Imiesa January 2018 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

INDUSTRY INSIGHT Steve Tinarwo Managing Director, Instant Tar

Transportation Traversing the KwaDabeka Valley ISSN 0257 1978

Municipal Focus Johannesburg’s infrastructure crisis

V o l u m e 4 3 N o . 1 • J a n u a r y 2 0 1 8 • R 5 0 . 0 0 ( i n c l . VAT )

COLAS We open the way

Environmental Gabions counter dam siltration

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volume 43 no. 01 January 2018

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IMESA

INSIDE

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INDUSTRY INSIGHT Steve Tinarwo, Managing director, Instant Tar.

Transportation Traversing the KwaDabeka Valley ISSN 0257 1978

COLAS We open the way

Municipal focus

Johannesburg’s infrastructure crisis

Environmental Gabions counter dam siltration

V o l u m e 4 3 N o . 1 • J a n u a r y 2 0 1 8 • R 5 0 . 0 0 ( i n c l . VAT )

Current budget restrictions now make it even more imperative that pavements are kept watertight and operational for as long as possible between scheduled maintenance interventions. Colas South Africa has the ultimate cold sealing and patch repair solutions, with extended workability a key feature. P6

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

3 5 9 56

Cover Story 6

Bitumen refinement served cold

Industry Insight A paving vision unfolds

Municipal Focus | Johannesburg A city on the cusp of collapse

industry insight The construction and maintenance of roads are among the top priorities for government. Steve Tinarwo, managing director, Instant Tar, speaks about the company’s plans to grow its base in this strategically important sector. P10

Vehicles & Equipment The road ahead with Ammann

15 19

Gabions coexist with the landscape 21

IMESA Conference

Pipes, Pumps & Valves PVC-O delivers in bulk

Tackling the slopes

Transport, Logistics, Vehicles & Equipment Finance direct to customers The road ahead with Ammann Evolution of a legend

29 30 32

SASTT Trenchless News Hammerhead goes underground Pioneering an industry

36 37

Pipes, Pumps & Valves A turnkey approach to pump installations PVC-O delivers in bulk

The future of waste management

39 43

Building Revitalising Kliptown

Environmental Engineering

Back to basics

Roads & BRIDGEs

Waste Management

Roads & Bridges Tackling the slopes A historic upgrade

Cement & Concrete New developments in concrete technology Strengthening the Serepta Bridge

50 53

Cement & Concrete New developments in concrete technology

We are there when you think

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EDITOR’S COMMENT Publisher Elizabeth Shorten MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson JOURNALIST Liesl Frankson Head OF DESIGN Beren Bauermeister DESIGNer Ramon Chinian Chief SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter ContributorS Gavin Clunnie, Bryan Perrie CLIENT SERVICE & Production MANAGEr Antois-Leigh Botma 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 ___________________________________________________

s we enter 2018, there’s a general expectation that major change will continue within the political sphere as the South African government prepares for the 2019 election. In the business sector, the hope is that this change will be a positive one, as any public policy decision will have a direct impact on the macroeconomic environment that determines the country’s future. Essentially, we’re all looking forward to a reversal in the current regressive state of the economy and to a second wave of infrastructure development similar to the one experienced in the lead up to the 2010 FIFA World Cup. But is this realistic? I believe it is, but on a smaller scale, if the Medium-Term Expenditure Framework (MTEF) (2017/18 to 2019/20) budgets are adhered to and supported by renewed local and direct foreign investment, and if the municipal sector is more disciplined when it comes to financial management. We definitely need to find ways to boost public sector support for the construction industry, which continues to experience a contraction in its capacity. According to recent statistics released by the Quarter Labour Force Sur vey, approximately 140 000 construction-related jobs were shed between Q1 and Q3 2017. The Construction Industry Development Board says that Gauteng, which traditionally contributes around 28% of total employment in this sector, was the hardest hit – with 118 000 jobs lost during Q2 and Q3 2017. These job losses are mostly attributable to unskilled, low- and semi-skilled labour.

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

Publisher: 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 2018. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton 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 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 SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesasck@imesa.org.za

So, while the forward outlook is hard to predict, the South African economy does

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.

struc www.infra

@infrastructure4

IMESA

turene.ws

Infrastructure News

magazine The official of the Institute ng l Engineeri of Municipa Africa of Southern

INFRAST RUCTUR

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.

continue to trade in positive territory, based on recent figures released by Statistics South Africa. According to their December 2017 press statement, “The South African economy grew by 2.0% in the third quarter of 2017 (seasonally adjusted and annualised), down from a revised 2.8% in the second quarter.” Agriculture was, by far, the largest contributor, growing by 44.2% in Q3 2017. Mining and manufacturing were the next biggest sectors, growing by 6.6% and 4.3% respectively. However, growth in construction was recorded at -1.1%, which underscores the urgent need for the revitalisation of this key sector. The upside is that the construction industry will eventually rebound; but to achieve a marked improvement in the short term, the tender awarding process needs to be accelerated significantly. Between 1998/9 and 2015/16, the public sector spent more than R2.5 trillion on infrastructure. Annualised expenditure figures have also been progressively rising. For example, R48 billion was spent in 1998/9 compared to R261 billion in 2015/16, according to National Treasury’s ‘Publicsector infrastructure update’ report. Meanwhile, public infrastructure spending over the next MTEF period is estimated at around R947.2 billion. However, ensuring actual implementation is another matter given the higher cost of borrowing, following recent credit downgrades, and a shrinking tax revenue base. Everything hinges on a surge in market confidence going into 2018. Let’s all work together to help make sure this happens.

GDP gains

WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za 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

The next wave

Y IND US TR INSIGHT

, Steve Tinarwo

Managing director,

E DEVELO

NANCE PMENT • MAINTE

• SERVICE

DELIVER Y

S LAway CO We open the

Cover opportunity

Instant Tar.

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.

Transportatio the

Traversing Valley KwaDabeka 7 1978 ISSN 025

focu Municipal rg’s

Johannesbu crisis re infrastructu

c l . VAT ) 50.00 (in 018 • R January 2 3 No.1 • Vo l u m e 4

Environmenta er Gabions count dam siltration

IMIESA January 2018

Africa’s most respected motor grader brand, Mitsubishi, has changed ownership and is being sold under the new name HIDROMEK. While the name may have changed, HIDROMEK motor graders are still manufactured in the same factory and can still be banked on for power, efficiency and comfort.

Power

Efficiency

Comfort

Still Tough Inside and Out

Distribution and Product Support

ELB EQUIPMENT - HEAD OFFICE: 14 Atlas Road, Anderbolt, Boksburg • Tel: +27 (0)11 306 0700• Fax: +27(0)918 7208 • e-mail: Elb@elbquip.co.za BRANCHES & DEALERS – SOUTH AFRICA: •BRITS: +27 (0)12 250 1565 • CAPE TOWN: +27 (0)21 933 2383 • DURBAN: +27 (0)31 464 6522 • EAST LONDON: +27 (0)31 464 6522 •GEORGE: +27 (0)21 933 2383• KIMBERLEY : +27 (0)53 841 0040 • MIDDELBURG: +27 (0)13 246 2312• POLOKWANE: +27 (0)81 826 4493 SUBSIDIARY: ELB EAST AFRICA: •NAIROBI, KENYA: +254 (0)20 807 0728 DEALERS – SOUTHERN AFRICA: •BOTSWANA: +267 (0)390 9972 • LESOTHO: +266 (0)28 313 926 • MOZAMBIQUE: +268 (0)76 022 8488 • NAMIBIA: +26 (0)46 123 4052 • SWAZILAND: +268 (0)518 5348 / 518 5602 • ZAMBIA: +26 (0)21 221 0642 • ZIMBABWE: +263 (0)77 236 2596 • Website: www.elbequipment.com

President’s comment

IMESA

Welcome to

aving experienced a fairly turbulent 2017, we’re hoping that the ride in 2018 will be a bit smoother, with financial markets responding positively to the prospect of an improving political climate for the SADC region in general, and South Africa in particular. How 2018 plays out in South Africa will certainly be decisive for the country in the run-up to the 2019 general election. Getting our house in order, especially at the municipal level, is a fundamental part of capacity building. We need to ensure that we have sufficient working capital to run our municipalities, with revenue streams chiefly sourced from water and electricity tariffs, and not from loans. Aside from funding grants, municipalities are expected to be self-sufficient. However, many are not and that needs to be addressed urgently. The problem is further compounded by South Africa’s prevalent non-payment culture. The seriousness of the problem was recently highlighted by a Department of Water and Sanitation (DWS) statement in November 2017. The press release stated that municipalities owe the DWS a total of R10.7 billion for water supply, “…of which R3.9 billion is owed to the water trading entity of DWS, and R6.8 billion is owed to various water boards.” The DWS is taking legal action against 186 municipalities for non-payment. But the question we should ask is: How did we get to this

point in the first place? The above drives home the fact that public sector management has reached a crisis point and, as an industry, we need to assist where we can in reversing this scenario.

Regional branch visits During 2018, I intend to visit as many of the IMESA branches as possible, starting with the Border region and Eastern Cape. I’m really looking forward to interacting with our members this year and in facilitating wherever I can to promote excellence in municipal engineering. We continue to benchmark our best practices based on those set by leading public entities across the globe and, in 2018, I will have the opportunity to travel to two international events as IMESA president. The first will be to attend the International Federation of Municipal Engineering (IFME) board meeting in Fiji during April. I have the honour of sitting on the IFME board as the South African representative. Then in August 2018, I will be attending the 19th World Congress on Municipal Engineering, being held in Kansas City, Missouri, USA. This congress is being hosted by IFME and will be held in conjunction with the 2018 American Public Works Association (APWA) Public Works Expo. The theme is ‘The Power of Public Works’, and the key role that engineers and allied professionals play in delivering the essential infrastructure that sustains economies.

IMESA president Gavin Clunnie

Where we can, we should adopt international strategies that will help correct the present impasse in South Africa and these conferences are a vital part of the knowledge exchange process.

82nd IMESA conference In the meantime, preparations are now well under way for IMESA’s 82nd annual conference, which will be held in Port Elizabeth between 31 October and 2 November 2018. This year’s theme is ‘Innovative infrastructure solutions’ and we certainly need them. For those wishing to present at the conference, the deadline for abstract submissions is 5 March 2018. Suggested topics for papers should ideally fall into the following broad areas: • ecological and environmental • financial and social • political, legal and regulatory • roads and stormwater • water and sanitation. The selection process is a rigorous one, but it ensures that only the best papers are chosen. For fur ther information, please visit www.imesa.org.za. On a closing note, I’d like to wish all our readers a prosperous new year. By working together, we can all make a real difference.

IMIESA January 2018

Bitumen refinement Current budget restrictions now make it even more imperative that pavements are kept watertight and operational for as long as possible between scheduled maintenance interventions. Colas South Africa has the ultimate cold sealing and patch repair solutions, with extended workability a key feature.

olas South Africa is on an expansion drive, with three key products spearheading its marketing strategy for 2018 to meet the pressing maintenance priorities of the local roads industry. These products comprise Colmat, Compomac and Colrub LT. On the microsurfacing front, Colmat is a well-known brand locally, which has been enhanced with improved formulations, while Compomac and Colrub LT are relatively new innovations in South Africa. All of these brands have become the mainstay on many projects in Europe and the rest of the world,

Colas worldwide A subsidiary of the Bouygues Group, the Colas Group, headquartered in France, is a world leader in the construction and maintenance of transport infrastructure, operating in 50 countries across five continents. Within the Southern African region, the business is focused on the manufacture and sale of emulsions, alongside a fullscale contracting division.

IMIESA January 2018

and thus have proven applications and benefits for the local market. “Colas’ renewed focus is to be the preferred and dedicated manufacturer, supplier and applicator of bituminous binders and slurries in the South African road surfacing market – as a service provider, not a contractor. We also aim to reach Level 2 BBBEE status in early March 2018,” explains Cédric Monnet, managing director, Colas South Africa.

Defying the ageing process The Colmat solution comes in four different variants for urban and secondary road maintenance scenarios. In terms of chemical formulation, Colmat is a cationic quickset bitumen emulsion mixed with selected crushed mineral aggregate, cement and water, and applied with a new purposedesigned spray system from Colas. Another key benefit is that Colmat products are very tolerant to varying aggregate qualities, which enables greater use of local materials rather than having to import higher-spec aggregates at greater expense. Colmat prevents the ingress of water into the underlying layers of a road by filling in the cracks and voids of the existing surface. It

The Colmat range provides optimal microsurfacing solutions for asphalt and concrete roads. This is a thin reseal solution (typical thickness of 8 mm to 12 mm)

also improves durability by preventing further oxidation of the aged binder. Of the four options, Colmat L is a popular choice for provincial and municipal roads departments. This is a quickset microsur facing emulsion modified with polymer, which is designed for existing surfaces carrying a wide range of traffic. Applications include existing blacktop surfaces or concrete pavements in single pass from 5 mm to 20 mm. “Once applied, no subsequent compaction via pneumatic or drum roller is required,” explains Herman Groenewald, marketing manager, Colas SA. “The Colmat mix drying time is drastically reduced, the road can be reopened to traffic under a wider range of weather conditions versus conventional slurry and chip seals. This makes it a very cost-effective solution for waterproofing and restoring wearing course rigidity.” Municipal end-users include the City of Tshwane, eThekwini Municipality, the City

COVER STORY Table 1: Differences between Colrub LT and conventional bitumen rubber Conventional bitumen rubber (S-R1) Manufacturing temperature Application temperature Shelf life Dynamic viscosity

Low-temperature bitumen rubber (Colrub LT)

200°C

180°C

195°C to 210 °C

165°C to 175°C

4 hours to 6 hours

± 7 days @ 160°C

20 dPa.s to 40 dPa.s

7 dPa.s to 35 dPa.s

55°C to 65°C

65°C to 80°C

Softening point

of Cape Town, Mogale City and Mbombela (Nelspruit). “In Mogale City, we sprayed a section that had an envisaged lifespan of five years, but is still performing well after 15 years,” he explains. This microsurfacing technique is also environmentally friendly. Key benefits include low tyre noise and the absence of harmful emissions during application and curing.

Colmat solutions While Colmat L is one of the best-fit products selected for South Africa, consulting engineers and contractors can choose any of the other three options available, depending on the application, as described below: • Colmat N is a normal quickset microsurfacing application that does not include polymer as one of its additives. Uses include existing surfaces carrying medium levels of traffic, and where traffic accommodation can be a problem for conventional slurry. In terms of overlay, the targeted applications are urban streets and provincial roads, and existing blacktop surfaces or concrete pavements in single pass from 5 mm to 20 mm. • Colrut is a coarse-graded quickset microsur facing product modified with polymer, which is designed as a costeffective remedial solution for improving road safety by restoring the road profile and its skid resistance. • Colpave is a medium-set polymer-modified coarse slurry that is ideal for mixing in a concrete mixer and is applied by hand for resealing small areas, such as sidewalks and car parks.

600mm

Storable cold-mix asphalt Alongside reseals is the pressing issue of how to cost-effectively fill potholes. That’s

where Colas’ Compomac solution slots in perfectly. This product was specifically developed as a cost-effective alternative to hot-mix asphalt, making it a very robust option thanks to extended workability. Compomac is a cold-mix asphalt emulsion, which can be produced in either a mix plant or a pan mixer. It can be stored for up to 12 weeks in bulk, buckets or bags, and is available in black or red – the latter colour being popular for bus rapid transit (BRT) routes in South Africa. Groenewald explains, “This product has been specially developed for the maintenance of roads with low or medium traffic density, with the added benefit that Compomac is ready to use whenever you need it for resurfacing or reprofiling tasks. Because it’s placed cold, the application period is lengthened, which also makes Compomac the perfect choice for labour-intensive construction.” Compomac is also environmentally friendly, since there’s no need to heat aggregates, plus reclaimed road stone materials can be used. “In most cases, Compomac can be mixed using locally available materials, which reduces transportation distances and costs,” he continues.

Low-temperature bitumen rubber Like Compomac, Colas’ Colrub LT solution is designed for a longer shelf life. This is also a ‘green’ solution, consisting of a blend of polymers, rubber crumbs and/or WMA modifiers. “Colrub LT is one of the best seals available on the market, especially for road surfaces that are slightly cracked, since minimal preparation work is required,” Groenewald states. The product can be blended at a central location and then transported to site over long distances.

Table 1 illustrates the main differences between Colrub LT and conventional bitumen rubber (S-R1). The key advantages of Colrub LT include: • the elimination of (costly) site establishment in many cases • reduced thermal degradation of bitumen, resulting in improved durability • reduced possibility of bleeding due to the binder’s high softening point • factors such as equipment breakdowns, inclement weather, etc. do not have an adverse effect on the quality of the binder • once reacted, the properties of the binder remain virtually constant. “To match its future vision, Colas is developing solutions that light the path ahead, particularly in terms of sustainability, ease and speed of construction, and product affordability. The three product groups that are central to our market engagement in 2018 address all of these priorities,” Groenewald concludes.

www.colas.co.za

IMIESA January 2018

82ND IMESA CONFERENCE

PORT ELIZABETH

31ST OCTOBER - 2ND NOVEMBER 2018

2018

CALL FOR ABSTRACTS OUR THEME

INNOVATIVE INFRASTRUCTURE SOLUTIONS

• Political, Legal and Regulatory • Ecological and Environmental • Financial and Social

A B S T R AC T S S U B M I T T E D BY

• Transport and Traffic • Water and Sanitation • Roads and Stormwater

Monday 5th March 2018 marketing@imesa.org.za | tel +27 031 266 3263 Call Melanie Stemmer for an entry form or download from the website

www.imesa.org.za

IMESA ORGANISER

THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA) TEL: 031 266 3263 DEBBIE OR MELANIE

2018

INFRASTRUCTURE NEWS

FROM AROUND THE CONTINENT

Kenya Full steam ahead for rail Eight of Kenya’s county governments have each agreed to commit Sh100 million towards a Sh25 billion rail project. The project will see the rehabilitation of a 240 km line from Nairobi to Nanyuki, which has been out of use for about two decades, as well as the construction of a new line from Nanyuki to Kenya’s border with Ethiopia. According to Atanas Maina, managing director, Kenya Railways, the existing railway line is dilapidated in places and is a 50 pound load type, which is only capable of carrying three light locomotives. The project will see the railway upgraded to an 80 pound load, allowing a single train to carry 1 400 tonnes of goods. It will also include the purchase of new locomotives and wagons.

Mozambique Strengthening the grid While Mozambique has made significant strides in expanding access to electricity (from 6% in 2006 to 26% at present), the country’s electricity grid still faces issues of efficiency and reliability. Mozambique has now received a $150 million grant to assist the county’s electricity utility, EDM, to improve the operational capacity of its electricity network as well

as its operational efficiencies. The bulk of the financial support will assist with the rehabilitation and upgrading of network infrastructure to improve the security and reliability of electricity supply. This will be achieved through the reinforcement of transmission and distribution lines, installation of additional transformers to increase capacity, and reactive compensation equipment in the cities of Maputo, Matola, Nacala, Pemba, and Lichinga. The remaining funding will be used to support EDM’s operational and commercial operations, the company’s capacity-building and implementation support, as well as capacity-building support for the Ministry of Mineral Resources and Energy.

Nigeria Unlocking thermal energy Nigeria will soon be home to a 540 MW gas-fired power facility worth $1.1 billion. The Nigerian government has signed a power purchase agreement with Qua Iboe Power Plant Limited (QIPP) to build what will be one of the lowestcost thermal power plants in the country, in Akwa Ibom State. The power plant is expected to unlock investment in transmission infrastructure, which will have a positive socio-economic impact on the country. This

infrastructure will include 58 km of new transmission line to be built by QIPP. The project is expected to reach financial close in the second half of 2018, with construction to commence shortly thereafter, and commercial operations to begin in the second half of 2021.

Tanzania SGR Phase II takes off Work has begun on Phase II of Tanzania’s standard gauge railway (SGR) line, which will link Dar es Salaam with the country’s capital, Dodoma. The Sh200 billion (R1.22 billion) contract to construct 336 km of railway has been awarded to Turkish firm Yapi Merkezi, which is expected to hire 1 000 engineers for the job. Estimated for completion in 36 months, the new railway will allow passenger trains to travel at speeds of up to 160 km/hour, and freight trains at 120 km/hour. Tanzania’s SGR is expected to eventually link Tanzania with other regional, landlocked states including Rwanda, Burundi, the DRC, Zambia and Uganda, through quick and timely access from Tanzania’s Indian Ocean ports.

Zimbabwe Saving Harare’s roads The Harare City Council has spent

Mozambique’s electricity grid still faces issues of efficiency and reliability

fast facts

240 km

of railway line will be rehabilitated in Kenya

1 000

engineers will be hired for Phase II of Tanzania’s standard gauge railway

Both Kenya and Tanzania are working to improve their rail networks

$150 million

to help Mozambique grow its electricity grid

Harare has spent US$6 million to repair roads ahead of the rainy season

US$6 million of the $26 million it received from Zimbabwe’s Emergency Rehabilitation Fund to repair roads ahead of the rainy season. Former president Robert Mugabe declared a state of disaster on Harare’s roads and road infrastructure in February. The city’s road network has reportedly not received any meaningful routine maintenance over the last 15 years and government has since pledged to assist in rehabilitating the capital’s 5 000 km road network. Thus far, $6 million has been spent on maintenance. The city is currently embarking on a phase of roadworks that will entail road reconstruction, rehabilitation, resealing, overlaying and marking of various roads. Roads including Granville Cemetery Road, Kuwadzana Extension and Ardbennie Road have been identified as requiring urgent attention. The city’s 2018 budget proposes that $12 million be allocated to roads and maintenance programmes.

540 MW

of gas-fired power will be produced in Nigeria

IMIESA January 2018

industry insight

A paving vision

unfolds

The construction and maintenance of roads are among the top priorities for government. IMIESA speaks to Steve Tinarwo, managing director, Instant Tar, about the company’s plans to grow its base in this strategically important sector.

IMIESA January 2018

he commissioning of an 80 tonne per hour Apollo Counter Flow 90 continuous mixing plant in February 2017 at its Benoni facility in Gauteng represents a key milestone for Instant Tar. This major plant acquisition spearheads the company’s strategic vision of becoming a top-tier paving contractor and asphalt supplier in the South African and broader Southern African region. Three mix designs are currently produced by the plant, namely medium asphalt, a bitumen-treated base (BTB), and fine asphalt. The Apollo plant is owned by sister company V&S Plant. Currently, V&S is operating on a temporary licence; however, an application for a full commercial licence is due to be completed during the second quarter of 2018. “Our goal, from the onset, was to provide a turnkey solution

Steve Tinarwo, managing director, Instant Tar

in asphalt pavement construction and the acquisition of our Apollo plant now means that we have complete control over the supply chain,” explains Steve Tinarwo, managing director, Instant Tar. “That’s important from a reputation management perspective, as it means we don’t need to rely on third parties when it comes to project delivery.” Instant Tar is currently a 5 CE PE contractor in terms of the Construction Industry Development Broad (CIDB) grading system and has gained extensive experience as a subcontractor working on projects across South Africa. “Our plan in 2018 is to apply for an upgrade to a CIDB 7 level, so that we can tender on a broader range of projects,” explains Tinarwo.

“Our client base extends from commercial property owners to national contractors and local authorities.”

Instant Tar’s paving operations are supported by an 80 tph Apollo Counter Flow 90 continuous mixing plant, which is owned by sister company V&S Plant

key services

walk-behind pedestrian roller. Instant Tar’s first paver was acquired in 2010, subsequently followed by pneumatic and compaction rollers that have opened up opportunities into a much broader market for urban and national road resurfacing. Instant Tar’s current paver units include a Vögele 1603 (equipped with a 5 m screed), a Wirtgen Super 800 (3.4 m screed) and a Blaw-Knox unit. Allied equipment includes chip spreaders, pneumatic and double-drum rollers, and tipper trucks. The company now also owns two low-bed trucks, which enables the rapid deployment of machines nationally for projects in diverse geographic locations, such as the Eastern Cape, KwaZulu-Natal and Limpopo. Ongoing projects within the Gauteng region include subcontract work for the Johannesburg Roads Agency (JRA), the City of Ekurhuleni, and the Gauteng Department of Roads and Transport. One of Instant Tar’s recent breakthroughs took place in the recycling market, and the company recently completed an R8 million project for the JRA, working as a subcontractor. “Whether it is for a patching, resurfacing or complete surface construction job, Instant Tar provides expert advice and ensures that the appropriate materials are used,” says Tinarwo. Instant Tar also provides a road marking service. The solutions offered are solvent- and water-based road markings.

• Milling and recycling

SMME support

• Road maintenance and rehabilitation

“There’s a definite opportunity for SMME contractors when it comes to earthworks projects, but the high cost of acquiring specialist paving plants still represents a major barrier to entry for most emerging

The company is 100% black-women-owned. “In fact, we’re the only black contractor in Gauteng that owns an asphalt plant,” he continues. Instant Tar is also a member of the Southern African Bitumen Association, ensuring it keeps up to date with current industry regulations and standards.

From civils to paving Established in 2007, Instant Tar’s current business model has progressively evolved. Initial activities concentrated on general civils work, like earthworks, stormwater drainage structures and concrete block paving, which it still offers on request as part of a total project solution. Having identified a gap, the company refined its strategy in 2008, shifting to a specific focus on asphalt paving – ranging from pothole patching, to residential driveway and light commercial parking area surfacing. This has been supported by a steady acquisition of specialised equipment, starting with a

• Single and double seals • Road construction • All asphalt works

companies. Plus the saving segment is not generally catered for by the plant hire industry. So, Instant Tar is well-placed for growth,” says Tinarwo. “However, we can create joint ventures with SMME civils contractors. This enables them to tender on multidisciplinary roads projects where Instant Tar is responsible for the black-top surfacing phase.” In the longer term, Instant Tar has an ambitious vision of being one of the top five asphalt suppliers within the SADC region. “As we expand, one of our future acquisitions could include a mobile asphalt plant, which would be ideal for supplying the megaprojects we hope to secure in the future as we climb up the CIDB rankings,” he expands. Outside South Africa, Instant Tar has a registered company in Zimbabwe, trading as Elshadhai Civil Construction. With the outlook in Zimbabwe starting to show marked improvement, Instant Tar plans to establish a full road paving line during 2018 to respond to local project opportunities. “In the meantime, our intention is to grow our municipal footprint in South Africa, while concurrently strengthening our relationships with key suppliers, since they play a critical role in ensuring that we provide high-quality solutions,” concludes Tinarwo.

www.instanttar.co.za

IMIESA January 2018

The City of Johannesburg is facing a massive infrastructure crisis. With only R10 billion available to address a R170 billion shortfall over the next 10 years, the city is fast approaching the edge of the metaphorical cliff. Executive Mayor Herman Mashaba opened up recently about the true state of the city. By Liesl Frankson

A city on the cusp of collapse

he reality is that the city’s infrastructure is in dire straits, with 27% of electricity infrastructure past its lifespan, over 45 000 leaks in the city’s water pipes, and a road network that is deteriorating at an alarming rate. “The truth is that much of our infrastructure was built in the dark days of apartheid, designed to exclusively service small white communities,” Mashaba said, speaking at the city’s State of Infrastructure Address. “Today, we live in a society where our communities are growing and diversifying, but the capacity of the city’s infrastructure cannot match this growth or the changing needs of these communities,” he explained. Supporting this notion are the recent statistics from the Johannesburg Road Agency’s (JRA's) 2017 Road Condition Index. According to the study, there’s a 25%

Potholes in Albert Street, Weltevredenpark

IMIESA January 2018

deterioration in the condition of the city’s road network, dropping from 89% in 2013 to 64% in 2017. In comparison to 2013 results, the study indicates that very good and good surfaced roads have decreased from 52% to 45%. Poor and very poor roads have increased from 27% to 32%, and 72% of gravel roads are in a poor or very poor condition. The study indicates that the roads are still deteriorating and the present funding allocated is inadequate to address the rate of deterioration. “The JRA’s R1 billion budget is inadequate even to just maintain the condition of our roads, let alone improve it,” Mashaba noted.

Joburg’s roads: From bad to worse MMC for Transport Nonhlanhla Makhuba painted a picture of just how bad the backlog is in her presentation on the state

of Johannesburg’s roads. According to Makhuba, the city needs R7.1 billion for surfaced roads alone, with only R240 million available for the resur facing and reconstruction in the current financial year. To upgrade gravel roads to tar, the city is looking at a R4.7 billion backlog with only R295 million available in this financial year; and things are bleaker on the sidewalk front, with no budget available in the current financial year regardless of the R2 billion backlog. Makhuba noted that the condition of the city’s bridges is also dire. “The overall acceptable condition indices for bridges in a very good and good condition should be 80% at minimum, but currently only 5.77% of the city’s bridges are in this acceptable condition. “Since 2013, 37 bridges have collapsed during rainy seasons,” she pointed out. These alarming results have led the JRA

Joe Nhlanhla Street Bridge over the Jukskei River

MUNICIPAL FOCUS | JOHANNESBURG

to start with another round of bridge assessments. Things are no better for dam, catchment and stormwater infrastructure, with the city facing a R61.2 billion deficit in funding.

City Power: A shocking situation The challenges facing City Power are not unlike those of the JRA. The utility is battling ageing network infrastructure on a massive scale. While 27% of the infrastructure has reached 100% of its useful life, an alarming 45% now falls into the high-risk category, having reached 75% of their useful life. These high-risk transformers need to be addressed urgently as they are under increasing pressure because they supply the most critical nodes, according to Nico de Jager, MMC for Environment and Infrastructure Services. In his presentation, De Jager identified ageing infrastructure as one of the utility’s biggest challenges. “It’s difficult to operate the obsolete circuit breakers that are still in operation – the oldest was installed in 1929. In addition, replacement parts are difficult to source,” he said. Theft and vandalism is another major concern, with the scrap value of copper making the city’s 17 000 km underground copper networks an attractive target. The backlog in asset renewal is another issue. “There is a constant shortfall between requirement and actual available capital budget,” he noted. “The total requirement from this point to the 2021/22 financial year is R19.8 billion. The

Our role is an unconditional responsibility, a contract with our residents, to turn this city around and get it working.” Executive Mayor Herman Mashaba, City of Johannesburg

A burst pipe in Oakdene, August 2017

indicative budget for the same period is R8.3 billion,” he added. In addition, a total of R481 million is required to electrify formal and informal settlements over the medium term. De Jager said the utility was evaluating alternative financing models to source funding for the high-risk substations, informal settlements and ageing underground cables. “To contain the network situation, we will be intensifying our maintenance efforts, monitoring high-risk equipment and assessing quick power restoration options such as mobile substations,” he added.

Joburg Water: A utility under pressure Turning to water, 25% of Johannesburg Water’s asset base has a remaining useful life of less than 10 years. During the 2016/17 financial year, the city had a staggering 45 177 pipe bursts, a 27% increase from the 2012/13 financial year; while sewer blockages increased by 29% from 44 613 in 2012/13 to 57 769 in 2016/17. To make matters worse, underfunding has left the city with an infrastructure renewal backlog of R5.8 billion. To address critical assets that require replacement or renewal, the city will need R12.65 billion over the next 10 years. De Jager said Johannesburg Water will mitigate challenges with infrastructure failures through short-term interventions that include improved pressure management, improved preventative maintenance programmes and first-line response teams to assist in reducing the time of water wastage during pipe bursts.

The road ahead Wrapping up the address, Mashaba noted that the aim of the briefing was not to give residents sleepless nights, “After receiving this news myself, I thought it would be inappropriate not to share this with society. “Our role is an unconditional responsibility, a contract with our residents, to turn this

Control plant wiring after being vandalised

city around and get it working. But, when you consider some of our biggest challenges, we must appreciate that they cannot be resolved overnight.” Mashaba said that as the city approaches the planning of the next budget cycle, the focus will be on redirecting resources for investment in city infrastructure. The city will also be moving away from a strategy that relies on repairs. “The repairs and maintenance we are engaged with, as a city, are quick fixes, and have us using time, people and funds fixing problems only for them to return in the weeks or months to come. We need to focus on refurbishment, the process of replacing our old infrastructure with new, higher-capacity infrastructure. “This means resurfacing and reconstructing our roads rather than just plugging the holes. It means new substations with higher capacities, and it means new water pipes with larger diameters to feed growing communities,” he said. He added that his objective is to turn the entire city into a construction site over the next four years. “My request to our residents is to please bear with us during this period, because the job of saving our city from the imminent collapse of its infrastructure cannot happen overnight. It is a process, not an event, but it is a process through which our residents need to accompany us,” he concluded.

A burst pipe in Weltevredenpark, November 2017

Enhancing Society Together Enhancing Society Together In partnership with clients, stakeholders and communities Once it was enough for engineers to ask themselves: how can peopleâ&#x20AC;&#x2122;s lives be made easier? Today, in the face of unprecedented challenge and change, we believe this question no longer reaches far enough. In response, we have focused the work and passion of our engineers and consultants towards a deeper level. How do we make lives not simply easier, but better? By working in partnership with our clients and other stakeholders, we are committed to make an impactful contribution to society through our projects. We are focused on solutions to the Global Challenges faced in respect of Urban, Water, Transport and Industry through our Business Lines of Water; Transport & Planning; Industry & Buildings; and Maritime & Aviation. The framework underpinning our focus on enhancing society rests on four simple questions. These are addressed in every project we undertake: n

Will our solution meet the demands of the stakeholders?

Will it add value for society as well as clients?

Are we providing the best solution now and in the long term?

Can we deliver what is required with an optimal use of resources and fossil fuel energy?

Working alone, we cannot change the world. Working together with our clients, stakeholders, partners and communities, we are in the process of moving towards a better future for all.

Royal HaskoningDHV Head Office Johannesburg, South Africa +27 (0)11 798 6000

www.royalhaskoningdhv.com/za

roads & bridges

Tackling the slopes Twenty years in the making, Main Road 577 will provide critical access to jobs for residents from Inanda, KwaMashu and Ntuzumato, as well as economic activity in the New Germany and Pinetown areas of Durban.

he Main Road 577 (MR577) project first began in the early 1990s when the KwaZulu-Natal Depar tment of Transport commissioned the design. Lack of funding delayed the project until 2003, when Henwood&Nxumalo and BCP Engineers (Royal HaskoningDHV) were appointed as project and construction managers for the construction phase of the full MR577 project.

Royal HaskoningDHV undertook a review of the original route location and proposed a radical change, which offered a more direct route with a high-level crossing of the uMngeni. This would see the uMngeni Viaduct, an impressive 410 m twin-deck viaduct, incrementally launched 40 m above the uMngeni River between 2008 and 2010. Although this change involved the construction of a larger bridge, the more

direct road saved approximately 1.4 km and reduced the steep gradients in and out of the valley, and was justified by the savings in road construction, travel time and cost.

The KwaDabeka Valley challenge The linkage from uMngeni Viaduct to New Germany, however, was planned to traverse the KwaDabeka Valley. Geotechnical investigations proved this would be challenging, as the valley features

IMIESA January 2018

Franki Africa is proud to have carried out the slope stability works through the Kwadabeka Valley for the MR577 Project.

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roads & bridges The road sweeps by the major rock cutting

Bus station platform complete

35- to 45-degree slopes on the valley sides. This would require careful management of the cut-and-fill slopes – even with the proposed split-level dual carriageway. The project was further complicated when, in 2012, the eThekwini Integrated Regional Public Transport Network (IRPTN) team proposed that eThekwini’s Bus Rapid Transit (BRT) be incorporated into the project. This would be more time- and cost-effective than retrofitting a two-lane BRT component into the project when it was completed. For the design team, this meant redesigning the four-lane split-level road, taking into account the different geometric requirements and pavement design inherent in a BRT project. Under normal circumstances, the bus lanes would be provided side by side in the median. However, this would not be possible given the up to 6.5 m difference in the level of the two carriageways. Instead, the decision was taken to provide a four-lane: two-lane split-level dual carriageway with reinforced concrete traffic barriers as separators. With much of the drainage installation already completed for the existing project, the redesign had to be carried out while the contractor was in full swing. This meant that two contracts for separate clients were under way on the same site at the same time – requiring extensive cooperation and engagement between all parties. With the Group Five Joint Venture already working on the KwaDabeka Valley project from KM 9+985 to KM 12+700 on MR577, the JV was also awarded the contract for the BRT lanes.

grade of 6.2%, and as steep as 9.7% in places, along the steep-sided valley of the KwaDabeka tributar y to the uMngeni, and then into New Germany and Pinetown. The steep terrain required well-planned methods for excavating the cut. In order to accommodate the alignment of the carriageways within the steep-sided valley, a rock slope cut at 63 degrees to the horizontal was selected to optimise the geometr y of the road and to minimise risk. A rockfall trap zone was incorporated in the design at the base of the cut slope adjacent to and below the road level. Due to the steep natural slopes located above the crests of the cuttings and the evident numerous sur face boulders, the vegetation was cleared to bar down all sizable boulders and stabilise or fragment potentially unstable large boulders that could not be moved. Rockfall interception measures were installed on in situ ground at the crests of the main cuttings by utilising a gabion basket structure, which was anchored back into the cut slope, incorporating guardrail structures in selected places to increase the height of the interceptor walls. The draping of steep rock and boulder outcrops with steel mesh was designed to control the downslope movement of boulders – particularly to protect construction personnel.

The KwaDabeka Valley was the most challenging portion of the MR 577 project

persons were employed and ten local subcontractors were appointed during the project. This facilitates knowledge transfer to help groom the next generation of South African engineers. It also demonstrates how infrastructure can contribute to enhancing social and economic development for the local communities.

Successful completion

Training and empowerment

The challenging MR577 project presented the designers with the prospect of literally being caught between a rock and a hard place. However, the team worked to overcome these challenges, and the public lanes of the MR577 through to New Germany opened in late July 2017. The BRT lanes on Corridor C3 Pinetown to Bridge City are expected to open in mid-2018.

In consultation with the KZN DoT and the local ward councillors, a training centre was established on-site, which provided construction-related skills training. A CPG value of 42% of the contract value was achieved, far exceeding the client’s expectations. A total of 637 local community

*Scan the QR code to watch how the MR 577 was built

Tackling the slopes The KwaDabeka Valley was the most challenging portion of the MR 577 project as the road had to climb at an average

The excavation continues down the slope with gunite operations following



IMIESA January 2018

roads & bridges

Geotechnical challenges Franki Africa was appointed by main contractor Group Five to carry out the lateral support works for the project. In order to construct the new road, a major cut-and-fill operation was required up the valley from the Umgeni River. Franki’s scope included temporary rock fall protection works and permanent lateral support with cuts of up to 52 m high in parts. The original scope of work was for close to 20 000 m of rock bolts, 7 000 m2 of shotcrete and 300 m of temporary rock fall catch fences. The most difficult aspect of the project was the access to the work areas. The natural slopes varied between 30 degrees and 45 degrees and stretched over 100 m from the valley to crest. Franki utilised tracked drilling rigs, an excavator-mounted drilling boom and two shotcrete teams on-site. With lateral support works starting approximately half way up the slope, access for plant, material and personnel proved challenging. Initial works included barring down loose rocks from the slope above the work area and erecting a temporary catch fence for protection during subsequent works below. Apart from the steep slope and risk of falling rocks, scorching temperatures of over 45°C and snakes on-site made tasks all the more challenging. The first two or three rows of rock bolts were installed through a gabion interceptor wall. Franki installed the bolts and then coupled extensions onto these as the gabions were constructed. With access along a single 3 m to 4 m wide bench, the coordination of material deliveries and construction works proved difficult, and resulted in frequent delays. Ongoing design changes as unexpected fractures, tension cracks and rock strata were uncovered also contributed to extending the contract period. Soil conditions varied from topsoil to loose talus to fractured sandstone of varying strengths, and the engineers found it difficult to keep up with continually changing design requirements. The scope of works increased considerably because of this, and the eventual value of the works was three times the tendered value, it included extensive rock anchoring and over 3 000 m2 of drape mesh, and took over three years to complete. Franki employed up to 50 people from the local community during this period. The difficult working conditions and continual changes led to extreme challenges but the final result is an impressive lateral support structure that has enabled the P577 to pass safely through the Kwadabeka Valley.

IMIESA January 2018

roads & bridges

A historic upgrade Traversing the mountainous terrain between Grahamstown and the Fish River Pass, a 47 km stretch of the N2 is being upgraded as part of Sanral’s long-term strategy to improve the quality of the roads between Port Elizabeth and King Williams Town.

ivided into three phases, the single-carriageway crosssection with 3.5 m lanes and 1.2 m gravel shoulders will be upgraded to 3.7 m lanes with 2.5 m surfaced shoulders and 0.5 m gravel shoulders. The new alignment will also allow for increased speeds.

History uncovered Undertaken by the Bosch Projects/Mott MacDonald Joint Venture, the project has gained fame for the fossils discovered during the blasting and excavation of the cutting at km 77. A number of new invertebrates, as well as excellently preserved plant fossils of the Devonian era, were discovered, many of which had not been previously documented.

Due to the geological and palaeontological significance of the rock formations, Sanral proposed that the area be used as a tourist attraction and that a rest area be established, with tourist boards displaying information about the geology and palaeontology associated with the area.

Phase 1 The first phase of the three-phase project from km 62 to km 78.7, valued at R380 million, is complete. This involved 900 000 m3 of earthworks, 300 000 m3 of layerworks, 13 km of subsoil drains, 2 km of concrete pipe culverts, 100 headwalls and grid inlets, and 240 000 m2 of 19 mm Cape seal surfacing. The project required the extensive horizontal and vertical realignment of the route, through rolling hilly terrain, including

a mountain pass and crossing of the Great Fish River. Material had to be sourced in the area, environmental approval obtained for the project and material sources to be mined, and the pavement had to be designed taking the available materials into consideration. The preferred source of crushed material for the project was a cut widening adjacent to the existing road. The quarry revealed potential reserves of 675 000 m³, with material suitable for use as crushed stone aggregate (G1 – G3), concrete aggregate and gabion aggregate. Three alternative pavement design methods were utilised. The first was TRH4: 1996 Catalogue Design for a Category A road, which was used for an ES10 and ES30 pavement in dry and wet regions. Secondly, various pavement design options were

roads & bridges

evaluated mechanistically using Rubicon Toolbox software. A G2 quality base was considered as an alternative should the available materials sources not provide G1 quality material. Similarly, different parent materials for a cement stabilised subbase were considered. As an alternative design method, and to provide a comparison to the results emanating from the mechanistic design, the Pavement Structural Number Design Method (TG2) was also used. The method is applicable to all pavement materials commonly used in Southern Africa and has been validated against pavement behaviour and performance in the region. The road had to be constructed while maintaining

two-way traffic, and numerous deviations and bypasses had to be designed to accommodate this. To achieve this, the proposed horizontal alignment was offset to a minimum of 3.5 m from the existing centreline, either to the left or right depending on the topography. The offset was greater where the vertical alignment was adjusted in order to maintain two-way traffic accommodation throughout the construction of the new road. This allowed for the existing pavement to be utilised to accommodate one direction of traffic. Nine temporary deviations/bypasses were incorporated in the design over the three construction phases of the project, where two-way traffic accommodation would not be achieved through half-width construction.

Upgrading the Pikoli pass Part of Phase 1 included the upgrading of the Pikoli pass, which traverses approximately 2.7Â km of steep, rocky terrain, and which required substantial blasting to achieve the required design levels. The R22 million

NEW CRUMB RUBBER TECHNOLOGY

IMIESA January 2018

upgrade was undertaken as a labour-intensive community development project that employed 43 people from the local Pikoli community. These locals were employed and trained to undertake the work, which included the installation of 2.5 km of subsoil drains, 400 m of concrete pipe culverts, 40 outlet structures, 2 km of concrete side drains, 2.5 km of concrete kerbing and 2 900 m3 of waterbound macadam base. The road will be used as a bypass during the Phase 3 construction contract when the Fish River Pass to the east of the Fish River Bridge is upgraded. With Phase 1 completed, the roadway from Grahamstown towards Peddie up to the Coombs Valley turnoff is now a 12.4 m wide roadway with 3.7 m wide lanes, including wide shoulders and climbing lanes where necessary, delivering a significantly safer driving experience. The breathtaking views from km 71, the quarry and subsequent rock formations that are now visible at km 77, and the excellent aesthetics and final riding quality of the roadway make for a spectacular driving experience.

Environmental Engineering

Gabions coexist with the landscape

Environmental engineers have a natural eye for the surrounding landscape and an exper t understanding of how to use in situ materials to make seemingly simple but enduring installations. In Africa, they also provide a more affordable and labour-intensive solution. By Alastair Currie

abion construction is an ancient technique that has seen major advances thanks to an intensive research and development focus on the galvanised and PVC-coated mesh compositions designed for diverse applications like river erosion control, marine quay wall stabilisation, road and rail embankments, and even housing, all of which could have considered other options like concrete. “These advances, combined with geotextile innovations, make this field one of the most fascinating civil engineering disciplines even though the applications can appear quite basic,” explains Louis Cheyne, managing director of Gabion Baskets. While South Africa remains Gabion Baskets’ primary

“Being highly permeable, gabions enable 55% of water flows to pass through without compromising their integrity, and can be vegetated to blend in with the environment.”

market, the company has always had a presence in the broader sub-Saharan region, and Cheyne says the potential here is enormous. “South Africa’s infrastructure challenges are significant, but don’t come close to the needs within our neighbouring countries, as well as further afield on the continent,” he explains. The company has recently secured a number of major orders going into 2018, one based in Malawi for a road project and another in the Democratic Republic of the Congo for a mining tip wall. Gabion Baskets completed the designs for both projects and will manufacture and supply the gabion baskets along with specified geotextiles. “There is growing demand in Africa for South African engineering and project management skills and we view the region as a major growth market,” Cheyne expands, adding that professional services and locally manufactured products tend to be more price-competitive compared to those sourced from regions like North America and Europe.

University of Venda Back in South Africa, Gabion Baskets has a strong order book going into 2018. This

HIGH RETAINING WALLS The above example of a well-constructed retaining wall was built in 2009 for a new manufacturing and distribution centre in Pretoria. This wall has a height of 5 m and a total length of 105 m. This work was undertaken by about 14 people together with a backhoe loader to help load the rock from the stockpile directly into the baskets. The typical work rate is one man per cubic metre per day. In this case, however, the man and machine combination increased the daily rate to approximately 1.5 m3 to 2.0 m³. A total quantity of 540 m³ of gabion walling was installed. The gabion facing was rotated into the embankment with a four-degree batter slope to further enhance the wall’s stability, with the base founded to a depth of 0.5 m. The wall’s base width was 1.5 m for the first two gabion levels, with subsequent layers of 1 m x 1 m. includes the manufacture and supply of 6 500 m3 of gabion baskets (equating to a total weight of 65 t) for a series of massgravity retaining walls being constructed at

IMIESA January 2018

Environmental Engineering

HIGH RETAINING WALLS

the University of Venda in Thohoyandou. These are designed to retain large platforms for facilities that include sports fields and student housing. Gabion Baskets put together a design recommendation based on the site and soil information supplied and will also be providing on-site training. Three to four walls will be installed by the contractor with a combined length of 147 m and ranging in height from 5.5 m to 11 m. From a quantities perspective, each 1 m3 basket holds approximately 1.6 tonnes of rock. Ideally, this should be composed of unweathered materials to get the best results in the longer term.

SABIE PROJECT

“As a rule of thumb, the rate of gabion construction is typically estimated to be one man per cubic metre per day, so it’s clear that projects of this nature create major employment opportunities for local communities,” says Cheyne. Another new order is for a roadworks project in Magoebaskloof, Limpopo, entailing 550 m3 of gabions.

Dam siltration and hydro chambers Erosion control remains one of the key benefits of gabion construction and, aside from retaining walls, another popular application is their use to slow down

SABIE PROJECT This gabion wall performs both an erosion control and retaining function for a road project near Sabie in Mpumalanga. Four walls were installed with various lengths. The first retaining wall is 4 m high and was used to retain the cut-slope embankment, reduce water velocities off the tailings slope and act as a rock catch wall. The second gabion wall below the roadway (halfway up the fill slope) is designed to prevent lateral movement of soils. This reduces the risk of roadway settlement and failure.

GABION WEIRS

A classic weir system installed for a municipal application

water velocity in river systems by building weirs. Here, the natural porosity of gabion structures comes into its own. Mini dams can also be constructed by installing an HDPE geotextile-lined hydro chamber on the upstream side of the weir. This ‘dammed water’ can then be used for a variety of purposes that include irrigation or as a supplementary resource for communities. When it comes to conventional dams, one of the key concerns for facility owners is the effect of siltration build-up over time and how to combat or limit this scenario. If left unchecked, siltration will steadily reduce a dam’s storage capacity and impact on the original envisaged lifespan and upfront infrastructure investment. One possibility is the use of expensive dredging techniques for more severe cases. Another is to install gabion weir silt traps upstream. In one past example in KwaZulu-Natal, Gabion Baskets assisted the contractor with an anti-siltration design solution within the catchment of the dam, which has worked very effectively. “It’s important to monitor these weirs after installation. Unless they are cleared on a regular basis, they will not perform

optimally. Left unchecked, the upstream end becomes fully trapped with silt, which then washes over and heads downstream. However, routinely deploying a backhoe loader or excavator to remove the silt does the trick. That’s far easier than trying to dredge a large, conventional dam,” Cheyne concludes.

Installation works to trap silt and counter severe soil erosion in the river catchment and dongas upstream of the Woodstock Dam, which is located on the upper reaches of the Tugela River in KwaZulu-Natal

Types of retaining walls Mass-gravity gabion retaining wall (dry) This wall is used in situations where the embankment is unstable and has no founding in a river – i.e. where a river mattress might be required. Mass-gravity gabion retaining wall (wet) This structure is typically founded in a river. A flexible river mattress apron is required to prevent scour at the toe of the gabion wall, especially if the structure is founded on soft river sand. Skin revetment gabion wall This wall is used where the embankment stability is safe. This wall type is used to prevent shallow-slope failures, plus rock falling out of the slope. Gabion mass-gravity catch wall This option is designed to catch rocks or soil falling out of the embankment. Gabion vertical-faced mass-gravity wall A vertical-faced gabion retaining wall is used in an area where limited spacing is available. Terraced gabion wall Popular for playgrounds and sports fields, a small terrace can be erected using garden gabions to make the slope of the land flatter.

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IMESA Conference

Back to basics Technology has improved lives and increased productivity in innumerable ways, including fast-tracking the pace of engineering work. But does this come at a cost? By Danielle Petterson

Keynote speaker Jacob Mamabolo, MEC, Gauteng Department of Infrastructure Development, and Gavin Clunnie, president, IMESA

nder the theme ‘Sustainable Engineering: back to basics for the future’, the 2017 IMESA Conference called into question whether engineers have forgotten the basic principles of engineering design as a result of technology. Gavin Clunnie, president, IMESA, chose this theme for the 2017 conference because of his passion for it. He believes many engineers have become too reliant on the assumed accuracy of computers and not their own judgement. While computers are able to crunch numbers and produce results at much faster rates, the interpretation of data is crucial and Clunnie believes many don’t stop to question whether the results are accurate. While those in the profession need to remain cognisant of the importance of the basics, the onus is also largely on educators to ensure those coming into the profession get the basics right. Addressing delegates as part of a panel discussion, Professor Kobus du Plessis, exco

Motivational speaker Ian Thomas, sponsored by BMK

member of IMESA, also highlighted the role of academic institutions, noting that maths and science are the building blocks that need to be addressed in the early phases of schooling. However, while academic institutions are responsible for teaching learners the basics, he added that the private sector has a big role to play in creating informed engineers. Chris Campbell, CEO, Consulting Engineers South Africa (CESA), added that

IMIESA January 2018

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CONNECT VNA... SETTING NEW INDUSTRY STANDARDS TO ENABLE INFRASTRUCTURAL SOLUTIONS FOR THE ECONOMIC DEVELOPMENT OF SOUTH AFRICA AND AFRICA. In constant movement towards change, we at VNA are focused on delivering seamless, safe and sustainable engineering solutions within the communities we serve. From 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. We understand the industry in Africa and the distinctive needs of the market. Our vision is to realise continental potential, ensuring built environment transformation of South Africa and beyond to benefit our local communities, urban and rural. Looking for a leading specialist with its heart in the community? Look no further than VNA.

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IMESA Conference

Members teed off at the Serengeti Golf Course ahead of the conference

The Oktober Bierfest themed gala event was a huge success and hailed one of the best IMESA events in memory

while engineers now have the opportunities to optimise the use of technology, they must be competent in the basics, which requires adequate development on basic applications. “Patience, commitment and passion to convert knowledge into

skill make a competent practitioner,” said Campbell.

Sustainable engineering Speaking to the theme of sustainable engineering, Clunnie noted that sustainability

has never been more urgent across all facets of life. “It is our collective responsibility to work towards solutions that not only institute measures that drive sustainability, but also provide education to our peers about the dire need to do so, and to continue the cycle of

2017’S BEST PAPERS Best paper presented by an IMESA member: Clyde Mario Koen, City of Cape Town ‘Innovative design and construction methodologies for the construction of the Cape Flats 3 Bulk Sewer ensuring sustainable conveyance of sewerage effluent for the next 100 years and more’ Koen highlighted the relationship between the Cape Flats Bulks Sewer 3 Phase 2 civil engineering project and the challenges posed by urbanisation, population growth and the broader limitations of bulk sewerage within the City of Cape Town (CoCT). Faced with installing a new bulk sewer pipeline along a challenging, highly congested route, the CoCT’s project team opted for a microtunnelling option for 1 200 m of pipeline where an open-trench system would cause substantial interruptions. Using this method, ductile iron jacking pipes were successfully installed across eight sections with a high degree of precision, ahead of schedule and within budget.

Best paper presented by a non-IMESA member: Robyn Tompkins & Mark Schapers, JG Afrika ‘Towards community ownership and management of rural water supply schemes’ Botswana recently approved a new policy that calls for the establishment of water committees in rural communities, moving toward a community-based management model – as is used in Namibia. Tompkins and Schapers presented a project based in the Habu community of Botswana (population: 1 500), which drew on elements of the highly successful Namibian community-based management approach, contextualised for the new policy in Botswana. The methodology was to use a simple scheme design, and also develop a governance and technical training course. Community-based management structures were established and a simple tariff system designed and implemented in the community. Most of the households have registered and are paying their monthly fee to collect water from the five standpipe taps, proving that the scheme could be a model for sustainable rural water management for remote communities in Botswana.

Gavin Clunnie thanks the 2017 conference organisers

IMIESA January 2018

IMESA Conference

Delegates attended technical tours to the new Johanneburg Council Chambers, M1 construction, Witwatersrand Acid Mine Drainage, and the Gautrain, sponsored by Deedscon

sustainability for generations to come,” he said. Delivering the keynote address, Jacob Mamabolo, MEC, Gauteng Department of Infrastructure Development, addressed the issue of sustainability, arguing that the economy and engineering both need to be re-engineered to be more sustainable. According to Mamabolo, the country’s economy has until now run on a model that has not only been very destructive to the environment, but has also been based on non-renewable resources. “We need ideas on how to build a sustainable economy that protects the environment,” he said. This, he believes, requires a new body of knowledge and methods as well as innovation. “If we don’t do that, the economy will not grow at the rate required to meet the demands of the people. If engineers don’t help us to re-engineer the economy, the costs for the country will be high,” said the MEC.

Back to basics, back to school Speaking to IMIESA, Mamabolo highlighted that a lack of education, training and reskilling is the source of many challenges facing South Africa. “We need a skills revolution to solve the problems of this country,” said the MEC. He argued that everyone, including politicians, needs to go back to class to upskill in order to keep pace with an ever-evolving environment.

IMIESA January 2018

The building blocks Closing what he believes was another successful conference, Clunnie thanked everyone for their valuable input on a topic

about which he is passionate, reminding those present to “get all the building blocks in place for a solid structure.”

Giving back In an effort to give back to the community, IMESA donated its extra delegate bags to two worthy causes: Elandspark School for children with special needs (LSEN) and Sunfield Fortuna Home for severely mentally disabled persons. Sunfield Fortuna is an organisation committed to facilitating the lifelong empowerment of intellectually disabled adults and children. Brenda Gouws, general manager, Sunfield Fortuna, expressed her sincere gratitude and appreciation for the donation. “It is people like you that make it possible for us to make a difference in the lives of our disabled residents,” she told IMESA. At Elandspark School, which offers education to LSEN learners, some children were using plastic packets to carry their books, and the bags have gone a long way in assisting those in need. IMESA member Johann Marx hands extra delegate bags to over Josua du Plessis, principal of Elandspark School for children with special needs

IMESA member Johann Marx hands over extra delegate bags to Sunfield Fortuna Home for severely mentally disabled persons

Transport, Logistics, Vehicles & Equipment

Finance direct to customers The Volvo Group will now offer financial services to customers through the newly established Volvo Financial Services Southern Africa.

olvo Financial Services (VFS) will provide financial services to the customers of the Volvo Group’s truck and bus industry brands currently operating as part of Volvo Group Southern Africa, including UD Trucks, Volvo Bus, Volvo Trucks and Volvo CE.

A global solution made local Formed in 2001, VFS is headquartered in the USA, manages a net credit portfolio of over SEK126 billion (R213 billion), employs over 1 400 people worldwide, and provides customer financing in over 45 countries. “While we are a global organisation, VFS leverages local expertise to ensure our South African customers’ unique business requirements are addressed through a tailored, competitive solution,” says Scott Rafkin, president, VFS. Volvo Trucks and UD Trucks have a combined market share of 25% in South Africa, making the country a strategic market for the group. “The South African truck market is an extremely competitive environment and we see a great opportunity for VFS as a captive financial solution provider to present our customers with a customisable transport solution,” says Jens Winkelmann, country manager: South

Africa, VFS. “By combining all the expertise inherent in the Volvo Group – from our classleading products to the level of support provided – our customers will ultimately reap the rewards of a successful business. And that is our main goal.” Torbjörn Christensson, president, Volvo Group Southern Africa, believes the launch of VFS in South Africa will not only provide customers with a total Volvo Group offering that includes product, service, parts and financial services, but also reinforces the company’s commitment to the country and the rest of Africa. “With VFS co-locating with Volvo Group Southern Africa’s businesses, our countrywide dealer networks will be able to provide a full range of integrated financial solutions to our customers,” says Christensson. “Although VFS will only initially be present in South Africa, we will aim to make it available to our customers across Southern and East Africa, as these respective product markets continue to develop,” he adds. VFS will also continue its alliance with WesBank, a division of First Rand Bank, with financial products that complement each other, to further strengthen the company’s offering of operating lease agreements, instalment sales agreements and finance leases to customers.

• Advanced Technology • Auto Powershift •4x4 • Fuel efficient • Hammer Piping • Low and easy maintenance

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Lesotho:

Office Tel: +27 (0)21 933 2383 Email: gertm@elbquip.co.za

Office Tel: +266 (0)28 313 926 Email: mollo@matobo.co.za

Durban:

Namibia:

Office Tel: +26 (0)46 123 4052 Email:erich@barex.com.na

Office Tel: +27 (0)31 464 6522 Email: brucev@elbquip.co.za

East London:

Swaziland:

Office Tel: +27 (0)31 464 6522 Email: brucev@elbquip.co.za

George (Service Depot): Office Tel: +27 (0)21 933 2383 Email: gertm@elbquip.co.za

Kimberley:

Zambia:

Office Tel: +26 (0)21 221 0642 Email: tony@ecmining.com

Zimbabwe:

Office Tel: +263 (0)77 236 2596 Email: bryan@torreafrica.com Email: mark@torreafrica.com

Office Tel: +27 (0)53 841 0040 Email: deonc@elbquip.co.za

Middelburg:

Bulawayo

Office Tel: +27 (0)13 246 2312 Email: lancec@elbquip.co.za

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Mozambique:

Office Tel: +268 (0)76 022 8488 Email: pedror@mrc.co.sz

East Africa:

Office Tel: +254 (0)20 807 0728 Email: elb@elbeastafrica.com

Website: www.elbequipment.com Distribution and Product Support by:

The VFS team present their offering to the South African market

IMIESA January 2018

Transport, Logistics, Vehicles & Equipment

The road ahead with Ammann Product experts from the Ammann Group recently shared key product updates during a customer day in South Africa, which included the announcement of its new paving series.

earing up for 2018, Ammann Construction Machinery South Africa (Ammann South Africa) held a comprehensive training workshop with its South African dealer, ELB Equipment, on 14 and 15 November 2017 ahead of its customer day on Wednesday 16 November 2017. The customer day was attended by around 120 delegates, representing the broader South African contractor and plant hire segments, and was held at Instant Tar’s facility in Benoni. This served as a platform for the unveiling of new product offerings destined for the local market in 2018, as well as an insight into some of the key research and development initiatives being spearheaded by Ammann. The day also provided an opportunity to showcase current Ammann products sold locally, alongside the AP600 paver, one of a suite of machines produced by the Ammann Group’s wholly owned Indian original equipment manufacturer, Apollo. International speakers at the customer day comprised Rajesh Chiddarwar, Ammann’s regional director for Africa and the Middle East, based in Dubai; Leos Tymel, commercial manager: Heavy Compaction, based at Ammann’s factory in the Czech Republic; Wladimir Drisner, commercial manager: Light Compaction from Ammann’s Hennef facility in

IMIESA January 2018

Germany; as well as Bartosz Kozik, director: Global Product Strategy Machines, also based in Hennef. “The event proved to be a great success, with a special thanks to Steve Tinarwo, managing director of Instant Tar, for allowing us to host our customers at their facility,” said Rocco Lehman, managing director of Ammann South Africa. Instant Tar is one of the first BBBEE companies in South Africa to acquire an Apollo Counter Flow 90 continuous mix asphalt plant, which was one of the focal points on the day, with delegates taken on a technical tour of the unit. The Ammann range extends from rammers and vibratory plates, walk-behind units, trench rollers, single-drum rollers (smooth and padfoot), to tandem and pneumatic rollers and wheeled pavers. The Apollo road construction range is equally comprehensive and includes pavers, pneumatic and compaction rollers, with selected models being phased into South Africa based on market demand. Ammann South Africa remains the direct customer interface for the Apollo asphalt plant series and the Apollo machine range. However, discussions are currently in progress for ELB Equipment to take on the Apollo construction machine line-up alongside the Ammann series. “We are proud

Dealer training day: ELB Equipment sales and after-sales personnel together with Ammann factory specialists and ELB and Ammann management

to be associated with the Ammann brands, which enable us to provide a complete solution for our road contracting customers,” said Desmond van Heerden, divisional director at ELB Equipment. ELB concluded its dealer agreement with Ammann some four years ago and, since then, Van Heerden says the company has achieved excellent market uptake. “Our national sales and after-sales teams went through two days of intensive theoretical and practical training, which was led by Rajesh Chiddarwar,” Van Heerden continued. ELB has seven branches in South Africa, seven dealers in Southern Africa, and subsidiaries in Kenya and Tanzania.

Heavy compaction In delivering his presentation, Leos Tymel underscored the fact that all new Ammann branded machines are defined by what the OEM refers to as ‘solid power DNA’ and based on three key design principles: productivity, ergonomics and serviceability. “Our design philosophy is focused on maximising productivity and cost of ownership,” he

explained. New products planned for global market introduction include an update on Ammann’s line of light tandem rollers within its Heavy Compaction range, with the AXR 23-2 and ARX 26-2 due to launch in June 2018. These will be followed by the ARX 36-2, ARX 40-2 and ARX 45-2 around December 2018. “These Dash 2 models are an evolution of the current series and are a refinement on an already excellent offering,” Tymel said. Keeping place with telematics and Industry 4.0 trends, Ammann is also investing in supplying and supporting remote and real-time management systems that will add greater efficiencies on the job site. These include: • telematic supervision • performance tracking • GPS geo-fencing • proofing the compaction process results on GIS maps • service planning • data logging • preparation of semi-autonomous machines.

Light Compaction Within its Light Compaction range, comprising products that include rammers, plate compactors and walk-behind rollers, Ammann has segmented its offering into three distinct classes, namely Premium, Classic and Value. They each provide exceptional functionality, but vary in terms of technology and price to meet all market requirements. “As with all Ammann products, these have been developed based on feedback from customers globally and our Light Compaction range has been tested rigorously for optimum operator comfort and intensive daily use,” explained Wladimir Drisner. “Future trends being explored include the development of zero-emission machines, alternative compaction technologies and autonomous driving machines,” he explained.

New paver series Alongside its other R&D initiatives, Ammann has announced the roll-out of its updated paving line. “In fact, the South African customer group present here is the first external client focus group to be presented with the new models,” said Bartosz Kozik. “Today, Ammann fields products that cover the full roadbuilding spectrum from gravel compaction through to final asphalt surface preparation,” he explained. The new

line-up comprises 16 models (12 tracked paver derivatives and four wheeled paver models), covering screed widths from 1.2 m to 14 m. Screeds can be either electric or gas-heated. Customers also have the option of selecting vario and rigidframe screeds, as well as high-compaction screeds, all depending on the application. “Based on customer requirements, we have developed two different operating platforms to cater for simplified or advanced controls. In other words, machines can be specified with a conventional control dashboard with easy-to-use toggle switches, or in a more advanced digital format. Either way, the machines have the same support level, quality, fit and finish.” An EcoMode feature provides reduced fuel consumption and noise levels, while Ammann’s patented TruckAssist ensures safe docking and efficient communication via preprogrammed settings. TruckAssist will prove particularly beneficial for less experienced operators.

Rajesh Chiddarwar, Ammann’s regional director for Africa and the Middle East, based in Dubai, addressing delegates at the recent customer day

Apollo “The Ammann Group’s acquisition of Apollo in 2013 has opened up new opportunities for growth, particularly within emerging markets, like South Africa, where its more competitive pricing is proving particularly attractive for SMME contractors,” said Lehman. “The Apollo AP600 paver, for example, has received very favourable reviews.” Based on Ammann South Africa’s analysis of the South African market, a number of new Apollo models will be launched during 2018. Alongside an expanded paving range, developments include the addition of an Apollo compaction line-up planned for introduction in the second quarter. This will include a 10 t single-drum roller. In the meantime, while ELB forges ahead on the machine side of the business, Ammann South Africa is intensifying its focus on the Apollo asphalt segment for its continuous mix plants and batch plants. “Within the past two years, we’ve established a good name for Apollo, which remains the dominant player in India. We’re equally confident that this class-leading brand will continue to grow from strength to strength in South Africa,” Lehman concluded.

Units on display at the recent Ammann South Africa customer day included an Ammann pneumatic roller and an ASC100 roller

The Apollo AP600 paver is produced by the Ammann Group’s wholly owned Indian original equipment manufacturer, Apollo

www.ammann-group.com Instant Tar’s recently acquired Apollo Counter Flow 90 continuous mixing plant

Transport, Logistics, Vehicles & Equipment

Evolution of a legend

racing its roots back to 1873, the name Atlas Copco has become one of the most famous original equipment brands in the mining and construction industries worldwide, constantly evolving over time. Now there’s a new entity and brand following the launch of Epiroc in November 2017. Epiroc is an Atlas Copco Group company. Going back in time, the name Atlas Copco started out in 1873 as Atlas, when the original company was established in Stockholm, Sweden. In the beginning, the

The Atlas Copco HB 4100 hydraulic hammer is a match for excavators in the 40 t to 70 t carrier weight class

company had a specific focus on supplying solutions to Swedish Rail. An ongoing diversification strategy subsequently led to the formation of Nya Aktiebolaget Atlas in 1890, with the renamed company manufacturing three distinct product lines, namely locomotives, commercial central heating systems and machine tools. Another significant milestone included the company’s entry into the pneumatic tools sector in 1901. In 1917, Atlas merged with Diesels Motorer, a manufacturer of marine and stationary diesel engines, and the new company was renamed Atlas Diesel. Several decades later, a new name was sought that would reflect the company’s operations and unite its foreign subsidiaries. Atlas Copco was chosen.

IMIESA January 2018

service and maintenance

advanced machine monitoring

cost-effective flexible funding

Victor Scott (left), business controller, Epiroc, together with Sanjay Ahuja, regional general manager, Epiroc South Africa

Birth of Epiroc One of the most recent developments in the story was the announcement that Atlas Copco had split into two separate international groups of companies, effective from 1 November 2017. Globally, the entire Mining & Rock Excavation Technique business area, together with

Atlas Copco fields a broad range of drilling solutions. Shown here is the SmartROC T40, which is optimally designed for quarrying and construction applications

the Construction Tools Division of Atlas Copco, has become part of Epiroc AB, while the industrial segment remains with Atlas Copco. With Epiroc dedicated to the mining and civil engineering sectors, and Atlas Copco focusing on the industrial market, the split provides the best growth opportunities for both listed companies.

Within the sub-Saharan region, Sanjay Ahuja has taken up the reigns as regional general manager of Epiroc South Africa. Under Ahujaâ&#x20AC;&#x2122;s leadership, Epiroc will build on the solid reputation of Atlas Copco Mining & Rock Excavation Technique and drive the mining and civil engineering businessesÂ forward.

CLOSE TO OUR CUSTOMERS

For your success. ROAD AND MINERAL TECHNOLOGIES. The WIRTGEN GROUP is a one-stop supplier of leading technologies encompassing the entire road construction cycle: From processing, mixing, paving and compaction back to rehabilitation. This is how close to our customers works, in the www.wirtgen-group.com/southafrica WIRTGEN GROUP. Find out more: www.wirtgen-group.com WIRTGEN SOUTH AFRICA (PTY) LTD. 52 Maple Street . Pomona . Kempton Park . 1619 . E-Mail: sales.southafrica@wirtgen-group.com

South Africa_WG_CAMPAIGN_6_BRANDS_220x130.indd 1

12.05.17 11:4

Trenchless News Hammerhead goes underground

Pioneering an industry

www.sastt.org.za

sastt trenchless news

Hammerhead goes underground

geing water infrastructure and associated pipe failures in urban areas throughout Gauteng are leading to a loss of millions of litres of potable water, while, in turn, sewerage leaks silently contaminate waterways and groundwater. Some of these installations range from 50 to over 100 years old, and urgent replacement strategies are therefore required. “Throughout Gauteng, we’ve built our towns and suburbs over these buried

pipelines and now it’s mostly impossible to manually dig trenches and repair or replace pipes,” explains Jan Bouwer from Gokor Construction, a specialist pipe-laying company. “We’re increasingly being called to find ways of replacing these pipes, often situated under layers of underground infrastructure, and below houses, hospitals, roadways and buildings. An illustration of the Hammerhead pipe-bursting replacement process

“One of the ideal approaches for the replacement of large-scale pipes is the application of pipe-bursting technology, an area where Gokor Construction has expert experience. At the business end is a purpose-built Hammerhead HG12 and Hydroguide pipe-bursting system, supplied and supported by local distributor ELB Equipment. This technology allows special tooling to pass through and burst existing pipelines, while simultaneously pulling in a new (often larger diameter) replacement pipe behind it. “In places like Tembisa, we were even able to replace a 70 m stretch in 38 minutes and the entire 170 m of pipeline in just two hours. In cases like this, it ensures the municipality is able to effect speedy upgrades and saves residents the inconvenience of digging up their properties, as well as providing a quick replacement service for water and sanitation,” Bouwer continues. Recent deployments include a project in Hyde Park: an urgent sewer upgrade for the replacement of 742 m of 250 mm pipe with new 350 mm HDPE pipes.

IMIESA January 2018

Trenchless Technology Specialist

Our range of services include: • Pipe Bursting • Horizontal Directional Drilling • Pipe Rehabilitation

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For more information you can contact us: +27 (0)21 761 3474 F +27 (0)21 797 1151 E info@tt-innovations.co.za www.tt-innovations.co.za

sastt trenchless news

Pioneering an industry Back in 1989, Tuboseal pioneered an industr y by offering specialist trenchless pipeline repairs to the City of Cape Town. The problem was clear: pipeline faults located in hard-to-reach or built-up areas caused significant disruptions to society and infrastructure when repaired through conventional methods. Thus, the niche for alternative, trenchless solutions was born.

ity officials back then were, however, faced with another set of challenges: tenders for trenchless pipeline rehabilitation did not exist. All trenchless repairs were done on a request for quote (RFQ) basis, placing severe limitations on the efficiency, scope and project size that could be accommodated in the municipal procurement systems for RFQs. Moreover, the methods and materials used in these modern techniques were foreign to virtually all municipal and consulting engineers responsible for the maintenance of the municipal pipeline networks. Very few local engineers knew the specifications or had the skills required for the successful application of trenchless technologies. During the 1990s, a collaborative process between pioneering trenchless contractors and City of Cape Town officials

culminated in the publication of the first formal tender documents dedicated to trenchless pipeline rehabilitation. These were aimed at institutionalising systematic pipeline rehabilitation through a panel of specialist contractors, which would ensure that pipeline networks were maintained and upgraded using modern technologies in Cape Town â&#x20AC;&#x201C; a major step by the city to create a progressive and cost-effective solution to maintain its pipeline assets. These technologies includedÂ CCTV inspections, pipeline cleaning, pipe-cracking, slip-lining and cured-in-place pipe (CIPP). In the years that followed, Tuboseal played an important role in working with the city to introduce improved specifications and mechanisms to ensure that trenchless technology gained credibility and ubiquitous acceptance throughout the municipal fraternity. Continuously improving tender

Trenchless pipeline rehabilitation solutions Esor Pipe Services has been party to every Southern African pipejacking record set since 1978, and has contributed extensively to bringing the viability of the technique to the civil engineering fraternity in Southern Africa. Now, with the acquisition of TUBOSEAL, Esor Pipe Services offers expert CCTV pipeline inspection, cleaning and rehabilitation solutions. All pipeline work is done with minimal disturbance of the surface area, allowing for the preservation of existing infrastructure. Grout and joint sealing Slip lining Pipe cracking

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sastt trenchless news

BEFORE

documents and specifications ensured that the city was provided with quality workmanship and properly executed solutions that surpass conventional methods, both functionally and commercially. Today, there are dozens of trenchless pipeline rehabilitation tenders in Cape Town and other municipalities throughout South Africa. Most often, they take the form of framework tenders, by which a panel of qualifying contractors is appointed to compete for rehabilitation projects during a two- to three-year period. This allows a great degree of efficiency and flexibility for city officials tasked with maintaining or upgrading pipeline networks. Tuboseal routinely competes on the following term tenders:

AFTER

• Trenchless rehabilitation of water mains through pipe-cracking. This typically entails the replacement of asbestos cement pipelines with HDPE pipelines. Pipelines can be replaced size for size, or upsized where the new HDPE pipe can be of a larger diameter than the original pipe. Minimal excavations are required and the exposure to hazardous asbestos material is minimised. • Trenchless rehabilitation of sewer mains through pipe-cracking and CIPP. This typically entails the relining of damaged sewer pipelines with CIPP liners, which ensures that pipelines are sealed, structurally reinforced and protected against corrosion for a design life upwards of 50 years.

• Trenchless rehabilitation of stormwater systems. This includes a wide range of trenchless techniques to clean, inspect and rehabilitate stormwater systems. While budgets for stormwater pipeline rehabilitation are often very limited, the frontiers of the trenchless technologies are often pushed due to larger pipeline diameters typically present in stormwater systems. Framework tenders for trenchless technologies owe their existence to the entrepreneurship and persistent pioneering work done by Tuboseal and other stakeholders over the last three decades. It has been a privilege to play a role in building an industry so vital to the sustainable provision of basic water and sanitation services in South Africa.

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pipes, pumps & Valves

A turnkey approach to pump installations Pumps and associated electromechanical elements are designed to work as interconnecting systems and need an integrated project management methodology to ensure the best return on investment. APE Pumps shares its thoughts with IMIESA on this topic based on case study experience in the water and wastewater sectors.

oday’s manufacturers and designers have a range of advanced tools like virtual reality modelling software packages that enable engineers to walk through proposed installation layouts with the client. These really add value, and are supported by developments in near-realtime monitoring and remote control that are especially beneficial for ensuring optimum uptime on mechanical interventions when it comes to day-to-day control, condition monitoring and output performance. These tools are invaluable, but they need to be supplemented by experience and the flexibility to develop out-of-the-box techniques that combine new and old approaches in the engineering and associated artisan disciplines. A company that understands and appreciates this is APE Pumps, together with its sister company, Mather+Platt, both of which form part of Indian multinational WPIL Limited. APE celebrated its 65th anniversary in 2017 as an original pump manufacturer. Within the WPIL group

“APE Pumps has been an innovator in the field of fluid transfer solutions since 1952.”

are a range of manufacturing companies that cover the full spectrum of pump, electrical and instrumentation process control. The group catalogue lists some 250 pump products, the largest of which is a pump that weighs around 32 t. Whether for high volume and low pressure, or high pressure and lower volumes, there’s a pump for any industry application, including multistage high-lift mine dewatering pumps.

Project Division In addition to supplying proprietary pump products, APE took the decision to enter the turnkey contracting market as a parallel offering for its customers in South Africa and further afield on the continent. APE is currently ranked as a 7 ME contractor in terms of the Construction Industry Development Board (CIDB) grading system and has now applied to move into the 8 ME category so that it can bid on larger projects of up to R130 million in the local market.

Water treatment upgrades in Africa “APE’s turnkey project services provide a pure construction approach or alternatively a

build, operate and maintain (BOM) service,” explains Richard Harper, project manager, APE. “We regard BOM projects as a major growth area in Africa, especially for water and wastewater treatment installations, whether these are conventional or modular plants.” From the many milestone projects completed to date, two recent ones in Malawi stand out as prime examples of how APE works with its sister companies to provide fit-for-purpose solutions. Completed for the Blantyre Water Board (BWB), the first entailed extensive rehabilitation and renewal works at BWB’s Walker’s Ferry raw water intake and high-lift pumping station; while the second entailed the upgrading of the downstream Chileka pump station. The combined contract value was approximately R200 million. The Chileka project was awarded in April 2013, followed by the Walker’s Ferry contract in October 2013. All works were completed by August 2015 and the defects liability period successfully concluded in September 2016. Overall, the scope required the total

IMIESA January 2018

pipes, pumps & valves

APE project capabilities associated concrete and allied housings. The mechanical, electrical and civils works were all carried out by the group. WPIL designed and manufactured the electrical components, with APE responsible for the mechanical and civil phases, and Mather+Platt for supplying the pumps. To illustrate the scale of the project, the equivalent of 52 km of cabling was installed.

• Pump design and manufacture • Pump technical engineering support • Pump supply and customer aftersales support • Inspection and design engineering • Turnkey projects • Project management • Build, operate and maintain • Mechanical pump installation • Connecting pipework installation • Electrical motor installation • Electrical transformer installation • Electrical panel installation • Operational support and monitoring

Water transfer

refurbishment and replacement of the major pump and valve elements at each location – some dating back to the 1960s – plus transformers and switchgear, and the

At Walker’s Ferry, situated alongside the Shire River some 60 km from Blantyre, raw water is pumped from the river through a water treatment plant via two pipelines to a high-lift pump station. After transferring to the purification plant, then two high-lift pump stations (each housing

WPIL designed and manufactured the electrical components for both the Chileka and Walker’s Ferry pump stations

three pumps in parallel and one on standby), water is transferred at up to 900 m3/h and 500 m head per pump set to Chileka over a distance of around 26 km. From there, the two off pump stations transfer the potable water to two off pipelines, carrying the water a further 13 km to feed reservoirs in the city of Blantyre. The scope of works at Walker’s Ferry was extensive. Critical infrastructure works included the supply and installation of 16 m long common header delivery pipes (800 NB); and the installation and commissioning of eight new raw water

IMIESA January 2018

APE Pumps - Pumps at the heart of Africa Mining Institutions

Water Processing Utilities

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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

Leaders in pump innovation

Regional water and wastewater milestone projects New pump station at Walker’s Ferry water treatment facility

pumpsets, each with a capacity of 1 350 m3/h and a head of 35 m. At Chileka, the scope included the installation of eight new 750 m3/h pump sets, including connection pipework to new common suction and delivery headers. “Precise planning and excellent teamwork all came together despite very demanding deadlines. One of the conditions of the contract was to maintain uninterrupted water supply to the city of Blantyre during all stages of construction. The minimum threshold stipulated was a 70% supply at all times, which was consistently met, and with minimal disruption to the existing supply to the city of Blantyre during the entire course of the project,” Harper states. That equates to between 2 700 m3/h and 3 000 m3/h throughout the approximately 18-month construction programme, and APE had 189 people on-site at peak. “We take a vested interest in our clients’ business by providing a total offering that includes comprehensive after-sales support. We want to enhance their operations by utilising our more than 65 years as an original pump manufacturer, which includes the supply and installation of complete turnkey projects, working locally as well as across Africa. Our work for BWB is a good example, since we’ve been supplying solutions on an ad hoc basis to this client since the 1980s,” Harper concludes.

Date: 2001 Client: Zomba Water Treatment Plant Location: Malawi Project: Turnkey mechanical/electrical, new water treatment plant, upgrading existing plant, new intake structure, pressure-reducing station Date: 2005 Client: Mopani Copper Mines Location: Zambia Project: Supply and installation of 450 NB high-pressure vertical rising main in the mine shaft, including connections on to existing pumpsets. Complete length of 550 m. Removal of the redundant 400 NB pipeline from mine shaft Date: 2011 Client: Lusaka Water and Sewage Company (in joint venture with civil partner RJR Construction Zambia Ltd) Location: Zambia Project: Overhaul of the Iolanda WTW, which delivers the bulk of the potable water to Lusaka. Alongside the civil requirement, the project included the mechanical/instrumentation supply and installation of a new river intake pump station (with APE vertical turbine pumps), as well as the overhaul of the other high-lift pumps and plants Date: 2015 Client: Blantyre Water Board Walker’s Ferry and Chileka pump stations Location: Malawi Project: Rehabilitation and renewal works, raw water intake pump station, and high-lift pump station at Walker’s Ferry and Chileka pump stations, each delivering 4 500 m3/h at 550 m heads, including all new high-pressure pumpsets, and all electrical and civils works. The supply contract was completed in association with APE’s holding company, WPIL Date: Client: Location: Project:

2016 (ongoing) Rand Water Board (Zuikerbosch Pump Station 6) South Africa (Gauteng) SLA maintenance (two-year contract)

Date: Client: Location: Project:

2016 (ongoing) Umgeni Water Board (Wiggens Pump Station & Reservoir Hills) South Africa (KwaZulu-Natal) SLA maintenance (two-year contract)

pipes, pumps & Valves

PVC-O delivers in bulk

ithin the bulk water sector, Sizabantu Piping Systems is leading the way with the manufacture and supply of TOM500 PVC-O (bi-axle orientated PVC) pipes, a revolutionary product that provides a zeromaintenance solution lasting well over 100 years. The pipe series starts with a 110 mm outside diameter (OD) and extends up to 800 mm OD in various pressure ratings. Sizabantu is currently the only manufacturer in Africa and supplies PVC-O pipe up to 800 mm diameter and 25 bar pressure. TOM500 PVC-O has many advantages, when compared to other thermoplastic piping systems, as well as that of metallic pipe materials used on bulk water pipelines, which is achieved through the manufacturing process of PVC-O. When manufacturing TOM500 PVC-O, the first step is to extrude a uPVC proforma pipe, which is approximately half the diameter of the PVC-O pipe required. This proforma pipe is then placed into an oven where it is heated to an optimal temperature, whereafter it enters the mould. In the mould, the proforma pipe is stretched longitudinally and circumferentially to create a molecularly orientated PVC pipe that now provides the ability to achieve larger diameters and much higher pressure classes. This also creates a product that has unsurpassed fatigue resistance over the lifespan of the pipeline, superior impact resistance and flexibility. Based on standard industry specifications, the minimum required strength (MRS) at 50 years for Molecor TOM500 PVC-O is 50 MPa. For U-PVC and M-PVC, the MRS is 25 MPa. Therefore, the strength of Molecor TOM500 PVC-O is 100% greater than that of U-PVC and M-PVC, resulting in increased pipeline lifespan.

Across South Africa, Sizabantu Piping Systems is gaining ground in the high-pressure bulk water supply sector. IMIESA speaks to Michael Nor tier, divisional director at Sizabantu, about market penetration in the Klerksdorp and broader Nor th West region. Competing head-on with steel “Sizabantu Piping Systems, together with our Spanish partners Molecor, introduced TOM500 PVC-O in South Africa in 2013. It has enabled us, for the first time, to compete with traditional metallic pipe materials, such as steel and ductile iron, by offering a product that is available in large diameters (up to 800 mm) and high pressure classes (up to 25 bar). TOM500 PVC-O requires no protection against stray electrical currents, does not require a lining or a coating, has zero corrosion, requires no welding due its socket system and requires virtually no maintenance over the lifetime of the pipeline,” explains Nortier, who heads Sizabantu Piping Systems’ North West/Klerksdorp Division, which has supplied a number of key projects during 2017. Sizabantu Piping Systems’ products are manufactured at a dedicated pipe factory in Richards Bay’s IDZ, which was commissioned in 2016 in a joint venture with Molecor, the developer of Molecor TOM500 PVC-O technology. Sizabantu Piping Systems also supplies a fitting range for its PVC-O pipeline systems. “Since introducing TOM500 PVC-O into Southern Africa in 2013, Sizabantu Piping Systems has supplied more than 1 400 000 m of PVC-O in various sizes and pressure classes. Sizabantu Piping Systems supplied the first 630 mm PVC-O pipe in Southern Africa in

“Sizabantu Piping Systems has supplied solutions to every major water authority and municipality in South Africa.” IMIESA January 2018

pipes, pumps & valves

The advantages of Molecor TOM500 PVC-O • The speed of installation due to the familiar push-fit socket system, compared to steel pipe welding, which requires coating, regular external and internal repair, plus the need to X-ray each joint. • No corrosion. PVC-O pipes have an estimated design life of 100 years, compared to the standard 50-year guideline for conventional PVC and metallic pipes. • Zero maintenance is needed for PVC-O. • Lower celerity enables higher design velocities that increase capacity. • No cathodic protection is required. 2013 and, again, supplied the first 800 mm PVC pipe on the African continent in 2016,” says Nortier.

Fast-tracking projects Due to the advantages that PVC-O offers the market, it has become a popular alternative. A further key advantage is that there is no specialised construction required. The system can, therefore, be installed by contractors who have experience in the laying of PVC pipe systems, as opposed to steel pipelines where there is some expertise required. This has resulted in some large 800 mm PVC-O pipelines being installed across South Africa, most notably for eMalahleni, Cape Town, Nandoni and, most recently, the Alabama/ Jouberton Bulk Water supply line for the

City of Matlosana Local Municipality. The Alabama/Jouberton Bulk Water supply line consisted of 800 mm diameter PN20 PVC-O pipe for a 2.5 km section in Phase 1. The total envisaged length will be 14 km, with the remaining sections to be completed in Phase 2 and 3, subject to available funding and tender approval. The contractor responsible for Phase 1 was KD Civils and the consulting engineer was NEP Consulting. The original contract period was scheduled to run over 10 months. Due to the ease of installation of TOM500 PVC-O, and the effortless handling of the pipe, KD Civils completed the project in two months. This underscores the advantages that TOM500 PVC-O offers for the contractor, consulting engineer and client. “Bulk water pipelines have traditionally been dominated by the larger construction companies, who have the experience and expertise to install metallic pipes, do the required welding of the pipe with specialist welders, and carry out the X-raying of welds and protection of the pipelines against stray electrical currents,” Nortier continues. “However, by choosing TOM500 PVC-O, barriers to entry for SMME contractors have been virtually removed. The use of TOM500 PVC-O also promotes labour-intensive construction techniques and, depending on the size, PVC-O pipes can be positioned by hand and only require small plant to assist with installation.” Additional advantages of TOM500 PVC-O include better hydraulic performance, lower

PVC-O pipe lengths are significantly lighter than their metallic alternatives. This means that PVC-O pipes can be laid in the trench using small plant as opposed to a crane or a specialised pipe-laying machine

IMIESA January 2018

pumping costs, and better surge or water hammer capabilities. The manufacturing process of TOM500 PVC-O is also substantially more environmentally friendly, leaving a smaller carbon footprint. During 2017, Sizabantu Piping Systems' North West Division has also supplied the following TOM500 PVC-O projects: • 7 500 m 630 mm PN12 TOM500 PVC-O – bulk water supply for Ikageng • 36 000 m 400 mm PN16 and PN20 TOM500 PVC-O – Wesselsbron bulk water supply. “We are also receiving enquiries from municipalities for the replacement of asbestos pipes with TOM500 PVC-O. In Wolmaransstad, for example, SPS is supplying 110 mm and 315 mm pipes as part of an ongoing infrastructure upgrade,” he explains. New projects going into January 2018 include a supply contract for the Taung bulk water supply scheme situated close to Vryburg in the North West. This project will consist of approximately 15 000 m of 355 mm PN25 TOM500 PVC-O. “PVC-O is an exciting new technology, with current research and development initiatives under way to produce diameters of 1 000 mm and 1 200 mm. Our extensive investment in the Richards Bay factory also underscores the fact that Sizabantu Piping Systems is committed to meeting the longterm needs of South Africa’s bulk water supply, and eradicating leaks and water wastage. Aside from new infrastructure rollouts, the county has a massive maintenance backlog and a major pipe leakage challenge, and this is where we believe plastic pipes are the answer,” Nortier concludes.

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INNOVATIVE INFRASTRUCTURE SOLUTIONS

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31st Oct - 2nd Nov 2018 Boardwalk Hotel Convention Centre

2018

THE FUTURE OF WASTE MANAGMENT Imagine your rubbish bin telling municipal authorities when it is full and needs to be collected, and municipal waste collection operations being able to optimise their fleet fuel consumption according to this data thanks to predefined schedules. This is not a far-fetched scenario thanks to the internet of things (IoT).

he future will see smart African cities that are able to achieve zero waste, improve ser vices to citizens and reduce municipalities’ operational costs thanks to smarter, more efficient waste collection systems. “The global technology revolution is transforming how we think about waste management,” says Nick Mannie, client manager: Government RSA, Aurecon. “The influx of people to the extended urban areas of poverty surrounding African cities and the consumption of products are only some of the things that are fuelling waste generation across the continent.” With higher population growth rates and increased consumer demands and consumption, a new connected approach is required. The global shaping of technology means that waste management practices and systems can be enhanced for government, service providers and consumers. A crucial part of this revolution is making sure that poor and developing countries also tap into

the changes and trends in technology that are emerging in the waste management industry, as the population growth in developing countries, and in Africa specifically, is the largest in the world. “IoT can help us provide integrated, timely and sustainable solutions. We’re moving towards creating a circular economy for waste management with the help of technology, which includes a cradle-to-cradle approach as well as relooking at how we can reuse and recycle products, components and materials to reduce the use of natural resources,” says Mannie. Globally, the smart waste collection technology industry is still in its infancy, but the use of IoT-enabled sensors and smart bins is already gaining traction.

Smart waste management strategies of the future Smart cities of the future will integrate technology, connectivity and communication to share data that can help with several waste management processes, such as optimising the routes that garbage disposal vehicles

follow for waste collection and removal, together with automating operations through sensors on garbage bins signalling that collection is needed when the bins are full. “The data that this automated process generates can transmit information in real time to a control centre to guide the driver on routes to take, collection points, bins to uplift, traffic situations, estimated time for collection, and provide analytical information on this process to determine the cost of waste collection per kilometre. After the bins are collected, information on the waste types can be analysed to determine, for example, which bins need to go to recycling centres or to disposal sites. The information can be used to clients them and provide them with invoicing information simultaneously via the cloud. This is already happening on small scales in other parts of the world and it’s time for African countries to follow suit,” explains Mannie.

Alternative waste treatment options Some of the alternative waste treatment options that are currently being used in the

did you know? In Sharjah in the United Arab Emirates, 10 solar-powered rubbish bins with built-in Wi-Fi technology have been installed across the city

IMIESA January 2018

In Helsinki, Finland, the world’s first robotic waste-sorting plant is being piloted and tested. The robots can detect recyclables among other rubbish

SOLID WASTE MANAGEMENT

“The global technology revolution is transforming how we think about waste management.” developed world and could be useful in African countries include the following: •M echanical biological treatment: Mechanical biological treatment combines both mechanical and biological treatment methods supported by a combination of pretreatment sorting techniques as well as a selection of emissions and qualitycontrol techniques. •A naerobic digestion: The decomposition of organic waste in the absence of oxygen. • Incineration: The mass burning of waste to reduce the volume of waste and enable the production of energy in the form of electricity and/or heat. • In-vessel composting: A way of accelerating the composting process with an enclosed environment. • Open-windrow composting: Composting is the simplest form of biological treatment and is suitable for the treatment of some source-segregated

biological or organic/putrescible waste streams. • Clean material recovery facility: A clean material recycling facility is suitable for the processing of dr y, mixed recyclables that are separated at source. • Dirty material recovery facility: A dirty material recycling facility involves separating valuable materials from a mixed ‘dirty’ waste stream. • Landfill gas-to-energy: Landfilling is the mass disposal of waste to landfill under controlled circumstances. Energy can be recovered from the waste through collection of gases resulting from the natural decomposition of waste. • Gasification: A thermal treatment wherein pretreated waste is exposed to very high temperatures in an environment with little oxygen. • Pyrolysis: A thermal degradation of a substance at high temperatures in the absence of oxygen.

• Plasma gasification: A variation on gasification that uses a plasma torch/ arc to produce gas. • Mechanical heat treatment: A mechanical sorting technique combined with thermal heat treatment processing. Waste management suppliers and experts need to work towards fostering a collaborative approach to finding solutions for the challenges that confront government. “Government faces technical, financial, institutional and social restrictions that aren’t easy to overcome when considering the future of waste management. Raising awareness of the looming threats and developing finance schemes are some of the steps we need to take to move in the right direction,” concludes Mannie.

Specialist Waste Management Consultants

JPCE

Tel: +27 21 982 6570

www.jpce.co.za

60 Bracken Street, Protea Heights, Brackenfell, 7560 P O Box 931, Brackenfell, 7561

building

Revitalising Kliptown

he Walter Sisulu Square of Dedication, completed in July 2017, was commissioned by the Johannesburg Development Agency (JDA) and forms part of the Kliptown Public Environment Upgrade. A distinctive feature of this imposing landmark is the 24 000 m2 of paving elements that form a key part of the square’s overall composition. “The regeneration of this vibrant area, steeped in cultural history, is a fantastic undertaking by the JDA,” comments Musa Shangase, commercial director at Corobrik. “The finished design works well to complement the existing structures and, among the many product benefits of pavers, the durability will minimise any future maintenance or replacement costs for the city.”

Kliptown is an area of historical significance, being the site on which the Freedom Charter was signed in 1955. “Our task was to reinvigorate the square and surrounding streets, including historic trading street Union Avenue,” explains Andrew Luke, director of GAPP Architects & Urban Designers. Working with GAPP on the project was Akweni Group, project manager; Bophelong Construction, contractor; and GMH/Tswelelo Consulting Engineers. The Walter Sisulu Square of Dedication is framed by two, large parallel buildings. The central square features the Freedom Charter Monument, which had fallen into a state of disrepair. To revitalise this area, new public open space was created, as well as sidewalks,

The Walter Sisulu Square of Dedication as seen through the pillars of the Freedom Charter Monument (Source: GAPP Architects & Urban Designers)

A bird’s-eye view of the Walter Sisulu Square of Dedication, which is situated in Soweto, Johannesburg (Source: GAPP Architects & Urban Designers)

street furniture, lighting, trees, public transport shelters and public art to further commemorate the historical significance of the square. Selecting 400 000 of Corobrik’s Burgundy pavers and 66 120 of the Cedarberg pavers, GAPP breathed new life into the square, as well as Union Avenue and Square Road, tying the entire area together with a network of pedestrian paths for increased access. “Paving provides for a really high-quality environment, with the herringbone pattern used here to create a strong, aesthetically interesting street surface,” Luke continues. “The interplay between colour and texture accommodates the various users, provides directional guidance, highlights key features in the public space and demarcates public and private thresholds. The variation in colour was also used to demarcate areas for traders, pedestrians and display space for shopkeepers.”

www.corobrik.co.za

IMIESA January 2018

cement & concrete

New developments in concrete technology Concrete’s endless flexibility enables designers and contractors to form purpose-built structures and there are many evolving application techniques. By Bryan Perrie

hile there have been changes and improvements in the performance and method of manufacture of concrete’s constituent materials, there have also been significant developments in concrete technology. These have been either in the method of construction or the performance of the finished structure. The most important of these developments are discussed below.

High-strength concrete The development of superplasticisers has permitted the production of concrete with very low waterto-cement ratios, but without a loss of workability. This has resulted in substantial increases in compressive strength. The

Bryan Perrie, managing director, The Concrete Institute

IMIESA January 2018

American Society for Testing and Materials defines high-strength concrete as having a design compressive strength of over 55 MPa. Strengths as high as 120 MPa are commercially available in the USA. Highstrength concrete has led to an increase in the construction of high-rise buildings using concrete, as it is often more cost effective than the steel-framed equivalent. High-strength concrete also provides an economical alternative to bulky columns in conventional concrete for the lower floors of high-rise buildings.

Self-compacting concrete The use of high-strength concrete with dense steel reinforcement has resulted in stronger and more ductile structures. Construction of such structures requires the concrete to be highly workable, but not to segregate or bleed excessively. In the 1970s and 1980s, researchers developed high-workability concrete mixes. Self-compacting or self-consolidating concrete (SCC) can be defined as a flowing concrete that can be cast into place without the need for compaction to form a product free of segregation, honeycombing and

Self-compacting concrete has been used by readymix concrete plants in South Africa, most notably for the filling of the steel pylons on the Nelson Mandela Bridge in Johannesburg

blowholes. Necessary ingredients for SCC include superplasticisers, viscosity-modifying admixtures and fine mineral admixtures. The fine mineral addition is often fly ash or ground limestone. Although the admixtures are expensive, the ability to place concrete rapidly and without compactive effort can result in savings that exceed the increased cost. Most SCC is used primarily in precast concrete plants but it has been used by readymix concrete plants in South Africa, most notably for the filling of the steel pylons on the Nelson Mandela Bridge in Johannesburg.

High-performance concrete High-performance concrete (HPC) possesses high workability, high strength and high durability. The American Concrete Institute has defined HPC as a concrete in which certain characteristics are developed for a

cement & concrete

particular application and environment. The primary applications for HPC have been for structures requiring long service lives, such as oil drilling platforms, long-span bridges and parking structures. However, HPC still requires good construction practice and good curing to deliver high performance.

A downstream view of the roller-compacted Grove Dam with its stepped spillway

Shrinkage-compensating concrete Shrinkage-compensating concrete is made with an expansive cement, which, when properly restrained by reinforcement or other means, will expand by an amount equal to or slightly greater than the anticipated drying shrinkage. Ideally, a residual compression will remain in the concrete, reducing the risk of shrinkage cracking. Care must be taken to ensure that continuous wet curing is provided for at least seven days after placing to ensure that the expansion develops. Care also needs to be taken to prevent plastic shrinkageÂ cracking. Expansive cements have been used to produce both shrinkage-compensating and self-stressing concretes for use in slabs, pavements, prestressed beams and roofs.

Fibre-reinforced concrete Conventional concrete containing discontinuous discrete fibres is called fibre-reinforced concrete. Fibres of various shapes and sizes produced from steel, plastic, glass, carbon and natural materials have been used. But for any reinforcement to be effective, it must be stiffer than the concrete matrix that it is reinforcing. Generally, the less-stiff fibres (made from plastic and natural materials) only offer benefits in improving the tensile

strength of plastic and semi-hardened concrete and are, therefore, mainly used to reduce plastic shrinkage and plastic settlement cracking. The stiffer fibres improve both the tensile strength and the toughness of hardened concrete. The most widely used stiff fibre is steel. The shape and length of the fibres play a role in their effectiveness in improving the properties of the concrete. The use of fibres in concrete can have a marked effect on the

The development of RCC has caused a major shift in the practice of constructing mass concrete dams workability of the concrete. This needs to be considered in the mix proportioning of fibre-reinforced concretes. Fibre-reinforced concrete has been used for precast panels, airfield and highway pavements, industrial floors, and in sprayed concrete for slope stability and underground mining applications.

Polymer-modified concrete Concrete containing polymers can be classified into three categories: • polymer concrete, which is formed by polymerising a mixture of a monomer and an aggregate • polymer-modified concrete, which is conventional concrete in which a part of the mixing water is replaced by a polymer emulsion • polymer-impregnated concrete, which is produced by impregnating a hardened Portland

cement concrete with a monomer and subsequently polymerising it in situ. Polymer concretes are often used for overlays on concrete floors as they bond strongly to old concrete and resist the entry of water and other aggressive solutions.

Roller-compacted concrete Roller-compacted concrete (RCC) is, as its name implies, concrete compacted by roller. It therefore differs from conventional concrete in its consistency, as it must support rollers in an unhardened state. The concrete mix must be dry enough to prevent sinking of the roller, but still allow for full compaction. RCC can be

used at low strengths for dams or conventional strength for roads and pavements. The development of RCC has caused a major shift in the practice of constructing mass concrete dams, which can now be finished as much as a year or two earlier than conventional mass concrete dams. Up to 18 000 m3 can be placed in one day. Extenders are extensively used in RCC to reduce costs and control temperature rises. RCC is constructed similarly to layerworks in road construction and using similar equipment. It is extensively used for concrete pavements, particularly in Canada and Spain.

Erratum: IMIESA October 2017 In the article ‘RMC is a job creator’, the captions and photo credits were reversed and should have been attributed as follows: TOP The construction of the RMC Mndwaka Dam provided abundant employment for residents of the isolated Wild Coast villages surrounding the dam (Source: CSSA) BOTTOM Construction of rubble masonry concrete dams and bridges is very labour-intensive (Source: Dr Rod Rankine)

IMIESA January 2018

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cement & concrete

hen Sujean Proper ty Investments acquired 120Â 000 m2 of land surrounding the old disused Serepta railway bridge in Bellville South, Cape Town, it was required to completely refurbish the bridge prior to redeveloping the area into a modern industrial mega park. Consulting engineers from Aurecon and Ingerop were subsequently appointed to devise a lasting design

Specialty concrete chemical formulations provide a new lease on life for an ageing rail link

Strengthening the Serepta Bridge intervention, with Exeo Kholeka awarded the construction contract. Sika products were specified for all phases. Prior to filling internal voids and cracks in the bridge walls, Sikadur-AP was used to close all surface cracks. An allpurpose, two-component epoxy paste adhesive, Sikadur-AP provides excellent adhesion on a wide variety of materials, and is ideally suited for vertical and overhead applications. With a convenient 1:1 mixing ratio, it is easy to apply on either dry or damp surfaces and provides high abrasion resistance. To treat spalling on the bridge, SikaTop Armatec-110 EpoCem was applied. As a cementitious, epoxy-resin-compensated,

three-component coating material with corrosion inhibitor, SikaTop Armatec-110 EpoCem meets the requirement of EN 1504-7 and is certified for application under dynamic load conditions. Product advantages include extended open times for repair mortars, excellent adhesion to concrete and steel, plus good resistance to water and chlorideÂ penetration.

Vertical applications Thick layer concrete was repaired using Sika MonoTop-615 HB, a high-build, cementitious, polymer-modified, one-component repair and reprofiling mortar, containing silica fume and Ferrogard corrosion inhibitor. With excellent workability characteristics, as well as excellent thixotropic behaviour, Sika MonoTop-615 HB

A strong foundation for infrastructure success

is especially suited for vertical or overhead applications and provides good resistance to water and chloride penetration. Prior to waterproofing the bridge, injection specialist Dampmen was subcontracted to inject Sikadur-52 ZA, a twopart, solvent-free, low-viscosity injection liquid, via ports into the bridge structure. Sikadur-52 ZA forms an effective barrier against water infiltration and corrosion-promoting media, and also structurally bonds concrete sections together. The product is suitable for use on dry or damp surfaces, even in low temperatures, and hardens without shrinkage. Some cracks in the bridge were so large that SikaGrout-212, a onecomponent, ready-to-mix, free-flowing, shrinkage-compensated expansive grout, was used prior to injecting Sikadur-52 ZA. The subcontractor then coated the entire bridge with Sikalastic-152, a two-component, fibre-reinforced mortar based on cement modified with special alkali-resistant polymers containing fine particle size, selected aggregates and adequate additives.

Plate installation

I15457

To cover all their bases and ensure absolute structural integrity of the bridge, the engineers specified Sika Carbodur S512 plates to be bonded on to the interior vertical walls using Sikadur-30, a thixotropic, structural two-part adhesive based on a combination of epoxy resins and special filler. Dampmen attached approximately fifty 4.2 m lengths of Sika Carbodur S512 plates to the walls. Sika Carbodur plates are pultruded carbon-fibre-reinforced polymer laminates designed for strengthening concrete, timber, masonry, steel and reinforced polymer structures. They are used to improve, increase or repair the performance and resistance of structures for increased load-carrying capacity, damage to structural elements, improvement of serviceability and durability, change of the structural system, resistance to possible events such as earthquakes, and to repair design or construction defects. The high-strength laminates are non-corroding, provide excellent durability and fatigue resistance, and are supplied in lightweight rolls that are easily transportedÂ and installed. The combination of all these solutions will significantly increase the longevity of the old Serepta Bridge.

Some cracks were so big that SikaGrout-212 was used prior to injecting Sikadur-52 ZA

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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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

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