Precast Concrete safety barriers for Cape Towns Formula E Race

Concrete Manufacturers Association member, Cape Concrete Works, supplied all the concrete barriers for the international Formula E Championship race which was staged to great acclaim in Cape Town on February 25, 2023. Cape Concrete was sub-contracted to Martin and East which won the barrier supply and deployment contract from E-Movement (Pty) Ltd, the authorised promoter of Formula E Cape Town. Skirting the DHL Stadium and winding through the city’s foreshore area, the 2.84km track was erected on a section of the city’s existing road network, specially adapted for the race.

The barriers lined both sides of the entire track as well as the pit feeder lanes, and Martin and East began the installation three weeks before the event took place. They were manufactured to a Formula E design which is approved by the FIA (Fédération Internationale de L’ Automobile), the governing body responsible for safety standards in motor racing, including Formula 1. In addition, Cape Concrete cast special concrete kerbs, which were lowered to create a flat surface during the race and then subsequently elevated into a conventional road kerb format.

Formula E uses five barrier types for its 17 global race events and four, Types 1, 2, 4 and 5, were deployed in Cape Town. All told Cape Concrete cast 1 988 units: 1 800 Type 1; 96 Type 2; 82 Type 4; and 10 Type 5. Type 1 is the standard size measuring 4m (length) x 1m (height) x 600mm (base width). Type 2, which is generally used on tight corners, has the same dimensions as Type 1 except for its length, which is 2m. Similarly, Type 4 has the same dimensions as type 1 apart from its height which is 600mm and is used on the pit lanes. And Type 5 is a replica of Type four but at 2m long as opposed to four.

Two shifts every 24 hours required

Due to unforeseen program revisions, the confirmation of the Cape Town race was delayed by several weeks. This meant that Cape Concrete was obliged to adhere to a very tight production schedule to meet the January 27 delivery deadline. It required two shifts every 24 hours as well as working through the December/January builders’ break. “Martin and East introduced us to Cape Concrete when our time frames were very tight,” said E-Movement chairman, Iain Banner. “However, after a visit to Cape Concrete’s plant, we were 100% confident that everything would be ready and in position on time, which it was.”

Cape Concrete Director, Johan Nel said, “We were fortunate that Martin and East had bought 15 Type 1 moulds from Pan Mixers South Africa (PMSA) before we were given the green light, which meant we were able to begin production during the first week of November. Further moulds followed and this enabled us to complete the order ahead of schedule.” Reinforced with normal stirrup rebar and steam cured for quick turnarounds, the barriers were cast to a 40MPa strength rating.

During installation, the barriers were interlinked with six steel loops, three loops having been cast into each barrier end. They were cast at slightly different elevations so that the loops of one barrier end overlapped those of the adjacent unit. The posts extended above the top of the barriers to facilitate the attachment of galvanized steel fencing which was mounted on the barriers and manufactured by Qhubeka in Blackheath. After casting, the barriers were spray-painted Dulux Atlantic Blue by Painters on Site and stacked in Cape Concrete’s yard prior to delivery at the end of January. They were also cast with two lifting points which were used with quick release pins during installation.