Imiesa August 2017 by 3S Media

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IMESA The official magazine of the Institute of Municipal Engineering of Southern Africa

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

Gautrain

Perfecting the integrated transport model

eThekwini

GO!Durban on the move

Roads & Bridges

Lessons in labourintensive construction

AfriSam

Laying firm foundations IN THE HOT SEAT Over the past four years, our customers have seen and experienced our supplier commitment and they do appreciate that. Hence our increased base of loyal customers in what is an extremely competitive environment.”

Werner Tessendorf Business Development Manager, Tosas ISSN 0257 1978

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www.infrastructurene.ws

IMESA The official magazine of the Institute of Municipal Engineering of Southern Africa

VOLUME 42 NO. 08 AUGUST 2017

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

Gautrain

Perfecting the integrated transport model

eThekwini

GO!Durban on the move

Roads & Bridges

Lessons in labourintensive construction

17 Women in Engineering A passion for the community

AfriSam

Laying firm foundations

Technical Paper

IN THE HOT SEAT Over the past four years, our customers have seen and experienced our supplier commitment and they do appreciate that. Hence our increased base of loyal customers in what is an extremely competitive environment.”

Lessons in labour-intensive construction

Werner Tessendorf Business development manager, Tosas

INSIDE

ISSN 0257 1978

V o l u m e 4 2 N o . 0 8 • A u g u s t 2 0 1 7 • R 5 0 . 0 0 ( i n c l . VAT )

AfriSam’s just-in-time readymix solutions are helping to accelerate delivery on a range of single- and multistorey residential projects. P6

Regulars Editor’s comment President’s comment Africa round-up Index to advertisers

Cover Story AfriSam: Laying firm foundations in housing

3 5 8 76

Tosas: Building roads, linking people 10

Municipal Focus | eThekwini

HOT SEAT Werner Tessendorf, Business Development Manager at Tosas, talks about the company’s evolving vision, project activities, the launch of its Chipseal™ emulsion and the issue of the ‘winter embargo’. P10

WOMEN IN ENGINEERING A passion for the community

A budget for the people 12 Go!Durban on the move 14 Work on Northern Aqueduct ramps up 16

Bitumen, Asphalt & Roads Cover Story: Time for the Chippy Reclaimed asphalt builds economies Upskilling road construction professionals N2 extension alleviates congestion Supply Chain Discussion Colas eltherm Kaytech SprayPave

Transport, Logistics, Vehicles & Equipment Perfecting the integrated transport model Excavating with intelligent control New screening solution launched

42 44 46

Speciality Chemicals Leading in the chrome value chain 47

Environmental Engineering Gabions and site assessments

Plastic Pipes

Hot Seat

IN THE

18 20

First Sappma policy on gaseous fluids Supply Chain Discussion Marley Pipes MacNeil Pexmart Sizabantu

57 59 61 63

Meters, Pumps & Valves 65 years of pump innovation New radar level transmitters

64 65

Pressure Management The case for pressure control in SA 67

23 27

Aggregates & Readymix

29 31 33 34

Cement & Concrete

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT Perfecting the integrated transport model

Materials on demand

Concreting a team approach Precast construction underutilised Building in precast

72 73 74

ENVIRONMENTAL ENGINEERING Gabions and site assessments

GORMAN-RUPP AFRICA (PTY) LTD

4 HAROLD FLIGHT ROAD, JET PARK, BOKSBURG | GAUTENG, R.S.A. 1459 PH: +27 11 397 3536 | WEB: WWW.GRPUMPS.CO.ZA | EMAIL: INFO@GRPUMPS.CO.ZA 518-GRA

AFRICA

EDITOR'S COMMENT

Teamwork and the economy

PUBLISHER Elizabeth Shorten MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson HEAD OF DESIGN Beren Bauermeister CHIEF SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter CONTRIBUTORS Gavin Clunnie, Robert McCutcheon, Ronnie McKenzie & Willem Wegelin CLIENT SERVICES & PRODUCTION MANAGER Antois-Leigh Botma PRODUCTION COORDINATOR Zenobia Daniels FINANCIAL DIRECTOR Andrew Lobban DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za PRINTERS United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________

he South African government’s inclusive growth action plan and its effective implementation will be decisive in lifting the country out of its recession and will come up for intensive debate during the medium-term budget policy statement address in October. Backed by an improvement in commodity prices, and growth in agriculture and manufacturing, we have the foundation for positive traction, but we need clear purpose and direction. Government’s inclusive goals include the development of a private sector participation framework, plus reforms within state-owned entities that could see the unbundling of non-core assets. Across the board, key drivers are inclusivity and transformation, with a major emphasis on restructuring procurement policies to promote and grow previously disadvantaged sectors of the economy. Transformation needs teamwork and cooperation to succeed.

ADVERTISING SALES Jenny Miller Tel: +27 (0)11 467 6223 Email: jennymiller@lantic.net ___________________________________________________

PUBLISHER: MEDIA No. 9, 3rd Avenue, Rivonia 2056 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za ANNUAL SUBSCRIPTION: R550.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2017. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za

Reviewed Mining Charter With teamwork, just about anything is possible; and if South Africa’s private and public sectors can find common ground, investor confidence will be restored. But that depends on establishing workable policy frameworks that foreign investors can also relate to. The Department of Mineral Resources’ proposed introduction of the Reviewed Mining Charter is a case in point when it comes to major disconnects. The Chamber of Mines’ response was to apply for an urgent interdict to prevent its implementation, stating that the Reviewed Mining Charter is “an unlawful exercise of power”, which places the mining industry under further threat at a time when a recovery is in sight. A High Court hearing date is proposed for September 2017.

BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Fax: +27 (0)43 743 5266 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Fax: +27 (0)41 585 1066 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Fax:+27 (0)31 266 5094 Email: imesakzn@imesa.org.za NORTHERN PROVINCE Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 Email: np@imesa.org.za

SAFCEC Q2 survey Within the construction sector, investment in road infrastructure remains one of the main sources of work according to SAFCEC’s State of the South African Civil Engineering Contracting Industry

SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za

Q2 2017 economic survey. Large and medium-sized companies generated around 47.8% of their turnover in the roads sector during Q1 2017, followed by the power segment (14.6% for bulk and 3.1% for services) and water and sanitation at 8.7%. Mining infrastructure represented 1.4% of turnover for Q1, which is indicative of subdued activity in this sector. In terms of public sector construction spend, KwaZulu-Natal led in Q1, contributing 27% to earnings, followed by the Eastern Cape (16%), Western Cape (16%) and Gauteng (12%) as the next largest contributors. Competition for work remains strong and 52.6% of the SAFCEC firms surveyed reported very low tender prices. This contributed to a steady drop in profit margins, placing pressure on employment. According to the report, “Employment fell by 1.4% q-q in the Q1 2017, following the 4.8% contraction reported in Q4 2016.” We know that job creation is essential, and potentially the Expanded Public Works Programme (EPWP) could make a real difference, especially for impoverished rural communities, while at the same time stimulating the construction industry. During his budget vote speech in May 2017, Minister of Public Works Nkosinathi Nhleko set a goal of creating six million work opportunities by 2019; and around 1.4 million for the 2017/18 financial year. That’s a great start. Supported by meaningful skills transfer, the EPWP prepares workers for permanent positions in the mainstream economy. Let’s create a legislative framework that achieves this so that we can bring everyone on board.

Alastair Currie

To our avid readers, check out what we are talking about on our website, Facebook page or follow us on Twitter and have your say.

FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Fax: +27 (0)86 628 0468 Email: imesafsnc@imesa.org.za

struc www.infra

@infrastructure4

IMESA

turene.ws

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magazine The official of the Institute Engineeri ng of Municipal Africa of Southern

THE ROAD TO

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ON TION INNOVA

All material herein IMIESA is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

-EDGE OF IS AT THE CUTTING CHANGE, VNA UTING TO THE MOVEMENT TOWARDS SERVICE DELIVERY, CONTRIBOUSE. MENT IN CONSTANT BUILT ENVIRON ECONOMIC POWERH SOUTH AFRICA’S A MEANINGFUL to EMERGENCE AS is the capacity g and key strengths CONTINENT’S CONSTRUCTION MANAGEMENT, ED FROM ROAD ASSET AND SPECIALIS ENGINEERING CTURE MANAGEMENT, TO INFRASTRU PAVEMENT SERVICES,COST ADMINISTRATION, AND GY AND DEVELOPMENT FORESIGHT, TECHNOLO VALUE WE HAVE THE CREATE THE HIGHEST EXPERTISE TO ALL OUR CLIENTS. RESULTS FOR

challengin One of our and deliver help plan, designand bridges. innovative roads the industry truly understand market and At VNA, we needs of the l potential, and the distinctive tion of to realise continenta our vision is environment transforma ensuring built and beyond. South Africa setting the for the a leading specialist solutions Looking for infrastructural South Africa... standard in nt of economic developme than VNA. look no further

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Cover opportunity

In each issue, IMIESA offers advertisers the opportunity to get to the front of the line by placing a company, product or service on the front cover of the journal. Buying this position will afford the advertiser the cover story and maximum exposure. For more information on cover bookings, contact Jenny Miller on +27 (0)11 467 6223.

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ced our supplier SEAT and experien rs have seen d base of IN THE HOT our custome Hence our increase past four years, that. Over the appreciate environment.” and they do ly competitive commitment an extreme rs in what is , Tosas loyal custome ent manager Business developm • August

dorf Werner Tessen Pinetown, 3610 Park 2000, Westmead, 4001 10 Kyalami Road, CORPORATE OFFICE: Mokaba Ridge, Berea, Durban, 596 Peter vnac.co.za HEAD OFFICE: Email: yesh.balaram@visit our website: www.vnac.co.za +27 31 700 2550, offices, please 2500, Facsimile: national and regional Tel: +27 31 700 regarding our For further information

• MAINTE E DEVELO PMENT

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IMIESA August 2017

PRESIDENT’S COMMENT

IMESA

Engaging with industry

year has passed since the August 2016 municipal elections, giving the new management teams appointed at local, district and metro level ample time to settle in and start applying their minds to implementing the 2017/18 budgets and maintaining momentum on their medium-term expenditure framework targets. We know from the latest Auditor General’s report that most of our municipalities need to raise their game significantly, and that means investing in the right skills so that we have the best decision-makers in place to address service delivery challenges. IMESA’s members, whether employed in the public or private sphere, are helping to lead the change. Plus, as a voluntary association, IMESA continues to engage with key industry bodies so that we can pool our expertise and coordinate common objectives more effectively. A case in point is a memorandum of understanding (MoU) concluded with the Southern

African Bitumen Association (Sabita). As the president of IMESA, I have been elected to the Sabita council, on which I am proud to serve. What an honour. Sabita makes a huge contribution to the bitumen industry by maintaining and revising standards, working to introduce new specifications, as well as developing manuals that form the benchmark for current and future application practices in the roads sector. Working with Sabita will help us form stronger links with municipalities in a host of different areas that include labour-intensive construction, SMME contractor development, and training. IMESA is now also in the process of revisiting its MoU with the South African Local Government Association (Salga) – one of our most important stakeholders. Salga has endorsed the annual IMESA Conference, being held in October 2017, and we will be meeting during the event to revisit our mutual goals. Salga remains committed to building capacity. The Small Town Regeneration and

Regional Economic Development initiatives, for example, are aimed at restarting economies, and sustaining existing ones. Going forward, sustainability is the key, and our industry and South Africa – as a whole – will only function effectively if we all work together.

In memoriam: Alec Hay It is with great sadness that I heard of the passing of Alex Hay, a member of both SAICE and IMESA. Alec was a stalwart in the municipal and civil engineering environment and served on numerous educational and engineering committees. He will be sorely missed but nevertheless remembered for his pasIMESA president sionate contribution to Gavin Clunnie the industry.

Gearing up for IMESA 2017 The 81st instalment of the IMESA Conference is drawing nearer, with time running out for discounted registration rates.

he theme for the 2017 IMESA Conference is ‘Sustainable engineering: back to basics for the future’, posing the important question, ‘Has technology in design made us forget the basic principles of engineering design?’ The speakers at this year’s event will be announced shortly, following the submission of more than 40 highly informative paper abstracts for consideration. The IMESA Trade Exhibition has grown steadily over the past 81 years and has become an important feature of the conference, attracting delegates from across the country. For the

exhibitors and sponsors, there are benefits in promoting their products and services directly to those people who formulate the recommendations and make the decisions. It also provides an opportunity to network with clients as well as other influential people in the industry. The majority of the exhibition space at this year’s conference has already been booked, with only about 20 stands left. Sponsorship slots are also filling up fast. “With all the challenges facing our industry today – economic, social, environmental or political – we need to adapt and be innovative. This starts with the local authorities, where most of us perform some function to serve our communities. But it goes beyond the government corridors – it stretches into the

ideas and solutions for taking municipal engineering into the future as envisaged and created by the engineers in South Africa,” says Gavin Clunnie, IMESA president and chair of the local organising committee.

Strategic partnerships The South African Local Government Association (Salga) is endorsing this year’s IMESA Conference – a first for the annual event. This follows on from the long-standing strategic partnership signed between Salga and IMESA in 2011. As part of the partnership, IMESA and Salga have agreed to collaborate on the goals of the partnership until they have achieved these objectives or until the partnership is terminated by mutual agreement.

IMIESA August 2017

COVER STORY

AfriSam’s just-in-time readymix solutions are helping to accelerate delivery on a range of singleand multistorey residential projects.

Renier Rossouw with some of the local labour benefitting from job creation and skills development during the project

firm foundations Laying

AfriSam supplied concrete for the 11 three-storey blocks as part of phase 1 of the RDP flats

in housing

n the frontline of supplying quality, affordable housing to South Africa’s growing urban population, construction materials leader AfriSam is working closely with Raubex Building on a new Valumax development in the Clayville Ext 45, Tembisa, area in Midrand, Gauteng. The substantial development comprises bonded properties for private sale, plus government-funded RDP flats built in blocks of different sizes. A member of the JSE-listed Raubex Group, Raubex Building – formed in 2012 by Barend Badenhorst, Gert van der Werff and Werner Muller – started life as Raubex Housing. After expanding beyond housing into commercial developments, the company changed its name to Raubex Building in early 2016. “We have been working with AfriSam since at least 2013, and have always been impressed by the reliability of service and quality of product,” says Renier Rossouw, quantity surveyor, Raubex Building. “Our projects are always constrained by budget and time, so we need partners that deliver on their promises, so that we can deliver on ours.”

Private sales

The new Valumax development in the Clayville-Thembisa area consists of both bonded properties for sale and governmentfunded RDP flats build in blocks of different sizes

IMIESA August 2017

On the residential units for private sale at the Clayville development, work has been ongoing since the beginning of 2015, with 822 houses constructed by June 2017. The designs detail three size configurations of 45 m2, 52 m2 or 56 m2 each.

The main demand for readymix on this project was for the raft foundations, with each house taking between 8 m3 and 9 m3 of 20 MPa concrete – depending on the size of the house. With four foundations being poured daily, AfriSam was delivering about 36 m3/day, according to Adele Wentzel, sales manager, AfriSam. “We delivered a total of some 7 000 m3 of readymix from our Olifantsfontein plant, which is only about 11 km from site,” says Wentzel. “This allowed us to keep costs to the customer at a minimum while meeting delivery deadlines. Our extensive footprint in the region allows us to coordinate alternative supply from another plant, if the need arises.”

First phase of RDP flats Not far up the slope from these houses are the first and second phases of a government-funded project to provide RDP flats for residents. According to Rossouw, the first phase started in January 2016 and was handed over to the client in February 2017. This comprised 11 three-storey blocks making up a total of 237 flats, each with an approximately 40 m2 floor area accommodating two bedrooms, a bathroom and an openplan kitchen. Raft foundations for this phase required AfriSam to supply about 1 100 m3 of 20 MPa readymix concrete, while the rib and block slabs between the levels of the flats used about 500 m3 of the stronger, 25 MPa concrete. On the ground floor, the concrete was manually power-floated to obtain a smooth finish, while a 15 mm to 20 mm screed was put down on the upper floors to get the required finish on the rib and block slabs.

Second phase Just 700 m down the road is the second phase of the RDP housing project, which will run until March 2018. Initially, Raubex was contracted to tackle 264 living units – a contract that was then expanded to 484 units. This time, the contract called for four-storey blocks, and a total of 18 will be built. The units in these blocks are also 40 m2 in size, and there are 20, 28, 32 or 36 units in each different-shaped block. About 1 800 m3 of 20 MPa readymix concrete will be delivered by AfriSam for the raft foundations by the end of this phase, as well as another 1 200 m3 for the rib and block slabs between levels.

Secure supply “Contracts like these demand a reliable supply of readymix, as our work is highly structured and

planned in detail,” says Rossouw. “AfriSam’s capacity is, therefore, important to us. If anything affects its production at one plant, it can ensure we get what we need from another of its operations.” He says it is also vital that the concrete is compliant with a range of quality requirements, as each pour must be tested and sent to independent laboratories – as part of company policy and contract requirements. Wentzel says AfriSam’s depth of expertise in cement and concrete technology allows the company to offer support to customers regarding testing and quality issues. “If requested, we can even offer skills training to customers’ employees on the processes for testing on-site and the various procedures to be followed,” she says. “AfriSam also conducts tests on-site for pours of over 50 m3 if the customer requires it.” She also highlights the importance of good systems and constant communication on both sides of this partnership, ensuring that each party knows what to expect, and when. Rossouw says Raubex Building appreciates the quick response from AfriSam’s control centre, which provides monitoring of all readymix trucks and operations so that any queries from customers can be answered efficiently and the required action taken.

Concrete innovation The adoption of the waffle raft foundation design on this project has been an important innovation to leverage the versatility of concrete, while also enhancing the job creation capacity of the work. Developed by civil engineer Terry Pidgeon, this design provides load-bearing capacity in the foundation, even where the soils are expansive, rocky or hydro-collapsible. The foundation is created by excavating a series of pod forms to create a grid of ribs. A continuous concrete pour creates concrete beams running throughout the footprint

and perimeter of the foundation (with voids between) in one operation. The completed slab then sits on the ground, bearing on the ribs created between the forms, while the void areas underneath the slab allow for soil movement. Strengthened with reinforcing bar, the waffle slab foundation is very stiff and can resist the impact of ground swelling due to surface drainage or flooding from any source.

Skills for growth There are about 260 workers on-site during this phase of the project – mostly locals who are engaged and trained by Raubex Building. “Our construction method is deliberately labour intensive to allow a high level of job creation and skills development,” says Rossouw. “Once delivered by the AfriSam readymix trucks, the concrete for the raft foundations is moved mainly with the use of wheelbarrows; for the same reason, the smooth surface is obtained with a manually operated power-float.” He says the company believes in employing local labour, wherever possible, to ensure the spreading of economic benefits and skills to the local area. These workers are trained by Raubex Building’s core team, which makes up only about 20% of the staff on-site at any given project. “We also engage subcontractors from the local area, mainly to handle the electrical installations in each residential unit, as well as the plumbing, glazing and ceilings,” he says. Skills are developed through the Raubex philosophy of ‘Bafana Teams’, where Raubex staff help locally based employees to work effectively together in teams, building their own skills while ensuring that project targets are met.

www.afrisam.com

IMIESA August 2017

INFRASTRUCTURE NEWS

FROM AROUND THE CONTINENT

AFRICA Urban development must go green A fast-urbanising Africa is rapidly degrading the environmental assets of its cities. According to a new World Bank report titled ‘Greening Africa’s Cities’, the unique features of Africa’s urbanisation – such as substantially lower per capita incomes, high reliance on biomass fuels, extensive informal settlement with poor service levels, and exposure to environmental disasters – is putting pressure on African cities’ natural environments and eroding the value of environmental assets (green spaces, forests and water resources). The report points out that there are important opportunities to change the trajectory of African cities to ensure that those areas that will eventually be covered by the built environment are developed with a comprehensive green urban development strategy.

Such a strategy must tackle the core problems of pollution and waste, overconsumption of natural resources and eradication of ecosystems, and the reduction of biodiversity. “The degradation of natural assets and ecosystems within African cities carries tangible economic, fiscal and social costs, including increased costs of water production, deteriorating human health, damaged infrastructure, reduced property values, and a loss of recreation and tourism value,” says Sanjay Srivastava, lead environment specialist at the World Bank, and contributor to the report.

“Fortunately, there are important opportunities to change the trajectory of African cities towards a more harmonious relationship between their natural and built environments. However, focused action is needed to make this happen,” he concludes.

BENIN Building a smart city Benin has launched an international call for projects, inviting potential partners to become involved in the development of Sèmè City. A unique project in West Africa, Sèmè City will promote synergies between education, research and incubation of innovative solutions to respond to the economic challenges facing Africa, and offer

opportunities for the future of the continent’s youth. Launched as part of Revealing Benin, the government’s programme of investment and development, Sèmè City will house elite educational establishments, research and development centres, and a business incubator supporting up to 250 start-ups. The call for projects includes potential partners interested in developing the infrastructure and services associated with Sèmè City. The project will benefit from state support at the highest level, and the government of Benin has planned to invest CFA207 billion (R4.8 billion) in the coming years. With the initial works commencing in 2017, Sèmè City

Burkina Faso plans to shift the country to renewable energy

FAST FACTS

250

start-ups will be supported by the Sèmè City project

<2%

of Liberia’s households have access to electricity services

200 km

of feeder roads will be upgraded in Ghana

$80 million will be used to develop low-cost solar in Burkina Faso

will become a sustainable smart city, capitalising on the natural benefits of the coast of Benin and integrating a full range of services for its partners and residents.

BURKINA FASO Diversifying the energy mix Burkina Faso’s energy strategy is to reduce dependence on costly, imported fossil fuels and gradually shift the country’s production mix to renewable energy and electricity imports at an affordable cost. The countr y recently received $80 million of credit to assist in incorporating low-cost solar resources into its energy mix and improve its distribution network. This approach will reduce the overall cost of electricity, which remains high in Burkina Faso, as well as minimise the countr y’s exposure to the risks of oil price and exchange rate volatility. To achieve this, energy production must be boosted to overcome the capacity deficit and respond to strong demand growth. The national distribution network will also need improving to facilitate the absorption of intermittent solar energy. Ghana will rehabilitate road links on the eastern border with Togo, as well as 200 km of feeder roads

The credit from the World Bank will assist electricity sector operators to build this capacity and provide transactional advice to promote the development of private sector projects for independent power producers.

Liberia will develop a 9.8 MW hydropower plant at Gbedin Falls on the Mano River

GHANA Major road upgrades on the cards Through its Transport Sector Improvement Project, Ghana plans to rehabilitate road links from Tamale to Yendi, and Tatale on the Eastern border with Togo, as well as about 200 km of feeder roads. The project, to be funded by a $150 million loan, will improve regional connectivity in the Northern Region and link agricultural value chains to provide access to markets and support agribusiness. The project will reduce travel time on selected parts of the road network, promote road safety, and strengthen the institutional management of the transport sector by using the Performance-based Contracting Methodology. It will specifically contribute to capacity building and the modernisation of the transport sector institutions, generating

efficiency gains in a sector that is a major contributor to growth and poverty alleviation.

LIBERIA Boosting renewable energy Liberia has been given a grant of $23.25 million to assist in transforming the country’s energy sector. Liberia has one of the lowest electricity access rates in the world – with less than 2% of households having access to electricity services nationwide. Expanding access to electricity is, therefore, vital and should be one of the country’s top priorities. The grant will be used to develop a 9.8 MW hydropower plant at Gbedin Falls on the Mano River in Nimba County and provide a low-cost, sustainable and reliable source of electricity to Liberia. The electricity to be generated here will be transmitted via the existing Liberia-Ivory Coast cross-border transmission line. Based on the annual average household’s electricity consumption that currently stands at 510 kWh for an average family of five persons, it is estimated that the project would supply electricity to about

500 000 people. The project is expected to reduce the use of highly polluting standalone diesel generators that are critical in powering not only Liberian businesses and households, but also in improving the conditions of health and education infrastructure.

MOZAMBIQUE Construction sector SMEs get a boost Mozambique will utilise a $1 million loan to finance the Nacala Corridor Business Linkages Technical Assistance Project. The project is aimed at improving the efficiency and competitiveness of SMEs in the construction sector situated in the Nacala Corridor, to enable them to take advantage of business opportunities provided by the Nacala rail and port projects and other large construction investments. In the next three years, the project will seek to strengthen the business management skills, industry knowledge and know-how of selected SMEs in the construction industry through training, coaching, mentorship and other support activities.

The Nacala Corridor Business Linkages Technical Assistance Project in Mozambique is aimed at improving the competitiveness of construction sector SMEs situated in the Nacala Corridor

IMIESA August 2017

Binding ro ads,

linking peopl

Continuously building the Tosas brand

IMIESA talks to Werner Tessendor f, Business Development Manager at Tosas, about the company’s evolving vision, project activities and the launch of its Chipseal™ emulsion. There’s also the issue of the ‘winter embargo’. What does the slogan “Binding roads, linking people” represent for Tosas? WT Tosas has been supplying and applying road binders for 45 years. However, we feel we do a lot more than just supply products. We build long-term relationships with our customers and our products help to link towns and communities, in the process interconnecting businesses and services, especially in remote areas previously not accessible by road. That’s why we recently added a second slogan, over and above our main one, which is “Binder Excellence”. Our additional slogan is “Binding roads, linking people”. Both of our slogans totally encapsulate our business and what we are about!

What’s unique in terms of Tosas’ solutions? We are constantly innovating and spend a lot of time and energy in our internal R&D Department – not only for product developments, but also in terms of equipment and technological improvements. In July 2017, we launched our new Chipseal™ emulsion. Chipseal™ is a modified cationic emulsion designed to stop run-off and allow for more binder to be applied than is conventionally possible with emulsion. This provides so many advantages for not only winter work, but also for labour-intensive resurfacing. We are also pleased to announce that our Ralumac® machines are currently undergoing final commissioning after the

We’ve worked very hard to restore customer confidence in the company and we believe we have become the preferred supplier in the market once again.” Werner Tessendorf, Business Development Manager, Tosas

Dusty road stone being applied to Chipseal emulsion

SABS homologation process and the first trials are taking place as we speak. We have, however, already successfully applied Ralumac® microsurfacing, as well as rut filling in the Komatipoort area, through one of our sister companies that also owns a machine capable of Ralumac® application. We are extremely proud to have the Ralumac® name as part of our product range and we look forward to many roads being given a second life through this superior product. On the bitumen rubber side and after many years of planning, research and application, it appears likely that our NCRT™ could be included in an addendum to the TG1 document in the not-too-distant future, and more than likely in the new categories of S-R2 and A-R2. These are major milestones and a feat we are truly proud of and will pave the way for the

HOT SEAT

application of high-quality rubber bitumen as a preferred binder onto many more roads in South Africa than was previously possible.

pressure on us to always maintain the position we’ve achieved through dedication and commitment, while we continuously improve and build our brand. Alongside our South African operations, Tosas does supply into the African market and we have branches in Namibia and Botswana. We also export products to many other SADC countries. We plan to increase our footprint and network in Africa and look forward to being a lot more involved going forward.

What are some of the key challenges facing the roads sector?

One of the most challenging issues we face as suppliers of bituminous products Has NCRT™ (or A-R2/S-R2) been is the so called “winter embargo”. This supplied on recent contracts? limits the period during which the road Yes, we have successfully completed a industry is allowed to seal on a large number of contracts with NCRT™ to date, scale with the more commonly accepted including some that were Sanral projects. In ‘summer products’. The ‘embargo’ is, line with the benefits of NCRT™, all of these however, regrettably unnecessarily applied, contracts were supplied from three fixed since it has been accepted by road owners plants, while the contracts were scattered that sufficient products are available to across almost all South Africa’s provinces. overcome challenges experienced in winter Would Tosas ever consider In August 2017, we will be commencing a time. The limitation that has been imposed becoming a road surfacing new flagship contract with Much Asphalt and or adopted by the industry is really for fear contractor? Roadmac Surfacing Cape for the Western of encountering negative results due to a No, most definitely not. We see ourselves Cape Department of Transport and Public cold-climate application of binders. purely as suppliers to the industry and will Works between Rooi Els and Gordon’s Bay. There are numerous ways and various not enter into the construction side of the This contract will require in excess of products that enable us to do winter seals industry. In other words, we never wish to 20 000 t of A-R2 asphalt to be supplied by and many kilometres have been sealed compete with our clients. Much Asphalt from their Eerste Rivier plant. historically, with, for example, winter-grade It is only on the Ralumac® microsur facing bitumen rubber. By applying the right What are prospects like in side that we get more actively involved techniques and products, there is, therefore, South Africa, as well as the in the application process, since the no reason why we cannot surface more cross-border market? licensed product requires total control of roads in the winter period. Implementing this Since Tosas was taken over by its new all aspects if the associated warranties will give customers and contractors a wider shareholder more than four years ago, are to be applicable. sealing window and alleviate any bottlenecks we’ve focused heavily on regaining lost Over the past four years, our customers with bitumen supply during ground in the South African market. This have seen and experienced our the summer months, was no easy task and was (and still supplier commitment and ultimately allowing is) very challenging within the current they do appreciate that. more roads to be environment. We’ve worked very hard Hence our increased surfaced per to restore customer confidence in the base of loyal customers year across company and we believe we have become in what is an the country, the preferred supplier in the market once extremely competitive something again. This, however, places continuous environment. I’m sure every person is in favour of across One of Tosas’ new Ralumac® units Flow of Chipseal™ the industry. 60% vs traditional cationic 60% Our Tosas team emulsion recently had the privilege of undergoing a seal training session with veteran engineer Adrian Bergh, and I will never forget his words, “We have built some of the best seals in the middle of the winter in the middle of the Free State.” He maintains that it is “nonsense” to have an embargo – you should just select the correct products and know what the constraints are!

www.tosas.co.za

IMIESA August 2017

MUNICIPAL FOCUS | eTHEKWINI

A budget for the people Hailed as ‘the people’s budget’, eThekwini Municipality’s 2017/18 budget aims to respond to residents’ concerns around poverty, unemployment, inequalities and underdevelopment.

elivering her 2017/18 budget speech, eThekwini Executive Mayor Zandile Gumede reiterated her commitment to improving the lives of all residents including those living in townships, rural areas, backroom dwellings, hostel dwellings, informal settlements and the homeless. This is the first time that eThekwini has based its budget on an extensive series of hearings held across the city. A total of 110 hearings were held across the wards, as well as six regional hearings, and further public consultations with various stakeholders, including business and civil society. “This budget is for the people by the people. It will respond to people’s concerns around poverty, unemployment, inequalities and underdevelopment. In my inaugural address, I promised to continue to improve people’s lives through accelerating service delivery, economic growth, job creation, and social and rural development. This budget is one that facilitates socio-economic transformation,” said Gumede.

2017/18 budget R45 billion is earmarked for the 2017/18 budget, consisting of an operating budget of R37.5 billion and a capital budget of R7.5 billion.

TABLE 1 Major capital programmes in the medium-term capital budget

Project/Item Low-cost Housing and Infrastructure EThekwini Transport Authority (including PTIS) Electricity Infrastructure Addressing Community Service Backlogs Water Loss Intervention Programme

Million ZAR 3 691.8 3 557.3 2 757.0 1 311.2 80.5

Roads Rehabilitation and Reconstruction, and New Access Roads

1 574.8

Wastewater Treatment Works: Upgrades/Expansion Northern Aqueduct – Water Western Aqueduct – Water Solid Waste Fleet Replacement Ablution Blocks-Upgrade: Informal Settlements

301.6 533.6 138.7 90.0 709.3

Inner City Regeneration and Warwick Development

211.5

Town Centre Renewals – Nodal Developments

212.5

Approximately 75% of the capital budget is allocated to meeting infrastructure and household services needs, as well as addressing backlogs over the medium term. Roughly R2.4 billion of this is directed to new housing developments and interim servicing of informal settlements. The increase of the operating budget from R34.9 billion in 2016/17 to R37.5 billion in 2017/18 is mainly due to the cost of addressing service delivery backlogs, the cost of bulk purchases of water and electricity, repairs and maintenance of infrastructure. The budget was tabled in what Gumede referred to as a tough economic climate, which restricts eThewkini’s ability to put forward an expansive budget. However, the mayor

“We want to become a smart city that manages its resources efficiently.” eThekwini Executive Mayor Zandile Gumede

believes that the R45 billion budget will effectively respond to a triple imperative, namely prudent control in tough economic times, providing a stimulus for economic growth and transformation, and service delivery to the people.

Facilitating catalytic projects Several catalytic projects are under way in eThekwini to assist in growing the economy, food security, job creation and women and youth development. These include the Cornubia Business and Industrial Estate, which has been completed and all sites sold. Construction is in the preliminary stages for a retail facility to provide retail and social services, and completion is planned for 2017/18. At the Dube Trade Port Industrial Development Zone, leases have been secured for all sites in Trade Zone 1, with a number of key factories constructed and operational. In 2017/18, construction will start on the multibillion-rand CIPLA

biotechnology hub, which will be a world–class, state-of-the-art facility. Environmental authorisation has been received for Trade Zone 2 and construction will commence in 2017/18. As part of commercially consolidating the Integrated Rapid Public Transport Network C3 project, the municipality has approved the selling of land to a black, empowered investor to build a shopping complex in one of the C3 stations. This investment by the private sector is estimated at more than R300 million and will create thousands of jobs. Work is also under way to renew the inner city. In February, council approved the implementation of Phase 1 of the Inner City Regeneration Programme, which included intensive urban management. This consists of increased visible security, engagement with business, alternative uses for all bad buildings and rationalising street trading as a positive contributor to livelihoods. R88.5 million is allocated for the programme in the Medium-term Expenditure Framework (MTEF). An additional R99 million is allocated to the Beachfront upgrade, R123 million for Warwick Junction, R61 million for the development of the Centrum site, and R90 million for enabling infrastructure for the Point Waterfront development.

Radical economic transformation “The biggest challenge of our time is to transform the South African economy – to grow it in an inclusive manner. Our economy must reduce inequalities, significantly decrease unemployment and eliminate poverty. The economy we have today is still largely informed by, and still reflects, our colonial and apartheid past,” said Gumede. The council’s radical economic transformation framework rests upon two pillars: 1. Economic growth and transformation in the ownership and control of productive assets in the economy

2. The delivery of basic services, housing and social goods to business and poor communities. The intention is that radical economic transformation will be about transformation and inclusive growth. Through adopting a Radical Economic Transformation Framework, eThekwini seeks to ensure that black businesses receive significantly greater preference through the municipal procurement process than has been the case previously.

Township regeneration Roughly R180 million has been budgeted over the MTEF for specific economic interventions in township areas. Gumede reported that significant progress has been achieved by bringing economic opportunities to township communities through a combination of improved urban planning as well as key investments funded by the municipality and National Treasury through grants such as the Neighbourhood Development Partnership Grant. The city has delivered on a range of township regeneration projects, such as Bridge City, where council spending has, thus far, leveraged R850 million worth of private sector investment. Significant projects have also been implemented in uMlazi in the form of the KwaMyandu development. In addition, eThekwini will be developing an industrial park for small business as well as an automotive hub at Ezimbuzini. Council’s investment in uMlazi has, thus far, leveraged R350 million worth of private sector investment.

A smarter city “Innovation and technology are key to addressing the current challenges cities face. To accommodate the growing number of citizens in our cities due to rural-urban migration, we also

OPERATING BUDGET The main drivers of the 2017/18 operating budget are: • Water services: R6.5 billion (11.7% increase) • Cleansing and solid waste: R2.1 billion (10.5% increase) • Sanitation: R1.9 billion (8.4% increase) • Electricity services: R13.4 billion (16.9% increase) • Engineering services: R2 billion (1.6% increase) • Community and emergency services: R3.2 billion (3.5% increase)

need to find smarter ways to manage complexities, reduce expenses, increase efficiency, and improve the quality of life of our citizens. Accordingly, smart city initiatives are crucial,” said Gumede. eThekwini has begun rolling out free Wi-Fi, with roughly 75 piloted free Wi-Fi sites already running. Another 250 will be rolled out, mainly in townships and rural areas. In addition to its free Wi-Fi campaign, the city is exploring numerous projects including prepaid and smart metering, cloud computing, fibre-optic networks, digital technology, and other technological improvements. Traffic, public services and disaster response will be operated intelligently in order to minimise costs and improve performance. “We want to become a smart city that manages its resources efficiently,” said the mayor. Concluding her budget speech, Gumede said: “I would like to thank everyone who contributed in making this budget truly the people’s budget. We thank all the councillors, stakeholders and communities for participating.”

IMIESA August 2017

MUNICIPAL FOCUS | eTHEKWINI

Go!Durban on the move

Significant progress has been made on eThekwini’s public transport system, GO!Durban, which promises to provide a sustainable, safer, and more liveable city by 2030. By Danielle Petterson

urban’s Integrated Rapid Public Transpor t Network (IRPTN), named GO!Durban, was designed to revolutionise the city’s current transport system. Over the course of the multiphase project, more than 190 km of road-based corridors will be developed, including eight bus rapid transit (BRT) routes and one rail corridor route. Along these routes, the buses will have right of way at intersections with traffic signalling providing ease of flow. Feeder buses from the outlying areas will bring people into the BRT stations and complementary routes will transport people moving directly from one hub to the next. According to Thami Manyathi, head of the eThekwini Transport Authority, this fully integrated public transport system will provide

IMIESA August 2017

people with easier access to work, goods and services as well as connect citizens to new opportunities.

Construction progress The first route of the project, which is expected to be completed in 2018, will include 27 km of road construction, 14 new bus stations and one terminal station at Bridge City. This first route, called C3, runs from Bridge City to Pinetown, west of Durban. The most extensive work to date has been on the construction of the BRT, dedicated bus lanes from Bridge City to Pinetown including significant work on the next route called C9 from Bridge City to uMhlanga corridor, which incorporates several major infrastructure upgrades. Work began on the C9 in 2016 with the construction of a bridge over the N2

just north of the Mount Edgecombe/uMhlanga interchange. This bridge is a vital link between Umhlanga Ridge and the national priority project Cornubia in Mount Edgecombe, and will accommodate the dedicated bus lane that will eventually come from KwaMashu. This bridge and the recently opened Bhejane underpass and interchange near Bridge City in KwaMashu represent the top and tail ends of the route. As the programme unfolds, the precincts around the various stations are planned for upgrade to help stimulate smaller economies around them. There are also bigger plans for further densification of the areas along the routes. Examples of this are Bridge City and Cornubia, both strategic mixed-use development projects being undertaken by Tongaat Hulett Developments together with eThekwini Municipality in a public-private partnership. “In order for the system to work optimally, there needs to be densification in terms of housing as well as retail and economic activity along these routes,” explains Manyathi. GO!Durban is central to the necessary infrastructure provision for these new development hubs. The C9 route will link uMhlanga Ridge to KwaMashu via Cornubia and Phoenix Industrial. Bridge City in KwaMashu will act as a hub for public transport where a bus terminal is currently under construction. This hub is already linked to the CBD via rail, which will be upgraded, and to Pinetown along the almost completed dedicated bus lanes that have been under construction since 2014.

The bridge over the N2 linking Umhlanga Ridge to Cornubia on the C9 route, which will link through to Bridge City in KwaMashu Station under construction at Regent Street in New Germany

CORNUBIA Located on the North Coast of KwaZuluNatal, Cornubia is a strategic landholding situated within the northern corridor of the region’s commercial hub, Durban. Officially launched in 2014, Cornubia is a national priority project and the first proposed sustainable and fully integrated human settlement in the region. It is a mixed-use development, comprising residential, commercial and industrial sites. The R25 billion development will be spread over 1 200 ha, with 80 ha earmarked for industrial development and the remainder for commercial, housing and other social and public facilities. According to Mtura Matshini, development

The C3 Bridge City to Pinetown corridor will be completed this year, says Manyathi. Although there are dedicated bus lanes, some sections of this route will require the buses to travel in ‘mixed-use’ traffic. Focus will now shift to the traffic signalling, landscaping, stations and completion of the walkways and pedestrian areas along the route. The C1 Bridge City to Durban CBD corridor constitutes an existing rail route, which is

being managed and developed by Prasa. New rolling stock is planned and signalling will be upgraded. Work has not yet begun on corridor C2 Bridge City and KwaMashu via Berea Road to Umlazi and Isipingo, Manyathi adds. Many of the substructures along the first route have been completed. The first station, which is a prototype, is nearing completion at Regent Street in New Germany. The stations are open-plan in style, allowing

BRIDGE CITY A new town centre located 17 km from the Durban city centre, Bridge City connects the communities of Phoenix with Inanda, Ntuzuma and KwaMashu, promising improved access to public transport and opportunities to work, travel, shop and do business in the area. Bridge City is expected to attract upwards of R10 billion in investments once completed, and roughly 65% of the 53 ha development area has already been sold to a mix of public and private sector investors. “Our vision for Bridge City is one that combines a mix of public sector facilities, services and infrastructure with a wide range of private investment opportunities. At its heart, it will have a world-class, intermodal transport system that links the areas of Phoenix and Inanda, Ntuzuma and KwaMashu to the CBDs of Durban, uMhlanga, Cornubia and Pinetown. This will become a bustling, mixed-use urban hub that offers attractive investment opportunities in a professionally managed, integrated and dynamic development node,” says Brian Ive, development executive, Tongaat Hulett Developments. The development forms part of eThekwini’s high-priority public transport corridor and, according to the Integrated Transport Plan, is a key destination for rail, buses and taxis in this region.

The BRT in Pinetown CBD nearing completion

executive, Tongaat Hulett Developments, it became necessary to improve access into the development because the surrounding existing road infrastructure was already operating at capacity. The roadworks include the construction of a bridge over the N2 motorway to connect Cornubia with the uMhlanga Ridge town centre, forming part of the GO!Durban C9 corridor, as well as upgrading the M41/Flanders Drive interchange and the construction of the first portion of the Dube East arterial, which will run parallel to the N2. All roadworks are due for completion by the end of August 2017. optimum visibility with glass exteriors at the same time providing protection from the elements, explains Manyathi.

Smartcard system Once operational, GO!Durban will work on a cashless smartcard system that allows users to tap in and out, thereby providing security and ease of access. Commuters will be able to load trips onto their Muvo smartcards at Muvo kiosks and SmartVans, which they will use to tap in and out of stations, as well as the different transport modes of the system. The card ensures that commuters have ease of entry in and out of the system, and that the system runs more efficiently as no time is wasted in boarding and alighting the buses at stations. With the construction on some routes nearing completion, activities along the route will soon turn to preparing the system for operations, such as the installation of fare management infrastructure. Manyathi concludes: “The development of the network will produce great prospects for the City of Durban and ultimately connect people and communities to opportunities, and enable socio-economic development and transformation.”

IMIESA August 2017

MUNICIPAL FOCUS | eTHEKWINI

Work on Northern Aqueduct ramps up

he existing Northern Aqueduct comprises a network of potable bulk water supply pipelines that serve the north-eastern portion of eThekwini north of the uMgeni River, south of the Ohlanga River and east of Ntuzuma. It also conveys potable water from Durban Heights Waterworks to terminal reservoirs that serve residents and businesses. With the aqueduct having reached maximum flow capacity, augmentation of the system has become a necessity. According to Ednick Msweli, head of eThekwini Water and Sanitation (EWS), there is sufficient water to meet current needs, but it is not being delivered efficiently to areas where it is needed most. This would be exacerbated by ongoing development to the north of Durban, which is essential to job creation and economic growth in the region.

Phase 5 Phase 5, which is expected to be completed by 2019, will benefit Newlands, KwaMashu, Phoenix, Cornubia, Waterloo, uMhlanga and Durban North.

Work on Phase 5 of Durban’s Northern Aqueduct Augmentation is due to begin construction in August 2017.

It comprises a new 1 200 mm diameter continuously welded steel high-pressure pipeline stretching from Durban Heights Reservoir in Reservoir Hills to Duffs Road and an incrementally launched reinforced concrete bridge over the uMgeni river. Project manager Martin Bright says key challenges include constructing the pipeline through densely populated, built-up areas, traversing major roads and railway lines, dealing with existing buried municipal services and rehabilitating environmentally sensitive areas. Following a thorough investigation to identify various potential pipeline routes, each of which was carefully scrutinised, Bosch Projects completed the detail design stage. The selected route offered the best ease of construction, while reducing disruptions to members of the public and traffic, minimising road and environmental rehabilitation, and lessening the relocation of existing services. Pipe jacking has been selected as the preferred method of installation where existing services could not be avoided. A large-diameter concrete pipe sleeve will be jacked under roads and railway lines, through which the Pictured on-site at Section F of the Northern Aqueduct Augmentation project are (from left): Zamani Khumalo, technical assistant; Sean Geeson of Esorfranki; Clyde Mudly, general foreman at Esorfranki; Heyman Booysen, engineer’s representative assistance; Petro Sibeko, general foreman; and Hector Nxumalo, truck driver

IMIESA August 2017

steel water pipeline will be installed. Where this cannot be done, the contractor will institute a traffic management plan to minimise traffic disruption and reduce inconvenience to residents and road users. In addition to the pipeline itself, a concrete pipe bridge will be constructed across the uMgeni River above the 1:100-year flood line. This will comprise a reinforced-concrete box-type bridge cross section, which will be incrementally launched and supported on five solid concrete piers, and will cross the river adjacent to the existing pipeline. Bright said the uMgeni River pipe bridge crossing was undoubtedly the most interesting and challenging part of the project. The new bridge will be constructed on a similar alignment to the previously collapsed steel suspension bridge and adjacent to the existing pipe bridge, approximately 9.6 km from the river mouth. The level of the bridge deck has been based on a detailed hydrological flood assessment of the uMgeni River at a height that is above the regional maximum flood level. River diversion works will be needed to cater for the river flow during piling and construction of the bridge substructure. Bright adds that environmental rehabilitation will be required during and after construction and Gibb has been appointed as the independent environmental consultant and impact assessor for this segment of the Northern Aqueduct Augmentation. Environmental challenges are expected to include wetland and riparian crossings, wooded-grassland crossings, biophysical and social impacts, amongst others. Gibb has developed a comprehensive environmental management programme, which includes a plant rescue and rehabilitation plan to cater for these.

Bitumen, Asphalt & Roads

National Cold Asphalt

ASPHALT IS OUR BUSINESS

BITUMEN, ASPHALT & ROADS | COVER STORY

Application of road stone aggregates with the Chippy

A hand-operated bitumen sprayer

Time for the Chippy

W THE CHIPPY ADVANTAGE Building infrastructure Creating sustainable employment Saving on capital expenditure Providing fast-tracked service delivery with proven results and healthier communities

A world first developed a few years back, the ChippyTM is the answer to many of South Africa and Africa’s pressing primary and secondary road surfacing needs, plus it’s a job creator. 18

IMIESA August 2017

hen it comes to upgrading a gravel route to a blacktop riding sur face, or when resealing an existing asphalt road, National Cold Asphalt (NCA) is a leading expert in these upgrade or repair interventions. Its technologies are also ideally suited for labour-intensive, communitybased projects, and these solutions are sustainable, both environmentally and in terms of lasting durability. This is clearly important when it comes to stretching municipal maintenance budgets, since getting the job right the first time round eliminates unnecessar y rework, and wasted expenditure. Ever y municipality has a directive to ensure that its infrastructure planning facilitates socio-economic growth, and roads are the main conduit. NCA has been involved on road repair projects since 2007 when trials were first conducted on potholes in the Western Cape. To date, these repairs remain intact and blend into the surrounding material, making them almost indistinguishable from the existing road. The NCA product range includes Coldmix asphalt, LT40 hot mix asphalt, and the

wheeled and manually operated Chippy machine for road maintenance and road sur facing.

Coldmix NCA’s cold asphalt is a storable, premiumquality product for permanent repairs to potholes and utility cuts. Coldmix can be stored in bulk; it has a minimum two-year shelf life and remains workable even in cold weather conditions. “The material is supplied in a 6.7 mm and 9.5 mm wearing course used for sealing all road repairs and also a -26 mm base prefill (base course) used as a long-lasting, durable, cost-effective filler for deep repairs,” explains Shane Mullins, operations manager at NCA.

Hot mix in a bag LT40 asphalt (commonly referred to as “hot mix in a bag”) incorporates an additive made from 100% natural and renewable resources. As Mullins points out, the product is per fect for edge breaks, reinstatement of trenches, patching and pothole repairs. “In addition to reducing waste and time lost waiting in queues at HMA plants, plus product loss from inclement weather, LT40 allows for higher productivity. You can proceed directly to site with all the necessar y tools and begin work immediately,” he explains. LT40 is supplied in 25 kg bags, has a shelf life of 12 months and is heated up to approximately 40ᵒC to 60ᵒC in a custombuilt oven that can be supplied with a purpose-designed trailer. Once the product has reached the required temperature, it is transferred on to a wheelbarrow and transported to the repair site. From there,

Based on the design put forward by the consulting engineer, three different stone specifications can be handled by the Chippy

the product is placed in the prepared area and compacted.

The Chippy At the business end is the Chippy, a patented South African innovation launched in 2004 and aimed at the local and broader African markets for the application of road stone aggregates. Typical projects entail the upgrading of gravel roads to sur faced standard, or the application of single and double seals for the maintenance of existing routes. LT40 would be specified in these instances to repair badly potholed roads before resealing. (Traditional cold mix products release volatiles as part of their curing process, which means

that resealing can only occur months later.) Based on the design put for ward by the consulting engineer, three different stone specifications can be handled by the Chippy, namely 13.2 mm, 9.5 mm or 6.7 mm products. During gravel-to-asphalt projects, the process entails the use of a high-pressure distributor to apply the elastomeric polymer modified bitumen, or a hand-operated bitumen sprayer, depending on the specification, followed by the application of the graded stone aggregate. NCA provides technical advice and support, including how to optimise the size of the work crews depending on the number of Chippy’s deployed on a given site.

Up to 65 job oppor tunities can be created around the sur facing process alone and, since there’s no mechanisation component, SMMEs are not hampered by the need to invest in specialist paving equipment, which would traditionally represent a major barrier to entr y in terms of expense and access to finance. “The Chippy complies with the Construction Industr y Development Board’s practice manual on job creation and contractor development regarding labour-intensive construction methods,” explains Mullins. “The Chippy method is, therefore, wellsuited for use by local authorities in line with the goals of the National Expanded Public Works Programme when it comes to job creation for unskilled and semiskilled workers, as well as in meeting the minimum 30% subcontractor component stipulated by the Preferential Procurement Policy Framework Act (No. 5 of 2000).” The Chippy has received many accolades and much recognition throughout the industr y, including the Southern African Bitumen Association's 'Award for Excellence'. In addition to South Africa, countries like Botswana and Zimbabwe have recently expressed interest in trialling the Chippy on local road projects. Meanwhile, further afield in Ghana, the Chippy is now a common feature thanks to ongoing labourintensive works funded by a Japanese NGO. “Depending on site logistics and conditions, as well as team size, the Chippy can comfortably meet single-seal production volumes of approximately 10 000 m2 per day,” concludes Mullins.

National Cold Asphalt

www.nationalasphalt.co.za

IMIESA August 2017

BITUMEN, ASPHALT & ROADS

Reclaimed asphalt builds economies

ew guidelines for recycled asphalt cover materials handling requirements, mix designs, environmental benefits and costing, among other key issues. The revised edition of TRH 21: Use of reclaimed asphalt in the production of asphalt was approved by the Road Pavements Form (RPF) task group on bituminous materials on 19 January 2017. This marked the culmination of a process that commenced in January 2016. Endorsed by the COTO Road Materials Committee, this 2017 edition replaces the

2009 version and incorporates the latest thinking and techniques in asphalt recycling. By definition, reclaimed asphalt (RA) is obtained from the milling or excavation of existing bituminous pavement layers or from stockpiles of asphalt production overruns and returned material. The RA material obtained is crushed and screened to ensure an acceptable maximum size and grading. The material obtained from pavement layers should always be processed before use to ensure uniformity. Stockpiling techniques for both unprocessed and processed RA are described in the revised TRH 21 document.

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BITUMEN, ASPHALT & ROADS

pitfalls through fair practices during the management of contracts involving reclaiming and recycling asphalt layers. Comprehensive guidelines cover key issues like mix proportions, the availability of mixing plant types, and pre-tender investigations of material types.

Scope for RA

RA binder replacement A significant deviation from previous TRH 21 versions is the new terminology used to define the proportion of RA in a mix, particularly when it comes to RA processing, design routines and testing compliance. The proportion of binder in a particular RA fraction is related to the aggregate size (or surface area). To account for this phenomenon, it was deemed appropriate to base designs on blends of binder, and aggregate on RA binder replacement. The RA binder replacement will determine the procedures to be followed in terms of

processing/fractionating of RA, testing of recovered binder, and design procedures. Testing regimens for aggregates, however, are defined by the total RA content of the mix.

Contract documentation It is common cause that erroneous or incomplete tender information/specifications invariably lead to contractual disputes, with resultant administrative burdens to all parties and overruns in the total contract value and time. Contractual arrangements regarding the use of RA are no exception. This new version of TRH 21 gives guidance on how to avert these

In 2014, it was estimated that the usage of RA in South Africa was in the region of 350Â 000 t, representing approximately 10% of annual asphalt production. Should industry specifications permit higher proportions of RA in asphalt mixes, 95% of reclaimed material available at the various fixed asphalt plants can be utilised to this end. Since 2009, asphalt manufacturers have gained experience in the use of higher RA proportions (up to 40%) in asphalt mixes on major road contracts. There is, therefore, considerable scope to pass on major financial savings by decreasing the percentage of virgin material used â&#x20AC;&#x201C; reducing the carbon footprint of the asphalt industry in the process. IMIESA August 2017

PERMANENT ROAD REPAIR

PREPARATION

FILLING & COMPACTING

COMPACTING & FINISHING

COMPACTED - TRAFFIC READY

COLDMIX NCA is a stock-able premium quality Cold Mix asphalt, incorporating MacFix Technology, for permanent repairs to potholes and utility cuts. The cold asphaly can be stored in bulk and has a minimum one year shelf life, whilst remaining workable even in cold weather conditions.

Contact Shane Mullins: (+27) 84 357 5580 shane@nationalcoldasphalt.co.za Office: (+27)86 146 6656 National Cold Asphalt

www.nationalcoldasphalt.co.za

BITUMEN, ASPHALT & ROADS

Upskilling o i n t profession c u r t s n o c road Every year, the South African Road Federation trains roughly als 1 500 people involved in the roads construction industry on a broad range of topics.

he South African Road Federation (SARF) conducts technical training courses around the country, as well as other parts of Southern Africa, with a large base of experienced professionals who are able to deliver industry-specific lectures. In addition to being ECSA accredited, 16 SARF courses are now also SACPCMP accredited. By working closely with partners in the industry, such as Sanral, the organisation is able to tailor courses to suit the current needs of the sector. One such example is SARF’s road safety audit course. Completing the appropriate Road Safety Audit training is a prerequisite for auditors working on Sanral projects. According to Basil Jonsson, operations director, SARF, roughly 200 South African engineers have already received this SARF training and Sanral reports that the quality of road safety audits that have been submitted have significantly improved. The organisation is now offering a new, more locally focused road safety audit course, developed by two engineers at Nova and approved by Sanral. This builds on some of SARF’s other popular training programmes, which include courses on infrastructure management, work zone safety and traffic impact assessments.

Empowering women in construction SARF is also committed to upskilling local labourers, particularly women. The Federation has worked with the City of Cape Town to empower women in the workplace, by providing them with skills for technical and physical work that is generally associated with men. Following a highly successful on-site training session of 19 women in June 2016, the City of Cape Town recently put out another request to SARF for further on-site training in best practices in road maintenance and repair. This time, 24 women who were previously on an Expanded Public Works Programme contract were trained by specialist John Onraet (as seen in the photo above). The training consisted of in-class learning on the basics of road maintenance – such as terminology, base preparation, the identification of correct materials, and application and compaction principles. This was followed by a critique of actual activities previously photographed. The second day was spent on practical applications – preparing base materials, and the priming, application and compaction of asphalt materials in two large patches. For most of the women, this was new technology and they carried out the work with high levels of enthusiasm, producing excellent work. They have all been permanently employed by the City of Cape Town.

2018 SAFR/IRF/PIARC REGIONAL CONFERENCE SARF is gearing up for its 2018 conference to be held in Durban. Next year’s event will be held in conjunction with the International Road Federation (IRF) as well as the World Road Association (PIARC). Over the past year, SARF has developed closer links with the IRF in Washington, assisting greatly in bringing the latest developments in road technology, policy and management global to the local industry. SARF operations director Basil Jonsson explains that, by bringing these international bodies on board for the conference, SARF will not only be able to attract people from abroad, but also bring international knowledge and best practice to South Africa’s road construction professionals.

IMIESA August 2017

9 - 11 OCT 2018 | DURBAN ICC

2018 SARF/IRF/PIARC

REGIONAL CONFERENCE FOR AFRICA

“Roads to Social and Economic Growth”

9 - 11 October 2018 | Durban ICC

Call For Papers An exciting opportunity exists for authors to submit abstracts for presentation at the 2018 SARF/IRF/PIARC Regional Conference for Africa in October 2018 Your insights could shape the agenda of this flagship event for road infrastructure in Southern Africa. The theme of the conference is Roads to Social Economic Growth. Road transport and mobility are the lifeline of a modern economy and contribute signicantly to scal progress and to the overall life of our communities. The 2018 conference will enjoy global support with the participation of the International Road Federation (IRF) and the (PIARC) World Road Association. This means your paper will attract exposure to a macro audience.

“Roads to Social and Economic Growth”

Be part of the journey to better, safer, smarter roads in Africa

Contribute To 7 Core Focus Areas

The conference content will centre around the development of a logical road nancing policy and the achievement of an efcient, safe and affordable road network to serve the needs of our growing region and continent. Your paper should add value to any one of these vital areas of emphasis: 1. Coherent road funding / nancing mechanisms 2. Optimal standards for road infrastructure 3. Preserving Africa's roads assets 4 .Safe transport by road 5. Innovative practice to optimise road network delivery 6. Impact of roads on the environment 7. Education and training in the road transportation sector For more detail on abstract specics and submission details, please visit www.sarf-irf2018.co.za/call-for-papers/ This is a valuable opportunity to raise the prole of your particular organisation. We are looking forward to receiving interesting submissions over the next two months.

Important Dates:

1. Abstract Submission: 31 August 2017 2. Notication of acceptance: 20 November 2017 3. Paper Submission: 1 March 2018 4. Notication of review outcome: 14 May 2018 Conference Secretariat Scatterlings Conference & Events Exhibition and Sponsorship Coordinator: Carina Du Plessis Email: carina@soafrica.com | Tel: +27 (0) 11 463 5085 Abstracts and Speaker Management: Simone Solomons Email: simone@soafrica.com | Tel: +27 (0) 21 422 2402

www.sarf-irf2018.co.za

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BITUMEN, ASPHALT & ROADS

N2 extension alleviates congestion

ork is progressing well on the construction of a 34 km section of dual carriageway on the N2 between the Mtunzini Toll Plaza and Empangeni T-junction on the KwaZulu-Natal North Coast. Valued at around R946 million, the development is one of the largest Sanral projects undertaken to date in the province and is designed to cope with increased traffic volumes along a key arterial route. The main contractor is Concor Infrastructure, with UWP Consulting monitoring the works. The new two-lane northbound carriageway includes the construction

of two major bridges over the Mlalazi and Mhlathuze rivers. Four agricultural overpasses over the N2 will also be lengthened; new bridges will be built at the R34 Empangeni/Richards Bay interchange and at the P537 Port Dunford underpass; two road-overrail bridges will be constructed, plus 16 major box culverts and numerous minor box culverts and other drainage structures. In addition, the design includes increasing the height of two overpasses using bridge-jacking techniques. The existing southbound single carriageway will be repaired and strengthened to become the new southbound carriageway once the northbound route is completed. Jonathan Pearce, contracts manager at Concor Infrastructure, comments: “We currently have 551 people on-site, including subcontractors and the engineers’ professional staff. As we are working at 16 work faces concurrently, we have four earthwork teams, two bulk backfill teams, six culvert teams and three bridge teams operating simultaneously,” he explains. Concor Infrastructure began work on the contract in March 2016 and the project is scheduled for completion in 2019, over a period of approximately 37 months. IMIESA August 2017

DELIVERY

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17 static plants • 5 mobile plants • extensive product range • stringent quality control • bitumen storage • industry training

T: +27 21 900 4400 F: +27 21 900 4468 E: info@muchasphalt.com www.muchasphalt.com

BITUMEN, ASPHALT & ROADS | SUPPLY CHAIN DISCUSSION

COLAS Lee McNeil | Branch Manager

What is Colas’ offering to the roads construction and maintenance industry? LM Colas South Africa has been well-known as the leading supplier and applicator of bituminous products in the South African road construction industry since the late 1920s. Our greatest asset remains our people – a team of committed individuals, recognised as leaders in their fields. Added to this are our products and services, which are backed by full technical support from our stateof-the-art testing laboratories in Cape Town and France. Our ISO9001 certifications mean a consistent level of quality at all our production facilities.

What is your take on labour-intensive construction for roads projects in South Africa? It is well-known that one of the greatest challenges currently facing South Africa is unemployment. To help remedy this, the new procurement legislation currently being introduced to all road construction tenders will force contractors to employ more labour-intensive road construction methods.

Labour-intensive methods are not new to the South African roads industry and have proved successful in many instances in the past. However, there have also been contracts where the incorrect implementation of labour-intensive construction methods has led to substandard quality. We believe that with the correct procedures, suitable products, and adequate training, there should be no reason why road construction can’t be done to the highest quality and still be costeffective using on labour-intensive construction methods.

Colas is introducing some new products to the local market. Tell us about these. There are many Colas products that have been successfully used for many years within the Colas group in Europe and the rest of the world. We are currently in the process of introducing several of these products into the SouthAfrican market. One of them, Colgrave, is a cold mix containing aggregates and/ or RAP and emulsion, which helps ensure savings in transportation, energy and new materials. Colgrave is adapted, via its

various mix designs, to different uses such as strengthening, base re-profiling, widening, minor maintenance and spot repairs. Another new product, Compomac, is the ideal solution for reinstating trenches, filling potholes, patching and small-scale paving projects. Very easy to use, it is durable, storable and ready-mixed cold mix asphalt in a bucket or bag. Compomac will make everyday routine, small-scale, road repairs simple and efficient. It is mixed and applied cold, making it environmentally friendly. We also recently successfully completed a trial section on a Sanral contract of Colrub LT, our low temperature (LT) bitumen rubber product with a shelf life of up to seven days. We are constantly working on improving the formulations of our emulsion used for quickset slurries, especially in areas where there have been unsuitable aggregate.

How will these new products contribute to labour-intensive construction methods? Both the Colgrave and Compomac products are specially developed as alternatives to hot mix asphalt.

Because they are placed cold, the application period is lengthened, making them perfect for use in labour-intensive construction. Other benefits are that both products produce no fumes and could result in reduced aggregate transport. The flexibility of use also allows for possible application without full road closure. We offer training and technical assistance to both the engineers and contractors on the proper application of these products.

What is your distribution footprint and how does this assist in meeting market demands? Colas currently has three manufacturing facilities and four depots strategically positioned around the country to ensure that we are close to our customers. We also have manufacturing facilities in Namibia, Zambia, Mozambique and Kenya. Our export division, managed out of Durban, currently exports Colas products into the Southern African, Indian and Atlantic Ocean territories. This ensures that our commitment to the entire Southern African road construction industry is total and unparalleled.

IMIESA August 2017

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BITUMEN, ASPHALT & ROADS | SUPPLY CHAIN DISCUSSION

ELTHERM Giles Maynard | General Manager What is eltherm’s offering to the bitumen industry? GM We offer a proven, costeffective, turnkey solution to the problems associated with pumping and transporting highviscosity bituminous products.

What exactly is heat tracing and how does it work? Electric heat tracing, also called heating tape, is a system used to maintain or raise the temperature of pipes, tanks, valves, pumps and vessels. Heat tracing takes the form of an electrical heating element (it looks like an electrical power cable) run in physical contact along the length of a pipe, or tank.

How does heat tracing apply to the bitumen industry? Heat tracing is used to improve the viscosity of bituminous products by maintaining a constant temperature along pipelines or tanks, thereby improving product flowability. We recently worked with one of the largest suppliers of asphalt. They needed to preheat the pipes across the

process plant to between 100°C and 120°C, and maintain the temperature when the pumps weren’t running to prevent the bitumen product from solidifying and clogging up the pipes. Our electrical heat tracing system ensured good heat distribution inside the pipes so the bitumen was more viscous and easier to pump, thereby reducing downtime. We also reduced moisture-related failures to almost zero. We eliminated the risk of operators setting controllers too high and burning out elements, as we installed a self-regulating cable that couldn’t exceed stipulated design parameters. We totally eliminated the use of gas flames on pipes, which decreased maintenance costs and damage to other components, and made the workplace safer. In addition to pipes, some of the heat tracing was fitted to particularly troublesome valves and fittings, to ensure that the quality and flowability of the product were never compromised.

What are some of the benefits of heat tracing for bitumen suppliers?

There are numerous benefits for bitumen suppliers. Electrical heat tracing reduces caking on the inside of pumps and vessels and reduces pump failures; we can heat your tankers and reduce the weight; we can reduce your downtime due to failing incoloy elements; and heat your entire bitumen value chain and cut costs.

Can this technology save companies money?

Electrical heat tracing is a technology that can most definitely save companies money, provided the correct product is specified and installed. Electrical heat tracing ensures that all processes maintain a constant temperature. This means the product flows easily, thereby decreasing the amount of downtime. Less downtime means higher efficiency, which means large savings for the customer.

IMIESA August 2017

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BITUMEN, ASPHALT & ROADS | SUPPLY CHAIN DISCUSSION

KAYTECH Garth James | Technical Director

What is Kaytech’s offering to the roads construction and maintenance industry? GJ Kaytech is the leading supplier of geosynthetics to the roads construction and maintenance industry. Beginning with the tried and tested bidim geotextile, our product offering has grown to include geocomposite drains, geogrids (TriAx) and composite geotextiles (RockGrid PC) for subgrade and base stabilisation, as well as glass fibre grids (GlasGrid) for asphalt reinforcement. With our resource of experienced staff and quality products, we pride ourselves on providing our client base with cost-effective and technically sound solutions.

What are some of the key road applications for geotextiles? The provision of subsoil drainage alongside the road prism or within the pavement prevents the ingress of water into the load-bearing layers. Kaytech pioneered bidim geotextiles as the filter layer into the standard “sausage-type” subsoil drains in the early 1970s. Kaytech then introduced geocomposite drainage systems to the roads construction industry in 1985. The most commonly used system is our Flo-drain, comprising a Flownet geospacer wrapped in a bidim filter jacket, which is connected to a Kaypipe or Flo-pipe collector. This system offers savings in time through speed of installation and savings in costs by reducing the need for expensive stone aggregate used in the conventional subsoil drains. Together, they offer the added benefit of reduced carbon emissions through less

quarrying and crushing of natural materials. The other system that offers all these benefits, plus the advantage of being a collector conduit in one, is the Megaflo panel drain system, which can be installed within the pavement layers or immediately adjacent to the road shoulder to relatively shallow depths.

Can you give us an example of a recent project where your products have been successfully used? Tau Pele is busy with the special maintenance of National Route R56 section 6 from Indwe (km 0.00) to Elliot (km 58.30) and section 7 from Elliot (km 0.00) to Maclear (km 68.51) where Sanral and KBK Engineers have approved the use of Megaflo in the subsoil drains. Over 74 km of this unique product is being installed. The new and innovative Concrete Canvas was recently used on the N4 near Watervalboven, Mpumalanga, to repair the invert of a degraded corrugated galvanised-steel culvert of 900 mm diameter and 48 m length.

How do your products contribute to labourintensive construction for roads projects in South Africa? The Flo-drain is premanufactured to order by Kaytech labour and then supplied to site with the geopipe lengths, where installation requires labour to attach the geopipe to the underside of the bidim/Flownet composite fin section and then fix the system to the face of the trench being drained. Careful handling is required for the installation of

the geocomposite drains to ensure maximum efficacy of the system after backfilling. As a matter of interest, our Multi-Cell system is used to construct concrete access roads in steep rural terrain. Local labour is employed to lay out the panels and work the concrete into the cells, which act as the formwork create a strong, durable and flexible surfacing.

Concrete Canvas was recently used on the N4 near Watervalboven

How does Kaytech assist in opening up the market to small contractors? In partnership with The Hope Factory, Kaytech runs a three-month mentoring programme helping emerging contractors understand the financial aspects of running a business and ensuring that they are legally compliant. This includes a training course on finance for non-financial managers and one-on-one mentoring with a financial trainer. Kaytech runs lecture courses on geosynthetics in civil engineering and assists with onsite training on the installation thereof.

What is your distribution footprint and how does this assist in meeting market demands? Kaytech has distributors in the major centres of South Africa, which has enabled us to steadily increase our distribution footprint into the SADC countries, East and West Africa, as well as the Middle East. Our experienced operational staff offer technical

Megaflo used in subsoil drains

and logistical support to all our distributors and agents, ensuring that the best geosynthetic solution is being utilised.

What can clients look forward to over the next year? Kaytech is busy commissioning a new state-of-the-art bidim manufacturing line at our factory in Atlantis, Western Cape. This production effectively more than doubles the capacity to manufacture non-woven continuous filament polyester geotextiles for supply not only into South Africa but also into the rest of Africa. This large investment will come into full production in 2018, coinciding with Kaytech’s celebration of 40 years of manufacture of bidim geotextiles in South Africa.

IMIESA August 2017

SPRAYPAVE Eddie Jansen van Vuuren General Manager What does SprayPave offer the roads construction and maintenance industry? EJvV SprayPave is one of South Africa’s leading manufacturers and suppliers of bitumen, modified binders and emulsions for road construction. The company was established in Alrode, Gauteng, in 1981 to offer binder spraying and hauling services, and expanded to include the manufacture of bitumen binders in 2007. In 2010, SprayPave purchased an emulsion business in Durban, increasing its footprint and broadening its range of bitumen emulsions, cutbacks, pre-coating fluids and primes. SprayPave opened its Cape Town emulsion plant in Parow in 2014 and commissioned the revolutionary multistage bitumen converter in 2016.

What are the hallmarks of SprayPave’s manufacturing facilities? Our plants are designed to produce dedicated lines of bitumen binders including emulsions, cutbacks, pre-coating fluid, primes and polymer-modified bitumen. Each branch has a weighbridge for bulk products

and a drumming plant with a scale for the accurate filling of drums. Our laboratories on each site are comprehensively equipped to perform all necessary tests and provide customers with certificates of analysis in accordance with the relevant standard, SANS BT or TG1. We strive to ensure that our products are differentiated by competitive pricing, extensive quality control, optimal lead times and efficient delivery processes.

Andre du Plessis, technical specialist at SprayPave, in the converter’s PLC room

Does SprayPave have a footprint outside the three major centres of South Africa?

SprayPave has responded definitively to the bitumen supply crisis. Can you provide the background to this situation?

SprayPave’s close association with all refineries in Southern Africa enables us to provide fit-for-purpose products to any destination on the subcontinent. Our completely autonomous and selfpowered mobile emulsion and modified binder plants manufacture up to 6 000 ℓ of product per hour and can remain on remote locations for months at a time. The mobile plants come with fully equipped quality-control laboratories.

Bitumen is an essential component of asphalt as a binder. It is produced by refineries as a by-product of crude oil, but can only be supplied in broad grade ranges that seldom meet asphalt design specifications. Bitumen production is not a priority for South Africa’s four refineries and each of these facilities experiences planned (and sometimes unplanned) maintenance shutdowns, which impact bitumen availability. Added to this, the Calref refinery in Cape Town only produces one grade of bitumen (70/100), which is unsuitable for asphalt production. The asphalt industry has experienced a shortage of bitumen supply for several years now, a problem we have in common with many other countries. Solutions have included creating expensive bitumen storage facilities and even importing bitumen. Unfortunately, these solutions are expensive and add to the already high cost of road construction and maintenance.

The company has undergone recent ownership and management changes. Can you tell us about this?

The multistage bitumen converter uses pressure, heat and air to manipulate bitumen on a molecular level

IMIESA August 2017

In 2015, Much Asphalt acquired SprayPave from Basil Read. Much Asphalt is the largest commercial producer of hot and cold asphalt products in Southern Africa and also celebrated its 50th anniversary in 2015. This year, I was appointed general manager of SprayPave.

Our vision is not to be the largest supplier of bituminous products in Southern Africa, but to be the best in quality, service delivery and environmental awareness. SprayPave’s professional and dedicated team shares my aim of being the preferred supplier to our clients.

What is SprayPave’s answer to this problem? In 2012, SprayPave started to explore global technologies to help mitigate the

BITUMEN, ASPHALT & ROADS | SUPPLY CHAIN DISCUSSION

bitumen crisis. The result was the acquisition of a multistage bitumen converter from Technix Industries in New Zealand. This technology, commissioned in Cape Town in 2016, is capable of converting bituminous products from one grade to another and will enable the predictable and repeatable modification of bitumen on a molecular level. What this means is that the equipment can change conventionally available refinery penetration-grade bitumen to grades that are both lower in penetration and higher in softening point than the feedstock bitumen to suit the asphalt specifications required by the road-building sector. While the modified bitumen can be transported anywhere in South Africa, the fact that the converter is located in Cape Town is particularly significant, as the Western Cape does not have any immediate access to the bitumen grades required to produce high-quality asphalt. Now these grades can be produced simply by inputting the 70/100 penetration bitumen supplied by Calref and converting this to whatever is required.

What impact will this technology have on the industry? This technology addresses current and future issues around local bitumen supply. It will ensure we have the bitumen quality required for the sustainable supply of highspecification asphalt, no matter how big the demand. With Performance Grade (PG) bitumen specifications soon to be implemented in South Africa, this technology will be ideal

for the conversion of locally available bitumen and other feedstocks into high-specification multigrade bitumen. The new PG specifications aim to improve the assessment of binders with regard to deformation resistance, fatigue properties, long-term performance and cracking potential.

How does the bitumen converter technology work? In basic terms, the technology uses pressure, heat and air to manipulate bitumen on a molecular level. Using this process, various properties of the bitumen – including softening point, penetration index and physical properties – can be changed to meet exact design specifications.

What tests are available to confirm high quality bitumen output? SprayPave owns one of the few Iatroscan units in Southern Africa that can analyse the elements of bitumen (SARA – saturates, aromates, resins and asphaltenes) to ensure that quality bitumen is produced at its facilities in Alberton, Durban and Cape Town, and to test the specifications and quality of the bitumen produced by the new converter. We have received the test reports for SABS certification, the results are all positive, and we are now awaiting formal certification.

Danashia Padyachee, SprayPave technical manager, performs a test on bitumen produced by the converter

What can the industry look forward to from SprayPave? Our multistage bitumen convertor is only the second to be commissioned worldwide. The first operates successfully in Fiji. We believe this technology has enormous potential across Africa. If we can expand our footprint by introducing more converters in strategic locations, we will be making a very positive contribution to infrastructure development on the African continent.

www.spraypave.co.za

IMIESA August 2017

WOMEN IN ENGINEERING

A passion for the community IMIESA speaks to Waseemah Isaacs, principal civil technologist at Knight Piésold Consulting, about her career choice, formative experiences and involvement in past and current projects, as well as the unique elements that women engineers bring to the profession. It’s all in the detail.

t Knight Piésold Consulting, one of the founding principles of the firm’s success over the past 96 years has been its focus on human resource development across its global workforce. This focus includes promoting diversity in terms of culture, leadership style, ethnicity and the way opportunities are developed for engineers. Academics are a baseline entry requirement, but from there, the playing fields are levelled when it comes to mentoring and growing pure engineering talent. As Waseemah Isaacs, principal civil technologist at Knight Piésold’s Cape Town office, emphasises, it’s all about hard work, dedication and passion. “Nothing in life happens by chance, and you must believe in yourself and embrace opportunities,” she explains. “I was drawn to engineering because I know that the infrastructure landscape we create

IMIESA August 2017

today is vital for our future. And as a mother and engineer, I fully appreciate the positive and direct socio-economic difference this makes for families and their communities. We were only three women in our civil engineering class at university some 14 years ago. However, when I look at the trend now, I can see that the number of women choosing to study engineering is definitely growing.” From her formative experience, Waseemah says one of the key things to emphasise at school level is a greater appreciation of the foundational importance of mathematics for most careers, but especially for fields such as engineering. “I feel that teachers should place more emphasis on the applied elements of mathematics since this opens one’s eyes to real-world examples in the fields of algebra, geometry, trigonometry, calculus and statistics. These are all tools we use as engineers, which we continue to develop over a lifetime of practice,” she explains.

As part of its corporate social responsibility programme, Knight Piésold is partnering with various schools in South Africa, and recently hosted its annual Consulting Engineers South Africa Job Shadow Day in May 2017, the focus being to encourage and support potential candidates wishing to enter the engineering profession. A number of Knight Piésold’s young engineers have been assigned to identify and grow potential talent as some of these candidates could become future bursary students. “If I had to consider where women bring something different to the profession, beyond maths and science, and ability, I would say it’s our empathy and natural organisational abilities, plus we listen well,” says Waseemah. “It may be a coincidence, but one of my key professional interests, alongside my specialisation in roads and infrastructure, is in project and programme management, the latter focusing on longer-term

WOMEN IN ENGINEERING

strategic planning and continuous improvement. I really enjoy seeing a project through from inception to the completion of the construction phases, including documentation and design. Beyond that, we’re engineers first, who want to build lasting structures.” Personal career highlights to date include involvement in the design and construction management of the Roggebaai Canal at the V&A Waterfront, which interconnects with the Cape Town International Convention Centre; the Sibaya Casino access road and interchange in Durban; and a three-year stint on Cape Town’s Robben Island for the refurbishment of the desalination plant.

Stock Road and N2 Wild Coast Waseemah currently forms part of a project team working on key Western and Eastern Cape projects. These include the Stock Road integrated rapid transit (IRT) project in Philippi, Cape Town, and specific portions of the greenfield N2 Wild Coast toll development, now in the initial preparation phases in the Eastern Cape. Both of these projects are prime examples of civil engineering developments that are helping to uplift previously disadvantaged groups. On the N2 project, Knight Piésold is currently completing an access management plan to determine how

this new single carriageway will affect the rural community living in the region. Historically, they have had limited access to mobile transport: essentially, these are pedestrians and farmers facing a major new transportation landscape. “We are analysing the potential impacts,” says Waseemah. “That includes making provision for elements like cattle overpasses and pedestrian underpasses at regular intervals along the route.” Appointed in May 2017, Knight Piésold’s scope entails the design and construction management of the road between the two new landmark bridges that will be built, namely the Msikaba and Mtentu, both of which cross major river gorges. “We will be working with the bridge consultants to ensure that the road programme advances in parallel, ensuring that the project end dates are synchronised.” Construction of the road is expected to commence during 2018. In addition to extensive community liaison, Knight Piésold’s tender documentation needs to make provision for smaller work packages. “Wherever possible, job creation initiatives will be created, especially for women, who frequently form the backbone of these communities,” says Waseemah. “There will definitely be job and skills transfer opportunities over the approximately 30-month construction programme. We also hope to contribute in terms of CSI ventures.”

Rapid bus route Meanwhile, back in Cape Town, construction works are at an advanced

stage on the Stock Road IRT initiative. The project is situated on the Cape Flats in a very impoverished area in Philippi. “This area has experienced major densification following the addition of informal settlements,” says Waseemah. The total route is around 2 km and runs between the R300 and Govan Mbeki Road (previously Lansdowne Road). Once the upgrade is completed, transit times will be greatly improved along what was previously a single-lane section. Currently, due to severe congestion, it can take more than 30 minutes to travel this relatively short distance on any given day. “We have redesigned the route to accommodate a 30 m wide roadway incorporating various elements. These include two lanes in either direction plus three bus stations. We’ve also added dedicated red-coloured concrete lanes for the buses, as well as non-motorised transport sidewalks to ensure space and safe movement for cyclists and pedestrians. All phases are due for completion by late 2018,” Waseemah explains.

Mentorship “Gaining experience on projects of this nature really hones your skills as a professional engineer and helps us to pass on the knowledge. I’m registered as a mentor with the Engineering Council of South Africa and play a key role in developing the next generation. Currently, for example, I’m mentoring one of our young women engineers through to professional registration. We share the same passion for roads and stormwater, as well as the much broader possibilities within civil engineering,” she adds. “On a final note to all aspiring engineers, men or women, I’d like to say that you will only achieve your goals if you work hard. Most importantly, ask questions all the time. That’s the only way you’re going to learn,” Waseemah concludes.

www.knightpiesold.com

TECHNICAL PAPER

Lessons in labourintensive construction

Modern labour-intensive construction techniques offer major potential for skills development and employment creation during the construction and maintenance of high-quality public infrastructure, where the consulting engineer has an essential role to play. Past examples in Africa prove the point. By Robert McCutcheon*

Setting out a district road in Botswana Checking levels on the gravelled district road

A series of profile boards for camber formation

The completed calcrete gravelled district road

IMIESA August 2017

outh Africa has an insistent demand for public infrastructure and housing; and the demands for public services lie at the core of current community discontent. Levels of unemployment are also extremely high, with job creation being a national priority. Within this context, construction and the maintenance of public infrastructure provide opportunities for the generation of local skills and employment. Elsewhere in sub-Saharan Africa, these factors have historically been addressed through large-scale, long-term programmes using modern labour-intensive methods for the construction and maintenance of rural roads. These methods resulted in a significant increase in productive employment per unit of expenditure when compared with conventional equipmentintensive methods. From the mid-1970s to the mid1990s, in Kenya, Botswana and Lesotho, well over 10 000 km of high-quality, rural roads were constructed and maintained; many hundreds of people trained as handson single-site supervisors and multisite supervisors; and tens of thousands of years of employment were created. The requisite skills required at single- and multisite level were generated within the programmes themselves, and the thorough training of skilled, hands-on site supervisors was a key component in the generation of a significant increase in employment per unit of expenditure From a South African perspective, given the fact that the 2011 National Development Plan

recommended that public employment programmes form a component of employment strategy until 2030, it is considered essential to revisit the principles, theory, potential, practice and lessons learnt from these past African projects. From this re-examination, it will be possible to derive recommendations for future practice and the essential role of consulting engineers. There are a number of complex factors requiring attention for the successful implementation of largescale, long-term programmes. These include ‘reengineering’, which is the responsibility of engineers and senior management, and the training of the ‘missing middle’ required for site implementation. Although it makes intellectual sense, modern labour-intensive construction goes against the grain of the conventional, heavy-equipment, fuel-powered industry. Proving its viability requires a sophisticated analysis of economic efficiencies. A full explication of concepts, principles and practice is beyond the purview of this short article. Below, only a few important points will be made.

Definition of labour-intensive construction (and maintenance) “Modern labour-intensive construction (and maintenance) is the economically efficient employment of as great a proportion of labour as is technically feasible – ideally throughout the construction process, including the production of materials – to produce as high a standard of construction as demanded by the specification and allowed by the funding available. Labour-intensive construction results in the generation of a significant increase in employment opportunities per unit of expenditure by comparison with conventional capitalintensive methods.” This definition is the result of extensive theoretical analysis, practical experimentation and large-scale implementation over a period of at least 40 years. Modern labour-intensive construction lays the platform for even more labour-intensive methods of maintenance.

TECHNICAL PAPER

By ‘significant’, what is meant is an increase of at least 300% to 600% in employment generated per unit of expenditure without compromising cost, time or quality. The range varies for different categories of construction. An illustration is useful here: conventional rural road construction is highly equipmentintensive; less than 10% of construction costs go to labour (a large proportion of this labour cost would be for operators and drivers). A 10% to 50% increase in the numbers employed might sound high, but it only amounts to an 11% to 15% increase in income devoted to labour. By contrast, in labour-intensive, rural road construction, 65% of construction costs goes to labour. A corollary to this is what it is not: it is not the use of large numbers of people on relatively unplanned emergency/relief projects to construct something of ill-defined quality and value. That is labour-extensive. It is not possible to successfully combine the provision of good infrastructure, constructed using labour-intensive methods with ‘make-work’ projects. This is not to say that humanitarian endeavours are not required in Africa; of course they are. But experience has shown that these cannot be combined with the labour-intensive construction of good-quality infrastructure, particularly high-standard infrastructure where the vast majority of public expenditure takes place. It is important to generate employment in the major economy, not just trivial social welfare

expenditures on the periphery. Essentially, modern labour-intensive construction has two main objectives: • a technically sound (good-quality), economically efficient product: equivalent to that achieved by conventional construction without jeopardising economic cost, time and quality • a significant increase in the use of labour per unit of expenditure.

Single-site success It is necessar y to address many factors in order to establish an alternative socio-technical system, even for single-site operations. Technical matters must be addressed from the outset. Consulting engineers of the stature of Scott Wilson Kirkpatrick played a major role in addressing technical fundamentals and related organisational factors. It was found that labour-intensive methods are viable for a wide range of construction activities; in particular earthworks (excavation, load, haul unload and spread), which comprise 50% of expenditure on civil construction. Success at single-site level requires implementation of the following: • r e-engineering of product and process to enable the use of efficient labourintensive methods • prior training of hands-on site super visors who are capable of the technical and

organisational skills required for the productive employment of teams of workers. On the African projects in question, certain conditions of employment were essential, such as outcomes-based remuneration (ILO terminology). Payment was related to the completion of set tasks. Extensive research and field implementation revealed the output a reasonable person could complete in an eighthour working day. The extent to which these tasks are reasonable may be judged by the fact that when the worker was told that they could leave the site when they had completed the set task, they generally completed the task in six hours. Activities within operations were balanced. For example, gravel sur facing consisted of excavation, load, haul, unload and spread activities; and for the excavation, load and unload components. The ratio of workers could be 4:2:1 (var ying according to soil conditions).

Large-scale, multisite success Multisite operations on a large scale, over the long term, require the establishment of a formally linked programme of training and construction, which also necessitates institutional building at local, regional and national level. It cannot be overemphasised that attention to training is far more important than either the amount of construction or the

IMIESA August 2017

81ST IMESA CONFERENCE 25 th-27 th OCTOBER 2017

GAUTENG

SUSTAINABLE ENGINEERING: back to basics for the future Has technology in design made us forget the basic principals of engineering design?

25 - 27 OCTOBER 2017 Online registration is open CO N F E R E N C E VENUE

E A R LY B I R D R E G I S T R AT I O N

EMPERORS PALACE GAUTENG

S TA N DA R D R E G I S T R AT I O N

L AT E R E G I S T R AT I O N

• Members: R5 200 • Non-members: R5 700

• Member: R5 400 • Non Member: R6 000

• Members: R5 900 • Non Member: R6 600

Earn 2.5 CPD points by attending

IMESA Conference endorsed by

www.imesa.org.za ORGANISER

THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA)

t +27 (031) 266 3263 email conference@imesa.org.za

TECHNICAL PAPER FIGURE 1 Actual large-scale, long-term development programme

of the programme, the overheads were 16% and site expenditure 84%. When linked training and construction programmes are established, training only amounts to 1.5% to 2% of total costs.

In summary

amount of employment to be created. The physical construction programme must only proceed at the rate at which competent engineers and supervisors have been produced.

Ratio of overheads to site expenditure Overheads on these projects included the following: institution building at local, regional and national level; re-engineering of product and process; orientation and training of engineers; extensive training of hands-on single- and multisite supervisors; and training of support staff. In the first three years, overheads represented 84% and site expenditure 16%. Over the 13 years

Since the 1970s, several countries in subSaharan Africa have used productive modern labour-intensive methods as a core component of public policy to achieve multiple objectives: high-quality infrastructure, skills development, employment creation and institution building at local, regional and national level. However, this was not achieved by superficial tinkering. To reveal the potential contained in its definition, modern labour-intensive construction requires paying attention to: appropriate policy and legislation regarding conditions of employment, methods of work and remuneration; re-engineering of the project and process; and thorough training, particularly at the level of the hands-on site supervisor (NQF4 in South African terminology). In general, any skilled artisan generates work opportunities for unskilled people around them,

who, besides gaining an income, will also be closer to opportunities to improve their skills. Artisanal development must, therefore, be at the core of national policy. In relation to modern labour-intensive construction, the hands-on site supervisor is the equivalent of the artisan. Elsewhere in Africa, several of the programmes came to an end. This was not because of the ineffectiveness of the use of labour-intensive methods. During the 1990s, for example, Botswana became too rich to qualify for aid funding; and aid to Kenya was reduced. Since much of this work was carried out from the 1970s to the 1990s, little institutional memory remains. Thus, from a broader African perspective, there are mutual benefits to be gained by countries in Africa from greater knowledge about the multifaceted experience throughout the continent. From the above, it may be seen that expenditure of public funds on high-standard public infrastructure may be done in such a way as to also develop skills and create employment. But these secondary benefits at the local level will not be achieved through the ‘parachute’ method or mere ‘tinkering’. They can only be achieved through a long-term programme approach that links the whole process, including the following: conception, design and contractual documentation, training at all levels, and site organisation and management. In South Africa, consulting engineers should play a greater role in re-engineering the provision of high-standard public infrastructure so as to also generate skills and employment. It is also suspected that Africa can relearn lessons from its own successes. *Robert McCutcheon is an employment creation and development specialist at MPA Consulting Civil and Structural Engineers. He is also a professor emeritus and honorary professor at the School of Civil and Environmental Engineering at the University of the Witwatersrand.

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

Perfecting the integrated transport model Gauteng’s rapid rail network is helping to grow the economy, change consumer perceptions about public transport and promote effective land use. By Alastair Currie

uring the 54-month construction period of the Gautrain high-speed rail network, around R3 million an hour was invested for five years to complete this landmark public-private partnership (PPP) project, which commenced in September 2006 and opened, on specific sections, in time for South Africa’s 2010 FIFA Soccer World Cup. The final stages were completed in 2012. The project was originally identified as part of the Gauteng Blue IQ investment initiative to grow major economic segments, such as manufacturing and tourism, along with the supporting infrastructure required to mobilise these developments. When the Gautrain proposal was initially opened to public comment, affected stakeholders were concerned about the negative implications for property values. However, this subsequently proved to be unfounded. In fact, the project has been a massive success in terms of spatial development and land use, which is why there is major market interest in the second phase, which is now in the planning stage. “With megaprojects of this nature, the scope is much wider than pure engineering. This is

IMIESA August 2017

underscored by the fact that we spent approximately R27 billion on the project and, in return, enabled the investment of some R47 billion in mixed-use developments around specific stations. That’s close to a 1:1 ratio and, in the process, thousands of jobs were created,” explains Jack van der Merwe, CEO, Gautrain Management Agency (GMA). “Our initial vision has worked brilliantly, which is why we’re so excited about Gautrain Phase II.” A greenfield development, Gautrain is acknowledged as unique in its execution and won the “Best Public-Private Partnership deal to sign in the world” in 2007 at the prestigious Project Finance International Awards in London. “Projects of this nature normally take up to 14 years, so it’s a significant achievement that we registered the PPP in 2000 and opened on time for the 2010 FIFA World Cup, as promised.”

Traffic growth Gautrain now runs approximately 6 600 train trips per month at 99.3% and above availability, and 98.5% and above punctuality. Van der Merwe points out that this level of efficiency has made the current and future consumer shift to public transport far easier.

The purpose for the Gautrain initiative was to make public transport a mode of choice for its targeted rider segment, being predominately private car users. “Currently, some 77% of our customers are car owners. That’s indicative of a major new trend and attitude towards public transport in this commuter segment. This would be the norm for high-speed rail services in developed nations in Asia and Europe, but traditionally not for South Africa. So it’s a major breakthrough.”

Adding new capacity

the present signalling system. Requests for proposal documents have been sent out to interested parties and GMA will announce the successful bidder by the end of 2017. There are three consortiums currently expected to bid. Among them is Bombardier, one of the original Gautrain PPP Bombela Consortium members.

The ongoing success of Gautrain is now placing increasing pressure on the network and GMA Bus services has announced plans to boost the system, GMA is also reviewing its current which includes the successive addition of new bus fleet and taking into account the rail cars, and the subsequent requirement evolving operating parameters of the for an expansion to the current Midrand BRT, city bus and taxi segments. As Van der Merwe points out, public depot, or alternatively transport models only work the construction of We spent if they’re integrated. “It was an additional and approximately never Gautrain’s intention neighbouring facility. Both endeavours R27 billion on the project to become a major bus operator,” he points out. prepare the way for and, in return, enabled Nine of the ten stations Gautrain Phase II, which the investment of some currently have Gautrain proposes to increase the feeder and distributor current 80 km network R47 billion in mixed-use bus services. by some 150 km, in the developments around According to a household process adding 19 new specific stations.” survey, the average Gauteng stations, plus three new commuter changes modes approximately tunnel sections. “Our peak period is getting fuller by the 3.7 times a day. “It’s what happens at the modal day. We’ve managed to streamline passenger transfer point that makes the key difference,” he volumes by introducing a three-fare system, explains. “At the Gautrain Sandton station, for namely red (peak), orange (shoulder) and example, there are three levels of parking: one green (off-peak). We’ve also implemented for cars, another for taxis, and one for the BRT other measures such as changing the seating buses, so everything’s integrated. It’s about to create more capacity. However, we’re now managing the ‘first and the last mile’ to ensure at the stage where we have to increase the a seamless door-to-door service.” current fleet to meet future requirements,” TOD scenarios says Van der Merwe. Gautrain currently moves around 1.4 million Transit-oriented development (TOD) will commuters a month on the trains, and some determine how cities of the future will be shaped. Over the years, Gauteng has developed 410 000 via 125 Gautrain buses. next to its freeway systems and that was a DBSA funding deliberate strategy from the start. GMA has sourced R4.5 billion in funding from Back in 1975, an engineering and town the Development Bank of Southern Africa to planning working group at the CSIR had already meet future expansion requirements. The put forward a proposed road infrastructure three immediate priorities are the supply of scenario for 1975, 1985, 2000 and 2015 48 additional rail carriages; the expansion of within what was then referred to as the PWV the Midrand depot, which currently houses and region, which largely covers the modern-day maintains the existing fleet; and an upgrade of Gauteng territorial footprint.

The Gauteng Department of Roads and Transport decided to revisit this study around 2013 and the end result is a 25-year Integrated Transport Master Plan (ITMP25) for Gauteng. “For effective transport planning, you need to predict the growth of three segments: the population, where jobs will be created and their type and skill requirements, and where the people will live,” says Van der Merwe. GMA has developed a traffic demand model and used this to predict future demand. This takes into account the proposed Gauteng freeway system, the three metropolitan BRTs, bus and taxi networks, plus the Metro Rail and Gautrain routes. “We calculated that there would be 18.6 million people living in the province in approximately 25 years’ time, but that figure keeps climbing and is now predicted as being closer to 19.1 million, of which an estimated 8.6 million would be workers,” he adds. “If you take into account the commuter needs of 8.6 million workers (8.6 million home–work and 8.6 million work–home trips), plus ‘home to school’, ‘home to leisure’ and ‘work–work’ travellers, this comes to around 24 million passenger trips every day. These are large numbers and our future transport and infrastructure planners need to take them into account in terms of Gauteng’s spatial development model. Gautrain will be a major player in the future transportation mix.”

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

Weighing in at a maximum operating weight of around 35 t, Doosan’s latest generation DX340LCA hydraulic excavator is gaining ground locally in the civils and quarrying markets, thanks to a proven reputation for reliability.

Excavating with intelligent control

ower on demand is provided by a Tier II Doosan engine producing a rated output of 185 kW (SAE J1349) at 1 800 rpm. Improved cooling performance reduces fuel consumption and minimises noise levels in heavy-duty and high ambient temperature conditions. The DX340LCA comes equipped with a 2.35 m³ bucket, and the shape of the excavation boom has been redesigned for improved load distribution throughout the structure. For greater strength, material thickness has been increased to limit element fatigue, increase reliability and extend component life.

For applications in construction, roads, utilities, rental, quarrying and many other industries, the high performance, durability and reliability of portable power equipment is key to boosting productivity on site. At Doosan Portable Power, our compressors, generators and lighting systems are designed and rigorously tested to ensure they give outstanding operation on the toughest sites and in the most extreme conditions around the world. Our ingenuity, innovation and steadfast customer service make us the coolest, hottest name in portable power today.

POWERING YOUR PRODUCTIVITY

www.doosansa.co.za

doosanportablepower.eu Doosan International South Africa • 9 Liebenberg Street • Alrode, Alberton • Gauteng Tel: +27 (0) 11 864 7574 • Email: sales.sa@doosan.com

THE SIX UNIQUE BENEFITS: - Power: 185 kW @ 1 800 rpm (SAE J1349) - Productivity: side lifting capacity of 9.33 t at 6 m reach and 3 m height - Excavation: maximum bucket digging force of 24.8 t - Traction: improved drawbar pull of 27 t - Simplified independent electronics for more reliability and easy maintenance - Increased maximum bucket size of 2.35 m

“For optimum excavator control, the new e-POS system (Electronic Power Optimising System) provides a perfect, synchronised communication link between the engine’s electronic control unit and the hydraulic system,” explains Rod Watson from Doosan Construction Equipment, adding that the self-diagnostic function enables technical problems to be resolved quickly. The choice between Standard and Power operating modes optimises performance in all conditions. Standard mode uses 88% engine power for general work and Power mode uses 100% engine power for heavy tasks. In Economy mode, the machine uses 76% engine power. “Ultimately, an excavator’s work rate depends on the performance of the person who controls it. That’s why the new DX340LCA was designed around the operator, with ergonomics that are specially developed to maximise efficiency and safety,” adds Watson.

JAGUAR XF

DYNAMIC, EVEN WHEN STILL.

One glimpse of the Jaguar XF and there’s no mistaking it for anything but a performance car. With its taut, athletic exterior made more pronounced by its beautiful curves and F-TYPE inspired design cues, the XF truly stands apart. Once you step inside, you’ll experience the contemporary style, exquisite craftsmanship and exceptional comfort that make XF so seductive. Distinctive lines. Dramatic beauty. No wonder XF turns heads, even when it’s stationary.

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A strong foundation for infrastructure success

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

New screening solution launched The recent local introduction of the Kleemann Mobiscreen MS 703 EVO by Wir tgen SA offers an efficient solution for the roads construction and allied industries.

The Kleemann Mobiscreen MS 703 EVO is a compact unit designed for road-legal transportation and rapid on-site deployment

I15457

esigned and developed in Germany, the Kleemann MS 703 EVO is a triple-deck mobile classification screen that precisely processes most types of coarse natural stone and residual construction materials. Measuring in at 1.520 m x 4.440 m, with a 75 kW engine and feed capacity of 350 t/h, the MS 703 EVO comes with either a diesel-hydraulic or diesel-electric drive, as well as various screening media options.

Classifying screens

ROCLA is South Africaâ&#x20AC;&#x2122;s leading manufacturer of pre-cast concrete products. Surpassing 100 years of product excellence, including pipes, culverts, manholes, poles, retaining walls, roadside furniture, sanitation and other related products within infrastructure development and related industries.

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Square mesh screen surfaces are the most common application and are predominantly used where a cubic shape is required. Different wire qualities and thicknesses are available: the thicker the wire, the longer the service life; the thinner the wire, the higher the production rate. Rectangular mesh screen surfaces are specified for screening cubic grain sizes and are often used to sort natural gravel at high throughput. Inserted on the lower deck section, Harp screening media are specified for screening damp material and other difficult products. The natural vibration of the longitudinal wires acts as a self-cleaning mechanism.

SPECIALITY CHEMICALS

Leading in the chrome value chain

IMIESA speaks to Ben Marais, country representative: South Africa and managing director, LANXESS, about the group’s South African operation – the key to the development of a proprietary range of chemical products that are shaping the future worldwide, including the multifaceted construction segment for building, wastewater and water treatment. Ben Marais, country representative: South Africa and managing director, LANXESS

ANXESS is the only company in South Africa that handles the entire chemical chrome value chain, from mining the ore in Rustenburg at LANXESS Chrome Mining (Pty) Ltd. to further processing at its plants in Newcastle and Merebank, where final chrome chemical production takes place. The mine supports LANXESS globally, shipping throughout South Africa, South America, Europe and Asia. Some 95% of South African production is exported. The Newcastle plant, operated by LANXESS CISA (Pty) Ltd., is one of the most modern chrome chemicals production facilities in the world, and employs advanced technologies in the production of sodium dichromate. This is used to manufacture chrome tanning salts, chromic acid and inorganic pigments (chrome oxides and chromate pigments). The plant also converts some of the sodium dichromate into chromic acid used in metal finishing. The production facility at Merebank is the next step in the process and is the final production stage. At Merebank, a basic chrome sulfate, along with other technically advanced mixed products, completes the In South Africa, LANXESS is the processing phase. only company Sodium dichromate from to handle the Newcastle is also used at entire chrome value chain LANXESS’s plant in Krefeld-Uerdingen, Germany,

LANXESS CISA (Pty) Ltd. in Newcastle is the world’s most modern chrome chemicals plant

ABOUT LANXESS LANXESS is a leading specialty chemicals company with sales of €7.7 billion in 2016 and about 19 200 employees in 25 countries. The company is currently represented at 75 production sites worldwide. The core business of LANXESS is the development, manufacturing and marketing of chemical intermediates, additives, specialty chemicals and plastics. Through Arlanxeo, the joint venture with Saudi Aramco, LANXESS is also a leading supplier of synthetic rubber. LANXESS is listed in the leading sustainability indices Dow Jones sustainability index (DJSI World) and FTSE4good.

IMIESA August 2017

Quality WORKS.

At LANXESS, quality means much more: we live quality. It’s at the very heart of our work. Quality means producing highperformance products that deliver on what is promised. We want our customers to be able to rely on us fully in all matters and at every stage of our chrome value chain. It is our commitment to our employees, customers, stockholders and partners. At LANXESS Chrome Mining (Pty) Ltd. quality means supplying the highest standard chrome ore for local and international use. From the first conversation to the perfect implementation. Fast, simple and efficient – fully in line with our motto “Energizing Chemistry”. Visit www.lanxess.co.za for more information.

SPECIALIT Y CHEMICALS

to manufacture chrome oxide pigments. These pigments are highly valued for their good lightfastness properties and are used to colour concrete, paint, plastics and coatings. “Chrome has such wideranging applications and finds applications in just about every industry,” says Marais. In 2004, LANXESS broke away from Bayer to become a wholly independent company. “Today, LANXESS is a leading specialty chemicals brand worldwide,” says Marais. “Our success since inception has been driven by a focus on quality and intensive customer interaction.”

Speciality chemicals for construction For the building industry, the list of potential applications for LANXESS products include anti-fungal coatings; fibre cement; bitumen additives; in situ concrete colourants; additives for precast products, such as masonry blocks, concrete block paving and roof titles; AND intricate façade elements. An excellent example of an outstanding façade design is South Africa’s Soccer City stadium, which was purpose built for the 2010 FIFA World Cup. “Soccer City was the most important stadium of the 2010 World Cup and is a true landmark in Johannesburg, serving as an outstanding example of scale, innovation, design and technology,” says Marais. The distinctive glass-fibre reinforced concrete panels that clad this colourful structure were created using LANXESS’s Bayferrox pigments. Iron oxide and chrome oxide pigments from LANXESS provide versatile design elements, providing colour accents from yellow to orange, red to green and brown to black. Well known under their Bayferrox and Colortherm brand names, these pigments are characterised by their outstanding lightfastness, weather stability and chemical resistance. Colortherm green pigments are unique in the industry, ranging from a pale yellowish cast to an intense dark green shade. They can also be mixed with brilliant yellow pigments with good stability to produce the saturated greens that are required, for example, by the household appliance industry.

To manufacture the Soccer City stadium coloured panels, the glassfibre-reinforced concrete was pigmented with LANXESS's Bayferrox pigments

Innovative products from LANXESS’s Material Protection Products business line are used in the manufacture of gypsum boards, waterbased glues and plasters, and for industrial applications like mineral slurries and polymer emulsions, as well as for the preservation of concrete admixtures.

Water and wastewater Allied to its architectural and building innovations, LANXESS has established itself as an industry pioneer and innovator in the all-important water sphere. Here, LANXESS’s Liquid Purification Technologies (LPT) business unit is one of the world's foremost suppliers of products for treating water and other liquid media. “We hold a leading position in the development and production of ion exchange resins and are very active in our new business line for reverse osmosis (RO) membrane elements,” says Marais. Areas of application include: • industrial process and wastewater treatment • water recycling • production of ultrapure water • drinking water treatment. “The market for RO membrane elements is currently projected to grow at an above aver-

age rate of 10% annually over the next three years. In the case of ion exchange resins, this is predicted to average 4% per year,” Marais points out. An efficient technology from LANXESS for treating water is the use of Lewatit ion exchange and specialty adsorber resins. Among other applications, ion exchange resins are used to remove pollutants from drinking water. “Industrial applications include the treatment of water for industrial processes in power plants. These costly facilities need large volumes of cooling and process water, which have to be demineralised to protect the systems against scaling.” Another area of application for RO membranes is the production of drinking water from both brackish water and seawater. This method is used on a large scale in cities and municipalities. LANXESS’s Lewabrane RO membrane elements lower the salt and particle content of the water and are often combined with ion exchange resins to form a highly efficient and very powerful demineralisation system. Lewabrane membrane elements are manufactured at a high-tech, fully automated production plant in Bitterfeld, Germany. The membrane chemistry depends on a strongly crosslinked polyamide layer that displays high resistance to chemical cleansers, higher rejection of complex salt mixtures and a low surface charge, which reduces the tendency towards fouling. Since their market introduction in 2012, tens of thousands of Lewabrane filter elements have been installed worldwide.

The production of the Lewabrane® membrane for water treatment

IMIESA August 2017

Gabions and

site assessments

hen it comes to gabion structures, ensuring their integrity depends on a combination of correct material specification, design and construction technique. Older gabion structures need to be revisited some years down the track where galvanised wire was used in their original construction, especially for river protection and hydraulic structures. “For any potentially corrosive environment, we always recommend Galfan-coated, softtemper steel wire for gabion construction,” explains Louis Cheyne, managing director of Gabion Baskets – a company that manufactures and supplies gabions and supporting geotextiles, along with design, training and installation services. “A further PVC coating is then applied during the manufacturing process to provide added

IMIESA August 2017

Constructing with gabions is a highly sustainable civil engineering application that ensures structures blend in with the environment, and it all starts with a professional design approach that maximises labour and minimises costs. By Alastair Currie protection when these products are installed in polluted environments where soils or water are acidic. This PVC coating usually has a nominal thickness of 0.50 mm, and helps to significantly preserve gabion structures for many decades. However, the same cannot be said for standard galvanised wire, which will inevitably fail.” Cheyne points out that climate change impacts need to be factored into future designs and remedial works. The increase in extreme floods and droughts, for example, has led to the rapid deterioration of gabion structures in river systems where incorrect techniques and products have been specified. Retaining wall installations also need attention for the same reason.

CASE STUDY Project scope: Embankment stabilisation Gabions: 115 m3 Wall footprint: 45 m2 Costing: R1 500 m3 to R2 000 per m3 Location: Parkhurst, Johannesburg Gabion production rate: Approximately 1.5 m3 per man per day Duration: Two and half weeks with some 15 personnel Challenges: Stone materials needed to be transferred over a distance of about 150 m Details A gabion skin revetment wall constructed for a private residential development in Parkhurst, Johannesburg. The wall is approximately 4.5 m high and has a 500 mm foundation. Unlike mass gravity walls, where the base width might be 55% to 60% of the height, a skin revetment is a thin gabion wall cladding on the external facing of the embankment to stop soil erosion. A 200 g/m2 geofabric was installed behind the gabion wall to promote drainage. The wall is stepped back at 500 mm intervals all the way to the top.

ENVIRONMENTAL ENGINEERING

Wing walls outflanked “Within river systems, designers need to take into account worst-case scenarios when they design hydraulic structures,” points out Cheyne. “For example, we frequently see examples of concrete wing wall designs on gabion weir systems that are inadequate as a protection measure, typically being too short. When river levels rise, these wing walls become outflanked.” This underscores the need for detailed surveys by hydrologists and geotechnical specialists to ensure that an accurate assessment is determined, which includes the founding requirements. From an insurance perspective, damage claims will always start with an investigation on whether the structure was installed correctly. “A proper foundation is vital and, here, gabion mattresses provide an effective solution in minimising the effects of up- and downstream flows, reducing water velocity and, subsequently, soil erosion,” he continues.

Culvert interventions Roadworks and stormwater protection systems form a large staple of the work carried out by gabion contactors. Culverts, in particular, are at risk when it comes to erosion around these rigid, monolithic structures. “Ideally, designers should factor in gabion interventions at the initial construction phase to counter up- and downstream erosion,” says Cheyne. “In the longer term, culverts do tend to experience erosion threats, but these can simply be countered with the installation of gabion mattresses, which are highly effective.” Typical erosion here entails downstream scouring, with deep holes forming and foundational soil loss. Installing gabion mattresses reduces water velocities significantly. These mattresses are tied into the concrete culvert structure with dowels. Thereafter, concrete is poured on to the top of the first 500 mm to 1 m section of the mattress to ensure a secure connection.

Fish farming Gabion design applications are limited purely by the imagination. In recent times, for example, Gabion Baskets has supplied solutions for South African fish farming ventures in regions that include Gauteng and KwaZulu-Natal. “Aquaculture is seen globally as a major growth industry and a meaningful solution in Africa to address protein deficiencies and food security in general,” says Cheyne. Past Gabion Basket installation examples entail the use of gabion walls in ponds to create natural separations for breeding fish populations. By continuously pumping through the gabion walls, this serves to naturally purify the water.

Retaining wall innovations Whether for building or civils work, retaining wall structures remain a core component of Gabion Baskets’ business, for both public and private sector clients.

FROM LEFT TO RIGHT Culvert inlet repair works under way at a game farm in Wellington, Western Cape, using a gabion mattress to counter scour. The final gabion installation will be capped with a concrete layer that ties in with the culvert structure A completed roadway wall installation adds aesthetic appeal while safeguarding a stormwater drainage structure in the Western Cape Construction in progress on a fish farm, built during 2012 in Cullinan, Gauteng

“In terms of volumes, retaining walls tend to require a higher labour component and, therefore, are ideal for meeting the need for job creation within South Africa’s unemployed communities,” Cheyne continues. “From a materials perspective, these construction works are also very cost-effective and can average around R1 500 per m3, so we believe their application should be far more widely adopted,” he concludes.

Our Products Gabions and Mattresses Woven and Weldmesh Geotextiles Gabion tool sets

Erosion control blankets Gab - Bloc / Sandbag Gabion rock

Our Services Site assistance & advice Gabion structure design Price estimates

Technical support Practical site training Experienced installers

81ST IMESA CONFERENCE Emperorâ&#x20AC;&#x2122;s Palace | GAUTENG SUSTAINABLE ENGINEERING: back to basics for the future Has technology in design made us forget the basic principals of engineering design?

25 - 27 OCTOBER 2017

Conference Social Activities GOLF The Serengeti Golf Club is situated within the Serengeti Golf and Wildlife Estate. The club and estate offers an opportunity of escapism without major inconvenience for those who seek it. Date: 24 October 2017 Venue: Serengeti Golf Club Time: Registration from 9:30-10:30 Cost: R550pp (Fee covers Golf only) For players account: Hiring of Golf Carts and Caddies

The Serengeti Golf Club

COMPANION TOUR Nothing can inspire you more than your own experiences. Unleash your creativity and express ideas, feelings and emotions visually in a variety of art media in an entrancing session of Artjamming. Chocolate lovers can indulge in a demonstration by Master Chocolatiers and learn the art of making Lindt Chocolate Truffles. Dates: 25-27 October 2017 Cost: R850pp (includes entry to Opening & Gala function)

Fun-filled tour

GAL A E VENT Join us for a (beer) barrel of fun and a German feast at our German Beerfest themed evening. Dress Code is smart casual or anything German inspired! Please note there is a limited bar, cash bar thereafter. Date: 26 October 2017 Venue: Emperors Palace Time: 18:30 Cost: Included in delegate full conference fee. Exhibitors may purchase discounted event tickets. Enquiries: conference@imesa.org.za

German Beerfest evening

Conference endorsed by

www.imesa.org.za

IMESA Organiser

THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERNÂ AFRICA (IMESA)

t +27 (031) 266 3263 email conference@imesa.org.za

Plastic Pipes

First Sappma policy on gaseous fluids Supply Chain Discussion Marley Pipes MacNeil Pexmart Sizabantu

54 57 59 61 63

PLASTIC PIPES

First Sappma policy on gaseous fluids The supply of gaseous fuels through plastic piping systems is a major growth area for the industry.

he Southern African Plastic Pipe Manufacturer’s Association (Sappma) has released the local industr y’s first policy statement for the supply of gaseous fuels using polyethylene pipes in order to ensure that the application and use thereof conform to SANS/ISO 4437:2014. “The gas industr y in South Africa is growing rapidly and gas pipelines will increasingly become an important part of the countr y’s infrastructure,” explains Jan Venter, CEO, Sappma. “Extended working lifetimes and uninterrupted, safe supply of gas are, therefore, essential and will only happen if the pipes and the pipelines are of prime quality. It is Sappma’s responsibility to ensure that the pipes used have been manufactured according to stringent specifications and adhere to global standards.”

IMIESA August 2017

PLASTIC PIPES

HDPE is currently the only viable plastic pipe material for gas pipelines, Venter points out. “Extensive tests conducted over the last 45 years have confirmed that the long-term strength of plastic pipes is unaffected by natural gas and its common constituents. HDPE pipes offer numerous benefits. They are lightweight and easy to handle, easy to join, available in a range of sizes and pressure ratings, and have low frictional resistance, with hydraulic properties that remain virtually unchanged over their useful life.” The pipe construction methods covered in the new policy statement include solid orange pipe, solid black pipe with orange identification stripes, as well as co-extruded pipe with orange outer layer and black inner layer. Sappma will be carrying out audits to look for evidence that this policy is being adhered to and that the requirements of the standard are being met.

PIPES XI conference An exciting development on the industry calendar is the PIPES XI conference, being on 4 and 5 September 2017 in Johannesburg and hosted by Sappma. More than 35 of South Africa’s and the world’s top experts on issues relating to plastic piping, water infrastructure and engineering will be presenting. This year, the event will be hosted in conjunction with the Plastic Pipe Conference Association (PPCA). Every two years, the PPCA plays host to the world’s biggest international pipe conference, which usually takes place either in Europe or the USA. Venter explains that this is the first time in PPCA’s history that its spin-off conference, which is organised every alternate year, will be coming to South Africa. “At PIPES XI, at least 10 of the best papers presented at Plastic Pipes XVIII 2016 in Berlin will also be delivered to our local audience,” says Venter. Themes carried over from Plastic Pipes XVIII include: • Main drivers and barriers for plastic pipe • Residual quality of excavated PVC-U pipes • Lifecycle assessment of PVC pipe • No-dig Technical Guide for PE100 pipe • What is new in PVC-O • Electrofusion jointing of large-diameter HDPE pressure pipe • Evaluation of long-term performance of structured wall HDPE pipe. “We cannot emphasise enough the importance of this event, and encourage local engineers, students, specifiers and decisionmakers to make the most of this opportunity to be exposed to the latest local and international trends,” he concludes. “South African polymer and pipe manufacturers are doing excellent work, and keeping abreast of the latest technologies is essential for the industry’s future.”

PLASTIC PIPES | SUPPLY CHAIN DISCUSSION

MARLEY PIPES Erna Lovell | Marketing Manager What, in your opinion, are the benefits of selecting plastic pipes for water and wastewater applications? EL PVC pipe systems have the benefits of easy installation and secure joints that require no special tools to establish. Also, minimal training is required. Marley’s waste system conforms to the relevant SANS standard and bears the SABS mark, in line with Marley’s commitment to quality and safety. The Marley waste pipe system offers corrosion resistance with excellent flow rates, is tough and offers resistance to impact. As a result, site breakages and other failures are minimal. The system is UV stabilised to prevent weathering and oxidation in South Africa’s harsh climate. Being white in colour, completed installations are neat in appearance and will provide many years of service-free use under normal operating conditions.

Marley Pipe Systems is the South African licensee of the Weholite pipework system. What are the benefits and applications of this international system? Weholite is virtually leakproof and is less susceptible to salt water and chemicals associated with sanitary sewage effluent. It will not rust, rot or corrode.

Weholite has a high tolerance for harsh environments and is virtually unbreakable, even in freezing conditions. Irrigation: Weholite pipes can be used for irrigation and low-pressure water conveyance applications. Sanitary sewers: Weholite offers high flexibility and abrasion resistance, and will not corrode or tuberculate over time. Culverts: The high axial stiffness and high resistance to hydrostatic collapse pressure caused by grouting simplifies installation and grouting procedures when used to reline deteriorated highway culvert pipe. Drainage and stormwater: The material has enhanced hydraulic flow and unparalleled chemical and abrasion resistance. Research has shown that the service life of Weholite is 50% longer than concrete in stormwater applications.

Can you tell us about any notable projects where Weholite has been used in South Africa? Marley supplied 1 300 m of Weholite structured wall HDPE DN/ID 900 mm pipe to WBHO in Rustenburg. This was to be extrusion-welded to replace outdated concrete pipes with a more cost-effective, easier-to-handle HDPE gravity water system. In a substantial pipeline upgrade project, Marley partnered

with Bofepi Project Management as part of the Department of Public Works’ infrastructure development programme. Marley teamed up with HT Pelatona Projects in a bid to secure the health and hygiene of the Bloemhof community by preventing sewage spillage into the Vaal River.

Marley also offers an extensive range of PE electrofusion fittings. Why should clients opt for electrofusion fittings in their water and wastewater pipelines? Electrofusion welding systems are now considered the most highly developed and safe method for joining polyethylene pipes. Thanks to its versatility, electrofusion can be used to weld together pipes or fittings from different polyethylene materials and different thicknesses, as long as there is a compatibility of melt flow index and raw material density.

How does Marley Pipes ensure that its electrofusion welding system meets the highest standards? Marley electrofusion welding and spigot fittings conform to international standards and undergo both destructive and non-destructive testing to ensure ultimate quality for project installations.

www.marleypipesystems.co.za | 0861 MARLEY (627539)

IMIESA August 2017

PLASTIC PIPES | SUPPLY CHAIN DISCUSSION

MACNEIL PLASTICS Derek Faulds | Managing Director What products and services does Macneil Plastics offer? DF Macneil Plastics manufactures the following products: • Amanzi-flo PVC-U (SANS 966-1) – 50 mm CL 4 to 400 mm CL 16 (Class 20 only in certain sizes) 3 Microbore PVC-U from 20 mm CL 16; 25 mm CL 12 and CL 16; 32 mm CL 12 and CL 16; 40 mm CL 9/12/16 • Esizayo-flo PVC-M (SANS 9662) – 110 mm CL 6–250 mm CL 16 – on the market from 1 September 2017 • Macvent SWV pipe (SANS 967) – 40 mm/50 mm/110 mm • Macflo sewer pipe (SANS 791) – CL 51 and CL 34 – 110 mm – 400 mm

3 We distribute multilayer 400 kpa sewer pipe – SANS 1601 from appropriately certified manufacturers for our customer convenience (the pipe is guaranteed by the manufacturer) • rainwater systems (SANS 11) and related products – half-round gutters, D-shape gutters, gutter fittings and downpipes •M acneil Plumbpipe (polycop – SANS 15874-2) – this is currently a very high-quality conformance product, backed by full manufacturer's guarantee (as per the standard) and will be certified again through SATAS imminently • Macneil Plumbing fittings – SWV fittings (SANS 967) and UG fittings (SANS 791/1601) • Aquamac HDPE (SANS 44272) – 20 mm CL 16; 25 mm CL 12/16; 32 mm CL 10/12/16; 40 mm CL 8/10/12/16; 50 mm – 250 mm CL 6/8/10/12/16. Services: 3 the Macneil Plastics QC laboratory is often used to test pipe samples for clients 3 assistance to clients in terms of pipe selection and application.

or it is not – there are no grey areas. From raw material procurement to batch testing as per the required SANS and ISO standards, Macneil Plastics adheres to all standards and does not waver from them. We take pride in never sacrificing product quality to meet other requirements in terms of costing. There may be cheaper products available but it is vital for end users to confirm that they meet the required standards before purchasing on price alone. Our manufacturing processes and quality assessments all exceed the required standards laid down for the products we produce. Water is our most valuable commodity and Macneil Plastics treats all water projects with equal respect to both the resource and health standards. Macneil Plastics has relationships with Roediger Labs, PESC and other related laboratories for independent product testing.

As a supplier, what is your viewpoint on product quality?

Macneil Plastics has ISO9001:2015 accreditation through TUV Rheinland and our products are all SATAS certified. We are a proud “large manufacturer” member of the Southern African Plastic Pipe Manufacturers Association, and a member of

Macneil Plastics has one nonnegotiable policy to ensure this – quality and manufacturing to specification. A product is either fit for purpose,

In line with your promise to provide quality products to the market, what professional accreditation does Macneil Plastics have?

the Institute of Plumbing South Africa, SABI, Plastics|SA, and the Plastics Convertors Association.

An increasing emphasis is being placed on cleaner production. How does Macneil Plastics work to reduce its carbon footprint and water consumption in manufacturing processes? Macneil Plastics is working very hard on an ongoing basis to keep electricity requirements to a minimum. In terms of water consumption, Macneil Plastics aims to cut reliance on water drastically in the production process and also to reduce reliance on municipal water through rainwater harvesting, the use of purified borehole water and so on. Our management programme and commitment to “zero plastics to landfill by 2030” are an essential part of our planning.

How big is your distribution footprint and how does this help to ensure good customer service? Although Macneil Plastics is based in the Western Cape, we offer a national footprint and deliver in bulk to construction sites. We have six trucks doing local breakbulk delivery in the Western Cape and release between 65 and 85 link loads for bulk national distribution on a monthly basis. With our proximity to the Cape Town port, we are ideally placed for exports into north-west and West Africa. We load containers to export customer specification on-site at the factory and export these on an FOB basis.

IMIESA August 2017

PEXMART Pexmart cc has a high performance team with an extensive knowledge of local terrains and conditions and a proven track record of delivery on time and within budget. Key staﬀ has national and international experience working in the mining, commercial and industrial sector. Manufacturing, fabrication & installation of plastic pipes & fittings HDPE, HDPP, LDPE, PVDF, PVC

Manufacturers of sabs and non sabs pipe • Water Reticulation • Sewer and Storm water • Fabrication and installation of bends, tee pieces, laterals & reducers • Butt welding, Electro fusion, Branch, Socket & Extrusion welding • Installation of Pipe lines and fittings (Above, Underground & Mining) • Suppliers of Stub ends, Steel flanges and related Fittings • Manufacturer of HDPE Manholes • Pipe Relining and Pipe Cracking • Re-sleeving of steel pipes with HDPE • Manufacturing of steel pipelines and fittings

Vision

Mission

Strategy

PEXMART is dedicated in delivering the best quality workmanship with excellence towards a reputation that will far exceed our vision.

PEXMART aim to promote strong relationships with the communities in the surrounding areas in which we operate and to assist our local community with provision of water and sanitation.

PEXMART experience in the industry has taught us that customer service is of cardinal importance and a wellsupervised, well-completed job is the best way of advertising the company.

Contact details below Please feel free to contact us via email: info@pexmart.com or telephonically 012 376 2347 / 012 376 0053, should you have any questions/queries or need any additional prices on quote requests.

www.pexmart.co.za

PLASTIC PIPES | SUPPLY CHAIN DISCUSSION

PEXMART Renier Pieterse | Sales and Marketing Manager What products and services does Pexmart offer to the civils and building industry? RP First and foremost is the manufacturing of solid wall, high-pressure HDPE pipe. We also manufacture Spiralite and structured wall HDPE pipe and recently started manufacturing corrugated drainage pipe, as well as sleeve pipe for the fibre industry. Our offering includes the fabrication of all relevant fittings for these pipes, as well as HDPE liners for the lining of steel pipelines. Pexmart performs installations of all pipe variations.

Pexmart specialises in the manufacture, supply and installation of HDPE pipes. What are the benefits of HDPE over other varieties of plastic pipe? HDPE is a versatile thermoplastic polymer with many performance benefits. Its overall toughness, flexibility and low-temperature impact resistance make it ideal for pipe systems. HDPE has a high resistance against acids, bases and aqueous salt solutions. The chemical resistance of HDPE makes it perfect for standard soil and waste systems. It is also elastic – making it suitable for dolomitic areas – UV-resistant, wear-resistant, chemical-resistant, recyclable, non-conductive, light in weight, and it can be prefabricated – which reduces installation costs.

Pexmart now manufactures structured wall pipes. What are the applications and advantages of these? Some of the main applications for Spiralite and structured wall HDPE are the following: sewer rising mains, stormwater

drainage, subsoil drainage, corrosion-resistant tanks, marine pipelines, landfill drainage, and mine drainage. The pipe is lightweight compared to other alternatives for these applications and is abrasion-, chemicaland corrosion-resistant. The pipe is also manufactured in longer lengths than other alternatives, saving on transport and installation costs, in addition to being easy to install.

Another of Pexmart’s specialised offerings is the lined pipe system. Could you tell us more about this? Pexmart Lined Pipe Systems, established in 2009, specialises in pipeline construction, internal HDPE pipe lining, pipe rehabilitation and plastic pipe systems. In recent years, Pexmart Lined Pipe Systems has refined the process of lining steel pipelines with HDPE liners to the extent where any diameter of pipe can be lined in the factory or on-site. We repair and rehabilitate old existing abrasion pipelines, manufacture and line new abrasion pipelines, manufacture and line new fittings and rehabilitate old fittings. We do continuous lining of pipelines on-site to the extent of 100 m to 1 000 m flangeless in-between.

What sets Pexmart apart from other plastic pipe suppliers? Pexmart is unequivocally dedicated to addressing clients’ needs and producing an outstanding and exceptional personalised service in respect of our different areas of expertise. We strive to provide a professional, reliable and effective on-time and within-budget service. Our business is built on referrals by meeting and exceeding our con-

tractual obligations. Experience has taught us that customer service is of cardinal importance, and well-supervised, well-completed projects are the best form of advertising. We will continue to build and maintain our promise to provide integrated solutions combining product excellence, complete technical expertise and full customer service, ultimately ensuring that our customers and end users have confidence in dealing with us.

IMIESA August 2017

PLASTIC PIPES | SUPPLY CHAIN DISCUSSION

SIZABANTU PIPING SYSTEMS Mike Smart | Specialist Consultant

What are some of the challenges surrounding the proper handling and installation of plastic pipes? MS Thermoplastic pipes are relatively lightweight compared to “conventional” material pipes. While this is one of their many advantages, it is also frequently the cause of damage during handling and installation. Their lightness frequently facilitates a carelessness that results in the pipes being dragged, thrown, dropped and struck. The resulting surface damage may constitute the removal of a significant proportion of the wall thickness of the pipe. All thermoplastic pipes exhibit creep characteristics, meaning that anything detrimental to the pipe – such as damage – may not result in immediate failure but will likely result in failure before the expected end of the asset lifespan. Therefore, careful attention to the handling, installation, and quality and compaction of the bedding, embedment and backfill of the pipeline is essential to ensure the realisation of a lifespan of over 100 years.

What do designers need to consider to ensure successful pipe installation? Two things are necessary – competency and on-site supervision. The competency of the contractor is essential to ensure a pipeline is constructed to the specified standard. The plant, equipment, processes and personnel must all conform to the applicable standards. The tender document will include items for the tests necessary to ensure conformance of the installation, including the requirements of the applicable construction standard SANS 1200-L (SANS 2001-DP2) Medium Pressure Pipelines, and the manufacturer’s recommendations. Furthermore, well-prepared documentation is of no value without competent and effective supervision by both the contractor and the consultant on-site. The appointment of a competent QA/QC contractor should be considered and may be money well spent.

How crucial is product selection for pipeline applications and how can designers ensure they

select the correct product for the correct application? There are many different thermoplastic pipes, each specifically engineered for a particular application. Although it might be possible to use a product on an application other than that for which it was intended, it may not be technically adequate or commercially competitive. With the numerous thermoplastic pipe systems available, there is likely a thermoplastic pipe system available that has been specifically engineered for your application. To ensure you use the correct product, only deal with competent and honest companies – e.g. Sappma or IFPA members – with a proven track record of successful projects and demonstrable technical competence.

How can Sizabantu assist with the quality supply and correct installation of plastic pipes? We live in the age of the specialist, who knows and understands the labyrinthine choices and technical nuances in each industry. Therefore, it is essential to deal only with companies that have the necessary competences.

Sizabantu Piping Systems has a network of divisions across South Africa, each run by a director with at least 10 years of experience in the industry, and particularly PVC pipe. At Sizabantu, we have seen it all. We have extensive experience in all matters regarding PVC pipe, from the handling of the product, storage and laying, to fault finding if failures occur. To this extent, Sizabantu decided to have its pipe crated. This has alleviated the problem of pipes being damaged during transport and storage, thereby assuring the best-quality material is delivered to site. Sizabantu Piping Systems recently formed a joint venture with Molecor Canalizianos, a manufacturer of PVC-O (Orientated PVC), which led to the establishment of a worldclass factory based in Richards Bay, Kwazulu-Natal. This factory is the first of its kind on the African continent and incorporates the latest global technology in PVC pipe, bringing forth international quality standards to the industry. As a manufacturer of mPVC, uPVC and now Molecor TOM500 PVC-O pipe, Sizabantu has earned a reputation of zero compromise on quality. An attribute that makes us PROUDLY SIZABANTU!

IMIESA August 2017

METERS, PUMPS & VALVES

of 65 years pump innovation

PE Pumps and Mather+Platt South Africa have close to seven decades of experience in the Southern African market, with their comprehensive range complemented by key solutions from Gruppo Aturia, a fellow WPIL Limited group company acquired in 2015. Since 2005, the Rotos Division of Gruppo Aturia has led an extensive research and development (R&D) programme specialising in the application, engineering and distribution of technically advanced, hermetically sealed, magnetic drive pumps. This R&D focus is grounded by more than 20 years of experience and extends from hydraulic ends to proprietary magnetic couplings. Rotos seal-less magnetic drive pumps are now available in 18 different designs with over 250 basic models. “This vast pump range allows our engineering department to meet exact process requirements,” comments Peter Robinson, managing director of APE Pumps and Mather+Platt South Africa. “These pumps comply with the latest standards, namely ISO 2858 for seal-less centrifugal magnetic drive pumps, and API 685 seal-less MDP pumps for the petroleum industry.” Gruppo Aturia represents the integration of five famous brands. Alongside Rotos, Aturia has a leading reputation for submersible pumps; the Marelli brand covers all industry sectors; while the Audoli & Bertola and Aris Chiappa ranges target the vertical pump segment. Products are divided into four lines: the Blue Line for submersible pumps with semi-axial and radial hydraulics; the Green Line for close coupled pumps, in-line, single-stage DIN 24255, multistage, split-case and vertical pumps; the Yellow Line of ISO 2858-5199 compliant pumps for the chemical industry, API 610 process pumps, magnetic drive seal-less pumps, and API 685 pumps;

and the Red Line for firefighting systems.

Product range Rotos is one of the mainstream solutions for the transfer of fluids with corrosive, acidic, or inflammable properties. The product range comprises: • STM seal-less regenerative turbine magnetic drive alloy pumps • PTM seal-less regenerative turbine magnetic drive nonmetallic pumps • SVM seal-less rotary vane magnetic drive alloy pumps • PCM seal-less centrifugal magnetic drive non-metallic pumps • SDM seal-less centrifugal magnetic drive alloy pumps. “Since magnets are the main driving force, this obviates the need for shaft sealing interventions, such as gland packing or mechanical seals. That’s because the design negates the need for a shaft extension from the pump casing,” explains Richard Harper, project manager at APE Pumps. “Therefore, there’s minimal risk of leakage in terms of fluid and vapour emissions. That’s especially important where chemicals, acids and corrosive liquids are factors. Maintenance interventions also tend to be far lower when compared to mechanical seal pumps. However, it’s important to understand that their roles are very different. Mechanical

Gruppo Aturia’s Yellow Line: the pump model shown is API 685 compliant

An example from Rotos’ SVM series of seal-less rotary vane magnetic drive alloy pumps

drives are designed to cope with solids in suspension, while magnetic drive pumps are not. Magnetic drives are purpose built for clean fluids transfer, and that’s where they really excel.”

www.matherandplatt.com

APE product milestones since 1952 1952 1953 1965 1970 1974 1977 1979 1980

APE Pumps enters the market under the name Sangus Sangus range of submersible pumps APE split-case range from 50 mm to 450 mm APE Nimbus end suction 80 mm to 300 mm range APE range of end suction pumps from 32 mm to 150 mm Introduction of the Byron Jackson petrochemical range APE vertical turbine range of pumps from 150 mm to 1 100 mm APE submersible range of dewatering pumps

IMIESA August 2017

1983 1985 1997 2002 2007 2012 2015

APE Robushi chemical process pumps APE Vac Seal range of pumps Introduction of the new range of APE submersible pumps from 100 mm to 250 mm APE Byron Jackson range of petrochemical pumps, 8th Edition PSV Holdings acquires pump division WPIL India acquires APE and Mather+Platt South Africa APE Pumps company group acquires Gruppo Aturia

METERS, PUMPS & VALVES

New radar level transmitters Krohne has added six new 24 GHz and 80 GHz transmitters to its Optiwave series of FMCW radar level transmitters.

he new transmitters work for liquid and solid applications in a wide range of industries. Each device has a particular target area of application, such as agitated and corrosive liquids, narrow tanks with internal obstructions, or powders and dusty atmospheres. All of the devices feature two-wire 4 mA to 20 mA HART 7 communication and come with an extensive choice of process connections, starting from three-quarter inch ones. They feature a large backlit LCD display with a four-button keypad, quick setup

assistant for easy commissioning and come with free PACTware™ DTM with full functionality. While approvals for hazardous areas are already available, other approvals, including SIL, are ongoing.

New 24 GHz and 80 GHz FMCW radar level transmitters for liquids and solids in the Optiwave series

Liquids applications For liquid applications, Krohne has designed the Optiwave 3500, 5400, 7400 and 7500. For liquids in basic process applications in the chemical, oil and gas, and power industries, the Optiwave 5400 is a 24 GHz FMCW radar. It provides accurate readings in closed tanks, in open-air applications

such as rivers or dams, and processes with fast-changing levels. The Optiwave 7400 is a 24 GHz FMCW radar designed for liquids in harsh environments, such as tanks with agitators containing corrosives or in non-explosive

APE pumps - Pumps at the heart of africa Mining

Waste Water processing

Manufacturers of: Vertical industrial turbine pumps Multi-stage high pressure pumps Split casing pumps End suction pumps

Power Generation

Petrochemicals

Vertical sump pumps API 610 pumps

26 Nagington Road, Wadeville Germiston 1400, South Africa Tel +27 11 824 4810 | Fax +27 11 824 2770 PO Box 14733, Wadeville 1422, South Africa Email: apepumps@mweb.co.za Website: www.apepumps.co.za

IMIESA August 2017

INSIGHT

METERS, PUMPS & VALVES

applications up to 700°C (e.g. molten salt in solar plants). Aimed at the chemical, petrochemical, power, and oil and gas industries, it comes with a large choice of antenna options, like the proven DROP antenna as well as heating, cooling or purging systems for metallic horn antennas. For applications with corrosive or dangerous liquids, a flange plate protection or a Metaglas second sealing barrier is available. The quick-coupling system permits the removal of the converter under process conditions. Covering the same industries as 7400 model is the Optiwave 7500, which is an 80 GHz FMCW radar up to 150°C, 40 bar(g). With its small beam angle and negliglible dead zone, it is aimed at liquid applications in small and narrow tanks with internal obstructions like agitators or heating coils, as well as tanks with long nozzles. This 80 GHz radar can even measure through tank roofs made of non-conductive material. It features a flush-mounted PEEK lens antenna and measures the level of a product from the antenna down to the tank bottom over a distance of 100 m.

Solids applications For solids applications, Krohne has designed the Optiwave 6400 and 6500. The Optiwave 6400 is a 24 GHz FMCW radar for solids – from granulates to rocks – in industries such as minerals and mining, chemical, agriculture, and power generation. It measures the level of solids such as stone or plastic granulates accurately and reliably. The proven DROP antenna minimises scaling and is unaffected by the angle of repose, thus eliminating the need for expensive antenna-aiming kits or purging systems. Aimed at the same industries, the Optiwave 6500 is an 80 GHz FMCW radar for powders and dusty atmospheres. It features specific algorithms and high signal dynamics to provide reliable and accurate readings despite the challenges linked to fine powders such as dust, lowreflective media, build-up and uneven surfaces. Thanks to the small beam angle of the flush-mounted lens antenna, it is best suited for high and narrow silos even in the presence of internal obstructions. These new 24 GHz and 80 GHz transmitters complement the two existing 6 GHz and 10 GHz devices of the Optiwave series.

TECHNICAL PAPER | PRESSURE MANAGEMENT

The case for pressure control in SA South Africa boasts several of the largest and most successful advanced pressure management installations in the world, some of which have received both national and international recognition. By Dr Ronnie Mckenzie* & Willem Wegelin**

he scope for reducing leakage from water reticulation systems in the country is significant and many municipalities are implementing new pressure management schemes. It is one of the most important water demand management (WDM) interventions in a comprehensive WDM strategy, and while it must be acknowledged that pressure management is not the answer in every case, it is often one of the most cost-effective measures to reduce leakage and wastage.

SAâ&#x20AC;&#x2122;s pressure-control history South Africa was one of the first countries in the world to adopt the principles of advanced pressure control initially developed in the UK back in the early 1990s. These techniques were first presented in South Africa in 1997, and following a series of small pilot projects, the full-scale Johannesburg Pressure

Management Project was completed in 1999, involving the design and commissioning of almost 50 advanced pressure control installations. Today, Johannesburg Water has over 30 advanced pressure management installations comprising more than 100 control valves equipped with various forms of electronic pressure controllers. Advanced pressure control is an integral component of the cityâ&#x20AC;&#x2122;s overall WDM strategy. Following the success of the Johannesburg project, one of the most ambitious pressure management projects undertaken anywhere in the world was designed and commissioned in Khayelitsha in 2001 for the City of Cape Town. At the time, this was the largest installation of its type in the world and was the forerunner to the even larger installation located in Emfuleni Local Municipality â&#x20AC;&#x201C; both of which received national and international recognition.

A third large-scale advanced pressure management installation was commissioned in Mitchells Plain for the City of Cape Town in November 2008, and it remains one of the most effective large-scale pressure management installations of its type to be constructed in South Africa. Each of these three installations controls the supply of water to approximately 500 000 residents from a single supply point. Many other pressure management installations have since been commissioned in various parts of South Africa in the past decade and they continue to help reduce water losses in an efficient and costeffective manner.

Concepts of pressure management Managing water pressures in a supply area is not a simple issue and there are a great many factors to consider. The common issue in every system is the fact that leakage is driven

IMIESA August 2017

TECHNICAL PAPER | PRESSURE MANAGEMENT

Sebokeng/Evaton pressure management installation

by pressure â&#x20AC;&#x201C; if the pressure is increased, the leakage increases. This applies to both the background leakage (many thousands of small leaks) as well as the burst leakage (larger leaks). If the water pressure in a system is reduced, even for short periods during low demand, the water leakage from the system will be reduced, as will the incidence of new burst pipes. No two systems react in the same manner to pressure and it is often very difficult to predict the reduction in leakage due to a decrease in pressure. Many theories have been postulated to explain the pressure-leakage relationships in a municipal water supply system and the most widely accepted theory is that of Fixed and Variable Area Discharges, which can be traced back to a paper by Ledochowski (1956) and is fully explained in the PRESMAC User Manual from the South African Water Research Commission. In short, the relationship between pressure and leakage will conform to a squareroot relationship in cases where the size of the leakage path (i.e. hole) remains constant during the change in pressure. This is the typical situation when the leak is a small hole in an iron or steel pipe, in which case doubling pressure will result in an approximately 41% increase in leakage. In the case of leaks from plastic pipes or from cracks in asbestos cement pipes, the surface area of the leakage path does not remain constant when the pressure changes, and such leaks will often open up to create a larger hole through which the water can leak. Such leaks are referred to as variable area leaks, and if the pressure is doubled, the leakage will increase more than from a fixed area leak. In some cases, the leakage will increase by as much as eight times the original level.

In most systems, there tends to be a mixture of fixed and variable area leaks and the split will depend on the proportion of steel/iron pipes to plastic/asbestos pipes. It is often found that certain factors play a more critical role in the pressure-leakage relationship, which are rarely, if ever, taken into account in any of the proposed formulae. For example, in many parts of South Africa, the quality of workmanship when laying the pipes is one of the most important factors influencing leakage. Two similar systems next to each other can have significantly different leakage characteristics simply because one system was laid properly while the other system was laid by a poorly qualified contractor. In such cases, there is no adequate theor y to explain the different responses of the leakage to changes in pressure. In order to reduce leakage through some form of pressure management, it is necessar y to reduce the water pressure without compromising the level of ser vice with regard

to the consumers and fire-fighting. Most systems are designed to provide a certain minimum level of ser vice in the system during the peak demand period as shown in Figure 1. In this example, it is assumed that a minimum pressure of 20 m is required. During the off-peak periods, which tend to be much greater than the peak periods, the system operates at a water pressure that is significantly higher than necessar y, as shown in Figure 2. In effect, there are long periods when there is significant scope for pressure reduction and this is the basis on which the pressure management inter ventions are designed. Reducing the water pressure in a system can be achieved in many ways, ranging from simple fixed outlet control valves to a variety of electronic or hydraulic controllers. Over the past 15 years, many new control devices have been developed, each of which offers greater sophistication and intelligence than previous devices. Smart controllers have become even smarter, with several of the latest devices incorporating artificial intelligence and feedback loops. Without detracting from the latest advances in pressure management, it is critically important that water supply managers not lose focus on the real problem issues, as no piece of equipment â&#x20AC;&#x201C; hydraulic or electronic â&#x20AC;&#x201C; can replace the need for a properly designed, well-managed and well-maintained network. Ensuring that boundar y valves are closed or open on a regular basis, as per the network design, is often of greater importance than pressure control, which, in any event, will not operate properly when a pressure management zone has been compromised

External view of the Khayelitsha pressure management installation

IMIESA August 2017

TECHNICAL PAPER | PRESSURE MANAGEMENT

by unauthorised opening or closing of boundary valves. Based on many years of practical experience, the authors have found that the key to successful pressure management is ensuring that the basic operation of the network is under control. This generally involves manually checking all valves in the system to ensure that all boundary valves designed to be closed are, in fact, closed and all internal valves designed to be open are open. This may seem a trivial and obvious issue, but it is possibly the most overlooked and underrated issue facing water managers in most water supply networks.

Summary While it must always be remembered that pressure management is normally only the first phase of a larger WDM strategy, it can often provide very significant savings in a short period of time. Pressure management also has many secondary benefits that are often overlooked, including extending the useful life of the water reticulation system. Such a benefit can often far outweigh the initial benefits as calculated from the water

savings but will only become apparent many years down the line. However, it is important to realise that it is not always necessary or appropriate to use the most sophisticated or expensive electronic or hydraulic controllers and the ‘appropriate technology’ to suit a specific situation may often result in the use of the most basic (and robust) equipment. The selection of the most appropriate form of pressure control will ultimately be based on many factors – i.e. cost, technical expertise within the water utility, technical backup for the equipment, topography, leakage levels as well as the main source of leakage. It is, therefore, important for the water supply manager to carefully select the most appropriate pressure management equipment for each zone to provide a sustainable and effective solution. From past experience, the greatest savings are often achieved from the most basic forms of pressure control and the incremental benefits of the more sophisticated forms of control must be weighed up against the costs and maintenance issues.

FIGURE 1 Typical pressure during peak-demand periods

*Dr Ronnie McKenzie is MD of WRP Consulting Engineers and is currently chairperson of the International Water Association’s Water Loss Specialist Group. **Willem Wegelin is a director at WRP Consulting Engineers.

CASE STUDIES There are several hundred advanced pressure control installations in South Africa, including three of the largest installations of their type in the world. Khayelitsha: City of Cape Town – 2001 At the beginning of 2000, the water supplied to Khayelitsha was almost 22 million m3/a. With a minimum night flow (MNF) in excess of 1 600 m3/hr, the level of leakage was estimated to be almost threequarters of the water supplied to the area. The main source of the leakage was household plumbing fittings, which had been badly damaged through constant exposure to a relatively high pressure of 80 m. The Khayelitsha Pressure Management Project was commissioned in 2001 to improve service by reducing the excessive water pressure and pressure fluctuations in the reticulation system. The average daily flow was reduced from 2 500 m3/h to 1 500 m3/h, representing an annual saving of 9 million m3/h or approximately 40% of the original water use. The MNF was reduced from 1 600 m3/h to 750 m3/h. Sebokeng: Emfuleni Local Municipality – 2005 In the Emfuleni Local Municipality, there had been a general deterioration of internal plumbing fittings over an extended period, causing high levels of leakage and an MNF of 2 800 m3/h – one of the highest recorded anywhere in the world. The estimated wastage was in the order of 80% of the water supplied to the area. In 2004, the municipality commissioned one of the largest advanced pressure management installations in the world as the first phase of a long-term strategy to reduce wastage in the area. Over a fiveyear period, this led to a saving of 50 million m3. Mitchells Plain: City of Cape Town – 2008 In 2008, the City of Cape Town decided to commission its second major pressure management installation in the Mitchells Plain area, which supports a similar population to Khayelitsha of some 500 000. Water savings of approximately 2.4 million m3/a were achieved by the installation, resulting in a pay-back period of less than six months.

FIGURE 2 Typical pressure during off-peak periods

IMIESA August 2017

READYMIX & AGGREGATES | PROFILE

Materials on demand

Afrimat’s unique multifaceted solutions offering is designed to fast-track construction projects.

Readymix product range • All grades of concrete • Pumped readymix concrete • Readymix mortars and plasters • Self-compacting concrete • Exposed aggregate concrete • Pigmented coloured concrete

n 3 November 2016, Afrimat Limited celebrated its 10th year on the Johannesburg Stock Exchange, marking a significant milestone for this specialist materials supply group. Backed by more than 50 years of experience, Afrimat operates nationally through six key divisions, namely Mining and Aggregates; Industrial Minerals; Contracting International; Concrete Products; Readymix; and now, more recently, Commodities, following the acquisition of Diro Iron Ore. “The group's capabilities enable Afrimat to service projects of any scale, irrespective of their location. These range from major infrastructure developments for state-owned enterprises and parastatals, through to small private sector contracts,” says Andries van Heerden, CEO, Afrimat. Afrimat’s Readymix Division supplies concrete solutions via either fixed or mobile plants, providing the flexibility to meet project requirements in urban and more remote rural areas. Another group advantage is that close to 90% of the aggregate materials required (excluding cement) are sourced from the group's own quarries.

Infrastructure partner “Afrimat Readymix sees itself as a key infrastructure partner, rather than a pure supplier of concrete,” says Ricus van Heerden, manager at Afrimat’s Readymix & Concrete Products Division. “That’s why we’re solution-focused, and explore all available options. Achieving the best possible turnaround times ensures we provide an industry-leading service, which frequently passes on savings to our clients in terms of time and resources.” The range of readymix products supplied to the market is comprehensive and includes

Readymix supply contracts for major infrastructure projects

Project De Aar North Wind Farm Gouda Wind Farm Vredenburg Wind Farm Touwsriver Solar Plant

Contractor CSV Construction Grinaker-LTA Haw- Inglis Group 5

Quantities 45 000 m3 25 000 m3 15 000 m3 12 000 m3

N7 Abbotsdale Upgrade

Stefanutti Stocks

18 000 m3

Woodstock Quarters

Isipani Construction

22 000 m3

De Aar Solar

Rock Construction

10 000 m3

Whale Coast Mall

Isipani Construction

15 000 m3

Ashton Montagu Bridge and Roads Upgrade

Basil Read

15 000 m3

IMIESA August 2017

the capability to meet requirements for specialist mix designs. Batching systems are fully automated and comply with the standards set by the South African Readymix Association (Sarma). “Our computerised batching systems ensure precise monitoring and reporting to prevent unexpected changes in the mix characteristics,” Van Heerden explains. Afrimat’s management team also reviews the group’s quality management systems at least once a year. “Research and development is a core focus, as is our ongoing investment in new technologies and processes,” he continues. Examples include the acquisition of the latestgeneration boom and trailer pumps to handle standard and more complex insitu pours over extended distances and at heights. The readymix truck fleet is also tracked via GPS in real time using predetermined notification settings, which assists from both project and programme management perspectives. Alongside supply contracts to general civil engineering and building projects, Afrimat has been involved in a number of high-profile solar and wind farm developments in the past five years. These include the Vredenburg wind farm and the Touwsriver solar plant, both situated in the Western Cape. “In fact, we now specialise in renewable energy projects alongside our other market offerings, which is where our other group divisions play their role in Afrimat’s total solutions approach to project delivery.”

International projects Entering the contracting market in 2006, Afrimat’s Contracting International Division is a strategically important one that supports ongoing penetration by the group’s businesses within the mining and construction segments, particularly for megaprojects. Recent examples include Eskom’s Kusile and Medupi power stations, road and railway developments, as well as wind farms. “For Afrimat, the goal is to provide turnkey solutions for our customers, alongside internal services for our aggregates, concrete and readymix operations when it comes to supply contracts,” explains Pierre du Toit, managing director, Afrimat Contracting International.

Contracting International provides a full package of drilling and blasting solutions (including blast designs), plus mobile crushing and screening services, stockpiling, and load and haul for the construction, quarrying and junior mining industries. In addition to readymix concrete, highspecification road materials such as G1 base course and road stone products are produced. “We also provide bid preparation and contractual services, which prove invaluable for contractors tendering on major projects, like new national road construction,” he continues. Past examples include the Gauteng Freeway Improvement Project (GFIP) Package A (E1 and E2), carried out by the Siyavaya JV. Here, Afrimat was responsible for drilling and blasting the cuttings and cut widenings. Completed in March 2011 over an approximately 2.6-year project duration, the total materials handled amounted

to 336 479 benched m³. On the same project and work package, Afrimat also carried out single- and two-stage crushing, producing some 934 343 t of road materials for the Siyavaya JV. Afrimat’s scope of work at the Kusile and Medupi power stations included the crushing of various materials, namely concrete aggregates, sub-base and base course. Afrimat’s Kusile project, completed in October 2014, entailed the total supply of approximately 1 835 000 t of material over a two-year period. Meanwhile, at Medupi, Afrimat supplied 1 832 252 t over a contract duration of eight years, which came to an end in December 2016. Earlier work by Afrimat at Kusile entailed drilling and blasting services for Eskom subsidiary Roshcon, amounting to 580 000 benched m³. Afrimat completed this project in March 2011, over a contact period of 20 months.

Alongside roads, recent projects in the railway sector include Eskom’s Majuba rail upgrade, carried out by main contractor Aveng GrinakerLTA. Afrimat’s scope here entailed drilling and blasting services (974 600 benched m3) and the multistage crushing of layers A and B for the rail bed (232 788 t). Afrimat’s two-year project was completed in November 2015. “Our business model in South Africa is well proven and supported by the ongoing acquisitions of quarries in strategic locations,” adds Du Toit. “Outside South Africa, Contracting International has established a strong foothold in Africa and operates internationally through a mobile hard-rock crushing and screening service, either for mining or construction. As business prospects improve in Africa, the potential also exists to roll out readymix and concrete solutions.”

A range of products built on the foundation of quality and durability Afrimat Limited is a leading black empowered open pit mining company providing an integrated product offering ranging from ®

aggregates, industrial minerals, commodities (iron ore), concrete products (bricks and pavers) to readymix concrete. Afrimat has established a strong foothold in contracting services comprising mobile crushing, screening, drilling and blasting. Backed by more than 45 years’ experience, Afrimat listed on the JSE Limited in 2006. As

Investing in diversified growth Aggregates Concrete Based Products Industrial Minerals Contracting International

part of its continued diversification strategy, the group is expanding its footprint into Africa. The group’s capabilities enable Afrimat to service projects of any scale from major infrastructure and construction projects for state-owned enterprises and parastatals through to small private sector contracts.

Commodities Tel +27 21 917 8840

www.afrimat.co.za

Fax +27 21 914 1174

info@afrimat.co.za

CEMENT & CONCRETE

Concreting a team approach Johan van Wyk, director of the Southern Africa Readymix Association

he Southern Africa Readymix Association (Sarma) has an important role to play in auditing and verifying that member companies adhere to strict quality standards, but its function goes way beyond this and is evolving in line with industry requirements. “In addition to ensuring that our readymix products and delivery mechanisms are world class, internally, we’re forming closer relationships with our member companies so that we can add value to their operations, and that includes skills development and training,” explains Johan van Wyk, director, Sarma. “Externally, we’re aligning our mission and operating scope with other leading associations in the cementitious industry to leverage key synergies. Initiatives include CPD-accredited training programmes in cooperation with The Concrete Institute (TCI), as well as the upcoming Concrete Conference.” The Concrete Conference, being held between 17 and 18 August 2017, is an industry first and will be hosted by Sarma, the Concrete Manufacturers Association, the Concrete Society of Southern Africa, and TCI. The anchor sponsors are AfriSam, Lafarge, PPC and Sephaku. “In the past, Sarma ran its own annual conference for the readymix industry, but it no longer made sense to host this event in isolation,” he explains. “The inaugural Concrete Conference establishes a new direction and is the only event of its kind dedicated to concrete,” says Van Wyk.

Conference programme Day 1 of this year’s Concrete Conference will comprise three sessions in the morning covering change management, the economic landscape, and a stakeholder panel discussion entitled ‘Prospects for the Concrete Industry’. The panel will be chaired by the heads of Consulting Engineers South Africa, Master Builders South Africa, the South African Institution of Civil Engineering, and the South African Forum of Civil Engineering Contractors. “There are a number of pressing issues that the construction industry needs to address collectively and we all need to be part of the solution,” says Van Wyk. “The conference is certain to be a highly engaging forum for debate.”

High-performance concrete The afternoon session on Day 1 covers the fascinating topic of highperformance concrete. This session kicks off with a presentation entitled ‘Myths and truths about high-performance concrete’. The presentations that follow then consider precast, structural and readymix high-performance concrete. These sessions also carry CPD points for ECSA-registered professionals via the Concrete Society. “As a starting point, it’s important to note that high-performance concrete doesn’t necessarily imply high strength, i.e. 60 MPa and above,” says Van Wyk. “For example, a 10 MPa no-fines concrete used to form low-density drainage structures could also qualify as a high-performance specification.” The Sarma AGM, gala dinner and Readymix Awards conclude Day 1.

The Concrete Conference brings the industry together in a unique way and addresses the changing construction landscape alongside new techniques and technological advancements. By Alastair Currie

IMIESA August 2017

Case studies Day 2 comprises six case studies from the Concrete Society’s 2017 Fulton Awards (both nominations and winning entries). These include the Mndwaka Dam, the V&A Waterfront precast parking garage, and the Mount Edgecombe Interchange. “It’s a great opportunity to showcase the technical details behind these leading developments,” he explains. “Our slogan for The Concrete Conference 2017 is ‘Just mix it’, and that sums it up perfectly,” Van Wyk concludes. “This is more than just a conference: it’s an invaluable platform for cooperation among public and private sector stakeholders in addressing the needs of our rapidly changing industry.”

CEMENT & CONCRETE

Precast construction underutilised Precision, quality and savings in time and cost are some of the major advantages

lthough a common technique in many parts of the world, the uptake of precast construction in South Africa still remains at relatively low levels and needs a more concerted focus. This is according to Gary Theodosiou, structural engineer and lecturer at The Concrete Institute’s School of Concrete Technology, who says that South African structural engineers are not fully utilising the many advantages that this method has to offer. As a result, clients may lose out on the most economic and best possible solution for their projects. Some of the key benefits include: • speed of construction by reducing propping time for cast-in-situ concrete • improved quality of the structural components, because of prefabrication’s controlled production conditions • enforced coordination and teamwork, because constructability, layout and connection details all have to be planned well in advance. Theodosiou believes precast concrete contractors should improve the marketing of their products and expertise. This will ensure that structural engineers become more aware of the design opportunities offered by precast concrete elements, particularly for columns, beams and stairs.

Steel versus precast “Those who perceive structural steel construction to be faster compared to conventional in-situ reinforced concrete construction should be made aware of the favourable production lead times precast concrete can offer. Concrete structures offer a huge amount of flexibility in the

Gary Theodosiou, lecturer at The Concrete Institute’s School of Concrete Technology

ways and methods in which they can be constructed,” he expands. Concrete elements – such as walls, columns, beams, trusses and slabs – can be constructed in situ, or precast on-site on the ground and lifted into their final position, as in the case of tilt-up and stack casting, or precast in a yard and transported to site and erected into position. “Concrete is one of the most durable materials on earth. Well-designed, well-constructed concrete offers exceptional durability and long life in any structure. The first line of defence against deterioration is good-quality, impermeable concrete. By producing precast concrete in a controlled environment – typically called a precast yard – it is possible to monitor all stages of production, including adequate curing, compaction, quality and depth of cover concrete, and ensure that the products fully comply with strength requirements.” Precast concrete is generally cast at ground level, which helps with safety and productivity throughout the project life cycle. “There is greater control of the quality and workmanship in a precast plant than concrete cast in-situ, which is often exposed and cast at awkward heights. Precasting results in improved durability with consequent savings in maintenance costs, materials and energy. “Furthermore, the forms used in a precast plant may be reused hundreds or even thousands of times before they have to be replaced, which ensures that the costs of formwork per unit are lower than for in-situ construction, bearing in mind that formwork makes up between 35% and 60% of the total cost of concrete,” Theodosiou adds.

IMIESA August 2017

CEMENT & CONCRETE

he Greater Giyani Municipality will soon take ownership of its new, modern administration offices, with the second and final phase of the development now nearing completion. By February this year, HBC Construction and its team of subcontractors were making steady progress on the outfitting of the superstructure, which is built entirely using a modular precast concrete system. Corestruc designed, manufactured and installed the 1 000 t of precast concrete elements, including 190 columns and beams, as well as the 2 900 m² of floor and roof slabs that make up the new administration block. A 160 t crane was deployed to lift and place each precast concrete element. As Coretruc’s Russell Hobbs explains, one of the key benefits of precast concrete structures is that they can be assembled swiftly by small teams. This highly efficient building method also does away with the need for the erection of scaffolding and propping, and the assembly of shuttering and formwork, since there are no in situ casting requirements.

IMIESA August 2017

Building in

precast

The columns were installed according to a template, which is placed on top of the building’s foundations and then aligned to achieve the required dimensional accuracy ahead of the installation of the precast concrete beams and floor slabs. By this stage of the build, a stable construction sequence had been established, and the process was repeated all the way to the fourth floor, ending with the placement of the roof slabs. The floor and roof slabs were then filled with a specially designed non-shrinking grout to provide high weather-proofing properties.

Council chamber extension For the final construction phase, Corestruc was also invited to extend the existing council chambers in line with later amendments made to the original design. Here, the scope of work entailed the installation of 18 additional precast concrete wall panels to lengthen the existing curved wall. Each 5.4 t panel is 9.7 m high, 1 m wide and 200 mm thick, and they are joined with Bartec-type couplers.

This modular approach provides a fast and efficient alternative to conventional in situ techniques. Again, Corestruc’s teams made quick work of this stage of the programme. They completed the installation of the additional panels in four shifts using a team comprising seven people, including a supervisor. The wall panels were placed and the connections then grouted ahead of completion of the second-stage in situ concrete foundations. “Once the panels were securely supported and attached to the existing structure, the 320 mm thick hollow-core roof slabs, with spans of 11.6 m, were installed in a day. A 100 mm thick reinforced in situ structural topping layer was then placed over the precast roof elements to complete the extension,” Hobbs adds.

This highly efficient manner of building does away with the need for the installation of scaffolding and propping, as well as the assembly of shuttering and formwork

PROFESSIONAL AFFILIATES AECOM siphokuhle.dlamini@aecom.com Afri-Infra Group (Pty) Ltd banie@afri-infra.com AJ Broom Road Products ajbroom@icon.co.za ALULA (Pty) Ltd info@alulawater.co.za AQUADAM (Pty) Ltd sales@aquadam.co.za Arup SA rob.lamb@arup.com Aurecon Fani.Xaba@aurecongroup.com Aveng Manufacturing Infraset cgroenewald@infraset.com Averda claude.marais@averda.com Bigen Africa Group Holdings otto.scharfetter@bigenafrica.com BMK Group brian@bmkgroup.co.za Bosch Munitech info@boschmunitech.co.za Bosch Projects (Pty) Ltd mail@boschprojects.co.za BVI Consulting Engineers marketing@bviho.co.za Civilconsult Consulting Engineers mail@civilconsult.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za Development Bank of SA divb@dbsa.org.za DPI Plastics mgoodchild@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering Leonardus.Basson@honeywell.com Engcor Engineers masham@engcorengineers.co.za Fibertex South Africa (Pty) Ltd rcl@fibertex.com GIBB yvanrooyen@gibb.co.za GIGSA secretary@gigsa.org GLS Consulting nicky@gls.co.za Gudunkomo Investments & Consulting info@gudunkomo.co.za Hatch Africa (Pty) Ltd info@hatch.co.za Henwood & Nxumalo Consulting Engineers cc pmboffice@hn.co.za Herrenknecht schiewe.helene@herrenknecht.de Huber Technology cs@hubersa.com Hydro-comp Enterprises dan@edams.co.za I@Consulting louis_icon@mics.co.za INGEROP mravjee@ingerop.co.za Integrity Environment info@integrityafrica.co.za IQHINA Consulting Engineers & Project Managers info@iqhina.co.za Ix engineers (Pty) Ltd hans.k@ixengineers.co.za JBFE Consulting (Pty) Ltd issie@jbfe.co.za JG Afrika DennyC@jgafrika.com KABE Consulting Engineers info@kabe.co.za Kago Consulting Engineers kagocon@kago.co.za Kantey & Templer (K&T) Consulting Engineers info@kanteys.co.za Kitso Botlhale Consulting Engineers zimema.jere@gmail.com Knowledge Base info@knowbase.co.za Lektratek Water general@lwt.co.za Lithon Project Consultants (Pty) Ltd info@lithon.com

Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Malani Padayachee & Associates (Pty) Ltd admin@mpa.co.za M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za Maragela Consulting Engineers admin@maragelaconsulting.co.za Marley Pipe Systems info@marleypipesystems.co.za Martin & East gbyron@martin-east.co.za Masithu Consulting & Project Management info@mcpm.co.za Mhiduve adminpotch@mhiduve.co.za Moedi Wa Batho Consulting Engineers (Pty) Ltd info@wabatho.co.za Mott Macdonald Africa (Pty) Ltd mahomed.soobader@mottmac.com Much Asphalt leon.alberts@muchasphalt.com NAKO ILISO hans.hartung@nakogroup.com Nyeleti Consulting ppienaar@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za PMA Consulting pragasen@pmaconsultingsa.co.za Pumptron info@pumptron.co.za Pragma nicojobe.mabaso@pragmaworld.net francisg@rhdv.com Royal HaskoningDHV SABITA info@sabita.co.za SALGA info@salga.org.za SARF administrator@sarf.org.za.co.za SBS Water Systems desere@sbstanks.co.za Sembcorp Siza Water info-sizawater@sembcorp.com Servotech (Pty) Ltd finance@servotech.co.za SiVEST SA garths@sivest.co.za Sizabantu Piping Systems (Pty) Ltd gregl@sizabantupipingsystems.com SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za SMEC capetown@smec.com SNA stolz.j@sna.co.za Sobek Engineering gen@sobek.co.za Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Syntell julia@syntell.co.za TPA Consulting roger@tpa.co.za Ulozolo Engineers CC admin@ulozolo.co.za UWP Consulting nonkululekos@uwp.co.za south-africa@vetasi.com Vetasi VIP Consulting Engineers esme@vipconsulting.co.za VUKA Africa Consulting Engineers info@vukaafrica.co.za Water Institute of Southern Africa wisa@wisa.org.za Water Solutions Southern Africa ecoetzer@wssa.co.za Wilo South Africa marketingsa@wilo.co.za WRP ronniem@wrp.co.za WRNA washy@wrnyabeze.com WSP Group Africa sam.herman@wspgroup.co.za

I M E S A A F F I L I AT E M E M B E R S

IMESA

INDEX TO ADVERTISERS Afrimat Shared Services AfriSam Ammann APE Aquadam Barloworld SEM BBF Safety Group Colas Doosan International Eltherm Gabion Baskets

IMIESA August 2017

71 OFC, 6, 7 IFC 64, 65 55 IBC 4 28, 29 44 30, 31 51

Gorman Rupp Pumps Africa IFAT IMESA Jaguar Land Rover SA

2 76 40, 52, 75 45

Kaytech

32, 33

Knight Piésold

36, 37

LANXESS SA

47–49

Macneil Plastics

58, 59

Marley Pipes

56, 57

Much Asphalt National Asphalt

27 17–19

National Cold Asphalt

Pexmart 60, 61 Quality Filtration Systems

Rocla

Sabita

Sappma

SARF

23–25

Sizabantu Piping Systems

62, 63

SprayPave

34, 35

Tosas

10, 11

VNA Wirtgen

OBC 20

QUALITY & AFFORDABILITY

+27 11 045 6169 | +27 11 045 6163 | bfang@bwsem.co.za

ON THE ROAD TO

I N N O VAT IO N

IN CONSTANT MOVEMENT TOWARDS CHANGE, VNA IS AT THE CUTTING-EDGE OF SOUTH AFRICA’S BUILT ENVIRONMENT SERVICE DELIVERY, CONTRIBUTING TO THE CONTINENT’S EMERGENCE AS A MEANINGFUL ECONOMIC POWERHOUSE. FROM ROAD ASSET MANAGEMENT, CONSTRUCTION MANAGEMENT, ENGINEERING AND SPECIALISED PAVEMENT SERVICES, TO INFRASTRUCTURE DEVELOPMENT AND COST ADMINISTRATION, WE HAVE THE FORESIGHT, TECHNOLOGY AND EXPERTISE TO CREATE THE HIGHEST VALUE RESULTS FOR ALL OUR CLIENTS.

One of our key strengths is the capacity to help plan, design and deliver challenging and innovative roads and bridges. At VNA, we truly understand the industry and the distinctive needs of the market and our vision is to realise continental potential, ensuring built environment transformation of South Africa and beyond. Looking for a leading specialist setting the standard in infrastructural solutions for the economic development of South Africa... look no further than VNA.

CORPORATE OFFICE: 10 Kyalami Road, Park 2000, Westmead, Pinetown, 3610 HEAD OFFICE: 596 Peter Mokaba Ridge, Berea, Durban, 4001 Tel: +27 31 700 2500, Facsimile: +27 31 700 2550, Email: yesh.balaram@vnac.co.za For further information regarding our national and regional offices, please visit our website: www.vnac.co.za