IMIESA July 2023

ROADS & BRIDGES

Concrete pavements are sustainable and resilient

High-performance bulk water pipelines made with SA steel

TRENCHLESS TECHNOLOGY

SWP proves itself on Cape Flats 1

GEOTECHNICAL ENGINEERING Drainage using geocomposites

WATER & SANITATION

Unlocking the value of wastewater

EARLY BIRD REGISTRATION

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Sustained bulk water delivery is the lifeblood of a functioning economy and society. IMIESA speaks to Kenny van Rooyen, managing director at Hall Longmore, about his company’s crucial role as a local content steel pipe manufacturer, its commitment to research and development, as well as partnerships with key stakeholders that deliver worldclass infrastructure solutions. P6

MANAGING EDITOR Alastair Currie

SENIOR JOURNALIST Kirsten Kelly

JOURNALIST Nombulelo Manyana

EDITORIAL COORDINATOR Ziyanda Majodina

HEAD OF DESIGN Beren Bauermeister

CHIEF SUB-EDITOR Tristan Snijders

CONTRIBUTORS Lester Goldman, Ismail Mahomed, Sibusiso Mjwara, Nato Oosthuizen, Janita Ramanlal

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Revitalised municipalities will make a positive difference

On the infrastructure front, intensified expenditure on national roads projects is welcome news as Sanral rolls out construction works in key regions. A prime example is an approximately R1.165 billion investment in two developments within Great Kei Local Municipality, where some R983 million has been allocated for the upgrading of National Route R63 between km 21.7 and the N2 past Qumrha.

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ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR.

© Copyright 2023. All rights reserved.

IMESA CONTACTS

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Manager: Ingrid Botton

P.O. Box 2190, Westville, 3630

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Email: admin@imesa.org.za

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BORDER

Secretary: Celeste Vosloo

Tel: +27 (0)43 705 2433

Email: celestev@buffalocity.gov.za

EASTERN CAPE

Secretary: Susan Canestra

Tel: +27 (0)41 585 4142 ext. 7

Email: imesaec@imesa.org.za

KWAZULU-NATAL

Secretary: Narisha Sogan

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Email: imesakzn@imesa.org.za

NORTHERN PROVINCES

Secretary: Ollah Mthembu

Tel: +27 (0)82 823 7104

Email: np@imesa.org.za

SOUTHERN CAPE KAROO

Secretary: Henrietta Olivier

Tel: +27 (0)79 390 7536

Email: imesasck@imesa.org.za

WESTERN CAPE

Secretary: Michelle Ackerman

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Email: imesawc@imesa.org.za

FREE STATE & NORTHERN CAPE

Secretary: Wilma Van Der Walt

Tel: +27 (0)83 457 4362

Email: imesafsnc@imesa.org.za

All material herein IMIESA is copyright protected and may not be reproduced without the prior written permission of the publisher.

views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

Novus Holdings is a Level 2 BBBEE Contributor: novus.holdings/sustainability/transformation

The remaining R182 million has been allocated for the resealing of the N2 Section 16 between Mooiplaas (km 49.9) and Qumrha intersection (km 70.2), with works on both phases due to commence from the Q3 2023. In the immediate and longer term, these investments will help to support and sustain the local economy, which is one of South Africa’s poorest and more under-developed regions, but with major potential for tourism due to its scenic coastline.

Refocus

Following the Covid years, and the current rate of sustained load-shedding, the South African economy is struggling to recover, and unemployment remains one of the country’s greatest social ills. For this reason, it’s crucial that local municipalities refocus their efforts on meaningfully implementing their local infrastructure development programmes, both to enable employment and to retain and attract commercial investors.

This is the rationale that drives the ongoing implementation of Cogta’s District Development Model concept, which needs far more accelerated implementation and visible gains on the ground nationally. Effective coordination between national, provincial and local municipalities is key, but the latter are the ultimate creators and implementers. They also need to account for how funds donated were spent.

Remuneration versus expenditure

For the 2021/22 financial year, overall municipal expenditure was around R472 billion, of which 28% was spent on employee remuneration costs. The

latter figure falls within National Treasury’s norm of 25% to 40%. However, local government entities also expended some R39 billion on contracted services during the period. This equates to around 8.4% of total expenditure, which is above National Treasury’s 2% to 5% range. So, what’s going on?

Exceeding the norm for contracted services could be supported where municipalities embrace the advantages of outsourcing certain services, like operations and maintenance on their water and/or wastewater treatment works or, for example, where independent power producers are involved. However, an overreliance on private contractors could also indicate inefficiencies or gaps in capabilities. A red flag should certainly be raised where municipalities spend well below the contracted services percentage benchmark, yet exceed the 40% remuneration threshold and have little to show for it.

Rightsized for success

If these were under-performing private enterprises, the investors – in this case national government, taxpayers and municipal residents – would step in and overhaul, rightsize, retrench or even close the ‘business.’ The point to make is that there is so much opportunity to effect change within the municipal environment – and no excuses not to. Plus, there are so many qualified candidates in the private sector who could make a major difference ‘overnight’ if given the chance to work and lead in the public domain free of political influence.

The smart money is on performancebased models and that’s what local and international investors want to see when it comes to eradicating sustained power outages, using construction to tackle youth unemployment, and ensuring that South Africa is future-proof. I believe it is. We just need to put those taxes to work more effectively.

Cover opportunity

The

BOARDWALK HOTEL

Gqeberha (Port Elizabeth)

BOOK NOW! CONFERENCE SOCIAL ACTIVITIES

GOLF DAY

Contact Debbie Anderson if you want to get involved as an IMESA Golf Day Sponsor?

DATE: 24 October 2023

VENUE: Humewood Golf Course

TIME: Starts at 10h30

COST: R600pp (excluding Golf Cart & Caddy)

COMPANION PROGRAMME

2½ Days O -site Ladies Programme @ R1,600pp

DAY 1: Township Tour (The tour covers a visit to 4 community upliftment projects and a number of historical & cultural sites. Lunch included)

DAY 2: Theescombe Wine Estate (Enjoy a walk through the vineyard and a talk on wine making with a tutored tasting of 4 wines. Lunch included)

DAY 3: Painting with Grapes (A 3-hour painting class with all equipment provided. Your artwork goes home with you. Light snack provided)

SOCIAL EVENING

DATE: 26 October 2023

VENUE: Tramways Building

TIME: Starts at 18h30

COST: Included in delegate fee

Theme: Denim & T’s

For more information, contact Debbie Anderson on 031 266 3263 / conference@imesa.org.za

t: +27 (031)266 3263

e: conference@imesa.org.za

marketing@imesa.org.za

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A MEETING OF THE MINDS BETWEEN FINANCE AND ENGINEERING

However, a major compounding factor within the municipal space is ineffective communication between finance and engineering – assuming that the required professional competencies are in place – when it comes to planning, budgeting, and executing priority infrastructure projects.

Municipal engineers, technologists and technicians should all be registered or in the process of registering with the Engineering Council of South Africa (ECSA) and adhere to ECSA’s strict code of professional conduct. The same should be the case in the financial arena administered by the South African Institute of Chartered Accountants (SAICA), with members either registered as a Chartered Accountant (CA), Associate General Accountant (AGA) or Accounting Technician (AT), depending on their experience and responsibilities.

To register with either body, candidates must demonstrate a high level of competency and meet stringent admission criteria. They will also be held accountable for professional misconduct and potential deregistration, barring them from the profession.

A two-way street

You wouldn’t want to be a passenger in an aircraft flown by non-certified pilots. So, why should it be any different when it comes to engineering and financial personnel responsible for implementing and administering the framework for water, sanitation, electrical and transportation services?

It’s a two-way street when it comes to service delivery. Where registered engineering professionals are thin on the

ground within municipalities, it’s challenging to implement approved municipal budgets. However, even where the capacity exists, implementation boils down to funding availability and disciplined fiscal expenditure.

However, as we’ve seen from the latest 2021-22 Auditor-General South Africa (AG) consolidated general report on local government audit outcomes, there are too many municipalities falling short of the mark. This is underscored by the fact that only 38 out of 257 municipalities received a clean audit. Staggeringly, fruitless and wasteful expenditure alone amounted to some R4.74 billion, while irregular expenditure totalled some R30.34 billion. On top of this, 220 municipalities spent around R1.61 billion on consultants to assist with financial reporting – more than 53% because the skills did not exist in-house.

Prevention is better than cure

To correct these and other serous discrepancies going forward, one of the measures put in place by the AG is a material irregularity process. This puts financial

leaders in the hot seat when it comes to compliance in the future where they’ve fallen short of the audit requirements. The same applies to municipal managers where audited infrastructure, like water and wastewater treatment works, are not performing to standard.

Some degree of municipal coalition government instability is a factor, but as the AG emphasises, “When political transition occurs, the administrative functions must continue to fulfil their duties.” The AG also noted, “Investing in preventative controls to address the causes of infrastructure project failures is more effective than dealing with the consequences of such failures…”

Collaboration

So that means more money needs to be spent on maintenance to minimise areas like technical non-revenue water losses due to leaks. In turn, that requires adequate funding, chiefly derived from the efficient collection of revenues paid for municipal services rendered. Without best practice financial management and controls, effective infrastructure delivery will be hampered in practice. And without competent engineers, no meaningful implementation is possible.

The next generation

Going forward, IMESA is close to concluding a memorandum of understanding with the South African Local Government Association (Salga) to drive programmes that will help with municipal capacity building.

However, we need to look much further down the road than this by creating a pipeline of aspiring young minds that will see a career in the municipal engineering space as a sought-after civil service. Within IMESA, this initiative is being spearheaded by our Young Professional Engineers (YPE) forum. They will focus on high schools, motivating the importance of STEM education, and speaking about their own developmental experiences. It’s okay if some of these learners become CAs in the process. Either way, social infrastructure is for the people and future generations.

Sibusiso Mjwara, PrTechEng, MIMESA, MSAICE, MWISA, MIPET

Fruitless and wasteful expenditure has become far too commonplace within the municipal and broader SOE landscape. Yes, there’s a degree of corruption.

High-performance bulk water pipelines made with SA steel

Sustained bulk water delivery is the lifeblood of a functioning economy and society. IMIESA speaks to Kenny van Rooyen, managing director at Hall Longmore, about his company’s crucial role as a local content steel pipe manufacturer, its commitment to research and development (R&D), as well as partnerships with key stakeholders that deliver worldclass infrastructure solutions.

Mafenya Reservoir, which was also constructed by M&D. This structure incorporates a dual design functionality, namely a 5 Mℓ backup reservoir within a 50 Mℓ reservoir. As in Phase II, the key beneficiaries are the mining industry and surrounding communities.

Led by Martin van Aswegen, head: Pipe Division at M&D, Phase II extends the pipeline by a further 28 km from Mafenya Reservoir –situated some 5 km from Sun City – and through to the Mafenya pumping station for onward transfer to the 30 Mℓ Thlabane Reservoir in Rustenburg. On average, the pipeline is between 2.5 m to 3 m deep, housed within a 1.7 m width trench.

Phase II pipe sections

For the project, Hall Longmore’s scope entailed the manufacture of some 5 400 tonnes of steel pipe sections (grade X42 PSL 1) to complete the 28 km bulk water line. The bulk of the order comprises DN 900 pipe, with the exception of a 240 m section where DN 1 200 was specified.

The average depth of the pipeline is between 2.5 m to 3 m, housed within a 1.7 m width trench

Aprime example of project excellence is Hall Longmore’s involvement on the Mafenya Pumping Station and Pipeline to Thlabane Reservoir project, being carried out by main contractor M&D Construction on behalf of Magalies Water in the North West province. Design, project and construction management are being carried out by MwB Consulting Engineers, based in Rustenburg. This infrastructure development represents Phase II of Magalies Water’s ongoing

For the Mafenya Pumping Station and Pipeline to Thlabane Reservoir project, Hall Longmore’s scope entailed the manufacture of some 5 400 t of steel pipe sections (grade X42 PSL 1) to complete the 28 km bulk water line

expansion and upgrade programme forming part of the Pilanesberg Bulk Water Supply Scheme. Phase I – entailing the installation of a 42 km pipeline – was awarded to a joint venture (JV) comprising M&D and WK Construction. Completed in 2016, it stretches from Evergreen at the Vaalkop water treatment plant and culminates at

Founded in 1924, Hall Longmore has stayed ahead of the curve by responding to customer demand both at home and abroad where the company exports to over 30 countries.”

All pipe sections supplied measure 18.288 m (60 feet).

Corrosion protection

To ensure that optimum life is achieved – the benchmark being around 50 years for steel pipe – various corrosion protection measures formed part of the Hall Longmore order. The external and internal pipe sections were coated and lined for corrosion protection, and life-cycle enhancement. To ensure the overall integrity of the buried pipe, a cathodic protection system will be progressively installed by M&D.

Hall Longmore offers different corrosion protection systems depending on design and environmental requirements. Examples of typical corrosion protection coatings include the company’s three-layer polyethylene system, the Xtalene 3935 proprietary fusion bonded medium-density polyethylene (FBMDPE) product for buried pipe and above-ground applications, as well as other traditional coatings.

“Xtalene 3935 is our latest coating innovation and is made from a uniquely formulated polymer composite material. This is a proudly South African FBMDPE coating sourced from South African raw materials and blended locally,” explains Van Rooyen.

“Some four to five years in the making, product development was carried out in conjunction with the CSIR Nanomaterials Industrial Development Facility, working with Hall Longmore’s technical experts. Sasol came on board as raw material suppliers, together with Xuba from a blending and manufacturing perspective. The result is a product that sets a new benchmark for performance,” Van Rooyen continues.

Key benefits include lower water absorption properties, improved penetration resistance, enhanced bond strength yield at over 30 MPa – where the standard requires 15 MPa – and improved cathodic disbondment results. Shore hardness and elongation are also higher.

Factory setup

To meet market demand, Hall Longmore has invested in the latest advances in fluidised bed technology to apply Xtalene 3935 along with allied coating products at its factories in Wadeville, Germiston, and Duncanville in Vereeniging. These two factories are geared up to produce some 230 000 tonnes of steel pipe annually, predominantly for the Southern African bulk water market, as well as the local and international oil and gas segments.

In terms of the latter, Hall Longmore recently invested R60 million in facility upgrades at its Wadeville factory to remain current with

Quality control with precision X-ray

At Duncanville, Hall Longmore has also invested in the latest automated radiographic testing (RT) technology for non-destructive testing on its helical welded steel pipe range, central to which is a specialist fluoroscopic X-ray machine to identify any weld defects.

The pipes were delivered at a rate of 1.5 km to 1.8 km per week. This kept pace with M&D Construction’s installation rate of around 900 m to 1.2 km per week

“This is one of the first digital RT systems to be installed by a South African steel pipe manufacturer and replaces a previousgeneration analogue system in use by Hall Longmore since around 1994,” says Van Rooyen.

Internationally, the accepted norm for pipes that fail the RT weld defect test should be less than 3%. Using the latest digital RT, Hall Longmore was well within that range for the Magalies Water project. Another major advance is that digital RT is around 10 times faster in

American Petroleum Institute standards –the global benchmark in this field. This essentially requires the production of 99.9% defect-free pipe.

From an enterprise development perspective, Hall Longmore formed a JV with a local supplier to progressively deliver the 28 km of pipe ordered

terms of inspection speeds. That translates into faster just-in-time pipe fabrication and delivery.

“From M&D’s perspective, that level of quality control (QC) is essential in ensuring that we deliver the best result for the client,” says Van Aswegen, adding that M&D’s QC team conducted two weekly inspections of work in progress at the Duncanville factory where the helical welded steel pipe sections ordered are produced.

Strategic partnerships

“M&D’s engagement with Hall Longmore dates back to around 2008 and we’ve always respected them for their manufacturing capabilities, flexibility and expertise. That was crucial in providing Magalies Water with a valueengineered solution,” Van Aswegen continues.

During the tender bidding process, a number of different material proposals – like GRP, plastic and steel – needed to be evaluated by the client’s consulting engineers, along with various coating and lining solutions. In addition to a local content provision, the tender also specified the need for community participation and enterprise development.

“Thanks to our track record for construction excellence, and Hall Longmore’s reputation as a renowned steel pipe specialist, M&D secured Phase II and is advancing well with the programme,” says Van Aswegen. “At M&D, we define our purpose in terms of our ‘4 Gs’,

namely Growing a Great company with Great people and Great partnerships.”

From an enterprise development perspective, Hall Longmore formed a JV with a local supplier to progressively deliver the 28 km of pipe ordered. M&D in turn has deployed local SMME subcontractors within the four different wards that the pipeline passes through for final project elements. As part of the contract, M&D is providing related training and mentorship.

The helical welded steel pipes supplied have a straightforward bevelled end that requires a standard internal and external welding technique to secure the individual sections. Having said that, the welding itself is a professional skill and an area of expertise within M&D.

All the special pipe fittings required – such as bends, tees, valve chambers, etc. – are manufactured at M&D’s fabrication facility in Kya Sands, Gauteng. The Kya Sands Shop is ISO 3834 Part 2 accredited and mainly supports M&D’s in-house requirement. Externally, these sections are wrapped with a viscoelastic (VeP) material for corrosion protection, with the internal coating adhering to the same specification as the solvent-free epoxy specified for the Hall Longmore pipe sections. The pipe section field joints are protected with the same VeP material.

Pipe delivery rate and storage

To optimise project and programme management, M&D has established pipe yards along the route. With Hall Longmore’s enterprise partner progressively stocking them with the ordered specification for each section, this has enabled M&D to proceed with confidence with its planned daily pipelaying targets.

“The pipe delivery rate was seamless, at 1.5 km to 1.8 km per week. That kept pace

with our installation rate, which is around 900 m to 1.2 km per week,” says Van Aswegen.

M&D submitted its tender for Phase II in March 2022, and was awarded the contract in July 2022.

The pipe order was placed immediately in July 2022 and the initial batches started to leave the Duncanville factory in February 2023.

Hall Longmore and its enterprise JV partner will deliver the final consignment at the end of July 2023. In the meantime, M&D is forging ahead for scheduled completion of Phase II by the end of April 2024.

“This is one of the best projects Hall Longmore has been involved on in terms of the efficiency of the tender, award, construction and supply chain process,” notes Van Rooyen.

Market outlook

From a pipe manufacturer’s perspective, Hall Longmore is very encouraged going forward by the renewed focus from the Department of Water and Sanitation on priority projects, as well as the approximately R40.3 billion allocated for the 2023/24 financial year, and some R43.9 billion and R48.4 billion for 2024/25 and 2025/26, respectively.

The approximately R10.1 billion allocated to municipalities for 2023/24 through the Regional Bulk Infrastructure Grant (RBIG), plus a further R4.6 billion through the Water Services Infrastructure Grant (WSIG), will also enable much needed upgrades in essential services within South Africa’s towns and cities.

“The ongoing consolidation of South Africa’s water boards will also help to achieve economies of scale, pool expertise and focus regional project execution more effectively, spurring an increased level of tender activity for design and construct projects. We are definitely seeing the green shoots of a project pipeline following a hiatus of five to ten years,” Van Rooyen continues.

“From a Hall Longmore standpoint, we’ve made a huge investment in the future of our country in support of essential infrastructure and the products and technologies leading contractors like M&D need to effect implementation. As a pipe manufacturer, we’ve been part of this landscape for close to 100 years, and remain firmly committed to South African construction,” Van Rooyen concludes.

www.hall-longmore.co.za

All the special pipe fittings required –such as bends, tees, valve chambers, etc. – are manufactured at M&D’s ISO 3834 Part 2 accredited fabrication facility in Kya Sands, Gauteng

The helical welded steel pipes supplied have a straightforward bevelled end that requires a standard internal and external welding technique to secure the individual sections

DATA SECURITY FREE OF CHARGE IN THE VEGA TOOLS APP

When a level or pressure sensor is taken out of service and replaced, it takes countless important sensor settings and data with it into retirement. However, the settings and measured values are not lost, because a new VEGA software tool saves everything that matters.

Smartphones and tablets are now standard equipment in industrial plants. Almost 40% of all VEGA sensors for level, point level and pressure are parameterised, read out and serviced via Bluetooth and the VEGA Tools app. To be sure, lots of ‘real work’ still has to be done on-site, but the adjustment of sensors in hazardous zones or hard-to-reach measuring points is made considerably easier with these wireless tools, as it can be performed from a safe distance of up to 50 m.

Wireless is now the standard

But even in less demanding ‘standard applications’, wireless operation via app is increasingly gaining

acceptance. Philipp Ketterer, product manager, VEGA, knows the reasons: “For Industry 4.0, there has to be fast, continuous data communication.”

Besides continuous transmission as required by IIoT, it includes above all an increase in convenience and speed. “Actually, the same arguments for Bluetooth in industry apply to the private use of wireless: it saves an enormous amount of wiring and time, and ultimately, costs,” Ketterer continues.

Backup and restore for better processes

Universally accessible process data is one of the most important prerequisites for reliable, cost-effective production. Sensors monitor the status and quality of the individual production steps and store important information on settings, diagnostics and the status of machines and systems. The users of these sensors, in turn, need the certainty that they have access to all sensor parameters at all times and that backup solutions are available if a worst-case scenario occurs.

To provide the best possible support for users, VEGA offers an innovative cloud solution. ‘Backup & Restore’ is the name of the new software tool that VEGA customers can now use permanently free of charge and, as the name implies, offers

them the option of backing up and restoring their sensor data.

No limits on security

Convenient access to this service is provided by both the instrument DTMs and the VEGA Tools app. With the app, VEGA sensors can be directly controlled and adjusted via smartphone or tablet. New here under ‘Instrument adjustment’ is the function ‘Backup & Restore’. Behind the serial numbers, which appear listed here via mouse click, the available backup data can be called up and – if you so choose – reinstalled.

“Our customers can access all the data ever collected, because the number of backups is not limited,” says Ketterer. “We thus offer a unique free service that brings significantly more efficiency to automated processes.”

Far more than just storage

In the industrial environment, too, data backup now means much more than just storage. Flexible backups and quick restores are important for ensuring that valuable process data is available for immediate reinstatement of device settings, diagnostics or process analysis. With ‘Backup & Restore’, VEGA has solved the problem many companies have, namely, keeping enough storage space available for ever larger quantities of data.

All parameters can be saved securely in the VEGA cloud at regular intervals. For medium-sized and small companies, as well as others, this is an ideal option for permanently securing their complex, evergrowing data flow.

SENEGAL

First project-financed solar PV and BESS

The Emerging Africa Infrastructure Fund (EAIF), a Private Infrastructure Development Group company, has committed an €11.5 million (R237 million) senior secured loan to develop the first project-financed solar PV plant and battery energy storage system (BESS) in Bokhol, north of Senegal. The Walo facility will be a 10 MW/20 MWh battery energy storage system (BESS) supplied by a 16 MWp solar PV plant. EAIF acted as co-lender alongside the Dutch development bank FMO, to support the development of the €42 million (R865 million) landmark project. A US$1.5 million (R25.2 million) capital grant extended by PIDG Technical Assistance will ensure the project is designed to maximise supply of clean power to Senegal’s grid, while remaining economically viable.

Upon completion, Walo will improve energy security in the country, demonstrating the importance of robust energy storage systems to support the electric transmission network and accelerate an efficient transition to renewable energy. Millenium Challenge Corporation, a US government foreign aid agency, recommended the installation of at least 80 MW battery storage, with Walo as one of the first in a series of projects.

Africa REN will construct and operate the facility under a 20-year power purchase agreement. The first-of-its-kind project will deliver a range of positive impacts, including

GHANA

Bui Power Authority improves operational coverage with eLTE Solution

The International Renewable Energy Agency estimates that Africa’s renewable energy capacity could reach 310 GW by 2030. The Bui Power Authority (BPA) hydro-solar hybrid power plant in Ghana is equipped with communication and operational management services that have been provided across Huawei’s eLTE

greater flexibility in energy management and improved reliability of grid operations. Beyond energy access and reliability of supply, Walo will also boost the local economy through the creation of 150 jobs during construction as well as 20 permanent roles when in operation.

The system will utilise reserve energy when there are deficits, bring power and grid assets online after failures, and supply electricity to the cities in the northern part of Senegal during power outages.

Within six years, Senegal has added more than 345 MW of clean power, accounting for nearly a quarter of its energy mix.

Broadband Network. Intelligent energy management is critical for ensuring efficient power generation, power plant operations and power distribution. ICT systems enable renewable energy to be integrated into the grid for the reliable, stable access and supply needed in order to achieve the country’s goal of universal electricity access by 2025.

Bui Authority and Huawei have built an eLTE broadband private network that penetrates the substantial concrete barriers and infrastructure

at the Bui plant. This is the first time that Huawei has deployed eLTE-based solution in the hydroelectric industry. The network – which carries voice, video and data services – enables instant communication between the control room and maintenance staff moving around the plant. It covers, without extensive cabling and installation, both indoor and outdoor working areas, including roadways inside the dam, generator rooms and employee living areas within the Bui vicinity.

ESWATINI

Planned new Eco Green City

The African Development Bank’s Urban and Municipal Development Fund is partnering with the Eswatini Water and Agriculture Development Enterprise on a new urban planning project, closely linked with the development of a transformative agro-industrial hub, which will boost economic activities and to attract tens of thousands of workers.

The Fund approved a grant of US$400 000 (R7.57 million) to the Eswatini New Eco-Green City Masterplan to support the planning of a new urban area in the Shiselweni region of the country, where population and economic activities are expected to grow quickly over the next few years.

This will be key for the design of the development plan and to identify the non-agricultural elements of the project, including energy and transportation. The fund will support the urban planning aspects of the project.

Shiselweni faces the highest level of poverty in the country yet is very suitable for agricultural activity due to its rich soil. It is the driest region in Eswatini with an annual precipitation of 500 mm. Reducing drought vulnerability and developing economic activities is a priority for the government, which is planning the construction of three dams to enable irrigation.

MOZAMBIQUE

Rail projects on track for completion

Mozambique Ports and Railways (CFM) has confirmed that construction of the new passenger terminal at Maputo Central Station is on track.

The project comprises the development of eight lines for boarding and disembarking, a new company headquarters, a shopping centre, a hotel, conference rooms, a car park and other services. Costing US$150 million (R2.84 billion), the project is being carried out in collaboration with Maputo City Council as part of the 25 de Setembro and Albert Lithuli Avenues will also be remodelled.

There is also a $82 million (R1.55 billion) project to double 50 km of track along the Ressano Garcia railway line, which links Mozambique and South Africa, from the Matola-Gare administrative post to Secogene in Maputo Province. The work includes the construction of four new bridges.

The $200 million (R3.79 billion) rehabilitation of the Machipanda Line covers 318 km between the Port of Beira in Mozambique and Machipanda, near the border with Zimbabwe. Work includes reducing the number of tight bends from 14 to 4 to cut the frequency of train derailments. Passenger services will also be reintroduced. The Machipanda project aims to boost the economy within the SADC region and increase the flow of cargo, including wheat and ferrochrome. Cargo volumes are expected to increase from 600 000 t annually to 3.5 Mt a year. The Machipanda Line was originally built in 1892.

KENYA

Schneider Electric to move manufacturing operations to Actom

Schneider Electric and Actom have reached an agreement where Actom will take over the production of Schneider Electric’s BlokSeT type-tested switchboards.

Schneider Electric will transfer its manufacturing operations, assets and people who currently operate the manufacturing and assembly plant to Actom.

Actom is the largest manufacturer, solutions provider, repairer,

maintainer and distributor of electromechanical equipment in Africa, offering a combination of manufacturing, service, repairs, maintenance, projects and distribution through its 33 outlets throughout subSaharan Africa and footprint across the globe.

“This will be a platform for the broader Actom group to not only enter the East African market but also to embrace East African economies where we will employ people and use our intellectual property to get actively involved, thus also growing both Actom South Africa and Actom Kenya,” says Mervyn Naidoo, CEO,

Actom. Schneider Electric Kenya will continue to run its sales, marketing, projects, services and logistics operations from Kenya, serving the East African market.

DRAINAGE USING GEOCOMPOSITES

The movement of groundwater is facilitated by the presence of voids or pores in the ground. These voids allow water to rise to the surface, particularly in areas with significant changes in relative levels such as steep slopes, intersections of rock and soil masses, or boundaries between soil masses with varying permeability.

By Janita Ramanlal*

However, when man-made structures impede this natural flow, it becomes essential to implement specific measures to preserve the integrity of the completed structure.

Traditionally, subsoil drains composed of sand and gravel have been employed to divert groundwater away from structures, ensuring their integrity throughout their intended design life. Drainage geocomposites offer a viable alternative to these conventional drains (see Figure 1).

Utilising drainage geocomposites presents numerous advantages, with the most notable being the reduction in construction costs and time. Minimising quarrying, and transportation of large quantities of natural materials to the site, reduces overall costs and installation duration. Furthermore, drainage geocomposites are lightweight and manageable, requiring less time and manpower to install than traditional solutions.

Compared to conventional gravel drains, drainage geocomposites can provide up to three times the drainage capacity with 60% less excavation. This makes them particularly advantageous in scenarios where the mineral

layer of steep slopes would be unstable, as drainage geocomposites offer stability without compromising drainage efficiency. Under practical usage conditions, the drainage capacity of these geocomposites is measured in laboratories, and their performance is guaranteed by quality control.

Drainage core

Drainage geocomposites are composed of a drainage core (Figure 2) that enables efficient transportation of fluid along its plane. To prevent clogging of the core by surrounding soil, geotextiles and/or geomembranes are coupled to the drainage core. The most widely employed drainage geocomposites are those produced by laminating one or two geotextiles with a filtering function onto a drainage element.

The geotextiles (typically non-woven) serving as the filtering component must have adequate permeability to gases and liquids in the direction perpendicular to the filter plane and must be able to separate the soil particles from the drainage core. The drainage core, which serves as the draining component, must have adequate permeability to gases and liquids in the direction planar to the drainage structure. When designed

correctly, drainage geocomposites provide an effective solution for fluid management.

Typical applications

Some of the main applications of drainage geocomposites are (and are not limited to):

• Retaining structures: Drainage geocomposites dissipate pore water pressures and help maintain the stability and integrity of the structural fill in both concrete and soilreinforced retaining structures.

• Road, railway, and airport applications: Wick/ trench drains, which can substitute subsoil drains, are commonly used in road, railway and airport projects. Drainage geocomposites are utilised in these applications to provide efficient water drainage, ensuring optimal performance and durability.

• Horizontal drainage and anti-capillary layers in embankments composed of fine and cohesive fills: Drainage geocomposites facilitate the removal of excess water from the embankment, preventing water accumulation and potential instability. Additionally, they can act as anti-capillary layers, preventing the upward movement of water through the embankment.

• Landfills: Drainage geocomposites are utilised for leachate collection and gas ventilation, aiding in the proper management of landfill fluids and gases or leakage detection. Additionally, these geocomposites serve as a protective layer, safeguarding geomembranes against puncture or damage.

• Roofing and deck pavement applications: Drainage geocomposites facilitate the efficient removal of water from surfaces, reducing the risk of water accumulation and moisturerelated damage.

• Drainage of sports fields: Drainage geocomposites effectively manage water. They help maintain optimal field conditions, prevent waterlogging and ensure consistent playability.

Subsurface drainage is the technique to control the flow of groundwater, through interception and/or deviation. An effective subsurface drainage system will reduce pore water pressures and increase effective stresses, thereby increasing the shear strength of the soil. Moreover, it will lessen the horizontal forces,

traditional subsoil drain

FIGURE 1 Excavation reduction by 60% when using a drainage geocomposite vs a

thus reducing overturning moments and the possibility of failure, as well as preventing the uncontrolled movement of soil particles (piping phenomena).

To ensure the successful implementation of subsurface drainage, groundwater must be removed in a controlled manner, without causing undue disturbance to the surrounding areas. This consideration becomes particularly important when the removal of groundwater may lead to movements or subsidence in the adjacent regions. Careful thought must be given to the positioning of the drainage system and the selection of appropriate materials to avoid any adverse consequences and maintain the stability of the surrounding areas.

Performance criteria

For a subsurface drain to be considered effective, it must meet the following three requirements:

1. The drainage system should be strategically placed and configured to intercept the seepage zone effectively. Proper consideration of the placement and layout of the subsurface drainage system is crucial to ensure it targets the intended area of seepage.

2. The subsurface drainage system should allow seepage water to enter with minimal resistance, while also minimising any disturbance or piping at the drain/soil interface. This is achieved by incorporating filters around the perimeter of the subsoil drains.

3. The subsurface drainage system must be designed to remove the required amount of groundwater from the soil in the required time interval. The dimensions of the drains, the selection of appropriate drainage media, and the configuration of the drainage system all contribute to its ability to perform satisfactorily.

Hydraulic gradient and pressure

The drainage capacity of a geocomposite depends on the hydraulic gradient as well as the pressure applied to, and the materials in contact with, the two faces. The design of a drainage system using geosynthetics is based on the evaluation

of the drainage capacity available under actual operating conditions and the flow rate required by the project. The drainage capacity can be assessed based on appropriate laboratory tests, while the required flow rate is evaluated based on hydrological and hydraulic considerations. By considering these factors, an efficient and effective drainage system can be designed to meet the specific needs of the project.

Case study

In the case history presented below, the challenge arose when installing modular schools along 9th Road in Midrand, Gauteng. The site was characterised by saturated soft clayey soils with a water table higher than ground level, resulting in a natural spring.

The in-situ soil did not allow for pore water pressure dissipation in a short timeframe, posing difficulties for construction activities. The presence of excessive pore water pressure therefore made it unsuitable to install the modular school equipment on-site because the school would likely settle over time due to consolidation as the pore water pressure dissipated.

Traditional methods of draining the water and increasing the bearing capacity were not viable due to time restrictions. Importing soil to provide a stable foundation was also not feasible because the introduced soil would mix with the existing in-situ soil and fail under any load.

This situation presented a significant challenge for the contractor, who needed an alternative solution to install modular schools within time constraints. In response, this entailed the use of geosynthetic materials and techniques to address the challenges of saturated soft soil and a high water table.

in-situ soil, and provide drainage to dissipate excess water pressure, an 11 mm thick drainage geocomposite was utilised. This geocomposite consisted of a geotextile separation layer combined with a geomat core for effective drainage.

The approach involved placing the drainage geocomposite directly on top of the existing in-situ soil without earthworks. It was then covered with 300 mm imported material. Additionally, woven geosynthetic grids were incorporated into the solution to minimise longterm settlement (see Figure 3).

Within three days, 2 000 m2 of layer works were constructed using drainage geocomposites and geosynthetic grids. In contrast, a conventional solution would have required excavating and replacing at least 1.5 m of in-situ soil with imported material, along with the installation of a herringbone drainage system beneath the imported material. Such an approach would have increased costs and construction time.

Conclusion

Drainage geocomposites may be used in various applications to divert groundwater in a controlled fashion away from structures by filtering water through and transporting it away from the structures. Plus, the fact that drainage geocomposites can provide up to three times the drainage capacity with 60% less excavation when compared to conventional gravel drains is a clear advantage. This allows for an overall reduction in the construction cost and time in an environment where natural materials are inaccessible.

To avoid contamination of the imported material with the www.maccaferri.com/za

FIGURE 3 Project solution with the geosynthetic grid at the top (yellow box) and drainage geocomposite at the bottom (red box)

FIGURE 2

Drainage geosynthetic –drainage core coupled with geotextiles

*Commercial Engineer, BSc (Hons) (Civil Engineering), ECSA Candidate Engineer

GABIONS ARE SCALABLE, FLEXIBLE AND DESIGNED TO BLEND IN

A mainstream choice for civil and environmentally engineered structures worldwide, gabions have stayed the test of time over centuries due to their flexibility and sustainability. Alastair Currie speaks to Louis Cheyne, managing director of Gabion Baskets, about recent projects where his company’s manufactured systems have provided functional and aesthetic solutions.

One of the key roles that gabions perform is earth retention and erosion control due to their characteristic rock-filled wire-frame composition. Combined with the use of geotextile liners, this enables the designer to control the degree of permeability,” explains Cheyne.

“That’s crucial for installations such as mass gravity retaining walls and for riverbank protection where hydraulic factors need to be carefully considered. Here, the approximately 35% voids composition of gabion baskets, mattresses and related systems provides unrivalled performance when designed by

experienced environmental engineers with an expert understanding of soil mechanics. With creative thinking, those designs can be shaped into a wide configuration of engineered structures that serve the dual purpose of form and function,” he continues.

Amphitheatre

A recent example is an amphitheatre built for Summerhill Preparatory School, nestled amid pristine riverine forest in the idyllic Hazyview region of Mpumalanga.

Recently, the school encountered a challenge when heavy rainfall triggered a troublesome landslide, affecting the surroundings of some classrooms.

Determined to find a sustainable solution, the school reached out to Fanie Joubert, director of Civil, Structural & Eco-Solutions, and the representative of Gabion Baskets in Mpumalanga and Limpopo.

Entrusted with the task of planning, designing and implementing an environmentally friendly remedy, Joubert conducted a meticulous survey of the affected area, leading to the creation of a oneof-a-kind, open-air amphitheatre classroom. Facing obstacles such as consistent groundwater seepage and highly erodible soil, Joubert installed fin drains to manage the water and successfully

A 7 m high and 75 m long land-based mass gravity wall was installed to counter embankment erosion caused by periodic flooding of the river

designed a layout that perfectly suited the unique characteristics of the area. The final design showcases six spacious platforms, each 3 m wide, with the longest platform stretching 21 m. With convenient walkways on both sides, these platforms provide easy access for everyone.

The benches, crafted using 500 mm x 500 mm gabions, offer a combination of strength and elegance. Then to ensure the safety of the learners and keep unwanted critters away, the exposed vertical sides of the gabions are lined with artificial grass. The finished product is a truly remarkable addition, reflecting the school’s unwavering commitment to providing an exceptional educational environment.

Seaview mass gravity wall

“A key advantage of gabion systems is their scalability and the ability to use a wide

range of fill compositions, depending on whether it’s an engineering or landscaped architectural application. For mass gravity applications, another key benefit is that gabion retaining walls tend to occupy a much smaller foundation footprint compared to those constructed with concrete retaining wall systems. This is especially the case as the height of the wall increases. That has major cost and practical benefits in terms of optimising land use,” Cheyne explains.

A recent example is an erosion intervention in the suburb of Seaview, eThekwini, where extensive flood damage resulted in major riverbank erosion, placing a bordering property, as well as neighbouring ones, at risk. As part of its turnkey offering, which includes installation training, Gabion Baskets provided a design recommendation. The proposal was for a 7 m high and 75 m long land-based mass gravity wall, with the client’s

The top of the wall facing the river

engineer, LSC Brunette Consulting Engineers, refining the final design based on the findings of the geotechnical report.

“As the normal flow of the river is about 15 m away from the buildings in question, it was decided not to employ a riverbank erosion protection wall and allied gabion mattress foundation setup. The goal was to position the mass gravity wall as close to the building perimeter as possible to mitigate future flood events,” Cheyne continues.

Stormwater channel

Erosion comes in many shapes and forms, and one of the chief causes is uncontrolled stormwater run-off. Here, the installation of gabion mattresses is proven to slow down stormwater velocities in a controlled manner that promotes sustainable drainage.

This was the case for a Durban-based homeowners’ association, where the Gabion Baskets project team was called in to assess an existing mattress installation that had failed over time. “This emphasises the point

SEAVIEW MASS GRAVITY WALL

A key advantage of gabion systems is their scalability and the ability to use a wide range of fill compositions, depending on whether it’s an engineering or landscaped architectural application.”

These wall sections demonstrate best practice in terms of rock selection and gabion packing technique, which is a practice that should only be performed by trained installers

that the best designs will fail if the incorrect products – combined with poor installation technique – are employed,” explains Cheyne, adding that all of Gabions Baskets’ wire products are Class A galvanised as per industry standards to minimise the risk of corrosion.

Gabion Baskets’ site assessment revealed that the existing mattress – installed some 10 years ago – was rusting in places. There were also sections where the rock fill had started to wash out of the mattress, progressively undermining its integrity.

A new, wider mattress channel was recommended to disperse water more evenly, which was accepted by the client. For added protection, the wire system supplied includes a PVC coating to extend the mattress’ lifespan. The new system was successfully put to the test during some heavy downpours experienced in June 2023.

“Because they essentially ‘breathe’ with the environment, while holding the earth in check, gabions are the obvious choice for erosion control. But as we continue to see, designers are increasingly exploring their aesthetic side, while infrastructure planners recognise their value from a labour-intensive construction and employment creation perspective. It’s a win-win all round,” Cheyne concludes.

Prepping the site for the gabion

STORMWATER MATTRESS CHANNEL

STORMWATER MATTRESS CHANNEL

A cross section of the stormwater gabion mattress channel designed for a Durban homeowners’ association. The Class A galvanised gabion wire specified included a PVC coating for added durability against corrosion

Extensive soil erosion caused by stormwater drain outflows. The existing gabion mattress installed some 10 years previously was too narrow and short to effectively dissipate water velocity flows. Its wire material frame was also showing signs of rust and deterioration

The gabion mattress system installed is a simple but highly effective way to reduce stormwater flow velocities that could otherwise result in a slope failure

The geotextile liner is a crucial part of the design to prevent fines losses that would subsequently undermine the gabion mattress

amphitheatre

The terraced amphitheatre at an advanced stage of construction

To ensure the safety of the learners and keep unwanted critters away, the exposed vertical sides of the gabions are lined with artificial grass

Nine decades

of project delivery and counting

Turning 90 is a major milestone for any organisation. In this case, it is Zutari – a leading consulting engineering and infrastructure advisory firm that has been an integral part of shaping South Africa’s socio-economic landscape then and now.

When we talk about making an impact, it is about the positive impact we have on society, our communities, the environment and in all aspects of the economy,” says Teddy Daka, CEO at Zutari. He adds that this is related to Zutari’s core value of ‘We Are One.’

“It is deeply rooted in Zutari and South African culture that the world we live in today is not just ours. It belongs to future generations. Impact is about ensuring we do not disappoint in this goal and create an environment for ourselves that is liveable, but also to declare our commitment to leaving behind a legacy for others to follow.”

Daka stresses that Zutari is unable to make this impact on its own. “It is only possible

because of the clients who give us challenges and problems to solve. Hence, we extend our gratitude to our clients for affording us the opportunity to work on projects that highlight how we can bring about impact with solutions that add value to people’s lives.”

Zandvliet

One of these projects is the Zandvliet Wastewater Treatment Works (WWTW) – the third largest WWTW in the City of Cape Town that serving some of its densest, fastest growing and poorest communities. For years, it has been overloaded and has polluted the downstream Kuils River, leading to severe degradation of the river and estuarine ecosystem on which communities depend for small-scale agriculture and fishing.

Over the past decade, the government has prohibited housing and development in the catchment because the receiving Zandvliet WWTW could not accommodate the additional flow. This development moratorium has left thousands without dignified housing and sanitation, and stalled economic development.

Zutari was appointed in 2013 to design a suitable solution and manage construction to increase capacity. Over the last decade, it has been steadily and methodically assisting the City through planning, concept and detail designs, licensing and environmental authorisation, contract administration, construction and commissioning. To date, Zutari has completed all designs and has implemented six out of the eight construction contracts for the Zandvliet WWTW.

VR exploration and implementation

“This project embodied a combination of technical mastery and digital acumen to co-create an engineered impact,” says Imraan Paleker from Water, Waste and Energy at Zutari. The project was a showcase for 3D modelling and the first to develop a virtual

Tasez Cluster 2 Ford Frame in Tshwane. The Ford Frame building has a massive footprint of 78 000 m² and a gross building area of about 100 000 m²

reality (VR) model, according to chemical engineer Daniel Petrie.

“It was particularly helpful as it allowed our client to understand the design. Looking at 2D drawings is not how we experience the world. Being able to look at it in 3D, even though it was virtual, gave the client the confidence that they wanted to take it on and operate it well into the future,” says Petrie.

Instrumentation and digitalisation

Another feature of Zandvliet is the sophistication of the instrumentation and information management adopted for a working plant. “It is unlike any wastewater treatment plant in the municipal space that we have had exposure to,” says Petrie. Real-life remote access to the data that is being accumulated will allow Zutari to track and pick up on any opportunities for process optimisation.

Zandvliet is a showcase of Zutari’s capabilities in the digital space, with the company embarking on a journey to become a fully fledged digital practice by 2025, says Dr Gustav Rohde, deputy chief executive.

“It will improve our delivery process, remove duplication and help to address any client pain points. We want to make sure

that our clients benefit not only from our increased efficiency, but our understanding of the digital space itself. The ‘digital world’ means we can now connect things; we can connect infrastructure to people.”

Tasez Cluster 2 Ford Frame

Another flagship project that is testament to the role that creating adaptable infrastructure plays in economic development is the Tasez Cluster 2 Ford Frame in Tshwane. The Ford Frame building has a massive footprint of 78 000 m² and a gross building area of about 100 000 m². It essentially serves as a manufacturing, painting and storage factory for the new Ford chassis in South Africa.

The vision for the project was to be the benchmark for special economic zones (SEZs) in South Africa and a major creator of new businesses, contributing to employment through transformation and socio-economic development, while prioritising the growth of the local automotive sector.

Similarly ambitious were the engineering challenges facing the project team – both technically and from a programming perspective – to effectively deliver a fit-forpurpose project on time and within budget.

“It is the largest automotive city in

Africa,” says Daniel Struwig, technical specialist: Structural Engineering. “The project was delivered in record time and involved a massive collaborative effort,” he adds. It generated 20 000 employment opportunities, of which 2 000 were permanent.

Conclusions

At the end of the day, Zutari “delivers long-lasting and futureproof infrastructure through human-centred design and engineering,” says Joe Ndala, chief financial officer. “Our approach delivers robust infrastructure with multiple life cycles.”

Webb Meko, chief clients officer, adds that Zutari “promotes the concept of responsible engineering to co-create impactful infrastructure. We believe this can be done in a manner sensitive to the environment.”

The concluding comment is from Dr Eduard Vorster, MD: Resources, who sums up by stating that, “Zutari showcases its inclusive methods to present opportunities for all stakeholders and result in solutions that deliver human dignity. At the end of the day, impact means accelerated equitable quality of life for all.”

Zandvliet is the third largest WWTW in Cape Town

More investment in rural infrastructure needed

This was the essential message presented to delegates by Shawn Gama, CEO of Zimile Consulting Engineers, at the 13th Rural Development Conference for Africa, which recently took place in Durban, KwaZulu-Natal.

Gama’s solution is an engineering-driven ‘eat the elephant’ approach that should begin with life-sustaining projects. Citing Greenpeace’s ‘Water Crisis in South Africa’ article from 2022, he states that about 19% of rural South Africa lacks access to reliable water supply and 33% do not have basic sanitation services.

“Let’s not even get into the need for sustainable housing, roads, healthcare facilities, bridges and so much more!” Gama stresses, adding that the result has been a steady migration to seek out better living conditions and employment, with around 67.85% of South Africa’s population now living in urban centres. However, that doesn’t mean they’re necessarily better off, given the

mushrooming of informal settlements within town and cities.

A way out of the poverty trap

Gama proposes the following solutions to drive enabling infrastructure development that helps balance the rural and urban equation:

- eliminate corruption within government and the private sector

- focus on quality more than costs

- everage the power of innovation and technology in delivering cost-effective projects

- professionalise the public sector vigorously

- drive community engagement as a priority in project implementation from concept stages until completion

- build sustainable and smart infrastructure

- improve procurement processes by removing red tape and shortening the turnaround times to appoint service providers

- partner with reliable consulting engineer firms.

On the last point, Gama stresses that that role of a consulting engineer is key to delivery.

“Consulting engineers possess a unique set of skills that enable them to tackle complex challenges and find sustainable solutions. Their expertise goes beyond technical knowledge; it encompasses creativity, critical thinking, project management and effective communication,” he explains.

In Zimile’s case, this experience has been successfully applied over the last decade on numerous rural projects that have helped transform communities. This past year alone, for example, the company was involved in more than 27 projects covering various disciplines – such as water, roads and stormwater –with community engagement prioritised from inception to implementation.

“By partnering with reliable consulting engineering firms, we can overcome the challenges that hinder progress and drive positive change in our society,” Gama concludes.

Shawn Gama, CEO of Zimile Consulting Engineers

South Africa’s dire need to address poverty and unemployment could be solved with the implementation of an ‘Infrastructure Marshall Plan’ that puts equal focus on the requirements of urban and rural communities.

Conradie Park precinct brings the community together

While many construction projects backed by TUHF entail funding a development entrepreneur for a small to medium construction project, that is not always the case. A prime example is the partnership between TUHF and Concor Construction for the funding of two and possibly more developments in the Conradie Park precinct within the City of Cape Town.

Conradie Park is billed as one of the Western Cape Government’s seven game-changer projects, and part of the provincial strategy to redress apartheid spatial planning. It encompasses social housing, FLISP housing, open market residential apartments, commercial and retail developments, plus two affordable private schools.

TUHF is currently providing development finance for the establishment of two residential blocks, namely Kings Blockhouse and Silvermine. Both are four-storey apartment buildings with the units on sale to the open market. Silvermine and Kings Blockhouse are due for completion in August and November 2023, respectively.

In terms of sustainability, all units have low-flow taps and double-flush toilets, while lighting is catered for through energy-efficient

LED technology. In the likely event of power outages, there are generators to power the larger blocks and UPSs for the smaller ones. However, a solar panel solution will be implemented into the buildings further into the Conradie Park development through Concor Construction’s Renewable Energies Division.

Infrastructure services

Unlocking the potential of Conradie Park, and of any building projects carried out within the precinct, has required a significant capital outlay to address traffic access, water supply, sewer and bulk electrical reticulation.

“Before we started on the site, we did a massive bulk infrastructure upgrade to all the surrounding roads. We built new pedestrian bridges and upgraded all the traffic intersections in the area to prepare for the future residential, commercial and

retail elements. That was always a concern of the surrounding communities,” explains Mark Schonrock, development executive at Concor Construction.

Given that, when complete, Conradie Park is slated to accommodate around 3 500 permanent residents, traffic from their home to the CBD, work and Cape Town surrounds has been a careful consideration as part of the development rezoning process. However, Schonrock stresses that should not be a problem, as Mutual Station is just 400 m away and caters to both the northern and the central line. There is also easy access to taxis that leave from the station, along with Golden Arrow buses. Furthermore, Concor Construction is currently in discussions with MyCiTi to bring one of its feeder routes closer to the development as soon as possible.

Benefits of PPP model

“It is truly remarkable for TUHF to be involved with a project of this nature in a year where we are celebrating 20 years of seeing potential where others don’t. The Conradie Park precinct development is a typical example of yet another successful public-private partnership that demonstrates how the private sector can collaborate with developers and government in redeveloping large tracts of land, thereby increasing revenues for the fiscus, and stimulate local economic development,” comments Velda Derrocks, regional manager: Cape Region, TUHF.

“The precinct is testament to how affordable housing has evolved, and we are proud to be collaborating with Concor on this exciting journey,” Derrocks concludes.

An interior view of one of the Kings Blockhouse units

Scada transition enhances Drakenstein’s power delivery

Drakenstein Municipality is currently partnering with Schneider Electric and system integrator partner Altek to upgrade its 25-year-old supervisory control and data acquisition (Scada) system to ETAP – a model-driven electrical software solution. This development is aimed at significantly improving fault finding, predictive and preventative equipment maintenance and overall customer service delivery. Moreover, the system

integrates with Drakenstein Municipality’s existing infrastructure and its GIS mapping solution.

In preparation for the upgrade, Drakenstein Municipality completed an eight-year communication network revamp, which now sees all its substations communicating through a wireless ethernet or a fibre backbone. The previous Scada system only allowed for radiofrequency communication.

Feature-rich

“The ETAP Scada system offers so many exciting features such as live insight into switching operations that provides us with valuable information on current loads and what you can and cannot move or implement on the system in order to safeguard equipment,” says Leon Laing, manager: Planning and Customer Services: Electro-Technical Services Department, Drakenstein Municipality.

“Also, as it integrates with GIS, the ETAP system will be able to accurately pinpoint which customers are being affected by power failures. That will allow us to drastically cut down on fault finding and turnaround times,” he continues.

The ETAP solution will also utilise Drakenstein Municipality’s communication backbone to provide remote access to operators, again improving on system monitoring. Moreover, it will provide preventative maintenance schedules, which will mitigate potential equipment failure and costly repairs. An added benefit is that, with the ETAP systems’ digital twin technology, the municipality will also be able to simulate maintenance processes.

The Drakenstein Municipality ETAP Scada project is earmarked for completion by 2025. “When the project is complete, we hope to benefit from a sophisticated Scada system that will not only deliver return on investment, but also enable us to react quicker to outages and failures, reducing fault finding, and ultimately enhance customer experience,” Laing concludes.

Power strategies for iLembe

This emerged from engagement between business operators, provincial and municipal officials in the iLembe district at a ‘Synergy for Energy’ seminar hosted recently by the Vuthela iLembe LED Support Programme (Vuthela). The latter is funded by the Swiss State Secretariat for Economic Affairs and implemented in partnership with the KwaZulu-Natal Department of Economic Affairs and Tourism, iLembe District Municipality, and the local municipalities (LMs) of KwaDukuza and Mandeni to create an enabling environment for inclusive economic growth in the district.

Representatives of the district and its LMs, private developers, business operators, CoGTA,

the Municipal Infrastructure Support Agent, as well as the iLembe Chamber of Commerce, Industry and Tourism agreed that a secure and reliable electricity supply was critical to maintain present economic activity and to sustain future development in the region.

Various energy improvement measures are in progress. These include a R24 million Scada system being installed by KwaDukuza LM, which is due for commissioning by the end of 2023. Sections of KwaDukuza’s electricity supply network are also being upgraded to provide additional infrastructure and power capacity.

Allied strategies include implementing webbased automatic meter reading, auditing

electricity resellers, weekly service connection raids and monthly inspections of meters. Due to these and other interventions, for example, electricity losses experienced by Mandeni LM due to billing errors, inaccurate reading, unmetered customers, meter tampering and illegal connections reduced by 15% in the past year.

Energy options being investigated

Going forward, several alternate and renewable energy options are also being considered by the public and private sector to produce additional power. These include using waste heat generated by industry, biomass fuels using waste from forestry, natural gas, wind generation and hydro-electric generators.

In terms of renewable options, a solar photovoltaic (PV) feasibility study has been conducted through the Vuthela initiative to augment Eskom power supplied to Mandeni’s Sundumbili Water Treatment Works (WTW) during load-shedding. The results of the study (based on the existing infrastructure and land area at the works) indicate that the site has sufficient space to install a combination of rooftop and ground-mounted PV systems to provide up to 9% of the total power required.

The entire system would cost about R5.2 million to install and about R60 000 a year to operate. Anticipated savings are approximately R4.8 million in the first nine years and about R12 million over 25 years. A longer-term solution that could eliminate reliance on the national grid completely would require additional land for a larger solar plant. iLembe District Municipality will now need to study the findings of the Sundumbili WTW feasibility study, consider funding models, institutional modalities for ownership and operation, and take a decision on implementing the system.

Allied to these measures, KwaDukuza established an Energy Office in 2021 to assess the energy sector and develop a policy around renewable energy sources like solar. The policy is nearing readiness for public comment. It aims to address issues around safety and compliance, installation regulations, and the technicalities of feeding solar power back into the national grid.

Moves to improve the efficiency of the electricity supply to the coastal areas of iLembe District Municipality are starting to take shape, but stronger collaboration between the public and private sector is needed to secure reliable power for the future.

Sibusiso Jali, executive director: Electrical Engineering Business Unit at KwaDukuza Local Municipality, presenting to delegates at the ‘Synergy for Energy’ seminar hosted recently by the Vuthela iLembe LED Support Programme

Overhead view of the Sundumbili WTW indicating the areas that could be used for ground-mounted and rooftop solar panels

Leak detection for renewable energy

Pipeline gas can consist of various renewable and non-renewable gases. There has been a massive uptake in natural gas consumption, and an increasing need for leak detection systems. The reliable and timely detection of gas leaks is critical to ensure the reliability of the natural gas infrastructure.

leak rates are typically 0.5% and below. Leak detection time is in seconds and confirmation is within minutes.

Case studies

The leak detection system was installed on a power-to-gas project in Germany, which was the world’s first demonstration plant for storing wind energy in the natural gas grid. PipePatrol was selected due to its ability to measure a product even in small leak quantities.

Some pipelines transport 100% hydrogen while others a blend with natural gas. CO2 can be transported as gas, liquid or in supercritical state. Therefore, the leak detection system needs to be able to work with these different mixtures and phases.

This is a problem for traditional leak detection systems. Negative pressure wave leak detection systems are affected due to damping in gas. Classical statistical systems are affected due to compressibility and linepack changes. This leads to long detection times or high thresholds. The systems react with a loss of sensitivity or, in the worst case, with false alarms.

Systems based on the real-time transient model (RTTM) try to consider all the different products and pipeline properties in its calculations. However there will be false results if the fluid cannot be accurately modelled by the system.

PipePatrol – E-RTTM

KROHNE’s PipePatrol uses extended real-time transient model (E-RTTM) technology that has signature analysis technology to make the system less sensitive against inaccuracies in RTTM calculations. Therfore, it can cope with challenging pipeline conditions and product parameters or mixtures like hydrogen blends.

PipePatrol creates a virtual image of a pipeline and uses standard process instrumentation for flow, temperature and

pressure measurements. The hydraulic profiles along the virtual pipeline are calculated from the measured pressure and temperature values. The model compares the calculated flow values with the actual values from the flow meters. If the model detects a discrepancy, the leak signature analysis module determines whether it was caused by changing pipeline operation, an instrument error or a leak. The technology is used for liquid, gas and slurry applications. The smallest detectable

Process scheme: leak detection on a CO 2 pipeline from an LNG plant

On another project in Australia, PipePatrol was used on a 7 km long pipeline that transports CO2 from the LNG liquefaction plant to the CO2 injection wells. This involved unique conditions, such as the properties of CO2 in a supercritical phase and flow measurements done by orifice plates with limited rangeability. Here, PipePatrol provides timely and accurate leak information for the pipeline segments between the LNG plant and drill centres.

KROHNE – a manufacturer of measuring technology and established supplier of systems to the pipeline industry – has more than 35 years of experience in leak detection and localisation systems.

REIPPPP AND THE POTENTIAL FOR COMMUNITY MINI-GRIDS

South

Africa’s Renewable Energy Independent Power Producer Procurement Programme (REIPPPP) has paved the way for the private sector and independent power producers (IPPs) to invest in the country’s renewable energy market. However, there could be an additional benefit to consider, says Nato Oosthuizen, partner and renewable energy expert at BDO.

Since its inception in 2011, REIPPPP has enabled 89 IPPs to provide a steady stream of over 6 000 MW of renewable energy to the country. The energy procured in Bid Windows 3 and 4 is expected to bring a further 100 MW and 75 MW online in 2024. In the meantime, three projects under Bid Window 5 have started construction at an investment value of over R12 billion.

As part of the REIPPPP bid process, awarded projects are required to spend a certain amount of their generated revenue on socioeconomic development (SED) and enterprise development (ED), as well as share ownership in the project company with local communities. What if, instead of the revenue going to various SED and ED initiatives, the government mandated this money to be specifically spent on electricity-related projects within the community – such as building minigrids that supply power to the community.

Project development teams have specific skills

in creating power generating facilities and could probably negotiate a good price with the engineering, procurement and construction (EPC) contractor that is building their own plant. That EPC contractor could then build a smaller plant at the same time in the affected community and the project could claim the costs back from the ED or SED fund. This way, the development of mini-grids can be pre-funded and accelerated by experienced individuals. Furthermore, the annual operation and maintenance (O&M) of these grids could be maintained by the same O&M provider that services the primary project.

To take it one step further, local community members could be trained to maintain, run and even provide security for the mini-grid, which would substantially increase skills development and drive local job creation. This approach would provide an opportunity for those who have the competence to become a much larger player in the solution through a twopronged approach that creates a sustainable renewable energy source and empowers a local community at the same time.

Probably the most compelling reason why this approach should be

considered is the fact that IPPs are signing a 20-year contract that locks them in to the community for the long term. These are institutions that have the skill, the staying power and the funds to impact the power crisis by being part of the solution.

A practical example

Assume the development of a 100 MW solar project where a community trust would be granted a 5% funded shareholding, and 2.5% of revenue would be paid to SED/ED contributions for local development.

In this example, rather than giving 5% funded shareholding, a 5 MW (5% of 100 MW) solar plant could be constructed close to the local community. The funding and repayment of this project cost would be funded by the main project, as it would be allowed to still build a full-size plant of 100 MW and earn 100% of the return thereon, rather than having a lower percentage shareholding in the total project. The O&M cost, insurance, security, management fees, etc. for running the project can also be paid for by the main project, substituting the payment of previously committed SED/ED costs. The synergies that can be obtained through this cost absorption makes it feasible for a smaller size project to be financially and technically viable.

The ownership of the project can be housed in a non-profit organisation. Furthermore, the electricity (or excess) generated by this plant, if not used by the community, can be sold to the local municipality or industry at discounted prices, with the proceeds being used for community projects.

SA initiative to promote cool-reflective coatings

It also guides the organisation’s collaboration with the Thermal Insulation Products and Systems Association of South Africa (Tipsasa). The two organisations have been working together for several years to establish a thirdparty, independent laboratory that would serve South Africa, the SADC region and the African continent at a cost far more affordable than the charges associated with an international testing process.

Funding support

The dream is now finally coming to fruition. This follows a R1 240 000 contribution by the Sanedi Energy Efficiency Programme to establish the Sanedi Cool Surfaces Product Testing Division within the Tipsasa passive energy insulation lab. The new product testing laboratory is a few short months away from being fully operational, pending the delivery of the last piece of equipment that will enable the three essential tests a coating must pass to be certified as a cool-reflective product.

Put very simply, this entails painting the outside of buildings, especially roofs, with coatings that disrupt solar radiation. It keeps buildings cool inside so that the people living and working in them need less – or even no – air conditioning to be comfortable. Such coatings, or paints, already exist and conservative estimates are that the market for them can grow at 7% per year. This growth, however, is hindered by two factors,

says Denise Lundall, project officer at the South African National Energy Development Institute (Sanedi). The first is that the lack of mandatory regulation in the passiveenergy cooling space destroys consumer confidence in the technology’s efficacy. The second relates to the prohibitively high cost of testing local products abroad, which has caused entrepreneurs, especially SMMEs, to have largely lost interest in participating in the manufacturing side of this highpotential market.

“An understanding of these opportunities and challenges is at the

Sanedi also facilitated the upskilling of senior laboratory technician Arno van der Walt by sponsoring his training on the American Standard Testing Method (ASTM) at the Lawrence Berkley Laboratory in the USA. South Africa has adopted the ASTM for cool-reflective product performance testing and published a local SANS equivalent.

All cool-reflective coatings used in Sanedi projects have to exceed the minimum SANS requirements of 65% efficacy. “Our standard is 75% or more, because the better the quality at the start, the better the performance over the lifetime of the roof,” adds Lundall.

Omega Test House, home to the Sanedi cool-surfaces laboratory, shares premises with the Aamsa and Tipsasa industry associations in Midrand

An energy-passive, low-cost and low-maintenance cooling technology for buildings sounds like science fiction. Fortunately, it is not.

PUMPS & VALVES

Building revamp repositions KSB for the future

Amajor renovation is underway to transform KSB Pumps and Valves’ (KSB’s) building in Activia Park, Germiston, into a modern and collaborative workspace.

“First occupied in 1970, the multistorey building was originally designed as a stores building and was not completely suitable as an office space. We realised the need to bring our admin staff together in one building and create a workspace that aligns with the future of work,” explains Terence Barkhuizen, facilities development manager, KSB, adding that the construction programme is due for completion by the end of April 2024.

“We are moving away from the traditional cellular office environment and incorporating contemporary ergonomic and flexible desks, kitchenettes, printing areas and quiet spaces on each floor,” he continues.

The revamped building will feature four floors, covering approximately 2 890 m², and accommodate around 100 staff members. Furthermore, the renovation project aligns with KSB’s commitment to sustainability and energy efficiency. In this respect, the fully glazed outer skin, along with a maintenance walkway acting as a shading device, will minimise glare and solar exposure. “We will also collect roof water for pump testing and capture rainwater run-off for landscaping, water features and irrigation," Barkhuizen continues.

KSB is still finalising the exact opening date and will keep stakeholders informed as the company progresses towards this exciting milestone. “We cannot wait to see our revitalised building come to life and witness the positive impact it will have on our employees and customers," Barkhuizen concludes.

Welding offers numerous benefits, such as providing a seamless and reliable joint, improving pipe strength and durability, and reducing the risk of leaks and failures

Precision welding and pipeline performance

Plastic welding is a key factor in ensuring structural pipeline integrity, making adherence to strict quality control practices and standards vital criteria. In the local market, these areas are being championed by the Southern African Plastic Pipe Manufacturers Association (SAPPMA) and Plastics SA, with a concerted focus on training.

“The quality of welding depends on the skill and expertise of the welder, the welding equipment and the welding technique used. Poor welding practices can result in weak or faulty joints, leading to leaks, ruptures and other structural failures. These failures can have catastrophic consequences, resulting in environmental pollution, property damage and even loss of life,” explains Kirtida Bhana, head: Academy for Learning & Development, Plastics SA.

She explains that Plastics SA is at the forefront of promoting best-in-class techniques through its various training programmes, which cover a wide range of thermoplastic welding methods. These include butt welding, electrofusion and extrusion welding, among others, for sectors that include construction and mining.

Adds Jan Venter, CEO of SAPPMA, “A major benefit is that Plastics SA’s training programmes promote consistency and uniformity in plastic welding practices, making it easier for regulators and industry players to monitor and enforce compliance.”

The existing KSB Pumps and Valves building in Activia Park, Germiston, prior to undergoing a major revamp

The modern interpretation of KSB’s iconic Activia Park building begins to take shape

SWP proves itself on Cape Flats 1 refurbishment

A series of refurbishment works in progress since 2022 are designed to extend the life of the Cape Flats 1 and 2 (CF 1 and 2) sewer lines, originally built in the 1960s. Alastair Currie speaks to Vuyo James – senior professional officer: Planning, Design and Projects at the City of Cape Town – about the experience to date.

Has the decision to go the SWP (spiral wound lining) route been the right one?

VJ Based on the profiling data we’ve captured so far on CF 1 and 2 – each measuring approximately 14 km in length and running in parallel – the SWP methodology is the most efficient and costeffective way of restoring the structural integrity of these precast concrete lines that vary in depth from 1-3 m below ground level.

The other option we did consider is a curedin-place pipe (CIPP) lining methodology. However, initial trials indicated that we weren’t going to achieve the meterage advance rate targets required.

From a City perspective, this is the first time we’re going the SWP route on this scale and the repair results to date (namely work packages 17 and 18) are of a very high standard. This underscores why

SWP is a preferred trenchless technology intervention worldwide.

What are SWP’s key benefits?

The SWP technique results in the installation of a watertight PVC liner within the diameter of the existing pipe under live conditions. The key advantage of SWP is that it improves the velocity of the existing pipe without reducing its capacity.

Plus, the installation technique is so efficient. SWP PVC profile strips are progressively fed through a manhole access point onto a winding machine inserted within the pipe, which progressively forms and advances the new ‘pipe within a pipe’.

The two SWP liner options are the R5 or R6. The latter is a slightly thicker liner well suited for pipe sections that show signs of extensive deterioration caused by intense

Vuyo James, Pr Tech Eng, senior professional officer: Planning, Design and Projects, City of Cape Town

The SWP lining process entails the feeding of a continuous strip of PVC, which is spirally wound into the existing pipeline via a winding machine positioned in the base of a manhole or access chamber. This process creates a single continuous PVC pipe in the existing host pipe

Source: Mainline

hydrogen sulfide (H2S) build-ups. Plus, you need to factor in soil and traffic loads, where applicable, when selecting either option.

How is the project being split up?

The overall CF 1 project has been split into multiple works packages spanning a term tender of three years. Cleaning, inspection and profiling has taken place on both CF 1 and 2. Both lines start in Athlone and end at the Cape Flats Wastewater Treatment Works (WWTW) in Zeekoevlei.

The fact that Cape Flats 1 Bulk Sewers was originally encased in concrete was an amazing foresight of the 1960s designers in extending their longevity, but that’s not the modern approach. However, it has made SWP a practical approach, rather than incurring the massive cost of a complete new pipeline replacement using technologies like microtunnelling.

As per the original programme, we started on CF 1 Bulk Sewers first. So far, we’ve completed a 1.2 km section with a diameter of 1 100 mm, starting at Pinati Estate in Athlone and extending to Govan Mbeki Road in Wetton.

In the next and current phase, we’ve awarded three new works packages for CF 1 Bulk Sewers, covering a distance of some 5 km. Overall, we plan to complete the CF 1 relining by November 2023, in the current 2023/24 financial year.

In the meantime, the profiling of portions of CF 2 is almost complete, and we’ll then hand over the data to the appointed consulting engineers so they can do further planning.

What are some of the key observations so far?

To profile CF 2, we diverted the flows into CF 1. As per standard procedure, we ventilated CF 2 to dissipate the H2S. However, as we headed towards the Cape Flats WWTW, the H2S values remained high, especially at pump station discharge points into the line. What is clear is that the turbulence created by pump stations increases the H2S values and accelerates deterioration in these areas, especially at places where industrial effluent enters the line.

This has a bearing on the installation of new future bulk lines. It’s clearly crucial to ensure that precast concrete pipes specified have internal corrosion-resistant inhibitors built in.

In the original plan, all the flows from CF 1 were to be diverted into CF 2 on completion of the latter’s profiling. However, in practice, we found that some sections of CF 2 were completely or close to being blocked. That required more intensive cleaning than envisaged. We have removed all the blockages, and that means we can now divert to CF 2 as originally planned.

As part of the solution to deliver the overall project, we’ve installed four sluice gates on the CF 1 and CF 2 lines. This means we can isolate and divert lines and flows where required. Having two lines running in parallel has been a blessing, because we can

minimise the expense of over-pumping though a coordinated flow diversion strategy.

Then there are the 331 plus brick constructed manholes that need to be addressed. Some are intact; others have partially collapsed and need to be replaced. Either way, they have been remarkably resilient structures. Where revitalisation is possible, restoring with calcium aluminate cement is an internationally accepted benchmark option. The City will be releasing a separate works package for this manhole phase in due course.

And in closing?

The key takeaway is that establishing the groundwork on any project, particularly a trenchless technology one, requires detailed investigation. With both lines being more than 50 years old, some surprises are going to be expected as we verify the actual level of deterioration.

As we progress, the lessons learnt on CF1 – and, subsequently, CF 2 – will be invaluable for other towns and cities across South Africa needing to upgrade ageing pipeline infrastructure, where the benefits of trenchless technology applications are evident.

Sections of PVC strip being fed into the winding machine

The SWP winding machine

The Blue Drop Watch Report: in numbers

The Blue Drop Watch Report focuses on the current condition of drinking water infrastructure and treatment processes from a technical perspective. This report is published prior to the release of the Blue Drop Report 2023 Report and comprises a technical overview of the country’s drinking water supply.

THE BLUE DROP WATCH REPORT COMPRISES:

144 water service authorities (WSAs) provide drinking water for domestic, commercial and business use via 1 186 water supply systems (WSSs). There are 1067 registered water supply areas, managed by 144 WSAs and supported by 26 water service providers (WSPs, including water boards)

Largest plant: design capacity of 4 800 Mℓ/day

Average plant: design capacity of 63.3 Mℓ/day

Smallest plant: design capacity

0.001 Mℓ/day

1) Technical site assessment (TSA) scores: Physical appearance of terrains and buildings, raw water abstraction and delivery networks, treatment plants, chemical handling, water processing units, bulk delivery systems, and distribution pump stations and pipe network.

2) VROOM: The Very Rough Order Of Measurement (VROOM) provides an estimate of funding required to restore existing treatment infrastructure to its original design capacity and operations, by addressing civil, mechanical, electrical and instrumentation defects.

3) DWQ: Drinking water quality (DWQ) compliance is measured against the requirements of SANS 241: 2015 and is reported in terms of the microbiological and chemical quality of drinking water (IRIS, 28 March 2023).

NUMBER OF WSAS AND SUPPLY SYSTEMS PER PROVINCE THAT WERE AUDITED IN THE BLUE DROP AUDITS OF 2022 TO 2023

Drinking water quality analyses indicate that 38% and 11% of systems achieve excellent and good microbiological quality, respectively, while the balance of 51% have poor to bad microbiological water quality status

TSAS

An average TSA score of 69% was achieved for the 151 systems assessed, which indicates that infrastructure and processes are on average ‘partially functional with an average performance’.

The report highlights that the majority of WTWs do not produce SANS 241 compliant water

PROVINCES

Out of 151 WSSs:

• 128 (85%) is found to be in ‘average, good and excellent’ condition

• 23 (15%) is found to be in ‘poor and critical’ condition

The best overall performing WSSs are found in Gauteng, followed by the Western Cape and Eastern Cape.

The worst overall performing WSSs are located in the Free State, Limpopo, Northern Cape and North West.

VROOM

The associated VROOM costs needed to restore and refurbish dysfunctional systems amount to almost R1.5 billion , with the bulk of investment needed for the Free State and KwaZulu-Natal.

Access to safe and reliable drinking water is embedded in our Constitution and we want to protect consumers from potentially unsustainable and unsafe services. We want to raise the standard requirements of our water services institutions and to ensure that we strive for excellence in these fields. We recognise that this requires partnerships and are encouraged by the support from

WATER QUALITY

This is the most concerning finding from this report. It highlights that the majority of WTWs do not produce SANS 241 compliant water, irrespective of their TSA condition and performance. The lack of water quality monitoring is alarming, as WSIs cannot operate and improve water services and quality if they do not know their basic status.

Drinking water quality analyses indicate that 38% and 11% of systems achieve excellent and good microbiological quality, respectively, while the balance of 51% has poor to bad microbiological water quality status.

Chemical compliance analyses show that 16% and 14% have excellent and good water quality, respectively, while the vast majority of plants fail to achieve chemical compliance (71%).

13 WSSs have no reported water quality data or no data has been uploaded or available at the time of the audit to enable analysis on compliance (four in the Free State, one each in Gauteng and Limpopo, three in Mpumalanga, and four in Northern Cape).

Lack of monitoring or information automatically translates to zero compliance.

Minister of Water and Sanitation

Senzo Mchunu

THE WAY FORWARD

The Blue Drop Watch Report will be used as a basis to inform appropriate regulatory and support with the objective to facilitate the correction, restoration and improvement of water services to consumers. The report further serves to inform stakeholders and government departments as to the current status of drinking water infrastructure in the field, with the intent to mobilise rectification measures without having to wait for the release of the Blue Drop Audit Report.

The regulator will continue to monitor performance in terms of Section 62 of the Water Services Act and will engage together with CoGTA, Salga and MISA, all water institutions that fail to meet safe drinking water standards. Should corrective actions fail, the DWS will consider civil action together with actions contemplated under section 63 of the Water Services Act (No. 108 of 1997) to ensure that ministerial directives are issued with timeframes for implementation. Failure to respond will trigger remedial action be taken at cost of the non-complying entity or municipality.

The DWS will take steps to improve its capacity to respond more effectively in this duty, in ensuring visible and measurable improvement in drinking water services. CoGTA and National Treasury will be engaged to explore ways of utilising conditional grants for the purpose of remedial intervention.

Isotopes help hydrologists combat contamination

Isotopes act as signatures for ‘fingerprinting’ – giving clues to trace the source of water and contamination

technology helps hydrologists to determine factors affecting water quality, such as subsurface processes, geochemical reactions and reaction rates. It can also be used to better understand the relationship between surface water and groundwater, and even to detect leaks.

Identifying the source of water contamination can be achieved with the help of isotopes, a proven technology and an invaluable investigation tool. This is showcased by a recent SRK Consulting case study on a metals processing plant.

Aparticular environment will acquire a characteristic isotopic composition or signature by virtue of the hydrogeochemical processes involved. We can use this isotope signature for ‘fingerprinting’ – giving us clues to trace the source of water, and hence the contamination.

By definition, isotopes are atoms with the same atomic number – in other words, the same number of protons in their nuclei; however, they may differ in mass because of variation in the number of neutrons. For example, protium (hydrogen-1) is a stable isotope of hydrogen with one proton and no neutrons, while deuterium (hydrogen-2) has one neutron and tritium (hydrogen-3) two neutrons.

Isotope signatures

Spatial variations in deuterium and oxygen-18 occur in the hydrological cycle; there is a lower proportion of these isotopes in rain that falls inland than in rain falling at the coast. These are among the variables we can use to identify whether the source of water is from surface dams or from groundwater – as the signature from the rainfall will be retained

By Ismail Mahomed

in groundwater. Evaporation also has an impact on this signature, as preferentially lighter isotopes will evaporate from the oceans and surface water.

Case study analysis

One of the aspects of the metals processing plant case study was considering the evaporation signature of some of the ponds on the client’s site – a signature that was different to the groundwater. Data analysed during this project suggested that there was some mixing of water from different sources in the underdrain of one of the ponds.

This underdrain had a calcium-nitratedominant chemical signature that differed from the other wastewater impoundments, underdrains and groundwater. The isotope results further illustrated the uniqueness of this pond’s underdrain signature.

Water vulnerability

Hydrology can benefit greatly from using isotopes in the tracing of groundwater, to help determine the vulnerability and sustainability of water resources. The

Cost-effective

Oxygen-18 and deuterium are particularly useful and can be easily and costeffectively analysed. While the traditional isotopes are well established, there are more novel isotopes – such as lithium-7, mercury-200 and copper-65 – that are gaining traction as more research is conducted and applications developed. These could be used in South Africa, but the analyses would need to be done by laboratories abroad.

ABOUT THE AUTHOR

Ismail Mahomed is a principal hydrogeologist at SRK Consulting. He has over 20 years of experience in hydrogeology, mainly in dewatering, due diligence, numerical groundwater modelling, isotope hydrology, environmental impact assessments and contaminated land assessments. He has also been involved in mine dewatering and pore pressure investigations, numerical groundwater modelling, feasibility studies and due diligence, assessing environmental impact and liability, subsurface contamination characterisation and assessments, water supply investigations, as well as surface water and groundwater quality monitoring and management.

LONG OVERDUE RECOGNITION OF PROCESS CONTROLLERS

By Dr Lester Goldman,

Regulation 3630 came into effect on 30 June 2023, announcing that all water and wastewater works must be overseen by someone who has the relevant qualifications and experience to ensure compliance and best practice principles. This is a major step in recognising class 5 and class 6 process controllers as professionals, similar to engineers and scientists.

Process controllers will need to register with WISA, the custodian of the professional process controller designation. WISA will assist process controllers in maintaining their professional status by honing their skills. In addition, we will provide guidance and support to new entrants into the field.

Professionalisation

WISA has, for many years, advocated for

the professionalisation of key positions within the water sector and are excited and encouraged by Regulation 3630. It adds a layer of accountability to the day-to-day operations of South Africa’s water and wastewater treatment works. Professionalisation standardises the education and training required for an occupation. This means that the public can at least anticipate the standard of the service provided. Professionalising key positions within the water sector will ensure that the right person is in the right job and, once they are in that job, they are professional. It will narrow down nepotism and political appointments. This can be done by simply identifying key legislation that needs to be changed.

A key way the public can hold a person within our industry accountable is if they belong to a professional body. A professional body such as WISA looks after the professional needs and

reputation of its members. If one of our member’s actions lack integrity and tarnish the reputation of our industry and profession, we are obliged to act and remove the process controller’s professional registration.

Every time a lack of capacity and competence is mentioned, training is required. WISA, LGSETA and EWSETA will work together with experts to ensure that all process controllers receive the required training to gain and maintain a professional status.

Regulation 3630 empowers both process controllers and members of the public. It presents process controllers with an opportunity to forge a career as well as constantly upskill themselves and will play an important role in improving water and wastewater services for the public. This is about improvement. All water and wastewater institutions must be compliant with Regulations 3630 by 30 June 2025.

Our champions of the water sector – process controllers – have been given the professional status they deserve with the promulgation of Regulation 3630.

CEO, WISA

Unlocking the value of wastewater

In the cycle of life, sewage treatment works are pivotal in providing safe sanitation, and in ensuring that treated effluent re-enters the environment for future abstraction.

Alastair Currie speaks to Kennedy Chihota, managing director at ERWAT, about his organisation’s role as the City of Ekurhuleni’s dedicated wastewater treatment company, as well as key action plans that could assist other municipalities nationally.

What’s your field of expertise?

KC I’m a civil engineer by profession with a core interest in water and wastewater. Over the years, I’ve worked on both small- and

large-scale projects within the municipal engineering space. These include rural municipalities in Limpopo, the City of Cape Town and Johannesburg Water, prior to joining the City of Ekurhuleni in 2013, where I started off as the divisional head responsible for strategic planning on key infrastructure projects. The latter included the progressive construction of some 40 reservoirs, where the objective was to increase the City’s overall average storage capacity from 24 to 36 hours to improve water supply security.

I was subsequently seconded to ERWAT (Ekurhuleni Water Care Company) in December 2021 to serve as acting MD and was officially appointed in a permanent capacity from 1 October 2022. I’m tremendously excited about the opportunity it presents to take ERWAT to new levels of performance.

Who owns ERWAT?

ERWAT is a municipal-owned entity and the

City of Ekurhuleni is the major shareholder (97%). The remaining shareholders are the City of Johannesburg (1.5%) and Lesedi Local Municipality (1.5%).

As an NPC, our operating mandate is ostensibly limited to the boundaries of the City of Ekurhuleni. This is definitely the case where we perform on-site services for private clients in terms of outsourced operations and maintenance (O&M) contracts. However, we can perform work for any municipality nationally if this is agreed to by a municipal council resolution.

The point to emphasise is that NPCs don’t pay out dividends to shareholders, but they still need to run as going concerns – and that requires money. For this reason, ERWAT has a responsibility to all its stakeholders to ensure it’s as financially self-sufficient. Essentially, we must ensure that sufficient funds are available to optimise the life and performance of our assets.

What’s ERWAT’s vision and operational strategy?

Our vision is to become a globally recognised water resources company – with a major emphasis on the word ‘resources’ because wastewater has a value. In this respect, we’re focusing on two major beneficiating streams: first, reuse – treating effluent to a standard acceptable for industrial applications, like cooling; and second, finding a commercial use for our sludge – the solids wastewater treatment by-product. Current volumes across our plants are around 200 t/day.

Kennedy Chihota, managing director, ERWAT

ERWAT’s Waterval Water Care Works

At present, we often end up transporting this treated sludge, at our own cost, to farmers, where they use it as a fertiliser – a common practice worldwide. But this is not financially sustainable, so we need to find a solution that makes our sludge a desired and saleable product. This requires investing in specific processes, like hydrolysis, that further improves the quality and commercial value to a broader market.

By ‘cooking’ the sludge through thermal hydrolysis, we can kill the pathogens, but retain the nutrients. The end-product can then be sold in small or bulk bags for domestic and/or industrial application.

An allied option is to use the sludge to produce methane to run gas turbine generators. This type of waste-to-energy concept has already been piloted in Europe and there’s strong interest locally.

Either way, our plan going forward is to investigate a public-private partnership (PPP) concession model for the beneficiation and sale of marketable sludge. Watch this space.

What is the percentage of effluent currently being treated?

Currently, Ekurhuleni buys some 1 000 Mℓ/day of bulk water from Rand Water. Of that, some 15% is consumed, so it doesn’t find its way into the sewer system, but the balance does, equating to a daily effluent inflow of around 850 Mℓ/day. This is a substantial volume to manage and treat to standard before it can be discharged back into the environment through rivers, dams and streams.

Of the 850 Mℓ/day treated, 630 Mℓ/day is what we are required to discharge in terms of ERWAT’s water use license conditions. Remember, there are other downstream users (predominantly municipalities, but also private industry and farmers) who will be abstracting this treated effluent for potable water treatment. So, the cycle must be maintained.

What happens to the surplus effluent?

We see huge opportunity in commercialising the 220 Mℓ treated surplus effluent. We can

Structa Technology’s Prestanks are hygienically safe, cost effective and a reliable way to store water for commercial sectors, private sectors and even for personalized storage. Temporary or permanent erection at mines, powerstations, building sites, hospitals, water affairs,municipalities, rural communities and agriculture.

polish it and sell it to industries that don’t require potable water for their operations. As opposed to buying potable water at, say R12.00/k ℓ , industrial users could potentially buy our treated reused water (not to potable standard) at as low as

R2.00/kℓ – a massive saving and a winwin from a sustainability perspective. Plus, ERWAT could raise some money that can be used to fund and upgrade facilities and services.

We’ve completed an off-taker feasibility study as part of preparing the business case. The next stage is to build a dedicated polishing plant, and we intend to advertise for design bid proposals in the coming months. Currently, we sell around 50 Mℓ/day of treated effluent to mines in the area, but we now want to upscale the whole operation.

Are all of ERWAT’s plants running at optimum capacity?

Process efficiencies are on par with local and international standards. The main challenge, however, is the diverse range and size of our 19 water care works (WCWs). For example, ERWAT’s Ester Park WCW facility is a 1 Mℓ plant, while our largest treatment works, Waterval, is designed to process around 174 Mℓ

The extreme variability in plant sizes is due to historical factors, namely the post-1994 integration of various towns as part of the establishment of today’s Ekurhuleni metro footprint. Since these towns were originally planned in isolation from each other, operational consolidation and streaming now needs to take place, which has been identified in the City’s 50-year masterplan. That will entail reducing the number of ERWAT plants to 10 and upscaling five of them, with a panel of external consulting engineers currently working on their redesign. There’s a possibility that two of the five, which includes Waterval, could be run as PPPs. That’s a key factor in bridging any National Treasury funding gaps. Waterval is also a logical site for our proposed new polishing plant.

Just to illustrate the point when it comes to scalability, the City of Johannesburg only has six plants, but they receive almost 15% more daily effluent than ERWAT. Johannesburg’s largest plant – Northern Works – is a modern facility with a capacity of 400 Mℓ. So, we need to follow a similar operating model to maximise efficiencies. Plus, we need to build additional capacity in preparation for future residential and industrial expansion.

Aside from new construction, bestin-class maintenance regimes are essential. The international benchmark is around 5% of turnover on repairs and maintenance annually. In ERWAT’s case, that’s about R400 million, mostly directed at electromechanical systems where the highest availability is critical.

How have the plants performed in terms of the Green Drop programme?

Green Drop certification is a very important initiative by the Department of Water and Sanitation, and ERWAT fully supports the bi-annual audit process.

According to the 2022 Green Drop Report, there are around 950 wastewater treatment plants in South Africa. Of these, only 22 were Green Drop certified following the most recent 2021 assessment. Seven were ERWAT plants. That’s good in terms of ERWAT’s overall performance, but really concerning for the country, with 334 WCWs in critical state.

I want to add that our other 12 plants that didn’t pass the Green Drop audit are far from dysfunctional. The Green Drop process is based on a multicriteria assessment. Examples include capacity management, environmental management, technical

management, financial management, effluent and sludge management. ERWAT incurred points deduction due to hydraulic overloads on seven WCWs, compliance in the other three main criteria notwithstanding.

Simply put, if a plant has a designed capacity of 10 Mℓ/day but is receiving 11 Mℓ/day – irrespective of whether the plant is performing to standard in all the other criteria – there’s an immediate 10-point deduction. The Green Drop ‘pass rate’ is 90%. In ERWAT’s case, we have eight plants that are hydraulically overloaded. They came close but didn’t make the cut.

What about load-shedding?

Of course, load-shedding is a factor, which we need to manage for now. In response, we’re progressively installing gensets as backups on critical process stages. Longer term, we need to look at alternative power solutions to minimise interruptions and save costs. Last year, for example, ERWAT’s electricity bill was approximately R157 million.

Our power requirement is around 28 MW to run all our plants and we believe investing in solar PV could meet a key part of this demand, based on a recent study. The anticipated capital outlay is around R800 million, with a payback period of between five to ten years. Since these PV installations can easily last 20 years, that’s a great return on investment, namely 10 years of free electricity.

And in closing?

Delivering world-class wastewater services is ERWAT’s first priority because without effective process performance in this area, no society can function. Since its formation in 1992, ERWAT has led the way in the adoption of new technologies and sustained our operations by investing in the best engineering and technical talent.

The fact that so many municipal treatment works in the country are not running to the required standard is distressing and we believe it’s ERWAT’s responsibility to assist wherever practical, either in terms of expert mentorship and/or O&M services. The seven Green Drop awards achieved by ERWAT testify to that.

Going forward, we need a universally adopted circular economy strategy on wastewater and a clear understanding of the vital imperative of reuse to sustain our environment and society.

Siza Water hosts IMESA KZN meeting

Members of the KZN Chapter of IMESA were hosted by Siza Water in Ballito. Following a highly informative presentation by Kobus Fourie, operations manager at Siza Water, attendees visited the Fraser’s wastewater treatment facility to gain an in-depth understanding of the processes. Several SBS Tanks are used at the plant for bulk water storage of effluent, with smaller tanks used in other areas within the process

These inspirational words – as part of Mjwara’s address to engineering professionals, Siza Water and SBS Tanks representatives at the IMESA KZN Chapter meeting on 30 June in Ballito – offer a challenge to not only those in attendance, but to all South Africans.

Hosted by Siza Water, the event included a tour of the highly successful Green Drop accredited Fraser’s wastewater treatment plant. The plant, which includes several steel panel water storage tanks of varying storage capacities from SBS Tanks, has supplied water services to Ballito and iLembe District Municipality since 1999.

As a Proudly South African company, operating under the wing of the South African Water Works, Siza Water deploys technologies and processes to render effective water treatment services to the region and was dubbed ‘South Africa’s Best Water Service Provider’, per the Department of Water and Sanitation’s 2014 Blue Drop audit.

“Siza Water proudly hosted the IMESA branch meeting, providing a platform for professionals and experts to convene and discuss the latest advancements in the industry,” says Sihle Mathenjwa, public relations officer, Siza Water. “These visits highlight Siza Water’s reputation as a leading water treatment facility, attracting attention from various organisations seeking to learn from their successes and contribute to the global water management efforts.”

IMESA KZN membership and knowledge sharing

The KZN Chapter of IMESA currently has 350 members and a goal to reach 1 000

signed-up members. It meets quarterly to bring municipal and consulting engineers together to disseminate relevant updates, network and share learnings between seasoned and young professionals. A diverse calendar of events is offered. These include project case study presentations and site visits, an annual golf day (with the added drawcard of free golf skills sessions for young professionals in preparation for the event) and a women’s month breakfast to bring female engineers together to build networks.

Public and private sector engagement

“The responsibility to improve service delivery, infrastructure, social and climate conditions in South Africa does not rest with the public sector alone,” says Mava Gwagwa, director at SBS Tanks. “We all have a role to play and public-private partnerships with reputable, trusted brands are key to expediting service delivery.

“I am pleased to be able to say that our company will leave a legacy of building for better, partnering with municipal engineers, consultants and teams to help ease the load,” Gwagwa adds.

“Our responsibility is not to leave the status quo as it is,” says Sibusiso Mjwara, president, IMESA. “It might take a very long time, we might be gone before change is seen, but we need to make a start somewhere.”

The Fraser’s wastewater treatment plant in Ballito, KwaZulu-Natal. L-R: Kobus Fourie, operations manager, Siza Water; Mava Gwagwa, director, SBS Tanks; and Sibusiso Mjwara, president, IMESA

ALTERNATIVE SOLUTIONS TO TRADITIONAL SERVICE DELIVERY CHALLENGES

Municipalities face many challenges in the delivery of essential services to rural and urban communities and the commercial sector. Budgetary constraints, key personnel shortages and, in the case of rural communities, lack of infrastructure all impact the provision and efficiencies of services. Key to managing these challenges is identifying alternative solutions to traditional services.

Are public-private partnerships the solution?

By partnering with commercial service providers and original equipment manufacturers, municipalities can leverage skill sets such as in-house engineering and project management teams, at no additional cost. This will have a positive spin-off on both efficiencies and cost of service delivery, especially in rural regions with smaller staffing and taxpayer bases.

“Identifying trusted commercial contributors with a vested interest in economic growth, and development and experience in service

delivery at both national and provincial levels will alleviate much of the pressure on the municipal sector,” says Mava Gwagwa, director, SBS Tanks. “The commercial sector needs to support the public sector in addressing socio-economic and climate concerns, and help drive progress in the achievement of the Sustainable Development Goals.”

Partnering with businesses in the commercial sector that have identified solutions to existing problems, such as the need for rapid delivery of basic water and sanitation services with a reduced carbon footprint, and renewable

energy generation solutions to ease the strain on the national grid, will assist municipalities to make further progress and impact.

Doing good is doing good business

Gwagwa, who has worked with the municipal sector in South Africa for several decades, believes that by supporting the delivery of basic services, such as clean water and sanitation and decentralised energy generation solutions, the private sector will not only provide the much needed support required to move delivery forward, but will also see a direct economic benefit.

“Doing good is good for business. That should be every business owner’s mantra – it certainly is at SBS Tanks. We ask ourselves daily, ‘Did I do what I could, with what I have, where I am?’ This helps ensure that the solutions we provide – whether it is bulk water storage, effluent processing tanks, renewable or backup energy or water storage systems – are adaptable, fit for purpose and go the distance.”

SBS Tanks, Africa’s leading manufacturer of bolted steel panel water storage tanks with an internal liquid storage liner, has worked with

A tank farm constructed in KwaGuqa, Mpumalanga

municipal and consulting engineers across the globe for 25+ years. With over 3 000 tank installations in more than 23 countries, SBS Tanks has earned the reputation as a trusted global brand that delivers exceptional quality and reliability.

Why SBS Tanks?

Why municipal and consulting engineers and professionals choose SBS Tanks:

• Professional support from an experienced team of in-house engineers, project managers and installers ensures a hasslefree installation. SBS teams work with municipal managers, engineers, consultants and contractors, alleviating the pressure on short-staffed and stretched municipal teams.

• Modular design and lightweight components allow for ease of transportation across any terrain. This is highly beneficial for regions with extreme terrain and where road infrastructure has not been completed. This also has an environmental spin-off, reducing the impact on flora and fauna, as well as community disruption.

• Solutions for water storage need to acknowledge that South Africa is a water-scarce region. The construction of concrete water storage reservoirs is water intensive, reducing the availability of water for communities.

• Water storage tanks from SBS Tanks utilise 2% of the carbon footprint of the equivalent

concrete reservoirs. Additionally, the modular design of SBS Tanks reduces environmental disruption and impact, embracing green building practices.

• Simple site preparation and quick installation with no heavy-duty or noisy equipment requirements.

• Safe installation from the ground up with in-house safety, health, environment and quality management teams.

• Over 500 tank size options with capacities from 7 000 litres to 4.2 million litres. Designed to suit the application, site location and project-specific requirements, SBS Tanks has become the preferred provider of modular water storage tanks in South Africa.

• SBS Tanks has developed liquid storage tanks to meet the needs of a wide range of industries and standards. These range from rainwater harvesting to bulk water, effluent wastewater or recycled water storage, mine water systems, backup or fire suppression water storage.

• SBS Tanks is a Proudly South African company that manufactures and supplies products to the local and global markets, supporting economic growth and development.

• Water storage tanks from SBS are ISO 9001:2015 and ISO 45001:2018 certified and produced in a world-class manufacturing facility.

“Municipal managers, planners, engineers and consultants have come to recognise that SBS Tanks is not only a trusted brand, but a partner that is ready and willing to ease the load,” says Gwagwa. “We have earned that reputation by delivering a premium product for more than two decades, honouring our ‘10-Year No Leak’ warranties, and providing project management, installation and service excellence. I am confident that no other supplier in the steel panel water storage tank market can say the same!”

With experienced sales, project management, health and safety and installation teams across the length and breadth of South Africa, as well as in East and West Africa, SBS Tanks is Africa’s leading manufacturer and supplier of ISO-certified steel panel water storage tanks fitted with an internal liner.

“SBS Tanks is willing and able to partner with municipal teams to build a water- and energysecure future for South Africa. We can and will go the distance – no matter how remote or rugged the terrain,” Gwagwa concludes.

Modular design and lightweight components allow for ease of transportation and installation, no matter how remote the location

An elevated water storage tank design for a municipal application

With over 3 000 tank installations in more than 23 countries, SBS Tanks has earned its reputation as a trusted global brand that delivers exceptional quality and reliability

HOW CONCRETE ROADS COMBINE SUSTAINABILITY AND RESILIENCE

at the recent

Poland, attended by

Awhite paper by the American Concrete Pavement Association (ACPA), ‘Concrete Pavements’

Role in a Sustainable, Resilient Future’ was presented at the symposium to underline the issue.

Perrie says concrete roads’ resilience is a particularly strong factor to consider by decision-makers for infrastructural development. “Sustainability deals with known events that can be quantified. Resilience, on the other hand, is the ability to anticipate, prepare for and adapt to changing conditions as well as withstand, respond to and recover rapidly after a disruptive event. In a changing global climate where extreme weather events are now becoming increasingly frequent, with far higher intensity than in the past, it is impossible to have sustainable infrastructure without resilience,” he explains.

Resilient systems limit the impact of relatively unexpected adverse effects

such as storms, floods and droughts, like those experienced recently in KwaZulu-Natal and the Eastern Cape. “The challenge is how to build more durable concrete structures while minimising the carbon emissions generated in producing and supplying cement and concrete,” he continues.

Life-cycle benefits

Perrie says the South African cement industry has already committed to net-zero carbon emissions by 2050. “While this focuses on cement’s value chain, it is also important to focus on the concrete value chain with a whole lifecycle approach – from material production through pavement design, construction, use stage, maintenance and preservation, and endof-life reuse or recycling. The essential tools for this are full life-cycle cost analysis (LCCA) and life-cycle assessment (LCA). While some life-cycle assessment is done in South Africa, it often does not include

the full LCA, including road-user delay costs during maintenance,” he expands.

As Perrie points out, it is critically important to address climate change and carbon reduction, but also essential to recognise that every roads agency, province and municipality is facing budget constraints, often being forced to make decisions based purely on economic factors. Where LCCA is carried out, in areas where there is minimal data on concrete roads, the results are frequently heavily biased.

The best way to improve the economic side of sustainability is to recognise the benefits of industry competition. According to the Massachusetts Institute of Technology (MIT) Concrete Sustainability Hub, US state agencies that have sustained a consistent competitive roads market – using both asphalt and concrete

The important role of concrete roads for sustainable and resilient infrastructure was emphasised

14th International Symposium on Concrete Roads in Krakow,

Bryan Perrie, CEO of Cement & Concrete SA.

pavements over multiple years – pay lower prices for all paving materials. The US, with the highest level of competition, has unit prices that are 29% lower for concrete and 8% lower for asphalt.

Perrie says that, while the environmental benefits of concrete roads are considerable, numerous easy and minor alterations can be implemented to improve the environmental impact of concrete. These include:

• optimising pavement designs to ensure minimum quantities of materials

• reducing concrete’s carbon footprint by using extended cements appropriately

• formulating concrete mix designs with optimised aggregate grading and optimised cement content.

Concrete pavements, because of their inherent stiffness, strength, brightness and durability, can also significantly reduce roads’ usage phase due to:

• fuel savings, particularly for heavy vehicles

• increased albedo or reflectivity, which minimises urban heat islands and can reduce required lighting at night.

CO2 absorption

One of concrete’s unique properties is its ability to act as a CO2 ‘sink’ for the planet. As concrete ages it absorbs carbon dioxide, helping to offset the amount produced when making cement. Covering concrete pavements with asphalt, either at construction or during the use phase, prevents this happening.

“Diamond grinding to provide an acceptable riding quality at construction or to improve it during the usage phase would increase CO2 absorption and be a far more sustainable practice, as would the use of concrete overlays for upgrading existing asphalt roads,” adds Perrie.

It should also be remembered that concrete is 100% recyclable and can be reused on the same site for base material, aggregate for new concrete and as filler.

“Concrete provides the most sustainable as well as resilient choice for pavement systems. Its long lifespan provides the greatest economic value over the long term for taxpayers and end-users with many environmental benefits. Choosing concrete roads for South African infrastructure is ultimately the most responsible choice for both sustainability and resilience,” he concludes.

Gabion Tool Sets

Slipform paving operations in progress

Concrete provides the most sustainable and resilient choice for pavement systems

Cape interchange upgrade gets AfriSam treatment

Since July 2021, well-established Cape contractor Haw & Inglis Construction has been proceeding apace on the upgrade of Cape Town’s Refinery interchange, supported by construction materials from AfriSam.

The project is due for completion in early 2024, delivering two new, higher and wider bridges over the busy N7 highway – a new road-overrail bridge alongside the existing bridge, which receives rehabilitation works and the upgraded access ramps among the key achievements.

Leiton Chan, construction manager at Haw & Inglis Construction, highlights that due to the capacity and height limitations of the existing bridge, the new bridges double the capacity and provide an additional 1.7 m clearance from the existing bridge for vehicles travelling on the N7. To accommodate existing traffic, the westbound carriageway was constructed alongside the existing eastbound carriageway. Once completed, the traffic was diverted onto the new carriageway to complete the eastbound carriageway. The existing bridge was demolished

in December 2022 to make space for the new bridge – currently under construction.

“Each bridge deck over the N7 was cast in two, consisting of a dual-spine, post-tensioned structure,” explains Chan. “The project is currently on schedule, with the estimated completion date for the eastbound carriageway bridge over the N7 being August 2023.”

AfriSam is providing around 6 300 m3 of readymix concrete as well as material for layer works, according to Bradley Thomas, territory sales manager at AfriSam. The company is also supplying some 15 000 t of aggregate to the project’s asphalt supplier, AECI Much Asphalt.

Piling and deck pours

“An important application of our readymix was for the piling under the bridges, which required almost 1 500 m3 of high-strength

40 MPa concrete for this purpose,” says Thomas. “A priority here was to avoid any jointing in the piles, so it was essential that each pour – about 3.5 m3 per pile – was continuous.”

He notes that the decks on the two main bridges over the N7 also require continuous pours, amounting to substantial volumes of 500 m3 of 50 MPa concrete per deck. Placement is carried out using a high-capacity 36 m boom placer. The readymix is supplied from AfriSam’s Contermanskloof plant in Durbanville, located 8 km from the site, with support from the company’s other nearby plants at Woodstock and Bellville.

The critical path is the two bridges, joined by a 1 000 mm stitch to resemble a single structure

Apart from extending the width of the bridge, the height has also been raised

The spreading of supply sources allows for further mitigation of project risk related to readymix deliveries, says Thomas. For instance, large continuous pours leave little room for error, and unforeseen events such as traffic congestion have to be factored into the resource planning.

“On the smaller-scale aspects of the project’s readymix requirements, our flexibility also allows us to effectively supply the smaller subcontractors on the project,” he adds. “We have therefore also been able to play a role in enterprise development, supplying the kerb mix to SMME contractors installing the precast kerbs.”

RAP component

For the road work, AfriSam is supplying about 50 000 t of aggregate for layer works from its Contermanskloof quarry. According to Chan, Haw & Inglis Construction has been able to incorporate a considerable amount of recycled material in the road fill. He points out that the westbound carriageway fill was made up of in-situ G7 sand material excavated from the bridge and mixed with recycled asphalt product (RAP). The RAP is milled material from the various road contracts conducted by the Western Cape Government.

In addition to carefully facilitating the traffic flow through the interchange during construction, the project has also had to navigate underground and overhead services from high-voltage power lines and diesel pipes to sewer networks and optical fibre lines, he says. A further environmental priority was not to disturb two small wetlands within the road reserve.

Attenuation design provides stormwater solution

The Eldoraigne Village Retirement Centre in Zwartkops, situated upon a sloping hillside, has large quantities of installed paving that hinders the natural infiltration of stormwater. This required the design of an effective stormwater management system with an attenuation pond constructed at the lowest point on the site. The latter was constructed using Technicrete’s Enviro-Wall retaining system for the supporting walls to create a durable and aesthetic structure.

Constructed from dry stacked interlocking, precast blocks, the simplicity of the Enviro-Wall design enables the blocks to be easily and quickly laid to form an effective retaining wall layout. Additionally, opening or closing the spacing between the blocks means that the Enviro-Wall structure configuration can be altered so that the open arrangement cavities between adjacent blocks can be filled with soil. This enables the moisture in these spaces to promote rapid plant growth.

A wide range of retaining wall/embankment heights can be accommodated by the system, which accommodates both concave or convex alignments, down to a relatively small (2 m) radius of curvature. In turn, angle of inclination of the wall may be set by using the base block at 70 degrees. Technicrete’s engineering team can assist on sites that require differing angles.

A highly versatile system, Enviro-Wall is suitable for earth embankments, bridge abutments, cut slopes, landscaping of cut and fill areas around buildings, as protection for steep channels and riverbanks, as well as culvert inlets and outlets.

The completed attenuation pond at the Eldoraigne Village Retirement Centre in Zwartkops. Technicrete’s Enviro-Wall system is easy to install, cost-effective and offers a variety of visual effects that are achievable due to its reversible block configuration

One other element of the project is the realignment of the interchange’s five access ramps to suit them to the upgrade bridge structure

The readymix is supplied from AfriSam’s Contermanskloof plant, with backup plants nearby in Woodstock and Belville

CCSA’S LEAFLETS PROVIDE KEY INSIGHTS ON BEST PRACTICE

Cement & Concrete SA (CCSA) has a wide range of informative leaflets available free of charge for all levels of expertise – ranging from basic to advanced – in the building and construction industries. The leaflets, which are updated when required, play an important role in keeping the market informed of latest developments in concrete and cementitious materials. The leaflets currently cover: Cementitious materials for concrete: standards, selection and properties. Guidance is given on selection for various applications and the leaflet includes graphs of strength performance and discusses the manufacture and properties of cementitious materials and fillers.

ADVISORY SERVICES

CCSA offers a free advisory service for general concrete technology queries. A consultancy service focused on concrete and related issues is also offered, including on-site investigation, troubleshooting and reporting. The technical team is available for consultation on construction sites anywhere in Southern Africa.

Concrete, plaster and mortar mixes for builders. This is presented largely in graphic form and contains the proportions for large and small batches of concrete, mortar and plaster. It also includes guidelines on quantities of materials to order.

Mortar mixes for masonry deals with the required materials and mix proportions to give freshly mixed mortars the necessary softness and plasticity. It also covers batching, mixing and handling of the mortar, as well as quantities of materials to order.

Trial concrete mixes: proportions and quantities for ordering provides trial mix proportions for concrete made with four stone sizes and with strengths ranging from 10 MPa to 40 MPa. A field test for assessing and adjusting stone content is also given.

Admixtures for concrete covers the most common reasons to use admixtures and looks, in some detail, at the five types most commonly used in construction. The properties, dosage, uses and practical considerations for each type are discussed.

Fibre-reinforced concrete explains how concrete’s tension weakness can be overcome by conventional rod

reinforcement and sufficient volumes of certain fibres. The leaflet looks briefly at the concept of toughness, the use of fibres, and the types of fibres and their properties.

Foamed concrete. This leaflet deals with materials for foamed concrete, how it is produced, its properties and typical applications.

No-fines concrete (NFC): a practical guide provides information for materials and mix proportions, manufacture, placing and compacting, protection,

curing and screeding for NFC. The latter is characterised by a coarse aggregate and cement paste composition with large interconnected voids and a much lower density than conventional concrete. Its structure is ideal as a drainage layer under reservoir and basement floors, as an insulating layer, and as a damp-proofing material.

Tests on concrete has been prepared to assist the operator and describes, step by step, the procedures for carrying out tests for measuring slump and how to make 150 mm cubes.

Repairing spalled joints in concrete floors provides guidance on the subject.

Sand-cement floor screeds and concrete toppings for floors is a moderately theoretical and technical publication with information needed by architects, engineers and contractors to specify and lay floor screeds of acceptable quality.

Health and safety is a leaflet on the safe use of Portland cements and concrete. It identifies the areas of risk, provides guidance on how to avoid unprotected exposure, and outlines basic first-aid procedures for concrete work.

How to make concrete bricks and blocks provides the technical information required to set up and run a block yard for small-scale manufacture of masonry units. Aspects dealt with include the feasibility study, selecting and establishing a site, selection of equipment, materials for blockmaking, trial mixes, production and quality control.

The manufacture of concrete paving blocks is a technical leaflet that covers basic principles and aims to assist manufacturers – particularly new ones – in the production of durable and consistent products.

Common defects in plaster lists the most common causes and discusses repair methods for each.

Concrete, plaster and mortar mixes for builders is presented largely in graphic form and provides the proportions for large and small batches of concrete, mortar and plaster. It includes brief guidelines on quantities of materials to order.

Mortar mixes for masonry discusses the required materials and mix proportions to give freshly mixed mortars the necessary softness and plasticity. It also covers batching, mixing and handling the mortar, as well as the quantities of materials to order for mortar mixes per cubic metre or per 50 kg bag of cement.

Repairing the surface of concrete – casting defects and minor damage is aimed at those responsible for specifying, supervising or carrying out relatively superficial repairs to concrete. Types of defects and their causes are given, as well as repairs of various types and the use of different materials.

Successful plastering covers the selection of materials, mix proportions, surface preparation and plaster application for conventional architectural purposes.

The full range of CCSA leaflets can be downloaded from the association’s website at www.cemcon-sa.org.za.

Precast design for luxury dwellings

Anew private residential development built in the upmarket suburb of Oranjezicht, Cape Town, demonstrates the versatility of precast concrete to build a striking and functional structure that doesn’t compromise on aesthetics. The dwelling is a single envelope comprising two four-storey units, each with four bedrooms and a total living space of 425 m2 per unit positioned on a 900 m2 erf.

“We chose the precast method due to a number of factors: speed of construction, ability to cast intricate shapes repeatedly, quality of surface finish and, of course, cost,” explains Anthony Svelto, architectural designer at A-I-R Inc in the USA.

Cape Concrete, as the precast supplier, entrusted the specialised skills required to meet the architectural concepts, tolerances and the element’s flush connections to Peikko SA, whose experience and range of precast connecting elements ensured a perfect fit between columns, beams and decks.

The striking design strives to implement sustainable elements derived from the Living Building Challenge spearheaded by the International Living Future Institute

IMESA AFFILIATE MEMBERS

AECOM siphokuhle.dlamini@aecom.com

AFI Consult banie@afri-infra.com

Alake Consulting Engineers lunga@alakeconsulting.com

ARRB Systems info@arrbsystemssa.com

Asla Construction (Pty) Ltd johanv@asla.co.za

BMK Group brian@bmkgroup.co.za

Bosch Projects (Pty) Ltd mail@boschprojects.co.za

BVI Consulting Engineers marketing@bviho.co.za

CCG puhumudzo@ccgsytems.co.za / info@ccgsystems.co.za

Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za

Dlamindlovu Consulting Engineers & Project Managers info@dlami-ndlovu.co.za

EFG Engineers eric@efgeng.co.za

Elster Kent Metering Mark.Shamley@Honeywell.com

EMS Solutions paul@emssolutions.co.za

ERWAT mail@erwat.co.za

ESCONGWENI BPH ENGINEERS (PTY) LTD info@escbph.co.za

Gabion Baskets mail@gabionbaskets.co.za

GIBB marketing@gibb.co.za

GIGSA secretary@gigsa.org

GLS Consulting info@gls.co.za

Gorman Rupp Cordeiro@gormanrupp.co.za

Gudunkomo Investments & Consulting info@gudunkomo.co.za

Hatch Africa (Pty) Ltd info@hatch.co.za

HB Glass Filter Media info@hardybulkinglass.com

Herrenknecht schiewe.helene@herrenknecht.de

Huber Technology cs@hubersa.com

Hydro-comp Enterprises info@edams.co.za

Infrachamps Consulting info@infrachamps.co.za

INFRATEC info@infratec.co.za

IQHINA Consulting Engineers & Project Managers info@iqhina.co.za

iX engineers (Pty) Ltd hans.k@ixengineers.co.za

Izinga Holdings info@izingalabezi.co.za

JBFE Consulting (Pty) Ltd issie@jbfe.co.za

JG Afrika DennyC@jgafrika.com

KABE Consulting Engineers info@kabe.co.za

Kago Consulting Engineers kagocon@kago.co.za

Kantey & Templer (K&T) Consulting Engineers ccherry@ct.kanteys.co.za

Kitso Botlhale Consulting Engineers info@kitsobce.co.za

KSB Pumps and Valves (Pty) Ltd salesza@ksb.com

KUREMA Engineering (Pty) Ltd info@kurema.co.za

Lektratek Water general@lwt.co.za

Loshini Projects muzi@loshini.co.za

Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za

Mariswe (Pty) Ltd neshniec@mariswe.com

Martin & East gbyron@martin-east.co.za

M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za

Mhiduve adminpotch@mhiduve.co.za

MPAMOT (PTY) LTD mpumem@mpamot.com

Mvubu Consulting & Project Managers miranda@mvubu.net

Nyeleti Consulting naidoot@nyeleti.co.za

Odour Engineering Systems mathewc@oes.co.za

Prociv Consulting & Projects Management amarunga@prociv.co.za

Rainbow Reservoirs quin@rainbowres.com

Re-Solve Consulting (Pty) Ltd maura@re-solve.co.za

Ribicon Consulting Group (Pty) Ltd info@ribicon.co.za

Royal HaskoningDHV francisg@rhdv.com

SABITA info@sabita.co.za

SAFRIPOL mberry@safripol.com

SAGI annette@sagi.co.za

SALGA info@salga.org.za

SAPPMA admin@sappma.co.za / willem@sappma.co.za

SARF administrator@sarf.org.za.co.za

SBS Water Systems marketing@sbstanks.co.za

Silulumanzi Antoinette.Diphoko@silulumanzi.com

Siroccon International (Pty) Ltd admin@siroccon.co.za

SiVEST SA info@sivest.co.za

Sizabantu Piping Systems (Pty) Ltd proudly@sizabantu.com

Siza Water (RF) Pty Ltd PA@sizawater.com

Sky High Consulting Engineers (Pty) Ltd info@shconsultong.co.za

SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za

Smartlock jp.alkema@smartlock.net

SMEC capetown@smec.com

SOUTH AFRICAN VALUE EDUCATION Sabiha@savegroup.co.za

Southern African Society for Trenchless Technology director@sasst.org.za

SRK Consulting jomar@srk.co.za

Star Of Life Emergency Trading CC admin@staroflife.co.za

TPA Consulting roger@tpa.co.za

V3 Consulting Engineers (Pty) Ltd info@v3consulting.co.za

VIP Consulting Engineers esme@vipconsulting.co.za

VNA info@vnac.co.za

Water Institute of Southern Africa wisa@wisa.org.za

Wam Technology CC support@wamsys.co.za

Wilo South Africa marketingsa@wilo.co.za

WRCON ben@wrcon.co.za

WRP ronniem@wrp.co.za

Zutari Rashree.Maharaj@Zutari.com

The build-up to the 2024 CMA awards

The Concrete Manufacturers Association (CMA) officially launched the 2024 Awards for Excellence competition on 9 May 2023. Members have until 28 May 2024 to submit their entries. There are two entry categories – namely Aesthetic Excellence and Engineering Excellence – each split into seven and eight subcategories, respectively.

The biennial event is one of the highlights on the construction industry’s calendar and presents an outstanding opportunity for members, both large and small, to showcase their products and to establish themselves as trendsetters.

“As in 2022, videos will be made of all entry submissions and these will be posted on the CMA’s social media platforms, which will provide outstanding levels of focused exposure in the lead-up to the judging in 2024,” explains Henry Cockcroft, director, CMA.

“For example, 210 000 views on social media –equivalent to 575 hours of accumulated social media view time – were achieved in 2022. And for the 2024 competition, we will build on our 2022 knowledge to make improvements and gain even more exposure.”

Besides the completed entry form, each submission requires footage comprised of seven photographs and/or videos accompanied by a 450-word project description motivating the entry.

Judging, done by an independent panel of construction professionals, will take place in July 2024 and the award results will be announced as soon as the digital winners’ book is completed in the final quarter of 2024.

Visit www.cma.org.za

information.

One of four CMA trophies up for grabs

Innovative app helps optimise crusher setups

On mobile crushing plants, setting the ideal machine parameters requires application experience in terms of the feed material and the desired result.

To simplify the process, Kleemann has introduced the Smart Job Configurator via app or touch panel.

Kleemann’s Spective Connect app provides a step-by-step guide for the operator based on the data entered. The latter includes the crusher model, machine, material and processing requirements. A suitable final product is then suggested, as are the tools required. When all parameters are entered, the tool creates an overview of the ideal machine configurations. The results of these calculations can then

The Smart Job Configurator on the machine’s Spective touch panel can be used as a ‘QuickStart’ for simple plant setup

The Smart Job Configurator in the Spective Connect app guides the operator in the selection of the correct machine settings

be exported as a PDF and shared with production and allied personnel.

Once accepted, the operator then uses the Spective touch panel on the machine to apply the settings via the Smart Job Configurator menu. The latter can also be used without Spective Connect as a ‘QuickStart’ on the touch panel. Again, the operator is sequentially guided through the machine configuration settings, which accelerates the setup. The operator also receives the same setting options that are offered in the app.

Sample application options

The Smart Job Configurator comes preloaded with various scenarios that have been created by Kleemann’s application technology team, while more ‘recipes’ are continually added. Customers can also contact Kleemann directly if special applications are required.

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