CONCRETEBETON - Golden Jubilee edition - Concrete Society of Southern Africa
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The official publication of the Concrete Society of Southern Africa NPC
NUMBER 156 . March 2019 ISSN 1682-6116
CONCRETEBETON
1969-2019
Golden Jubilee
edition
PLATINUM MEMBERS
CONTENTS
Editor’s comment..................................................................................................................4
President’s message..............................................................................................................6
SOCIETY HISTORY
A Journey Through Time.................................................................................................7
FULTON AWARDS WINNER
Sol Plaatje University Library............................................................................................13
ACCREDITED TECHNICAL PAPERS
Precast Concrete Panels for Rapid Full-Depth Repair of CRCP........................................17
ASR expansion due to use of reactive fine and coarse aggregates,
and its effect on concrete compressive strength............................................................23
INDUSTRY NEWS
Growing readymix markets with Chryso technology......................................................29
Modern flooring products save time..............................................................................30
Chryso to expand concrete offering in 2019.................................................................31
Heritage and height mark Concor Western Cape’s landmark project.............................32
Metrorail safety wall built with Echo panels ................................................................34
Smart new floor for the Ekurhuleni Municipal Police Department..................................35
Afrisam takes leading role in SAFA’s youth soccer
development programme – Ima Nathi...........................................................................36
a.b.e. flooring system used for Douglas Green Winery walls..........................................37
Heritage and future......................................................................................................38
SIKA 2018 sales exceed CHF 7 billion for the first time..................................................40
Air-purifying concrete can reduce atmospheric pollution...............................................41
Ash is the 21st century’s next big thing.........................................................................42
Kaytech raises the B-BBEE bar......................................................................................43
Post-budget analysts at AfriSam gathering call for new beginnings...............................44
SOCIETY NEWS
University of Pretoria Civil Laboratory opens its doors to Inland Branch members..........45
Members visit the site of Deloitte’s stunning new R1 billion headquarters......................46
Fulton Awards 2019 attracts many iconic structures......................................................48
Bursaries awarded to celebrate the Society’s 50th Anniversary........................................49
Inland Branch Honours Construction Materials Executive...............................................50
ACTIVITIES CALENDAR...............................................................................................51
MEMBERSHIP DETAILS...............................................................................................53
CONCRETE BETON 3
editor’s comment
Welcome readers to this special Golden Jubilee issue of
Concrete Beton - we’ve published a bumper edition for you
in celebration of this great milestone in our history.
I
n these austere times it was difficult to justify major expense on celebrating this anniversary, but
we have embarked on some key initiatives to ensure a legacy.
As part of our celebrations this year, the Board of Directors decided to formally recognise the
loyal support that we have been afforded by the major Universities over many, many years. This
will be in the form of presentations to six universities of specially designed and produced concrete
seats to be installed on their campuses. Unveiling of these will take place at the universities in
April and members will be invited to the short ceremonies. The academic institutions involved
are the University of Johannesburg, University of Pretoria, WITS, University of KwaZulu-Natal,
Stellenbosch University and University of Cape Town.
Coupled with this is the awarding of two bursaries this year for students conducting research
in the field of cement‐based materials. More details of these can be viewed under the Society
News section.
My thanks to Hanlie Turner our Immediate Past President who has taken the time to research
and write a short history of the Concrete Society (see pages 7-12). Not an easy task when so
many of the older members are no longer with us, and the only written source of information has
been the 155 issues of this journal published since March 1976. Anyway, it is a factual yet fairly
light-hearted article, so enjoy the read.
Now turning to the issue of consolidation of the various concrete-related organisations.
I reiterate what I said in my e-mail to members late last year when I advised that it has been
decided that before any consolidation can take place, a strategy for the whole industry should
be formulated and agreed.
From this, consolidation of the industry service offerings may be required based on a strategic
approach that maximises value creation for members and other key stakeholders.
Under the auspices of two independent professional facilitators, separate meetings have now
taken place with TCI, CSSA, SARMA and CMA, where the needs and wants of the various bodies
were aired and discussed. The combined outcomes of these discussions will be made available
shortly, and these will be communicated to members.
With any exercise of this nature, there is bound to be uncertainty and speculation, but I
implore you as loyal members, to support us through this period, and enjoy the current benefits
that the Society has to offer.
For the love of Concrete,
John Sheath
Editor
OUR VISION HONORARY LIFE MEMBERS The Concrete Society of Southern Africa NPC
To be the most relevant forum for those who P R A Flower, D P Samson, C J Thompson (CSSA), its directors, officers, employees,
have an interest in concrete. M O de Kock (Prof), M G Alexander (Prof) representatives and agents are not liable for any
death, harm or injury caused to any person or
OUR MISSION EDITORIAL COMMITTEE any loss, destruction or damage caused to any
To promote excellence and innovation in the Chair: W P Boshoff (Prof), G C Fanourakis (Prof), person’s property or possessions arising from
use of concrete and to provide a forum for G P A G van Zijl (Prof), E P Kearsley (Prof), goods supplied, or services rendered by
networking and for sharing knowledge and H D Beushausen (Prof) the CSSA.
information on concrete-related matters.
Editor: P J Sheath © COPYRIGHT All editorial material published
OFFICE BEARERS in Concrete Beton is reserved to the Concrete
Design, layout and production: Society. Requests for permission to use any of the
President: M G Alexander (Prof), DesignWright, Tel: +27 83 448 4264 material, in part or in full, should be addressed to
Vice-President: R Raghubir, the Chief Executive Officer of the CSSA.
Reproduction and print:
Immediate Past President: H Turner.
Jetline Corporate Print Solutions (Pty) Ltd, Although the CSSA does its best to ensure
Tel: 011 566-0501 that information contained herein is accurate,
ELECTED DIRECTORS
W P Boshoff (Prof), R Jacobs, B D Perrie, no liabilities for negligence are accepted by the
OFFICIAL PUBLICATION OF THE
R Maliehe, J Kanjee. CSSA, its offices, its members, publishers or
Concrete Society of Southern Africa NPC
agents.
CHIEF EXECUTIVE OFFICER Physical: Suite 423, The Hillside,
P J Sheath 318 The Hillside Street, Lynnwood, 0081.
Postal: P O Box 75364, Lynnwood Ridge, 0040
BRANCH CHAIRS
Tel: +27 12 348 5305
P Flannigan, G Smith, M Taliwe, T Coetzee.
E-mail: admin@concretesociety.co.za
ADMINISTRATOR Web: www.concretesociety.co.za
N L Pols
4 NUMBER 156 | MARCH 2019
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president’s message
These voluntary contributions are not always a ‘perfect storm’! The net effect is that our
understood or fully appreciated by the various voluntary associations and other civil-society
role-players, but they represent huge value, bodies are in many cases languishing.
and they have helped to build the Society and
industry over time. Simply put, the CSSA has So – how do we take something positive out
brought, and continues to bring, enormous of this? I think as follows:
value to our various constituencies. 1. First, we need to value collective effort
But I must also speak about the fact that and mutual learning, value human worth
the Society, in keeping with the construction and progress. If people are our ‘greatest
and concrete industries it serves –– is at a asset’, we need to craft policies and
crossroads. This presents both opportunities practices around this. We must recognise
and threats. The threats in our current context our individual responsibilities and actions.
relate to the ability to sustain the CSSA. Even Will we value and promote these?
now, we are struggling to retain membership,
2. We need to re-discover the value and
partly because of the uncertain outcome of
joy in undertaking voluntary activities
the consolidation initiative, but also because
– in our vocational and professional
of broader industry and societal challenges.
societies, in our places of worship, in our
These impact negatively on our membership
neighbourhoods, and in civil society more
and capacity.
broadly. Especially professionals, who
At all levels and in all sectors, the
have benefitted greatly from a sound and
overarching requirement within companies
thorough education, have a duty to stand
and organisations to cost out each hour
out and stand up. Academics need to take
of each day, to account for the time spent
the role of ‘public intellectuals’ who can
on non-revenue generating activity, and
advocate for positions and actions that
the like, is in my view beginning to strangle
I
benefit society as a whole.
take opportunity of this Golden Anniversary our associations and our profession. Even
message to depart from my themes of recent universities, long bastions of ‘academic 3. Appealing to my engineering consultant
Concrete Beton issues, to dwell briefly on freedom’ and the opportunity to pursue one’s colleagues in particular, I encourage you
this historic occasion, to try and assess where own research interests, are coming under to consider afresh the opportunities to
we are, and how we can move forward as similar stress due to escalating bureaucratic serve the broader profession and society
CSSA into the coming years. I refer you also processes, increasing student numbers, through involvement in CSSA (and other
to the companion articles in this issue, from and the constant pressures of teaching and voluntary associations).
our CEO John Sheath, and our Immediate Past publication.
President Hanlie Turner – they are both worth Thus, people will claim (and sometimes Enough of philosophising! But I do hope
a serious read! justifiably so), that they ‘have no time’ for people will heed these points.
I wish to strike a sober but intentionally engaging in activities of voluntary societies My final remarks concern 2019 and the
hopeful note. such as the CSSA. Or they may not be CSSA. Excitingly, we have the 2019 Fulton
From humble beginnings in Richmond, supported financially by their organisations Awards coming down the road, and we are
Johannesburg in 1969, when the Prestressed to participate in Society seminars and lectures looking forward to another excellent event in
Concrete Development Group was where considerable benefit to their careers can the Drakensberg in June. A National Roadshow
transformed into the Concrete Society of be gained. This, coupled with the pressures on durability and site practice is planned for
Southern Africa at the suggestion of the late of modern living, is taking its toll. Where later in 2019. Also, in 2019, our CEO, John
Dr Sandy Fulton, with Steve Halstead as our companies in the past saw it as part of their Sheath, will finally be hanging up his gloves,
first Director, the CSSA has grown to what it is contribution to the profession and industry but we intend to keep him fruitfully involved
today – an influential and respected voluntary to allow their members to contribute to such for the near future at least, particularly
association that punches well above its weight societies, regrettably this is often no longer regarding the issue of consolidation.
in South Africa and further afield. Ours has the case. Lastly, I wish to express our gratitude to
been a noteworthy journey. We have had our Why is this so? I have made some allusions all our faithful individual members for their
‘fat years’ and our ‘lean years’, but through above. Briefly, I suggest, from my admittedly continuing support, to our sustaining sponsors:
all, the Society has continued to serve the limited and personal perspective, that the Platinum, Gold, Silver and Bronze company
concrete industry and concrete construction causes can be found in the intersection members, and to our office staff complement:
professionals in South Africa with dedication of a number of social and generational John, Natasja, and Marike. Thank you all!
and distinction, consistently and excellently. phenomena, namely: corporatisation, where
Hanlie Turner’s accompanying article makes we value our companies and corporations Yours in concrete,
this very clear. only in terms of the ‘bottom line’;
Which brings me to the inherent worth Mark Alexander
monetisation, where if no direct monetary
of the Society to the industry, the profession, PrEng
value derives from an activity, it follows that
and indeed the country. If one were to add President
it is ‘worthless’; commodification, where
up the countless hours invested by so many we treat something as a mere commodity’,
individuals in a voluntary capacity to Society including the commodification of engineering
activities over the years, this would amount skills and services which can be sold at the
to a vast sum which in monetary terms, cheapest price. Then there are other factors
would place the value of the Society in a such as generational and social shifts, and
true perspective. These people have given the destructive cancer of ‘fee tendering and
of their extensive knowledge, expertise, and discounting’ in the consulting profession. Any
organisational abilities freely and voluntarily one of these factors taken on its own can
via CSSA branch committees, workshops, cause great damage to our profession and
meetings, forums, seminars, and so on. industry, but taken together, they seem like
6 NUMBER 156 | MARCH 2019
society history
A Journey Through Time
History of the Concrete Society of Southern Africa 1969-2019
by Hanlie Turner, Immediate Past President
W
hat started as a project documenting the history of the CSSA
over 50 years, soon became a nostalgic journey. This article is
a mere snap-shot of the Society’s rich history.
The Society is inextricably linked to the people, the colourful
characters involved in shaping this organisation which, despite many
challenging times, has survived and flourished for half a century.
The truth of the quote from Scripture; “Whatever is, has already Administration
been, and what will be, has been before” was clearly visible while Steve Halstead was appointed first
researching the Society’s passage of time. For 50 years there has been director of the Society in 1969 and it
the same quest to grow membership, to secure sustainable funding, was clear that the development of the
to find the best model of addressing the needs of members, to host Society in those days was attributable
relevant events, to add value for all stakeholders and to remain relevant. in a large measure to Steve’s dedication
Various snippets from early issues of Concrete Beton revealed and enthusiasm.
unintended humorous glimpses, and in some cases, controversial Steve was succeeded by Vivienne
statements: Mister as administrative executive
• The first Fulton Awards criteria listed one qualifying attribute as Secretary in December 1976, with
“value for money -not to be confused with cheapness”. a sub-committee to handle the
• An extract of the introduction to the late Grahame Bendall’s term technical side of the Director’s duties.
as 1981 president, read: “His charming wife will no doubt support She subsequently served as Director
him at various functions where ladies are invited”. Steve Halstead
between 1977 and February 1981.
• When Chris Thompson was inaugurated as President for 1982, John Lane took over as Acting Executive Director for a few months
he was hailed unique in a geographical sense, as he was the first and during the latter part of 1981 Greg Griffiths was appointed
President of the CSSA not to be resident in the Johannesburg- Executive Director, a position he held to the end of 1985.
Pretoria area, being domiciled in Cape Town”. In January 1982, a pivotal year for the Society, it took over full
responsibility for its expenditure until the funders of the PCI (C&CI later)
• Dr. Sandy Fulton was quoted as saying that in his opinion the “cult
agreed to a percentage of funding for the concrete-related bodies of
of exposed aggregate finishes was largely a passing phase”.
South Africa, of which CSSA was one.
• A letter from Prof Yunus Ballim in 1991, suggested that the
From 1986 the Society was run by an administrative officer, Jean
title “Concrete Man of the Year” be changed to the non-sexist
Edwards, with the assistance of a technical officer.
“Concrete Personality of the Year”.
By the second quarter of 1989 Vincent Vogt was appointed
• The formation of branches in 1977 was promoted as an opportunity Director. Early in 1993 he was succeeded by Dave Kirkman.
for members residing outside Transvaal “to talk shop and discuss In November 1997 the cement manufacturers reduced their funding
local ideas and problems related to concrete as well as those of contribution to the Society to about 15% of the former levels. This had
national and global nature”. far-reaching implications for the Society. Sadly, the position of full-time
director was made redundant and a decision was taken to administer
CSSA: the beginning the Society through the Secretariat - Jean Edwards, once again.
In 1969 the late Dr Sandy Fulton, Director of the Portland Cement In July 2000 the official secretariat was dissolved and the offices
Institute, suggested that the name of the Prestressed Concrete the Society occupied at Portland Park were vacated. Irma Dyssel was
Development Group which was in existence since 1952, be changed appointed as part-time administrator, a position she held until 2007,
to the Concrete Society of Southern Africa. The Society’s wide scope where after Natalie van Wulven assisted the Council with secretarial
included virtually everything related to concrete, with emphasis on the duties, but only for a short while.
dissemination and exchange of information. In 2009 a measure of financial stability returned and the Council
At its inception the Society’s founding patron, the Portland Cement announced that they were once again seeking to appoint a full-time
Institute, carried all its financial obligations. director.
CONCRETE BETON 7
society HISTORY
In the meantime, Natasja Pols was
appointed Administrator and Jeanine
Steenkamp as Administrative Assistant.
When Jeanine left, Marike van Wyk joined
as Membership & Events Co-ordinator.
After serving just a year of his term as
President, John Sheath was appointed as
the Society’s new CEO from the beginning
of 2011 and as a result had to relinquish
the role of President.
Currently John, Natasja and Marike still
comprise the Head Office full-time staff.
John Sheath Natasja Pols Marike van Wyk
Membership National Council and Board
During the early years the Society consisted of individual members The Society has had 36 Presidents over the past 50 years, the names
only. We were fortunate enough to be able to trace the Society’s of whom are listed below. The positions of President, Vice-President
second member to join back in 1978 - Gordon Forrester (see below). and Immediate Past-President have continued since inception:
In 1982 with the changes in funding, eight grades of membership Discussions with some past presidents (Chris Thompson, Dave
were introduced: Individual, Honorary, Group, Organisational, Sponsor, Samson, Mick Latimer and Peter Flower) relating to their respective
Industrial Division, Student and Retired member. years in office, revealed similarities in the challenges and highlights
Membership categories were revised from time to time until it which resonate even today.
reached its current structure: Individual, Academic, Country, Retired, Mick Latimer, President in 1994, the Society’s Silver Jubilee year,
Honorary, Bronze, Silver, Gold and Platinum. recollected the very successful three-day Convention arranged at Sun
Honorary membership has been conferred on a relatively small City to celebrate this milestone.
number of deserving individuals over the years, namely: Dr Sandy Dave Samson, President in 1999 took great personal pride in the
Fulton, Steve Halstead, W M Johns, Dr A J Ockleston, Dr Niko publication of the first edition of the still popular Concrete Source Book,
Stutterheim, Dr Derek Davis, R Rowe, R Fisk, Dr Charles Liebenberg, which is now available in both print format and as an on-line edition.
Russell Copp, Tony Dutton, Prof Gert Loedolff, Dave Samson, Chris The Society was managed by a Council comprising many prominent
Thompson, Prof Michiel de Kock, Prof Mark Alexander and Peter engineers, architects and academics. In 1982, Council appointed a new
Flower. Board and Committees to expand the Society’s influence in technical
Today the Society’s membership and office bearers are a spheres, and to create an independent identity to distinguish between
true reflection of the diversity of South Africa’s geography and the Society’s activities and those of the then Portland Cement Institute.
demographics. The tiered management structure of 1982 consisted of Branch
Committees, the Executive Committee (EXCO) and the Council (Fig a).
Year(s) President Year(s) President
1969/70 L H West 1993 D Peters
1971/72 Dr E Benard 1994 M G Latimer
1973/74 A R Dutton 1995 Prof M G Alexander
1975 V R Boardman 1996 C H Waterson
1976/77 Prof T J Olivier 1997 B A Raath
1978/79 Dr C W Wolhuter 1998 P R A Flower
1980 M A Vasarhelyi 1999 D P Samson
1981 G D Bendall 2000/01 G Maritz
Gordon Forrester 1982 C J Thompson 2002/03 P R A Flower
1983 K C Tucker 2004/05 V A da Silva
1984 E P J van Vuuren 2006/07 D C Miles
1985 A R Dutton 2008/09 F B Bain
1986 D P Samson 2010 P J Sheath
1987/88 J E Hodgkiss 2011 N P van den Berg
1989 R J Snowden 2012/13 Prof W P Boshoff
1990 P C Graham 2014/15 R Maliehe
1991 C J Lloyd 2016/17 H Turner (Mrs)
1992 V E Blackbeard 2018/19 Prof M G Alexander
8 NUMBER 156 | MARCH 2019
society HISTORY
Key changes brought about by The
Fig a: Structure as at 1982
Companies Act 2008 which came into force in
2013, required that the acronym ‘NPC’ (Non- National Council
Profit Company) be used after the Society’s full Industrial Divisions | EXCO | Elected members | Co-opted Members
name; the addition of three elected directors (4) (5) (6) (2)
in addition to the office-bearers and the
change from a ‘National Council” to a “Board
of Directors”. President
In March 2016, with succession planning Vice-President
in mind and adopting a business strategy Past-President
essential for survival, the number of elected PCI Rep
directors was increased from three to five. The Executive Director
current structure is shown in Fig b.
Division Chairs Branch Chairs CommitTee Chairs
Divisions & Branches
Pipes Border Educational Advisory
The Society’s mission has always been to
Pre-stressed Natal Editorial
provide a professional body encompassing
GRC Transvaal Technical Activities
all aspects of concrete. In 1969 two
Admixtures Western Province Finance
technical divisions were formed to focus
Long-range Planning
attention on prestressed concrete and
concrete pipes.
In 1977 new divisions were introduced:
Prestressed Concrete, Formwork, and GRC. Fig b: Current structure
Later, more divisions were added, namely
Admixtures, Additives and Auxiliary Products
and Roof Tiles. Subsequently, some of these BOARD-APPOINTED
divisions were incorporated into the Concrete COMMITTEES
PLATINUM MEMBERS
Manufacturers Association (CMA) and the • Finanace Committee
• Nominated representatives • Membership Committee
segmentation by divisions within the Society • Education Committee
fell away. BOARD OF DIRECTORS (9) • CPD Committee
In the same year Council established Non-Executive Directors • Editorial Committee
branches in Cape Town, Port Elizabeth and • President (Chair)
• Vice-President
Durban and an informal branch in East London
• Immediate Past President
to augment the work done in the Transvaal. An • 5 x Elected Directors
official Transvaal Branch was only inaugurated
Executive Director
in 1981. REGIONAL BRANCHES HEAD OFFICE
• Chief Executive Officer
Many of the current events and much • Inland Chair • Chief Executive Officer
• Western Cape Chair • Administrator
of the activities of the Society take place
• KwaZulu-Natal Chair • Membership & Events
at branch level. All four branches operate • Eastern Cape Chair Coordinator
autonomously, with guidance and assistance Volunteers
from the National Office and within the policy
framework set out by the Board. Full Time Employees
Inland Branch Annual Concrete Boat Race Day Knowledge transfer through seminars
CONCRETE BETON 9
society HISTORY
Site visits – always very popular with members Egg Protection Device competition
Members are able to enjoy various local technical meetings, seminars
and site visits where the transfer of concrete knowledge is the primary Concrete Beton
objective. In addition, there are further networking opportunities at The first issue of Concrete Beton was published in March 1976. Printed
golf days, Branch Chairs’ breakfasts, awards functions and more. in black and white, carrying one technical paper, no advertisements,
Regional competitions (Strongest Cube and the Egg Protection much personal chatter and humour from the editor, it was published
Device) and student events (Concrete Canoe Race first hosted in 1991 in-house and sold for R1 a copy.
by the Transvaal branch), and more recently the Concrete Quiz Nights,
have been part of the Society’s portfolio to add value for students and
younger members.
The value added by the Branches is enormous and particularly
noteworthy as all four are managed and run entirely by volunteers.
International and professional ties
Since its inception the Society had close relationships with FIP
(Fédération Internationale de la Précontrainte) and The British Concrete
Society. During 2012 The Society became a National Member Group of
the Fédération Internationale du béton (fib).
In 2004 the Society registered as an industrial partner with the
National Research Fund which administered the THRIP funding scheme
for the Ministry of Trade and Industry. The Society used the Education
Fund to gear up funding for postgraduate students to conduct research
into concrete.
Whilst relationships with the American Concrete Institute have
been promoted over the years, in 2005 a Partnership Agreement was
signed with ACI and this was re-established during 2018 when the
International Business Development Director of the ACI paid a visit to
South Africa.
The Society is registered as a Voluntary Association with ECSA and The technical content of the journal clearly demonstrated the
is able to allocate CPD points to professional members and providing advances in concrete and construction technology, while skills
registered engineers with partial exemption of their annual ECSA fees. development, education and training always part of the debate. Early
It is also a founder member of the recently formed South African Forum issues of Concrete Beton dedicated much discussion to metrication and
for Engineering (SAFE). the use of the correct SI symbols.
During 1989, Concrete Beton was placed on the “List of Journals
for Subsidy purposes” by the Department of National Education. This
greatly enhanced the prestige of the journal and has entrenched it as
the foremost South African journal of concrete technology, a distinction
it still enjoys.
The January 2000 edition moved to more of a blend of technical
information and Society/industry news.
At different times the production and distribution was moved to
commercial publishing houses, but in 2014 the Board decided to bring
the publication of Concrete Beton in-house. The 150th edition of the
journal was published in September 2017.
10 NUMBER 156 | MARCH 2019Congratulations to the
Concrete Society of
Southern Africa on their
50th Anniversary
and the fantastic support
they have given to
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CONCRETE BETON 11society HISTORY
From 1989, and for some years thereafter, the Tricee Award, Some of the noteworthy projects over the past 38 years that have won
spearheaded by the late Richard Robinson, was awarded on an annual awards include:
basis to the author who had submitted the “most interesting and
thought-provoking” technical paper in Concrete Beton. 1983 – Bloukrans Bridge, Western Cape
1996 – Standard Bank Centre, Johannesburg
1998 – Katse Dam, Lesotho
2001 – Mozal Aluminium Smelter, Mozambique
2005 – Constitutional Court, Johannesburg
2009 – Soccer City Stadium, Soweto
2015 – Gouda Wind Farm, Western Cape
2017 – Mount Edgecombe Interchange, Durban
National Events
Seminars, symposia, meetings and site visits have always formed part of
the Society’s technical offering to its members. A wide variety of topics
have been addressed at these events such as quality, standards and
The Tricee Award last presented in May 2005.
specifications, self-compacting concrete, recycling initiatives, flooring,
admixtures, water retaining structures and repair, to name a few.
Today, Concrete Beton is a world-class publication, with content One of the most interesting and topical symposia of the time, was
reflecting the interests and needs of both individual and corporate when the CSSA in 1978, in collaboration with the Cruising Association
members. The journal is available electronically on the CSSA website of SA and the Yacht Racing Association, organized a symposium on
and an “open-access” facility of the technical papers is also provided ferrocement hulls for yachts and other sailing craft.
for researchers Modern day trends have seen a decline in attendance at all events,
a sentiment lamented by all professional bodies, but the quest for
Fulton Awards relevant and stimulating technical seminars and meetings to add value
The now prestigious Fulton Awards was first hosted in 1980 as an for the members remain high on the Society’s list of priorities.
award for excellence in the use of concrete, in each of two categories:
Building structures and Civil Engineering Structures. QuO vAdis
Initially, it was an annual award and the form of the award was a During 2013 John Sheath, with the support of the Board and a strong
framed certificate and a specially designed plaque to be displayed on mandate from the Society’s members, started advocating some form of
the winning structure. consolidation and cooperation between the different bodies to eliminate
Currently Fulton’s are hosted bi-annually. Categories for the awards duplication and to provide better value for money for all stakeholders.
and the criteria have been revised regularly to include sustainability, The rationale was to have an all-inclusive, member-based (company
environmental issues, aesthetics and innovation. These days the only and individual) organisation, truly independent and impartial, and built
tangible evidence of the award is a ‘concrete’ trophy, together with on a technical base to provide, inter alia, information, technical and
the framed certificates issued to the nominated principal agents, training services.
contractors and subcontractors involved in the winning project. While the Society took the pro-active lead, the process is now being
taken forward by the Board of TCI.
CSSA has remained true to its mission for 50 years. However, Mark
Alexander, current President, summed the present situation up with
these words: “Our operating environment has changed substantially,
and this has posed major challenges for the Society to remain attractive
and relevant for our members”.
We are up to the challenge!
Despite the current cycle 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
concrete.
That same commitment and enthusiasm will ensure that the ethos
of the Concrete Society of Southern Africa will be carried forward in
one way or another….for the love of concrete. s
Bloukrans River Bridge
12 NUMBER 156 | MARCH 2019fulton awards winner
Sol Plaatje University Library
With this increasing specialisation, traditional materials come under pressure
to demonstrate their much wider performance capacities and attributes.
This project showcases these key differentials.
BACKGROUND
The project arose from three conditions: 2. Thorough, advanced and specific Urban Design [UD] parameters
1. Sol Plaatje University [SPU] being an entirely new university meant defined the 3-dimensional envelope of all new projects on the
there was the absence of institutional capacity at the time of project campus, of which this is one of the last to be delivered in this phase.
initiation and therefore, there was effectively no programmatic brief. 3. The Department of Higher Education construction budgets are
determined by a fixed rate per square metre
for Assignable Square Metres only [ASM],
with non-Assignable Square Metres [NASM]
receiving no allocated budget.
The architect’s response to the evolving
brief was to provide deep, highly serviced
flat floors that maximise flexibility. They
pushed the building enclosure up against
the 3-dimensional envelope defined by the
UD parameters, and optimised floor plate
efficiency to ensure that all constructed space
is effectively assignable.
Synthesis of these actions located all
vertical movement and services in a continuous
2.7-metre wide perimeter void between the
external envelope and the floor plates. This
results in an envelope as an integrated ‘wall
and roof’ shell that is functionally, structurally
and technically independent of the ‘building’
within it. The container is independent of its
contents.
CONCRETE BETON 13fulton awards winner
By involving the building contractor early
during the design phases of the façade, Murray
& Dickson Construction Group was able to
share critical insights on shuttering, staging
technology and construction sequencing.
In addition to advising on an acceptable
consistent concrete colour variation, the
building division also helped optimise the
programme and align costs to the client’s
budget.
Once the design and construction process
had been validated, the contractor built a 1:1
scale “sample” wall to test the process. Special
attention was also paid to the complicated
interface of the shuttering panels with the
sloped roof of the structure, as well as ensuring
consistent concrete flows.
Only minor refinements to the proposed
construction process had to be made at this
stage to achieve the desired end result.
Construction process
The 220 mm-thick walls were climb-formed
by Murray & Dickson Construction while
supported eccentrically off slender steel
columns. As the wall progressed, it was tied
to the floor slabs by steel struts which resist
the overturning nature of the design and
ultimately create the illusion of a façade that
is floating off the ground.
The two striking, internal in-situ concrete
A-frames relied upon an intricate construction
sequence, starting with building of the large
temporary support columns.
Ultimately, the A-frames were jacked
upwards by 400-ton jacks to remove the
temporary shim plates, and then deflated
to allow the A-frame to span free, before
demolishing the two temporary concrete
columns.
Murray & Dickson Construction achieved
tolerances within a few millimetres of the
engineer’s design.
The reinforced concrete fire-escapes on
the western wall were hung with tension rods
and the internal steel stair cases hung from the
sloping roof slabs.
Meanwhile, the construction of the
courtyard façade also entailed extensive
upfront planning ahead of its construction
and demanded utmost precision in execution.
Like the external façade of the structure, the
contractor had to achieve the desired smooth
and silky finish at first attempt. This process
was refined during the preparation stages of
the floating façade and entailed building a
small sample wall.
14 NUMBER 156 | MARCH 2019fulton awards winner
Quality of Concrete
Extensive research identified concrete as the optimal technology and
material combination. Concrete uniquely integrates structure, climatic
envelope, thermal performance, build-ability in the Kimberley reality,
and the final finish.
Maximum flexible useable built area, optimised site area, inherent
climatic performance, cost for benefit [value], and iconic status are the
primary client expectations directly delivered by the project.
Considering the very high risks involved, the contractor and
engineer embarked on a six-month-long planning phase to refine the
process ahead of the actual construction, while work commenced on
the core of the structure.
Importantly, significant consideration was given to limiting the
influence of concrete shrinkage on such a large, continuous in-situ
concrete element.
Specialist supplier, Lafarge, helped design a concrete mix with
the necessary low-shrinkage properties. The design also incorporated
600-mm wide shrinkage pour strips that would run the full vertical
height of three sides of the building and remain open for 90 days
thereafter. This enabled unrestrained movement of up to 50% of
the expected shrinkage movement in the walls. In addition, Murray
& Dickson followed a stringent concrete-curing regime which further
limited the effects of drying shrinkage.
This high-slump concrete mix with a smaller-sized aggregate was
carefully vibrated in-and-around the closely-spaced reinforcement and Reduced glass area delivers optimal internal natural light levels
other embedded cast-in elements. across the deep spaces and is further aided by the 2.7 m perimeter that
A client-driven process to enable the early selection of a suitable distributes light across three floors that would otherwise be limited to
builder for the project enabled real collaborative engagement to define the floor height related directly to the corresponding window height.
optimal shuttering and staging technology, sequencing, concrete lifts, The limited number of big openings are aligned with the imperatives of
no remedial surface work to the concrete. As well as an acceptable the concrete design and construction.
consistent colour variation, programme optimisation, and cost that
aligns with the explained budget equation. Inventiveness / Innovation
There was no budget nor desire to represent this strategically The fundamental attributes of concrete are accepted as primary design
driven response in a decorative outcome. All energy was directed at opportunities. Rather than an exercise in stretching the formal potential
buildability of a single architectural proposition. of concrete, this is an exercise in the optimisation of the true nature of
While there were more cost-effective and practical ways to construct concrete in the full realities of the project context.
the façade, they all had their limitations that would compromise the Shuttering a simple group of concrete columns and slabs for
high-quality finish that was required by both architect and client. A cast the internal ‘building’ is standard frame construction. A direct paint
in-situ ‘liquid-stone’ façade was therefore considered the only available finish to this frame reduces the demand on any follow-on trade and
option to achieve the demanding end result, despite the high risks is forgiving on the concrete quality whilst allowing the texture and
involved, especially in Kimberley. pattern of the formwork to add to the richness of the building finish
The aesthetic success is directly dependent on overall building form, and the expression of how it was constructed.
openings in this form were defined with the Energy Consultant to On the contrary, staging and shuttering of huge areas of free-
achieve optimal climate and light-harvesting objectives. The relentless standing external envelope walling is an unusually demanding challenge.
rhythm of the shutter lines and concrete lifts give proportion to the The contractor has been able to deliver this at to the highest possible
form in the most delicate way, like a fine pin-stripe suit: invisible from standards collectively agreed and was able to constantly increase turn-
afar, precisely crafted from close-up. around times per lift. These are also the benefits of limiting the scope
Specifically focussing on the objectives has resulted in the contractor of activities so that each can receive their proper attention.
delivering a highly refined, unmatched, consistently silky, off-steel
surface finish.
Effect of Concrete on the Architectural Landscape
Concrete is gradually becoming a fashion, a finish of equal appeal to
Sustainability – Green Building Initiatives any other finish, including wallpaper. This project asserts the inherently
The 2.7 m gap between the external shell and the occupied floor plates
authentic nature of concrete as ‘liquid stone’. It is in the tradition that
acts as a thermal ‘duvet’ between the non-insulated external shell and
begins with the Egyptian Pyramids, moves through the heart of European
habitable building with it. Thermal loading on this habitable space is
Modernism and finds its culturally aligned expression in contemporary
successfully buffered. TABS [thermally activated building structure]
Latin and Latin American Architecture. It becomes intensely local
piping in all concrete slabs and roofs augments a mechanically-
and contextual in its reflection of the ‘container and contents’ logic
assisted cross ventilation system to provide seasonal and diurnally
of regional ‘Brakdak’ construction where grass reinforced mud is the
predictable top-up heating and cooling requirements while retaining
precursor to modern concrete technology.
desirable fresh air volumes.
CONCRETE BETON 15fulton awards winner
Significance of the Use & Application of the
Innovation
Innovation centres on the essential nature of the material as an
integrated structure and envelope; essential solidity and inherent mass.
It is acutely purpose driven. As in airplane, ship or bicycle design, the
magic derives from the exclusion of anything other than the essentials.
This is uncommon in the South African and even international context
where complex narrative insists on materials being subservient to
something other than their own natures. This is innovation within the
unrelenting realities of cost, value, performance, and final memorable
and imageable impact.
Sustainability Contribution
In a context of increasing disparity between technological gadgets
aimed at sustainability and the design of the buildings to which they are
applied, this offers direct and total integration. There is no need for any
augmentation to what is essential. Sustainability is totally integrated
into one final whole.
Conclusion
Because concrete has the capacity to be simultaneously structure,
envelope, climatic mediator, final finish and at the same time be thin,
it stands alone in an increasing flood of new material innovations,
each claiming to do some specific that none of the others can. The
building material market is predictably transitioning from segmentation
to fragmentation. s
PROJECT Team
Client: Sol Plaatje University
Principal Agent: Aecom
Main Contractor: Murray & Dickson Construction (Pty) Ltd
Specialist Sub-Contractor: Lafarge
Formwork Supplier: Uni-Span
Editor’s Note: This project was the winner in the ‘Buildings of
>3-storeys’ category and it received a judges’ commendation in the
Architectural Category.
16 NUMBER 156 | MARCH 2019accredited international technical paper
Precast Concrete Panels for
Rapid Full-Depth Repair of CRCP
Maintaining continuity of longitudinal reinforcement.
by Steve Gillen, Daniel J. Gancarz, and Shiraz Tayabji
T
his article describes a recently implemented method for making The Tollway recognized that the repair strategy needed to have minimal
rapid, full-depth repairs of continuously reinforced concrete impact on traffic and maintain a safe work zone, and so it selected the
pavement (CRCP). The method is based on the use of precast PCP repair system to provide:
concrete panels (PCP), and it results in continuous longitudinal
reinforcement throughout the repair area, making it suitable for the
•• Continuity of the longitudinal steel through the repair areas by
matching the steel content of 0.8% in the existing pavement using No.
repair of multiple lanes or large areas with minimal impact on traffic. 10 deformed bars in the PCP and the splice zones, with center-to-
In 2004, the Illinois State Toll Highway Authority (Tollway) started a center spacing of 330 or 343 mm, depending on precast panel width;
capital improvement program that included the conversion from manual and
toll collection to electronic, open-road tolling. The conversion required new,
open-road toll plazas, and these were constructed with CRCP with integral •• Cast-in-place concrete splice zones between the PCP and the
existing CRCP at the ends of the repair area or between precast
treadle frames and loop detectors. To ensure that these features could be
panels within the repair area, with continuity and load transfer
repaired or replaced in the future, the Tollway initiated the development of
established by lapped No. 10 deformed bars.
a PCP pavement repair system capable of maintaining the continuity of the
longitudinal steel in the CRCP over multiple lanes and providing for load
transfer at construction joints.
Repair Plans and Specification
The plans and specification for the repair work included detailed notes
The Tollway has established generic plans and specifications for the
on panel fabrication and panel installation, with requirements for all
PCP system, allowing it to be used to rapidly execute isolated repairs of
materials, shop drawings, quality control, preplacement meetings,
CRCP as well as multiple-lane repairs of CRCP as required at toll plaza
tolerances for removals and placements, smoothness on finished surfaces,
or other upgrades. Under these specifications:
••
and criteria for opening the work zones to traffic. The plans called for PCP
The designer must determine and identify the specific transverse
repairs to be executed in the ramp lane and in Lanes 2, 3, and 4 of the
boundaries of the distressed areas that require a PCP repair in each
expressway. The plans also called for cast-in-place patching, using rapid-
lane; and
setting concrete, in Lane 1 and in the gore area (the divergence zone
•• The contractor must survey the repair areas to determine the between Lane 4 and the ramp lane).
widths, lengths, and number of PCPs for each repair area; design The specification dictated requirements for the concrete used for
each precast panel; and provide an installation plan for Tollway fabrication of precast panels, grout material required under precast panels,
approval. shims and sealants placed at panel joints, and concrete used for splice zone
In 2017, the PCP system was applied to repair localized damage in
multiple lanes of a CRCP. A cast-in-place concrete system appropriate
for single-lane repair of CRCP is described in Reference 1. Continuously Reinforced Concrete Pavement
Continuously reinforced concrete pavement (CRCP) has longitudinal
Project Parameters reinforcement comprising from 0.65 to 0.80% of the gross
Construction of the Illinois Tollway system began in the late 1950s. The concrete section. As with any concrete pavement, reductions in
system now consists of 473 median km of expressway pavements in concrete volume resulting from cement hydration, temperature
northeastern Illinois, mainly in the Chicago metropolitan area. Recent drop, and external drying are restrained by the pavement base,
capital improvement programs have included the reconstruction and resulting in tensile strains in the concrete. In jointed plain concrete
widening of a 8 km section of I-80/I-294, south of Chicago and just west pavement, closely spaced joints prevent tensile strains from
of the Indiana-Illinois border. This section of the Tollway system, also known exceeding the cracking strain. In contrast, CRCP generally has
as the Tri-State Tollway corridor, has an annual average daily traffic of more joints only as required at end-of-day construction locations, at
than 88,000, with about 22% of the traffic comprising commercial trucks. bridge approaches, or at transitions to other pavement types.
A 300 mm CRCP was used to reconstruct four lanes in each direction in Thus, tensile strains build up until transverse cracking occurs and
2004 and 2005. The CRCP was built over a 100 mm asphalt stabilized base the tension carried by the concrete is transferred to the longitudinal
placed over a 300 mm aggregate base. The CRCP was reinforced with reinforcement. Tension is transferred from the reinforcement back
0.8% longitudinal steel content, which was provided using No. 7 bars into the concrete through bond, until the strain in the concrete
supported on No. 4 transverse bars spaced at 1.2 m. again builds up sufficiently to cause cracking. Ultimately, a crack
The pavement section remains in excellent condition; however, the spacing of about 0.6 to 1.8 m results, and the continuous
installation of a retrofitted weigh-in-motion system in all four lanes in reinforcement holds these cracks tight. Generally, transverse cracks
the westbound direction resulted in the saw-cutting of the longitudinal are less than 0.5 mm wide, so traffic-induced shear forces are
reinforcement in the CRCP. This ultimately caused localized failure of carried across the crack largely through aggregate interlock.
the CRCP in all four lanes as well as within an adjacent CRCP ramp lane.
CONCRETE BETON 17accredited international technical paper
backfill. The concrete placements in the splice zones were required to be Pavement removal and precast panel installation was done one lane at
completed during nighttime lane closures, as the pavement sections had to a time, starting in the ramp lane and then proceeding with Lanes 4, 3,
be opened to traffic before 6:00 a.m. the next morning. The specification and 2. The cast-in-place concrete patching in Lane 1 (the lane nearest
called for the concrete in the splice zones to be an approved high-early- the median) and within the gore area was completed on weekends
strength concrete (HESC) or an ultra-high-performance concrete (UHPC). after all precast repairs were done. The steps for the PCP repairs in each
The specification further called for the UHPC to have a 4-hour compressive lane are described in the following sections.
strength of at least 17 MPa and a 28-day compressive strength of less than
138 MPa. Night one
The closure of traffic started at 9:00 p.m. During the repair of the CRCP
Panel design and reinforcement ramp pavement, only one traffic lane had to be closed. During other
The PCP design called for longitudinal reinforcement comprising No. 10 repairs, two traffic lanes were closed between 9:00 p.m. and midnight.
epoxy-coated deformed bars placed at middepth of each panel. The A third lane was closed at about midnight, leaving one lane open to
longitudinal bars were fabricated with threaded couplers at each end. traffic until 5:00 a.m.
This was done to simplify the formwork for the PCP as well as simplify The perimeter of the repair area was marked and the pavement
the design of the temporary panels installed at the end of the first night was cut over its full depth. Additional full-depth saw cuts were made
of PCP placement. The couplers allowed the contractor to install splice within the repair area to ease removal of the interior concrete (the
bars the night that the splice zones were backfilled with either HESC or following night).
UHPC, thus allowing the temporary precast panel between precast All traffic lanes were reopened to traffic by 5:00 a.m.
panels to be a solid section. Temporary panels with notched bases were
required only at the splice zones adjacent to the existing CRCP at each Night two
end of the repair area. The first two traffic lanes were closed at about 9:00 p.m., and the third
The design length of the precast panels was generally 3.2 m, and the lane was closed at midnight. This left one intact lane to carry traffic
design thickness was 292 mm. Leveling hardware was required near until 5:00 a.m. The CRCP in the repair area was removed. The lift-out
each corner of each precast panel, so the working surface of the PCP method was used for initial removal, but the bulk of the repair area
could be adjusted to match the surface of the 300 mm. thick CRCP pavement was removed using an excavator. No damage to the
prior to placement of high-early-strength grout under the PCP. surrounding pavements was observed.
Depending on time available before the pavement had to be opened to Following the removal of the CRCP in the repair area, the exposed
traffic, the contractor had the option of leaving the newly installed PCP asphalt stabilized base was prepared for the installation of the
directly on the base until a subsequent night. Figure 1 shows a plan precast panels:
view of a typical repair area with multiple precast panels. •• At isolated locations where bond between the CRCP and the
stabilized base was not broken, base material was removed with
Splice zone details the concrete pavement. These locations were repaired by placing
The transverse splice zones were designed as 450 mm long. To maintain and compacting a dense-graded coarse aggregate;
continuity of the longitudinal reinforcement from the existing CRCP into
the precast panels, the minimum lap length for the No. 10 bars was set at
•• Splice bar locations were marked on the transverse vertical faces of
the CRCP at each end of the removal area. Using a gang drill, 2 in.
355 mm. As indicated previously, full-depth, temporary precast panels were diameter holes were drilled 405 mm into the existing CRCP. Some
placed in the splice zones during the first night of PCP placement (Fig. 2). of the specified hole locations were too close to the longitudinal
These temporary panels were designed to be removed during the next joints and therefore had to be manually drilled. Other hole locations
night of repair operations, allowing the zones to be filled with HESC or had to be adjusted slightly to avoid longitudinal tie bars that were
UHPC mixtures. not accounted for in the design drawings;
Steel connection at existing CRCP •• After dust was cleared from the drilled holes using blasts of
compressed air, epoxy adhesive was injected into the holes and No.
The repair design also called for 810 mm long No. 10 bars to be
10 deformed bars were inserted;
anchored in the existing CRCP at each end of the repair area. Bars were
to be anchored in 50 mm diameter, 405 mm deep holes drilled •• Vertical surfaces of the CRCP around the perimeter of the removal
horizontally below the longitudinal reinforcement bars in the existing area were cleaned using compressed air, and a form release agent
CRCP, thus resulting in 405 mm bar extensions in the splice zones. The was applied to prevent bonding of bedding grout or splice zone
specification called for the bars to be anchored using an epoxy adhesive backfill concrete to the CRCP surfaces; and
meeting ASTM C881/C881M2 requirements for the class and grade at •• Once the base had been restored, 38 mm diameter foam backer
the ambient air temperature expected during construction. rods were nailed into the exposed base along the expected
perimeter of each precast panel. The purpose of the backer rods
Installation of PCP System was to create a continuous dam that would prevent the bedding
After the contractor completed the final design and submittals had grout from flowing into the splice zone or into the longitudinal
been approved, production of the precast panels began. Tollway joint gaps.
inspectors visited the precast plant to inspect the fabricated panels and
ensure the panels complied with the shop drawings. Once the panels Four steel plates were placed on the prepared base at locations
were cleared for shipment and the Tollway approved the installation matching the leveling screws in each precast panel. After it was
techniques for the precast panels for the I-80/I-294 project, overnight determined that 100 by 100 mm did not provide an adequate
installation of the panels was authorized to begin in October 2017. placement tolerance, 300 by 300 mm plates were used for the
remaining panel placements.
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