Increasingly hemmed in by urban development, AfriSam’s Jukskei quarry and ready-mix plant has been applying stringent controls and standards to remain an environmentally friendly neighbour while juggling efforts to withstand a stagnating construction sector.
Click to download and read pdf
When the Jukskei quarry began operation some seven decades ago, its location was decidedly rural. However, the surrounding area of Midrand developed rapidly, and in the past 10 to 20 years in particular, various neighbours have closed in around the Jukskei aggregate and ready-mix operation.
“Today, we are surrounded by residential, commercial and industrial developments,” says Zielas Du Preez, regional manager for AfriSam’s Gauteng aggregates operations. “This process, alongside the changes in environmental regulations, means we are constantly improving the way we work.”
Noise, dust, blasting and water quality are among the most important areas of the company’s focus. To minimise the impact on surrounding areas, noise monitoring is regularly conducted. Measuring points around the operation feed back information on how noise is being dissipated. The data populates an annual survey where performance can be checked.
With the crushing of blasted granite into various aggregate products, and the constant movement of trucks and other equipment, dust is inevitable. A number of strategies to control dust are applied, Du Preez explains. These range from sprays inside the high-speed crushers, activated on start-up, to water spray systems along the roadways to suppress air-borne dust. The success of these activities is measured with the monthly analysis of Dust Fallout Buckets, strategically placed in numerous positions around the operation. The collection and analysis of these buckets is performed by an independent consulting group.
Monitoring of water quality is also critical, both upstream and downstream of the pit. This is done at seven sample points, ensuring that any seepage from the quarry is not negatively affecting water quality.
Controlling blasts in the quarry leverages the latest technologies to keep noise, vibration and other impacts low. Du Preez notes that electronic blasting has revolutionised the quest for more effective and better controlled blasts. “Using electronic blasting technology and blast planning software, we can simulate each blast within optimal parameters,” he says. “We keep air blast, vibration and fly rock to a minimum, while still achieving our required fragmentation for the crushers.”
Adding to this, operations manager Kevin Naidoo says, “Ready-mix is a high-speed game. It has become vital for material suppliers to get smarter while remaining environmentally conscious. The poor state of the market, and the continuous entry of new players, only adds more pressure for us to be faster and better, but this cannot be to the detriment of the environment.”
Naidoo highlights that quality remains a critical factor for ready-mix in the construction sector, as lives depend on concrete performing as expected. He also emphasises the role of technology and how Afrisam’s pursuit of excellence means that systems and technology should always be advancing to harness productivity while prioritising control. He believes the increased risk of using ready-mix concrete suppliers without the necessary quality controls encourages customers to come back to AfriSam.
“Despite the weaker demand seen by industry, our standards remain high,” Naidoo says. “This gives our customers the confidence they need in the quality of our systems and our products. Customers rely on that from us. They know that our affiliations demand rigorous auditing – both internal and external – of our operations. This is vital in managing the considerable risks inherent in their projects, especially in infrastructure and large building projects.”
Managing the tight economic environment also means getting the most of operational assets, says Naidoo. He highlights the importance of constantly checking basic elements like accurate measurement of material and plant equipment. “Digital communication technology is among the tools that are embraced by the group. With a world-class computerised batching system, the plant’s scale calibrations are conducted internally every two weeks. “In another such application, variances in plant performance can be communicated directly to managers’ mobile phones,” he says.
An external service provider also does a full range of calibration tests every month. These are all conducted within SANAS specifications. “At Afrisam, though we are in the business of making business, we concern ourselves with every aspect of the plant, and that includes people. We have included a public engagement element to the blasting programme, where neighbouring properties are kept informed about certain blasting activities through a roll-call list. In pursuit of safety, we also engaged with the helipad next door to declare the quarry area a no-fly zone during blasting.
“All these extra measures have been applied in the quarry including lighting, surveillance and security, to ensure that as human settlements encroach ever closer to the plant, Afrisam can still continue productions without encroaching on the lives of its neighbours,” concludes Du Preez.
All 40 of Afrisams ready-mix operations nationwide are certified for the ISO 9001 quality standard. They are also fully accredited members of the Southern Africa Ready-Mix Association (SARMA).
