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TerraLOCK Technologies Company Profile 2025

Vision

To supply a superior product to our clients while empowering and developing the entrepreneurial spirit of South Africans.

About the Company

TerraLOCK Technologies (Pty) Ltd is a registered Company and is an approved Ecobond distributor and applicator with over 20 years’ experience in Road Maintenance, Construction and Dust Suppression.

The Company was formed after the need for Road Construction, Dust Suppression and Road Maintenance; especially on Mine Haul Roads was identified. Taking into account the extreme water scarcity within certain regions of Southern Africa.

We are committed to engage in Local Economic Development and with each project we work towards building entrepreneurs within the local community through skills sharing, and offering opportunities to local business people to own and run a TerraLoc Application Company.

We provide a team of Specialists to deliver on Batching and Mixing of Chemicals, Calibration of Equipment and Application of Chemicals. Furthermore, all Application Teams will have access to a Qualified Mechanic, Health & Safety Specialists as well as a Project Manager to ensure compliancy and quality if required.

We have an established “Back of House” team, who will provide outstanding after-sales service, which includes all Admin, Financial, Operations, and Sales related queries. TerraLOCK Technologies (Pty) Ltd has a reliable Credit Record, and has access to capital to purchase equipment and infrastructure based on the client’s needs and project requirements.

About Our Products

TerraLOCK Technologies (Pty) Ltd has a range of products including:

• BituForce – BSM Base Course Material for Road Rehabilitation (Cold In-Situ Stabilization)
• Duragrav – Used on Gravel roads for Stabilization and Dust Control
• TerraDust – Dust Suppression
• TerraLoc – Underground Cable Protection

Dust Suppression

TerraLoc Dust Control Chemicals are strong and water resistant, not sticky in warm weather; it penetrates into the surface to increase support, does not leach out, is inert and will degrade through natural processes. TerraLoc / Ecobond is the only Polymer based product which has been certified by Agrement SA (Certificate #2015/496).

The product consists of a polymer resin and SS60 Bitumen. The resin can be applied without the bitumen if required.

The product is cold-mixed on site into a calibrated water tanker and is then sprayed onto the road surface. The surface is drivable within a couple of minutes and will not damage or stain the customer’s vehicles. The average mix is 4% of total volume of water in the water tanker depending on soil type. The average spray per square meter is between 1lt and 1.5lt.

Due to the composition of TerraLoc, build-up of the product can be expected on the road surface, which in turn means fewer sprays, using less water — translating into a saving for the customer, as well as the added benefit of not having water tankers congesting the mine roads. Each client’s requirements will be studied in detail, from soil analysis to laboratory tests, in order to tailor make the chemical to the soil conditions and guarantee longevity of the application.

Fields of Expertise

• Road Construction (Layer Works)
• Road Sealing (Hot Asphalt, Chip & Spray, Pothole Fixing and Brick Paving)
• Road Maintenance
• Dust Suppression (Gravel Roads, Mine Dumps, etc.)
• Dust Suppression Application

Project Portfolio

Below is a brief summary of some of our completed projects.

1. Black Top Ecobond Slab Road, Duvha, Witbank – 1996

A 100 mm thick 2% Ecobond base was constructed on a G6 Sub Base (G7 & 8 selected layers) and surfaced with 6.7mm bitumen slurry seal. It carried more than 3 million trucks (1 000 per day) and 7 million other vehicles in the first 10 years. A new 13mm bitumen single seal was added in the tenth year and the road remains in excellent condition. First 12 years maintenance included only 1 pothole (caused by a steel belt caterpillar in year 6), replaced at approximately R5.00 material costs plus labour. By 2011, 27 million E80kN axle loads had been carried — compared to the 10 million E80kN design life of a class V road.

2. Black Top Ecobond Road Slab, Louis Trichardt – March 2001

100 mm thick 1.6% Ecobond slab supported a 3mm bitumen sand seal. C4 Strengths were attained with 1.5km G9 and G10 fine sand, and C3 (2 to 2.4 MPa) strengths with 1.5km G7 sand. This bus route was calculated cheaper than a gravel road over a five-year monitoring period.

3. Black Top Ecobond Slab, New Denmark Colliery Haul Road, Eskom – 2004

This coal truck haul road used 1% Ecobond dosage in a 150mm sub base on metres of heaving clay, and 2% Ecobond 150mm base course under an asphalt seal. Coal trucks have been using the road for 7 years. The previous road failed regularly as the cement stabilization was too rigid and brittle. Ecobond’s water resistance keeps more water out of the lower layers, causing less movement of the clay, while remaining elastic enough to accommodate motion yet stiff enough to carry heavy loads.

4. Black Top Ecobond Slab, Caledon / Hermanus – 2007

A 100 mm 2.5% Ecobond Slab just below a mountain pass was constructed under a bitumen double seal. After heavy rain and traffic it is in good condition, providing very low life cycle costs with minimal maintenance.

5. Black Top Ecobond Slab, TFMC, Kempston, Port Elizabeth – 2002

A 100 mm thick 3% Ecobond Slab was constructed for an entrance road and hard stand to load / off-load / store heavy machinery. A 30mm asphalt seal was added and remained in excellent condition 9 years later despite heavy use.

6. Black Top Ecobond Slab, near Mokopane, Limpopo – 2003

A 150 mm thick Natural Ecobond Slab Provincial Road Section was constructed in two 75mm layers, labour intensively, on a 3% CBR sub-base. The lower base course used 2% Ecobond and the upper section 2.8% dosage. CSIR tested 296% CBR strength 6 weeks after construction. Water poured onto the surface does not penetrate but runs off. A bitumen seal was added later (requiring only 60% CBR support strength). The 30-worker construction team was slightly cheaper than using a water truck, grader and roller.

7. Natural Ecobond Slab, Upington, Northern Cape DOT – 2003

3.5 km, 2.4% dosage, 75mm thick Ecobond slab was constructed in the surface of the existing provincial gravel road near Upington. Despite heavy truck, car, bus and tractor traffic, the road has performed well for 5 years at very low life cycle cost.

8. Natural Ecobond Slab, Sandhurst Towers, Sandton – 2005

A 125 mm, 3% dosage Ecobond Slab was constructed on a 6m high embankment using 75% imported crusher sand mixed with 25% very weak in-situ soils. The steep incline road carried many trucks through a very wet summer with no visible wear. Group 5 reported the Ecobond road was still performing very well 5 months later even after the embankment had been removed and recompacted.

9. Natural Ecobond Slab, Vaalwater, Limpopo Private Game Farm – 2001

4 km of 3%, 100mm Ecobond Slab roads were constructed with relatively fine Kalahari type sand. No bitumen seals were used to retain the natural Bushveld aesthetic. The durability of the roads was rated excellent, despite some wear on sharp bends caused by twin rear axles. The higher dosage, thicker sections showed hardly any wear.

10. Natural Ecobond Slab, Jozini, KZN – 2003

A 100 mm thick 3% Ecobond Slab was constructed using in-situ fine sand (81% passing the 0.425mm sieve). Ecobond strengthened the fine sand extremely well — Soilco Vryheid laboratory tested 5mPa UCS strength after 11 days — and made it highly water resistant.

11. Natural Ecobond Hardstand, Mpongwe, near Ndola, Zambia – 2007

6 000 m² 3%, 100mm thick Ecobond Slab was constructed for a road and hardstand for maize storage, including a weighbridge at 4% dosage. Loaded trucks exceeding 60 tons began using the slab just 4 days after construction. No visible damage was caused after more than 20 000 tons of maize was trucked onto the Ecobond Slab.

12. Natural Ecobond Slab, Coegha Harbour – 2003

A 300m, 100mm, 3% Ecobond Slab was constructed with in-situ sea sand as a temporary haul road for dumping rocks into the harbour. The road lasted very well for 7 months during which 13 million tons of aggregate and rocks were hauled at very low road building cost.

13. Ecobond Slab Parking Lot, Meyerton – 2004

A large parking lot with an asphalt seal remained in excellent condition after 7 years with no maintenance. On-site manganese waste was utilised as aggregate for stabilization.

14. Natural Ecobond Slab / Seal, Piggs Peak, Swaziland – 2005

3km of Ecobond Slabs and Seals were constructed on steep Drakensberg slopes with severe drainage problems. The road surfaces were strengthened considerably without a bitumen seal. The Ecobond Slab (mix-in) and Ecobond Seal (spray-on) lasted 6 years without maintenance.

15. Modikwe Ecobond Slab Road, Northwest Province – December 2005

3.5km x 7m x 100mm 2.4% Ecobond Slab was constructed near Rustenburg. Lab tests showed excellent C3 strength. A 6.7mm bitumen slurry seal was added and the road remained in good condition after 7 years.

16. Ecobond Slab Pond Lining, Savuti, Botswana – 1996

150mm thick 3.5% Ecobond Slab pond lining has been under water for 12 years with dozens of elephants, buffalo and other game daily. Previously used concrete linings were too brittle and could not handle the heavy traffic.

17. Ecobond Natural Slab, Chintsa, East London – 2007

A 3.5km x 7m x 150mm, 2.7% Ecobond Slab wearing course was constructed. Despite heavy rain during construction, the imported Sabunga gravel was considerably hardened and waterproofed by Ecobond polymers to carry design traffic without a bitumen seal. Still in good condition with no maintenance after 4 years.

18. Ecobond Slab Pond Lining, Bapsfontein, Gauteng – 2007

A 75mm thick, 3.3% Ecobond Slab was used to line the sides of a 20 000m² dam which could never previously be filled due to excessive leaking. The dam is now full (3m deep) with no leaks.

19. TerraLoc Cable Trench Protection, Boksburg, Ekurhuleni, Gauteng – 2007

10km of Ecobond Cable trenches were backfilled with Ecobond reinforced soil and a 3m wide, 75mm + 75mm thick Ecobond Slab inspection road was constructed over them. Not a single cable theft was reported since installation.

20. Ecobond Low Dosage Slab Selected Layer, Qumbu, Eastern Cape – 2008

3.5km x 150mm thick 1% Ecobond Slab was mixed into the selected layer along a 23km provincial road. The result was considerably increased strength and water resistance, helping to ensure adequate support for the sub base, base and bitumen seal.

21. Ecobond Slab Access Road, Eikenhof, Rand Water Board – 2008

A 1.2km x 150mm 2% Ecobond Base Course was constructed with imported G2 material and surfaced with a 6.7mm slurry seal. The Ecobond layer is remarkably strong and water resistant and serves as an access road to the pump station.

22. Ecobond Natural Slab, Hekpoort, Gauteng – 2008

1.5km x 4m x 75mm 3% Ecobond Slab Road in a rural area, without bitumen seal, providing a durable all-weather wearing surface while preserving the natural environment.

23. Ecobond Slab Haul Road, Hendrina, Mpumalanga – 2008

A 16km x 150mm 2.5% Ecobond Slab was constructed on top of an existing gravel road and surfaced with 30mm asphalt to carry coal trucks from the Total coal mine to the Hendrina power station at Pullens Hope.

24. Ecobond Wearing Course Modification, Phola Mine, Mpumalanga – 2010

1 km of internal inspection roads had become impassable due to poor quality material and drainage problems. 1.5% Ecobond was mixed into a 100mm thick layer and compacted to improve bearing capacity and reduce water ingress.

25. Ecobond Township Road, Parys, Free State – 2010

A low volume tertiary road, stabilized in-situ with 1.5% Ecobond, surfaced with cold asphalt and finished with low-cost curb-stones.

26. Ecobond In-Situ Road Recycling, Eskom & Bigen Africa – 2010

In-situ recycling of 9km of an old, unusable provincial road using 0.5% Ecobond. The road carries approximately 2 000 coal trucks per day. Initially designed as a 3-month temporary road, it has been in service for 9 months with a permanent Ecobond base course and bituminous seal planned for long-term use.

27. Ecobond Urban Road, Stockville Road, Pinetown, Ethekweni Municipality – January 2010

Reconstruction of an old, unusable urban road using 2.5% Ecobond. The previous asphalt, ETB and concrete road had failed. A 150mm Ecobond base course was installed and surfaced with asphalt.

28. Ecobond Wearing Course, Rabie Ridge, JRA – July 2011

G6 material was imported on top of an existing failed gravel road. With a 3% Ecobond StabilMix dosage mixed into a 100mm aggregate layer, an effective and durable wearing course was provided to give the local community all-weather access.

29. Ecobond E-Base, Parys – 2012

A 2% Ecobond 100mm E-Base road was constructed in the township and sealed with 25mm cold-mix asphalt. This proved to be an ideal, durable, low-traffic-volume solution that can create much employment and improve conditions for many communities, extending existing road budgets further.

30. Ecobond Asphalt Base, Hungary – 2012

Several Budapest roads were recycled using Ecobond modified asphalt as an effective wearing course. Ecobond treated aggregates can bend and return without cracking, making this application ideal for sub-zero temperatures. Ecobond makes bitumen less temperature sensitive, with its resin component remaining stable up to 173°C and reducing cracking at low temperatures.

31. Ecobond Road Shoulders, Zwartkops, Pretoria – 2012

Dangerous edge-breaks on the Old Johannesburg–Pretoria road were addressed by mixing Ecobond in labour-intensively, placing and compacting it. This reinforced the road aprons considerably and greatly reduced erosion and costly re-gravelling. The application can also be extended to bicycle paths, pedestrian paths and sidewalks.

32. Ecobond Base Course, Soshanguve, Pretoria – 2012

A pavement structure designed around a 2% dosage Ecobond BituForce base reduced the overall road cost by approximately 30%. Tests showed exceptional UCS & ITS strengths even after soaking. Tshwane City Council constructed 11km of roads and continues to reorder and benefit from Ecobond.

33. Ecobond Base Course, Radiokop – 2012

An Ecobond BituForce base-course was designed for JRA by Ledwala Consulting Engineers for several urban road sections in Johannesburg. Sealed with 30mm hot-mix asphalt, these roads eased service delivery in an economical and effective way.

34. Ecobond Base Course, Manzini, Swaziland – 2012

This Ecobond E-Base was constructed in 2011 and endured traffic and weathering for almost a year before the bitumen seal was added, without any significant erosion or maintenance. Several similar roads were ordered and constructed by Manzini Council.

35. Ecobond Base Course, Namibia – 2013

11km of Ecobond BituMod sub-base was constructed in very fine in-situ Caprivi sand, reducing costs and quarry material. A low dosage of 0.75% Ecobond effectively bound the fine sand, allowing the road to be used as a wearing course before an imported base-course and seal was later added.

36. Ecobond Base Course, Villiers – 2013

Ecobond E-Base of 150mm depth with 2% dosage was constructed to support the asphalt seal under very heavy traffic at the Engen 1 Stop on the N3 south-bound. Designed and supervised by GMH Consulting Engineers.

37. Ecobond Dust Control, Westonaria Landfill – 2013

An Ecobond ModSpray with 0.5% dosage, 150mm deep, was constructed on unstable sub-layers leading to a refuse dump. The wearing course is maintained by spraying Ecobond SprayOn onto the surface as required — with no resprays needed for almost 2 years.

38. Ecobond Dust Control, Kwamahlanga – 2013

The Ecobond SprayOn is a unique way to control dust and reduce erosion of gravel road surfaces in township and rural areas. It improves the quality of life of the community and reduces the maintenance cost of regular grading and re-gravelling. Respray frequency depends on traffic, climate and soil type.

39. Ecobond Base Course, Soshanguve, Pretoria – 2014

Part of the ongoing construction of roads in Soshanguve by Tshwane City Council.

40. Ecobond Base Course, Mogale City – 2014

Following the success of the Ecobond roads in Soshanguve, Mogale City tested Ecobond at a SANAS accredited laboratory. Laboratory tests showed excellent wet strength. The council was very satisfied and is now specifying Ecobond BituForce roads in future projects.

41. Ecobond Dust Control, DRC – 2015

200-ton Caterpillar 777 off-highway haulage trucks leave no or very little dust while travelling on Ecobond SprayOn. ReSprays are typically needed only once or twice a week, compared to at least 21 water sprays per week for traditional dust inhibitors — at significantly greater cost.

42. Ecobond Base Course, DRC – 2015

In-situ stabilization of an un-cohesive sand for an urban road in Kinshasa, surfaced with a bitumen slurry seal.

43. Ecobond Base Course, Zakkariya – 2016

In-situ stabilization of an existing surfaced road in Johannesburg, surfaced with an asphalt seal.

44. Ecobond On-Site Batching Plants, Postmasburg and University of Limpopo – 2020

On-site batching plants established to support projects at Postmasburg and the University of Limpopo.

Many other examples — including pothole / road maintenance, airstrips, pond linings and labour-intensive applications — can be provided on request.

COTO Standard Specifications (2020 Edition)

The new COTO Standard Specifications for Road and Bridge Works for South African Road Authorities was approved by the Committee of Transport Officials (COTO) on 18 August 2020 as a Draft Standard (DS), replacing the COLTO Standard Specifications (1998 Edition). Ecobond is one of the only applicable products in South Africa under these new specifications (2021).

Non-Traditional Stabilising or Soil Treatment Agent

The use of non-traditional stabilising or soil treatment agents may be specified in the Contract Documentation. Should the Contractor propose the use of such an agent, the following information must be submitted for review by the Engineer:

• Detail of the type of agent and basis material
• A cost comparison showing it to be economically viable compared to traditional stabilising agents
• Test results confirming the agent is effective in achieving the specified material properties for the applicable layer
• Accreditation by a recognised body such as Agrément South Africa, or project details of previous successful use with test results, references and contact details
• Application specifications from the supplier, a method statement describing the application and processing of the stabiliser, and an equipment list

Resources

Equipment and Plant available includes: TLBs, Graders, Tipper Trucks, Water Bowsers, Various Compaction Rollers, Chip Spreader, Asphalt Paver and a Recycler.

TerraLOCK Technologies (Pty) Ltd has a reliable credit record and access to capital to purchase additional equipment and plant as required by the contract.

Our company has access to Engineers, Civil Technicians, Surveyors, Site Agents, Mechanics and Health & Safety Specialists, as well as a competent “Back of House” system including Financial, HR, Operations and Sales Departments to handle any queries.

Local Economic Development Programme

TerraLOCK Technologies (Pty) Ltd is committed to the upliftment of the communities we operate in and is actively involved in skills sharing and empowering local entrepreneurs who wish to get involved in our industry.