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Friday, 03 March 2017 20:47

Davos | World Economic Forum | Future of Construction

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moladi - World Economic Forum - Future of Construction moladi - World Economic Forum - Future of Construction moladi

Davos | World Economic Forum | Future of Construction

moladi Future of construction

moladi - Future of Construction

Strong population growth in many developing and emerging countries and mass urbanization – an estimated 40,000 people moving into African cities every day – create a strong demand for affordable housing. Beyond housing, many developing countries are lagging behind in access to social infrastructure and public services such as schools, hospitals or the justice system. Consider Tanzania: the country faces a shortage of 3,115 courtrooms.

Moladi Construction System aims to address that magnificent challenge by providing a scalable, low-tech and low-skilled affordable building solution using in-situ casting. Founded in 1986 by South African social entrepreneur Hennie Botes, the company aims to replace the classic brick-and-mortar construction with an easier method: using lightweight, removable and re-usable plastic formwork that are filled with a patented fast setting aerated mortar to cast entire houses on-site. The process is deliberately designed to be labor intensive and mostly uses local supplies (apart from the reusable formwork and a special additive (MoladiChem) to boost local employment and local production without requiring prior construction experience.

Train the unemployed to build for the homeless - Hennie Botes - Founder and CEO

The main advantage of this affordable construction solution is its social acceptance – a challenge encountered by any affordable building project, especially if the solution is imported from abroad. In the case of Moladi, its integration into a wider effort to boost the community and the fact that people can knock on the cast walls to check for solidity – the sound is the same solid sound as traditional brick-and-mortar walls – helps to gain immediate approval. Gypsum-board walls for instance are regarded as less strong  and weather resistant. As a consequence, the solution has been applied in 20 countries in Africa (e.g. South Africa, Nigeria, Tanzania), South Asia (Sri Lanka) and Latin America (Mexico, for two-storey buildings and Panama) and the company is currently planning expansion into the United Kingdom.

Due to its strong track record and advantages, the government of Tanzania has selected Moladi as the most cost-effective solution to address its courthouse shortages. A 1,200 square metres pilot project has been successfully completed – faster and cheaper than alternative solutions – and the courthouse was inaugurated by the Tanzania’s Prime Minister.

Download the full case study to read more about the application of Moladi’s Construction System to these larger projects and the special barriers the company had to overcome. - Download

building the future moladi

Building the Future 

For more information on moladi visit - www.moladi.co.za

Read 906 times Last modified on Saturday, 04 March 2017 23:13
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moladi - Plastic Formwork -low cost housing affordable Housing building construction

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  • Beyond brick and mortar houses

    Beyond brick and mortar houses

    The inefficiencies of moulding a brick or block in a mould then tasking an artisan to lay them. Then chase the walls for water and electrical services. Then relying on another artisan to plaster the walls. Dependent on the skills and ability of artisans to produce a house. At what cost?

    Conventional brick and mortar construction process:

    • How many bricks or blocks are laid per day?
    • Are the quantity of bricks or blocks laid per day the same for every day of the week?
    • What happens when the bricklayer does not come to work?
    • Is the dagha (mortar) mix to lay the bricks or blocks consistent?
    • How many bricks or blocks are wasted or broken or stolen?
    • Are walls straight plumb and square?
    • How long to chase for electricity piping?
    • How long to chase for water piping?
    • How long does it take to do beam filling?
    • How long does it take to plaster window reveals?
    • Is plaster thickness consistent or does it vary?
    • Is the plaster mix consistent?
    • Any rework?
    • Rubble to clear?
    • At what cost?

    “If you can't measure it, you can't manage it.” - Peter Drucker

    This leads to the question: Are the inefficiencies of the brick and mortar construction process making homes unaffordable for most?

    The moladi Injection Moulding Construction Process

    Beyond Brick and mortar houses

    Casting a house in a moladi mould employing unskilled workers – Eliminating the dependence on skilled artisans - Eliminating the need to chase, plaster and beam fill. Completed in a day. At a known cost.

    moladi Construction Process

    • Erecting the formwork by unskilled labour is constant.
    • No stays.
    • No propping.
    • No consumables.
    • Formwork holds a constant precise volume.
    • Mortar a known cost.
    • Mortar is a known consistent compressive strength.
    • Reinforcing a known weight/cost.
    • Time to position and bind reinforcing constant.
    • Filling the formwork is consistent.
    • Removing the formwork is constant.
    • Labour is not skilled.

    “If you can't measure it, you can't manage it.” - Peter Drucker

    This is why moladi was selected for the Tanzanian Courthouses Project and funded by the World Bank - Read more at - Future of Construction - World Economic Forum

    To view a video on the sequential step-by-step process - Visit the link to our latest project in Gauteng - South Africa - Gauteng Education Department

    moladi designed to create jobs for the unemployed food for the hungry shelter for the homeless

    What if we told you the solution to the global youth unemployment and the million-plus housing backlog was already in our back yard? And what if we told you jobless, unskilled people could become entrepreneurs in the house building sector and be able to build homes in their communities at a fraction of the cost and in less than a week?

    What would you say if we told you there is a company that is not only prepared to certify you, but to empower you too and give you a market, technology and the opportunity to grow personally and professionally? Build a community in a month

    For more on moladi visit www.moladi.co.za  

  • Injection moulded construction process - moladi

    The moladi injection moulded construction process

    The inefficiencies of moulding a brick or block in a mould then tasking an artisan to lay them. Then chase the walls for water and electrical services. Then relying on another artisan to plaster the walls. Depending on the skills and ability of artisans to produce a house vs casting a house in a mould employing unskilled workers – eliminating the need to chase and plaster, in a day, at a known cost. This we refer to as the moladi"injection moulding construction process". Future of Construction - World Economic Forum

    Molding or Moulding Process

    Molding or moulding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern, a model or formwork of the final object.  
    A mold or mould is a hollowed-out block (cavity) that is filled with a liquid or pliable material such as plastic, glass, metal, ceramic raw material or mortar (sand and cement). The liquid hardens or sets inside the mold, adopting its shape. A mold is the counterpart to a cast.

    Injection moulded construction process

    Disruptive Innovation

    A disruptive innovation is an innovation that helps create a new market and value network, and eventually disrupts an existing market and value network (over a few years or decades), displacing an earlier technology

    Modern Building Methods Using Modern Building Materials

    moladi Construction System aims to address the challenge by providing a scalable, low-tech and low-skilled affordable building solution using in-situ casting. Founded in 1986 by South African social entrepreneur Hennie Botes, the company aims to replace the classic brick-and-mortar construction with an easier method: using a patented lightweight, removable and re-usable plastic injection moulded formwork system that is filled with fast setting aerated mortar to cast entire houses on-site. The process is deliberately designed to be labour intensive to boost local employment and local production without requiring prior construction experience or skills. The moladi construction process mostly uses local supplies apart from the reusable formwork and a special additive to aerate the mortar (concrete without stone) to reduce the density, thereby enhancing the thermal properties of the structure. The other function of the additive is to water proof the wall and enhance the flow ability of the mortar within the formwork eliminating the need to vibrate.

    Through creative engineering and sophisticated manufacturing, moladi aims to advance living standards and spaces affordably. moladi is an advanced building technology that utilises an innovative re-usable plastic formwork system to reduce the required skills to produce quality affordable homes and other structures that are socially acceptable by speeding up delivery and thus reducing cost. By emulating the methodology of the automotive assembly line, moladi implements the principles applied by Henry Ford; reducing cost by increasing production output by de-skilling the production operation, making homes affordable

    The advantage that moladi brings to the “production process” is that the process can measured and maintained, ensuring consistent speed and quality within budget.

    Conventional Masonry Construction

    • How many bricks or blocks are laid per day?
    • Are the quantity of bricks or blocks laid per day the same for every day of the week?
    • What happens when the bricklayer does not come to work?
    • Is the dagha (mortar) mix to lay the bricks or blocks consistent?
    • How many bricks or blocks are wasted or broken or stolen?
    • Are walls straight plumb and square?
    • How long to chase for electricity piping?
    • How long to chase for water piping?
    • How long does it take to do beam filling?
    • How long does it take to plaster window reveals?
    • Is plaster thickness consistent or does it vary?
    • Is the plaster mix consistent?
    • Any rework?
    • Rubble to clear?

    Therefore, “If you can't measure it, you can't manage it.” - Peter Drucker

    By using moladi the above variables are excluded from the equation.

    moladi Construction Process

    • Erecting the formwork is constant.
    • No stays
    • No propping
    • No consumables
    • Formwork holds a constant precise volume.
    • Mortar a known cost.
    • Mortar is a known consistent compressive strength.
    • Reinforcing a known weight/cost.
    • Time to position and bind reinforcing constant.
    • Filling the formwork is consistent.
    • Removing the formwork is constant.
    • Labour is not skilled.

    Injection Moulding Process

    Mould closes – Material Injected – Cools – Ejects the finished component. A known cycle time at a known cost.

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    This we refer to as the moladi "injection moulded" construction process. A “lean construction” principal.

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    One of the important principles under a lean production paradigm is termed ‘lean assembly’. This refers to simplifying the process of assembly through industrialisation, modularisations, standardisation, and continuous flow processes. The reduction of operations required for a production process means less chance of the occurrence of errors, waste and rework.

    This follows from the same logic that the fewer the number of operations, the higher the quality of the product and a predictive timeline, resulting in cost savings. moladi formwork system provides and assists with the full range of requirements involved in the transfer and use of a proven low-cost construction technology.

    Jobs Food through Shelter

    moladi supplies technology and supports transfer of know-how to empower individuals to achieve self-worth, by meaningful action to raise those at the “bottom of the pyramid” to a higher level, supplying a proven technology with an impressive track record (Est. 1986). This is how moladi can address the delivery of quality homes in less time, creating jobs by employing unskilled local labour - developing skills and entrepreneurs.

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    moladiA Technology Supplier

    We skill entrepreneurs, contractors, business owners and construction companies how to “produce” using moladi construction technologies - “What if we told you the solution to the 25% national unemployment statistic (36% youth unemployment) and the million-plus housing backlog was already in our back yard? And what if we told you jobless, unskilled South Africans could become entrepreneurs in the house building sector and be able to build homes in their communities at a fraction of the cost and in less than a week? What would you say if we told you there is a company that is not only prepared to certify you, but to empower you too and give you a market, technology and the opportunity to grow personally and professionally?" - Link

    References:

    World Economic Forum - Future on Construction – World Bank

    How Elon Musk and other pioneers (moladi) are shaking up the construction industry | World Economic Forum #WEF #Tesla

    The $300 House Blog - Affordable Housing: Moladi's Hennie Botes on Innovation & Perseverance

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    Insanity: doing the same thing over and over again and expecting different results

    "Injection molded Houses" implementing lightweight injection molded modular plastic formwork as a re-usable "mould" to cast homes in-situ - Video

    Prevent shack fires from occurring and destroying people’s lives

    The only structures, built as a show unit after the earthquake that struck in 2010, standing in the show village after Hurricane Matthew in 2017

    Certification and Awards

    SABS | Agrément Certification | NHBRC | Bank approved (1993)

    2017 –World Economic Forum - Boston Consulting Group – Future of Construction – World Bank funded project

    2016 – Best of African Design - moladi showcased for a year at the Cube Museum in the Netherlands

    2014 – Africa is now - moladi displayed at Design Indaba Cape Town

    2012 – moladi selected as a finalist of the international Frost & Sullivan Green Excellence Award for Sustainable Development.

    2012 – International Case Study conducted by FSG and the Rockefeller Foundation on ‘Shared Value in Emerging Markets’ featuring moladi.

    2012 – Nominated by the Europe Business Assembly for the International Socrates Prize in economy and business category.

    2012 – Co-operative Finalist with Kingston University in the international Hult Global Case Challenge in association with the Clinton Global Initiative.

    2011 – moladi selected by the Smithsonian Institute to exhibit the technology in association with its Cooper Hewitt Museum at the UN Headquarters in New York.

    2010 – International Case Study on moladi conducted by the UNDP (United Nations Development Programme) on ‘Growing Inclusive Markets’.

    2010 – Hennie Botes, CEO of moladi, is awarded South Africa’s Science and Technologies best man by Men’s Health magazine.

    2009 – moladi named winner of the Affordable Housing Competition held by Data Bank in Accra, Ghana.

    2006 – Housing Innovation Award Winner of the ABSA Bank and NHBRC (National Home Builders Council) national competition in South Africa.

    2005 – Finalists in the TT100 (Top 100 Technology Awards), South Africa.

    1997 – Winner of the prestigious SABS (South African Bureau of Standards) Design for Development Award, South Africa.

    1991 – Winner of the International PRW Award for excellence – United Kingdom

     

    For more information visit www.moladi.co.za or www.moladi.com or www.moladi.net

     

  • How to get South Africa WORKING

    How to get South Africa WORKING

     A "TOOL" to get the unemployed working - Fight unemployment, hunger and crime through housing

    The backlog for Affordable Housing in South Africa are in the millions. The main culprit in increased cost and affordability is "skilled labour*. The lack of artisans in the construction trade continuously escalates due to the fact that there are no new "apprentices" enrolling. Bricklayers and plasterers are only two of the key artisans that effect the cost of building.

    moladi has embarked on developing technology primarily to reduce the dependence on skilled labour in order to reduce cost of construction, and also to increase production quality consistently eliminating costly rework.

    Although moladi formwork technology is primarily a manufacturer of a re-useable machine made patented formwork system that allows walls to be cast stronger faster for less, the principal focus is on the delivery of the “whole house”. A house consists of many components and the” assembly process” needs to be project managed in its entirety. That means windows, doors, roof, bath, toilet, paint, ceiling, glass, electrical hardware, etc. etc. needs to be planned ordered and supplied in order to avoid a “bottle neck” that would stop production creating “waste” resulting in an increase in cost. This in turn makes the product, the home, unaffordable to the majority of people.

    Through creative engineering and sophisticated manufacturing, moladi aims to advance living standards and spaces affordably. moladi is an advanced building technology that utilises an innovative re-usable plastic formwork system #plasticformwork to reduce the required skills to produce quality affordable homes and other structures that are socially acceptable by speeding up delivery and thus reducing cost. By emulating the methodology of the automotive assembly line, moladi implements the principles applied by Henry Ford; reducing cost by increasing production output by de-skilling the production operation, making homes affordable. #moladi

    Many people believe that if a house is produced, we have a customer. But, in Africa (and in the rest of the World) we need to create jobs for the customer in order for them to earn money, before they can actually buy the product. So, it is no use producing a house in a factory and trying to sell it to someone that doesn’t have an income or a job. Our focus and passion is to uplift the community by creating job opportunities producing homes" 

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    Insanity: Doing the same thing over and over agai expecting different results 

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    "Produce moulds to produce components to produce formwork to produce houses to produce jobs to produce income to empower PEOPLE" - Hennie Botes

    Click on the link to view the interview conducted with Hennie Botes - Inventor and CEO of moladi - Link 

  • moladi classrooms for Gauteng Education Department

    moladi cast classrooms in record time

    moladi classrooms Gauteng strip

     

    Erect - Fill - Strip the next day. Two classroom with storage facilities (157 sqm). What a brilliant TEAM we have on site . All local labour that has never worked with moladi before . Our "teacher" taught them to produce this "superior" product in record time at a rate lower than conventional brick and mortar. The classroom project demonstration is key to the roll out in the education departments - Gauteng and all other provinces in South Africa - Thank you TEAM moladi !!!

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  • Slag use in building system offers multiple benefits

    Alternative construction system company Moladi has developed a means of incorporating mine slag into its Moladi mix, offering mining companies a viable method for recycling their waste material and reducing construction costs when developing mine-site accommodation.

    Moladi founder and CEO Hennie Botes explains that its cement admixture is poured into plastic moulds to form walls. “Using slag instead of sand in the mortar will result in substantial cost savings for mines during the construction of housing units and other site buildings.”

    Further, he notes that, with mines having problems disposing of mine slag, this solution will enable mines to use their waste material to build infrastructure.

    Business consultancy MJC Business Consulting director Marius Lotter adds that, traditionally, mines made use of conventional building methods to construct the various site buildings. However, he suggests that a lack of quality management, logistical challenges, rigid deadlines, theft as well as excessive costs – including those relating to the use and rental of various types of heavy machinery, the contracting of a skilled labour force and the use of labour intensive methods – have resulted in mines looking to alternative building technologies.

    Lotter notes that the Moladi system not only addresses most of the aforementioned issues but it also creates jobs. This assists mining companies with the legal obligation to, firstly, provide adequate housing and living conditions for staff and, secondly, “facilitate economic linkages to sectors other than mining” – which are the requirements in the 2010 Social and Labour Plan Guideline published by the Department of Mineral Resources.

    Lotter adds that Moladi has been successful in implementing its entry strategy for the mining industry and it “foresees that as many as 150 houses will be completed in 2017”.

    The company is also set to supply 150 staff accommodation units at an Mpumalanga project, which has already been approved, and is awaiting the approval of 22 000 units to accommodate staff at another mining project.

    Global Acclaim
    The company was featured in a World Economic Forum report called ‘The Future of Construction’, published in January, which forms part of a multiyear global economic initiative to guide and support the engineering and construction industry.

    The report notes that Moladi has an advantage over other affordable housing technologies, particularly those using prefabricated building components, because developing countries have notoriously inadequate road infrastructure, which makes transporting fully prefabricated units unviable and could result in the damage of prefabricated components. As Moladi’s system involves the use of lightweight plastic formwork, which is easily transported, it is unlikely to be damaged, regardless of road conditions.

    The system’s formwork is assembled by clipping together a set of injection-moulded, 30 cm × 10 cm × 20 cm plastic panels that are removable, reusable and recyclable. With this system, a building can be constructed in as little as two days.

    The formwork panels are assembled on the first day. Window and door frames, as well as piping and wiring are positioned within the wall cavity before the mould is filled with the Moladi mix.

    To illustrate the speed of the process, Botes explains that constructing a 40 m² house takes a team of 18 workers about four hours: two hours to erect the formwork and another two hours to pour the mortar.

    On the second day, the formwork is removed, the walls are painted with a cementitious water-based paint and the lighting and sanitary equipment are installed.

    The entire process can be monitored by one Moladi supervisor who provides on-site training and assistance to local workers with no prior construction experience or special construction skills.

    Moladi’s system is generally associated with small affordable housing units, but it can be applied to various infrastructure assets, including schools, hospitals or courthouses, site offices and multistorey buildings.

    Its main advantages are the speed and ease of production, the lower costs and reduced environmental impact, the quality of the end product and a localised supply chain that benefits local communities.

    The cast walls have a strength of between 7 N/mm² and 15 N/mm² – which is significantly stronger than traditional structures.

    The technology has undergone extensive testing and received certification from several African building and standards authorities, including the South African Bureau of Standards and the Tanzania Bureau of Standards. The structures are also reported to be “very earthquake resistant” according to tests conducted by the University of Panama.

    The system has been used to construct several thousand units in 20 countries in Africa, including South Africa, Nigeria and Tanzania. It has also been used in Sri Lanka, Mexico and Panama.

    Moladi is reportedly preparing to expand its footprint to include the UK and other industrialised countries that have a shortage of affordable housing. The report noted that one of the virtues of the Moladi system is that it can be easily adapted to local building codes and conditions by integrating the required reinforcing structures into the cast.

    It concludes that the system is limited to single- or two-storey buildings, but Moladi is working with engineers to upgrade its construction processes and mortar to qualify the use of its system for multistorey buildings.

    Read more - How Elon Musk and other pioneers (moladi) are shaking up the construction industry | World Economic Forum #WEF #moladi #Tesla #HennieBotes #ElonMusk https://www.weforum.org/agenda/2017/03/elon-musk-innovation-construction-industry/

    For more information visit www.moladi.co.za

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