BLUBLOK UPS THE ANTE IN WESTERN CAPE PAVING MARKET

New management and the launching of a paving manufacturing plant has seen newly appointed Concrete Maunfacturers Association member, BluBlok, realise substantial growth over the past two years.

Until 2022, when fresh blood in the guise of Jess Brews took over as managing director, sales were static and production was confined to concrete bricks, blocks and kerbs.

Brews first worked for BluBlok between 2015 and 2017, and in the five intervening years before he returned to the company, he was immersed in the Johannesburg construction industry.

“On rejoining in 2022 my primary goal was to expand the business, and because it was situated in the high-growth area of Somerset West, we were presented with a golden growth opportunity. Hence our decision to begin manufacturing top-quality concrete block pavers,” said Brews.

“As we were housed in a 10 000m² building we had plenty of under-roof space available for production expansion. Moreover, we were able to piggyback the new venture on our existing infrastructure and administration.

“Financially backed by substantial third-party funding, we made the decision to pursue a third plant predominantly dedicated to manufacturing pavers. This job in general is a difficult. The market is not sympathetic to quality. You have to manufacture the best possible quality product at a price the market is willing to pay for it and the only way you can achieve that is by taking large capital risks and running your business as efficiently as possible. Magnitude, capital, efficiency and volumes are the only way to survive”

“After visiting all the major paving plant manufacturers in Germany in 2022 we settled for the ‘Rolls Royce’ of paving machines which was commissioned in April 2024. It offered state-of-the-art compaction and vibration performance and incorporated topping technology which allowed additional 10-20mm layers of more expensive and more attractive materials to be cast on top of the paving blocks.

“There is a general misconception in South Africa that topped pavers are inferior. But I always tell people that it is common practice in Germany where pavers are produced in far greater varieties and volumes and at higher quality levels than our local equivalents. We decided to follow the European model and we are managing to produce superb pavers in a variety of toppings”

“The versatility of modern paving machines means they can offer a variety of paving types and configurations. For instance, we are able to deliver product which people think is only available through wet-cast production, and we do so at a fraction of the price. We also use chemical additives for colour enhancement and the reduction of phosphorescence.”

“And it goes without saying that we make the traditional paving range familiar to the SA market, such as the bonds, double cobble and ZZ interlockers, as well as a grass block and the long thin Klompie block, predominantly used for borders and smaller places. But we are also firmly committed to introducing new shapes and styles to the market and there is absolutely no reason why we shouldn’t be able to offer a wider scope of product as is done overseas.

“We also produce the I paver, an interlocker used all over the world in residential and industrial applications. I think we are the only company in SA that does it. Our customers love it once they see it laid out. The shape is not new to the local market but quality problems, to which our new plant is not prone, were experienced with earlier versions of the product.

“Our brick and block machine is a fully automated Schlosser plant, and depending on how busy we are, we either run it in single or double shifts. In busier months we can run the machine non-stop. BluBlok has always made more expensive, better-quality bricks and blocks. Although 99% of the block industry is price driven, our customers are drawn from those companies which build high-quality structures.

“We also produce a high-quality wet-cast product range with a very smooth finish and currently we are unable to meet the demand. We sold 30 000m of kerbs in November and we intend to double our capacity during 2025.

‘As from the beginning of 2025 we’ll be showcasing part of our paving range at Hathersage Homestead, a small but picturesque farm on the banks of the Lourens River. The balance of the farm, which roughly spans 30 hectares, lies on both sides of the Lourensford River and borders Morgenster Farm,” said Brews.

Roughly 4 000m² of I pavers have been laid at Hathersage. The paved areas include the main road leading to the farm gate and the driveway between the gate and the main house. A 60mm I paver together with a charcoal bond paver was used to pave the driveway and an 80mm paver was used for the main road. Our E3 edging kerb was installed on the borders of the roads. The river flooded twice in 2024 which meant the G5 sub-base material required substantial re-working.

The paving was installed by All Fence Civils together with PN Construction and Civils. The former has been in the industry since 1996 and has been working with BluBlok since 1998.

Commenting on the performance of the I paver, Eugene van Vuuren of All Fence Civils mentioned that it is a very clean product and all the lines are clearly defined.

“It is very easy to lay because each block is identical. They have a very nice edges and fit exactly into each other. They also come with half-blocks which makes for straight borders and edging. What’s more, they need very little cutting and this meant there was very little wastage on the Hathersage project,” said Van Vuuren.

“I enjoy the manufacturing environment and I particularly like the raw materials side of the business. I learnt about paving from the team of people I’m surrounded by, especially Willem Smit, who can pick up a pile of dust and tell you whether it will make a good paver or not.

“We have a very low staff turnover at BluBlok, most of whom have been here since 2011. I’m very lucky to be supported such a strong team and our mission is simply to become the biggest,” concluded Brews.