IMIESA July 2019 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

Mather+Platt

Proudly South African pumps

Green Buildings

Sustainability is not an option

Asphalt Technology Putting RA to work

ISSN 0257 1978

V o l u m e 4 4 N o . 7 • J u l y 2 0 1 9 • R 5 5 . 0 0 ( i n c l . VAT )

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volume 44 no. 7 JULY 2019

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

INSIDE

infrastructure development • maintenance • service delivery

Mather+Platt

Proudly South African pumps

Green Buildings

Sustainability is not an option

Asphalt Technology Putting RA to work

ISSN 0257 1978

V o l u m e 4 4 N o . 7 • J u l y 2 0 1 9 • R 5 0 . 0 0 ( i n c l . VAT )

The year 2019 marks a key milestone for APE Pumps and Mather+Platt, as the Group celebrates its 68th year in business, underscoring its design, manufacturing and project management capabilities. P6

Roads & Bridges Putting RA to work

Water & Wastewater UV LED curing: the future of pipe rehab

Tshwane embarks on biogas initiative

Dams & Water Storage Regulars Editor’s comment

President’s comment

Index to advertisers

Roads & Bridges Putting RA to work

Sydney bridge designed in SA

SHE excellence in bitumen

Green Building Sustainability in buildings is not an option

Empowerment Promoting diversity and inclusion

Municipal Feature Turning Joburg into a construction site

Building Materials 34

Waste Management

Water & Wastewater Tshwane embarks on biogas initiative

Environmental Engineering Countering overturning

Municipal Feature | Johannesburg Turning Joburg into a construction site

Elevated tank delivery

PET bottles crest SA’s recycling wave

Industry Opinion Causes and solutions to counter site invasions

Investing in brick

Cover Story Proudly South African pumps

Climate change impacts on dams and water security

Cement & Concrete Fulton Awards: Concrete masterpieces

Concrete health and protection

Smoothing out imperfections

Flood control with permeable paving

Saving space with CRB

Transport, Logistics, Vehicles & Equipment Pedestrian roller partnership concluded

Accurate milling, perfect paving

Environmental Engineering Countering overturning

EDITOR’S COMMENT

Moving forward together

MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson JOURNALIST Nombulelo Manyana Head OF DESIGN Beren Bauermeister Chief SUB-EDITOR Tristan Snijders ContributorS Songo Didiza, Andrew Geel, Randeer Kasserchun, Lisa Reynolds, Peter Townshend OPERATIONS & PRODUCTION MANAGER Antois-Leigh Botma Production COORDINATOR Jacqueline Modise financial MANAGER Andrew Lobban BOOKKEEPER Tonya Hebenton DISTRIBUTION MANAGER Nomsa Masina Distribution coordinator Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za Printers Paarl Media KZN +27 (0)31 714 4700 ___________________________________________________

overnment’s decision to adopt a district-based approach to municipal deliver y aims to greatly improve efficiencies, both in terms of fiscal management and infrastructure service execution. Announced by President Cyril Ramaphosa during the State of the Nation Address (SONA), the focus will be directed at all eight metros, as well as the 44 district municipalities within South Africa. It’s a critical step in ensuring that municipalities have the skills and funds in place to function effectively. Suppor ting these initiatives is National Treasury’s recent implementation of cost containment regulations, with the intention of effecting improved municipal governance. In terms of the regulations, effective from 1 July 2019, every municipality or municipal entity is required to have an approved costcontainment policy in place, which needs to be reviewed annually. By ensuring that expenditure is accurately monitored and tracked, the regulations will go a long way in reducing wasteful expenditure. This has been a recurring issue in recent Auditor General reports on municipal performance. Given the current infrastructure backlog, the weakened state of the construction sector, and the economy in general, it’s even more essential that public funds are correctly allocated and expended. Within the infrastructure space, adopting more sustainable construction methods is definitely part of the solution in lowering costs, while simultaneously reducing environmental impacts. Within the roads segment, a prime example is the use of recycled asphalt, while a greater understanding and acceptance of green building systems is essential in the property sector. The latter has benefits in terms of lowering our carbon footprint, while passing on energy savings that reduce the demand on an already pressurised grid.

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

Publisher Jacques Breytenbach Novus Print (Pty) Ltd t/a 3S Media 46 Milkyway Avenue, Frankenwald, 2090 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 www.3smedia.co.za Annual subscription: R600.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2019. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Email: imesakzn@imesa.org.za NORTHERN PROVINCES Secretary: Ollah Mthembu Tel: +27 (0)82 823 7104 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Email: imesasck@imesa.org.za

Buy local Another positive point raised at SONA is a call to action for all South Africans to buy local. That’s key to the revitalisation of our industries, lowering the cost of imports and increasing export opportunities, led by the Department of Trade and Industry. One of the SONA objectives is to improve the ease of doing business in South Africa as a means of unlocking local private sector funding and spurring foreign direct investment (FDI). The competition for FDI inflows is intensifying among African nations. According to the World Bank Group’s Doing Business 2019 survey, Mauritius holds pole position within sub-Saharan African; South Africa ranks 82nd. The upside is that South Africa remains the second highest ranked country after Egypt for FDI inflows, based on the United Nations’ World Investment Report 2019. Comparing the 2017 and 2018 periods, FDI for South Africa was recorded at US$2 billion (R28.6 billion) and $5.3 billion (R75.8 billion), respectively. Expanding South Africa’s special economic zones (SEZs) will be a key element in sustaining and attracting additional funding. A prime example is the ongoing establishment of the OR Tambo SEZ in Gauteng, which holds major potential. Backed by the commitment of the Public-Private Growth Initiative, and enabled by improved municipal deliver y, the medium- to longer-term outlook for construction remains positive. It all boils down to investing in infrastructure development.

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 Email: imesafsnc@imesa.org.za

Alastair 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.

@infrastructure4 struct www.infra

urenews.co

.za

Infrastructure News

IMESA magazine The official of the Institute Engineerin g of Municipal Africa of Southern

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.

infrast ructure

develop ment

• mainten

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delivery

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Proud n South Africa s pump

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Sustain ability

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1978 ISSN 0257

) ( i n c l . VAT • R50.00 July 2019 4 No. 7 • Vo l u m e 4

Cover opportunity

In each issue, IMIESA offers advertisers the opportunity to get to the front of the line by placing a company, product or service on the front cover of the journal. Buying this position will afford the advertiser the cover story and maximum exposure. For more information on cover bookings, contact Jenny Miller on +27 (0)11 467 6223. IMIESA July 2019

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President’s comment

IMESA

Municipalities are key enablers The State of the Nation Address (SONA) 2019, delivered by President Cyril Ramaphosa, placed major emphasis on the need to accelerate infrastructure rollouts to create an enabling environment for investment.

inding solutions to the challenges faced at Eskom, and the current risk it poses to the economy, is top of the agenda. Revitalisation plans include the appointment of a chief restructuring officer and the earlier reprioritisation of the R230 billion in fiscal support earmarked for the stateowned enterprise over the next 10 years. A key factor in the process is the need to find solutions to the debt owed by municipalities, as well as individual users. The central theme was about improving efficiencies, and creating a far more enabling framework for doing business in South Africa within the current Industry 4.0 environment. The rapid pace of technology in all spheres of industry now provides unprecedented opportunities for improved competitiveness in terms of programme management and project execution. For this reason, it’s vital that South Africa keeps up to date with the current trends in meeting the country’s Vision 2030 objectives. SONA 2019 identified the need to focus on seven priority areas. At the top of the list is economic transformation and job creation; another key priority is spatial integration, human settlements and local government. In both of these, we can play an enabling role as municipal managers and municipal engineers in implementing basic services and critical infrastructure that serve as socioeconomic catalysts. Government’s strategy is to ensure that municipalities are adequately resourced and supported in the quest to speed up service delivery. Taking a district-based approach, 44 districts and the eight metros have been identified in the first phase.

Investment framework President Ramaphosa stated at SONA that of the R300 billion identified at government’s inaugural 2018 Investment Conference, “Just over R250 billion worth of projects has entered the implementation phase.” Via the Public-Private Growth Initiative, the private sector has, to date, also committed to investing around R840 billion over the next five years. A total of 43 projects have been identified across 19 sectors, which are expected to create some 155 000 jobs. The anticipated implementation of government’s Infrastructure Fund will also add a welcome boost to local construction activity. This will be managed by the Development Bank of Southern Africa, with an oversight role played by the Department of Public Works and Infrastructure. Government has apportioned R100 billion to seed the fund.

patterns, which includes ageing populations and urbanisation trends. The one constant is change. Some of IFME’s medium-term priorities include creating a content deliver y platform for professional development and establishing the right tools for project management at local government level. IFME’s mission is to facilitate international exchanges in public works and municipal engineering, thereby growing and strengthening member countr y associations. It’s a mission shared by IMESA, as we fulfil our mandate to be the best when it comes to local delivery. We build world-class infrastructure projects that receive international acclaim. We just need to speed up the process of implementation.

International benchmarks As a member of the International Federation of Municipal Engineering (IFME), IMESA works closely with its global counterparts to ensure that our local standards are aligned with global best practices. As South Africa’s representative on the IFME board, I recently took part in a series of strategic planning workshops during our June 2019 meeting in France. It’s refreshing to note that member countries face common challenges. That makes knowledge sharing critical to identifying sustainable solutions. The three issues identified by IFME in terms of future impacts are: the exponential evolution of technology; how globalisation is changing our world; and a shift in demographic

Randeer Kasserchun, president, IMESA

IMIESA July 2019

Cover story

Proudly South African pumps

The year 2019 marks a key milestone for APE Pumps and Mather+Platt, as the Group celebrates its 68th year in business, underscoring its design, manufacturing and project management capabilities.

ince inception in 1952, APE Pumps has been an innovator in the field of fluid transfer solutions across industries that include water utilities, mining, petrochemicals and the energy sector. This is a comprehensive skill set that is aligned with its sister company, Mather+Platt, which traces its own heritage back to England in 1845. “As an OEM, we’ve always prided ourselves on being at the forefront of the market through home-grown product innovation,” says John Montgomery, general manager, APE Pumps and Mather+Platt. “We focus on continually repositioning our brands for sustained growth within a highly competitive market. This includes the Group’s ability to meet the Department of Trade and Industry’s local content provision for pumps. Our products are designed, cast and assembled in South Africa and we are 100% compliant.” In May 2019, the Group took this a step further by becoming a member of the Proudly South African family. “Carrying the Proudly South African mark underscores our commitment to local industry and government’s goal of tackling the triple challenge of inequality, unemployment and poverty. It also aligns us with current and future clients who are already members and

IMIESA July 2019

dedicated to building a better future for every South African,” says Montgomery. The manufacturing sector is one of the most important drivers in revitalising the South African economy. “Like most sectors, manufacturing has been in decline and a key contributing factor has been the rise in imported goods. We need to combat this,” he continues. The end goal of Proudly South African is to ensure that private and public sector procurement is spent on locally produced goods and services. This will help to foster much-needed employment and the creation and sustainability of SMMEs, seen as a catalyst for socio-economic transformation. To become a Proudly South African member, companies need to meet the minimum local content threshold, adhere to set quality and environmental standards, and demonstrate fair labour practices. “As a new Proudly South African ambassador, our role is to help inform our industry about the critical importance of boosting domestic capacity,” Montgomery explains. “We’d like to encourage current and future clients to visit our Germiston facility to experience the energy and innovation that drive our current and future vision. This all hinges on our investment in plant upgrades

and equipment, and our diversified workforce. Our training and development focus is one of the main reasons we’re market leaders today,” he expands. The Group is an accredited MerSETA trainer, and in addition to pattern- and mould-makers, prepares apprentices for qualification as boilermakers and fitters and turners, among other trades. The Group recently increased its service and repair facility by around 5 000 m2 to cater for current and future expansion. This includes offering an operations and maintenance service for clients.

Product leadership Backed by a history of research and development dating back to the first Industrial Revolution, the Group is now firmly entrenched in today’s Industry 4.0 environment. Mather+Platt manufactures horizontal multistage pumps designed for highpressure applications, and split-case pumps chiefly for high volumes. In turn, APE Pumps specialises in the design and manufacture of vertical industrial turbine pumps, split-case and end-suction

pumps for most industries. APE Pumps and Mather+Platt also provide an installation and commissioning service. A prime example of proven product durability in the power generation sector is the CW concrete volute vertical end-suction pump series. Designed for cooling water applications, APE Pumps’ CW units are renowned for their high efficiencies. During 2018, the Group was responsible for overseeing the maintenance of six 1.6 m diameter CW units at Lethabo Power Station. These units were originally installed by APE Pumps in 1981. Each pump has the capacity to supply up to 7 350 ℓ/s of water at a head of 21.5 m. When inspected, four of the pumps were still in excellent condition after 37 years of continuous operation; the remaining two showed signs of wear and were shipped to APE Pumps’ Germiston facility for refurbishment.

Malawi bulk water upgrade Within the utilities arena, the work carried out by APE Pumps for the Blantyre Water Board (BWB) in Malawi is a classic example of how the Group executes turnkey projects. Divided into two contracts, the scope entailed the design, supply and installation of a range of solutions led by APE’s Projects Division. The first project entailed rehabilitation and renewal works at BWB’s Walker’s Ferry raw water intake and high-lift pumping station; while

the second involved the upgrading of the downstream Chileka pump station – both vital installations in terms of ensuring Blantyre’s water security. At Walker’s Ferry, situated alongside the Shire River some 40 km from Blantyre, water is pumped through a water treatment plant via two pipelines to a high-lift pump station. After transferring to the purification plant, two further pump stations, each housing three pumps in parallel and one on standby, transfer the water at up to 750 m3/h and 550 m head to Chileka over a distance of around 26 km. From there, pipelines carry 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 six new raw water pump sets, each with a capacity of 750 m3/h and a head of 350 m. At Chileka, the scope included the installation of eight new 750 m3/h pump sets, including connection pipework to existing common suction and delivery headers.

thanks to its wooden patternmaker expertise. In fact, APE is one of the few companies in South Africa that provides apprenticeship training in this field and it’s an essential one, especially when tackling retrofits on pumps that no longer have available design drawings to work from. Standard, customised or retrofitted, the Group has a solution for every fluid transfer application, with future performance backed by OEM parts and comprehensive after-sales and warranty programmes. Since inception in 1952, the Group has never discontinued a product, so spares are always available. “We strongly discourage the use of non-OEM replicated parts, and especially pirate parts, since this has serious implications for overall system performance,” says Montgomery. “It’s rare for replicated parts to exactly fit the original OEM tolerance specifications,” he adds. “By supporting our OEM parts and services, clients are also buying local, and that’s Proudly South African,” Montgomery concludes.

Integrated solutions Whatever the age or date of installation, APE has the ability to design, fabricate and retrofit. Not an easy task, but one it can successfully deliver

www.matherandplatt.com

IMIESA July 2019

Industry Opinion

Causes and solutions to counter site invasions IMIESA speaks to Webster Mfebe, CEO, South African Forum of Civil Engineering Contractors (SAFCEC), about the escalation in illegal work stoppages on construction projects, and the motives behind them.

he escalation in project work stoppages threatens the wellbeing of the construction industry at a time when this sector is experiencing a particularly severe contraction in tender awards. Civil engineering, together with its allied multidisciplinary engineering branches, is primarily focused on maintaining and establishing infrastructure services, so when the pipeline of government tender work dries up, this has a devastating ripple effect on the industry, the communities it serves, and the overall economy. “When affected communities face service interruptions, such as sewer, water and electrical outages, the official process is to lobby their municipalities for a solution,” says Mfebe. “However, when months pass and nothing has been done to remedy the situation, frustrations can and do lead to violent protests out of sheer frustration, plus legitimate concerns about health and safety.” Where works are in progress, Mfebe points out that there’s also a perception that members of the community should be par t of the process. Provision is made for this within the legislation, but

IMIESA July 2019

awarding subcontractor work, whether via the Expanded Public Works Programme (EPWP) or the municipal tender award framework, must still follow a formal due diligence process. “A high percentage of members in these affected communities are unemployed: they then see the gap in infrastructure deliver y as an oppor tunity to become employed, or self-employed as an SMME,” he continues. “However, a key concern for us is the perception that construction is an open industry, with low-hanging fruit and unlimited barriers to entry. That’s true for basic experiential EPWP initiatives, but is not the case for engineering works, which require years of dedicated training.”

Level 1s dominate Currently, the Construction Industr y Development Board (cidb) has around 97 635 businesses registered. Level 1 – the basic, semi-skilled entr y point – constitutes 87% of this figure, so there is a real skills and enterprise development gap to address. The highest grade is 9, which qualifies contractors to bid on

projects with unlimited value. Level 1s have ver y limited access. However, communities want answers and jobs. Businesses want to fulfil these needs, but alongside this is a disturbing growth in entities that want to exploit the situation for their own commercial ends, whether they are registered or not. They haven’t been officially awarded a project, but arrive on-site to demand a share in the project: a refusal by the contractor to comply frequently results in the use of force, and the destruction of plant and property. “The margins on construction works tend to range between 2% and 4%, which hasn’t changed much in past decades. So if managed professionally, there’s a small net profit at the end,” says Mfebe. “The point to emphasise is that the perception that our sector provides quick and easy profits is far from the case. However, the upside is that this sector is an excellent training ground for future artisans, technicians, technologists and engineering entrants.” According to Mfebe, the solution to addressing work stoppages begins within the three spheres of government – most importantly, at municipal level. The critical

Industry Opinion

factor is to ensure that those appointed to run engineering services departments are engineers with the right level of experience. On top of this, municipal managers need to ensure that community protests are handled with empathy and that the approved procurement infrastructure interventions are implemented on time and within budget. Here, project planning is critical, as is fair access to work. According to the latest cidb Transformation Monitor, of the total registered entities, blackowned companies (51+% ownership) from cidb level 2 to 8 are over 70% transformed; the figure for level 9 entities is around 40%. “So, level 9 represents the last mile in our quest for a fully transformed sector in terms of majority black ownership,” he says. “The next challenge is to ensure business sustainability. We have a multibillion-rand infrastructure backlog, so the opportunities are there, but it depends on actually implementing government’s stimulus and recovery package. We have to see that

happening, as well as an equitable distribution of contracts nationally,” Mfebe adds.

Two types of entrepreneurs “When it comes to procurement, there are two types of entrepreneurs that need to be considered,” he explains, which also points to why the so-called ‘construction mafia’ approach started in the first place. “There are those who enter the construction sector out of sheer necessity, while there are opportunistic entrepreneurs equipped with the right skill set who have identified a real business case: an opportunity to fulfil a need. “We need to put countermeasures in place when it comes to unqualified ‘necessity’ entrepreneurs, either born out of desperation or with a corrupt intention in mind. That’s the seed that sows site invasions and the rise of the construction mafia,” he continues. Working with government, SAFCEC is committed to providing a framework to

promote construction that empowers SMMEs, contractors and communities. The same view is shared by government’s Public-Private Growth Initiative, which takes into account the concerns and needs of domestic and international investors. “The future of sustainable construction depends on policing and intelligence interventions surrounding illegal activity, transparent tendering compliance, the need to meet community expectations, and the creation of a construction sector job pipeline that is linked to the provision of technical, primary, secondary and tertiary education,” emphasises Mfebe. “In these respects, we are looking forward to engaging with the Department of Public Works and Infrastructure, and allied departments, for greater clarification on the way forward. The construction industry is a significant contributor to the economy. The goal is to achieve inclusive participation by all stakeholders in a multifaceted construction industry,” he concludes.

Municipal Focus | Joburg

Turning Joburg into a construction site

When the current administration took office some three years ago, the City of Johannesburg had an infrastructure backlog exceeding R170 billion. In response, a detailed action plan was put in place to reverse the decay and accelerate growth, with active projects now in progress and more coming on stream. By Nombulelo Manyana

uring the 2016/17 period, the city’s housing backlog stood at more than 300 000 units, and there were 4 000 km of poorly maintained roads and 700 crumbling bridges. The estimated cost of addressing the transportation network backlog alone was around R18 billion. This is why the City of Johannesburg decided to embarked on its ambitious Inner City Rejuvenation Programme, which seeks not only to turn Johannesburg into a construction site, but also to create jobs. Speaking at the 2019 African Construction and Totally Concrete Expo in Midrand, Executive Mayor Herman Mashaba announced that tenders for 24 developments, spanning 84 properties and pieces of land, had already been rewarded. Throughout their lifespan,

these 24 developments are expected to create 11 000 direct jobs, with construction set to start in the next six months. “This is honestly the single biggest property investment the City of Johannesburg has ever made through private sector development,” Mashaba explained. “There is simply nothing comparable to it, especially if one takes into consideration similar projects that have been attempted in partnership with the private sector.” The properties are in Johannesburg Central, Yeoville, Berea, Vrededorp, Fairview, Salisbury, Marshalltown, Wolhuter, Turffontein, and City and Suburban. The 24 developments would be in addition to the three already under way in Hillbrow and Newtown, bringing the total to 27 projects under construction in the Johannesburg inner city at the same time.

Spatial integration and growth In September 2017, the city council approved the Inner City Plan, which is a longterm development programme that seeks to address spatial, social, and economic inclusion in the CBD – a project that is expected to see more residents living and working in there. Mashaba said the city expects to realise between R16 billion and 20 billion in investment value, and create affordable housing by releasing city-owned properties to the private sector to develop. “This project also lends itself to becoming the biggest mixed-use development with a special focus on affordable residential units and student accommodation,” he added. According to the plans, there will be approximately 6 500 units made up of one and two bedroom units, and provision for

IMIESA July 2019

NEW!

TAKING YOU TO THE NEXT LEVEL OF PERFECT FLOORS

about 1 500 student beds. Monthly rentals will range from R900 to R4 500 per month per unit, excluding utilities. In the request for proposals, the city insisted that for each development, there should be a minimum non-negotiable stipulation that 20% of the total development cater for the R900 per unit per month rental category. The developers have also had to develop student accommodation in compliance with the minimum norms and standards for student housing. The tenders in question are intended to result in mixed-use development, with emphasis on affordable residential units, student accommodation and retail spaces for small businesses. Mashaba highlighted that the city’s plan is to use property development and construction as the core drivers of its goal of growing Johannesburg’s economy by 5% per annum by 2021. Mashaba believes this will also serve as a catalyst for new empowered entities to enter the construction sector. “But we know that without the private sector and external investment, we cannot succeed,” he emphasised. “We operate off the clear understanding that our relationship with business requires government to pave the way for the private sector to unleash its potential and its balance sheet in our city, where profits can be made and jobs created.”

New developments

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Two private developers recently committed a total investment of R204 million, which is set to yield 384 low-cost housing units. This follows the advertisement of a tender in October 2017, offering 13 inner-city properties to the public. This was followed up by a council resolution to approve a further 71 properties, bringing the total number of properties up for grabs to 84. “We are eagerly awaiting the submission of tenders for a second batch of a further 70 properties that council recently approved for offer to the private sector,” Mashaba explained. “More will follow, as we have already identified about 500 properties throughout the inner city, and beyond, which have been either abandoned or hijacked.” In an effort to ensure projects are inclusive, Mashaba said the city will give preference to companies with the best BBBEE credentials. Other bidding criteria for tenders were stipulated as follows: • Companies must have a strong balance sheet (prove that they have the capacity to build). • Companies must be able to show how many jobs will be created. • Companies must stipulate how many buildings will be built. • 20% of the units that will be built must cater for the R900 per month rental category. “We are clear that we do not want the fly-by-nights of the past, trading off political connections rather than an ability to handle projects. We want companies that will succeed based on know-how, and not know-who,” he added. “Although the project programme is still very much in its infancy, the overwhelming interest shown by investors and property players indicates that we are on to something transformational. Slowly but surely, we are restoring confidence in the inner city, as well as other important nodes, and building it where none existed before,” Mashaba concluded.

IMIESA July 2019

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Roads & Bridges

Putting RA to work Backed by engineering analysis and experimentation, proposals for reuse of the City of Cape Townâ&#x20AC;&#x2122;s reclaimed asphalt (RA) stockpiles are being implemented. By Andrew Geel*

aced with various options for the ef ficient reprocessing of its RA stockpiles, the City of Cape went with BVi Consulting Engineers Western Capeâ&#x20AC;&#x2122;s recommendation to crush and screen the RA for downstream reapplication. Other alternatives that could have been considered included its recycling into bituminous stabilised material (BSM), the use of

the material in a granular form, or for use as a wearing course in lowrisk applications. The city subsequently issued a framework tender for the ad hoc crushing, screening and management of its RA materials. Martin and East, a CIDB 9 CE contractor, was awarded the contract, and subsequently its first work package. By going the fractioning (crushing and screening) route, the city could

produce a material that is freeflowing, uniform in quality, contains a defined range of particle sizes, and can be reused in a wide range of applications. A horizontal shaft impact crusher was specified for the contract, with research and practical application having shown that this type of crusher is best suited for the task at hand. A horizontal shaft impact crusher is able to break the RA down into its

IMIESA July 2019

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Roads & Bridges

constituent particles, without crushing the aggregate or causing clumping. The first work package was awarded in October 2018 for the crushing and screening of RA at the city’s Ndabeni depot. The scope entailed the reduction of approximately 5 000 m3 of RA to a maximum particle size of 20 mm, and a further 300 m3 to 10 mm. The work package also allowed for 100 m3 of trial crushing to a maximum fraction size of 20 mm, and stockpile yard management. The system developed included the control and documentation of in- and outgoing material, plus the identification and allocation of separate stockpiling areas for RA, granular materials and concrete.

Quality control and targets Quality control took the form of grading tests on the processed material, per formed according to SANS 3001 – AG1: 2014 Edition 1.2, and amended to reduce the temperature of the dr ying oven to 40°C. The amendment was made in order to ensure that the dr ying temperature did not exceed the softening point of the residual bitumen contained in the RA. The contract document stipulated that samples for grading analysis for acceptance control were to be taken at a frequency of six samples per lot, or day’s work. At inception, it was estimated that the contractor would be able to produce approximately 250 m 3 of processed material per day, and that one grading sample per 40 m3 would be sufficient for acceptance control. The target grading envelopes for acceptance control were set based on laborator y samples that were taken from the Ndabeni stockpile and processed through a laborator y crusher, modified according to the grading requirements for BSM according to Sabita’s Technical Guideline 2: Bitumen Stabilised Materials (TG 2). Two grading envelopes were provided to the contractor, and if material fell within the target grading, payment would be made at 100% of the volume measured. If the material test results fell outside of the target grading envelope, but within the partial payment envelope, payment would be made at 85% of the volume measured.

Material challenges After trial crushing and laborator y testing, it was found that the material did not

meet the grading specifications, as it was found to be deficient in fines (percentage passing the 75 μm sieve), with excess coarse material (percentage passing on the 5 mm to 28 mm sieves). Alterations to the impactor settings were made, with various settings tried. It was assumed that by closing the gap settings on the impact plates, more fine material would be generated. However, the contractor had to guard against choking the machine or crushing the aggregate, by making the impactor gap too small, or by not processing the material sufficiently, by making the settings too large. After much trial and error, and retesting using different methods, a final acceptable grading was achieved. Once these issues were resolved, the contractor was able to resume full production and produce material. It was then decided that samples of the material be sent to BSM Laboratories in KwaZulu-Natal for a BSM mix design to be produced. The material was accompanied by samples of crusher dust and crushed G2 aggregate in order for BSM Laboratories to blend the materials if required, and in order for the laborator y to determine the bitumen and cement content of the BSM.

The final recommended mix design included 85% RA, 15% crushed G2 base, 1% cement and 2% foamed bitumen. The requirement for the addition of granular material, and the possibility of replacing the lime with cement, will be investigated once the revised edition of TG 2 is published shortly. The processed material that is currently held in stockpile is intended for use in a BSM base for a city project that is going out to tender shortly. BVi and city representatives are also currently developing a cold-mix asphalt recipe, utilising the -10 mm processed material. Other uses for the processed RA are also being investigated and developed, and will be implemented in trial sections once the designs are complete. The contractor completed the first work package successfully, and produced on average 300 m3 of material per day, with a peak output of 420 m3 on one day. The objectives of the contract were met in that a free-flowing material, capable of being used in a variety of applications, with defined particle sizes, was produced. *Andrew Geel is an associate at BVi Consulting Engineers Western Cape.

IMIESA July 2019

Roads & Bridges

ydney Metro Northwest, stage one of Australia’s biggest public transport project, has opened to the public. The Mott MacDonald, KBR and SMEC design joint venture (JV) worked on behalf of the John Holland-Leighton infrastructure JV, part of the Northwest Rapid Transit Consortium, to deliver the project. The cable-stayed bridge and its temporary works were designed by SMEC South Africa’s Cape Town-based structures team. The team first conceived the winning

Sydney bridge designed in SA concept in a design and build tender. It then went on to develop the detail design and undertook the erection engineering work for its construction. It was a mammoth task that absorbed a team of up to 15 SMEC South Africa staff for over four years. SMEC was also the design lead on the surface works, viaducts and civils components of the project. Delivering over 36 km of new metro rail for Sydney’s growing north-west, the AUS$8.3 billion (R82.71 billion) development will improve travel time and

increase reliability using a new generation of fully automated trains. It comprises eight new stations, five upgraded stations and 4 000 commuter car parking spaces. The innovative design devised by the Mott MacDonald, KBR and SMEC JV reduced the use of raw construction materials and enabled the architectural design of the stations to be implemented within budget. Using prefabricated elements also increased the efficiency and sustainability of the project both in terms of construction and future maintenance.

Roads & Bridges

SHE excellence in bitumen

he Sabita CEO Merit Award for Health and Safety was introduced to the bituminous product industr y in 2010, with the first nominations received and evaluated the following year. The nomination criteria include: • innovative excellence in the implementation of HSE initiatives in the workplace • a strong advocate and champion for HSE

ABOVE The Tosas Bitumen Rubber Management team (from left to right) are Tosas MD Deon Pagel, Dickie Werner, Cornelius Vorster and Pierre Karsten

• demonstrating significant improvement over previous conditions • maintaining good safety per formance over several years • r ecognition for special effort given to a specific aspect of safety in the bitumen industr y.

Francois Kemp (left), MD of Actop Asphalt, together with Gugu Sithole, senior safety officer at Actop Asphalt, and Saied Solomons, CEO of Sabita

Professor Geritt Jordaan (right) received the Sabita Award for Outstanding Achievement in the Sustainable Use of Bituminous Products

Since its inception, nominations received from industr y have been of a ver y high standard and this year was no different. “The quality of nominations received each year bodes well for the superb safety management drive being implemented overall in the bituminous products industr y. This invariably led to a decision to have joint recipients of the award for 2018,” says Saied Solomons, CEO, Sabita. At the recent Sabita Annual General Meeting & Awards event held in Gauteng, the 2018 individual recipient was announced as Gugu Sithole, senior safety officer at Actop Asphalt, while the group award went to the Tosas Bitumen Rubber Management Team. The Sabita Award for Outstanding Achievement in the Sustainable Use of Bituminous Products was awarded to Professor Gerrit Jordaan for his involvement and sterling dedication to projects during a career spanning more than 40 years.

IMIESA July 2019

Green Building

Sustainability in buildings is not an option There’s a disconnect between the resource crisis being experienced in South Africa and the drive for sustainable design in buildings, with greater understanding, focus and commitment needed. By Lisa Reynolds & Songo Didiza*

he Regulation for Energy Efficiency for Buildings was promulgated in November 2011. Why, then, after seven and a half years is it not the norm? Especially given that load-shedding in South Africa is. Green building rating tools have been available in South Africa since 2007. So, why is sustainability in buildings still perceived to be a ‘nice to have’ as opposed to a ‘need to have’? Many South African cities have committed to a low-carbon future, which includes net zero-carbon buildings by 2030. The National Development Plan also commits South Africa to zero-carbon buildings by 2030. For this reason, the need to meet and go beyond the mandator y requirements is a fundamental necessity. This is the foundation on which these higher aspirations are built. One of Green Building Design Group’s current projects entails the training of building control office staff within different municipalities on the application of SANS 10400-XA – Energy Efficiency in Buildings. This training is largely aimed at the major cities of Cape Town, eThekwini, Johannesburg and Tshwane. These cities view

IMIESA July 2019

the understanding of SANS 10400-XA as the first small step in the journey to net zero-carbon buildings. Part of the training is a ‘shared learning’ component. The comments that arise are always enlightening. For example, there’s a perception among some property owners, developers and builders that energy efficiency in buildings is not mandator y and thus SANS 10400-XA is seen to be merely a guideline to ‘better’ buildings. This perception is obviously false and concerning. The whole of the SANS 10400-series is based on minimum standards. Professionals are encouraged to design, commission and build to beyond the minimum. The premise that SANS 10400-XA is a guideline for better than ‘business as usual’ defeats this objective.

Costs of energyefficiency design Enforcing SANS 10400-XA has

been somewhat challenging, often due to perceived cost savings. In these cases, no consideration is given to life-cycle or operational costs. For example, specifying cavity walls with insulation in building designs passes on measurable energy savings. However, this does go beyond the current deemed-to-satisfy requirements in SANS 10400-XA. But consider how a single-digit percentage saving on material costs can adversely affect the occupants in terms of a double-digit percentage electricity price increase. What about cost versus investment?

Health and safety in energy efficiency There is also a socioeconomic benefit to enforcing SANS 10400-XA in the building industr y as a whole, and not just

*Lisa Reynolds is the executive director and Songo Didiza the founding director of Green Building Design Group.

in the commercial sector. For instance, putting the correct insulation in ceilings has been proven to eliminate black mould in governmentsubsidised houses. The occupants of these houses – especially the children – were becoming prone to lung diseases like asthma. The solution to this problem was a more energy-efficient house. The National Norms and Standards for government-subsidised housing was amended in this area to include ceilings with insulation and plaster on the exterior and interior of the external walling. Adherence to standards is essential, since cutting corners can have knock-on health effects.

Water efficiency – the next step in the regulation process Although water efficiency in buildings is not yet a mandator y requirement, these standards and regulations are in the pipeline. This is anticipated to come in the form of SANS 10400-XB. But why should we wait for the mandator y requirements? Why should we wait for the next water crisis? This is the ideal time to embrace innovative water-saving solutions. Innovation can be applied at a building, campus or even precinct level. This is the time to influence solutions – before the enforcement of solutions.

Energy Performance Certificates The regulation for mandator y display of Energy Per formance Certificates in offices, places of public assembly and places of instruction is expected soon. These are for public buildings of 1 000 m2 or more and for private sector buildings of 2 000 m2 or more. Energy Per formance Certificates don’t save energy, but they are a tool towards energy efficiency in existing buildings. Not only will property owners and managers know the energy consumption of their buildings, but the potential tenant market will know them too. This will lead to retrofitting of energyinefficient buildings to remain competitive. The challenge that the property owners face is that they are paying the retrofit capital costs and the tenants are receiving the benefits of the utilities savings. This is not a good reason for deciding not to retrofit. Innovative ways of shared savings and/or green leases will result in win-win scenarios.

Conclusion Version 2 of SANS 10400-XA will be published in 2019. It was

supposed to be published in 2016 (five years after Version 1). The building industry should not complain about the speed at which the changes are taking place, as they are being implemented slower than planned. Be flexible and adapt. The building industry will also need to equip itself with the necessary knowledge tools to embrace these upcoming changes in the regulation. Be innovative and creative in the sustainability space. Embrace it.

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Empowerment

Promoting diversity and inclusion

In line with its global diversity and inclusion goals, integrated infrastructure delivery company AECOM is driving transformation and corporate social responsibility (CSR) initiatives in Africa and the Middle East. business or company goals, which are then deployed on various projects,” Meyer highlights.

A global platform All of AECOM’s local CSR initiatives are aligned with its global platform – Blueprint for a Better World – focusing on three main pillars: Opening Doors, Creating Opportunities and Protecting Tomorrow. “Our projects, CSR and BBBEE strategies all have to be monitored carefully to remain within budget, as well as comply with all legislative requirements, policies and procedures spend, which is quite a balancing act,” Meyer admits. Local initiatives are also undertaken with targeted CSR partners such as LIV Village, LEAP and the Robin Hood Foundation.

ECOM’s approach is underpinned by a Level 1 BBBEE accreditation. This is important for South Africa, where transformation is the main driver, encompassing affirmative action, employment equity, supplier development and skills development. Elsewhere in Africa, localisation is more important, with an emphasis on local supplier development. “The aim is to develop sustainable project transformation programmes, taking client objectives and goals into account and, in so doing, creating shared value,” says Shirley Meyer, transformation specialist, AECOM. “Our clients, in turn, develop in-house transformation strategies aligned with their

Diversity and inclusion Diversity and inclusion is another global focus for the company, dovetailing with its sustainability programme as well. “Diversity and inclusion is not just about including different races or genders. It is much broader, extending to technology, religion, ethnicity, disability, the younger generations and ethical values, for example,” Meyer adds. In this regard, AECOM has established what it terms diversity and inclusion champions throughout the region. “Research has shown that diversity and inclusion initiatives result in a happier workplace, boosting both innovation and profitability, and will ultimately assist AECOM to create a competitive economy in a globalised world. Diversity and inclusion is, therefore, an important focus for the company both globally and in South Africa.”

IMIESA July 2019

The cycle of solutions – water technology by KSB Water is crucial for our survival – for every one of us, for all nations and peoples. Clean water supplies and efficient sewage treatment have never been more important. Prosperity and well-being depend on it, worldwide. KSB’s know-how and extensive pumps and valves product range help you meet all water supply and treatment requirements, efficiently and affordably. We are one of the few suppliers worldwide with endto-end solutions addressing all stages of the water cycle – from water extraction to sewage treatment. KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za Tel: +27 11 876-5600

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Water & Wastewater

UV LED LED curing: curing: UV the future of pipe rehab South Africa now has a highly competitive alternative to traditional cured-in-place pipe (CIPP) projects thanks to the power of UV.

nveiled at IFAT Africa 2019, Nu-Flow South Africa is changing the way building, sewer and water pipeline systems are relined with the introduction of its Nu-Cure UV LED activated liner system for CIPP projects. Coinciding with this development is Nu-Flow’s local launch of Pro-Kanal’s revolutionary MasterGun, a compact, trolley mounted, inversion unit, operating with either compressed air or water pressure. Nu-Flow is Pro-Kanal’s appointed South African dealer, and will sell and support the Master-Gun series. The modular design of the Master-Gun ensures flexible use for sewer and potable water lines from 50 mm to 300 mm and for larger pipes up to 1 300 mm. “With Nu-Cure and Master-Gun, we’ve devised the perfect CIPP system for local operating conditions,” says Deon Pohorille, managing director, Nu-Flow South Africa. Nu-Flow South Africa is an official master licensor of the multinational Nu-Flow Group. “With our new

system, we offer training support with inhouse and third-party test laboratory for certification.”

mind. The ability to be connecting water back on within 20 minutes of installing the liner is unheard of in the industry.

Nu-Cure is unique

Local manufacturing

Key benefits of the Nu-Cure liner include its 4 000+ e-modulus rating, offering the dual advantages of material stretch from 70 mm to 100 mm, 100 mm to 150 mm, or 150 mm to 200 mm, etc. Nu-Cure liner is designed to be installed in pipe diameters from as small as 50 mm. What makes Nu-Cure unique is that these liners are pre-impregnated with the specified resin at Nu-Flow’s factory and delivered to the customer in sealed packaging. Although saturated, they remain uncured indefinitely until exposed to the exact UV light range. The curing of small diameter is by LEDs of Pro-Kanal’s purpose-designed UV LED light train, which comfortably negotiates multiple 90-degree bends. Nu-Flow also supplies an LED light train fitted with a CCTV camera for precision installation and optimum installation verification. “The Nu-Cure resin impregnation process achieves some of the best bonding of resins and liners. This allows for warranties to be issued knowing internationally recognised bodies have certified the system. Traditionally, once the liner had been impregnated, the curing process began immediately, so if the installation is delayed for any reason, liner materials may harden prematurely. “Our Nu-Cure liners are’factory impregnated’, ensuring far greater quality control and implementation times,” he points out. The curing process only begins once the UV LED light train has been turned on, functioning within a specific UV spectrum. The resin hardening time is 10 minutes. Absolutely minimal shrinkage and quick, simple working times mean this system can be deployed in areas where quality control of a pre-impregnated liner allows peace of

Nu-Flow has been manufacturing liner systems locally since 2014 according to strict quality standards audited by Nu-Flow global. “We remain the only South African company producing liners and resins as a complete system in-house,” explains Pohorille. “We will now be producing Nu-Cure liners to the same quality control standards, backed by an investment in extensive stock and equipment holdings with our new partners.” Third-party certifications as well as in-house laboratory testing are all documented for maintaining and improving standards. “We see huge potential not only on sewer for Nu-Cure but in the municipal potable pipe market for pipe diameters from 50 mm to 1 200 mm, a prime example being for the rehabilitation of asbestos cement potable water pipes. In these and other areas, Nu-Cure is a revolutionary breakthrough for CIPP,” Pohorille concludes.

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IMIESA July 2019

Water & Wastewater

Tshwane embarks on biogas initiative

The City of Tshwane will soon be embarking on a wastewater-to-biogas initiative in a bid to improve sustainability within the wastewater space as well as the city at large. By Danielle Petterson

lectricity is one of the highest cost items on the budgets of many of South Africa’s wastewater treatment works (WWTWs); however, the methane-rich biogas produced via anaerobic digestion at these plants presents an untapped renewable energy resource with several prospects for the South African wastewater industry. The City of Tshwane will soon be implementing a small-scale combined heat and power (CHP) system at its Zeekoegat Wastewater Treatment Works to transform the biogas produced via anaerobic digestion into energy.

The case for CHP The possibility of biogas-to-energy was first introduced to Tshwane by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) after it conducted

full-scale feasibility studies on a number of WWTWs. Its study showed that a 350 kW CHP project, using only the sludge from the Zeekoegat WWTW, required an estimated investment of R12.8 million (value estimated in 2017), which will replace 21% or 2.55 million kWh/year of consumed power. The payback period was projected to be between 8.2 and 9.3 years, while preventing 30 767 tonnes of CO2 equivalents from being released into the atmosphere – a reduction of 72%. With grant funding from the Department of Energy’s (DoE’s) Energy Efficiency Demand Side Management programme and technical assistance from the C40 Cities Finance Facility, Tshwane is busy with its own fullscale feasibility studies. The City of Tshwane joined the C40 Cities Climate Leadership Group in 2014, marking

its commitment to addressing climate change challenges in a responsible and cost-effective manner, to lower carbon emissions through retrofitting existing areas and development. With the help of the GIZ and C40 Cities, the city is putting together a project plan and conducting risk analyses, energyefficiency auditing, bankability case studies and financial contract modelling, with the ultimate goal of having contractors on-site as early as January 2020.

Zeekoegat WWTW Waste-to-Energy project According to Kerneels Esterhuyse, acting deputy director: Technical Support and Compliance Management, City of Tshwane, the city has eight WWTWs with available anaerobic digestion units. The Zeekoegat WWTW was identified as a highly favourable

This is a learning curve for us. We have no in-house knowledge on the running of CHP plants, so we want to build capacity and then explore expansion possibilities once we have a successful plant in place.”

IMIESA July 2019

Water & Wastewater

and suitable plant for CHP because it is relatively new and has good infrastructure and processes in place. Having been commissioned as recently as 2016, the plant doesn’t require any civils upgrades, making the capital requirements for CHP much lower. The aim is to install a small-scale, modular CHP plant at Zeekoegat that can be scaled up and replicated where needed. “This is a learning curve for us. We have no in-house knowledge on the running of CHP plants, so we want to build capacity and then explore expansion possibilities once we have a successful plant in place,” explains Esterhuyse. With this in mind, Tshwane plans to enter into a three-year build, operate and transfer contract to ensure skills and knowledge transfer. “We must ensure that the plant

can be operated by the municipality and that we employ and upskill the necessary people to successfully achieve this,” Esterhuyse continues. The city is busy verifying the feasibility study for the plant, revisiting the financial modelling and compiling a new bill of quantities. These will inform the tender documents, which are being compiled with the assistance of US-AID, under the DoE’s South African Low Emissions Development Program. The tender documents are expected to be ready by August, after which they will be scrutinised by the city before going out to tender. Esterhuyse expects construction to begin by January 2020, with the CHP plant up and running by the end of the city’s financial year.

Tshwane going green The Zeekoegat WWTW Waste-to-Energy

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project is expected to produce enough energy to cover roughly 20% of the plant’s energy needs. All of the energy produced at the CHP plant will be put back into the running of the plant, reducing its reliance on the grid. “We are making Zeekoegat a greener plant and, ultimately, we would like to have a zero effect on energy consumption,” says Esterhuyse. The city will also be replacing some of the plant’s equipment and motors with more energy-efficient alternatives, replacing high masts with LEDs and exploring solar as a way to reduce the plant’s consumption from the grid. These initiatives all form part of Tshwane’s overarching strategy to reduce its impact on the environment and achieve its Vision 2055 through the development of a resilient and resource-efficient city.

NOT ALL PLASTICS ARE ALIKE

PIPES XII

27 & 28 AUG 2019

Plastics is a generic term covering a very wide array of materials and applications. It could be a simple bag to carry your groceries and needing to last one day, a colourful toy for a toddler, a bearing to enable low-friction rotation of a fast rotating shaft, an impact resistant body part on a modern car, or a large diameter pipe to carry a fluid under pressure and required to last a hundred years. Each application requires a different grade of polymer and obviously a vastly different design and manufacturing approach. High performance plastic pipes are made from very specialised polymers that were unknown half-acentury ago. It enables pressure pipe sizes with diameters more than 3 000 mm or operating pressure capabilities up to 2 500 kPa. MOST CERTAINLY ARE NOT ALL PLASTICS ALIKE!

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R3500 + VAT per delegate R2600 + VAT per delegate (SAPPMA and IFPA Members) R1900 + VAT per delegate (Group bookings 5+)

SPONSORSHIP AND MARKETING OPPORTUNITIES AVAILABLE. FOR MORE INFORMATION VISIT OR CONTACT:

Admin@sappma.co.za or visit www.sappma.co.za “A great platform for learning and interacting with my South African and international peers” - Safripol “A high quality conference with excellent networking opportunities” - Chemsystems

Dams & Water Storage

Climate change impacts on dams and water security Sediment build-up caused by erosion steadily reduces dam storage capacity, posing a longerterm threat. The problem is exacerbated by extreme weather; however, it can be combatted, given the right engineered solution, which also presents opportunities for capturing extra flows during flood conditions. By Peter Townshend, Pr Eng*

Strong discharge from a scour gate in the Lesotho Highlands Water Scheme to effectively remove sediment

cientific studies on the effects of global warming show definite changes in weather patterns. Longerterm predictions indicate that some areas will suffer lower rainfalls, such as South Africa’s Western Cape, while other regions to the north of the Zambezi could experience higher precipitation. What is conclusive is that extremes in weather patterns will occur more frequently. This was made evident by the recent largescale devastation caused by the cyclones landing in Mozambique, Malawi and parts of Zimbabwe. Conversely, droughts will become more prolonged. Over the last four or so years, there has hardly been a city or town in

Droughts denude the vegetation cover so that when intense rainfall occurs, the resulting erosion is severe and seriously reduces the storage capacity in dams Weir gate on the Runde River, Zimbabwe

South Africa that hasn’t had to institute water restrictions, with adverse effects on their economies. Cape Town received extensive media attention for its ‘Day Zero’ water shortage challenge. Nelson Mandela Bay Metro and the broader Eastern Cape area have also been similarly affected, as have inland regions. The prolonged drought periods are generally followed by heavy and intense rainfall, resulting in flooding. Both extremes are damaging to humanity, livestock, the economy and property. The ecology also suffers. Droughts denude the vegetation cover so that when intense

rainfall occurs, the resulting erosion is severe and seriously reduces the storage capacity in dams. Dams are designed to offset these effects, but are they still able to do so with changing weather conditions? Presently, the dams in Southern Africa are designed purely as storage dams, with ver y little flexibility to be used to mitigate the effects of climate change.

Sustainable storage Dams should be fitted with moveable, preferably automatic spillway gates. These can be used to increase the storage in existing dams to offset the long-term effects of droughts. They can also be opened ahead of predicted heavy rainfall

IMIESA July 2019

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HOW DOES UNRELIABLE WATER SUPPLY IMPACT YOUR PEACE OF MIND?

Dams & Water Storage

events in the catchment to then create additional storage in the dam, plus help attenuate the forthcoming flood. Weather prediction with satellite forecasting is now an almost exact science. It provides an early warning mechanism, enabling a dam owner to plan ahead and release water from the dam before the storm hits. It will also give downstream users ample warning of flood waters to come. For river weirs and low dams of up to 25 m in height, use should be made of automatic self-operating scour gates placed in the base of the structure. They can also be retrofitted to existing dams or weirs, even for dams higher than 25 m. These automatic bottom opening gates will add to the discharge capacity of the dam in a flood but, more importantly, they open when the flood is running to pass sediment-laden water through the base of the structure. These are effective in minimising sediment build-up in the reser voir. As South Africa is a semi-arid countr y, consideration should be given to recharging underground aquifers, as is the case in Australia. In arid areas, the temperatures are increasing dramatically and the loss to evaporation is considerable. There should be schemes on non-perennial rivers in those areas that are subjected to flash floods to extract the surplus flood flow and diver t it to settling ponds, then to a reedbed cleaning system before feeding back in boreholes to recharge the aquifers. This is the safest place to

RIGHT Spillway gates on the Avis Dam, Namibia BOTTOM RIGHT Scour gate for a dam in Tanzania BELOW Spillway gates on the Belfast Dam, Mpumalanga

store water. It does, however, require a moveable weir with a gate that will allow sediment to pass, as well as a control gate to divert excess flood water to the settling and cleaning ponds.

Choosing the right gate The choice of gates is important in the context of this sub-continent, where maintenance is minimal and the level of the operators is questionable. Electromechanical-type gates, such as radial or ver tical roller gates, are not suitable in these conditions. There is a long histor y of gate failure for electromechanical gates. However, a range of automatic selfactuating gates has been designed in South Africa to effectively overcome the problems associated with electromechanical gates. These gates are activated purely on water forces and triggered by the water level to open and then close again to retain

The choice of gates is important in the context of this sub-continent, where maintenance is minimal and the level of the operators is questionable

the full supply level. This range of gates does not require any electromechanical mechanism or operators and is essentially vandal-proof. They are, therefore, ideally suited for conditions in Africa. A number of these control gates have been working successfully in Southern Africa over the last 30 years. They can be viewed with animations of the equipment on the website www.amanziflow.com. *Peter Townshend, Pr Eng, is the managing director of Amanziflow Projects. IMIESA July 2019

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Elevated tank delivery

The two new tanks designed and built for Ritchie were manufactured using SANS 1431/GR 300WA structural steel

he addition of two Prestank installations at the Ritchie Water Treatment Works upgrade project support the ongoing growth of this Northern Cape farming community. These new, elevated water storage solutions join a series of existing Prestanks installed some years ago that remain in operation. Designed, manufactured and installed by Structa Technology, these Pretanks are galvanised according to SABS 1461 specifications to ensure long-lasting corrosion protection. Materials were transported to site from Structa Technology’s Meyerton, Gauteng, factor y and then erected to specification by Structa’s specially trained installers. The new units have a designed storage capacity of approximately 1 452 ℓ and 1 659 ℓ, respectively. Both tanks have a height of 4.8 m and are supported on a 20 m high tower fitted with an integrated landing and walkway around the tank base. The smaller of the two tanks has a length and width of 18 m and 16.8 m, respectively, while the larger unit measures 19.2 m by 18 m. As an added ser vice, Structa Technology supplied the civils contractor with the foundation templates. This enabled the exact and easy pouring of the concrete for the elevated stand footings supporting the tanks’ multiple columns. Holding-down bolts were also supplied. Prestanks range in capacity up to around 4.2 Mℓ and cater for either temporar y or permanent installations. Key sectors include municipalities, the power and industrial segments, and the building sector.

IMIESA July 2019

Building Materials

Investing in brick

A school swimming pool and pavilion constructed in Corobrik’s Firelight satin face brick

Once fully commissioned, Corobrik’s new Driefontein factory is expected to produce around 100 million bricks per year, supporting renewed growth in South Africa’s construction sector.

orobrik’s new R801 million Driefontein facility is designed to meet larger-volume orders for major construction and infrastructure projects, working alongside the company’s existing 13 clay brick factories and 14 kilns, which produce a mix of plaster and face bricks for the residential and commercial markets. Corobrik currently sells about four million bricks per working day. Construction at the new plant is progressing well and Corobrik expects to see the first bricks exit one of two kilns in March 2020. Works commenced in July 2018, with the building scheduled for completion by the end of 2019. “We are committed to South Africa and believe that it is just a matter of time before the construction sector improves,” says Dirk Meyer, chief executive, Corobrik. “The construction industry and the associated brick industry have traditionally been, and still are, cyclical. Corobrik has always invested strategically at the bottom of the cycle in order to be better prepared to reap the rewards of an upturn,” he explains. Corobrik does not intend to shut down its older Driefontein factory. Meyer says the company is exploring the feasibility of running both production facilities by introducing new product offerings in the market.

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Building Materials

Employment creation In preparation for the construction programme, 30 people from the local community and family members of the current staff have completed a 12-week bricklaying course. The main contractor will employ these newly trained bricklayers for the duration of construction. The new plant will create around 60 jobs in the factory and will require at least 800 bricklayers to bring in the bricks produced and sold. It would also be necessary to upgrade existing skills, in order to operate the state-of-the-art factory. More than a million bricks will be used to build the new facility. Designers have used mainly face bricks manufactured at the current Driefontein factory. This includes 720 000 Blue Barley, 50 000 Country Classic Travertine and 163 000 Golden Wheat face bricks, together with smaller numbers of Maize Travertine, Onyx Satin, Roan Satin, Agate and plaster bricks.

Energy efficient Meyer says the new Driefontein factory will use considerably less energy than the older adjacent facility. It will fire bricks at an average

natural gas consumption of less than 40% compared to the current facility. All surface water will be channelled into one of the existing quarry dams and then reused as process water. A new effluent treatment plant will also be constructed. Other green initiatives include the installation of photovoltaic panels on the north-facing roof to convert solar energy into AC power and act as a grid tie-in system to supplement Eskom supply during the day. It is estimated

Pictured at the groundbreaking of the new Corobrik factory at Driefontein: (L to R) Lerato Mokgotsi and Rehab Mathobela, directors, Corobrik; Peter du Trevou, chairman, Corobrik; and Bryan Soldaat, director: Resource Based Industries, Department of Trade and Industry

that the electrical energy produced will be approximately 10% of the factory’s daytime electrical power requirement. IMIESA July 2019

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Waste Management

Treasure from trash: informal collectors transporting their recyclables through the streets of Johannesburg for sale to the closest buyback centre

PET bottles crest SA’s recycling wave As the global movement away from single-use plastics gathers momentum, South Africa continues to make significant strides in its polyethylene terephthalate (PET) plastic recycling effor ts.

he industry body PET Recycling Company (PETCO) has announced a year-on-year increase in the recycling of PET plastic bottles – a trend that bodes well for the environment and municipal landfills. According to the latest statistics released by PETCO, 98 649 tonnes of post-consumer PET plastic bottles were recycled last year, saving 612 000 m3 of landfill space and lessening the country’s carbon

emissions footprint by 148 000 tonnes. This represents a 6% increase on the 2017 figures of 93 235 tonnes of PET bottles recycled. Cheri Scholtz, CEO, PETCO, says an average of 6.2 million PET plastic bottles were collected for recycling across South Africa every day last year, creating 68 000 income-generating opportunities for small and micro-collectors – up from the 64 000 total for 2017. In addition, an estimated R1.2 billion was injected into the downstream economy through the manufacturing,

distribution and sale of products made from recycled PET. Describing the results as “encouraging”, Scholtz says it means that PETCO is on track to meet its target of seeing 70% of post-consumer PET bottles recycled by 2022, adding that 2018 had seen unprecedented pressure and attention on plastics in the public space. “Now, more than ever, companies failing to address environmental performance in product design and development will find it increasingly difficult to compete in the global market,” she explains. Globally, product stewardship or extended producer responsibility (EPR) has become the requirement for all producers. In South Africa, the Waste Act (No. 59 of 2008) now makes this a legal requirement. “Clearly, it cannot be right to allow plastics to leak into the environment, but neither is it acceptable to lose the opportunity to utilise plastic as a fit-for-purpose and costeffective material for so many applications,” Scholtz continues.

Industry waste management plan She says PETCO responded to the call by the Department of Environmental Affairs and submitted an industry waste management plan last year, which she describes as a “massive collaborative effort” by all stakeholders in the PET value chain. “Creating the right balance of legislative drivers and positive long-term business conditions will allow for a viable and resilient system to be established, which demonstrates the value of plastics as a circular material and prevents plastic in the natural environment. EPR is seen by

Makhabisi Recycling and Trading is committed to being an inclusive green business. Pictured here at its Boksburg site is one of the 60 employees from the local community

IMIESA July 2019

Waste Management

How is PET recycled? PET bottles are made of one of the few polymers that can be recycled into the same form – a new beverage bottle – again and again. This neatly closes the recycling loop and enables ‘cradle to cradle’ packaging solutions. As with virgin PET, recycled PET (rPET) can be used to make many new products, including polyester staple fibre or filament used for apparel (clothing), home textiles (duvets, pillows, carpeting), automotive parts (carpets, sound insulation, boot linings, seat covers), industrial end-use items (geotextiles and roof insulation), and new PET packaging and bottles for both food and non-food products. It is generally blended in a ratio of virgin to recycled, depending on the application required.

many as one of the key drivers to achieving these aims,” says Scholtz. Dr Casper Durandt, chairman, PETCO, who is also head of sustainable packaging for Coca-Cola’s Southern and East African business unit, explains that high collection and recycling numbers can only be achieved by industry players working together as a team. “Brand owners must design packaging to be 100% recyclable by, for example, removing colour, PVC and multi-layered packaging,” he points out. “We in the PET industry must also work together in collaboration with other material streams to optimise the collection of post-consumer packaging and create sustainable jobs in the process,” Durandt concludes.

Plastic power: Nzima Recycling in Humansdorp, Eastern Cape, started with an average of 9 tonnes of PET in 2017 and is currently processing 20 tonnes every month. The business buys in PET plastic from landfill sites and the local community

Countering overturning Gabion retaining wall systems are naturally permeable, due to their rock-fill composition, which means that when well designed and correctly installed, with the correct wire specification, they will withstand the elements for decades. But there’s a safety threshold that needs to be considered in all instances. By Alastair Currie

s a countermeasure to soil erosion, mass gravity gabion retaining walls are the ideal intervention for a wide range of applications, extending from road embankments to river systems and building foundation support.

Rock-filled Gab-Blocs

Geotextile A2 (U14) An example of a Gab-Bloc protection structure

IMIESA July 2019

The use of gabions to create boundary walls is becoming increasingly popular

“Most mass gravity gabion walls in the civil engineering space are up to 4 m high, but can be extended further depending on the site footprint,” explains Louis Cheyne, managing director, Gabion Baskets. There are three safety factors to consider, namely: overall stability, sliding of the structure, and overturning of the structure. The minimum factor of safety in all instances is 1.5. “Mass gravity walls need to have a base width of 55% of the height, as a minimum. The wall also needs to be founded to a depth of 10% of the height,” he explains. Another option that competes costeffectively with concrete retaining wall blocks (CRB), at wall heights below 4 m, is the stepped-back gabion revetment system. Standard gabion basket dimensions typically have a width and depth of 1 m, respectively. Gabion Baskets has also developed a mini-gabion system for wall heights up to

1.5 m. Known as the Gab-Bloc, these units measure 300 mm in width with a length of 1 m and are an ideal alternative to CRB options or a concrete cantilever wall for the building of skin revetments. A further benefit is that the Gab-Bloc reduces the amount of rock material required. Designers can also opt for a reinforced soil system. This entails single 1 m x 1 m gabion baskets at the face interconnected with a 2 m long Gab-tail horizontal steel-mesh tieback or, alternatively, high-strength geogrids. Each Gab-tail unit system is progressively stepped back in layers as the height of the wall increases. These systems can be designed for heights up to 20 m. Tie-backs are ideally suited for reinforcing the soil in a fill situation, such as landfill embankments, or property developments with sizeable cut-and-fill requirements. Since gabion baskets are only employed on the front face, this also reduces the overall construction cost compared to traditional mass gravity stepped-back gabion walls. In the latter case, a typical 4 m high wall

Environmental Engineering 3x2x1 Gab-tail PVC-coated Class A galvanised hexagonal mesh unit Geotextile A4 (U24) Construction in progress on a mass gravity wall system

would have a base width of 2.5 m, with the progressive installation of gabion baskets above it, requiring a much higher percentage of rock fill. As a rule, gabion rock materials represent around a third of the overall project cost. “Experience is always a key factor in gabion designs, and that includes adhering to sitespecific soil laboratory sample analysis prior to installation, to determine the optimum compaction requirement,” Cheyne expands. “The results of the soil sample determine the optimum moisture content to achieve the maximum density. With ultimate compaction, a density of around 1 850 kg/m3, for example, could represent a 100% result. For backfill compaction requirements, the minimum range is 90% to 93%, being 1 665 kg/m3 to 1 721 kg/m3, for backfill and compaction on the in situ soil.”

Battering The angle of the front face is equally important, as is the correct establishment of the foundation to prevent the wall structure from sliding forward. The exact establishment of the foundation requires a professional survey. “Where the ground conditions are particularly challenging and the foundation is poorly

Geotextile - A4/F-34

compacted, the structure might slip forward from the base, and collapse,” he explains. For mass gravity walls above 2 m in height, the recommended approach is to batter at 6 degrees, to intentionally create a front-faced wall structure that has an inward slope. With near-vertical or stepped-back structures, this achieves greater foundational stability, since battering shifts the centre of gravity towards the front of the wall. This ensures a far greater factor of safety, minimising the risk of sliding, or overturning, typically caused by thrust or surcharge loads exerting pressure on the wall.

The Gab-tail system uses less rock material

Freestanding walls and cladding Alongside traditional retaining structures, another popular application for gabions is their use in the construction of freestanding walls as an architectural element. Cheyne says that the recommended width is between 300 mm to 500 mm, with a wall height of up to 3 m. “To ensure the wall’s integrity, an internal steel support needs to be installed, anchored into a concrete foundation,” he explains. “The wall will then be able to withstand wind or minor impacts. The same principle applies for gabion boundary walls.

Gabions employed as an architectural cladding element

“We’ve also seen an increasing trend towards the cladding of buildings with gabion-cladded walls, using bolted-in panel sections, which creates an amazing architectural effect,” he continues, adding that for the best cladding results, a welded mesh is required, with a 6 mm wire diameter. Compared to the hexagonal woven mesh used for river and wall gabions, welded mesh is flatter and stronger, and achieves a flat vertical finish. “Whether for building or civil engineering applications, the natural appearance of gabion structures makes them a firm favourite with designers. However, with every installation, taking into account the factor of safety is a critical requirement,” Cheyne concludes.

Examples of vertical front face mass gravity gabion walls with a 6-degree batter

1 m high wall

Geotextile A4/F-34

Geotextile A4/F-34 3 m high wall

2 m high wall

4 m high wall IMIESA July 2019

83RD IMESA CONFERENCE

02-04 October 2019 DURBAN INTERNATIONAL CONVENTION CENTRE

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Cement & Concrete

Creating space for new sports fields on a steep slope using Terraforce concrete retaining wall elements

Concrete masterpieces The winners of the 2019 Fulton Awards have been announced. This year’s victors include a range of innovative building and civil structures that embody excellence in concrete. Katembe Bridge and North Link Roads

New Arch Bridge over the Olifants River

Winner: Infrastructure more than R100 million

The 680 m long Katembe suspension bridge over the Bay of Maputo has provided an essential link between the city of Maputo and the suburb of Katembe. The new bridge and link roads will assist with the development of the entire area south of Maputo. Prior to the construction of the bridge, the only means of crossing the bay was via a ferry that can carry a total of 16 vehicles at a time. This often resulted in delays of up to three hours, followed by another three hours of travel on a 4x4 route. The US$750 million (R10.8 billion) bridge used a total of 340 000 m³ of highly durable concrete. All concrete was site-batched and the stringent quality control system required testing of over 51 000 compression cubes, with durability indices being tested in South Africa. The pylons and bases, cable anchors and balanced cantilever spans that were curved in plan all pushed design and concrete capabilities to the limit. The judges called the megaproject a bold and overt statement of the strength and robustness of concrete, stating that it will set a new benchmark for concrete on the African continent.

Project team: • Submitted By: Gauff Engineering: Gauff GmbH & Co. Engineering KG • Client: Empresa de Desenvolvimento de Maputo SUL; E.P. • Main Contractors: China Road and Bridge Corporation • Suppliers: CM Cimentos de Moçambique; Ulula Ash

Winner: Infrastructure less than R100 million The new Olifants River bridge forms part of an upgrade to the N7, which will see the important economic link being upgraded from a single to dual carriageway in the vicinity of the Olifants River, about 280 km north of Cape Town. The 166 m long bridge uses the ancient structural form of an arch in an innovative way, giving an aesthetically pleasing modern version of the form. The 93 m long arch structure must resist large compression forces, making concrete the best suited construction material for the task. The deck profile is constant along the full length of the bridge, and the twin columns and arch result in a less bulky and more open structure. The judges cited the bridge’s unique design features and construction techniques that make this bridge a testament to excellence in the use of concrete.

Project team: • Submitted By: Aurecon South Africa; Stefanutti Stocks Coastal, a division of Stefanutti Stocks • Client: South African National Roads Agency • Principal Agent: Aurecon South Africa • Main Contractor: Stefanutti Stocks Coastal, a division of Stefanutti Stocks • Suppliers: Lafarge Industries SA

IMIESA July 2019

Cement & Concrete

Battery Park

Winner: Buildings greater than three storeys Battery Park is a 12 000 m2 urban park situated at a key entranceway to the V&A Waterfront in Cape Town. The space, which was developed as the nucleus of a larger urban vision for the district, incorporates a park and piazza, a concealed multilevel parking facility, as well as new pedestrian routes. The site is of archaeological importance, as it contains the remnants of one of the city’s oldest structures, the Amsterdam Battery. The use of concrete as a primary material allowed for the development to be clearly distinguished from historic elements. Battery Park makes inventive use of various concrete elements, most notably the interpretation pavilion features a total of 123 precast panels, concrete treads, seats and park benches, and the skate park, which was constructed by hand-packing 90 m3 of concrete. The judges’ citation noted Battery Park’s amazing display of the versatility of concrete, with an end product that shows off exceptionally detailed and finished concrete elements.

Project team: • Submitted By: dhk Architects • Client: V&A Waterfront Holdings • Principal Agent: Igual Project Managers • Main Contractor: Group Five • Specialist Subcontractors: Concrete Units; California Skateparks, KTW • Suppliers: Megamix; Chryso SA; Ciolli Readymix

N17-1 Regents Park Pedestrian Bridge Commendation: Innovation in concrete projects

Pedestrian traffic counts at the Regent Park site showed that high volumes of pedestrians were crossing the busy N17, posing a serious safety risk. The solution of the construction of a 58 m long bridge was conceived to enable the future widening and clear span of the highway. The use a simple self-anchored suspension bridge with an in situ concrete deck slab cast on staging proved to be the most economical option. The bridge demonstrates excellence in the use of concrete in a number of ways, including the use of self-compacting concrete for concrete pumped upward into the pylons’ formwork. This achieved a flawless, composite anchorage to the enclosed structural steel anchorage assembly for the suspension cables at the top of the pylons. This was particularly effective in providing a high level of quality assurance to an inaccessible, but critical, component of the structure. This is also the first bridge constructed in South Africa utilising the design of a self-anchored suspension bridge with suspension cables in grouted steel pipes.

Project team: • Submitted By: SMEC South Africa • Client: South African National Roads Agency • Principal Agent: SMEC South Africa • Main Contractor: Stefanutti Stocks Civils • Specialist Subcontractor: SSL Structural Systems (Africa) • Supplier: AfriSam SA (Nigel Plant)

IMIESA July 2019

Origins Centre: Rock Art Gallery

Commendation: Architectural concrete The Origins Centre Rock Art Gallery located on the Wits University West Campus houses a number of rock exhibits. The judges called the project a powerful symphony of form and space that celebrates concrete as a material. Known for its flexibility, concrete was pushed and successfully tested to meet design challenges of accommodating the required space on the book-end site given, and to shape these spaces in a cave-like nature. While the man-made art is being experienced through an exhibition of rocks, the building seeks to offer an example of a contemporary experience of a cave, appropriate to the tradition and time being referenced. The structure of the building is made entirely from concrete, and the design of the building and experiential use of concrete is informed by a depth of ethnographic research involving the history and meanings of rock carvings, paintings, and the inherent forms and symbols used.

Project team: • Submitted By: Mashabane Rose & Associates CC • Client: University of the Witwatersrand • Principal Agent: University of the Witwatersrand • Main Contractor: Murray & Dickson Construction • Specialist Subcontractor: Viva Formwork & Scaffolding • Supplier: WG Wearne Ltd

Cement & Concrete

eThekwini Municipality M25-C9 Underpass

Water City: New Water & Sanitation Head Office

The M25-C9 Underpass carefully negotiates space and level constraints to provide an essential connection between Bridge City and Phoenix Industrial Park in Durban. The structure consists of a fully integral bridge, with one curved abutment, coupled with an extremely skew deck, presenting several design challenges. The project highlights the structural flexibility of reinforced concrete and shows how reinforced concrete can literally flex and bend, and adapt to a wide range of support conditions and complex structural constraints. This allows the structure to dispense with expansion joints and bearings, and the associated costs. The underpass was designed in-house by eThekwini Municipality’s structural engineering branch, which also takes ownership of and responsibility for its long-term maintenance. This means that any long-term risks associated with cracking can be carefully monitored and managed.

Situated in Bellville, Cape Town, the building integrates the various departments of Cape Town Water & Sanitation into one facility, with ancillary facilities such as an auditorium, canteen, post office and library. The choice of concrete for the building was obvious in terms of the brief, providing the needed space flexibility. The concrete finish is a Grade 2 off-shutter, together with a cementitious coating to create a smooth, durable and economical finish. The sustainability aspects of the building were also notable, with the overall clinker content of the concrete being approximately 62%, and complete on-site water reuse. The judges called the building a welcome departure from traditional municipal buildings, stating that it will become an iconic structure in this Bellville Precinct, raising the tone of the whole area.

Project team:

• Submitted By: City of Cape Town • Client: City of Cape Town • Principal Agent: Van Zyl & Associates (obo WorleyParsons RSA (Pty) Ltd) • Main Contractor: Group Five Coastal • Specialist Subcontractor: Mandukas Formwork, a division of Mandukas Investments CC • Suppliers: Megamix; Sika

Commendation: Infrastructure less than R100 million

• Submitted By: eThekwini Municipality – Roads Provision Department – Structures Branch • Client: eThekwini Transport Authority – GO!Durban • Principal Agent: eThekwini Transport Authority – GO!Durban •M ain Contractor: WBHO Construction (Inanda JV) • Suppliers: Lafarge Industries SA; Natal Portland Cement

Commendation: Buildings greater than Three Storeys

Project team:

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Cement & Concrete

Concrete health

and protection

hen dry cement is exposed to water, a chemical reaction called hydration takes place, resulting in the release of a strongly alkaline (and caustic) fluid. Since this can cause alkali burns, safety measures should be observed. “Although South African cements typically contain less than two parts per million of hexavalent chrome (widely regarded as a safe level), it may serve as an

Bryan Perrie, managing director of The Concrete Institute

IMIESA July 2019

Appropriate precautions are advised to prevent tissue damage when handling fresh mixes containing water and Portland cement

aggravating factor in cases of exposure to alkaline fluids,” says Bryan Perrie, MD, The Concrete Institute. When fresh concrete or its bleed water comes into contact with human skin, the alkalis react with the oils, fats and proteins, causing tissue damage. Other organic tissues, such as mucous membranes, can also be attacked, leading to burns that can sometimes be severe. In addition to protective clothing, impermeable gauntlet-type rubber gloves and high-length rubber boots should be worn to prevent direct skin contact. Trousers should overlap the boots rather than be tucked in. Hydrophobic alkaliresistant barrier creams should also be applied to hands and any areas of skin likely to come into contact with fresh concrete. Ordinary barrier creams are likely to be inadequate. However, these precautions may be ineffective if the skin itself is not clean and free of concrete residue. Even a tiny trace of cement dust remaining in contact with

As with many other materials, there are potential risks involved in handling or working with Por tland cement and related mixes.

wet skin will raise the pH significantly. For this reason, some authorities recommend the use of disposable gloves rather than reusable ones. Additionally, workers need to ensure that their clothing remains free of concrete splashes and fluids.

Suspended dust Airborne cement dust is another factor to consider. Dust from demolishing or cutting hardened concrete may contain unhydrated cement and could cause respiratory problems. In addition, if the coarse or fine aggregate used in making the concrete contains crystalline silica, the inhalation of these suspended particles could expose workers to the risk of developing silicosis. When the generation of dust cannot be avoided, suitable respiratory protective equipment is a must. Site workers should also not kneel on fresh concrete during placing, compacting and finishing operations. If kneeling is unavoidable, thick waterproof kneepads should be worn: a kneeling board will prevent the pads from sinking into the fresh concrete. “In severe cases of alkali burns, a medical practitioner should be consulted as soon as possible,” Perrie concludes.

Although South African cements typically contain less than two parts per million of hexavalent chrome (widely regarded as a safe level), it may serve as an aggravating factor in cases of exposure to alkaline fluids.”

Smoothing out

imperfections

elf-levelling cementitious compounds require minimal application effort and can effectively level out large floor sur faces quickly. The thinner consistency of these self-levelling compounds, compared to other types of cement screeds, also facilitates the easy and effective filling of uneven areas. The best results require a flat, level and smooth substrate prior to the application of floor surfaces like ceramic tiles, textiles and elastic floor coverings. Within this field, the Sikafloor Level cementitious range meets or exceeds all the latest standards and requirements for both new work and refurbishments. A key product in the series is Sikafloor-200 Level, which is suitable for interior and exterior residential and non-industrial applications. This flooring system has applications in manufacturing industries, institutional, residential and domestic buildings, as well as the levelling of precast concrete planks and pre-levelling for roof membranes. Two competitive edges of Sikafloor-200 Level are the pot life of approximately 40 minutes at 20°C and its foot-traffic readiness after around four hours. Other valuable product and end-result features include low emissions, improved surface finishes, increased durability, enhanced safety and improved appearance.

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Cement & Concrete

As the rate of urbanisation intensifies, Installing permeable paving traditional stormwater networks are coming under increasing pressure. Among the proven responses are sustainable urban drainage systems (SUDS), which help to capture water run-off and present oppor tunities for reuse.

Flood control with permeable paving

UDS and their subsequent engineering design start with the intention of creating newly developed sites that mimic their pre-development state. Their purpose is to ensure that most of the in situ stormwater flows infiltrate into the ground, thereby replenishing critical below-grade water tables and aquifers. The goal is to manage stormwater on-site and have as little as possible passing into municipal systems. Technicrete’s range of Aqua blocks, manufactured to SANS 1058-2012, subscribe to a form of SUDS known as permeable paving, whereby vertical ‘slots’ between adjacent pavers provide drainage channels. They allow stormwater to flow from the surface, through the paving layer, into suitably designed layer works below. The premise behind a permeable paving system is such that voids, inherently present between stones (19 mm to 63 mm) making up the structural layer works of the pavement, can accommodate water capacity up to 25% of the volume of these layers.

Design considerations A general design consideration for the paving block is to allow water to flow through this layer

IMIESA July 2019

at a rate of approximately 9 000 ℓ/m2/h. A geotextile placed between the bedding and storage layers will have the effect of throttling this flow-through rate to approximately half, or 4 500 ℓ/m2/h. However, at the design stage of the overall system, one generally uses a rate of 10% of the maximum, namely 900 ℓ/m2/h, as this allows for up to 90% potential blocking up of the system over time. Accordingly, a heavy rainfall event can be managed such that the entire volume of water is maintained and managed within the site boundaries. A secondary consideration at this stage of design is whether to capture this water only for attenuation (slow release) or retention and reuse, both of which offer a myriad of further options. As such, three basic design philosophies prevail, namely a full-infiltration system, a partial-infiltration/partial-discharge system, or a tanked storage system. A full-infiltration system is underlaid with a pervious geotextile and is suitable for use where it is feasible to infiltrate stormwater directly into a suitable subgrade. A partial-infiltration/partial discharge system enables attenuation into the municipal network at the rate prescribed for the site, as well as infiltration into the ground below.

The third option, the tanked system, is lined with impervious LDPE or HDPE membranes to create a ‘tank’ and thereby capture and store the water for reuse in grey-water and irrigation systems. With additional treatment, this stored water could be made available for potable use. In some instances, the impervious membrane is required to restrict water from entering the subgrade, thereby preserving the structural integrity of this layer. This could be an important factor where clay subgrades are encountered, in dolomitic areas, or where soils/stormwater are expected to be contaminated.

Permeable paving advantages An additional advantage of permeable pavement design is the element of contaminant treatment. Studies have shown that heavy metals – including but not limited to cadmium, copper, lead, nickel and zinc – are partly removed from the water through percolation in the stone layer works, such that water flowing out of these systems is within potable requirements for these metals. Hydrocarbons have also been seen to be broken down by microorganisms that grow in the geofabric and other layers that are generally kept moist. Technicrete’s permeable paving systems can be installed on almost any installation where traditional segmental concrete block paving has been specified. Applications include industrial complexes, car parks, residential estates, truck stops and container terminals. As with all Technicrete products, the company’s in-house engineering team is always available to advise and assist with the design of the optimum permeable pavement system.

Cement & Concrete

Saving space with CRB Terraforce walls installed at an 85-degree angle

hen faced with steep slopes or restricted footprints, concrete retaining block (CRB) walls provide one of the most cost-effective solutions for foundation, bank stability and erosion control. A prime example is a recent residential development in Victory Park, Johannesburg, where the developers and architect needed to make the plan work. The solution entailed an interconnecting CRB wall network designed by Silvio Ferraris of Remacon Products and installed by Powergate Construction, using the Terraforce retaining wall system. Remacon is a licensed Terraforce manufacturer based in Gauteng. For this project, Ferraris specified Terraforce L11 blocks. The installation features a series of near-vertical walls measuring up to 3 m in height, with a solid yet textured block finish. This was achieved by turning the flat section of each block to face outwards. The blocks were also cut to create a range of sharp corners, maximising every centimetre of space for the apartment blocks and gardens. A number of old palm trees also needed to be preserved.

The walls create space for parking

Geogrid for piling Most walls were positioned at an 85-degree angle. Where piling next to the walls was required, these sections were reinforced with Secugrid 40/40 Q1 polypropylene grids. Piling augers can cut through these grids without affecting their structural integrity. Where piling was not required, Rockgrid PC 50/50 polyester was used as the geosynthetic liner. Corners were reinforced The Terraforce L11 with hooped Y12 steel standard block and filled with concrete to prevent future movement and corner cracking. “Groundwater had to be dealt with

The installation features a series of near-vertical walls measuring up to 3 m in height with a solid yet textured block finish

Wall sections were reinforced with Secugrid 40/40 Q1 polypropylene grids where piling was required through these areas

by placing adequate drainage at the base of the walls,” explains Ferraris. “In some cases, blanked drains were deployed at the base; in severe cases, pilot dump rock was required. In all cases, 100 mm wick drains were used against the natural soil cut faces.” To minimise future maintenance, the design brief specified that the blocks remain unplanted. In today’s increasingly arid environment, that helps during water restriction periods.

IMIESA July 2019

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Pedestrian roller partnership concluded Stampede Construction Equipment’s new-look machines will proudly display both the Kemach and Stampede brands

emach Equipment has par tnered with Stampede Compaction Equipment to supply and support Stampede’s locally manufactured walk-behind pedestrian rollers in South Africa. Kemach is a leading distributor of JCB earthmoving equipment in South Africa. Kemach Equipment holds an approximate 2.5% market share in walk-behind rollers in Southern Africa, with sales exceeding 100 machines over the past seven years. “So, when JCB decided to discontinue its range of walk-behind rollers, we were keen to continue supplying this type of machine, prompting us

to look for a suitable partnership,” says Mark Senyard, national support and marketing manager, Kemach. “We could not have asked for a more qualified partner in Stampede Compaction Equipment.” Stampede is a proudly South African company with a 25-year track record. The company’s range of walk-behind and rideon rollers, rammers/tampers and plate compactors are engineered and built at its 2 000 m2 manufacturing operation in Isando, Ekurhuleni. Kemach will supply Stampede’s complete walk-behind roller range. These comprise the PR39 trench compactor; the PR 62 and 75

general-purpose rollers; and the PR90 heavy-duty roller. “These robust machines, available in drum widths ranging from 380 mm to 890 mm, with operating weights between 495 kg and 1 080 kg, are versatile workhorses renowned for their simple, easy operation and efficiency. We are eager to unleash these machines into the market,” remarks Senyard. Comments Marco Capazario, managing director of Stampede Compaction Equipment: “The timing of this partnership could not have been better for us, as we want to concentrate all our efforts on our core competencies of manufacturing and product development.” Kemach’s initial focus will be on the South African market. “Once we have successfully accomplished this, the opportunity is there to offer this product to our sister companies in Botswana and Zambia, and further afield to other JCB dealers in Mozambique and Zambia,” Senyard concludes. IMIESA July 2019

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Accurate milling, perfect paving

ir tgen’s Per formance Tracker uses a laser scanner to measure the cross-sectional profile to be milled. Sur face milling performance and milling volume are then precisely measured using GPS positioning and other sensors. The machine operator can then continuously track the most important information in real time on the control panel’s display. “After completing the milling work, a report with all of the relevant performance and consumption data is generated automatically in Excel and PDF format, and sent to the machine operator by email,” explains Waylon Kukard, sales manager, Wirtgen South Africa. “This documentation feature allows milling jobs to be billed quickly and on the basis of transparent information.” Accurately measured performance and consumption data also makes it easier to evaluate the efficiency of current and future construction sites. In addition, data can be used to determine which machine model is the most efficient for specific jobs.

The Vögele S1603 Classic paver

In addition to the new F-series, Wirtgen large milling machines built from 2010 onwards can now be retrofitted with Performance Tracker.

New paver model launched A recent addition to Wirtgen’s local paving line-up is the Vögele S1603 Classic paver. Designed to achieve a laydown rate of up to 600 tph, this machine is equally at home working on confined urban job sites or constructing rural roads. When combined with the AB 480 extending screed (fitted with the tamper and vibrator compacting systems), the S1603 can achieve a maximum paving width of 6.3 m.

“The paver comes with a high-performance hydraulic system. The hydraulics provide an accurate drive for materials handling systems, thus ensuring an optimal head of mix in front of the screed at all times,” explains Kukard. The Classic line is equipped with the intuitive and clearly structured ErgoBasic operating concept, which was developed on the basis of the proven ErgoPlus operating system. Other key features include a significantly smaller turning radius, and the new and easy-to-use Niveltronic basic system for automated grade and slope control.

Precision milling: an efficient flow of information is the key to making processes easier, faster and more cost-effective, which is achieved via the Wirtgen telematics solution, WITOS

IMIESA July 2019

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