Alternative building blocks from alien trees

The nonCrete Team. Pic by nonCrete_WEB
The nonCrete Team. Pic by nonCrete_WEB

Bricks made from alien trees, vaulted floors and ceilings … innovative design for Cape housing project addresses environmental issues and climate change, using old-school technology to reduce the fossil fuel footprint of construction.

An innovative collaboration between the Cape Town-based company nonCrete, the Institute of Technology in Architecture at ETH Zurich, Switzerland, and the South Africa’s Council for Scientific and Industrial Research (CSIR) has created a potentially game-changing design and construction methodology for housing alternatives.

The methodology is being implemented in a three-year project co-funded by the WWF Nedbank Green Trust and the CSIR’s Circular Economy Demonstration Fund. “Alien biomass to housing” started in April 2024 in partnership with nonCrete, the non-profit organisation Phuhlisani, and the Elandskloof community near Citrusdal in the Western Cape.

The Elandskloof community is on a farm that has been restored to approximately 500 inhabitants under the land reform process. They were dispossessed of their land in 1962 by the apartheid government, and it was returned to them in 1996. Nearly 30 years later, the residents are still living in informal dwellings.

Finely chipped alien biomass is included in the nonCrete bricks. Pic by nonCrete_WEB
Finely chipped alien biomass is included in the nonCrete bricks. Pic by nonCrete_WEB

Pilot project

The project is a potential life-changer for the Elandsklowers, and they are engaged in every stage, starting with a pilot 8m x 8m crèche to demonstrate the non-Crete method.

Stephen Lamb from nonCrete explains, “The bricks are the size of conventional bricks, but are made from the biomass of local alien invasive trees that are felled from the riverbanks, put through a chipper, and combined with a specially developed binder to create a low-carbon material”.

Elandskloof is situated in the valley of the Groot Winterhoek Strategic Water Source Area. It supplies water to Atlantis, Ceres and Saldanha and is one of 22 key water sources in South Africa. Its riverbanks are full of black wattle, and removing alien invasive trees within a 50 km radius will greatly impact freeing up available fresh water.

Using the alien invasive biomass, the nonCrete method significantly reduces the amount of stone, sand and cement used in standard concrete bricks. The bricks also have a higher degree of fire resistance and thermal qualities, helping to keep homes warm in winter and cool in summer.

In addition to the bricks, nonCrete has developed a vaulted floor and roof system in collaboration with the CSIR and the head of the Institute of Technology in Architecture at ETH Zurich, Prof Philippe Block.

Peter Mafuwe a member of the One-Nil construction team who does the material mix design of the vaulted floor. Pic by nonCrete
Peter Mafuwe a member of the One-Nil construction team who does the material mix design of the vaulted floor. Pic by nonCrete

Strength through geometry

“This exceptional design follows the motto of ‘strength through geometry. It is inspired by the arches constructed by master builders in the Gothic cathedrals of Europe that are still standing 500 years later and which we are using in European design”, Block explains.

“The floor and roof system significantly reduces the amount of steel and concrete required and has 75% lower carbon emissions than a conventional concrete flat slab. It complies with Eurocode load requirements for multilevel construction in residential, office and other buildings”, he says.

Once the demonstration crèche has been constructed, the Elandskloof Communal Property Association members can decide whether to use the method to build their homes.

The head of the Institute of Technology in Architecture at ETH Zurich, Prof Philippe Block. Credit Elisabeth Real_WEB
The head of the Institute of Technology in Architecture at ETH Zurich, Prof Philippe Block. Credit Elisabeth Real_WEB

“We are currently helping facilitate negotiations with the municipality and the provincial and national departments for the application of the housing subsidies to pursue the larger housing project”, says Phuhlisani’s David Mayson.

The plan involves on-site training of community members in alien invasive tree clearing and wood chipping, brickmaking and construction, which would create self-employment opportunities for community members.

 “We’re excited to see how catalytic this low-emission building system can be as it has vast potential and is increasingly gaining ground in research and construction locally and internationally”, says Poovi Pillay, Executive Head of Corporate Social Investment at Nedbank.

“The methodology has the potential to be duplicated across the country, starting in Elandskloof, and replace conventional, carbon-heavy building materials and practices. What is so effective is that carbon absorbed by the trees is locked into the buildings”, says Pillay.

“Our goal is to share this technology and acquired knowledge with South Africa and, where requested, to train people to build their own houses in all areas with an abundant supply of alien invasive tree species, which applies to many parts of the country,” says Lamb of nonCrete.

“We have been collaborating with One-Nil Construction, led by Grabeth Nduna, the CSIR and WWF SA. Nduna and nonCrete’s Peter Mafuwe and Mojalefa Thelingoana, have been pivotal in creating the material mix designs we require”, explains Lamb.

“NonCrete’s methodology aligns with the urgent need worldwide to change how we design and build our structures and disrupt the concrete, steel and carbon-intensive construction technologies for architecture. The exciting part is that with this Elandskloof project, we are taking a great idea and making it happen”, remarks Block.

Original article by Heather Dugmore, edited by Chris Chapman

Thinking “buite die blikkie”

CP Firewood owner Clinton Fielies holding up hig bags of wood
CP Firewood owner Clinton Fielies holding up hig bags of wood

Clinton Fielies was born in the Garcia forestry village 39 years ago. He grew up in one of the classic wooden bosbou (forestry) houses around the corner from where he lives today with his wife and children. After working for MTO as a chainsaw operator in the Western Cape for many years, he says he decided to think “buite die blikkie” (outside the box).

With MTO’s help and ongoing advice he registered his business, CP Firewood. Today he employs about 10 people and supplies packs of firewood to shops and restaurants in Riversdale, and his Garcia community.

The SA forestry and forest products sector marks 15 years of transformation

The Forest Sector Charter Council (FSCC) marks a decade and a half of overseeing and reporting the forestry and forest products sector's progress in achieving its Broad-Based Black Economic Empowerment (B-BBEE) codes of good practice targets.
The Forest Sector Charter Council (FSCC) marks a decade and a half of overseeing and reporting the forestry and forest products sector's progress in achieving its Broad-Based Black Economic Empowerment (B-BBEE) codes of good practice targets.

The Forest Sector Charter Council (FSCC) marks a decade and a half of overseeing and reporting the forestry and forest products sector's progress in achieving its Broad-Based Black Economic Empowerment (B-BBEE) codes of good practice targets.

The B-BBEE Act aims to advance economic transformation and enhance the economic participation of black people in the South African economy. The FSCC was established through the Forest Sector Code. Its mandate is to oversee transformation in the forestry sector's growers, contractors, fibre (pulp and paper), sawmilling, poles and charcoal industries.

The council consists of industry, government, community and labour representatives. It reports to the ministries of forestry, fisheries and the environment (DFFE) and trade, industry and competition (DTIC). It is chaired by Nelly Ndlovu, CEO of Mondi Zimele.

Forestry South Africa (FSA), Sawmilling South Africa (SSA), and other industry bodies encourage its members to continue reporting on B-BBEE and to share their certificates and underlying reports with the FSCC. The council's annual status report is the only truly objective means of assessing transformation in the sector, and it is critical to prevent selective and biased reports or generalisations about the sector from being made.

The facts

The South African forestry and product sector contributes around R39 billion to the economy and provides employment for around 150,000 people.

Speaking at the anniversary event celebrating the progress made in 15 years, FSCC chairperson Nelly Ndlovu said transformation in the sector "has not been a finite destination but a journey, lengthy, and at times difficult. It is a process of real change".

This is evident in the industry moving from beginning at Level 6 to achieving Level 3 in 2023 and again this year.

Itumeleng Langeni of MTO, Khozi Mavimbela of the FSCC and Busi Mnguni of FSA's small growers group at the 15th anniversary celebration
Itumeleng Langeni of MTO, Khozi Mavimbela of the FSCC and Busi Mnguni of FSA's small growers group at the 15th anniversary celebration

Discussing the sector's progress, FSCC Executive Director Khosi Mavimbela noted that in 2009, it committed to improving its B-BBEE track record. "The sector, comprising several forestry landowners and producers of sawn timber, pulp and paper, and charcoal, has sought to include black South Africans through meaningful economic participation", she said.

Mavimbela noted that while there has been fluctuating and inconsistent reporting in the past, there has been a significant rise across the three categories of enterprises:

Reporting MLEs grew from three in 2009/2010 to 35 in 2023/2024. In 2009/2010, five QSEs submitted reports, while the number of reporting EMEs grew from 19 to 100.

Scorecard progress

Since 2009, the number of reporting entities across the enterprise size categories has increased from 27 to 191.

The sector has made notable progress across the five B-BBEE scorecard elements between the 2009/2010 and 2023/2024 reporting periods. However, when considering the sector's overall performance, some companies have met their targets but only exceeded them in one of the five elements.

  1. Ownership: increased from 11.6 to 18
  2. Management control: 9.6 to 10.1 (when combined with employment equity)
  3. Skills development: 7.95 t o14
  4. Enterprise and supplier development (preferential procurement): 28.5 to 39
  5. Socio-economic development has exceeded the target score 5 by 2 points since 2009.

MLEs moved from Level 5 in 2009/2010 to Level 3 in the recent reporting period. QSEs progressed from Level 3 to Level 2, while EMEs moved from Level 4 to Level 2.

Sharing success

Several success stories of transformation and socio-economic development were championed at the 15th-anniversary event in Sandton, Johannesburg, on 9 October.

The Forestry Sector Charter Council marked a decade and a half of overseeing and reporting the forestry and forestry products transformation progress
The Forestry Sector Charter Council marked a decade and a half of overseeing and reporting the forestry and forestry products transformation progress

Delivering the keynote address, Bernice Swarts, Deputy Minister of Forestry, Fisheries and Environment, said, "I believe that the forestry sector has developed resilience and has often course-corrected to achieve its various milestones, not least of which being the upliftment of employees, communities, and the many stakeholders it engages.

"Because of its national reach, it plays a key role in tackling our country's triple burden of unemployment, poverty, and inequality, especially in rural areas where opportunities are scarce".

A panel discussion, chaired by Talk Radio 702 presenter Gugu Mhlungu, reviewed the milestones and considered solutions for more inclusive growth, sustainable practices, and enhanced community development.

The panellists were:

They shared their thoughts and experiences on transformation and empowerment.

Grassroots upliftment

A series of videos were shared during the event. Forestry contractor Zinhle Mbuyazi explained that she took over the family business from her father, drawing inspiration from his passion for forestry. She has thrived and encourages young women not to give up. "If you have your brain and heart, you will succeed," she said.

Another example was the Komasi Woodwork Project in the rural community of Weza, KwaZulu-Natal, supported by a local sawmill. Locals learn essential woodworking skills through the initiative and refurbish desks for underprivileged schools.

She is Forestry

The She is Forestry initiative, backed by FSCC and FSA, encourages women in business and students, graduates, scientists, and contractors to share their personal stories. The videos are welcomed by girls in rural schools because they expand their horizons and inspire them to overcome self-doubt, peer pressure, and life-changing teenage pregnancy.

"You can live from the soil. You can educate your children, provide for them, and have a home. All because of the soil. The soil changes everything," said timber farmer Rejoice Shozi, who took over the family timber-growing business when her mother passed away in 2015. Shozi is one of 3,600 small timber growers who gained practical support from a corporate forestry programme.

Reflect and adapt

"FSCC sees 15 years of transformation as an opportunity to do more than simply celebrate the achieved milestones. It is the chance to reflect on the lessons learnt and adapt our approach appropriately to capitalise on the transformation opportunities ahead of us", said Makhosazana Mavimbela, FSCC Executive Director.

The Shire Eco Lodge and nursery focuses on sustainability

Rob Scott uses the Wood-Mizer to cut wood for his building and furniture projects and custom orders
Rob Scott uses the Wood-Mizer to cut wood for his building and furniture projects and custom orders

Rob Scott, owner of Shire Eco Lodge near Stutterheim, says the curved shape of the chalets is unlike standard timber buildings and posed so many problems that it took over a year to complete the shell of the first lodge.

The design of the chalets takes its cue from nature. "I wanted the design of the chalets and their location on the margins of the indigenous Xholora forest to be a win-win for all", Rob explains.

Construction started in 2004, and the first chalet was up and running in 2008. The 20-acre Shire Eco Lodge and indigenous nursery is owned by entrepreneur Rob Scott and his family in South Africa's Eastern Cape Province.

Recalling scenes of the film version of the fertile vales of the shire in JRR Tolkien's The Lord of the Rings, the Shire Eco Lodge is home in the peaceful afro-montane forests of the Amatola mountain range. The rich trove of waterfalls, mountain streams, ancient yellowwood, stinkwood and lemonwood forests, surrounded by pockets of fynbos, leaves an indelible impression on visitors. 

An inside view of a chalet built by Rob Scott
An inside view of a chalet built by Rob Scott
Rob Scott in his furniture factory
Rob Scott in his furniture factory

Lessons learnt

The curved A-frame timber chalets are uniquely designed and built. Rob recounts several obstacles they had to overcome because of inexperience. These included timber bending techniques, the value of bracing, bent timber breaking and bending glass windows.

"My father, Hamish, supplied the solution to the breaking problem. Laminating thin strips of wood together. This is a fascinating process and has, in fact, become an art. It worked well and is now used for other parts of the building's anatomy", explains Rob.

"Once all the laminated ribs are in place, the wall planks are fastened over them in layers, moving upwards as you go. Once the walls are complete, the roof ribs (about 50 laminated bow-shaped beams) are attached to them, giving the roof a curved shape and Asian-like appearance.

"It was then time to start the interior work, which also took time because all the walls, cupboards, etcetera had to be profiled in the curved shape of the walls. There was a new lesson every day. I became an electrician, plumber and painter in a few months."

Wood-Mizer

Rob's reliance on buying sawn timber from suppliers sparked the idea of getting a sawmill to produce sawn timber. It was further strengthened by the uncommon widths and thicknesses needed for the curved and bent components of the chalets.

He decided to invest in a Wood-Mizer LT15GO portable sawmill, which lets him move it to wherever it's needed to cut fallen hardwoods and invasive alien trees.

Some of the blocks, slabs and boards are sold as is. The bulk of the sawn wood goes to Rob's furniture workshop. It is supplemented with heavy, fine-grained spruce stringers sourced from Mercedes-Benz in nearby East London. He uses the wood to build custom furniture for his projects and discerning customers nationwide.

Shire Bulbs is an indigenous nursery selling bulbs, plants and trees across South Africa
Shire Bulbs is an indigenous nursery selling bulbs, plants and trees across South Africa

Shire Bulbs nursery

A brief stint at a plant nursery during a gap year in the UK kindled Rob's passion for botany, laying the foundation for the start of Shire Bulbs in 2003.

The Shire Bulbs' initial successes quickly duplicated into further expansion, with the current bulb production site now comprising four shade houses and expansive open beds. It produces over 150 species of indigenous bulbs that are shipped to customers worldwide. The international acclaim is proof of Shire Bulbs' successes.

But it's about far more than the monetary value of bulbs for Rob. The business partners with Fruit and Trees for Africa, a Non-Profit Organisation that addresses food security, environmental sustainability, and greening.

"Many of the plants we grow are threatened, and so in addition to the conservation and protection of wild populations, we have prioritised the conservation of the rarer species through cultivation", he says.

Our guests get to experience this unique location to revitalise tired spirits. At the same time, The Shire and local communities benefit from tourists visiting and job opportunities created," Rob continues.

The unique chalets at the Shire Eco Lodge blend into the forms and shapes of their environment
The unique chalets at the Shire Eco Lodge blend into the forms and shapes of their environment
The Shire Eco Lodge is in a peaceful valley near Stutterheim in the Eastern Cape
The Shire Eco Lodge is in a peaceful valley near Stutterheim in the Eastern Cape

Organic farming

Organic farming is another arm of Rob's vision to harness business as a tool for greater sustainability, community upliftment, and self-reliance. His mother, Monica, is his partner in this part of the business, which produces organic fruits, vegetables, and crops that are sold and delivered free to nearby communities that need fresh produce.

Sawdust and chips from the furniture shops are also used as animal bedding for Rob and Monica's geese and duck flocks, allowed to roam free to rid the crops of pests. The rest of the waste is sold to nearby farmers, who use it to improve the health and well-being of their animals.

"We have an abundance that we like to share with the community to ensure that they also benefit from our bounty," Rob says, smiling.

Weston Agricultural College wins the Forest Rehabilitation Challenge

The Weston Agricultural College boys celebrate their victory in the tree planting challenge at Ferncliffe forest
The Weston Agricultural College boys celebrate their victory in the tree planting challenge at Ferncliffe forest

Husqvarna recently teamed up with a conservation NGO and two prominent KwaZulu-Natal (KZN) schools to host a Forest Rehabilitation Challenge in the Ferncliffe natural forest on the edge of Pietermaritzburg.

Ferncliffe is a beautiful mist belt forest that has been heavily invaded by alien vegetation that is becoming a significant threat to biodiversity.

The challenge involved learners from Durban High School (DHS) and Weston Agricultural College competing in a tree-planting race designed to raise awareness of the need for environmental stewardship and contribute to the restoration of the Ferncliffe forest at the same time.

"We were truly touched by the enthusiasm of DHS and Weston, who signed up despite the boys' busy schedules and approaching school holidays," said Timothy Isabirye, Husqvarna South Africa's Marketing Manager.

The Husqvarna team partnered with local conservation NGO Ferncliffe Forest Wilding to host the event.

"With our sales office in Pietermaritzburg, it was natural to give back to our immediate community", explained Timothy. "And our commitment to sustainability and local environmental protection aligned perfectly with NPO Ferncliffe Forest Wilding's mission, making them the perfect partner for this initiative".

Janine Stephen, a representative from Ferncliffe Forest Wilding, said, "We were really excited when Husqvarna approached us with the idea of the challenge. Collaborating with schools and businesses like Husqvarna to protect and restore endangered mist belt forest habitat is exactly the kind of community-driven action we need in a world where so much biodiversity is threatened".

Competitive fun

In an exhilarating race, boys from each school, armed with spades and gloves provided by Husqvarna, were tasked with digging 15 holes as quickly as possible. As expected, the competitive spirit was high. Still, focusing on making a positive difference in the environment stayed at the top of everyone's mind.

In the end, it was Weston Agricultural College that emerged victorious. They earned bragging rights and a Husqvarna battery-operated leaf blower worth R10,000, including accessories for their school and a trophy to celebrate their achievement.

The DHS boys who participated in the tree planting challenge
The DHS boys who participated in the tree planting challenge

DHS didn't go home empty-handed. They were rewarded with a R5,000 e-commerce voucher to use on the Husqvarna South Africa website. Participating learners also received a certificate recognising their contribution to this impactful initiative.

Fantastic opportunity

"This challenge was a fantastic opportunity for our learners to step up and contribute to something greater," said Barry Coskey, DHS Head of Marketing and Admissions. "At DHS, we aim to develop responsible, motivated young men with strong moral convictions, and today, they truly embodied those values".

Amber Pollock, Head of Marketing for Weston, said, "At Weston, we love embracing challenges, particularly those safeguarding our environment. We also strive to instil a strong work ethic and sense of responsibility in our learners, and this initiative provided an excellent opportunity for them to rise to the occasion."

The event has laid the foundation for what is hoped to become an annual event, expanding its reach and impact in the coming years. "This is just the beginning. We're committed to making this challenge an annual celebration where schools come together to compete and create real, lasting environmental change," Timothy concluded.

The Husqvarna Schools Forest Rehabilitation Challenge is part of the brand's sustainability and community engagement commitment.

Husqvarna's locally crafted chainsaw pants redefine safety and performance

A chainsaw operator's lightning-fast reflexes aren't enough to prevent chainsaw injuries, making personal protective equipment (PPE) an unwavering necessity. While most professional chainsaw operators use essential PPE gear like goggles, eye protection, and gloves, protective pants are a vital component that often remains overlooked.

Studies reveal a stark reality: just under half of all chainsaw-related injuries target the legs. This is why Husqvarna, a global leader in outdoor power products, introduced an essential addition to their arsenal of protective gear – the Husqvarna Chainsaw Pants.

Made in South Africa

Designed and manufactured meticulously in South Africa, the chainsaw pants embody Husqvarna's dedication to exceptional craftsmanship, innovation, and, more importantly, safety. Added to this, it showcases Husqvarna's commitment to supporting local industry.

Pieter Smuts, Husqvarna South Africa's Managing Director, describes the chainsaw pants as a "passion project" for him. Husqvarna South Africa, purposely used local manufacturers.

"South Africans are talented, resourceful, innovative, and our new chainsaw pants epitomise our faith in the synergy between innovation and local ingenuity", Smuts said.

Safety first

Certified Class 1 – 20M/S, they withstand chainsaw speeds of up to 20 meters per second. Meeting the ISO 11393-2 international standard, Husqvarna Chainsaw Pants are ideal for forestry, arboriculture, farming, municipalities and homeowners.

The pants are constructed with flame-retardant and acid-repellent materials, providing comprehensive protection against chainsaw-related hazards and environmental risks. Additionally, their water-resistant properties enhance their versatility, making them indispensable for professionals working in demanding conditions.

The pants are available in waist sizes between 77 and 132.

Husqvarna's Business Development Manager, Charles Henderson, said, "In my line of work, safety is paramount. These pants perfectly balance protection and comfort, letting me work confidently."

Foresters know manual harvesting is dangerous work. Chain saws can cause injuries, resulting in expensive health care costs, lost productivity from work, and potentially permanent damage.

All countries' health and safety legislation stipulates that when a hazard cannot be removed or controlled sufficiently, personal protective equipment (PPE) must be used. This equipment and clothing protects against health and safety risks at work. It includes safety helmets, gloves, eye protection, ear protection, high-visibility clothing, and chainsaw pants.

Researchers have identified four body areas prone to lacerations when working with a chainsaw: hands or fingers, knee, lower leg or ankle, and the upper leg.

Smuts said, "This unveiling is not just another product release. It is a commitment to innovation, safeguarding, and the journey of those who rely on chainsaws to shape the world around them".

Husqvarna Chainsaw Pants are available through certified Husqvarna Dealers or can be purchased directly from the official Husqvarna eCommerce site: [https://za-promo.husqvarna.com/].

Sources: Husqvarna South Africa and https://incident-prevention.com/blog/the-risks-and-rules-of-chainsaw-operation/

Profit pointers for wattle growers

Open for business. Rob Thompson delivered the good news that NCT's Richards Bay mill are back up and running just over a year after the devastating fires that stopped their chipping and export operations.
Open for business. Rob Thompson delivered the good news that NCT's Richards Bay mill are back up and running just over a year after the devastating fires that stopped their chipping and export operations.

A recent wattle field day organised by NCT Forestry provided an ideal opportunity for local tree farmers to pick up some pointers from the wattle “experts” who have been working with wattle for decades. The field day was hosted on Elands Farm near New Hanover in the KZN midlands, owned by Terry Wolhuter.

Chris Chapman reports that the key takeaways from the field day were:

Friedel Eggers of UCL urges foresters to plant the best black wattle clones on the right sites to reap the benefits of good bark and timber yield
Friedel Eggers of UCL urges foresters to plant the best black wattle clones on the right sites to reap the benefits of good bark and timber yield