Concrete_conference_banner

To inquire about The Concrete Conference and book a stand:  Tel: (011) 805-6742 or E-Mail: marketing@cma.org.za

rss

CMA NEWS & ARTICLES

CMA News & Articles

2016 CMA Awards Winners


CMA AWARDS FOR EXCELLENCE 2016 - WINNERS

AESTHETICS COMMERCIAL
TROPHY WINNER

No. 1 Silo, V&A Waterfront, Cape Town

Project description
Over 1 000m² of precast concrete panelling were used to clad a section of the external façade of
No.1 Silo, one of Africa’s most advanced sustainable buildings. The panelling effectively demonstrates how, when correctly designed and applied, concrete facades can be extremely attractive.
Concrete panelling, manufactured by Concrete Units, was specified to dress masonry cavity walls on the building’s two service cores and to distinguish them from the glazed façades of the building’s atrium and office sections. Both textured and flat panels were specified for aesthetic reasons and to give different functions distinct identities.
Incorporating numerous green-design attributes, recycled waste and heat, the use of seawater in the cooling plant, and a roof garden, to name a few, No.1 Silo was one of only two buildings to have been awarded a six-star design rating by the Green Building Council of South Africa when it was completed in 2013.
Judges’ comments
Precast concrete has been deliberately chosen as a primary material. It has been carefully handled to create a finish that is slick and functional.
Product information
Precast concrete façade panels in various sizes.
Average size 1 705 x 3 730mm (1,9 tonne)
Project team
Owner: V&A Waterfront
Architect: Van der Merwe Miszewski/Rick Brown & Associates
Engineer: Sutherland
Quantity: surveyor MLC quantity surveyors
Main contractor: WBHO Construction
Manufacturer of precast concrete elements: Concrete Units

AESTHETICS COMMERCIAL
COMMENDATION WINNERS


Thaba Moshate Hotel Casino and Convention Resort, Burgersfort, Limpopo


Project description

Paying homage to the mineral wealth of the platinum-rich reef on which it was built, the IsiNdebele and Sepedi-inspired Thaba Moshate Resort nestles near Burgersfort in the Moroni Mountains.
The natural concrete-coloured paving, manufactured by SmartStone Midrand, has an understated yet elegant layout in which bright orange accent walls take centre stage to create a modern feel with a decidedly local flair.
The architects achieved a uniform contemporary design with SmartStone’s smooth Cosmopolitan pavers in two sizes, 600mm x 300mm and 300 x 300mm. Another paver, the Escourt, measuring 500 x 500mm was also selected as a contrasting design element.
Judges’ comments
Concrete pavers have been used in an understated manner that merges well with the landscape context.
Product information
Cosmopolitan pavers 600 x 300mm and 300 x 300mm (grey)
Escourt pavers 500 x 500mm
Smart coping (grey)
Escourt coping (grey)
Project team
Owner: Peermont Group
Architect: Green Inc Landscape Architects
Main contractor: Breet Construction
Manufacturer of precast concrete elements: SmartStone Midrand

BMW Head Office, Midrand


Project description

Light lines and simplicity define BMW’s (South Africa) head-office refurbishment. Originally designed by Hans Hallen, this architecturally iconic building has been modernised to reflect BMW’s corporate identity.
The design of the courtyard was integral to the refurbishment process in which concrete block paving played an important role.
The landscape architects sought timeless paving material which wouldn’t dominate but would rather enhance the form and shape of the surrounding landscape. They specified extra-large drycast paving blocks measuring 900mm x 600mm in a light mottled concrete colour to be used in combination with cast in-situ slabs. Manufactured by Bosun, the pavers have straight edges and were installed with small jointing gaps.
Slight tonal changes add life and interest and although difficult to install, the large-scale pavers create a sophisticated simplicity which matches the iconic style of the building.
Judges’ comments
A sensitive vocabulary that responds well to the existing architectural language.
Product information
Urban XXL – 313m² (granite)
Smooth Ethnic - 756m² (grey)
Project team
Owner: BMW South Africa
Landscape Architect: African Environmental Design
Engineer: Spoormaker & Partners
Quantity Surveyor: BWR Quantity Surveyors
Main Contractor: Barrow Construction
Sub-Contractor: Plant Elite
Manufacturer of precast concrete elements: Bosun

AESTHETICS RESIDENTIAL – PRIVATE SINGLE DWELLINGS

COMMENDATION WINNER

Floating in Space, Pretoria, Gauteng

Project description
Situated among mixed residential and small business properties on the eastern side of Pretoria, the building was designed to blend in with its ever-changing suburban surroundings and be used either as a house or an office, or a combination of the two. Adaptability and optimisation of resources were interwoven into every level of the development, from the shape of the building and construction materials used to its positioning on a small stand.
Bosun’s grass blocks drew the parking areas and the garden into a single space. Large, unbevelled concrete pavers provided a solid pathway to the entrance – very much like a carpet rolled out to the front door.
Judges’ comments
The use of vegetation combined with paving softens and yet complements the strong forms of the architecture.
Product information
Grass blocks (grey)
Urban pavers large (granite)
Urban pavers large (marble)
Project team
Owner: George Sutherland
Architect: W Design Architecture Studio
Engineer: Hugo and Partners
Main contractor: Asikol Construction
Manufacturer of precast concrete elements: Bosun

COMMUNITY UPLIFTMENT
TROPHY WINNER

Walmer Township, Port Elizabeth, Eastern Cape

Project description
This Nelson Mandela Bay Metropolitan Municipality project formed part of the Triennial Premix Tender Works Packages. It involved upgrading roads in Walmer Township, and in addition to creating jobs, simultaneously provided local community members with an opportunity of learning valuable skills.
In total 25 people were hired and they showed a tremendous willingness to learn the following skills:
 Laying pavers, kerbs and channels
 Pricing bill of quantities for future tenders
 Measurement
 Management of labour
 Invoicing
What were once dusty gravel roads were transformed into aesthetically pleasing and practical low-maintenance surfaces using 80mm interlock pavers manufactured by Shukuma Bricks.
Judges’ comments
The depth of involvement by the community beyond mere employment ensured that valuable skills filtered down.
Product information
80mm Interlock pavers class 40/2.6 (grey)
Project team
Client: Nelson Mandela Bay Metropolitan Municipality
Engineer: Worley Parsons
Main Contractor Rand Civils
Manufacturer of Precast Concrete Elements: Shukuma Bricks

COMMUNITY UPLIFTMENT
COMMENDATION WINNERS

Kassiebaai Roads, Arniston, Southern Cape

Project description
The upgrading of the gravel roads in this quaint, historical Southern Cape fishing village was six years in the making. The project required input and approval from Heritage Western Cape which was granted after prescribed conditions pertaining to the type of pavers used and their layout were agreed to.
Another condition was the use of local labour as the area has a high unemployment rate.
In total, 6 400m² of concrete block paving, manufactured by C.E.L Concrete Products, was laid and 28 jobs (13 skilled and 15 unskilled) were created to the complete satisfaction of the residents and client. Dust generated from the gravel roads as well as washed-out roads from heavy downpours have been virtually eliminated.
Judges’ comments
A technical and social success in a harsh corner of the country.
Product information
190 x 50mm Marble Chisselstone
125 Vintage pavers
104 x 104 x 50mm Modern Granite Euro cobbles
Project team
Owner: Department of Rural Development & Land Reform
Beneficiary: Cape Agulhas Municipality
Architect: Veridian Landscape
Engineer: WEC Consult
Main contractor: Cape Agulhas Civils/Annev Construction
Manufacturer of precast concrete elements: C.E.L. Concrete Products

The Radway Green Project, Eastern Cape

Project description
This was an Alternative Building Technology (ABT) project which took place on a small piece of land near Grahamstown in the Eastern Cape. Initiated by the Department of Rural Development, it enabled 27 displaced families to build their own houses using local materials and to acquire valuable building skills. The project also employed members of the Department’s Youth Programme.
Phase one entailed training participants to appreciate the importance of high-quality blocks and how to achieve quality in the production process. In all, 126 000 blocks were made during the project using two Hydraform block making machines.
Phase two focused on laying the interlocking dry-stacked blocks in the construction of the 64m² houses. In addition, the Department’s youth team were taught artisan skills in plumbing, electrical work and carpentry, among others, which were used in the construction of the houses.
Approximately 50 previously unskilled and semi-skilled individuals were employed on the project. The skills they learnt can now be utilised in other projects.
Judges’ comments
Assuming that government worker programmes continue, skills have been developed to feed into the process.
Product information
126 000 interlocking blocks
Two Hydraform machines (yellow)
Project team
Client: Department of Rural Development
Engineer: Mr Nicholas Heüer
Main contractor: Hydraform
Manufacturer: Hydraform

TECHNICAL EXCELLENCE
TROPHY WINNER

Gouda Wind Farm, Gouda, Western Cape

Project description
Gouda Wind Farm is Africa’s first wind farm project in which concrete rather than steel was the primary construction material. Forty six 100m towers were erected, each tower supporting a three-bladed turbine which weighs 170 tonnes.
Gouda’s tower segments, 782 in all, were designed according to European structural concrete codes as opposed to the SANS code. The Gouda towers have a characteristic strength of 75MPa, which made for lighter concrete sections.
Each completed tower comprises five 20m high tapered concrete sections and each section was assembled using the precast concrete segments manufactured by Concrete Units. The segments were joined in a vertical plane by inserting reinforcing and grout into the hollow chambers formed by the segments’ two opposing channels. Once assembled, the tower sections were lifted into position by crane and joined in a horizontal plane using starter bars, ducting and grouting. The flawless execution of this process required extremely accurate casting and very tight tolerances.
A maximum of five segments was cast daily using five moulds. Mould sections were attached using laser technology and special jigs were used to ensure that the steel reinforcing was accurately positioned. Various inserts and sockets were cast into the concrete segments to facilitate the installation of mechanical and electrical equipment inside the towers.
The tower segments were manufactured with self-compacting concrete. Without it, the project would have been much more complex, involving external vibration and more expensive moulds.
The towers were designed to bend with the wind. This lateral movement is facilitated by the use of steel reinforcing inside the tower walls and additional strength was gained by linking six 90mm post- tensioned steel cables from the inner walls of the topmost tower sections to the concrete base of each tower.
Judges’ comments
An effective and cost-effective alternative to satisfy extreme technical demands made for an impressive solution.
Product information
782 precast concrete wind tower segments weighing 60 tons each
Project team
Owner: Acciona Wind Power
Main contractor: Acciona Wind Power
Manufacturer of precast concrete elements: Concrete Units

TECHNICAL EXCELLENCE
COMMENDATION WINNERS

Mouille Point Sea Wall Rehabilitation Project, Cape Town

Project description
Precast concrete panelling and coping was specified by the City of Cape Town for re-lining a 600m section of sea wall between Three Anchor Bay and the Mouille Point Lighthouse in Cape Town.
Built over 70 years ago and dressed with granite blocks, continual exposure to wave action meant that sea water had eroded the original wall’s mortar jointing penetrating and eroding backfill and dislodging some of the blocks,
After extensive research into the most suitable replacement material by the consulting engineers and the City of Cape Town, precast panelling, manufactured by Concrete Units, was chosen to face the new wall using the original foundation and its mass concrete core; cost and time savings were the overriding factors which influenced this decision.
Intermittent wave action during high tides shortened the period in which rehabilitation work could take place. Therefore any process which saved time was advantageous and precast concrete panelling, which measured 2.5 x 1.2m apiece, met this objective. Another benefit was that concrete panelling has a limited number of joints for the sea to penetrate and is produced in a factory environment under strict quality controls.
The moulds for the panelling were made using granite samples from the old wall which gave the new wall a similar look and feel to the granite structure. Comprising a 30% fly ash blend and reinforced with galvanised rebar, the panels are rated at 50MPa and satisfy a minimum design service life of 50 years.
Judges’ comments
A necessarily rapid solution under difficult conditions made for a successful combination of performance and technicality.
Product information
Precast concrete rock print panels using moulds formed from the original granite blocks.
Project team
Owner: City of Cape Town
Engineer: Ingerop
Main contractor: Exeo Khokela Construction
Manufacturer of precast concrete elements: Concrete Units

Tweefontein Optimisation Project, Emalahleni, Mpumalanga

Project description
Close on 800 giant precast concrete culverts, three-and-half metres high and just over five metres wide, were deployed in the construction of two buffer (stockpile) tunnels at Tweefontein Colliery. Manufactured by Aveng Infraset and weighing 12.8 tonnes each, these were some of the country’s largest culverts to date.
This is the first time that the main engineering consultancy had used concrete culverts for assembling coal stockpile tunnels. Although steel and in-situ concrete were also considered, durability and maintenance concerns with steel tunnels and time constraints with in-situ concrete construction prompted the decision to opt for precast concrete.
Produced from solid steel-reinforced concrete, the culverts were designed to handle well in excess of the buffer zones’ maximum 20 tonne loading. Each culvert contained 600kg of reinforced steel and measured 3.5m (height) x 5.3m (width) x 1m (depth). The walls were tapered, with a maximum thickness of 350mm at the top end narrowing to 300mm at the base.
The initial requirement was for a height of 4.7m but this would have rendered the culverts too large for road transport. To make up the required height, the foundations were built with elevated uprights.
Given the culverts’ non-standard dimensions, six custom-made steel moulds were used for the casting, which was done horizontally. Seven 200 x 200mm steel utility plates were cast into the inner sides of each culvert to be used as attachments points for the channelling electrical cabling and other types of conduit.
Special lifting beams were designed for the project so that the culverts could be easily raised and lowered into position on the foundation.
Judges’ comments
Non-standard dimensions made this an excellent technical project .
Product information
4 700 x 3 000mm portal culverts (13 tonnes each).
Project team
Owner: Glencore
Engineer: DRA Mineral Resources
Quantity surveyor: Basson & Close
Main contractor: WBHO
Manufacturer of precast concrete elements: Aveng Infraset

INNOVATION
TROPHY WINNER

Castle Bottom Kerb

Project description
The Castle Bottom Kerb is patented (SA2012/09544), clear evidence of innovation. Prerequisites for a patent are that an invention should be novel and hold clear advantages over existing and similar products.
Advantages of Castle Bottom Kerbs:
1. Cavities provide grip for installers making for much easier handling.
2. The cavities make the kerb much easier and quicker to install. In instances where unlevelled screed surfaces force installers to lift fill and relay conventional kerbs, Castle Bottom Kerbs are much easier to manoeuvre into place.
3. Because the Castle Bottom Kerb has more load points it sinks into the screed, providing much better adhesion in all directions.
4. The Castle Botton Kerb eliminates air pockets in the screed which could create weaknesses under the kerb after installation.
Judges’ comments
An effective and cost-effective alternative to satisfy extreme technical demands, made this an impressive solution.
Product information
Castle Bottom Kerb
Manufacturer of precast elements: Bosun

INNOVATION
COMMENDATION WINNERS

Gouda Wind Farm, Gouda, Western Cape

Project description
Gouda Wind Farm is Africa’s first wind farm project in which concrete rather than steel was the primary construction material. Forty six 100m towers were erected, each tower supporting a three-bladed turbine which weighs 170 tonnes.
Gouda’s tower segments, 782 in all, were designed according to European structural concrete codes as opposed to the SANS code. The Gouda towers have a characteristic strength of 75MPa, which made for lighter concrete sections.
Each completed tower comprises five 20m high tapered concrete sections and each section was assembled using the precast concrete segments. The segments were joined in a vertical plane by inserting reinforcing and grout into the hollow chambers formed by the segments’ two opposing channels. Once assembled, the tower sections were lifted into position by crane and joined in a horizontal plane using starter bars, ducting and grouting. The flawless execution of this process required extremely accurate casting and very tight tolerances.
A maximum of five segments was cast daily using five moulds. Mould sections were attached using laser technology and special jigs were used to ensure that the steel reinforcing was accurately positioned. Various inserts and sockets were cast into the concrete segments to facilitate the installation of mechanical and electrical equipment inside the towers.
The tower segments were manufactured with self-compacting concrete. Without it, the project would have been much more complex, involving external vibration and more expensive moulds.
The towers were designed to bend with the wind. This lateral movement is facilitated by the use of steel reinforcing inside the tower walls and additional strength was gained by linking six 90mm post- tensioned steel cables from the inner walls of topmost tower sections to the concrete base of each tower.
Judges’ comments
An innovative and accurate casting technique.
Product information
782 precast concrete wind tower segments weighing 60 tonnes each.
Project team
Owner: Acciona Wind Power
Main contractor: Acciona Wind Power
Manufacturer of precast concrete elements: Concrete Units


Photovoltaic Cabins, Lesedi, Northen Cape, and Letsatsi Free State

These two Renewable Energy Independent Power Producer (REIPP) photovoltaic projects required 128 precast concrete cabins to house expensive and sensitive electronic equipment - sourced, installed, tested and certified in a turnkey project by Rocla, the manufacturer of the cabins.
Each cabin has a generating capacity of 1MW, has a mass of 28 tonnes and is 8.7m long, 2.6m wide and 3.1m high.
Documentation was finalised in February/March 2013. Deliveries at a rate of one cabin a day began in July and the project was completed in January 2014.
The project involved some ground-breaking advancement for Rocla:
1. Twelve cubic metres of concrete were cast daily, the largest single component requiring eight cubic metres. A pumping framework was introduced to supply a fast and steady concrete flow.
2. Self-compacting concrete was used for its superior finish, reduced casting time and lower noise emissions.
3. Production, which was outdoors, began in mid-winter. Optimal electrical and steam curing was used internally and externally in combination with thermal blankets which were used to cover exposed surfaces.
4. Concrete accelerators were used and monitored daily to make adjustments for ambient temperatures and curing conditions. This enabled stripping to take place approximately after 16 hours.
5. Each cabin consisted of more than 200 items, including concrete works, steel fabrications, electrical cabling and equipment. A production line was initiated to ensure that each cabin was ready for delivery within seven working days after casting.
Each cabin had delivered mass of 38 tonnes. In total 3 584 tonnes of concrete were manufactured and delivered on schedule.
Judges’ comments
Vandal proof and quick to assemble.
Product information
128 precast concrete cabins 8.7m long x 2.6m wide x 3.1m high.
Cabin mass totalled 3 584 tonnes of concrete
Project team
Owner Lesedi PV and Letsatsi PV
Main contractor Conycento/Firefly Investments 261
Manufacturer of Precast concrete elements Rocla


PRECAST FOR LIFE
TROPHY WINNER

The Waterfront Knysna Quays, Western Cape

Project description
A trip along the Garden Route is not complete without a visit to the famous Knysna Waterfront. Arguably one of the most popular leisure and shopping destinations in the region, boasting a superior marina, the waterfront offer various restaurants, boutiques and other speciality shops.
This project was completed in October 1998. Signature Fan cobbles line the marina and offer an overflow area for the restaurants. After 17 years these cobbles are still beautiful and their installation pristine.
Judges’ comments
Has withstood the harsh climatic conditions and heavy pedestrian traffic.
Product information
Fan Cobbles (charcoal)
Project team
Owner: SA Ports and Harbours
Main contractor: Asla Construction
Manufacturer of precast elements: SmartStone George

PRECAST FOR LIFE
COMMENDATION WINNERS

Croydon Residential Estate, Western Cape

Project description

Acting as a ‘welcoming mat’, the paved entrance to this exclusive residential estate is situated in the rural Western Cape.
The paving requirements were for a product which would tone in with the rustic environment. Due to the high profile of this development, the developers needed to be certain that the pavers selected would be beautiful, hard-wearing and make a statement to all those who entered the estate.
Consistency of finish was also an extremely important requirement as the same pavers were to be used for the adjoining estate at a later date. C.E.L’s Brownstone paver suited all the requirements and, more than 10 years later, the surfaces speak volumes for the durability of the product. Careful attention to the construction of the earthworks and laying of the paving blocks has produced roads with no rutting or deformation.
Judges’ comments
Excellent example of the durability of precast concrete products.
Product information
190 x 125 x 70mm exposed aggregate Brownstone pavers.
Project team
Architect: Planning Partners
Engineer: Ninham Shand
Main contractor: Burger & Wallace Construction
Manufacturer of precast concrete elements: C.E.L. Concrete Products

Houtkapperspoort Mountain Retreat Cottages, Constantia Nek, Cape Town

Project description
The original asphalt roads and entrance to this upmarket Constantia Nek resort had deteriorated badly from years of use.
In 2003 the new owners upgraded the entrance and road facilities throughout the entire resort. They chose C.E.L Concrete Products sandstone Vintage pavers and charcoal Double Cobbles, both for their long-term appeal as well as the colour blending.
The paving blocks’ irregular shapes, random rippled chamfers and three-coloured sandstone blend, complements the laid-back nature of the location and creates the ambience required by the client.
Twelve years later, the pavers have aged extremely well. The details of the surface colouring is unchanged and the structure of the paved surfaces has remained uniform, blending in with its surroundings.
Judges’ comments
Excellent example of the durability of precast concrete products.
Product information
190 x 125 x 50mm Vintage Pavers (sandstone)
200 x 100 x50mm Double Cobbles (charcoal)
Project team
Designer: Grant Ambrose
Main contractor: SA Paving Cape Town
Manufacturer of precast concrete elements: C.E.L. Concrete Products



Comments are closed.

Showing 0 Comment

Categories