How We Turned Challenges into Strength - A 10-Day Story of Discovery, Innovation, and Transformation
Have you ever walked on paving blocks that looked weak, uneven, or discolored and wondered why? TEMACO Builders asked itself the same question. As an industrial producer of paving blocks, TEMACO noticed that some of its own products were not meeting the high standards it promised. Instead of ignoring the problem, the company decided to take action. This began a 10-day journey of research and innovation that transformed the way TEMACO produces its pavers.
1.0 A Simple Question
Have you ever walked on paving blocks that looked weak, uneven, or discolored and wondered why? TEMACO Builders asked itself the same question. As an industrial producer of paving blocks, TEMACO noticed that some of its own products were not meeting the high standards it promised. Instead of ignoring the problem, the company decided to take action. This began a 10-day journey of research and innovation that transformed the way TEMACO produces its pavers.
2.0 The Journey Begins
The journey started with a team of TEMACO managers, engineers, and experts visiting competitor sites, suppliers, mix design lab and local crushers in Kigali. What we found surprised us: most of the aggregates and sand contained mud. This mud was the hidden enemy. It weakened the bond between cement and stone, turning strong pavers into fragile ones and changing the color from clean grey to a muddy brown.
TEMACO team visiting crusher sites during the research journey.
The team did not stop there. They traveled to Ngororero and Rwamagana, where they found cleaner sand and aggregates, although more expensive. This discovery showed that better materials existed, but also pushed TEMACO to think of a bigger solution.
3.0 The Turning Point
Instead of depending only on suppliers, TEMACO decided to create a solution in-house. Together with Isaac, an mechanical and reverse engineer from Kenya, TEMACO designed a sand separator machine. This machine performs three critical functions: it separates sand from mud, washes the sand to remove fine dust, and cleans aggregates so they bond properly with cement. Made from scratch with our local materials with automated system. In simple terms, it was like giving the factory its own washing machine for raw materials.
With this innovation, TEMACO could guarantee the quality of the materials it used, leading to stronger and more durable pavers.
Prototype of the sand separator machine at TEMACO.
4.0 Small Changes, Big Impact
Not every change was as big as building a new machine. Some were simple but powerful:
- Instead of using wheelbarrows or guessing quantities, TEMACO switched to calibrated buckets for measuring materials. This made every batch consistent.
- TEMACO re-introduced admixtures—special helper chemicals like Sika ViscoCrete 90HE and Sika 20. These reduced water use, made concrete flow better, and increased durability.
- Standardized vibrating table timing (50–60 sec per layer, clean surface).
- The curing process was changed. Pavers stayed in molds for 24 hours before being removed, then cured in stacks with airflow for at least 4 days. Like cheese or wine, the longer curing gave pavers their strength and quality.
TEMACO staff testing new mix ratios and curing practices.
5.0 Lessons We Learned
The most important lesson was that quality is not an accident. It is built step by step. From choosing the right sand, aggregates, to measuring carefully (cement, sand, aggregate, sika and water), mixing ratio, layer level, collecting the mixed concrete, vibration timing, to curing with patience, each stage matters. TEMACO learned that discipline and innovation together create excellence. By training staff and introducing SOPs, the company made sure that these lessons became part of everyday practice.
6.0 Looking Ahead
This journey is just the beginning. TEMACO plans to introduce centrifugal mixers to make top layers smoother, organize storage, develop metal pallets, explore eco-friendly pavers with recycled materials, and design tools for production support. Beyond paving, the company envisions growth in concrete and fiberglass products.
From mud to mastery, TEMACO Builders is building not just pavers but trust, innovation, and excellence—step by step.
Stay tuned to our next creation, research and innovation
Stacks of cured pavers after adopting the improved process.