Imiesa July 2017 by 3S Media

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

infrastructure development • Maintenance • service delivery

INDUSTRY INSIGHT

City of Ekurhuleni

The 10-point economic plan

Tumelo Gopane Managing Director, ERWAT

One mission, one vision

Dams & Reservoirs

New labyrinth spillway for Tzaneen

SBS Tanks

Water on demand

IN THE HOT SEAT The extensive experience gained on our first and subsequent PRT projects has really honed our skills in the design and establishment of township infrastructure, which is definitely one of the most pressing social needs in our country.” Kibiti Ntshumaelo Managing director, Lekwa Consulting Engineers ISSN 0257 1978

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

volume 42 no. 07 JULY 2017

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INDUSTRY INSIGHT

City of Ekurhuleni

The 10-point economic plan

Dams & Reservoirs

Tumelo Gopane Managing Director, ERWAT

New labyrinth spillway for Tzaneen

One mission, one vision

16 Water Treatment

SBS Tanks Water on demand

Usuthu expands its output Upgrading the Temba Water Purification Plant

INSIDE

ISSN 0257 1978

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

Neptune Reservoir gets a makeover New labyrinth spillway for Tzaneen

Regulars 3 5 9 60

Hot Seat Lekwa: Building tomorrow’s megacities

Industry Insight ERWAT: One mission, one vision

IN THE

HOT SEAT Kibiti Ntshumaelo, managing director of Lekwa Consulting Engineers, talks about the company’s amazing journey since its founding back in 2002, and the upcoming celebration of its 15th anniversary. P10

dams & reservoirs New labyrinth spillway for Tzaneen

Municipal Focus | Ekurhuleni Unlocking Ekurhuleni’s economic potential A delivering city by 2020 Partnering for safety on-site Advancing ground engineering Embrace the digital future Ekurhuleni geared for rapid growth

29 32

Environmental Engineering Retaining with gabions Reinforcing structures with sustainable solutions

Cover Story SBS Tanks: Water on demand

Dams & Reservoirs

SBS Tanks is leading the market with specialist storage solutions that meet pressing infrastructure backlogs and accelerate service delivery. P6

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

36 38

Fleet Management The importance of availability

Transport, Logistics, Vehicles & Equipment Bell concludes Kobelco alliance Introducing the Croner Scribante expands Gauteng footprint

42 43 45

Building The benefits of brick Promoting sustainable building materials

46 49

Energy 15 16 18 19 21 23

Constructing Africa’s largest wind farm What is SA’s energy future?

51 53

Health & Safety Combating workplace intoxication 54

Cement & Concrete Pipes, Pumps & Valves New-generation pump is a winner 24

ENVIRONMENTAL ENGINEERING Retaining with gabions

Bridging the divide in Ga-Ntata Car parks need concrete

56 58

ENERGY What is SA's energy future?

BEYOND CONCRETE IS GOLD.

As SANRAL, we are proud to be the trusted custodians of our national roads. We deliver a world-class and safely engineered road network. Recently, the Umgeni Interchange upgrade in KwaZulu-Natal won the prestigious Fulton Award. The award recognises excellence and innovation in the design and use of concrete. We are honoured to receive this engineering award, but we are even more honoured to keep South Africa moving.

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EDITOR'S COMMENT

The way forward

Publisher Elizabeth Shorten MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson ONLINE JOURNALIST Rianté Naidoo Head OF DESIGN Beren Bauermeister Chief SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter ContributorS Gavin Clunnie, Frank Stevens, Louis Strijdom, Jacques van Rooyen, Nigel Webb CLIENT SERVICES & Production MANAGEr Antois-Leigh Botma Production coordinator Zenobia Daniels financial manager Andrew Lobban HEAD: DIGITAL MARKETING Roxanne Segers Administration Tonya Hebenton DISTRIBUTION MANAGER Nomsa Masina Distribution coordinator Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za Printers United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________

ervice delivery protests remain a common feature across South Africa and part of the problem could be related to staffing issues at local municipalities. Statistics SA’s recent Non-financial Census of Municipalities for the year ended June 2016 reveals that the total vacancy rate rose from 13.3% in 2015 to 14.4% in 2016. That translates into 45 096 funded, but unoccupied posts, with the highest vacancy rates recorded in the environmental protection (26.1%), road transport (22.3%) and wastewater management (19.9%) departments. Some of the reasons given during the Statistics SA survey include uncertainty concerning personnel structures, moratoriums on recruitment, plus outdated organograms. Regardless, it’s clear that local municipalities urgently need to reassess their skills requirements and streamline efficiencies as South Africa works its way out of the current recession.

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

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

CESA economic survey Consulting Engineers South Africa’s Bi-annual Economic and Capacity Survey was released towards the end of June 2017, and indicates a ‘softer outlook’ over the medium term. The survey is an analysis of the July to December 2016 period. Speaking during a media briefing, CESA CEO Chris Campbell said that poor service delivery, especially at municipal level, remains a burning issue and is particularly concerning given the public sector’s sizeable contribution to CESA member fee income streams. Within this context, payments outstanding for longer than 90 days are still a problem and averaged around 23.1% of total estimated income in the December 2016 survey. Campbell said, “It’s therefore critical to support government by partnering on initiatives such as the recent implementation of Standards for Infrastructure and Procurement Delivery Management, supported by CESA through National Treasury. CESA is currently facilitating a countrywide programme for built environment practitioners and public sector employees on the

BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Fax: +27 (0)43 743 5266 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Fax: +27 (0)41 585 1066 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Fax:+27 (0)31 266 5094 Email: imesakzn@imesa.org.za NORTHERN PROVINCE Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Fax: +27 (0)86 628 0468 Email: imesafsnc@imesa.org.za 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.

standard to improve service delivery, as well as accountability.”

Municipal audits The 2015/16 local government audit outcomes report recently released by the AuditorGeneral South Africa shows there’s definitely room for improvement. Auditor-General Kimi Makwetu said that, overall, “Local government had failed to maintain the promising five-year momentum gained in the years 2010/11 to 2014/15,” and emphasised the need for much stronger internal controls. During 2015/16, 15% of South Africa’s 263 municipalities showed an improvement, while 13% regressed and 67% remained unchanged in terms of their audit outcomes. Plus, the financial health of 65% of these municipalities was rated as either concerning or requiring intervention, compared to 60% in 2014/15. The report states that “82% (40) of the municipalities with clean audit opinions in the previous financial year obtained this outcome again in the year under review” and that “only one metro (City of Cape Town) and 14 district municipalities (32% of all district municipalities) received clean audit opinions.” The Western Cape (80%), KwaZulu-Natal (18%) and the Eastern Cape (16%) were the three leading provinces. Major contributors to under-performance include leadership gaps in key positions, such as municipal managers and chief financial officers, alongside specialist engineering personnel.

Alastair Currie

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IMESA

turene.ws

Infrastructure News

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

INFRAST

Y IND US TR INSIGHT Tumelo Gopane

One mission,

PMENT RUCTUR E DEVELO

Managing Director,

• MAINTE NANCE

• SERVICE DELIVER

uleni City of Ekurh ic plan

The 10-point ERWAT

econom

rvoirs Dams & Rese for Tzaneen

New labyrinth

spillway

one vision

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.

s SBS Tankand Wa ter on dem

has really SEAT our first and subsequent PRT projects which is IN THE HOT p infrastructure, gained on ment of townshi e experience Ntshumaelo and establish The extensiv country.” Kibiti in the design needs in our honed our skills pressing social of the most g Engineers definitely one Lekwa Consultin 2 No.07 managing director, Vo l u m e 4 978 1 ISSN 0257

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President’s comment

IMESA

Risk management and mitigation

he value and commitment of municipal engineers and suppor ting personnel really came to the fore during the recent Cape storms and when responding to the devastating fires that consumed parts of the Western and Eastern Cape. Disaster management planning and emergency response measures were outstanding and helped to mitigate the losses experienced by so many residents. Well done to all the IMESA members and local municipalities that played their part. As an indication of how rapidly things can change, I was visiting this region in May for the IMESA Southern Cape/Karoo branch AGM, and the discussions then were mostly about the extended drought and the

necessary responses. What a turnaround a few weeks later when a deluge descended. This emphasises the critical importance of ongoing risk assessments and contingency management: we must have the resources and infrastructure in place to counter extreme weather events, as they’re becoming more prevalent. The Southern Cape/Karoo meeting, opened by George’s executive deputy mayor, Gerrit Pretorius, included a series of technical presentations by industry experts on the burning issues of potable water delivery and sanitation, especially for rural communities. Topics included the benefits of plastic piping as a highly durable and labour-intensive solution, and the adoption of wastewater treatment package plants for small dwelling clusters (10 or more), as well as

schools. Wherever practical, the Southern Cape/Karoo branch will channel a portion of its funds to assist rural projects in these and other areas. On another note, IMESA has drawn up a memorandum of agreement with Consulting Engineers South Africa that furthers our vision of greater industry engagement and cooperation. We believe our combined strengths will help us make a difference in addressing South Africa’s pressing infrastructure needs. Going forward, we all need to work together and IMESA president Gavin Clunnie do more with less.

Remembering an industry icon In memoriam: Don Macleod, 1928 – 2017

t was with sadness that the municipal engineering family – and indeed the civil engineering fraternity of South Africa – learned of Don’s passing earlier this year. Don was an Honorary Fellow Member of IMESA, and served as its president in 1984. He was also an Honorary Fellow Member of SAICE, and served as its president in 1987. He was active on both bodies’ branch committees for a number of years. Don’siconic municipal career commenced in 1948 when he joined Durban City Engineers as an assistant engineer. While working his way through the ranks – under the early

guidance of municipal engineers such as Alec Kinmont – he was involved with many strategic projects throughout the city and was personally responsible for the delivery of major projects. These include three large wastewater treatment works and Durban’s two sea outfalls, which raised much interest and were acclaimed internationally. Don was appointed as the Durban City Engineer in 1975, a position he held until his retirement in 1992. He always showed an interest in the well-being of his staff and had a passion for the development of young engineers, technologists and technicians.

Early years His personal background and achievements also make for fascinating reading. Don was born in Johannesburg in 1928 and, having lost his mother during childbirth, was raised by an aunt. Despite a difficult childhood, Don excelled at school and matriculated as Dux of Christian Brothers College in Kimberley at the age of 15.

He graduated as a civil engineer at Howard College (now UKZN), Durban, at the age 19. Don and Pam enjoyed 68 years of happy marriage, having four children and eight grandchildren. As most people know, Neil Macleod, the recently retired head of eThekwini Water and Sanitation, is Don’s son – himself an Honorary Fellow of both IMESA and SAICE and a past president of SAICE. IMESA’s Executive Committee, Council and members wish to express their sympathies to Pam, their children and families at this difficult time. It is appropriate to close by quoting the words of Don Macleod, as used in his presidential address some 30 years ago: “We should never see the fruits of technology as being greater than people. Our respect for the dignity and immeasurable value of the human being should always be upheld.” Prepared by Frank Stevens, with the kind assistance of Neil Macleod.

IMIESA July 2017

COVER STORY

Water on demand

SBS Tanks is leading the market with specialist storage solutions that meet pressing infrastructure backlogs and accelerate service delivery.

cross South Africa and for all industries and communities, the need for intensive water security planning and implementation has been reinforced by the recent extended droughts across most of the country. This requires a change in consumption behavior when it comes to conventional water management, and highlights the need to introduce supplementary measures like rainwater harvesting and storage tanks, as backups that reduce the demand on dams and reservoirs. “In addition to potable water requirements, for municipal clients, our solutions also include effluent, leachate and water treatment storage,” says James Preston, Marketing Manager for SBS Tanks. The SBS range extends from 12 kℓ to 3 300 kℓ and the units are relatively fast to build. “As an indication of the turnaround time, our largest tank takes around 12 to 15 weeks to manufacture.”

Cover story

One of SBS’s distinctive design features is the internal PVC liner, which meets stringent Australian drinking water standards, acknowledged as an industr y benchmark worldwide. The PVC material specified by SBS is 1 000 g/m2 and is unique to the South African market. “These liners carry a 10-year ‘no leak’ warranty and if damaged can be easily repaired,” says Preston, adding that SBS’s tanks meet strict ISO 9001: 2015 SABS approval standards. With the majority of the materials sourced locally by SBS’s tanks, all fabrication takes place at its Pinetown factory in KwaZulu-Natal. “Zincalume is a specialised coating system, which exhibits exceptional anti-corrosive characteristics, and we specify this for all our tanks,” Preston explains. This coating comprises an aluminum, zinc and silicon composition. The tank structure, if used and maintained in accordance with SBS requirements, has a life expectancy of more than 60 years.

Water for Joe Qgabi District SBS is a leading solutions provider to municipalities across South Africa. A recent example is a turnkey project in the Eastern Cape for the Joe Qgabi District Municipality. Here, SBS supplied and commissioned 16 reservoir storage tanks for rural villages in Ugie, Maclear and Mount Fletcher. These ST10/03 tank models have a design capacity of 100 kℓ and each tank serves the requirements of 500 to 1 000 users. “The modular nature of SBS’s products makes transportation and rapid installation in remote locations a reality,” explains Mava Gwagwa, SBS’s New Business and Key Accounts Director for the municipal market. SBS’s scope included all project phases, from site excavation to the construction of the steel reinforced concrete ring beams on which each tank sits, plus the pipework and mains connections. “Wherever possible, we used local labour to level the ground for the platforms, which were excavated by hand, as well as for the in-situ casting of the ring beams.” The project commenced in October 2016 with a request by Joe Qgabi District to accelerate the completion date, where practical. “These tanks replaced older concrete reservoir systems that were mostly in very poor condition,” says Gwagwa. “Many villages were relying on other sources, such as wells or boreholes yielding substandard water quality.” By 16 December 2016, all the SBS tanks were in place and most were already connected to the municipal bulk water mains. “This made a huge difference for those communities,

especially since the number of people generally rises over the holiday season as family members return home, placing additional pressure on supply.” Final works were commissioned in February. In March 2017, SBS officially handed over the project to dignitaries from Joe Qgabi District Municipality. Thanks to this initiative, the municipality can now pump in clean, potable water.

Theewaterskloof Municipality Another turnkey example, completed in 2016, entailed the commissioning of a 2.2 Mℓ (ST31/06 model) at Riviersonderend for the Western Cape’s Theewaterskloof Municipality. Here, SBS’s tank ties in and serves as a backup to an older concrete reservoir, which could no longer cope with rising demand. “Theewaterskloof Municipality specified SBS’s bolted steel panel tank route for two reasons: the speed of erection and the cost of the structure,” says Gwagwa. From the time the tender was awarded on 12 May 2016, SBS had 14 weeks to complete the project, which included a weather contingency allowance. “Due to the time constraints, on-site civil works had to run concurrently while the tank was being manufactured back in Pinetown,” Gwagwa continues. Once on-site, it took just under two weeks for SBS to assemble and connect the tank to the infrastructure grid. “There was a scheduled four-hour interruption in water services during the final leg as we completed the interconnection to the concrete reservoir.”

Rainwater harvesting SBS supports its ongoing project activities with a comprehensive research and development programme. One prototype that has transitioned to the commercial production stage is SBS’s new rainwater harvesting tank. To prove its benefits, SBS installed a rainwater tank at its Pinetown facility in October 2016.

“We calculated the size of the tank based on the 1 046 m2 roof surface area of our fabrication shop and determined that a 156 kℓ storage capacity was adequate,” says Preston. Based on Durban’s average seasonal rainfall, SBS expects to capture around 907 000 ℓ per annum, which will then be used as potable and general-purpose water throughout the cycle. The tank has an installed purification system and SBS uses this water for most of its potable requirements. “We’re receiving strong interest from the market and have already sold a number of these tanks, all purpose-built for the client’s specific harvesting flows.”

School and hospital projects When situations like water rationing or reticulation failures occur, no one can face the risk of being without water, and a core business area for SBS is the installation of standby tanks. Recent SBS municipal projects include a hospital in Stanger, northern KwaZulu-Natal. SBS is also currently installing five backup tanks at two schools in Pinetown. “The legal requirement is that if a school doesn’t have water within three hours, it has to be temporarily closed, which causes major disruptions,” says Preston.

Exports Alongside South African opportunities, SBS is aggressively building its export base, and has successfully penetrated key global regions that include the USA. “Prime opportunities in Africa include the DRC, Kenya and Malawi, and our intention is to establish local distributors that will help grow our continental footprint where there is a pressing need for potable water storage solutions.

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IMIESA July 2017

81ST IMESA CONFERENCE 25 th-27 th OCTOBER 2017

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INFRASTRUCTURE NEWS

FROM AROUND THE CONTINENT

Ghana is piloting a new chlorine-free technology for the disinfection of water

Gambia Eradicating open defecation The Gambia is prioritising sanitation in an effort to end open defecation within the next months. The Gambian government, with the support of UNICEF, has implemented the ‘open defecation free’ campaign with the aim of freeing the Gambia of open defecation by November 2017. Under the campaign, the Kiang East District was recently declared the first of the Gambia’s 35 districts to be free of open defecation. According to Gambian Minister of Health and Social Welfare Saffie Lowe-Ceesay, more than 1 million of the country’s people lack access to basic sanitation. She believes that the campaign, with the support of UNICEF, has allowed the country to become part of the global map for sanitation. The governor of Lower River Region, Fanta Bonjang Samateh Manneh, believes that the Gambia will become the first West African country to be declared free of open defecation.

Ghana New water treatment technology

The Ghana Water Company Limited (GWCL), in partnership with Evoqua Water Technologies, is piloting a new technology that replaces the use of chlorine for the disinfection of water for domestic consumption. The technology, which has been deployed on a pilot basis at the Kpong and Weija Water Treatment sites for six months, will use salt, water and electricity to disinfect the water. This is expected to prolong the life of equipment and protect it from the debilitating effects of chlorine. According to Dr Clifford Braimah, managing director, GWCL, treating water with chlorine gas imported from India and China had become too expensive. Disinfection with electrolysers or electrochlorination is, therefore, being employed to reduce the cost of water production in Ghana. The new treatment method will also offer additional benefits such as opening up the salt industry and creating employment.

Namibia Progress on major solar plant Namibia will soon be home to one of sub-Saharan Africa’s largest

photovoltaic solar power plants. The 45.5 MWp plant being developed by Nampower has an estimated annual production capacity of 116 GWh, which will meet 3% of the countr y’s energy needs. Located on the outskirts of Mariental, the plant will occupy 100 ha and consist of around 140 000 cr ystalline silicon panels mounted on solar trackers that will move ever y day from east to west on a horizontal axis. The project has already started the financial closure and implementation planning phases, with commissioning scheduled for early 2018. ALTEN Energías Renovables won the tender to develop, execute and operate the plant, which has an investment forecast of $45 million and a useful life of 25 years. The company will be responsible for developing the energy production plant, its financing, managing the construction and its subsequent operations and maintenance. Namibia has one of the best electricity infrastructures in Africa and a high level of electrification, but it is also highly dependent on imported energy. The new infrastructure will make the countr y's energy mix more balanced and reduce its energy dependency on other countries in the region by nearly 5%.

Zambia Improved rural connectivity Zambia has received a $200 million credit to improve selected rural roads in six of its ten provinces. Rural road upgrades in the remaining four provinces will be funded by government. According to the Rural Access Index, only 17% of Zambia’s rural population lives within 2 km of a good road, leaving roughly 7.5 million people disconnected from the country’s road network. The Improved Rural Connectivity Project will benefit 460 000 people in the targeted rural areas. The majority of the rural population depends on subsistence farming, and the project will facilitate agricultural development in the country by improving farmers’ accessibility to markets. The project will also contribute towards addressing institutional capacity challenges, particularly in the area of road maintenance and road safety in Zambia, where feeder roads are largely in poor condition, explains Justin Runji, senior transport specialist at the World Bank. “Besides the project providing improved connectivity to schools, markets, health facilities and jobs for the rural communities, it has the transformational potential of positioning Zambia as the regional food basket, contributing towards economic diversification,” adds Ina Ruthenberg, country manager: Zambia, World Bank.

Namibia is developing a 45.5 MWp solar PV plant, which will be one of sub-Saharan Africa’s largest

fast facts MORE THAN

1 MILLION

of the Gambia’s people lack access to basic sanitation

100 ha

is the area on the outskirts of Mariental in Namibia where sub-Saharan Africa’s largest photovoltaic solar power plant will be built

$200 MILLION

is the amount of credit Zambia has received to improve selected rural roads in six of its provinces IMIESA July 2017

HOT SEAT

Building tomorrow’s

megacities

IMIESA speaks to Kibiti Ntshumaelo, managing director of Lekwa Consulting Engineers, about the company’s amazing journey since its founding back in 2002, and the upcoming celebration of its 15th anniversary in October. How did it all start? KN Back in 2001, we were a shelf company and it was only in 2002 that the Lekwa brand was registered and started trading. Gert Smit, my business partner, was the founder, and a former director of Klomp Consult East, a subsidiary of the Klomp Africa Group. I joined Lekwa as a non-executive director from 2002 to 2006. During this time, I also continued to work as a civil engineer for Spoornet and was part of the team responsible for the Coal Line, which was and still is a vital route linking through to the

Richards Bay Coal Terminal and ensuing export markets. Being involved on such a strategic project passed on invaluable skills and this prepared the way for me to join Lekwa full-time as managing director in 2006. We’ve grown from humble beginnings to a firm that now generates an approximate annual turnover of R20 million and employs around 40 personnel, with offices in Alberton, Ermelo, and Newcastle.

What’s the core business focus? From inception, our business

“Our experience has shown that a system design approach must start with an analysis of the end-use requirements.” Kibiti Ntshumaelo, managing director, Lekwa Consulting Engineers

IMIESA July 2017

has focused on the general civil engineering and allied infrastructure markets. Our watershed year came in 2006 when we were awarded the lead on a professional resource team (PRT) initiative for the Gauteng Department of Human Settlements. PRT projects are very multifaceted and include the project and programme management of all the major built environment professions, from electrical and civil engineering contractors to architects and builders, social facilitators and community liaison officers. We’ve found that liaison officers are especially critical in ensuring effective social facilitation and buy-in. The extensive experience gained on our first and subsequent PRT projects has really honed our skills in the design and establishment of township infrastructure, which is

definitely one of the most pressing social needs in our country. We’ve perfected the turnkey model and we’re now experts in this field. The scope includes land acquisition, town planning, environmental impact assessments, and geotechnical investigations, through to the design and establishment of the underground services and houses, the design and construction management of the road networks, plus the final handover of the title deeds. In the last 10 years, we’ve constructed more than 10 000 high-quality BNG homes and, in the process, made a real difference affected communities. We have also completed over 12 new township developments.

Has Lekwa received special recognition for human settlements projects? We’re proud to state that the

HOT SEAT

work done by Lekwa on the Nellmapius Ext. 22 project in Mamelodi, situated within the City of Tshwane, was recognised by the Gauteng Provincial Government at the Premier’s Service Excellence Awards 2017. Lekwa was nominated in the Sustainable Development category for the Infrastructure Development Award, taking second place. This BNG PRT project, which is now at an advanced stage, entails the construction of 1 232 low-cost homes, 98 military veteran units, plus 550 rental units. This project is a good example of sustainable and inclusive human settlement development.

At Lekwa, we understand the critical importance of continuous productivity improvement.

How is Lekwa developing future engineers and technologists? As consulting engineers, our real asset, and investment, lies in our personnel, and the future talent we hope to attract. We’re pleased to report that we’ve concluded a commitment and undertaking with Engineering Council South Africa (ECSA). The end result is that our professional engineers are now registered ECSA mentors. Their role is to develop and empower aspiring graduates, whether engineers or technologists.

What measures are in place to ensure quality delivery?

What is your view on the PPPFA legislation?

From inception, we have maintained our own in-house quality management systems. We’ve committed to taking this a step further and have set a goal of being ISO 9001 compliant by mid-2018. We already apply the quality management systems stipulated by Consulting Engineering South Africa.

Simply put, if nothing is done now, nothing will change meaningfully for those wishing to enter the construction sector. As consulting engineers and project managers, we are one of the major change agents in facilitating this process. In terms of the PPPFA legislation, contracts valued under R50 million will be adjudicated

on the 80/20 principle, 80 being the price, and 20 being the preferential points system, which, in both cases, has a direct bearing on how we design and execute future projects. Provision is now made for BBBEE enterprises, a 30% subcontractor component, townshipbased companies, women- and youth-owned businesses, those with disabilities, military veterans, as well as project location – i.e. rural or urban centres. Everyone accepts and wants the construction industry to transform. The PPPFA sets out to achieve this by eliminating fronting and that’s real empowerment in practice.

Are drones part of the industry's future? We’re reaching for the skies and already have a qualified drone pilot on board, pending approval and licensing of our drone unit by the South African Civil Aviation Authority. Drones are the new frontier for most industries. For civil engineers, the benefits of precise aerial surveying and realtime situation analysis are clear. For example, onboard drone

software systems now enable a perfect interface with geographic information systems.

What is Lekwa’s strategy going forward? Like any business, we want to keep on growing. One of our strategies is to form collaborative joint ventures with the larger firms in South Africa, as well as leading global multinationals working here, as well as in Africa, where we see major opportunities. We’ve already concluded a memorandum of agreement with Nyeleti, a major South African firm, as we prepare to enter new markets. One of our goals, for example, is to qualify for Sanral contracts, but we first need greater internal capacity. On the human settlements side of the business, we’ll be sharing our vision at the upcoming 81st IMESA conference in October 2017, which coincides with our 15-year anniversary celebrations. Our paper is entitled ‘Creating sustainable and lively neighbourhoods’, which responds to the challenges of building South Africa’s new megacities and transforming them into integrated socio-economic development zones that are inclusive. This is a goal that Lekwa is fully committed to.

www.lekwa.co.za

One mission ,

one vision ERWAT’s role as Ekurhuleni’s dedicated wastewater ser vice provider is critical in suppor ting major infrastructure programmes within the metro, which are designed to attract investment and meet rapidly growing population requirements. ERWAT is now ramping up its presence within the countr y as well as outside South Africa’s borders.

oining ERWAT in September 2016, managing director Tumelo Gopane has implemented a series of processes to streamline efficiencies, which includes the way in which the organisation integrates with its major stakeholder, Ekurhuleni Metropolitan Municipality to effectively meet development goals. Gopane says one of the main shifts has been the move to a more proactive approach in terms of how the

city’s current wastewater model is managed. “ERWAT has an outstanding record for downstream quality efficiencies, but needs to move with the times in terms of future spatial development planning, particularly when it comes to the rising pressure of urbanisation,” he points out. “Without the basic fundamentals like water, power, sanitation and roads, our infrastructure goals cannot be realised.” ERWAT operates 19 plants, of which 13 are now registered as being over capacity, a clear indication of the rapid socio-economic expansion experienced across Ekurhuleni. This is

Without the basic fundamentals like water, power, sanitation and roads, our infrastructure goals cannot be realised.” Tumelo Gopane, managing director, ERWAT

now being addressed through intensive infrastructure planning and ERWAT has classified its plants into three categories in terms of its intervention framework, namely red, yellow and green. Red plants are clearly the priority, since these are defined as above 100% capacity. Three plants are defined as yellow and are within the 80% to 100% threshold; with three plants defined as green, or within 80% of capacity at present. The ideal time to commence with feasibility studies is between 80% to 100% in order not to go beyond 100% capacity. Only 4 of the 19 plants are interlinked via pipeline connections; the rest are standalone facilities. The reason for this is that the Ekurhuleni metro was formed through the amalgamation of a number of small towns, many of which operated their own independent wastewater treatment plants. “That’s why we’re now rationalising and regionalising these plants so that the ones we retain within the ERWAT wastewater system are all interlinked via a dedicated pipeline network. This will require a substantial capital outlay, but will reduce operating costs in the long term,” Gopane expands.

Fifty-year master plan ERWAT’s plant and conveyancing regionalisation and 50-year master plan will be completed by the end of 2019. When finalised, the entire existing and proposed ERWAT network will be overlaid on to Ekurhuleni’s Spatial Development Framework. “In the meantime, we’ve responded to the immediate challenges with a detailed five-year

Industry Insight capex plan that’s now actively in progress and we’re currently taking a number of projects through to completion,” says Gopane. For the 2017/18 financial year, ERWAT has an approved capital expenditure budget of just over R300 million. From the 2018/19 financial year, the proposed annual capex provision ramps up to around R1.4 billion for the balance of the initial five-year plan. A 20-year capex plan is now also in progress.

Red plant upgrades Priority plants, namely Vlakplaats, Welgedacht, Waterval and Ancor have been identified for design upgrade interventions (refurbishments and expansions) from 2017/18 based on the use of existing conventional systems. The balance of ERWAT’s other plant feasibility studies will explore the introduction of new proprietary technologies. Prime examples already under way include the imminent commissioning of a Nereda technology solution at ERWAT’s Hartebeestfontein facility; and the HYBACS system being installed at Tsakane, which is now in the implementation phase. Across the board, stricter environmental measures are being introduced, which starts with what Gopane refers to as a water management "river-to-river" philosophy. “As the leading wastewater treatment company in South Africa, and probably Africa, ERWAT’s newly reviewed wastewater tariff could well serve as a pilot for other metros and municipalities on how to implement sustainable life-cycle costing models that don’t compromise the environment by cutting corners on treatment interventions. It’s about balancing revenue collection with non-negotiable environmental compliance standards.” Backing these and other initiatives is a renewed investment in research and development. ERWAT has established a technical forum, and will, in the future, be participating across all Water Institute of Southern Africa streams (and not just the water stream). “We are focused on boosting our ongoing capabilities, which means greater quality and competency. Our immediate plan is to obtain ISO 14000 certification, and within the next three to five years ISO 9001, and ISO 55000, the latter focusing on maintenance and asset management.”

“We’re actively encouraging industries to outsource their non-core waste water treatment component to ERWAT, which now offers on-site dedicated operations and maintenance packages, including laboratory services. Outsourcing wastewater treatment minimises the business risk of penalties for non-compliance and, over and above this, ensures that operations are positively contributing to the preservation of our ecosystems. We cannot allow non-standard processed wastewater to be pumped back into our rivers and ERWAT is here for the market,” he expands. ERWAT will be exhibiting at the IMESA 2017 Conference in October and the Mining Indaba in February 2018, among other key expos, which demonstrates its desire to engage with industry and to reposition ERWAT as a national and multinational state-owned company. “The added revenue stream will help to make ERWAT more self-sufficient and thus enable Ekurhuleni to channel funds into non-revenue areas, like roads and stormwater. We could even become a cash cow for the city.”

Memorandums of understanding ERWAT has recently concluded a memorandum of understanding (MoU) with the Department of Public Works, and the first target is to assess and improve the wastewater treatment plants housed within the Department of Correctional Services. An MoU has also been concluded with Lepelle Northern Water, headquartered in Polokwane, to collaborate with them in upgrading, operating and maintaining their wastewater treatment plants to bring them up to compliance levels.

Industrial outsourcing ERWAT is also actively pursuing opportunities in the private sector. Some of the existing FMCG clients include Heineken, Nestlé, and Kellogg’s. ERWAT is also moving into two new areas, namely mining and specialist industrial manufacturing, particularly for those industries needing to dispose of paint and chemical-type products.

PPPs Proposed public-private partnership opportunities in wastewater reuse are included in ERWAT’s 50-year master plan. As previously stated, ERWAT’s rationalisation process seeks to reduce the number of plants currently in operation, while at the same time increasing the capacity

and efficiency of the remaining facilities. Some of these plants could potentially be identified for self-sustainable PPP ventures, based on the city’s future spatial development framework and planned residential and industrialisation nodes. ERWAT is also addressing Ekurhuleni’s pressing informal settlement needs, of which there are currently an estimated 120. Here, the introduction of off-grid package plants provides the best and most immediate response. This plug-and-play wastewater treatment solution is also well suited to low-cost housing developments planned for construction in the immediate future. Eventually, these off-grid plants would be replaced by formal wastewater treatment networks as Ekurhuleni embarks on its megacity developments in the coming decades.

www.erwat.co.za

IMIESA July 2017

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Municipal Feature | Ekurhuleni

The City of Ekurhuleni has adopted a new strategic approach to transforming and developing the region, by embracing the Aerotropolis concept. The city recently hosted the Ekurhuleni Investment Conference 2017 to assist in bringing this strategy to life.

ccording to the City of Ekurhuleni’s executive mayor, Cllr Mzwandile Masina, the city is plagued by apartheid spatial planning, a declining manufacturing base, high levels of poverty and homelessness, ageing infrastructure and service delivery capacity constraints. “These socio-economic challenges are further exacerbated by the perception of corporate exploitation, corruption and wastage, which, in turn, breeds mistrust between the government, business, civil society, labour and communities,” said the mayor. To address this, the city has resolved to achieve radical economic transformation – a fundamental change in the economic distribution mechanism, structure, systems, institutions, patterns of ownership, management and control. “This approach enables us to unlock and open the economy to nontraditional economic players who, in turn, would trigger economic activity and enable the economy to be more dynamic, competitive and inclusive,” said Masina.

Unlocking Ekurhuleni’s

economic potential “The position to radically transform our economy is underpinned by the imperative to push back the frontiers of poverty, underdevelopment, unemployment and inequality in partnership with our social partners. “Having appreciated the role of the private sector in catalysing inclusiveness in the structure and ownership patterns of the economy, the relationship between government, business, labour and civil society requires a renewed social compact,”added the mayor.

Investment destination of choice According to Masina, the Gauteng city region remains the top destination and recipient of greenfield and brownfield investments in South Africa due to locational advantages. Moreover, despite the Fitch and Standard & Poor’s credit downgrades for South Africa on sovereign considerations, Moody's rating agency has maintained its positive rating of Aaa.za/Prime-1 investment grade for the City of Ekurhuleni. “This is a vote of confidence in our good financial performance, which reflects strong revenue growth,” said Masina. Masina noted a number of mega private sector investments – large-scale mixed-use developments, which are part of the city’s investment pipeline of over R300 billion project value over the next 15 years. “Our efforts as the City of Ekurhuleni are poised to ensure that we are a destination of choice for investment, trade

and tourism, as we leverage our Aerotropolis properties, locational advantages and associated infrastructure and economic clusters to our advantage. The City of Ekurhuleni encompasses what is claimed to be the largest concentration of industrial activity in South Africa, and in sub-Saharan Africa.” According to Minister of Finance Malusi Gigaba, Ekurhuleni has 30% of the country’s industrial capacity. “This country needs massive industrialisation in the secondary sectors in order to grow and create jobs and wealth on a sustainable basis in pursuit of the radical economic transformation we seek in order to achieve inclusive growth,” said Gigaba. “Accordingly, we need cities like Ekurhuleni to do exactly what you are doing here: forge strategic partnerships between government and business, particularly, including other social partners, to promote investment in growth industries such as advanced manufacturing, which can drive economic development over the next decade or more,” he said. Gigaba added that National Treasur y will increase its collaboration with the city to drive inclusive economic growth and confront the challenge of South Africa’s inefficient and inequitable spatial histor y.

The City of Ekurhuleni increased its capex budget from R2 billion in 2011 to R7 billion in 2017 IMIESA July 2017

Municipal Feature | Ekurhuleni

The City of Ekurhuleni’s 10-point economic plan lays the foundation for major growth.

A delivering city by 2020

well-mapped-out strategy was recently presented by the City of Ekurhuleni during the metro’s budget speech, delivered by Cllr Dr Nkosindiphile Xhakaza, MMC for Finance and Economic Development. The budget outlines Ekhurhuleni’s Integrated Development Plan (IDP) and the Medium Term Revenue and Expenditure Framework (MTREF) for the 2016/17 to 2020/21 periods, and sets high standards for delivery. “This budget is an investment in radical economic transformation as expressed in our 10-point economic revival plan. This is our deliberate programme to position the City of Ekurhuleni as the primary anchor and rubberstamp our footprint on the national economy. We have also paid special attention to the Gauteng city region’s TMR (Transformation, Modernisation and Re-industrialisation), which seeks to position our province among the best in the world,” said Xhakaza. Within the budget, the central focus is on improving living standards and creating opportunities for all stakeholders through job creation projects, skills and community bursary funding schemes, and SMME development. Integral to this is township economic revitalisation, with R269 million allocated over the next three years for various enterprise hubs. R12 billion has been set aside for procurement

opportunities specially targeting local entrepreneurs, service providers and enterprises over the MTREF, which will certainly serve as a welcome catalyst. Of this amount, R3.5 billion has been made available in the 2017/18 financial year.

Investment destination Key growth areas identified include smart and advanced manufacturing, aviation and aerospace, and the logistics and transportation industries. Among the initiatives identified is the Aerotropolis Master Plan, which is expected to be approved by year end, and sets out to position the regional economy as an ideal destination for trade, tourism and investment. R570 million has been allocated for the Aerotropolis infrastructure roll-out programme over the MTREF. Ekurhuleni will profile and facilitate five Aerotropolis investment projects within the next three years, and launch requests for proposals for various development projects, as identified in the master plan. “At least R200 billion in investment will be facilitated as part of the Aerotropolis,” said Xhakaza. “Our Growth and Development Strategy (GDS) 2055 indicates that the city has entered a time of profound strategic choice with powerful longterm consequences. As the industrial and logistical core of the Gauteng city region, Ekurhuleni is pivotal to South Africa’s growth trajectory to 2020, 2030 and beyond,” he added. “The GDS thus recommends a concerted programme of re-industrialisation, remobilisation,

Cllr Dr Nkosindiphile Xhakaza, MMC for Finance and Economic Development, City of Ekurhuleni

re-urbanisation, re-governance and regeneration. This will lead the transition from a currently fragmented city to a delivering city by 2020, a capable city by 2030 and a sustainable city by 2055.” This vision includes transforming Ekurhuleni into a digital city, backed by an ongoing investment in related infrastructure, with R609 million allocated to the city’s Information and Communication Technology (ICT) Department in 2017/18 and R1.8 billion over the MTREF. Projects to be undertaken here includes Phase 1 of the ERP system, which has an MTREF budget allocation of R1 billion, broadband rollout, and the improvement of Ekurhuleni’s network capability. “We remain the only metro in Gauteng that continues to provide free Wi-Fi/internet connection to our citizens. We already have 1 400 km of fibre for this purpose and 2 500 Wi-Fi nodes servicing 250 sites with a reach averaging 300 000 users a month. The city has set aside an amount of R33 million per annum to broaden this service to our people. Our target is to average 500 000 users per month by the end of the year,” said Xhakaza. Across the board, Ekurhuleni has committed to controlling costs and maximising billed income with a target set of 94%, which will help sustain MTREF goals. The city also plans to reduce the percentage of non-revenue water losses to below 25% in the next five years though a concerted War on Leaks campaign. In the previous financial year, the city lost R759 million through water losses, a revenue stream that could have been effectively used to help fund city projects.

Municipal Feature | Ekurhuleni

The point economic plan 1

Manufacturing revitalisation

Aerotropolis Master Plan implementation

Acceleration of IDZ/SEZ (special economic zone) programme

Land availability for strategic development

Support of SMMEs through public procurement

Implementation of township economy strategy

Enabling public transport system

Massive public infrastructure investment

Promote localisation and production

Skills, capability development and workplace stabilisation

2017/18 budget highlights The total Ekurhuleni budget for the 2017/18 financial year is R36.6 billion, funded as follows: • Generated revenue: R26.2 billion • Operating grants: R5.4 billion • Assessment rates: R5 billion.

Key facts by sector: Economic development R664 million allocated for the 2017/18 period. Of this amount, R619 million is for bulk infrastructure roll-outs to enable economic development initiatives. These include an amount of R45 million for the revitalisation of four traditional industrial parks in Wadeville and Labore. Public transport R2.6 billion over the MTREF, starting with R831 million in 2017/18. R1.9 billion has been allocated for the second phase of the BRT project (Harambee), which links Kempton Park and Katlehong. Human settlements R1 billion for 2017/18 and R3.4 billion over the MTREF. Energy • R718 million for the 2017/18 financial year and R2.2 billion over the MTREF. An amount of R655 million has been assigned for the electrification of informal settlements over the next three years, and R169 million for the installation of public lighting in areas that include Daveyton, Duduza, Katlehong, Vooslorus and Tembisa. • An amount of R1 billion has been allocated for repair and maintenance in 2017/18, while R3.5 billion has been provided for the same purpose over the MTREF.

Water and sanitation R599 million for 2017/18 and R2.3 billion for the MTREF: • R687 million for reservoirs, pressure management systems and pipe networks. • R555 million for sewer networks. • R272 million for meter repairs and replacements. • R607 million in 2017/18 and R2 billion over the MTREF for operations and maintenance of water and sanitation leaks, unblocking of sewer blockages and reservoir maintenance. • R170 million to improve the 1:10 ratio for portable ablution facilities to 1:5 as per the council’s revised policy. Roads and stormwater R683 million in 2017/18 and R2.5 billion over the MTREF. • R846 million is allocated for repairs and maintenance, potholes, road surfacing and stormwater-related works in the 2017/18 financial year, while the total is R2.7 billion over the MTREF. Health and social welfare R91 million allocated in the 2017/18 financial year and R348 million over the next three years for projects that include the construction of 12 new clinics and maintenance of existing facilities. Waste management R166 million allocated for 2017/18 and R502 million over the MTREF. This includes R113 million for 2017/18 and R377 million over the MTREF for waste removal programmes and recycling work. Information and communication technology (ICT) R609 million allocated in 2017/18 and R1.8 billion over the MTREF.

IMIESA July 2017

Municipal Feature | Ekurhuleni

he Gibela Rail Transport Consortium train manufacturing facility at Dunnottar in Ekurhuleni, Gauteng, achieved 500 000 LTI-free (lost-time-injury-free) hours late last year. Located near Johannesburg, the 50 000 m2 manufacturing facility is currently under construction by eight principal contractors, each with their own individual work packages. Gibela itself is a consortium aiming to deliver 580 trains, comprising 3 480 coaches, to revitalise rail transportation in South Africa. Aecom won the bid to design, procure and manage the construction and commissioning of the Gibela facility as the main engineering, procurement and construction management consultant. The company has also provided expert health and safety advice to the client and contractor pool.

A collaborative approach “A critical area of our scope of work was to inculcate a common approach to safety management in order to ensure that the client’s performance expectations were met,” comments Cara-Mia Key-

Partnering for safety on-site

ser, manager: Environment, Health & Safety for Buildings & Places in Africa, Aecom. Key challenges in this regard were the project’s size, and its focus on supporting local enterprise and supplier development. “This drove our approach to addressing environmental, health and safety challenges through partnerships and engagements,” she adds. According to Keyser, building a common approach to the project’s safety management through partnership and engagement was critical in achieving the 500 000 LTI-free hours. Aecom, in conjunction with Gibela, conducted a series of kick-off meetings and extensive workshops to assist new contractors with coming

to grips with the stringent project’s environmental, health and safety requirements. These meetings and workshops initiated an engagement process aimed at supporting all contractors by providing them with the knowledge and vision to contribute to achieving safety excellence. “This resulted in related events to assist in fostering a shared commitment to safety,” Keyser reiterates. “Aecom has implemented programmes to ensure that the high environmental, health and safety standards set by Gibela are achieved. We took a hands-on approach to contractor management in order to ensure that performance expectations were met,” Keyser concludes.

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Municipal Feature | Ekurhuleni

Advancing ground engineering

orldwide, Uretek’s geopolymers for floor and foundation relevelling, ground stabilisation and void filling have been extensively proved to be highly cost-effective, non-disruptive and fast ground engineering solutions. Two recent South African projects highlight typical interventions that address structural defects using the Uretek patented technologies of Slab Lifting and Deep Injection. In the first example, the concrete floor slabs on an apron section at O.R. Tambo International Airport were showing signs of settlement and surface cracking, being regularly subjected to the weight of incoming and outgoing aircraft. “We drilled a series of 14 mm holes in a grid pattern to the underside of the concrete and injected our patented structural resin through injection tubes into the ground,” explains Tony Pappalardo, Uretek Geo Systems' managing director, based in Midrand. The process was tracked throughout by

using monitors and a rotary laser to ensure that the slabs were not lifted out of alignment. The injected resin follows the path of least resistance, filling all voids and increasing the bearing capacity of the weak areas encountered. The term used to describe this process is soil densification. At O.R. Tambo, Uretek’s resin reached 90% strength in 15 minutes,and the apron section was then ready for normal use.

Cricket stadium In the second example, Uretek was appointed to provide a remedial solution at the Buffalo City Pavilion cricket stadium in East London. 20 column bases had subsided beyond normal settlement conditions. “Our task was to drill through the concrete bases to reach the weak soil layer,” says Pappalardo. “What made the task particularly challenging was the depth of the concrete below normal ground level.”

In some cases, the main contractor had to excavate close to the top of the concrete bases to provide an effective staging point for Uretek’s drills. “Our longest 16 mm drill bit only reaches 3 m, and in some cases the bases were located at a depth of 4.5 m. ”As with the O.R. Tambo project, the injection process was monitored throughout, recording a lift of between 5 mm and 8 mm of the concrete bases. When a minimum lift of 0.5 mm to 1 mm wasachieved, it indicated that the ground had been densified sufficiently to carr y the upward thrust. “In other words, the bearing capacity of the ground below the concrete had been increased considerably to facilitate the upward expansive force, which is caused by the chemical reaction of the two resin components injected simultaneously, and not by exerting hydraulic pressure” adds Pappalardo. IMIESA July 2017

WE HAVE LIFT-OFF

Uretek Geo Systems recently stabilized a test area of OR Tambo Airport successfully. The surface was ready for traﬃc within 15 minutes ,with no disruptions to the busy airport. Uretek specialises in industrial,commercial and residential applications. Uretek have also helped rehabilitate and stabilise highways countrywide, with our advanced technology, backed by extensive experience. Uretek deep injection patented technology,uses high density expanding polymers to stabilize soils at depth and increase their bearing capacity. This allows the foundations, oor slabs, or road areas to be realigned as needed. Most importantly, Uretek slab lifting method returns your roads and concrete oor slabs to their original integrity, with a stronger sub-base and improved soil structure. Regardless of whether your problem is routine or complex, Uretek can draw from extensive resources to develop the best solution to your needs. Uretek loves a challenge and an opportunity to be innovative. For more information about what makes Uretek the best choice, contact: info@uretek.co.za (011) 238 7154 www.uretek.co.za

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PROFILE | Ekurhuleni

ith the rise of smart cities, the public sector is increasingly looking to harness digital technology to improve performance and service delivery, while managing costs efficiently. It makes little sense for municipalities to replicate technology infrastructure purchases. Instead, they can significantly reduce costs and improve efficiency by adopting a shared services model. This will also increase service delivery, transparency and, ultimately, citizen satisfaction.

Municipalities need to modernise too Modernising and digitising municipalities’ infrastructure and operations can significantly impact their billing and ability to operate effectively. In order to make the vision of smart cities a reality, municipalities will have to invest in infrastructure and technology that supports their digitisation efforts. However, municipalities don’t need to carry the burden as an individual unit. If these solutions are rolled out at a metropolitan or even district level, providing shared services to the smaller local municipalities, the impact they have will be much bigger. It will enable all municipalities within that district or metropolitan to deliver the same quality of services to their citizens, subsequently driving down the cost of service delivery and improving overall transparency. Moreover, by moving infrastructure to a central location and having a core team in place, you

Embrace the digital future eliminate fragmentation and lower the risk of billing delays. This is particularly important where high staff turnover is an issue. By centralising core functions, the required expertise to support the environment remains in place should someone leave, having little to no impact on the overall billing process and ultimately the municipality’s performance.

Getting a handle on big data National, provincial and local governments are also faced with growing volumes of big data. Analysis of big data can be used to increase citizen integration, provide real-time insights and create smart cities. It can also help government departments understand how citizens perceive their services so that they can be adapted in order to meet end users’ needs and expectations. Digitalisation is about supporting government to find the best way of achieving its goals by using digital technology such as cloud computing or big data management. It is more than a reduction in IT costs, it is about creating the right digital strat-

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BCX has strategic global technology partnerships with best-in-class vendors to ensure superior endto-end ICT services are delivered to customers. The company’s extensive African footprint – with international subsidiaries in countries such as Kenya, Nigeria, Tanzania, Namibia, Zambia and Botswana – as well as a presence in Dubai and the UK make BCX the ideal strategic ICT partner for clients doing business in Africa or those wanting to navigate Africa’s growth opportunities.

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Municipal Feature | Ekurhuleni

Ekurhuleni geared for rapid growth Ekurhuleni prides itself on being known as the smart, creative and developmental city. With a rapidly increasing population, an explosion in commercial and industrial activity, and plans on the horizon for several mega housing projects, the management of water-related infrastructure has become an integral part of the city’s sustainability. By Louis Strijdom*

etween 2001 and 2011, the number of households in Ekurhuleni Metropolitan Municipality (EMM) increased by 36.1%, making it the third largest city in South Africa in terms of households. Its population of 3.2 million is growing at a rate of 2.5%, which significantly exceeds the national growth rate of 1.7%. To unlock the economic benefits of having the largest and busiest airport on the African continent, the metro has prioritised the Aerotropolis project, an initiative aimed at transforming O.R. Tambo International Airport into a R300 billion multimodal “airport city” commercial core. Even the manufacturing and distribution sectors are aggressively being revitalised through projects like the next-generation inland port at Tambo Springs and the new Prasa Gibela manufacturing facility in Dunnottar. The Human Settlements Department is also keeping track with this rapid growth, with plans to roll out 100 000 new housing units and 59 000 new serviced stands within the next five years to address the current housing backlog.

Managing water-related infrastructure The phenomenal growth and development anticipated will no doubt result in a substantial increase in water demand and sewage flow, adding to the strain already experienced on existing water-related infrastructure. Although a budget has been allocated to water services infrastructure, the correct balance between acquiring new infra-

structure and maintaining existing infrastructure still needs to be struck. The rate of providing new water and sanitation services is currently at the highest it has ever been. It is, therefore, crucial that expenditure of the remaining budget earmarked for the upgrading and maintenance of existing services should be planned optimally. To assist EMM in this planning process, GLS Consulting was appointed to prepare a comprehensive master plan for the water and sewer systems.

Hydraulic modelling The core of the master plan comprises a set of fully digitised hydraulic water and sewer models capable of accurately simulating system performance. These models have been compiled and maintained over GLS’s long-standing relationship with EMM since the late 1980s, and are currently being updated monthly. GLS utilises Wadiso (water) and Sewsan (sewer) specialist modelling software for the analysis and evaluation of its systems. GLS’s Swift software is utilised to load the hydraulic models with actual water consumption figures extracted from EMM’s billing system.Dynamic hydraulic models allow the municipality to evaluate current system performance and to improve operations and maintenance. Furthermore, the system not only allows infrastructure data to be accessed and integrated in real time, but also allows for a holistic view that is graphically represented in the IMQS, GIS-based system.

*Louis Strijdom is an engineer at GLS Consulting.

Dynamic master planning Taking all anticipated future development into consideration, future system models are compiled to represent the ultimate future scenarios for the planning horizon. Analysing and evaluating the ultimate future hydraulic models allows for the identification of future deficiencies in the systems. Subsequently, new bulk, upgrading and renewal projects can be identified to address system deficiencies. For each project, a preliminary design is done, a cost estimate prepared, a priority allocated and an estimated implementation year calculated. “Essentially, the prioritisation of required projects and the associated spreading of projects over time is the key to our department’s infrastructure and budgetary planning,” says Danie van der Merwe, chief engineer: Water Services Planning, EMM. “The master plan serves as our strategic decision-making tool.” Dynamic master planning systems are essential components of building smart, resilient cities that can intelligently approach the challenges faced due to rapid growth, such as experienced in EMM. With having these systems in place, EMM has made serious strides in gearing itself for the development boom that is surely to hit the smart, creative city.

IMIESA July 2017

WATER TREATMENT

New-generation is a winner

pump

In Africa, a pump range stands out once it becomes a trusted name in dominant water user sectors and among implementing agents in charge of domestic water supply. These industries prioritise versatility, efficiency and reliability.

he latest generation of KSB Pumps and Valves’ standardised Etanorm water pump series meets these criteria, making it one of the longest-running popular pump types in use in Africa, as well as worldwide. First produced in 1936, the Etanorm has sold more than 1.5 million units, which have proved themselves over more than eight decades. In its latest form, the pump comprises 43 pump sizes, which can be driven by either two-series or four-pole motors. The selection chart has also been extended with additional pump sizes, so that sizes closest to the best efficiency point can be selected.

Efficient design In intensive work with computational fluid dynamics for flow simulation, KSB’s

development engineers have also optimised the hydraulic contours, making it more efficient to easily meet tough global efficiency requirements, including the benchmark EU requirements of Commission Regulation 547/2012/EC for water pumps. According to Dave Jones, regional sales manager, KSB, the engineers placed particular focus on obtaining an excellent suction and a low net-positive suction head value, thus minimising the risk of cavitation and obtaining a smooth and stable pump operation even in difficult operating conditions. This means the pumps run reliably and contribute to a greater availability of the overall system. A diverse material range consisting of

cast iron, nodular cast iron, bronze and stainless steel and a large choice of seal variants have extended the suitability of the new series to applications beyond those of water. The space allocated to the mechanical seal has also been enlarged to enhance venting and the new spacious design facilitates the dismantling and reassembly of mechanical seals. Operators benefit from the type series being manufactured at four different sites – in Germany, India, China and South Africa – which all comply with the same quality standards. This makes global procurement much easier, with pumps and parts readily available.

C E L E B R AT I N G

Years

1947-2017

Usuthu expands its output

Zululand District Municipality is currently in the process of expanding its Usuthu Water Purification Plant to increase its output by 20 Mℓ/day.

ased in Nongoma, KwaZulu-Natal, the water purification plant, along with the reser voir and access road, was first commissioned in 2015 as part of a long-term project established by the Zululand District Municipality to address the water and sanitation needs of the community. The current expansion involves a multidisciplinar y approach led by Isimo Engineers, Stefanutti Stocks as the main contractor, and Water Purification Chemical & Plant (WPCP). WPCP is responsible for the mechanical and electrical phases and allied plant element installations. WPCP’s project scope includes all pipe items (HDPE, steel and uPVC); chemical dosing equipment, including a new chlorination plant; equipping eight new rapid gravity filters; the installation of CADAR false floors, backwash pumps and blowers; and motor control centres and plant lighting. WPCP has been in the water treatment works business for 15 years. “We deal with the chemical aspects of drinking water treatment, the finer details of filtration, or the design of major water purification and wastewater treatment plants,” comments Martin Over y, head of WPCP, which is an 8 ME contractor in terms of the Construction Industr y Development Board grading system. Plasti-Tech is mandated to supply HDPE pipes and ancillar y fittings in diameters of 500 mm, 710 mm, 800 mm and 900 mm PN8. The Usuthu Water Purification Plant expansion project commenced in Januar y 2017 and is due for completion in September 2017.

IMIESA July 2017

WATER TREATMENT

Upgrading the Temba Water Purification Plant

image 1 The existing Kudube Dam spillway with the new outlet structure and spillway section under construction

The City of Tshwane has embarked on a project to upgrade the existing Temba Water Purification Plant. By Jacques van Rooyen*

he Temba Water Purification Plant (TWPP), which currently supplies 60 Mℓ/day, is being upgraded through the construction of a new 60 Mℓ/day conventional treatment works, combined with a 120 Mℓ/ day advanced process plant comprising ozone and granular activated carbon (GAC) filtration. Aecom SA was appointed by the city to per form the detailed design and construction super vision for the works related to the extension and upgrading of the existing plant. The project includes all structural, civil, mechanical and electrical work at the treatment plant and ancillar y works, including modifications to the Kudube Dam, upgrading of the raw water and high-lift pumps, additional on-site storage and the replacement of one of the existing raw water pipelines. The new and existing plants are also to be integrated, with both plants operating on the same Scada system.

IMIESA July 2017

image 2 The front end of the HDPE pipe with end cap used for the pipe cracking Table 1 Current, future and ultimate flow distribution from TWPP

Area

Current plant (Mℓ/day)

Future plant (Mℓ/day)

Ultimate (Mℓ/day)

Babelegi and Hammanskraal Sekampaneng Reservoir Local Temba Network Hammanskraal West TOTAL

15.5 23.0 15.2 3.7 57.4

26.2 47.1 17.4 32.9 123.6

30.2 53.6 19.0 37.8 140.6

image 4 Casting of a GAC filter false-floor bay

bar

l/s °C

image 3 One of the three OCT screw pumps being delivered to site

m3/h

m/s

fact

Precise monitoring of water flows and leak detection in irrigation networks

Phases 1 to 5 are already completed and Aecom is currently implementing the sixth phase of the project.

Process overview Raw water is abstracted from the Apies River at the Kudube Dam, where the new outlet structure is being constructed (Image 1). The water is abstracted through two 1 000 mm ND pipes, flows through a new flow measuring chamber and a new valve chamber and into the upgraded raw water pump station– the capacity of which is being increased to match the requirements of the new 120 Mℓ/dayplant and provision is made for the next phase of 165 Mℓ/day. From here, it is pumped along the new steel pipeline and the existing steel pipeline to the treatment works in Temba. The new pipeline includes 1 300 m of 850 mm ND HDPE piping (Image 2), which was installed using pipe cracking technology. This is the first time this has been done on this scale with a pipe diameter of this size. Currently, the raw water arrives at the TWPP and is treated at the existing 60 Mℓ/day purification plant, which has been constructed in five phases over a period of 40 years. Treated water is stored on-site, from where it is transferred into the distribution network and to command and distribution reser voirs surrounding Temba, as listed in Table 1. The implementation of Phase 6 doubles the existing capacity of the plant to 120 Mℓ/day. Flow from the raw water pipeline entering the new inlet tower will be split by controlling the

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WATER TREATMENT

image 5 Existing services complicating construction

result is that almost 100% of the water pumped to the water treatment Works is used with minimal losses. This has a big cost saving on the pumping of the raw water from the dam as an additional 5% to 10% or 6 to 12 Mℓ/day can be used. Although the new (Phase 6) and the existing (Phases 1 to 5) plant will operate independently, water from the previous phases will again join Phase 6 at the ozone contact tank (OCT) sump. Therefore, the OCT as well as the GAC filters were designed for the total combined capacity of the treatment plant. In the upgraded plant, water will be dosed with ozone in the following positions: • Pre-ozone: dosing of ozone at the inlet tower for the oxidation of iron and manganese. • Intermediateozone (sand filters): dosing of ozone at the inlet to the sand filters for the oxidation of organic material to improve the nitrification of ammonia; • Intermediateozone (OCT): dosing of ozone in the OCT for the oxidation of organic material and disinfection of the water.

image 7 Insufficient capacity of existing plant leading to spilling on-site

image 8 Sludge handling pump station, thickeners and centrifuge decanter building

Construction image 6 The high water table saturating the bedding

water levels at the inlet tower of Phases 1 to 5 and at the settling tanks inlet of Phase 6. Water will be gravity fed from the inlet tower through all the processes up until the inlet at the OCT. There, three inclined screw pumps (see Image 3) will create sufficient static head to transfer the water through the GAC and to the TWPS. The GAC filters will remove dissolved organic carbon, colour, odour, and microcystin toxicity. Image 4 is a photograph taken during the first cast of one of the GAC filter false-floor bays. The TWPS conveys the water to the new 10 Mℓ reservoir through a 1 100 mm ND mild-steel pipe, from where the high-lift pump station transfers water into the distribution network and to several command and distribution reservoirs surrounding Temba. The new process water pond serves as a balancing dam for all the process water used in the new Phase 6 and also all the sludge and process water for Phases 1 to 5. The overflow water is returned to the intake tower and the

IMIESA July 2017

The engineer and especially the contractor are constantly faced with the challenge of managing a construction project in and around an operating plant. Simple tasks such as excavating trenches for pipelines are complicated by the number of existing underground ser vices. Image 5 shows the number of existing ser vices located on a short section of the 1 100 mm ND pipe running between the TWPS and the 10 Mℓ reser voir. To add to the complexity of construction, the water table is located at approximately 2 m below natural ground level. The high water table has provedto be a big frustration to the contractor, especially with the construction of the interconnecting pipework Image 6 shows the high groundwater table saturating already installed bedding. In many cases, the high water table forced the contractor to use soilcrete rather than the approved river sand in order to ensure the specified compaction. Adding to the contractor’s problem of dealing with water, the sand filters of the existing plant regularly spill into open excavations, as it cannot cope with the designed volume of raw water in its current state of operation, as shown in Image 7. The sludge handling facility was originally planned to be sludge ponds but the location

was in the 1:100 floodplain and the environmental licence was declined. This forced the relocation of sludge handling to the main plant. Because of the limited space, a centrifuge in combination with two thickeners is used. The nature of the project is highly mechanically intensive and most of the equipment has been installed. This includes the process water pump station that will form the heart of the process, the screw pumps, the raw water pump station and the ozone generators. There are over a hundred actuated valves that will be controlled together with the existing plant with one Scada. With the majority of the construction work completed, construction works on Phase 6 is expected to be completed by August 2017, with the final takeover date expected to be in the first week of Januar y 2018. *Jacques van Rooyen is a resident engineer and associate: Dams and Hydropower at Aecom SA.

DAMS & RESERVOIRS

r i o v r e s e v e o e r k R a e Neptun m ts a

iet Meyer, managing director of Aquatan, argues that implementing geosynthetic solutions to conserve and optimise water use is one of the most economic, efficient and reliable ways of sustaining water supplies, even, and perhaps especially, in times of drought. “It is also important that we efficiently utilise existing storage facilities, as we live in a water-scarce country. Long-term water-preservation strategies should become the norm,” he says. Furthermore, it may be worthwhile to consider the Western Cape’s current severe drought within the context of a number of exacerbating factors. It is recorded that the city has experienced a 55% population increase since 1995. Rainfall patterns are also changing owing to global warming. The above are a stark reminder that it is vital not only to construct new dams and reservoirs but more so to maintain infrastructure already in place. A very good example is the recent rehabilitation of an important reservoir in the Cape. Simon’s Town has two reservoirs – the Prince George and Neptune reservoirs. Both circular reservoirs were constructed in 1940 and originally uncovered. Later, residents started complaining about the taste of the water and it was discovered that strong winds were dumping pollen into the reservoirs. In 1989, it was decided that a roof should be installed. The cost of a concrete roof was prohibitive, so Aquatan suggested installing a Hypalon/HDPE combined floating cover system. The novel idea was accepted and the cover was installed in

Aquatan’s commitment to protecting water resources and the environment has underpinned its cutting-edge innovations from the time of its founding in 1966.

New floating roof on the Neptune Reservoir, Simon’s Town

also to fit new rainwater removal pumps that would connect newly laid discharge piping to a manhole.

the 55 Mℓ Neptune Reservoir, which has a diameter of 112.6 m and a wall height of 6 m. Aquatan had been earning praise for its innovative floating cover design since the installation of its first cover in 1984. The 1989 Neptune floating cover consisted of HDPE (projected floor area) and Hypalon (vertical walls), and included a series of buoyant floats and weights to maintain the cover under tension. The life expectancy of the original floating cover roof was 10 years. However, it serviced the community for 28 years. The time finally came to replace the cover and Aquatan was awarded the tender to do so in June 2016.

What Aquatan found As the reservoir had been covered for 28 years, it was not possible to gauge the condition of the concrete before starting the work. Once the cover was removed and recycled, 3 600 m of bitumen-sealed expansion joints – varying in widths from 75 mm to 100 mm – were discovered on the floor. The walls had 30 vertical expansion joints, each measuring 300 mm wide, also sealed with a bituminous emulsion. It became clear that it was impractical to seal these joints with conventional sealants due to their inconsistent size and the huge accompanying cost.

Proposed solution Original scope The intended scope of the project was to remove and dispose of the old cover, including the stainless steel straps at the top of the wall and the existing abrasion layer. Minor concrete repairs were intended as well as resealing of the expansion joints of the wall and floor. A new cover would then be installed, with a new abrasion layer on the wall and new steel strapping at the top of the wall. Aquatan was

The City of Cape Town asked Aquatan to supply alternative costings to either line the entire reservoir with a 2.0 mm linear lowdensity polyethylene (LLDPE), or install a polyolefin bandage over each joint. The lining of the entire reservoir proved to be the more holistic, cost-effective and practical solution because it would also address remediable cracks difficult to detect in the concrete. In the value engineering process, Aquatan proposed

IMIESA July 2017

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DAMS & RESERVOIRS

installing 300 mm wide aluminium strips over all the floor expansion joints – to avoid the LLDPE liner being forced into the varying joints by the near 5.6 m water head on the 2.0 mm LLDPE at full capacity of the reservoir. The wall joints were addressed by installing an engineered high-density foam to bridge the joint width. To mitigate the unexpected additional cost to the City of Cape Town, and following a technical evaluation of the 28-year-old stainless steel baton and bolts, Aquatan proposed sandblasting and reusing the same baton strapping at the top of the wall. The site included various civil engineering disciplines such as earthworks, as well as civil and mechanical pipe and valve works, which, together with the LLDPE liner and floating cover, required full-time management by an experienced site agent. Aquatan also proposed a leakage detection system comprising a 4 mm high spacer layer (750 Hidrain) across the entire floor area of the reservoir under the LLDPE liner. The leakage detection system monitors and mitigates potential leaks in the lining. This was well received by the City of Cape Town because it would mitigate water losses. In order to connect the gravity-driven leakage detection system to the atmosphere, a pipe was installed by core drilling through the reservoir wall into the scour sump (lowest point of the reservoir) and directional drilling through the soil to daylight in a constructed headwall structure to which any leaks would flow and be monitored.

The drilling was required in terms of the city’s contract condition that no vegetation was allowed to be removed, damaged or disturbed. This condition required Aquatan to relocate 13 snakes and one tortoise, as well as temporarily barricade the breeding ground of a spotted thick-knee. Aquatan’s Electric Leak Detection system, a post-construction quality assurance method, was applied on the LLDPE on both the floor and vertical walls of the reservoir to detect and eliminate any discrepancies in the liner before cover installation.

Getting it done The LLDPE was delivered to site in 7 m wide rolls and lowered into the reservoir by a crane. Using the floor of the reservoir, and careful measurements, the wall panels were pre-manufactured in predetermined, carefully measured modules, and the floor liner was pre-cut to the required lengths after taking the curvature of the reservoir into consideration. The same process was used for the reinforced polypropylene (RFPP) floating cover roof material, which was pre-cut and seamed at Aquatan’s factory in Isando, Johannesburg. The wall modules, both LLDPE and RFPP, were then installed using custom-made tools, which minimised the handling of the liners and the very complicated vertical seams on-site. The floor of the reservoir was then installed, with both liners following one another, like building a puzzle.

The result BELOW (from left to right) Rehabilitated wall joints 2 mm LLDPE lining and 300 mm aluminium strips over floor joints in progress The reinforced flexible polypropylene floating cover being installed on the floor of the reservoir

Aquatan completed the works on 26 May 2017 – 10 working days before the stipulated end date of 6 June 2017. It is noteworthy to mention that, among all the other benefits associated with a floating cover, the RFPP

cover and LLDPE liner withstood the recent reported Western Cape wind speeds of up to 150 km/h. Anver Seconds, senior professional officer: Planning, Design & Projects at the City of Cape Town, comments: “I would like to extend my appreciation towards all involved in the successful completion of the contract – in time and within the approved budget allocation. I appreciate the professionalism with which the project was completed and congratulate all for their dedication and efforts.” UWP Consulting was appointed by the city as the consulting engineer for the project. Ehrane Holderness from UWP Consulting adds: “My sincere thanks for Aquatan’s huge effort to make sure that this was completed on time, within budget and to high quality standards. “I also believe that significant value was added through Aquatan’s recommendations to improve infrastructure impacting on the safety, functionality and aesthetics of Neptune Reservoir. The efficiency with which unexpected issues after the practical completion were handled is also commendable,” she continues. According to Meyer, the success in completing projects such as this can largely be ascribed to the company’s 50 years of experience in the lining business. “Aquatan has always been known for its innovative installation methods and its professional site agents and installation crews. “Aquatan’s crews predominantly consist of IAGI Certified Welding Technicians. However, no amount of experience, expertise or certification can make up for constant communication with the client and other stakeholders involved in the project,” he concludes.

IMIESA July 2017

DAMS & RESERVOIRS

New labyrinth spillway for Tzaneen Background

The raising of the Tzaneen Dam spillway will provide much-needed additional capacity for the town that it borders, as well as the surrounding industrial and agriculture sector, which is one of the main vegetable producers in South Africa. By Alastair Currie

category three dam, Tzaneen Dam was completed in 1976 and the design made provision for the raising of the spillway at a later date. That time is now drawing nearer as the construction implementation programme gathers momentum on a strategically important infrastructure upgrade, with the main raising works scheduled to commence in April 2018. The dam raising forms part of the Department of Water and Sanitation’s Groot Letaba River Development Project, which includes the construction of the new Nwamitwa Dam situated some 40 km downstream. Nwamitwa Dam, located on the confluence of the Groot Letaba and Nwanedzi rivers, will have a wall height of around 36 m and a storage capacity of approximately 144 million m3.

IMIESA July 2017

After several studies by the Department of Water and Sanitation (DWS) within the Letaba Catchment, a need was identified to increase the capacity of Tzaneen Dam. The DWS then appointed Lepelle Northern Water (LNW), as an implementation agent, the appointment made history since the project was the first of its kind to be implemented by LNW. To augment its construction capacity and accomplish the assignment, LNW further appointed Blackhead Consulting as the PSP (professional service provider) to undertake the planning and designing of the Tzaneen Upgrade Project.

Blackhead Consulting is the appointed professional service provider (PSP) for the raising of the Tzaneen Dam. The team is headed up by the project manager, Hilton Sparks, Blackhead’s technical director and a civil engineer with more than 40 years of project management experience. He is assisted by Harry Lyimo, a civil and structural engineer at Blackhead Consulting. As implementing agent for the Department of Water and Sanitation, Lepelle Northern

BELOW LEFT Material stockpiles for embankment raising BELOW Stockpiles for embankment clay core raising BELOW RIGHT Mukhtar Nagdee inspecting reinforcement on the demolished spillway

Water appointed Blackhead Consulting for the design of the raising works in November 2015. The design team is backed by a highly experienced group of subconsultants: • T he APP is Dr Quentin Shaw of ARQ Consulting Engineers. • T he dam engineer is David Cameron-Ellis of ARQ Consulting Engineers. • T he structural engineer is Don Midgley of Ritchie Midgley Consulting Engineers. • T he hydrologist is Hendrik Peens of Peens and Associates. • T he environmental control officer is Bradly Thornton of Kongiwe Environmental. The feasibility studies and environmental process for both Nwamitwa and Tzaneen dams had already been completed, with a record of decision in place, which was due to expire on 26 September 2016, so

DAMS & RESERVOIRS

the preparation for the construction programme needed to be accelerated. “The raising of Tzaneen Dam by 3 m serves two purposes: first, to act as a storage backup for the Nwamitwa Dam and second, to ensure additional storage capacity over the long term,” explains Sparks. Tzaneen Dam’s capacity will be increased from 150 million m3 to 193 million m3.

Spillway design study The starting point for the project was to reevaluate the feasibility study completed in 2008 for Tzaneen Dam in terms of the hydrology. The feasibility considered four spillway options, namely the original ogee spillway, fuse gates, a labyrinth weir, or a PK weir. Model studies were undertaken at the Department of Water and Sanitation’s laboratories in Pretoria West to determine the optimal design approach from cost and project timeline perspectives. ARQ tested the viability of retaining the current ogee crest, or opting for a PK labyrinth weir. Tzaneen’s current spillway is approximately 100 m long, and the non-overspill crest around 1 km in length. “We needed to carry out a cost-benefit analysis for different configurations of the spillway. In the end, our studies showed that opting for a conventional labyrinth was the most feasible option – this following extensive analysis by the dam engineer. This provides a cost-effective and

ARQ DAMS

RIGHT Toe of Tzaneen Dam spillway BELOW RIGHT Hand demolition of the dam spillway

low-maintenance solution,” explains Lyimo, the assistant project manager. If the ogee approach had been selected, this would have required the raising of the spillway and non-overspill crest by the same height, namely 3 m. “However, by adopting the labyrinth weir method, it was determined that we could get the same quantity of water over the spillway for less height,” Lyimo continues. “This now means that the height of the non-overspill crest only needs to be raised by 1.5 m, requiring approximately 20 000 m3 of material.” A detailed design of the new labyrinth spillway has been completed and a tender document drawn-up. The raising of the spillway will be carried out by an external contractor still to be appointed by the Department of Water and Sanitation.

Initial works: stockpiling & demolition When initial construction commenced in early September 2016, Tzaneen’s dam level was down to 13%. Blackhead took advantage of this opportunity to excavate the

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6 Daventry St,

dams@arq.co.za

Lynnwood Manor,

012 348 6668

Pretoria

With an involvement to date in more than 80 dam projects in 28 countries, ARQ offers services in all aspects of dam engineering for all dam types, with a particular specialist focus on RCC and arch dams. Experience in the design and construction of 36 new dams (highest 275 m) and 13 dam raising and rehabilitation projects and a track record of successful innovation ensures that ARQ always identifies optimal solutions.

Engineering solutions

for a better

tomorrow

Blackhead Consulting (Pty) Ltd is a 100% black owned and managed professional engineering service provider established in 2004. As an emerging professional service provider, Blackhead Consulting has gained tremendous experience over the years by working with different clients on a variety of projects. Blackhead Consulting prides itself as a company that boasts a variety of professional capabilities. We have different departments within the company that are headed by registered professionals providing the following services: ● ● ● ● ● ● ● ● ● ● ●

Civil & Structural Engineering Quantity Surveying Architecture & Town Planning Project & Construction Management Electrical & Mechanical Engineering Geographic Information Systems (GIS) Program Management Land Surveying Public Participation & Social Engagement Environmental Investigation & Compliance Geotechnical Engineering

CONTACT US Gauteng office: 33a Peter Place, Lyme Park, Sandton, 2060 T: +27 (0) 11 958 2248 Limpopo office: 3 Hospital Street, Medi Park, Tzaneen,0850 T: +27 (0) 15 306 0498 E: info@blackhead.co.za www.blackhead.co.za

Machine demolitions on the spillway

Outlet works of Tzaneen Dam

required material for the raising of the earthfill embankments from the dam basin and stockpile it for the main raising works. These works were carried out by Construction North, the Department of Water and Sanitation’s construction wing. Then cyclone Dineo hit in Februar y 2017 and the dam level has risen to around 60%. Fortunately, the stockpiling operations were completed in the same month. The maximum capacity threshold during the construction of the spillway is 72% with diversion works in place. A coffer dam will also be established downstream as part of the spillway works to carr y out dam toe foundation inspections and improvements. In preparation for the raising of the spillway, the existing ogee structure is being demolished by 4m down to the level suitable to anchor the raising, and will then be raised by a total of 7 m – a net raising of 3 m. A platform was built on the upstream side to access the spillway with mechanical breakers. The original drawings indicated that the spillway was composed entirely of mass concrete. However, a nominal amount of steel reinforcing was encountered, which has required some blasting to speed up the demolitions. Demolition will be completed in August 2017 and work on the raising of the spillway is expected to commence in April 2018, with construction due for completion in September 2019.

Once the Tzaneen spillway is raised, water will back up on to the wall of Ramadiepa, so certain remedial works are required. “We are ver y excited to be working with the Department of Water and Sanitation and Lepelle Northern Water to achieve the sustainable development targets set out by the GLeWaP initiative, and also to be working with a world-class professional consulting team that has vast experience in dam engineering,” adds Sparks. “The experience will prove invaluable as Blackhead Consulting expands its in-house capabilities. Over the years, our core civil engineering and project management focus has expanded to include electrical, mechanical, structural, environmental, occupational health and safety, social facilitation and quantity sur veying departments. The experience gained with Tzaneen will enhance the already strong foundation of the company.”

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Programme management To track the construction programme, Blackhead Consulting is employing an innovative cloud-based project monitoring system using tablets, which has already been successfully applied by the firm on human settlements projects. Daily site instructions are completed and signed on the tablet and uploaded to the cloud, enabling the project management team to download this information and monitor progress in real time for specified categories – e.g. demolitions or stockpiling, with monthly reports generated automatically. This is combined with the deployment of a drone to complete aerial photos and video. When the main construction commences, all stages will be colour coded for specific monitoring requirements and to keep the project on track and within budget. This tool will also be used during ongoing OHS environmental monitoring for key areas like dust, noise, and water quality at a number of points around the dam. Allied to this project, a separate component will entail the upgrading of Ramadiepa Dam, a privately owned structure situated upstream of Tzaneen. This is a categor y two dam.

IMIESA July 2017

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ENVIRONMENTAL ENGINEERING

A well-established art dating back thousands of years, the application of gabion structures is one of the most sustainable construction methodologies in practice to this day. By Alastair Currie

he flexibility of gabion designs makes this method of construction a highly versatile one for projects that can range from building and architecture to massive retaining wall structures. “The process goes way beyond ‘throwing rocks in a box’,” says Louis Cheyne, managing director of Gabion Baskets and a recognised expert in the field. “In fact, it’s a highly skilled environmental engineering discipline, which has the advantage of using relatively simple fabrication and installation techniques – often combined with available in situ materials – to create highly sustainable solutions that promote the use of labourintensive opportunities, and in parallel, skills development training and SMME startups. Design and installation techniques remain the responsibility of registered civil engineering professionals.” Gabion Baskets manufactures a wide range of gabion configurations, including river mattresses. The company also provides a design, construction and project management service, as well as certified training programmes that combine classroom and on-site practical instruction for aspiring contractors, including how to price contracts. The company also specialises in the sourcing of specific rock materials via approved suppliers to ensure the right quality and final finish.

IMIESA July 2017

Retaining with

gabions

Creative use of gabions to stabilise telephone poles on a project in Paarl, Western Cape

Retaining walls remain one of Gabion Baskets’ core business activities and these typically range from 1 m upwards, depending on the requirements. The higher the wall height, the wider the base,

BELOW The use of gabions for municipal applications is far ranging and in this case, provides a protective foundation for a public lighting installation

which is one of the few design restrictions imposed when working within the confines of a building or roadworks project; but for mining applications, like primary crusher tip walls, this footprint restriction is often not an issue. Tip wall installations completed by Gabion Baskets in Southern Africa include a project for Barrick Gold in the DRC, with a height of 11 m and a base width of 5 m to 6 m.

ENVIRONMENTAL ENGINEERING

Gabion installations form their own foundation, so there is no need for a concrete base. From a strength and flexibility point of view, gabions also naturally absorb any settlement, which is particularly beneficial in clay soil conditions, which are notorious for their unpredictable, and seasonal, expansion and contraction characteristics.

Using available materials “The fact that in situ materials can be used to fill gabion baskets is a great advantage, saving on the cost of needing to import commercially sourced stones. Even building rubble can be used, which makes it a really viable choice for the low-cost construction of a wide range of structures,” Cheyne continues. “We’re also receiving enquires from architects involved in eco-alternative home designs, either for the luxury market or for low-cost housing applications, where, in both cases, gabions are being used for internal and external wall layouts. This is alongside the traditional architectural gabion cladding market, where we are actively involved in supplying products for private and municipal projects,” Cheyne expands.

From hexagonal to welded mesh Civil engineering applications have traditionally specified woven mesh gabions for their installations, and this remains a popular choice. Alongside this option, Gabion Baskets also manufactures welded mesh configurations for both building and civil projects. “Welded mesh gabions are square in shape, as opposed to the hexagonal appearance of woven products,” Cheyne explains. “Welded mesh also has a more aesthetic appeal:

The installation of sandstone-dressed sections creates an aesthetic element for this gabion retaining wall structure

Gabion walls provide an innovative alternative for low-cost housing BELOW A square mesh gabion installation, incorporating geotextile to prevent the washing through of fine soil. This installation is approximately 3 m high: 1 m for the base, and then stepped back in 0.5 m intervals. The founding is typically 10% of the height of the structure, with a base width of around 55%. That translates into a base width of 1 m to 2 m, founded to a depth of around 200 mm to 300 mm, with a geotextile layer below and behind the structure. The gabion installation acts as its own foundation

the square design enables very tight tolerances and a clean appearance, making this product well-suited to building and architectural applications. However, for river erosion countermeasures, where there are often soft founding conditions and movements of clays, woven mesh is the only option due to its flexibility. Welded mesh would fail in this application due to its rigidity.” In terms of SABS standards, the tolerance on length is typically 10%, which is easily achievable with welded mesh, at around 10 mm, but not with woven mesh, which can be out by 200 mm on a 3 m to 4 m long basket installation.

Lacing and geotextiles An area that needs particular attention is the gabion basket lacing technique, which becomes especially important with greater wall heights and the ensuing increase in compressive base loads. If the panels are not correctly laced together, this tensile force on the mesh can lead to structural failures. “That’s why it’s always important to have an engineer involved,” adds Cheyne. “This also applies when it comes to hydrostatic pressure management behind gabion walls. Although these systems are naturally freedraining, with a void ratio of around 35%, it’s important to counter erosion in sandy backfill conditions by installing a bidim-type non-woven geotextile between the wall and the soil.”

For clayey soils, he says that this wouldn’t be necessary in most cases, and could actually be counterproductive since a geotextile in this instance would prevent efficient drainage. However, in cases where it may be required, there are tape-type geotextile materials, with a square interlocking filter fabric, that provide a large aperture for effective drainage. Where required, drainage systems are installed behind gabion structures. Contractors can also reduce rock quantities by using geotextile socks. The Canal Walk development in Cape Town is a good example. Here, all the canal systems have been lined with erosion control gabions: the baskets are filled with sandfilled geotextile bags, which naturally selfcompact when saturated. “On many of our installations, we also make provision for indigenous vegetation growth through and on top of the structure, which really enhances the natural look and feel of these environmentally engineered ‘art forms’,” adds Cheyne.

IMIESA July 2017

ENVIRONMENTAL ENGINEERING

Reinforcing structures

with sustainable solutions Over the past decades, the development of soil reinforcing solutions has significantly extended the original role played by gabions in environmentally engineered retaining wall designs. It hasn’t replaced them, but it’s opened up new frontiers that keep evolving. By Alastair Currie

ithin the environmental and geotechnical engineering field, there are few companies that have stood the test of time like Maccaferri, an Italian multinational headquartered in Bologna, which celebrates more than 130 years in business and operates across the globe. “Our extensive product portfolio and in-depth technical knowledge have enabled Maccaferri to develop specific solutions for diverse geographic markets and soil conditions,” says Marco Vicari, Maccaferri’s above LEFT A view of the slip failure prior to the embankment stabilisation of the Bluff in Durban, using a combined Terramesh and Green Terramesh system. Construction commenced in August 2016 LEFT Work in progress at the Bluff in February 2017

technical manager for the Europe, Middle East and Africa regions. Vicari visited South Africa in June 2017 from Maccaferri’s corporate office in Italy to train South African personnel on new hydraulic product developments. Maccaferri’s first projects were in river works, and this remains a core area of expertise, employing the company’s classic doubletwisted mesh designs for the fabrication of gabions and mattresses. “Although we continue to roll out advanced geotextiles and geosynthetics, and even an articulated concrete block mattress for applications like underwater pipeline protection, gabions will always be an important part of our business, and frequently function alongside our more advanced proprietary products as integrated solutions. A good example is the Terramesh system for rock-faced reinforced soil walls.” As Vicari points out, the main issue about gabions is the availability of stones to build the structures. If the stones have to be imported, with the associated expense factor, the alternative is to use the local soil as much as possible by applying a reinforced soil Installation of the combined Terramesh and Paragrid system on road P728 in the uMgababa area of KwaZulu-Natal

IMIESA July 2017

ENVIRONMENTAL ENGINEERING

approach. The choice is made from a commercial viewpoint, by presenting to customers the most suitable and affordable solution.

Advanced coating standard In 2014, Maccaferri founded an R&D company within the group known as the Maccaferri Innovation Centre in Bolzano, Italy, which is responsible for developing new products, manufacturing process improvements and new applications, including technical tools and design software upgrades. One of the central themes is product sustainability. A recent breakthrough is the launch of Maccaferri’s proprietary Polimac wire coating in July 2017. This sets the future standard for twisted mesh products and provides significantly extended durability for severe environments subject to pollution, corrosion and hydraulic abrasion.

uMgababa project Two recently completed projects in KwaZuluNatal serve as prime examples of integrated Maccaferri solutions, both designed using its MacSTARS mechanically stabilised earth wall software. The first involved the design and

supply of a 270 m long and 9 m high retaining wall system forming part of the improvement works for road P728 in the uMgababa area of KwaZulu-Natal. The project engineer was Simani Consulting. Maccaferri supplied a Terramesh solution designed to absorb a surcharge load of 12 kN/m², with its ParaGrid geogrid product used primarily for soil reinforcement. This solution proved to be easytoinstall and cost-effective, and helped create employment with the use of unskilled labour from the local community. In addition to technical performance, the selection of the Terramesh and ParaGrid hybrid solution offered other key benefits, including cost savings. Terramesh, for example, requires significantly less rock fill than other solutions, including gabions; while Maccaferri’s ParaGrid geogrid can be used with most types of backfills, including marginal fills. This often enables the reuse of site-won materials as structural backfill, which reduces the amount of imported materials.

Green Terramesh in Durban In the second project example, a serious erosion problem needed urgent remedial action

following a major slip on an embankment in Durban’s Bluff area, during a period of excessive rainfall. As the soil washed away, a large void was created. This posed a potential threat to the railway line situated next to the embankment, so any further erosion needed to be countered immediately by building a mechanically stabilised earth wall. EThekwini Municipality’s Coastal and Stormwater Department contacted Maccaferri to assess the damage and requested a collaborative effort to formulate a solution. After further analysis and calculations, the best solution selected was a combination of Maccaferri’s Terramesh and Green Terramesh systems. The Green Terramesh system consists of prefabricated units of double-twisted wire mesh lined with an erosion control blanket and stiffened with a welded mesh panel. The angled front face and the erosion control blanket are designed to facilitate the establishment of natural vegetation. The structure incorporated Maccaferri’s Terramesh system at the toe, followed by the Green Terramesh system. The polymeric soil reinforcement used consisted of Paragrid and

Gabions & Mattresses® in hydraulic applications

Years

Telephone: +27 31 705 0500 Branches: Durban (HO), Johannesburg, Cape Town, Eaﬆ London, Tongaat (Factory)

www.maccaferri.com/za

ENVIRONMENTAL ENGINEERING

Road Mesh

The completed structure of the embankment at the Bluff in May 2017

MacGrid, which varied in strength and length, to optimise the solution in terms of cost. The appointed contractor was Devru Construction. Work commenced in June 2016 and was completed in May 2017.

IMIESA July 2017

Another product that has been supplied with great success in South Africa is Maccaferri’s Road Mesh, which, as the name implies, is primarily designed for roads, but has also been successfully specified for largescale industrial projects. Road Mesh is a planar grid material. Placed within the upper bound layers of the pavement, it reinforces the asphalt layers, extending fatigue life. The product is engineered from double-twisted hexagonal woven steel wire, with integral transverse reinforcement bars woven into the mesh. Maccaferri also supplies MacGrid AR glass fibre and polyester geogrids that inhibit reflective cracking. Aside from pavement stabilisation, Road Mesh was successfully used on a recent project in Maydon Wharf, Durban, to counter very challenging geotechnical conditions. When an old warehouse was demolished to make way for a new one, it was discovered that the soil conditions comprised very poor

materials. The conventional approach would have been to go the piling route, but at a much higher cost and a longer construction time frame. Road Mesh proved to be a more viable option, since its design composition allows it to work in both directions to eliminate or substantially reduce differential settlements. On the Maydon Wharf project, Road Mesh was installed in layers sandwiched in-between compacted materials to form a raft foundation over a footprint of around 8 000 m2. “Our systems are far-ranging and that’s why we invest in the training and development of our personnel to keep them up to date,” concludes Adriano Gilli, Maccaferri Africa’s managing director. “Externally, we provide annually updated Continuous Professional Development programmes for contractors and consulting engineers. As most of our projects include a labour-intensive component, we are also well positioned to assist larger and SMME companies in meeting the South African government’s Expanded Public Works Programme requirements, as well as the recently gazetted requirement of using 100% South African steel content in public projects.”

FLEET MANAGEMENT

The importance of availability Investing in public fleet management and outsourcing to industry specialists will reap major financial rewards and other benefits. By Nigel Webb

ithin the fleet management industry, it’s often said that your cheapest vehicle is the one you don’t have. Perhaps a frivolous statement, but the message is clear: realistic total cost of ownership models need to be established for each vehicle in order to ensure high availability. Unless properly managed, lower availability will impact on the overall performance of the fleet, which means that owners end up with more vehicles than necessary, each at a high cost. So what are the causes of poor availability and how do we correct them and raise the bar? Downtime has its roots in accidents, maintenance and repair time. Within the public sector, bureaucratic processes can impose extensive authorisation and budgetary approval obstacles, without recognising the urgency of getting vehicles back on the road. Payments to supplier are delayed and some eventually choose not to provide their services. This scenario has been successfully overcome by outsourcing to specialists who take early ownership of vehicle service requirements. These services include claims, and accident and maintenance management. The fleet owner still has strict control of the service provider through agreed-upon expenditure limits and reporting.

evaluators. Quality expenditure reports also add value to the supply-chain process, as does driver training for correct vehicle and equipment usage. A necessary and complementary requirement is the measurement of availability using telematics systems, which routinely provide detailed activity reports for parameters such as driving time, standing, hours of usage, distance travelled and, importantly, driver behaviour. Telematics allows you to establish performance benchmarks, analyse actual usage and manage the variations and trends.

Vehicle selection and utilisation All of these services and management controls will improve utilisation and reduce your fleet size and costs. However, managing your fleet is not just about the numbers. It’s also about selecting the right vehicle for the job; for example, do you really need a 4x4 when a standard bakkie will do? Also consider using outsourced rental services to cater for seasonal or specialised and infrequent usage. It’s about understanding your needs and having information available to facilitate decision-making. The financial benefits of improved utilisation are substantial. For a fleet of 200, a 5% improvement reduces this number by 10 to 15 vehicles, depending on current availability levels. This has a minimum cost benefit of approximately R1 million per annum, depending on vehicle type. In today’s terms, the typical total cost of ownership for a new LDV is around R100 000 per annum and R250 000 for a heavy commercial vehicle. When you start to multiply these figures in terms of the corresponding fleet size, the implications for poor availability become very clear. *Nigel Webb is the head of Latitude Fleet Services.

Insurance claims The outsourced claims management process, which precedes and authorises repair, is now available as an online service. The accident report, photographs and driver’s details are initially captured and reported to insurers. The accident management interface provides costing and supplier details. This facilitates online workflow management and expenditure authorisation. With accident management, the specialist supplier applies a strictly time-managed process to obtain quotations, assess them, appoint a supplier and, importantly, ensure prompt repair. The managed maintenance process is very similar and draws from an extensive database of job cost standards and skilled technical

Transport, Logistics, Vehicles & Equipment

Bell concludes Kobelco alliance fast facts

1930

Kobelco introduces the 50K shovel (1.5 m3) – the first such construction machine produced in Japan

Famed for its distinctive blue livery, the Kobelco brand has been a pioneer from inception.

1963

Japan’s first wheelmounted hydraulic excavator rolls off the production line

ell Equipment has signed an agreement with Kobelco Construction Machinery for the exclusive distribution and support of the Kobelco excavator range in Southern Africa. Kobelco is a division of Japan-based Kobe Steel. The full product line-up will be available locally, starting with the 1 t Kobelco mini excavators through to the largest 85 t units.

1967

Kobelco launches the H208 (0.3 m3) – the first crawlertype hydraulic excavator to be produced using the company's proprietary technology

"We are fortunate to have teamed up with a leading capital equipment distributor in Southern Africa, and also a like-minded company that believes in listening to its customers and reacting quickly," says John Boyd, managing director of Kobelco Construction Machinery Middle East and Africa. "With Bell Equipment's broad product range, extensive distribution network and strong reputation for customer support, we believe that we have found the right partner for our products in this region." Kobelco has 10 production centres located in Japan, China, Southeast Asia, the USA and India.

Eco-friendly

The Kobelco SK260 LC hydraulic excavator is powered by a Hino engine and has a maximum operating weight of around 25 600 kg, depending on the configuration

IMIESA July 2017

All Kobelco excavators have two digging modes: H-mode for heavyduty and higher performance, and S-mode for normal operations with lower fuel consumption. “Real-life situations show that S-mode can deliver around a 20% reduction in fuel consumption

2006

Kobelco introduces the world's first hybrid excavator

2012

The SK200H, a hybrid hydraulic excavator in the 20 t class, is released

when performing the same tasks as like-sized machines, while engagement of the H-mode delivers 8% more productivity at the same fuel burn as competitor machines,” Boyd explains. “Our 'true-blue Kobelco evolution' is about creating value, building a future and changing the world, with the distinctive colour acting as a reminder of these underlying values.”

Dealer preparations Teams from the respective companies are currently in the process of laying the foundations to ensure that they are able to meet customer expectations. "Stocking of parts in the Bell Global Logistics Centre is under way, with technical staff being upskilled to deal with the new products,” says Stephen Jones, group marketing director, Bell Equipment. Both companies agree that the new partnership has the potential to shake up the excavator market in the Southern Africa region. "We have no doubt that the market will react quickly to the association between a fantastic product and a strong, well-established dealer network. We look forward to introducing these excavators to our customers," adds Jones.

Transport, Logistics, Vehicles & Equipment

Introducing the Croner

Models UD Trucks Southern African has launched a new range of heavy commercial vehicles in South Africa – the Croner.

ewly launched worldwide, the Croner range features 13 variants, with up to 21 customisable configurations to maximise productivity and uptime. Specifically developed for UD Trucks’ growth markets, the brand is continuing its Japanese legacy of building “the truck the world needs today”. The range is already being assembled at the company’s plant in Rosslyn, Pretoria, and will be introduced to other markets in the region during the next year. According to Jacques Michel, president: Sales, Volvo Group Trucks Asia, there are a few hundred trucks already in South Africa, with a few hundred more being shipped in, ensuring that there is adequate supply to meet immediate sales demands.

Making every moment count Named after Chronos, the Greek god of time, Croner was designed and engineered to help customers save time and money. This is achieved through longer service intervals, smart aftersales support, continued driver training, and accessible parts to ensure faster turnaround times.

Put to the test Durability testing was conducted over an equivalent of three million kilometres, putting the Croner to the test in the toughest weather conditions and terrains around the world. Some 1.4 million km of field tests in actual customer operations were carried out across six countries (including South Africa) and three continents over a period of 18 months. “We wanted to develop and deliver a smart and modern HCV truck with ultimate dependability. Croner is built with a vision:

to create a truck that will help our customers optimise the use of time, to make every moment count,” says Toshi Odawara, vicepresident: Product Management, UD Trucks.

Croner range The range features three gross vehicle mass (GVM) models from 9.5 t to 17 t: MKE, LKE and PKE. The range of wheelbase variants can be configured to suit operators’ specific needs, with flexibility in everything from GVM and wheelbase choices to cab, driveline, axle and suspension. The Croner range offers automatic transmission available for all models, optimised for on-road logistics and garbage compactors. The manual six-speed and ninespeed transmissions are robust and durable, and are able to cope with the toughest demands in various operating conditions. The new 5 ℓ and 8 ℓ fully electronically controlled common rail engines deliver high torque of up to 1 050 Nm and provide better pulling power and easier driving. Computer-controlled injection, fuel quantity and atomisation are finely controlled for varying situations, and for each cylinder, giving outstanding fuel consumption and low emissions. All Croner models are equipped with a built-in fuel coach – an on-board solution providing real-time instructions to the driver to use optimal revs and reduce unnecessar y acceleration. Croner has some of the highest axle capacity in its class, with increased carr ying capacity delivering more uptime and productivity in heavy-load-use applications such as construction. Both axles are built extra tough to enable high loads and extended oil change inter vals. All models are fitted with a rear-

MKE GV 9.5 t – 11 t Compact-sized HCV trucks specifically optimised for urban usage, with better manoeuvrability for narrow roads and city deliveries LKE GV 12 t – 14 t This multipurpose model has in-city and city-to-city distribution in its sights, focusing on transport efficiency, and features a 2.1 m day cab PKE GVM 15 t – 17 t Caters for medium- to heavy-duty usage with a powerful engine for regional, long-haul and heavier loads

axle multileaf spring and air suspension, also available on the 16 t variant with mechanical height control valve and dump switch. The improved stability and cushioning are per fect for sensitive cargo freight. A full air-braking system with reliable S-camtype drum brakes is offered on all variants. Croner’s larger brake capacity provides better stopping power and lasts longer between ser vice inter vals. Less need for maintenance and replacing parts means boosted uptime and lower life-cycle costs. UD Telematics Ser vices comes as standard on the Croner range. The high-tech wireless communications system is designed to help customers manage their fleets effectively, keeping them on the road while reducing operational costs. This includes real-time location, fuel utilisation, fuelloss alert, proactive maintenance support and geofencing. UD Trucks also offers UD Driver Training, a programme that will improve the capabilities of fleet drivers, which includes optimising operation, fuel-efficiency and safe driving. “With 36 dealers in South African and 14 other markets across Southern and East Africa, customers are assured of on-time support no matter where they operate in the region,” says Gert Swanepoel, managing director of UD Trucks Southern Africa.

IMIESA July 2017

QUALITY & AFFORDABILITY

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

Transport, Logistics, Vehicles & Equipment

Scribante expands Gauteng footprint Scribante Concrete has added 35 new FAW mixers and tippers to its fleet, bringing its total FAW units to 89.

he fleet expansion comes alongside some sizeable investment into plant, equipment and staffing by Scribante Concrete, a division within the larger Scribante Construction Group. The company is currently expanding its reach in Gauteng with the commissioning of two concrete batching facilities in Muldersdrift and Laezonia. “The Scribante Construction Group saw the opportunity, crunched the numbers and, with very careful consideration and planning, decided to invest and expand our Gauteng footprint,” explains Troy Petzer, operations manager, Scribante Concrete. Going into operation at the West Rand batch plants, the new FAW units include 27 FAW 35.340 FC 8 m3 mixer trucks, six FAW 33.330 FC 6 m3 mixer trucks, and two FAW 28.280 FT side-tipper trucks.

“We’ve been running FAW mixers and tippers in our fleet for close on three years now. Based on the total cost of ownership calculation, together with superb aftermarket service and support, our choice fell to FAW as we replaced older vehicles in the fleet and started equipping for the West Rand plants,” says Petzer. “We’re not new to the pressures of transportation in Gauteng – highways with high traffic volumes, extended peak-time congestion, eTolls, and generally aggressive driver behaviour. Key to our efficiency formula is the net cost per cube of our concrete product. We intend to continue securing contracts, offering competitive pricing by ensuring we have a high-volume throughput from our West Rand operations.” According to Petzer, the volume targets for the West Rand plants are aggressive and will

demand superior customer service on the part of Scribante. In turn, the demand on the truck fleet will be for maximum uptime, easy and efficient driving, highly effective parts supply, and lowest cost of operation.

Made to spec Scribante requested and designed specialised truck modifications for the mixer trucks, chassis and mixer bodies. These have been incorporated by FAW SA into its offering for the benefit of other clients. “Together with Scribante Concrete, we at FAW SA have literally refined our robust and durable mixer trucks to provide even stronger and longer-lasting operational efficiency. This serves both our customers’ and our own interests – really a win-win situation,” concludes Vernon Rudman, regional manager, FAW. IMIESA July 2017

BUILDING

The benefits of brick

With South Africa’s rapid urbanisation rate, there remains a strong demand for low-cost housing. Face brick may be the answer for affordable, lasting building solutions.

ver its 115-year lifespan, Corobrik has focused on providing masonry products and services to the entire built environment. The company is now expanding its footprint in the affordable housing market, having been involved in projects that span the human settlements spectrum, from affordable to RDP, gap and rental stock housing. These projects range from inner-city rejuvenation to turning informal settlements into established suburbs. “The affordable market is a growing one, and we want to reignite and reclaim that market, without neglecting our formal market,” says Dirk Meyer, managing director, Corobrik.

IMIESA July 2017

Why build with bricks? Brick offers numerous benefits for residential buildings. Meyer believes that human dignity is the most compelling argument for choosing face brick. Because inner-city affordable housing projects are cost-driven, Corobrik is often chosen, as it offers a wide-range of products across all pricing spectrums. Corobrik offers both a premium and standard range. While the premium range caters to the higher-end market, the standard

range competes competitively with other building materials, explains Meyer. Moreover, with the small margins associated with low-cost housing, quality can become an issue. “If you’re constructing a home from concrete, you should be using around 8% cement. But in many cases, only 4% is used in order to reduce costs, bringing the quality of that product into question. If you buy face brick, there isn’t that variable degree in quality,” Meyer elaborates.

Inner-city rejuvenation One million of Corobrik’s Terracotta Satin face bricks were used in the Heritage View development in Brickfields, Newtown, Johannesburg. The low-cost housing development was developed by the Johannesburg Housing Company and comprises eight blocks with 164 middle-class units, strategically designed using a face brick and plaster façade. The project aims to provide quality accommodation where people work, drawing people back into the central business district.

BUILDING

Social housing initiative Pietermaritzburg’s largest social housing project, Aloe Ridge, was recently completed, constructed entirely of Corobrik’s face brick. Conceptualised by non-profit organisation Msunduzi Housing Association, Aloe Ridge provides much-needed, reasonably priced rental accommodation for the lower- to middle-income earners in the area. Aloe Ridge, which will house an anticipated 4 000 people, consists of 952 two-

He also argues that from a purely functional point of view, face brick is more durable and sustainable than other masonry products as well as most alternative building materials. “You are intrinsically getting a quality product that is also aesthetically pleasant. It looks more like a home, not a concrete block or a shed,” says Meyer. The high-rise nature of

bedroom apartments in three-storey walk-ups separated into two villages. Of these, 287 units will cater for households earning up to R3 500 per month and the remaining 665 units will cater for households earning up to R7 500 per month. This is one of the biggest South African social housing developments constructed entirely of face brick.

many of these projects means the structures are exposed to the elements. Face bricks are maintenance-free, saving costs on repairs and upkeep. Costs are further saved as a result of the thermal efficiency of brick, which is slow to heat in summer and retains warmth in winter, explains Musa Shangase, commercial director, Corobrik. The sound insulation properties

YEARS IN PARTNERSHIP 19 27 - 2 017

of face brick make it a particularly good choice for the inner-city area and affordable housing schemes. Face brick also creates a more fireresistant building, improving safety measures in such high-density residential areas. The natural clay substance also gives off no volatile organic compounds, making the building a healthier environment in which to live.

THE

SECURE

SAVE

SUSTAIN

STYLE

Y F THE CLA

Environmentally Friendly

IN D U S T RY

CLAYBRICK.ORG THE SMAR T CHOICE FOR LIFE

Photograph courtesy of Corobrik

CUT HEATING & COOLING COSTS Clay Brick is naturally warm in winter and cool in summer Clay brick is nature’s solar battery. Brick masonry absorbs and stores heat during the day and then releases that warmth when it is needed most – at night. This keeps indoor temperatures comfortable without air-conditioning or heating.

■ lowest electricity use ■ maximum fire ratings ■ superior thermal & noise insulation ■ tough, safe & strong ■ beautiful & versatile ■ low VOCs & emissions ■ superb investment ■ low maintenance Go to www.claybrick.org to find your nearest supplier

BUILDING

Promoting sustainable building materials The construction sector has historically been linked to high CO2 emissions and global climate change. A first step towards improving this is ensuring the sustainability of building materials.

he National Greenhouse Gas Emission Reporting Regulations, promulgated on 3 April 2017 and driven by the Department of Environmental Affairs, was designed to improve quantification and support the reduction of emissions in South Africa. The clay brick sector is committed to playing its part in meeting these targets.

Professor Piet Vosloo (right) of the University of Pretoria hands over the completed Life Cycle Assessment study to the Clay Brick Association's president, Musa Shangase (centre), and technical director, Nico Mienie (left)

Determining clay brick’s life cycle “The Clay Brick Association of Southern Africa (CBA) has led research in brick production and building design for 54 years,” explains Musa Shangase, president, CBA. “Our objective is to improve the performance of clay brick by maximising thermal comfort and energy efficiency of homes of offices, while reducing production emissions and costs.” The sector recently completed a project to publish a definitive Life Cycle Assessment (LCA) of clay brick products. This LCA uses an internationally and scientifically recognised approach that measures the environmental impact of a product by analysing all the inputs (e.g. raw materials and energy) and outputs (e.g. emissions and waste) that occur during manufacture, transport, construction, use, maintenance and eventual disposal. The study is the culmination of almost a year of planning and preparation, followed by four years of intense research. It was performed using specific production

data from 86 of the 102 clay brick production sites in South Africa, ensuring the results are a relevant and valid assessment of the industry. The analysis was conducted in accordance with the ISO 14040 and 14044 standards with an external review in order to aim at the highest quality standards. The results were summarised in an extensive report produced by a highly qualified research team from the University of Pretoria, led by Professor Karel Bakker (dean of the Faculty of Architecture), project coordinator Professor Piet Vosloo and research assistant Greg Rice. The project was coordinated by the CBA Technical Team led by Nico Mienie.

Sustainability ratings “While some building materials simplify their sustainability rating into embodied energy and thermal resistance, these aspects form just a fraction of the total life-cycle considerations of any material,” explains Mienie. “Using this narrow perspective, what appears good in theory can actually work against the objectives of sustainability. Therefore, the CBA’s LCA considers energy

used in extraction, manufacture, transport to site, construction, operation of the building, demolition and disposal.”

Environmental factors Factors considered include damages to human health and ecosystem quality, the contribution to climate change and the consumption of non-renewable resources for the six main brick manufacturing technologies (and the industry average weighted through the various production volumes) with respect to the production of 1 kg of fired brick. This sets a benchmark for clay brick, allowing professionals to calculate and compare the overall environmental impact of a clay brick building against other building materials.

Socio-economic factors The CBA’s LCA is one of the few to incorporate a socio-economic assessment. This is a critical measure for any construction project in a country like South Africa, with its low skills base and high unemployment. This LCA assesses how a product affects workers, the community and the consumer in terms of socio-economic factors such as human rights, working conditions, and health and safety.

Thermal performance Good thermal performance reduces the environmental impact of brick as a walling material over its lifetime of 50 years. The thermal performance of clay brick walling structures was compared to those built from other

IMIESA July 2017

BUILDING

across South Africa’s six climatic zones, as per SANS 10400XA. The results indicate that clay brick is the preferred building material due to the low operational energy required for comfortable living, resulting in significantly reduced costs for heating, cooling, humidifying and damp control.

Continuous improvement

methods, such as the LSFB walling systems. A thermal modelling study of clay brick was undertaken, comparing their associated thermal performance to other construction materials.

Several buildings were compared, namely a 40 m² house, a 130 m² house and a small 2 000 m² office. Each construction method was analysed across three designs, as well as

The LCA is part of a larger sustainability initiative that commits the clay brick sector to continuous improvement in terms of water and energy saving, as well as limiting the use of coal as a firing fuel. The assessment will serve as a guide to manufacturers who want to identify and switch to technologies that offer the greatest benefits in terms of fuel use, air quality and environmental impact. A regular Brick Sustainability Report will be prepared to show how the clay brick sector in South Africa is performing against its collective sustainability strategy. It will demonstrate progress against the targets set in the areas of fossil fuel use, waste and resource consumption.

IMIESA July 2017

ENDING EROSION Technicrete Armorflex erosion control system provides an alternative for a wide variety of erosion control and drainage projects. When your project calls for protection that can withstand severe applications and climatic conditions, with quick installation with no in-situ concrete or even under water, Armorflex from Technicrete is the engineered solution. Suitable for:

Specially designed:

•

• • • •

Rivers, Estuaries, Dams, Reservoirs Areas subject to wave action Access roads Parking areas Stormwater drift crossings

• • •

Compressed concrete blocks (solid or vertical holes

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energy

A strong foundation for infrastructure success

Constructing Africa’s largest wind farm

I15457

he Lake Turkana Once the Lake Turkana Wind Power project’s Wind Power 365 turbines are fully (LTWP) project commissioned, some represents one 300 MW of reliable, lowcost energy will be added of the single biggest private to Kenya’s national grid, investments in Kenya’s hiswhich is equivalent to tor y, and aims to supply about 15% of the country’s 300 MW of reliable, low-cost current installed electricity generating capacity wind turbine generator capacity to the countr y’s national grid. This is equivalent to about 15% of Kenya’s current installed generating capacity. WorleyParsons’ South African team was contracted in November 2014 by the LTWP consortium to provide overall project management, engineering review and construction management ser vices. The project scope includes 365 wind turbines of 850 kW each, an electric grid collection system and a high-voltage substation, upgrades to 210 km of existing road, an internal site road network, and a self-contained permanent village. A key milestone was recently reached when 120 wind turbines attained ‘Ready for Energisation’ status in Januar y 2017: the installation of all 365 turbines was completed on 5 March within a 362-day timeframe. The wind turbines are expected to be commissioned in the last quarter of 2017, upon completion of the 428 km transmission line provided by Kenya Electricity Transmission Company. “Despite some logistical, climatic and community challenges, we have delivered our scope of work to date for the LTWP project within the stipulated time frame and budget,” says Tim Gaskell, business unit manager: Power for WorleyParsons RSA. “We have worked closely with the customer and with the subcontractors to address these challenges and propose workable solutions. For example, as Lake Turkana is located within a desert-like environment, it seldom rains, but flash floods do occasionally occur and the existing road designs did not factor this in. We assisted with improving the road design to cope with flooding.”

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ENERGY

What is SA’s energy future?

he Department of Energy, together with Eskom, has put the country on a trajectory Many of South to nuclear power, which has, in many cases, been met with resistance. Africa’s coal-fired According to Dave Nicholls, chief nuclear officer, Espower stations kom, there are four power-producing technologies that have been proved to work on a large scale across the are nearing the end globe. These are: of their lifespans. 1. Hydro This, coupled with 2. Gas 3. Coal the environmental 4. Nuclear. pressures on coal and While hydro offers clean energy, South Africa does not have the natural resources the associated costs, to make it a feasible option, explains means South Africa needs Nicholls. South Africa has shale gas to establish what will power reserves in the Karoo that may be viable, but there are currently no the countr y into the future. contracts in place for the proviBy Danielle Petterson sion of gas. This leaves only coal and nuclear as feasible options for South Africa. But with the environmental costs of coal, nuclear presents a far more environmentally friendlylongterm option.

IMIESA July 2017

Nicholls stresses that, with only a few solutions available, South Africa simply cannot take the risk of implementing any technologies that have not proven successful in other parts of the world.

The case for nuclear in SA South Africa is no stranger to nuclear energy. Cape Town’s Koeberg Power Station has been in operation for over 30 years and provides Cape Town with the greenest power in the country. According to Nicholls, Koeberg also has the lowest operating costs in Eskom’s fleet, with its fuel costs being only 10% to 15% of that of coal stations, and 3% of gas turbines. A figure of R1 trillion has been identified as the expected cost of the nuclear build programme. However, Nicholls explains that the expected spend is the same magnitude as Eskom’s spend on the coal and renewable programmes, with the build expected to be in line with the construction costs of the Medupi and Kusile coalfired power stations.

Progress to date According to Phumzile Tshwane, CEO, Necsa, there has been a fair amount of progress on the nuclear build programme. Two sites have been identified as preferred locations – Thyspunt in the Eastern Cape, and Duynefontein in the Western Cape – and Necsa is awaiting the environmental impact assessment and site licences before construction can begin. “Although we are waiting, a lot of work has taken place over several decades to ensure that a proper study has been done around these sites,” said Tshwane. According to Nicholls, authorisation to progress with the nuclear programme was given on 14 December 2016, but the process has halted due to the recent nuclear deal court case brought by Earthlife

ENERGY

R300 billion The amount the energy sector currently contributes towards South Africa’s GDP and accounts for 90 000 jobs

Africa Johannesburg (ELA) and the Southern African Faith Communities’ Environment Institute (SAFCEI). Loyiso Tyabashe, senior manager: Nuclear New Build, Eskom, added that Eskom is technically ready to proceed with the nuclear build. “We understand what it is that we want in terms of the plants; we are well on our way in understanding the infrastructure around the site, the skills and enterprises that we need to support the programme, and procurement,” he said, adding that all role players must ultimately work together to ensure success.

The nuclear deal court case in short On 26 April, the Western Cape High Court delivered its judgment in the nuclear deal court case brought by ELA and SAFCEI against the South African government. The court ruled in favour of the applicants, setting aside the nuclear deal between South Africa and Russia on the basis of it being unlawful and unconstitutional. Jan Glazewski, professor of law, University of Cape Town, explains that the court case did not explore the advantages or disadvantages of nuclear, but rather the procedures followed. The case was brought forward on two grounds: 1. Before progressing with the nuclear build programme, the Minister of Energy must issue a declaration under the Electricity Regulation Act. While this was done, a second declaration was issued by the minister, stating the Eskom would be the procurer and not government. The court ruled that the process was not procedurally fair and, due to the implications for the country, the process needed to be opened up for public consultation. 2. South Africa entered into intergovernmental agreements with three countries – the USA, South Korea and Russia. These do not affect local law unless government ratifies them. However,the Constitution states that agreements of a technical, administrative and executive nature don’t need Parliament’s approval. While the minister argued this, the judges ruled that the agreements were far reaching and had to be ratified by parliament. The implications? Government must go back to square one and restart the process.

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SHEQ

Combating workplace intoxication

outh Africa is ranked by the World Health Organization as one of the top 20 biggest drinking nations in the world. According to Rhys Evans, director at ALCO-Safe, there is a prominent drinking culture in South Africa, where alcohol consumption is widely socially acceptable and considered the norm. But this often leads to employees arriving at work still intoxicated and unable to properly function, or not coming to work at all.

Dangers of workplace intoxication Alcohol is a depressant; it slows down electrical processes in the brain, resulting in slower reaction times, impaired judgement and coordination, decreased hearing, tunnel vision, a false sense of confidence, tiredness, an inability to carry out simultaneous tasks, as well as other health risks. “A reaction time that is delayed by even one second can put employees at serious risk of injury and significantly increase the chance of accidents,” says Evans. In addition to the dangers of on-site accidents, employees under the influence of alcohol or drugs are more likely to damage expensive equipment and be unable

IMIESA July 2017

Workplace intoxication is more prevalent than many people realise. And it poses serious safety concerns in environments where working under the influence can result in accidents and even death. By Danielle Petterson to effectively complete their daily tasks. Absenteeism also puts pressure on the rest of the workforce, which needs to carry the workload of colleagues. In a time when companies and municipalities are focused on cutting costs and reducing wasteful expenditure, they can ill afford the losses that absenteeism or alcohol-induced mistakes incur.

High prevalence According to Evans, many employers do not expect the problem to be as big as it is. In fact, many believe that they will be able to tell if someone is too intoxicated to perform their tasks without the use of testing equipment. However, Evans cautions that well-seasoned drinkers are often able to appear sober when, in fact, they are not. In one case, ALCO-Safe implemented a daily testing programme at a large manufacturing company in Rosslyn with a workforce of over 1 000 people. After 10 days of daily alcohol testing, more than 200 people

had been found to be under the influence of alcohol at work. Evans adds that at some of the company’s mining clients, which have had compulsory testing in place for years, some 30 to 40 employees still test positive for alcohol every month.

The benefits of monitoring While some companies have very good monitoring programmes in place, others lag behind. Municipalities, in particular, don’t monitor as well as they should, says Evans. Having a monitoring programme in place generally acts as a deterrent of both workplace intoxication and absenteeism. In its 40 years of operation, ALCO-Safe has conducted approximately 15 studies into the prevalence and effects of workplace intoxication. The company’s studies show that 20% to 45% of all workplace accidents are alcohol-related. In one specific company, daily testing led to an overall decrease in accidents by 50%

SHEQ

DRUNK AT WORK? 1 1 unit hour It takes 1 hour for the body to process 1 unit (10 ml) of pure alcohol.

after just six months. Disabling injuries were reduced by 52% and non-disabling injuries by 45%. But alcohol and drug testing doesn’t only benefit the company. Aside from improved safety at work, employees can experience fewer alcohol-related health problems, save money by consuming less alcohol, and reduce incidences of injuries and abuse at home. “About 50% of domestic accidents are alcohol-related, so there is a knock-on effect for the families,” explains Evans.

The legalities Section 2A of the General Safety Regulations under the Occupational Health and Safety Act (No. 85 of 1993) states that: “...an employer or a user, as the case may be, shall not permit any person who is, or who appears to be, under the influence of intoxicating liquor or drugs to enter or remain at a workplace... no person at a workplace shall be under the influence of or have in his or her possession or partake of or offer any other person intoxicating liquor or drugs.” “This means that it is completely legal for employers to require compulsory alcohol and drug testing,” says Evans. However, he cautions that it is best to have a policy in place that informs employees that they will be tested. “If this policy is in place when someone joins the organisation, they are agreeing to it when they agree to work for the company. If it is a new policy, they have the choice to leave if they do not want to comply. A refusal to take the test is usually considered an admission of guilt. The people who have a problem with it are usually the ones with something to hide.”

Education is key “Safety and sobriety go hand in hand. But those who are the first to complain about workplace safety are usually the first to oppose

alcohol and drug testing,” says Evans. In these cases, educational programmes can go a long way. Employers often experience backlash from employees and union groups when implementing a monitoring programme. But this is often due to the fact that employees do not understand how the process works. Evans explains: “People often think it means that they can’t drink at all or that if they take cough mixture when they are sick, they will test positive for alcohol. It is important to show them that this is not the case. If we educate people around how much they can drink and how long it takes for alcohol to work through their system, we not only help them feel more comfortable with the process – we create a more educated consumer.”

Taking the right steps “People are often worried about the legality and costs associated with implementing a monitoring system, but the law is on the employer’s side,” says Evans. However, it is important to work with a reputable company that is able to assist in implementing a programme and can provide quality testing equipment. While there is an initial cost involved with implementing these programmes, Evans stresses that the long-term benefits far outweigh the initial costs. “A monitoring programme will create a more productive workforce and lead to fewer accidents and breakages. It will pay itself off very quickly. There is simply no reason not to do it,” concludes Evans.

A bespoke dolly-bogie system is used to transport the items to site. Offloading is performed using a special side loader

CEMENT & CONCRETE

Bridging the divide in Ga-Ntata

Two new, all-weather bridges being built across the D3212 and D3213 at Ga-Ntata, Limpopo, promise to bring critical relief to poor rural communities living within the region’s Mopani District. Beam design

Two new, all-weather bridge structures are being built on the D3212 and D3213 at Ga-Ntata in Limpopo’s Mopani District

hese bridges replace an inadequate crossing over the Molototsi River that collapsed in late-2016 as a result of heavy flooding in the area. This latest intervention is being led by the Roads Agency of Limpopo (RAL), with Nyeleti Consulting appointed as the consulting engineers and Axton Matrix as the main contractor. Corestruc and Coreslab were responsible for manufacturing and installing the highquality inverted I-beams that form part of the superstructures. Their teams arrived at Ga-Ntata earlier this year to start

IMIESA July 2017

surveying activities once Axton Matrix had completed the abutments and piers, plus the installation of the bearing pads upon which the bridge beams rest. This ensured accurate alignment and rapid beam installation. Corestruc’s Russell Hobbs says that a total of 86 items were manufactured at Corestruc and Coreslab’s state-of-the-art batching plant in Limpopo and installed at the two construction faces. “Most of the bridge beams are 24 m long, with some 27 m, and they vary between 50 MPa and 60 MPa,” he says.

Based on Nyeleti Consulting’s design requirements, the precast elements were pre-formed with holes through which transverse reinforcement was installed to brace the structures. The main contractor then filled the spaces between each precast concrete unit to produce a robust concrete slab. The consulting engineer also specified an extremely slender profile for the bridge beams, and Hobbs says this was achieved by paying meticulous attention to the detail of the design of the prestressed cables prior to manufacturing. A bespoke dolly-bogie system was used to transport the items to site and offloading was performed using a special side loader. The latter system did away with the need for two mobile cranes just to offload and place each item at the laydown stations, with cranes only deployed in the actual installation phases. “Using a 160 t crane, we were able to maintain a steady production rate by placing up to six beams a day. However, we have almost doubled production at other related projects using this method, where site conditions have been much more favourable,” adds Hobbs.

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CEMENT & CONCRETE

Car parks need

concrete

Attractive, durable parking areas hold many civic benefits.

oncrete offers a number of major advantages when it comes to the construction of parking areas, one of the most significant being a measurable reduction in life-cycle maintenance costs. Typically, all that’s required annually is routine joint sealing and cleaning. “Asphalt parking surfaces, on the other hand, need to be maintained regularly and resurfaced at least every 10 years. Such maintenance work can be very disruptive,” points out Bryan Perrie, managing director of The Concrete Institute and a global authority on concrete pavements. “Parking areas are more than just driving surfaces for cars. They serve, for example, as attractive welcome mats for municipal centres, sports stadiums, office complexes and airports.” Studies in the USA have shown that over the typical 20-year life of a concrete parking area, the cost of maintenance is minimal compared to an equivalent lot surfaced with asphalt. In one specific example, maintenance expenditure over the period ended up being as much as 80% of the initial construction cost. On another US project, main-

tenance requirements were even higher, ending up costing twice as much after 20 years than a similar concrete facility.

Bryan Perrie, managing director at The Concrete Institute

Energy savings Savings can also be achieved when it comes to public lighting. It has been estimated that three of ten lamp fixtures can be eliminated without impairing illumination levels by constructing parking areas with light concrete surfaces. The lighter colour of concrete can also significantly reduce the heat island effect and even lower cooling costs for adjacent buildings. This can result in up to an 11°C difference in temperature between an asphalt and concrete pavement. Concrete parking areas, particularly those with brushed finishes, are more skidresistant and allow for easy installation of rumble strips. Concrete pavements also do not rut or develop potholes when carrying heavy loads. “The environmental aspects of concrete parking lots should also not be overlooked,” says Perrie. “The run-off is low in toxicity and cooler than from asphalt surfaces. Moreover, permeable in situ and interlock-

ing concrete pavements substantially reduce stormwater run-off, resulting in less need for attenuation ponds. What’s more, to add to the sustainability point of view, the concrete mix used for parking lots can include secondary materials such as slag, fly ash, and also recycled concrete.”

Aesthetics Then there’s the important question of appearance. Selecting concrete to pave a parking area offers the designer unlimited choices of texture, pattern and colour for aesthetic appeal; and the parking areas can be blended with adjacent greenbelts or equipped with water features. Colour themes can also be used to identify specific parking zones for buses, trucks and visitors’ vehicles, as well as directional signs for pedestrians. “There’s also a strong case for the greater use of concrete when it comes to roadbuilding in general,” adds Perrie.

Permeable in situ and interlocking concrete pavements substantially reduce stormwater run-off, resulting in less need for attenuation ponds.”

IMIESA July May 2017 2017

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