AfriSam, a leading construction materials company, has reaffirmed its dedication to the sustainable development of the communities surrounding its operations with the completion of the Verulam Community Hall. This initiative not only showcases AfriSam’s commitment to social responsibility but also highlights its support for local small, medium, and micro enterprises (SMMEs) and the creation of employment opportunities for community members.

The Verulam Community Hall, constructed by a local SMME, stands as a testament to AfriSam’s ongoing efforts to uplift and empower the communities in which it operates. The hall, which has been thoughtfully designed to meet the needs of the community, features a fully equipped kitchen and modern ablution facilities, ensuring a comfortable and functional space for various community activities.

In line with AfriSam’s commitment to environmental sustainability, the Verulam Community Hall incorporates several eco-friendly features. A water tank has been installed to collect rainwater, promoting water conservation and reducing reliance on municipal resources. Additionally, the hall’s surroundings have been enhanced with the installation of paving, providing a safe and accessible area for community members, and a dedicated parking area has been provided to accommodate visitors.

By engaging a local SMME for the construction of the Verulam Community Hall, AfriSam has not only contributed to the economic growth of the community but has also fostered skills development and job creation. The project has provided employment opportunities for local community members, empowering them to contribute to the development of their own community and improve their livelihoods.

Commenting on the completion of the Verulam Community Hall, AfriSam’s Community Development Professional, Senzi Mabaso, stated, “We are proud to have partnered with a local SMME for this project, as it aligns with our commitment to supporting local businesses and uplifting the communities in which we operate. The Verulam Community Hall will serve as a hub for various community activities, fostering social cohesion and providing a space for personal and collective growth.”

AfriSam remains dedicated to its sustainable development initiatives, continuously seeking opportunities to make a positive impact on the communities it serves. The completion of the Verulam Community Hall is a testament to AfriSam’s commitment to creating concrete possibilities for all.

Manufacturing concrete products is an industry segment that faces its own special demands, and AfriSam’s 90 years of experience allows it to take some of the weight of these challenges off its customers.

“Some of the country’s leading concrete product manufacturers (CPMs) have been our customers for over 40 years,” says Adele Wentzel, Sales Manager Cement Manufacturing Gauteng at AfriSam. “Relationships like these give us real insight into their daily concerns, and how we can add value to their operations.”

With its need for efficient production lines and quick cycle times, the CPM segment relies extensively on AfriSam’s Rapid Hard (52,5R) cement and its High Strength (42,5R) cement. Concrete products need to be removed from moulds as quickly as possible, and in most cases there are stringent demands on quality, finish and strength.

“While many customers have applications that need our ‘Rolls Royce’ product – the Rapid Hard cement – there are also segments where their concrete products are better suited to other classes of cement,” explains Wentzel. “Whatever the application, though, customers rely on the AfriSam service team to ensure they receive the right cement and the optimal mix to achieve the best results.”

Among current priorities in the CPM segment is to reduce energy consumption – as steam curing is generally energy intensive. A key resource for AfriSam customers is its Centre for Product Excellence (CPE), which helps find innovative and cost effective solutions. 

“The CPE’s depth of expertise – backed up by sophisticated testing and laboratory infrastructure – means there are specialists available in the field of concrete products,” she says. “One of our initiatives has been a collaboration with a leading admixture provider, combining our skills and products with theirs to find ways to reduce costs for customers.”

These initiatives include focused interventions for customers to achieve strategic improvements in their operational efficiency, she notes. 

“Our ability to provide these value-adds stems from the trust we’ve built over many years within the CPM segment through sustained relationships,” she emphasises. “Throughout the years, we have practically demonstrated our contribution to customers’ businesses, providing a tangible contribution cementing the necessary trust.”

This trust is a vital foundation for a segment faced with varying levels of loadshedding, as CPMs rely heavily on electricity supply for curing concrete products. 

“With our flexibility, responsiveness and qualified specialist advice, we help customers to manage operational uncertainties while still ensuring the highest quality of product,” she says. 

Started in 1934 as only the second cement manufacturer in South Africa, AfriSam has built a 90year legacy of quality and expertise that ranks with the world’s best. 

According to Richard Tomes, Sales & Marketing Executive at AfriSam, this success is driven as much by its technical performance and service, as by remaining relevant and true to the communities it serves. Tomes highlights the leading role taken by AfriSam in driving product quality alongside rising sustainability concerns to reduce carbon emissions. At the same time, the company plays a broader role in strengthening livelihoods and cohesion in the economies and communities in which it operates.

AfriSam’s 90 years began as Anglovaal Portland Cement Company, diversifying early into readymix concrete and aggregate production as Anglo Alpha. Its more recent history saw the business acquired by the global leader in cement, Holcim, before returning to local ownership. He points to the world class skills and infrastructure within the business, an example of which was its Ulco cement factory being ranked as third-best performer in the Holcim group during its time in that stable.

“To reach 90 years old in a sector like construction really demands a constant commitment to being ahead of the game, and to delivering leading edge solutions at the highest level,” he says. This allowed AfriSam to play a central role over the years in iconic structures from Johannesburg’s 50-storey Carlton Centre in the 1970s to the Gautrain in the lead up to the 2010 Soccer World Cup.

The company is today arguably the most trusted name in South Africa’s readymix industry, having retained and enhanced its institutional skills base in concrete technology. This has been vital for the beleaguered local construction sector, where the right-sizing of most large contractors has left them with fewer in-house resources on this front. 

“Our many years in business has taught us more about our broader responsibility, where we are also proud to play an active role as a responsible corporate citizen,” he says. “This ranges from our leading efforts in making cement production more sustainable, to supporting initiatives that build communities and promote social cohesion.”

AfriSam was the first cement manufacturer to launch a ‘green’ cement, through the scientific addition of cementitious extenders to reduce the content of energy-intensive clinker – while not compromising quality or performance. Through its continuous investment in research and development, it has taken South Africa to the forefront of cement technology related to the use of ground granulated blast furnace slag (GGBFS) and pulverised fly ash as extenders. 

Returning to AfriSam’s positive local economic impact over the decades, Tomes highlights the key role played by its cement, concrete and aggregate experts in building the country’s infrastructure to its current levels. 

“Irrespective of economic cycles and other disruptions, we consider it essential to maintain and sharpen our expertise and industrial capacity in service of Africa’s development,” he explains. “Even if economies stagnate for long periods, they can recover if there is a core of critical skills to build the necessary infrastructure.”

In this way, he says, AfriSam is creating the opportunities for communities to build livelihoods, especially in an environment where housing shortages are common. Alongside its leading edge technology, for instance, is its quality Starmix readymix solution – a cost effective product suited for the residential builder, which can be ordered in small quantities.

“We recognise the value of sport in improving lives and attitudes, so have over the years partnered with teams from Orlando Pirates to the Springboks,” says Tomes. “Youth entrepreneurship is another important focus for us, to inspire and empower future generations.”

Taking an unconventional route into the construction sector, EB Construction’s Ben Wagner has built a solid contracting business that serves residential, commercial and industrial clients. Partnering with responsive and trustworthy firms like construction materials specialist AfriSam has been one of his secrets of success.

Wagner studied mechanical engineering and started his career in the motor trade. However, his work took the direction of building planning and management, and he soon developed a strong interest and skill set in construction. With his entrepreneurial flair, it wasn’t long before he decided to go his own way, and started out in what he describes as handyman work.

“When my wife and I started a family, I didn’t want to be boxed into a job that demanded long days that would not allow me to be part of my children’s growing up,” he explains. “I needed to be more in control of my time and destiny, and I started EB Construction to give me that.”

The jobs started off small, he says, but soon grew to include substantial home renovations and new builds. Much of the early insurance-related work dealt with fire-damaged homes, which usually involved extensive demolition and reconstruction. He also operated a plumbing team that would deal with issues like burst geysers and the resultant damage.

“Within about three years, I was able to move out of insurance work and take on my own residential, commercial and industrial projects,” he said. A meeting with AfriSam Sales Manager Adele Wentzel opened up an important supply link for cement and concrete. He acknowledges that any business in construction is highly sensitive to the cost of its inputs, but explains that this cost cannot be reduced to the simple price of products.

“As EB Construction moved into larger residential, commercial and civils projects, we went beyond purchasing AfriSam’s bagged cement and into procuring readymix and other construction materials,” says Wagner. “Our projects became more complex, and this meant stricter timeframes and an even closer focus on quality – to mitigate project risk.”

He notes that his company had built its reputation on its attention to detail and on the lasting quality of its workmanship. From its base in Johannesburg, its footprint of projects grew quickly to include working on buildings and infrastructure in quite remote areas of the country.

“It soon became clear that not many of AfriSam’s competitors could meet the high level of its service, as well as the breadth of products and solutions,” he says. “Our larger projects – especially those located some distance from the main urban centres – needed close collaboration combined with flexibility, while not compromising on quality.”

The relationship grew on the strength of the two companies’ shared commitment to the highest standards – whether in service, materials or final construction. Wagner highlights how much a contractor relies on supply partners’ ability to communicate and plan well – as well as to adapt plans when necessary.

“We are often in unusual situations which require both the contractor and supplier to go the extra mile,” he says. “Building in a sensitive wildlife area, for instance, would require readymix deliveries to meet certain unexpected conditions; AfriSam accommodates these in its stride, right from the call centre through to management and truck drivers.”

AfriSam’s depth of expertise – including its Centre of Product Excellence – and its choice of solutions for different applications, has also made a valuable contribution to EB Construction’s growing volume of contracts. At a recent project in the rural hospitality industry, the work included demolition, infrastructure, construction and structural engineering.

“We built the roads with interlocking pavers, so made use of AfriSam’s Roadstab stabilising cement in the sub-base, as well as AfriSam’s StarBuild 32 5N and AfriSam’s All Purpose Cement 42,5N for grouting on the paving,” he says. “AfriSam was also able to supply the readymix for the culverts and bases, and for the off-shutter concrete structure for a wedding venue.”

In addition, this project included a large steel structure over a dam, which required numerous large concrete plinths. AfriSam supplied about 36 m³ of readymix for each plinth, despite the considerable distance to the site. Wagner says he could also rely on the quality of AfriSam readymix, so there were never any issues when engineers required density tests, for example.

Wentzel emphasises that working with EB Construction has been positive for various reasons, including the regular communication during projects, and the feedback they constantly provide.

“Our long working relationship with EB Construction is a good example of how we position our business,” she says. “Good working partnerships are built on trust, which we develop over years of meeting our promises.”

AfriSam Roadstab Cement is a specialised, high quality composite cement engineered specifically for road stabilisation tasks. Available from leading construction materials supplier, AfriSam, this cement is designed to optimise the properties of soils used in road construction, notably by reducing their plasticity and enhancing their strength and stability. 

The formulation of AfriSam Roadstab Cement aims to address the vital requirements of road construction projects by ensuring the durability and stability of road bases. The unique composition contributes to its efficacy, particularly in working with challenging soil types like clay. This addition not only improves the workability of the cement in various soil conditions but also facilitates easier handling and application during the construction process. 

Stabilisation using cement also improves the properties of granular materials. When cementitious material is mixed with granular material in predetermined portions and is adequately mixed, compacted and cured, a bound material with significant strength is the result.

An important advantage of AfriSam Roadstab Cement is its extended open working times as it provides ample time for the proper placement and compaction of materials. This type of flexibility in the construction timeline is crucial for achieving optimal results in soil stabilisation, ensuring that the stabilised layers meet the required standards for strength and durability.

Tailored to meet the demanding needs of road stabilisation, AfriSam Roadstab Cement offers superior performance across a wide spectrum of road material types. Its consistent quality and ability to reduce soil plasticity make it an essential component for constructing durable and stable roads. 

By enhancing the strength and stability of road bases, AfriSam Roadstab Cement plays a critical role in the longevity and reliability of road infrastructure.

AfriSam All Purpose Cement is recognised as a fundamental component in various construction applications, embodying versatility, reliability, quality and affordability. This premium product is designed to meet the needs of a wide range of construction projects from large-scale commercial and infrastructure developments to smaller residential and DIY projects. 

Ease of use and the ability to produce consistently excellent results make AfriSam All Purpose Cement a preferred choice among construction professionals. Manufactured in AfriSam’s state-of-the-art facilities, where quality management systems of the highest standard are a priority, the cement complies fully with the SANS 50197 specification for common cements. Its constant monitoring and maintenance of composition ensure it delivers high quality performance within the 42,5N MPa strength class.

The addition of fly ash and slag, where indicated, to this specially developed cement improves the overall workability of concrete as fly ash introduces microscopic spheres that effectively reduce the water demand of mortars and plasters. This makes the mix not only more cohesive but also enhances its ease of application. The improvement in texture and consistency ensures a superior bond in plaster applications, attributed to the increased stickiness of the mix. Consequently, this leads to a more efficient application process and results in smoother, more durable finishes in construction projects.

The unique composition of AfriSam All Purpose Cement addresses the industry’s need for a cement that reduces heat hydration in mass concrete works and enhances concrete’s resistance to chemical attacks including sulphate, chloride and exposure to soft water. 

The use of AfriSam All Purpose Cement in projects also significantly improves resistance to alkali-aggregate reactions and decreases the permeability of concrete in water-retaining structures, contributing to the sustainability and longevity of these projects.

AfriSam All Purpose Cement is suitable for a wide range of applications, from structural concrete and residential projects to brick and block making, as well as plaster mortar and shotcrete.

The new DHL Express Service Centre in Waterfall City is a prime example of modern construction that harnesses the functionality and aesthetic appeal of concrete. This tenant-driven project, developed by SOM for Portimix Pty Ltd and used by DHL Express, showcases a blend of office space and a substantial warehouse, strategically located to optimise logistics operations.

Abbeydale Building & Civils undertook the construction, with Empowered Spaces Architects managing the project. EMArchitecture provided the architectural design, while structural design was the forte of Struxit Projects. The project is distinguished by its innovative use of concrete, supplied by AfriSam, which was critical to meeting the high standards set by DHL.

The building’s design is notable for its highway-facing façade that presents a bold, linear impression with wavy concrete columns. These columns, resembling waves, align with DHL’s core business and are visible from one of Africa’s busiest highways, the N1. The office frontage, combined with the functionality of the warehouse, reflects a design that is both aesthetic and efficient. The warehouse was specifically designed for high-volume parcel throughput, ensuring rapid loading and unloading processes, crucial for DHL’s operations. The uninterrupted operation flow was made possible by the by removing all columns within the operational floor and achieving a 47 m clear span within the warehouse.

As a P-Grade building, the DHL Express Service Centre stands out for its superior quality, modern amenities and a striking façade that enhances DHL’s branding. The design also aimed for a timeless appeal, ensuring the building remains fashionable and appealing for decades.

Concrete played a pivotal role in this project, not just in terms of structure but also in aesthetics. The distinctive V-shaped columns were created using custom-designed steel shuttering, requiring a highly flowable concrete mix with a reduced aggregate size to achieve the desired finish. A strut and tie structural system design was implemented to accommodate the exaggerated angles on the slanted column façade. The strut and tie design concept uses the best properties of each structural material. Compression forces are resisted and transferred using concrete, and the tension forces are transferred through the reinforcement steel. The combination of these two properties in the concrete and reinforcing steel enabled the elegant and durable slanted column design of the DHL facade. Slanted concrete columns, along with the external elements of the building, required meticulous planning and execution.

Less obvious, but equally impressive concrete structural element within the building are the book end concrete walls, cantilevering 5 m from the building while still supporting floors from above. The large cantilevers could be achieved by using the mechanism of Vierendeel Action within the concrete wall. The concrete and steel used within these walls were carefully planned and detailed to activate the Vierendeel Action and produce the impressive cantilevering walls.

The structural design technique used within the mentioned concrete elements is not often used in conventional concrete building or designs, which makes the use of the concrete in this building truly exceptional and unique.

The warehouse’s concrete floor was constructed with large panel floors to a FM2 specification, ensuring durability and supporting efficient logistics operations.

The design of the building also focused on energy efficiency and sustainability. The strategic placement of horizontal fins and high performance glass reduced cooling costs and glare, while the potential for solar panel installation aligns with DHL’s sustainability goals. The concrete design was critical in achieving these objectives, with AfriSam providing a tailored mix for optimal performance.

The DHL Express Service Centre in Waterfall City stands as a testament to the capabilities of concrete in modern construction. Its design and execution reflect a synergy between aesthetics, functionality, and sustainability, setting a benchmark for future construction projects in the logistics sector.

It was a sombre tone at this year’s annual AfriSam Budget Breakdown event, but sales and marketing executive Richard Tomes reminded stakeholders that the company’s 90 years in business should be an inspiration that the construction sector remains so resilient.

AfriSam’s Executive Chairman Eric Diack agreed the company had seen many ups and downs, and hailed the Johannesburg event as an important forum for AfriSam and its stakeholders to gain vital insights to chart the path forward.

A regular contributor to the Budget Breakdown, Econometrix Chief Economist Dr Azar Jammine highlighted that the construction and building industries were still in the doldrums, with little sign of emerging from it soon. Dr Jammine pointed to the low economic growth rate and the poor level of gross fixed capital formation as the key culprits of the challenging milieu. While the Budget Speech contained a theoretical commitment by government to focus on infrastructure, there was not much to boost confidence.

He noted that private sector capital investment in South Africa had shown some improvement, but this was mainly in machinery and equipment. Investment in construction – including civil engineering – and building had declined 40 to 45% over the past decade. The slight recovery in residential building between 2020 and 2022, as a result of the Covid-19 pandemic, had faded.

“This is horrific, and there is little sign of it recovering,” he said. “The big loser is in the commercial space, which has fallen by 80% in terms of plans passed.”

Employment in the construction industry also continued to drop, and isnow 40% down from 2019 figures. The sector’s contribution to national employment is today only about 4,5%, having been over 6,5% around 2017.

“No other sector in the economy has been performing as badly,” he said. This was also reflected in the retail sales at builders’ merchants, which now ranked as the weakest segment of the retail sector.

Dr Jammine reiterated that crime was also a central factor in holding back progress in the construction industry, and was encouraged by the Business Leadership South Africa’s workstreams to work with government on energy, transport and crime.

“I don’t need to remind members of this audience of the debilitating effect that the construction mafia are having,” he said. “I only hope that government will listen to the private sector and involve them more in finding the solutions.”

With the ‘semi-gration’ of many South African professionals to the Western Cape, he noted that this province had recently taken the lead over Gauteng in terms of residential building plans passed. There had been a slight rise in numbers in Gauteng recently, however, which may point to a revival.

According to Richard Tomes, AfriSam Sales and Marketing executive, the insights from Dr Jammine confirmed that the construction industry will remain under pressure for some time.

“However, what we can learn from AfriSam’s 90-year legacy is that the industry is very resilient,” he said. “Over the past 90 years we have seen good times, and we have also survived through extremely tough times.”

He said he believed the construction sector – as with AfriSam – will come through this challenging period and will continue to create concrete possibilities for South Africa.

“As AfriSam, we look forward to being the construction industry’s partner of choice through thick and thin,” he said.

As the important mineral component of its cement, limestone will soon be mined from a new deposit by AfriSam’s Ulco cement plant in the Northern Cape. 

The relocated quarry will be capable of providing security of supply for about 40 years, and will need to deliver around two million tons of limestone to Ulco each year. According to Gavin Venter, Manager Saldanha and Strategic Projects at AfriSam, the enabling infrastructure for this quarry has been significant. 

“After conducting a number of wide-spaced prospecting campaigns – as well as close-spaced drilling across 100 hectares – we identified the best limestone reserves on our mining right on the opposite side of the R31 national road, which runs between the new site and the plant,” says Venter. “This means it is necessary to construct tunnels under the road to facilitate safe access between the new quarry site and the existing plant. Adding to the complexity is that the large Gamagara water pipeline runs parallel to the road.”

The R31 road between Kimberley and Postmasburg carries high volumes of large ore trucks and abnormal load mining equipment. It will be diverted in early 2024 to accommodate this traffic for about six months while extensive excavation and civil engineering work is undertaken to construct the tunnel underpass system. 

“In compliance with the road authority’s requirements, the tunnels will traverse the full 32 metre width of the road reserve – to allow for future road widening, in addition to the pipeline servitude,” he says. “The two tunnels themselves will be over 50 metres in length, and will be separated to enhance safety as there will be counterflow traffic to and from the plant.”

The 5 metre high by 5 metre wide tunnels will be excavated to 12 metres below the R31 road level, and constructed as large culverts with steel reinforced in-situ cast concrete. The design work ensured a tunnel alignment to suit the future possibility of an in-pit crusher and conveyer belt. If such an option was financially justified in future, it would provide an alternative method to feed crushed material to the existing pre-blending stockpiles. 

The civils works also has to accommodate the 700 mm diameter Gamagara pipeline, supplying the Northern Cape with water from the Vaal River. To avoid the risk of disrupting this water supply, a concrete bridge has been constructed parallel to the existing pipeline, inside which a new 100 metre stretch of pipeline was laid. 

“This provided the necessary support for the pipeline so that excavation and controlled blasting can be conducted underneath,” he explains. “As a further precaution, there is also a 100 mm per second vibration limit applied to any blasting activity around the pipeline bridge.”

Work on the pipe bridge began in late 2022 and excavation work began in the third quarter of 2023, creating the initial slot on the south side of the R31. Once the road is diverted, the excavation of the tunnels can begin and this is expected to be complete by end February 2024. This will be followed by the construction of the two tunnels. The supply of readymix – which will include AfriSam cement – will come from Kimberley, about 80 km south. With ambient daytime temperatures that can rise to 40 degrees, this will require careful use of admixtures to achieve the required slump by the time readymix trucks arrive on site.

“Mining is expected to begin in the second half of 2024, with an unusual topography in which the quarry will be mined into an escarpment,” says Hannes Meyer, Cementitious Executive at AfriSam. “Transportation of mined material is therefore mainly downhill. With the gradient of the haul road slopes limited to 5 degrees, AfriSam’s truck-trailer combinations have been designed to be much more energy efficient than conventional off-road dump trucks.”

AfriSam commissioned various specialist studies as part of its environmental impact assessment (EIA), to investigate the new quarry’s potential effects on wetlands, terrestrial life, hydrology, heritage and traffic. Authorisation was granted to mine in the vicinity of water features on the proposed mining area, with a seasonal drainage line that had to be diverted to avoid the exit slot of the new haul road.