three times longer than current designs, we can by reducing the pathways of water and contaminate ingress.
reduce the need to rebuild them as often and, in so doing, alleviating “SCP is a colloidal silica product that enters the concrete through
the burden on existing resources,” Carl White, Managing Director of capillary voids. Once inside, the colloidal silica reacts with calcium
SprayLock Africa, says. hydroxide to form more Calcium Silicate Hydrate, or ‘C-S-H’, essentially
filling the capillary and pore structure with more concrete. This action
dramatically reduces permeability for the lifetime of the concrete,”
he explains, adding that SCP penetrates a minimum of 38 mm into
the concrete effectively enhancing and creating a more durable
concrete cover.
Using life cycle modelling software, such as Life 365, laboratory-
derived permeability parameters can be set to reflect the improvements
to permeability gained with SCP products. Comparisons can also be
made between untreated concrete and that which has been treated
with SCP technology. These comparisons can estimate a percentage in
life cycle expectancy gained with the use of SCP products.
The assessments have demonstrated that SCP can enhance the life
expectancy of concrete by as much as two to three times. For example,
the permeability of the concrete of a bridge in a marine environment
can be reduced to elevate its life expectancy to between 60 and 90
years or more after treatment with SCP technology. This is opposed to
SCP can enhance the life expectancy of concrete by as much as two only 30 years with the current mix design.
to three times. White says that this focus on improving the durability of concrete
complements an array of other existing characteristics that make
concrete a very suitable choice for sustainable construction.
“Among these is concrete’s thermal mass which absorbs and retains
heat, reducing the need for heating and cooling. This is complemented
by its reflectivity, which minimises the effects that produce urban heat
islands. Moreover, concrete can be produced in the quantities needed
for each project, reducing waste. It is also
encouraging to note the work that is being
undertaken in South Africa into recycling
concrete for use in various applications,
such as road layers. These traits position
concrete, which is used more than twice
as much every year, than all other building
materials combined, as a champion of
sustainability,” he concludes. s

Contact: [email protected]
Built environment professionals have turned their efforts towards Carl White, Managing
improving the durability traits of concrete. Director of SprayLock
Africa (Pty) Ltd.

28 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

Giving back in a time of need

Thárros, the Greek word meaning courage, is the name
given to the Child and Youth Care Centre situated in
Hankey, Eastern Cape.

I
t is a temporary haven for babies and children under the age of 12. These children
have experienced some form of abuse, trauma, abandonment, and neglect. In
this home, where they have been placed as a ward of State, they will assuredly
find warmth and care during their 3 to 6 month stay.
The primary goal of this care centre is to reunite these children with their
biological family. In situations where this is not possible, permanent foster care
is sought. During this period of
waiting, partnerships are made
with external social workers to
ensure the best outcome for
these children.
Like most non-profit
organisations, Thárros relies
predominantly on donations and
support from the community
and business, to keep the care
centre running. Usually, regular
fundraising is done in the form
of jumble sales and quiz nights,
but unfortunately none of
this has been possible due to
Covid-19. This ‘spanner in the
works’ adds an extra weight of
concern to the selfless team of
carers at the centre, who already
have enough on their shoulders.
It was in July 2020 that
Therese Sampson, the Project
Director at Thárros, contacted
Sika with a request for assistance. The roof of the Thárros building was leaking in
various places, resulting in damage to the ceilings. Urgent assistance was required
to nip this leak in the bud before further damage ensued.
To repair the damaged roof area, 100 litres of waterproofing paint was required.
With this being one of Sika’s specialities, it was without question that Sika was
readily willing to donate towards such a worthy cause. Twenty Sika® RainTite® Kits
were happily donated, with Ros Bosch, one of Sika’s sales representatives in the
FOUNDATION OF PRECISION
Eastern Cape, facilitating the handover. 1. Cement compliance testing
The Sika® RainTite® Kit provides a waterproofing system that can be used to 2. Core drilling and testing
seal joints on various kinds of roofs, as well as parapet and external walls. The kit 3. Aggregate testing
consists of the Sika® RainTite® Kit Waterproofing Compound which comes in a
4. Concrete testing
5-litre bucket, as well as the Sika® RainTite® Kit Membrane, which is 200mm x
10m roll of membrane. 5. Site services
This kit is an easy to use single component acrylic and is vapour permeable. It 6. Consultation
is UV resistant, has excellent adhesion, and is flexible and durable. These are the
exact components needed to keep the roof of this building in good condition for CONTACT
years to come. Email: [email protected]
The Thárros team were extremely grateful for this donation. Their initial request Email: [email protected]
had been for a discount on the required products; however, Sika went above and Tel: 011 979 1422
beyond by donating all the product at no charge. Donating in a time such as this is Cell: 083 635 3154
something that Sika is proud of! s

Contact: https://zaf.sika.com

CONCRETE BETON 29
INDUSTRY NEWS

PPC and CHC-SA PrimX Jointless Flooring

propelling SA construction forward
J
ohannesburg, 15 October 2020 - Focused on Traditional concrete floor specifications of casting and begin to curl, eventually leaving
providing the market with quality materials will require a standard 30MPa mix supplied severe joint damage. Clients begin to carry
and solutions that are 100% local, PPC and daily by a ready-mix plant without any specific huge maintenance costs to repair the 100s of
CHC-SA PrimX Jointless Flooring partnership effort to address shrinkage. This method is joints and damaged equipment while making
has become an example of what the future of limited to 4,5mx4,5 saw cuts or 30x30m an effort to manage the hazard this becomes
construction promises to bring to South Africa. (900m2) Steel Fibre Reinforced jointless in the workplace. Armed with the knowledge
With the global pandemic having shown the panels. Depending on the load requirements that traditional concrete cracks and curling
value that comes with flexibility and innovation (e 75KNbtb 150 KN), a slab of 180mm could were a result of the drying due to shrinkage,
to solutions, this partnership raises the design be constructed. If shrinkage is not addressed, the partnership between PPC and CHC-SA
and execution methods of concrete floors. 100m of joints begin to open within months PrimX Jointless Flooring optimizes the concrete
mix for improved shrinkage characteristics
presenting a real focus on quality to the South
African market.
“Seeking out partners who are invested
in the innovation of the sector has been an
integral part of our business. Having invested
128 years into the research and development
of our materials, the science behind the
development and innovation of our materials
has been developed to position us as a catalyst
that strengthens the capabilities of the sector,”
explains Dave Miles, Business Unit Head, PPC
Materials,
As a customer-focused business, PPC
continues to create a team that is empowered
to pioneer new ways of doing business. This
includes understanding and facilitating the
outcomes and ambitions of the contractor
who is determined to be competitive through
the inclusion of world-class technology
into the construction process. With South
Africa’s construction environment being
about 30 years behind global developments,
the partnership between PPC and CHC-SA
PrimX Jointless Flooring propels South Africa’s
construction environment forward.
“PrimX provides high-performance SFR
concrete with a focus in reducing shrinkage
through the addition of special additives,
careful mix optimization and quality control
throughout the whole production process
to ensure a predictable standard for PrimX.
Finding a partner who is was able to obtain a
quality washed crushed sand as well as washed
natural river sand filler was key for our success
in South Africa and on the African continent,”
explains Brett Meadway, PrimX Technical Sales
Manager. “We are uncompromising on the
quality, strength and density of the concrete
we must receive throughout the project.
With testing taking place from supply to final
product, we have created an ecosystem that
is driven by a commitment to ensuring our
product guarantee is achieved.”

30 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

“Limited only by day joints, our solution

saves 100s of meters of joint damage, allowing
for a load requirement of 75 kN btb 150 kN on
a 90mm lab. With no additional reinforcement
with mesh, construction time for the same size
of a slab is approximately 30% shorter! This
gives a project manager about a month extra
in construction projects while saving clients’
money due to the no curling and controlled
shrinkage PrimX floors when cast flat, stays
flat for its lifetime,” continues Meadway.
At the forefront of this partnership is a
labour force of young South Africans who
are provided with training that is on par with
their international counterparts who work on
similar projects. Jabulani Moeketsi, who has
been working on the project since the start and asking questions daily, I have become With the backup support from a concrete
describes his contribution to the project, “I someone trusted by Brett. I learn and share engineering team in PrimX’ lab, the ongoing
have seen what the future of my job will be my knowledge with my team as we watch support of PPC and its scientists, a predictable
here in South Africa. Here we are saving time how what we make, and the quality control consistent quality in PrimX jointless flooring
while removing curling and shrinkage in our measures we put in place give us something has been made available in South Africa. s
jointless flooring. Working with my hands we can be proud of.
Contact: www.ppc.co.za

Fibres tailored
to your project

CHRYSO® Fibre expertise

Provides a targeted response to specific needs for fibre-reinforced concrete:

Unique expertise in formulating fibre-reinforced concrete

An extensive range of synthetic macrofibres and microfibres tailored to each application
Optimized fibre dosage to deliver the expected performance levels
Dedicated service offer including a complimentary design service.
Gauteng (Head Office): 26 Malcolm Moodie Cresent, Jet Park | T: +27(0)11 395 9700 | W: za.chryso.com
INDUSTRY NEWS

One-time waterproofing treatment

versus topical solutions
S
pray-Lock Concrete Protection (SCP) One of the biggest challenges associated A further challenge is that all topical
technologies are being used widely with the use of protective film sealers are sealers must be reapplied when removing
in South Africa as a cutting-edge surface traffic and correct application. Acrylic flooring placed over the sealed surface.
waterproofing strategy. and epoxy sealers, for example, require Certainly, conventional penetrating sealers
Developed in the United States by regular maintenance because of their high also create challenges during the installation
Spray-Lock Concrete Protection to provide wear potential. While polyurethane sealers are of floor covering systems, considering that
enhanced concrete durability, protection, thicker to provide a durable abrasion-resistant they must be removed from the surface prior
and performance, SCP is a colloidal silica/ finish, there cannot be any water on the to installation.
post placement pozzolan one-time treatment surface area when they are applied. While SCP products also penetrate the
that penetrates the concrete matrix, reducing surface, White explains that they work
water migration levels to an acceptable differently than other penetrating sealers on
range for most coatings, adhesives, and floor the market.
coverings. “Colloidal silica chemically reacts with
Carl White, Managing Director of the available alkali in concrete to create more
SprayLock Africa, the African distributor calcium silicate hydrate (C-S-H), filling the
for SCP technologies, explains that most capillaries and pores and chemically stabilising
waterproofing sealers can be classified into the pH within. Within the interaction zone
two subcategories, namely “topical” and of SCP, the concrete becomes permanently
“penetrating”. dampproofed over its entire lifecycle. Unlike
“Topical sealers, which include acrylics, topical treatments, SCP does not wear away
epoxies and polyurethanes, form protective or need to be reapplied,” White says.
barriers on top of the concrete surface. Notably, SCP treatment also provides
Meanwhile. penetrating sealers include many additional benefits, including reducing
silanes, silicates, siliconates and siloxanes. They drying shrinkage by up to 91% and vapour
penetrate the top surface of the concrete and transmission by up to 88%. No potable water
react within the top of the concrete capillaries and plastic sheeting need to be placed onto
of the concrete to stop the migration of SCP is a colloidal silica/post placement fresh/green concrete and SCP out-performs
moisture and deicing chemicals,” White says. pozzolan one-time treatment. water cured concrete.
The technology has been deployed
globally in commercial, industrial, and
residential developments as a state-of-the-art
waterproofing solution.
This includes as a moisture membrane
over a 120 m² surface area at Nedbank’s
head-office; over 200 m² at Secunda Mall;
and over 280 m² at the Department of
Environmental Affairs head-office before
torch-on was applied. Moreover, it was used
as a waterproofing agent for a 1 490 m² deck
at Cambridge Shopping Centre and over 19
000 m² of various levels at Illovo Point Office
at the time of pour. SCP was also used to
waterproof the 40 000 m² top level parking
deck at Fourways Mall and CRC Church
Johannesburg’s 8 000 m² parking deck,
among other applications.
“Spray-Lock Concrete Protection strives to
be at the cutting edge of concrete solutions
by offering more durable concrete. Solutions
that save owners and general contractors time
and money are a driving force behind product
innovation,” White concludes. s
The technology has been deployed globally in commercial, industrial, and residential
Contact: [email protected]
developments.

32 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

TCI finalises online concrete MEGAN WEYERS

training programme for next year – CSSA BURSARY
The Concrete Institute’s School of Concrete Technology (SCT) has FEEDBACK
finalised its programme of online training courses for 2021. Fourteen
courses are planned, including the start of the pinnacle of concrete
diploma courses: Advanced Concrete Technology.
John Roxburgh, senior lecturer at the SCT, says the SCT ran its
last lecture-driven course at the end of March 2020 and was forced,
due to lockdown regulations, to abandon lecture room training after
that. “But we fortunately had experience in delivering e-learning
courses through SCT41 and SCT42, the UK’s Institute of Concrete
Technology’s General Principles and Practical Application courses,
which the School has presented on an e-learning basis for several
John Roxburgh years. This proved invaluable for a fast conversion of all the more
popular SCT courses onto an e-learning platform and within two

T
months, the SCT could offer 10 different courses online. These courses, where applicable, he CSSA 2020 bursary was awarded to
have been granted the same CPD accreditation as the lecture room-based courses.” Megan Weyers from the University of
Roxburgh says the SCT quickly learnt that the online course versions offer some Pretoria towards her MSc studies.
surprisingly good advantages. These included: The title of her dissertation was
• Substantial reduction in costs (major online discounts will still apply next year); “Optimised Mix Composition and Structural
• Flexibility for the student with work- or time-constraints; Behaviour of Ultra-High-Performance Fibre
• No travel and accommodation needed; Reinforced Concrete (UHPFRC)”. The over-
• More time available to study; all objective of the study was to develop
• Better understanding of the subject through a three-pronged approach that includes an optimised Ultra-High-Performance Con-
self-study with tests, videos that can be watched repeatedly, and face-to-face contact crete (UHPC) matrix based on the modified
with the lecturer on electronic meeting platforms. Andreasen and Andersen optimum particle
“Because of these significant benefits, the concrete and concrete-related industries have packing model by using available South Af-
welcomed online training and the School’s training has resulted in many satisfied students rican materials. The focus of the study was
graduating and receiving online course certificates in 2020.” to determine the optimum combined steel
The School is gearing to present its fibre and superplasticiser content for UHPC
next Advanced Concrete Technology (ACT- by using a response surface design.
SCT50) course for the Institute of Concrete Various changes in mechanical proper-
Technology at the beginning of 2022. “As ties resulting from different combinations
acceptance for this prestigious programme of steel fibre and superplasticiser contents
requires a pass in the SCT41 and SCT42 were investigated. The addition of fibres
courses, it is advisable for prospective ACT- significantly improved the strength of the
SCT 50 students to complete the SCT41 and concrete. However, if a more workable mix
SCT42 courses next year. The examinations is required, the superplasticiser content
for these will be written in May 2021.” can be increased without decreasing the
Roxburgh adds: “For those looking for strength significantly. The optimum com-
a career in concrete technology, there are bined fibre and superplasticiser content also
many opportunities available. South Africa depended largely on the required mechani-
has a massive need for competent concrete cal properties and cost. Using the modified
ONLINE practitioners in admixture sales, laboratories, Andreasen and Andersen particle packing
EDUCATION construction companies, ready mixed and model and surface response design meth-
PROGRAMME odology, it is possible to efficiently produce
2020/2021 precast concrete suppliers, concrete repair
facilities, cement and aggregate production, a dense UHPFRC with a relatively low binder
The School of Concrete Technology
and mining, to name just a few sectors. The amount, low fibre content and good work-
SCT has structured a progression of course ability. This can result in more cost-effective
levels that will allow a prospective student UHPFRC, thus improving the practical appli-
to enrol at a level that matches his or her competency. There are no short cuts to becoming cation thereof.
a good concrete technologist and study is essential. The SCT has all the educational Having completed her MSc degree, she
requirements to help meet these goals,” he states. s is currently enrolled for a PhD at the Univer-
sity of Pretoria, extending on her previous
For more information and the full 2021 online training programme, visit research, focussing on the development of
www.theconcreteinstitute.org.za or email [email protected] or high-density nuclear shielding concrete in
[email protected], or phone 011 315 0300.
South Africa. s

CONCRETE BETON 33
INDUSTRY NEWS

Tiber Construction and Tjeka Training Matters

take training to new heights for prestigious
public-sector development
T
jeka Training Matters, a leading registered Training commenced in September 2019 provide should also allow for Services Sector
private Technical and Vocational and will be completed at the end of December Education and Training Authority grants and
Education and Training college, is training 2020. South African Revenue Services tax rebates.”
60 unemployed people from Thembisa for A total of 15 candidates are being trained Tiber Construction’s ongoing focus
a Tiber Construction project that is being in carpentry, 15 in bricklaying, 15 in plastering on quality training as a key component of
undertaken on behalf of a leading public- and 15 in painting. business is evidenced by this leading building
sector client body. Classroom theorical training was initially contractor’s excellent delivery and high quality
Compass Consultants, which facilitated conducted in Thembisa, and the simulated of workmanship.
the training and implemented the learnership practical and workplace training phases It has always been the company’s policy to
on behalf of Tiber Construction, appointed undertaken at the construction site. ensure that all employees have the necessary
Tjeka Training Matters to undertake the Tjeka Training Matters’ Neville Carolissen skills, knowledge and ability to exceed
training. This decision was based on Tjeka and Vernon Geduld are providing instruction performance standards as required for their
Training Matters’ 20-year-long track record in carpentry; Gaidien Amadien painting; and jobs and those of the construction industry.
providing quality training to the construction Kassiem Davids bricklaying and plastering. This focus has provided Tiber Construction
sector throughout southern Africa, as well as Leonora Chetty, Human Resources Director with a strategic competitive edge within the
its Construction Education Training Authority of Tiber Construction, says that the company construction sector, especially during these
accreditation. only partners reputable training providers with challenging times for the industry.
“Compass Consultants knew that we a solid track-record serving the construction Dishani Garach, Tiber Construction’s
had the expertise and resources, including industry. Human Resources Clerk, says that the company
extremely competent practitioners, to “Importantly, they must be reliable and remains proud of the many employees it has
successfully execute this programme, which committed to ensuring a positive outcome by helped develop vibrant careers in the local
involved training many candidates over a prioritising the development and empower- construction industry.
period of 18 months. Thus far, the training ment of our staff,” Chetty says. “It is exciting to see enterprising
has been a resounding success, despite “Moreover, Tiber’s training providers members of our team rise up the ranks and
interruptions as a result of the Covid-19 must be accredited and offer recognised into leadership positions. We, therefore,
lockdown that brought many construction qualifications; follow a quality-assurance encourage all employees to participate in
sites to a standstill until it was eased later this programme to ensure the highest possible accredited training programmes to improve
year,” Frans Toua, Chief-Executive Officer of standard of training; and offer a variety of their skills, as well as employment prospects
Tjeka Training Matters, says. flexible skills paths. The training that they for the future growth of the economy. These
initiatives are complemented by our robust
mentorship programmes that are designed to
ensure that our staff stay abreast of the latest
developments in the industry.”
Notably, the company places just as much
emphasis on imparting its knowledge and
experience throughout its robust supply chain,
which includes qualifying small enterprises
and exempt micro enterprises. Undertaken
via its Enterprise and Supplier Development
programmes, this emphasis has assisted many
of the company’s partners achieve success in
their respective disciplines. Tiber Construction
is, therefore, contributing towards meaningful
growth and equity and, in so doing, towards
the long-term sustainability of the industry.
Toua concludes that he is proud of
Tjeka Training Matters’ association with yet
another prominent South African contractor
that is known for delivering high quality
developments. s

www.tjeka.co.za
A total of 60 candidates are being trained by Tjeka Training Matters for Tiber Construction.

34 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

Concrete Repair
D
o we ever really notice how many
concrete structures surround us every
day?
Most of us do not realise, in our evolving
urban landscapes, how many concrete
structures facilitate our everyday activities.
They are everywhere, in every form, shape and
size; working to support our needs. Yet, even
in its strength and durability, concrete needs
to be maintained. Just as we are affected by
the stresses and strains of everyday life, so too
is concrete subject to deterioration over time.
How do we know this? Sika has more
than 100 years’ experience on large and small
concrete projects, all over the world. We have setting, three-component, epoxy modified,
documented successful project references cementitious sealing and protective mortar.
dating back to the 1920’s. We are proud that Sikagard®-720 EpoCem can be used as
Sika is the company with the most concrete sealing mortar (0.5 – 2.0 mm) on concrete,
repair project awards worldwide, with 84 mortar or stone. It can also be used for repairs
ICRI* awards in the last 16 years. to fair faced concrete in chemically aggressive
To start at the crux of the problem, why environments, or as a pore sealer on
does concrete deteriorate? Deterioration horizontal and vertical surfaces. In addition,
of concrete may occur due to corrosion, it also provides a temporary moisture barrier
structural damage, water infiltration, seismic (2.0 mm).
activity or a multitude of other reasons. Years Once the concrete repair process is
of research, coupled with decades of practical complete, it is imperative that a concrete
experience, have enabled Sika to develop a protection product is applied.
fully comprehensive solution to restore and suitable for restoration work, repair of spalling The most common causes of steel
rehabilitate concrete structures. and damaged concrete in all types of structures reinforcement corrosion in concrete are
Why do we repair? We repair concrete to including buildings, bridges, infrastructure carbonation or chloride ingress with water.
address defects, restore structural integrity, and super-structures. Our latest edition to our Understanding the root cause of steel
restore aesthetic and geometric appearance repair mortar range is the Sika MonoTop®-412 corrosion determines the most effective repair
and ultimately restore durability. A wide range NFG. This product differentiates itself as and protection strategy. Sika provides a full
of products are needed for the concrete repair a 1-component, polymer modified, fibre range of products to prevent further corrosion
process, and Sika South Africa have developed reinforced, low shrinkage structural repair of steel reinforcement, by properly protecting
the complete product solution. mortar with Sika’s world-renowned Sika® the concrete around it. Our corrosion
Most concrete repair processes would start FerroGard® corrosion inhibitor. That is a 3-in- management systems allow flexibility to select
with a bonding primer and corrosion inhibitor. 1 advanced product solution. the most cost-effective and suitable solution
Corrosion protection and bonding primers Sika MonoTop®-412 NFG has unique for any project. Sika® FerroGard®-903 Plus
are used for bonding concrete repair mortars properties that allow it to be an excellent has innovative technology that not only
to existing cementitious, or steel, substrates wet-spray mortar. This application method delays the start of corrosion but reduces the
and provide additional corrosion protection improves the compaction of repair mortar and corrosion rate when it occurs. This results in
to reinforcement steel. This is especially so increases the application rate of the product. an increase in the service life of a reinforced
in areas of low concrete cover and in the The other quantifiable factor is that the concrete structure, making it the product of
presence of chlorides. Exposed reinforcement Sika MonoTop®-412 NFG is a 1-component choice.
steel bars should be properly prepared and product as it does not require a bonding At Sika South Africa, we pride ourselves
protected with anti-corrosion slurry. SikaTop® primer even when manually applied, it is a in knowing that our advice and support to
Armatec®-110 EpoCem® is the primary rebar 3-in-1 advanced repair mortar, resulting in our customers is second to none. We take
protective coating for concrete repair. further time and money savings. Our repair the full journey with them. From concept,
The next step is to select an appropriate mortars all come with either a class R4 of EN to successful completion on site, providing
repair mortar. Mortars are specifically designed 1504-3 or Class R3 of EN 1504-3 standard. only the best products necessary for the task.
for restoring or replacing the original profile Prior to coating or levelling of concrete, Entrusting Sika, a supplier with over 100 years’
and function of the damaged concrete. They special mortars are necessary to fill the experience, ensures your concrete repair will
help to repair concrete defects, improve surface pores or “honeycombs”. Sika’s stand the test of time. We have concrete
appearance, restore structural integrity, solution for repairing minor defects, such as evidence! s
increase durability and extend the structure’s repairing pores and honeycombed concrete,
longevity. Sika concrete repair mortars are is the Sikagard®-720 EpoCem. It is a normal Contact: https://zaf.sika.com

CONCRETE BETON 35
INDUSTRY NEWS

Complexity in design – Capitec Project Ikhaya

I
n January 2019 Macsteel partnered with Schalk Marais PrEng, Aecom Practice Area superstructure. The shape combined with
Aecom & LRJ Steel on a project for the Lead says, “Whilst the project was impressive the height restrictions on the site and the
design and development of Capitec Bank’s from a technical perspective, the overall divergence between the column grid in the
new head office and adjoining parking design of this building was geometrically lower parking levels resulted in a complicated
structure. Succeeding the consultation with complex due to the curve-linear shape of the structural frame.”
the architect, the understanding was to design
and build a contemporary, open office building
that allowed for a fluid and collaborate work
environment.
From the start of the project, the team
used Building Information Models (BIM), which
represented the actual construction, allowing
all partners involved to fully understand
the configuration of the planned structure,
ensuring a collaborative vision of how the
various components interacted. This was
further improved but the open mindedness of
the contractor’s team to implement something
unique and out of the ordinary.
The design solution was predominantly a
concrete framed structure however structural
and composite steel and concrete construction
were used in a complimentary way.
Additionally, bridge links and the floor over
the main entrance required light, long span
structures with limited headroom implications
and the parking structure required the use of a
solution that would be removable in the long
term to allow conversion of the building for a
different use.

A variety of structural framing was used to

bring this innovative building design to life,
namely:
• Macsteel/Westok Cellular Beams with
Bond-Dek composite flooring were used
for the Headquarters Walkway Bridges
• Macsteel/Westok Cellular Beams with
Bond-Dek composite flooring and
Macsteel/Westok Ultra-Shallow Floor
Beams with Voidcon permanent formwork
floors spanning between floor beams
were used for the main entrance floors in
Capitec Bank Headquarters
• The use of I-Section portal frames with
transfer systems supporting rectangular
hollow section roof light pods were
implemented for the roof at headquarters
• I-Section roof framing; supported on
slanted circular hollow section columns for
the entrance canopy at headquarters
• And lastly the parking structure infill
floors which were comprised of H-Section
columns supporting I-Section composite
floor beams with Bond-Dek composite
flooring

36 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

Moreover, there was a requirement to

have long-span pedestrian bridges crossing
the central building atrium and the need for
a very open reception area and combining this
with a shallow ceiling system and exposed
concrete soffits forming a specific design
language throughout the building posed
challenging.

M2 FREEWAY REHABILITATION
The pedestrian bridges crossing the atrium
had more ceiling space available and also
served as links for services crossings. The use

T
of composite cellular beams provided a cost- he M2 freeway, located in the south of Johannesburg’s CBD, is one of the city’s main
effective long span system that could cater motorways. As an important link between the N1 and N3 freeways, this roadway required
for the dynamic performance requirements some attention and rehabilitation. The project was commissioned as an emergency, after
and allow services to cross without paying the sections of the road gave way and collapsed, due largely to lack of maintenance and increased
penalty in terms of weight. road traffic. The closing of the motorway obviously caused major inconveniences to businesses
The ceiling requirements from the and residents alike. After Johannesburg Road Agency made the decision, the rehabilitation
architect above the main entrance resulted started on the 8th February 2019, and was completed nine months later in October 2019.
in a very shallow available floor depth and a The contractor assigned to this project was Stefanutti Civils, who brought in an experienced
long span. The total span in this area between engineer, Andre Oosthuizen. Interestingly, Andre was part of the initial road design team
columns is 18m. Bridging this span was done about 60 years ago. As many of the original drawings for this road could not be located,
by using a thickened reinforced concrete his input and sound advice on the project were invaluable. The rich history of this roadway
floor cantilevering over the support columns, necessitated the use of the best products for the job, and so it was only fitting that Sika were
supporting a simply supported Ultra-Shallow honoured as suppliers of choice.
Floor Beam (USFB) system spanning almost Four of Sika’s products were used on the span of the road. Sikadur®-32 Normal, a
13m. bonding agent, was used to bond the new concrete to the old. Sika MonoTop®-412 NFG is
The USFB system comprises of asymmetric the latest addition to the Sika mortar range. It has excellent performance for local conditions
steel sections with circular voids in the webs. and was used for structural repairs of the road. It is suitable for restoration work, structural
The top flanges are narrower to allow strengthening, and for preserving passivity. Sika® Ferrogard®-903 Pluswas applied to the
permanent formwork to be dropped in, to concrete surface as a corrosion inhibitor. As a product that is based on organic compounds,
span from beam to beam, resting on the it both delays the start, and reduces the rate, of corrosion. Finally, SikaTop® Seal-107 ZA, a
bottom flanges. Composite action is achieved waterproofing, chloride and carbonation protective coating was used for coating the barriers.
by using conventional reinforcing bars placed An approximate 150 million Rand was spent to refurbish this bridge – and looking down
in the web openings (bars perpendicular to the road, it was most definitely money well spent. s
the beam span; plug composite action). Due
to the long spans a propped construction
methodology was adopted to limit the final
deflection.
To add an additional layer of complexity,
the tips of the concrete edges supporting the
USFB floor system on the building edge, had
to be column free at ground level to create
a weather canopy. This was accommodated
by suspending the perimeter of the 1st and
2nd floors using high capacity rods from a
cantilever transfer beam at roof level.
“This project was a benchmark in
demonstrating the benefits of using steel
as a material. Some structural systems and
configurations necessitate the use of steel with
its long-span and overall weight reduction
capabilities; however, this project displays how
steel can be used successfully in a combination
of ways, complimenting conventional concrete
construction”, concludes Marias. s

CONCRETE BETON 37
INDUSTRY NEWS

Concrete trumps on municipal sport and

recreational projects
C
oncrete remains one of the preferred African sports sector. Bear in mind that the bar. This eventually leads to the deterioration
building materials for the construction of social infrastructure serves as the foundation of the long-term performance of concrete
grandstands for sports and recreational of the country’s entire sport and recreation structures, some of which have been designed
facilities in previously marginalised areas of system and is key to delivering the 2030 vision to last for up to 100 years.
Limpopo. of “Active and Winning Nation”. Conventionally, a low permeability
This is considering the durability of the Impressively, the grandstands that have material is designed by raising the compressive
construction material that helps reduce the been built in Limpopo have been constructed strength of the concrete and lowering the
maintenance requirements of these structures using precast-concrete elements that are no water-to-cement (w/c) ratio. However, many
over their useable lives. less than 55MPa. enterprising precast concrete companies
Adequate maintenance of sports and The high durability of these elements, continue to find other novel ways of testing
recreational facilities remains a challenge including columns, raker beams, seating traditional limitations in concrete mix designs
as outlined in the National Sports and benches and side panels, can be directly to enhance the overall performance of
Recreational Plan. The plan notes that this, in attributed to the use of a concrete with a low their systems.
addition to lack of access to these facilities, permeability. For example, Corestruc, which has
has had far-reaching negative impacts on the Water penetrates concrete with a high manufactured and constructed many
transformation and development of the South permeability and corrodes the reinforcing grandstands for municipalities in Limpopo, has
also introduced silica fume, an industrial by-
product, into its concrete mix to supplement
some of the cement content to produce a
denser concrete micro-structure.
Meanwhile, ongoing developments in
construction chemicals and additives have also
greatly assisted the industry in innovating as
is demonstrated by concretes with lower w/c
ratios and higher compressive strengths than
those mixes commonly used on traditional
cast-in-place projects.
Importantly, these high slump mixes
without extra water have also ensured
improved “flow-ability” of the concrete in
the various moulds and forms to enable the
manufacture of consistently high quality
precast-concrete elements.
This is undertaken in a factory environment
Corestruc can construct a 1000-seater in as little as two weeks after the foundations have that is far removed from the many variances
been completed. that are encountered on a typical construction
site to ensure a higher quality product. For
example, accurate quantities of chemicals and
admixtures can be easily added to a mixer
to produce identical batches of concrete to
ensure consistency on projects.
Corestruc’s focus on constantly maintaining
high quality manufacturing standards starts
with the various basic raw materials, namely
the washed sand and aggregates that are fed
into its state-of-the-art factory.
Sensors inside the operation also
continuously monitor the temperature and
moisture content of the mix before the
concrete is poured into specialised forms and
moulds to ensure high levels of precision.
Moreover, a separate steel-fixing yard
ensures a high-quality reinforcing in the
concrete casing to further bolster quality
levels.

38 NUMBER 163 | NOVEMBER 2020

 INDUSTRY NEWS

Notably, the company is also tasked This leading precast-concrete specialist Justice Ramothwala, owner of FR Civils,
with installing the systems, while working worked alongside FR Civils, which is due says that he his impressed with the
alongside the principal contractors that have to complete the three-year project that is workmanship of Corestruc.
been appointed to construct the sport and being funded by the Municipal Infrastructure “We have developed a sound working
recreational centres. Grant, in October 2021. Morula Consulting relationship with the contractor on this
By outsourcing the manufacture and Engineers & Project Managers was the design project and will certainly work with them on
building of the grandstands to a specialist, engineer and is supervising the construction another project if given the chance. The team
the client and its professional team have programme. made lightwork of the grandstand, one of the
removed most of the risk associated with the Impressively, this project has already first items that had to be constructed as part
construction of the facility and, therefore, employed between 20 and 25 people from of the project. This is despite a slow start due
provided immense scope for increased the surrounding community, and the number to the very complex ground conditions that
participation by emerging contractors and of locals working on the project will increase resulted in us having to excavate significant
unskilled labour. to between 40 and 50 when the project peaks amounts of clay material and backfilling
For example, this approach to the next year. the deep excavations with suitable material
construction of the stadium has mitigated They are being trained by FR Civils as part that was imported from a nearby quarry,”
the need for specialised skills to accurately of this Expanded Public Works Programme Ramothwala says.
install the scaffolding and formwork, and project. Some of the skills they acquired Willie de Jager, Managing Director of
working at heights is restricted to Corestruc’s on the project included palisade fencing Corestruc, concludes that he is proud of
experienced team. installation, bricklaying and plastering, as well Corestruc’s involvement in the lion’s share of
Corestruc can construct a 1000-seater in as the packing of gabion baskets. sport and recreational centre projects in the
as little as two weeks after the foundations Between 60% and 70% of the project province, as well as the opportunity to work
have been completed. A case in point is was completed by mid-September 2020. with many enterprising contractors, such as
the grandstand, which seats 660 people, FR Civils’ scope of work encompassed the FR Civils, in helping deliver state-of-the-art
that the precast-concrete specialist recently earthworks, as well as the construction of the social infrastructure to poor communities. s
constructed for the Greater Letaba Local pitch and ablution facilities. This is in addition
Municipality as part of the newest sport and to the installation of the lighting masts and Contact: [email protected]
recreational complexes that is being built in the border fence, as well as the construction
the municipal jurisdiction. of the foundations for the stadium.

We are there when you celebrate

Need to excel in concrete? Our School of Concrete Technology offers

internationally recognised courses for anyone interested in concrete.
Master concrete with us.

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

Concrete that works fine – without any sand

No-fines concrete (NFC) is obtained by eliminating the fine material – sand - from
the normal concrete mix. Instead, single-sized coarse aggregates are surrounded
and held together by a thin layer of cement paste to add strength.

A
mong the main advantages of NFC and flaky aggregates should be avoided. The most commonly used
is economy in materials, higher aggregate is 19mm crushed stone. Smaller stones may be used
thermal insulating values, lower and mixes made with smaller stone are in fact easier to handle and
shrinkage, and lower unit weight and place, but consume substantially more cement.
density. It is mainly used for load-bear-
ing, cast-in-place external walls of single For most applications, mix proportions range from 200 to 300 litres of
storey and multi-storey housing, small re- aggregate per bag (50 kg) of cement. The water content of the mix is
taining walls or damp-proofing sub-base critical: if the paste is too dry it will not coat the aggregate properly; if
material for concrete floors cast on grade. it is too wet, it will run off the aggregate particles and possibly block
Here Bryan Perrie, managing director of the voids at the bottom of the pour. Experience has shown that the
The Concrete Institute (TCI) sheds some water content should be between 18 and 22 litres of water per bag of
Bryan Perrie
light on this type of concrete. cement.
NFC consists of coarse aggregate and A cubic metre of compacted NFC requires about 1.05m3 of stone,
cement paste. In the hardened state, the aggregate particles are cov- measured in the loose state. Cement content is between 260 and
ered by a thin layer of cement paste and are in point-to-point contact 180kg, depending on mix ratio.
with each other. At each contact point, the paste forms a small fil- NFC should be machine-mixed as hand mixing is difficult and labori-
let and these fillets hold the particles together and give strength to ous. If hand mixing is unavoidable, it is best to mix the cement-water
the concrete. paste in a container prior to mixing the paste with the stone. When
mixing the paste, mix the cement into the water rather than the other
way around.
NFC must be placed and compacted as soon as possible after mix-
ing as it tends to dry out rapidly because of its open structure. Compac-
tion is achieved by rodding the concrete - vibration must not be used
and heavy tamping is not necessary.
Because of its open structure, NFC must be protected from drying
out and must be thoroughly wet cured for at least seven days unless it
is plastered, screeded or covered before that time.
NFC has a rough surface texture for plastering. Normal plaster mix-
es are used and the surface of the NFC must be dry when applying
the plaster. Plastered NFC walls have some excellent qualities, but one
drawback is that neither conventional wall plugs nor masonry nails can
be used for attaching fixtures to the walls.
When used in underfloor drainage, roof insulation and domestic
floors, NFC should be screeded within 72 hours of placing with particu-
lar attention paid to wet-curing the screed. Normal screed mixes of 100
to 130 litres of concrete sand per bag of cement should be used with
No-fines concrete is produced without the addition of the usually enough water to produce a mix of plastic consistence.
essential part of the concrete mix: sand. NFC has negligible flexural or tensile strength. Compressive strength
is usually between 5 and 10 MPa at 28 days for mixes in the range men-
NFC therefore has large interconnected voids and a lower density tioned previously. Higher strengths may be obtained by including 50kg
than conventional dense concrete. The structure of NFC makes it ideal of fine sand per bag of cement. This increases the size of the fillets, and
for use as a drainage layer under reservoir and basement floors and it hence the strength, but reduces the voids and increases the density
can also serve as an insulating layer and as a damp-proofing material. correspondingly. s
Note, however, that NFC is definitely not suitable for drainage purposes
where the water is soft or aggressive to concrete. For further information, contact [email protected] or
visit www.theconcreteinstitute.org.za or phone 011 315 0300.

Materials:
• Cement – Common cement that complies with SANS 50197 should
be used for NFC. Masonry cements are not suitable.
• Water – Water that is suitable for making conventional concrete
should be used.
• Aggregates – Clean, single-sized concrete stone should be used,

40 NUMBER 163 | NOVEMBER 2020

 MEMBERSHIP DETAILS

PLATINUM
COMPANY CONTACT TEL E-MAIL

AfriSam SA (Pty) Ltd Mr Mike McDonald 011-758-6000 [email protected]

Chryso Southern Africa Group Mr Norman Seymore 011-395-9700 [email protected]

Murray and Dickson Construction Mr Rukesh Raghubir 011-463-1222 [email protected]

GOLD
COMPANY CONTACT TEL E-MAIL

Corestruc (Pty) Ltd Mr Willie De Jager 087-288-0063 [email protected]

Sika South Africa (Pty) Ltd Mr Paul Adams 031-792-6500 [email protected]

SILVER
COMPANY CONTACT TEL E-MAIL

Department of Water and Sanitation Mr Harry Swart 021-872-0591 [email protected]

NPC (Pty) Ltd Ms Theresa Du Plessis 031-450-4411 [email protected]

SNA Civil & Structural Engineers (Pty) Ltd Mr Kenneth Malcomson 012-842-0000 [email protected]

The Concrete Institute Mr Bryan Perrie 011-315-0300 [email protected]

BRONZE
COMPANY CONTACT ADDRESS TEL E-MAIL
A.Shak Construction Chemicals Ms Cindy Engels PO Box 10449 Edenglen 011-822-2320 [email protected]
(Pty) Ltd EDENVALE 1613

Africoast Consulting Engineers Mr Kevin McRae PO Box 5104 041-505-8000 [email protected]

WALMER 6065

Afrimat Readymix Cape Mr Peter Grove PO Box 5278 021-917-8840 [email protected]

TYGERVALLEY 7536

Amsteele Systems Mr Michael Hildyard PO Box 7014 ALBEMARLE 011-827-6721 [email protected]

1410

BAMR (Pty) Ltd Mr Graham Duk PO Box 23973 CLAREMONT 021-683-2100 [email protected]
Western Cape 7735

Beton Lab cc Mr Alan De Kock PO Box 10583 ASTON MANOR 011-979-1422 [email protected]
1630

Carmix South Africa Mr Bruce Cousins PO Box 585 MODDERFONTEIN 011-608-2868 [email protected]
Gauteng 1645

Concrete Manufacturers Association Mr Henry Cockcroft Postnet Suite 8612 011-805-6742 [email protected]
Private Bag X32 KEMPTON PARK
Gauteng 1620

CONCRETE BETON 41
MEMBERSHIP DETAILS

BRONZE
COMPANY CONTACT ADDRESS TEL E-MAIL
Corrosion Institute of Southern Africa Mrs Gregory Combrink PO Box 5656 010-224-0761 [email protected]
HALFWAY HOUSE 1685

Dick King Lab Supplies (Pty) Ltd Mr Richard King PO Box 82138 SOUTHDALE 011-499-9400 [email protected]
Gauteng 2135

Echo Prestress (Pty) Ltd Ms Monique Eggebeen Private Bag X 1 Edleen 011-589-8800 [email protected]
KEMPTON PARK 1625

Empa Structures cc Mr Cameron Bain PO Box 3846 DURBANVILLE 021-979-1129 [email protected]

Western Cape 7551

Form-Scaff Mr Klaas Pouwels PO Box 669 ISANDO Gauteng 1600 011-842-4000 [email protected]

Ibhayi Contracting Mr Tseli Maliehe PO Box 34913 NEWTON PARK 041-365-2871 [email protected]
Eastern Cape 6055

J G Afrika Mr Jacobus Burger PO Box 794 HILTON Pietermaritzburg 033-343-6700 [email protected]

KwaZulu-Natal 3245

L & S Consulting (Pty) Ltd Mr Simon Griffiths PO Box 1546 RANDBURG 011-463-4020 [email protected]
JOHANNESBURG Gauteng 2125

Letaba Lab Mr Jayson Wingrove PO Box 22874 Exton Road 087-285-0816 [email protected]
BLOEMFONTEIN 9313

MaxLife Solutions Mr Brannin Schorn PO Box 71037 BRYANSTON 2191 082-086-3020 [email protected]

Melt Wahl Concrete Services Mr Melt Wahl PO Box 977 BELLVILLE 021-946-1334 [email protected]
Western Cape 7535
C
Metier Mixed Concrete Mr Jurgens Du Toit Postnet Suite 546 Private Bag X4 031-716-3600 [email protected]
KLOOF KwaZulu-Natal 3640 M

Naidu Consulting (Pty) Ltd Mr Josiah Padayachee PO Box 2796 West Way Office Park 031-265-6007 [email protected] Y

WESTVILLE KwaZulu-Natal 3635

CM

Nyeleti Consulting Mr Stephen Humphries P.O. Box 35158 Menlopark 012-361-3629 [email protected] MY
LYNNWOOD Gauteng 0081
CY

Pan Mixers South Africa (Pty) Ltd Mr Quintin Booysen PO Box 75098 GARDEN VIEW 011-578-8600 [email protected]
Gauteng 2047 CMY

K
Penetron SA Mr Wiljee Blom PO Box 7467 HALFWAY HOUSE 011-314-8310 [email protected]
Gauteng 1685

Post Tensioning & Structural Mr Gary Williams PO Box 1055 073-274-9911 [email protected]
Solutions (Pty) Ltd KLOOF KwaZulu-Natal 3640

Shukuma Flooring Systems Mr Meiring Ferreira PO Box 10332 LINTON GRANGE 041-372-1933 [email protected]
(Pty) Ltd Eastern Cape 6015

Spalling Worx Mr Kevin McGeer PO Box 1559 031-764-0631 [email protected]

HILLCREST 3650

Spraylock Africa (Pty) Ltd Mr Carl White PO Box 1426 Bassonia 064-732-1437 [email protected]
JOHANNESBURG 2061

Stefanutti Stocks (Pty) Ltd Mr Matthew Horwill PO Box 12394 Aston Manor 011-571-4300 [email protected]
1630 South Africa

Structural Solutions cc Mr Rigo Govoni PO Box 40295 WALMER 041-581-3210 [email protected]

Eastern Cape 6065

Stutt Group Mr Davrin Marais PO Box 197 STUTTERHEIM 043-101-0146 [email protected]

Eastern Cape 5201

UPAT SA (Pty) Ltd Mr Kevin Owen PO Box 53059 TROYEVILLE 011-624-6700 [email protected]
Gauteng 2139

Verni-Speciality Construction Mr Vernon Botha PO Box 75393 GARDEN VIEW 011-552-8393 [email protected]
Products (Pty) Ltd Gauteng 2047

VSL Construction Solutions Mr Brendon Williams PO Box 531 BERGVLEI 010-492-1811 [email protected]
(Pty) Ltd 2012

Xypex Chemical Corporation Mr Lewis Lynch 8 Leeukloof Drive Tamboerskloof 021-426-0243 [email protected]
CAPE TOWN Western Cape 2001

42
42 NUMBER
NUMBER 163
163 || NOVEMBER
NOVEMBER 2020
2020
 Emission Reduction
Mine and Management
Rehabilitation

Community
Upliftment

Waste
Management

Water Consumption
Reduction and Biodiversity

100%
TODAY FOR
TOMORROW’S
GENERATION
AFRISAM HAS A LONG HISTORY OF CARING FOR THE ENVIRONMENT.
As leaders in sustainability we have undertaken significant initiatives in the areas of energy
optimisation and emission reduction; rehabilitation of mines; optimally using resources and
holistically reducing our carbon footprint.

We have a responsible attitude towards the environment which informs all our business
practices, thereby sustaining life for future generations.

www.afrisam.com Creating Concrete Possibilities