Imiesa October 2017 by 3S Media

www.infrastructurene.ws

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INDUSTRY INSIGHT

Construction

Going labour-intensive

Frikkie Oosthuizen Executive: Contractual Affairs & Support Services, SAFCEC

National Asphalt Leading the field since inception

Gauteng Infrastructure Cracking the code

Roads & Bridges

Building the Wild Coast’s iconic bridges

IN THE HOT SEAT The initial enquiry by municipalities is often the starting point for a proactive discussion that ends with the best final outcome.” Mava Gwagwa New Business & Key Accounts Director, SBS Tanks ISSN 0257 1978

V o l u m e 4 2 N o . 1 0 • O c t o b e r 2 0 1 7 • R 5 0 . 0 0 ( i n c l . VAT )

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EDITOR’S COMMENT PUBLISHER Elizabeth Shorten MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson HEAD OF DESIGN Beren Bauermeister CHIEF SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter CONTRIBUTORS Imraan Amien, Bernhard Botes, Gavin Clunnie, Dirk Immelman, Robert McCutcheon, Wessel Pienaar, Frances Ringwood, John Roxburgh CLIENT SERVICE & PRODUCTION MANAGER Antois-Leigh Botma PRODUCTION COORDINATOR Zenobia Daniels FINANCIAL DIRECTOR Andrew Lobban DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za PRINTERS United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________

Educating for change

peaking at the recent Tax Indaba in September 2017, Minister of Finance Malusi Gigaba said, “The most important step we can take to develop our country is to get more South Africans working.” The key problem, though, is that the number of jobseekers keeps growing exponentially, and opportunities keep shrinking. Each year in October, South Africa’s matric learners sit for their National Senior Certificate (NSC). It’s the first major staging point for life as a young adult and a vital one. A total of 798 289 learners have enrolled to write this year’s NSC examinations, compared to 828 020 in 2016. If you add up the numbers, plus the successive wave of matriculants coming through in 2014 and 2015, that’s a very large volume of jobseekers entering an economy where unemployment stands at around 27.7%. Unfortunately, we also have to factor in a growing percentage of learners that leave school with a grade 10 education or less, practically excluding them from the formal economy. In terms of future job opportunities, agriculture, construction, manufacturing, mining and tourism are among the more viable. In the past, and the future, a percentage of the scientific, technical and engineering skills requirements have and will be bolstered by state-owned enterprises like Eskom, Sasol and Transnet. However, they can only do so much, plus the pace of investment in bursaries and technical training has definitely waned in this tough trading environment.

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

No. 9, 3rd Avenue, Rivonia 2056 PUBLISHER: PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za ANNUAL SUBSCRIPTION: R550.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2017. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Fax: +27 (0)43 743 5266 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Fax: +27 (0)41 585 1066 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Fax:+27 (0)31 266 5094 Email: imesakzn@imesa.org.za NORTHERN PROVINCE Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 Email: np@imesa.org.za

Project readiness Regaining lost ground and repositioning for growth is clearly a common goal. In this issue of IMIESA, there’s an article

SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Fax: +27 (0)86 628 0468 Email: imesafsnc@imesa.org.za

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

@infrastructure4 struc www.infra

Infrastructure News

IMESA

turene.ws

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

INFRAST RUCTUR

E DEVELO PMENT

• MAINTE NANCE

• SERVICE DELIVER

Cover opportunity

Construction

Y IND US TR INSIGHT

Going labour-inte

nsive

Oosthuizen

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

about the proactive steps the Gauteng Department of Infrastructure Development (GDID) is taking to move the construction sector forward. The department’s MEC, Jacob Mamabolo, recently unveiled the GDID’s Project Readiness Matrix, which has 162 compulsory steps that need to be followed for every project roll-out as it cracks down on wastage and inefficiencies. Currently, there are 152 GDID projects under way, valued at R2.4 billion, in various project stages, together with an approximately R32 billion property portfolio. In addition to rejuvenating building usage, the GDID also has a broader role to play in promoting capital formation via the spatial development of vacant state land. That helps create jobs. The Expanded Public Works Programme (EPWP) is another focus area for the GDID in addressing poverty alleviation and unemployment. It also supports the depar tment’s back-to-school campaign. In the future, Mamabolo wants all GDID projects to have a 50% EPWP component. The GDID is currently in discussion with Gauteng’s seven TVET colleges and plans to work with these institutions to help drive a skills revolution. That will address concerns expressed by many that the EPWP only achieves a short-term job solution, with limited skills transfer beyond specific projects and communities.

Frikkie al Affairs & Executive: Contractu SAFCEC Support Services,

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

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IMIESA October 2017

www.infrastructurene.ws

IMESA

INSIDE

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INDUSTRY INSIGHT

VOLUME 40 NO. 10 OCTOBER 2017

Construction

Going labour-intensive

Frikkie Oosthuizen Executive: Contractual Affairs & Support Services, SAFCEC

National Asphalt Leading the field since inception

Gauteng Infrastructure Cracking the code

Roads & Bridges

Building the Wild Coast’s iconic bridges

IN THE HOT SEAT Often, the initial enquiry by municipalities is the starting point for a proactive discussion that ends with the best final outcome.” Mava Gwagwa New Business & Key Accounts Director, SBS Tanks ISSN 0257 1978

An early adopter of new technologies, National Asphalt has led from inception. MD Sean Pretorius talks about the company’s history before and after its acquisition by Raubex Limited in 2007, and the road ahead. P6

V o l u m e 4 2 N o . 1 0 • O c t o b e r 2 0 1 7 • R 5 0 . 0 0 ( i n c l . VAT )

Frikkie Oosthuizen, executive: Contractual Affairs and Support Services, SAFCEC

Frikkie Oosthuizen, executive: Contractual Affairs and Support Services at SAFCEC, gives his views on key developments affecting the civil engineering industry. P14

CEMENT & CONCRETE PPC turns 125

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

1 5 8 120

Cover Story The asphalt innovator turns 29 6 Hot Seat Water value engineering

Municipal Focus Ekurhuleni

Industry Insight Ensuring proactive representation

Cement & Concrete PPC turns 125

Partners in Infrastructure

IN THE

HOT SEAT Meeting the current and future potable and wastewater needs of South Africa’s rural and urban communities is a top priority. Mava Gwagwa, new business and key accounts director, ® SBS Tanks , talks about the company’s innovative responses. P10

Cracking the code Gabions and geotextiles work together An industry in focus Building fire resistant structures Successful EME trails

PARTNERS IN INFRASTRUCTURE

20 22 24 29 35

READ INSIDE Cracking the code

Gabions and geotextiles work together

An industr y in focus

Building fire resistant structures

Successful EME trails

Roads & Bridges Building SA’s mega bridges 37 Designing Mtentu Bridge 38 Hydro demolition used in M1 bridge repair 40 Taking a multi-axial approach 41 Connecting the Eastern Cape 43 Cost-benefit analysis of road projects 45

PARTNERS IN INFRASTRUCTURE An industr y in focus

IMIESA October 2017

Technical Paper Engineering and labour-intensive construction

108

Cement & Concrete

Consulting to Local Government CESA Aon Engineering Excellence Awards Managing emerging risks Fit-for-purpose engineering

ROADS & BRIDGES Designing Mtentu Bridge

49 53 57

Forming infrastructure for 83 years 112 RMC is a job creator 115 Precast student blocks 118

INTELLIGENT INFRASTRUCTURE

Intelligent Infrastructure A collection of excellence

Water & Wastewater Revitalising a corroded station 69 Securing Amajuba’s water 70 Water reuse, the smart way 72 Effective, alternative water treatment 74 Changing lives through Umgeni Water flagship projects 77 Flexible water solutions 79 Ending Cape water crises 80

Transforming business

through technology

IMIESA October 2017

WATER & WASTEWATER

Pipes, Pumps & Valves The politics of piping Pipeline app launched An end to pump corrosion Energy-efficient water pumping

83 87 88 91

TRANSPORT, LOGISTICS,VEHICLES & EQUIPMENT

Transport, Logistics, Vehicles & Equipment

READ INSIDE Revitalising a corroded station

Changing lives through 77

Securing Amajuba’s water

Umgeni flagship projects

Water reuse, the smar t way

Flexible water solutions

Effective, alternative water treatment

Ending Cape water crisis

IMIESA October 2017

102

Taking an integrated approach Moving the earth with Leeboy Building routes with Roadtec Leading in mechanised demolition A mobile breakthrough for asphalt The latest in pothole repairs New backhoe brand

94 96 98 101 102 105 107

READ INSIDE Taking an integrated approach

A mobile breakthrough for asphalt

102

Moving the ear th with Leeboy

The latest in pothole repairs

105

Building routes with Roadtec

New backhoe brand

107

Leading in mechanised demolition

101

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT A mobile breakthrough for asphalt

118

CEMENT & CONCRETE Precast student blocks

SOUTH AFRICA’S FUTURE IS CAST IN CONCRETE

SANRAL has been announced as a winner of not only one, but two 2017 Fulton Awards for excellent work. The N2/M41 Mt Edgecombe interchange in Umhlanga, won the award in the category ‘Civil Engineering Structure Greater Than R100 million’. This is for projects where totally new materials, techniques, technologies, applications, designs and concepts using concrete as the principal material, have been developed or utilised. The cherry on top was when SANRAL’s Eastern Region was also awarded the 2017 Fulton Award as a joint winner in the category ‘Innovation in Concrete’ for the work done on the Van Zyl Spruit Bridge in the Free State. At SANRAL, we are extremely proud of these awards - as we are committed to delivering world-class infrastructure landscape but also sustains the economy of the country.

SANRAL. Beyond roads.

BLUEPRINT 1707/E

that not only changes our country’s

An agency of the Department of Transport.

IMIESA October 2017

PRESIDENT’S COMMENT

IMESA

Visiting down under

uring August 2017, I had the privilege of attending the International Federation of Municipal Engineering (IFME) board meeting in Perth, Western Australia, where key information sharing and proposed technology exchanges were explored by delegates from across the globe. The IFME board meeting was held at the IPWEA’s 2017 International Public Works Conference, which brought together key private and public sector stakeholders. The city of Perth is a vibrant one and is experiencing strong residential and commercial expansion. Major infrastructure highlights include the city’s investment in port upgrades similar to those experienced in recent years at Cape Town, Durban and the Port of Ngqura, South Africa’s newest deep-water harbour. South Africa is an arid country, but Australia is even drier and regions like Western Australia are among the most waterscarce on earth, with extensive desertification. That places growing pressure on cities like Perth, which is experiencing intensified urbanisation. It’s a similar scenario in South Africa, particularly for metros like Cape Town, although this city still enjoys a marginally higher annual rainfall of around 788 mm compared to Perth’s 715.8 mm (2016 data). However, Perth’s population is now around 2 million, while Cape Town’s is closer to 3.7 million – so our water discipline should and must be a lot tighter.

Because we’re so acutely aware of the severe drought conditions being experienced in South Africa, I was expecting water conservation topics to be high on the agenda at the Perth conference. They weren’t. That’s because Australia has had an entrenched water conservation culture stretching back for decades: responsible usage is second nature, in both domestic and commercial contexts.

Non-revenue water Like many of our cities, some of Perth’s underground services are over 100 years old, so ongoing inspections are necessary. During 2015/16, a programme was launched to inspect more than 4 400 km of water mains across the Perth metropolitan area. This resulted in a saving of about two billion litres of water by repairing non-visible leaks. That also translates into a substantial saving when it comes to non-revenue losses. Additional income flows can then be reinvested to upgrade services. The World Bank recommends that municipal pipeline water losses should not exceed 25% and Australia is comfortably within this threshold. For South Africa, however, unexplained water losses remains a serious concern, ranging anywhere from 35% to 50% – we don’t have precise data to work with – so we have far less funding leverage for maintenance.

Stormwater At the International Public Works Conference, there were a number of excellent papers on stormwater attenuation and water reuse. One case study that stood out was Sydney Water’s Green Square stormwater drain project. This 2.4 km underground system is being built using a combination of open trenching and microtunnelling, with work happening across multiple locations simultaneously. Back in South Africa, we can proudly say that we are at the forefront when it comes to trenchless applications and innovative remediation techniques. At this year’s IMESA Conference, two of the presentations cover landmark sewer pipeline projects. Plus, we have a very interesting presentation from the City of eThekwini on water conservation at municipal treatment plants. In many cases, South Africa sets the benchmark. In other instances, we learn from our international counterparts. Either way, we are making progress in the municipal engineering arena. IMESA president Gavin Clunnie

IMIESA October 2017

COVER STORY

The asphalt innovator turns

oday, National Asphalt is a market leader and fields a wide range of solutions in the hotand cold-mix segments, backed by a sustained focus on innovation, research and development. For those old enough to remember, the company started out from its KwaZulu-Natal roots in October 1998 with a single 200 000 t per annum plant in Cliffdale, near Durban. Today, Cliffdale is National Asphalt’s flagship operation and is capable of producing in excess of 50 000 t per month. It is equipped to produce up to 60% recycled asphalt (RA) mixes, among other products. Cliffdale has a bitumen storage capacity of over 10 000 t and is able to support all the group’s regional asphalt operations, of which there are now 16. As an indication of scale, in the past financial year, Cliffdale supplied

IMIESA October 2017

An early adopter of new technologies, National Asphalt has led from inception. IMIESA talks to Sean Pretorius, managing director, National Asphalt, about the company’s history before and after its acquisition by Raubex Limited in 2007, and the road ahead.

570 different entities in the private and public sector, including most parastatals. National Asphalt now has the capacity to produce in excess of two million tonnes per annum from its strategically located plants nationwide. “National Asphalt is also currently one the few South African companies that own fully mobile, locally manufactured asphalt plants capable of introducing up to 40% RA into its mixes,” says Sean Pretorius, managing director, National Asphalt.

Steel Flow “What sets us apart is the fact that we continue to explore the best solutions for the market,” he adds. A prime example is National Asphalt’s acquisition of a 60% shareholding in Shisalanga Construction in 2014. Shisalanga is a turnkey

GO!DURBAN BRT National Asphalt supplied product solutions for various contractors on the GO!Durban BRT: Crossmoor for three sections, WBHO for two and Stefanutti Stocks for one. Total volumes were in the region of 128 000 t. National Asphalt also supplied and paved two sections for Group Five, and one for Afrocon Construction. The quantities for Group Five and Afrocon were 42 000 t and 16 000 t, respectively. All sections were a JV between three government entities: Sanral, DOT and eThekwini. The inside bus lanes comprised an EME base and A-P1 modified wearing course, and the outer DOT traffic lane an A-E2 wearing course.

COVER STORY

contractor in the black-top and layer-works markets, as well as the inventor of Steel Flow, a steel-slag-manufactured asphalt. The application of Steel Flow allows for 12 mm to 15 mm asphalt overlays. This ‘thin layer’ technology enables a wider surface area at half the cost of traditional UTFC applications. So far, Shisalanga has supplied around 25 000 t. Shisalanga is also a leader in the hydro-cutting field, which is a rapidly growing business unit. The technique, referred to as hydro-texturising, is a cost-effective solution for repairing flushed bituminous pavements. Other key investments include Belabela Asphalt, a company based in Botswana. National Asphalt acquired a 49% interest in 2015. Belabela is currently setting up a plant in Gaborone.

History of innovation From UTFC to EME, and a wide range of products in-between, National Asphalt has been at the forefront. A case in point is its key role in the development of warm-mix asphalt. “The M4 southern freeway in Durban, linking the N2 from the Umlazi side to the Durban city centre, was our first full-scale night operation and it was done over a four-year period,” explains Wynand Nortje, technical manager at National Asphalt. “Phase 1 proved to be very problematic in achieving compaction using a latex-based modified bitumen at night, and we had to revert to Sunday day-time operations for the final surfacing stone mastic asphalt layer.” National Asphalt began investigating an alternative modifier and came across an FT wax, well proven in European applications, which allowed the company to work at lower temperatures. Following discussions with eThekwini Municipality, the owner of the M4 road, a series of trial sections were carried out, which proved to be very successful. Subsequently, Cliffdale is National Asphalt's flagship plant

the municipality decided to use the FT wax modifier for the next three phases on the M4. Since the Raubex acquisition, this modifier has continued to be used on the N3 western portion going into the city of Durban after the N2 and N3 intersection.

First hybrid solution for SA National Asphalt also spearheaded the local application of the first hybrid modified binder. This product was supplied on Umgeni Road, which links the Umgeni Industrial area with Durban’s CBD. A combination of FT waxes and SBS, this product has since been successfully used on a number of major road networks. Another interesting and recent project is the experimental use of PelletPAVE™, a proprietary product owned by Phoenix Industries in the USA. To date, the product has been successfully trialled on the M13 Fields Hill section. About 300 t has been placed and is now being monitored. A second trial section is planned for the current N2 EB Cloete to uMhlanga rehabilitation project. “Our industry still tends to have a conservative approach, but we are steadily gaining new ground and acceptance for our own and internationally proven technologies that will contribute to long-lasting, low-maintenance infrastructure,” says Pretorius. “Alongside these endeavours, we continue to grow our footprint in South Africa. We recently set up a plant at Portland quarry in Cape Town, and this will help support further expansion plans within the Western Cape, where we see major opportunities.”

MILESTONE PROJECTS POST 2007

2008

Western Freeway: eThekwini Municipality: Group Five/ Milling Techniks JV The project included red asphalt for the bus lanes and won an IMESA award

2013

Vaal River to Kroondal Plaza One of the first Sanral contracts with 40% RA in the base and overlaid with a UTFC – National Asphalt’s ULM under licence from Jean Lefebvre (UK) and certified by Agrément SA N2 New Guelderland to Mtunzini After the initial success at Kroondal, 57 km of the N2 was repaired with an A-P1 modified base and, again, 40% RA (50 000 t) and overlaid with the ULM (57 000 t) N3 Candella to Paradise Valley The first contract in South Africa to combine EME and RA: 66 000 t EME with 20% RA and a 10/20 pen binder. This was overlaid with 16 000 t ULM Inanda Road, Hillcrest Warm-mix asphalt with 25% RA and the first use of Foam Tech technology for the Department of Transport. 27 000 t supplied from Cliffdale

2014

N2 Murchison to Marburg 69 000 t A-P1 base with 40% RA and 10 000 t ULM

2015

N3TC Mooi River/Estcourt 72 000 t modified wearing course and base, of which 14 000 t had 20% RA

2016 www.nationalasphalt.co.za

Pier 2, Transnet Introduced Transnet to EME for the heavily trafficked Pier 2 at Durban Harbour. This was overlaid with a SALPHALT wearing course (20 000 t)

2017

N3 Harrismith to Warden 55 000 t of different mixes using AE-2 binder. 104 000 t of continuously coarse graded asphalt using AR-1 binder with rolled-in chips R61 Marburg 20 000 t, of which 12 000 t was for the ULM overlay Hammarsdale Interchange Project Currently carrying out UTFC plant trials at Cliffdale: 22 000 t to be supplied

IMIESA October 2017

INFRASTRUCTURE NEWS

FROM AROUND THE CONTINENT

Construction has begun on a mass housing project in Namibia

KENYA Solar access for the underserved The World Bank recently approved credit of $150 million to enable marginalised communities in Kenya to access modern energy services through off-grid solar. Kenya’s Off-grid Solar Access Project for Underserved Counties will serve an estimated 1.3 million people in 277 000 households across 14 counties. It will reach homes, schools and health centres, with maximum private sector involvement and investment to ensure sustainability. The project will use a combination of investments to provide modern energy services using practical business models that attract private sector investment, knowledge, sustainable services and other key efficiencies. The project will include a substantial technical assistance component that will enable a consumer education campaign to inform and engage with citizens around the project. The technical assistance will also enable an inclusive county capacity-building programme to

be identified through an assessment. “The uniqueness of this project, which entails collaboration of public and private sector, embedded operation and maintenance, as well as the innovative financing of the solar home system component, will be the hallmark of success in accelerating off-grid electrification, which has been hard to achieve. We appreciate the partnership and support of the World Bank in the conceptualisation and implementation of this project,” says Charles Keter, Cabinet Secretary for Energy and Petroleum.

20 MW solar PV tender, expected to become the first utility-scale solar PV project in Lesotho. The power generated will feed into the national grid in the Mafeteng district, promoting power supply independence. The project will contribute to a strategic phasing-out of costly power imports from Mozambique and to reducing reliance on imported coalgenerated power from South Africa, thereby achieving

Funding has been provided for Lesotho’s first utility-scale solar PV project

LESOTHO First utility-scale solar PV project The Sustainable Energy Fund for Africa (SEFA), managed by the African Development Bank, approved a US$695 500 grant to NEO I SPV, a subsidiary of OnePower Lesotho, to support the preparation of a bankable business case for the development of the winning project of the 2016 Lesotho

FAST FACTS

1.3 million

The number of people to get access to solar power in Kenya

IMIESA October 2017

$700 million The cost to build Rwanda’s new airport

substantial savings in the national budget and abating regional CO2 emissions. The project will contribute about 13% to Lesotho’s maximum system demand of around 150 MW. By substituting 20 MW of costly imported power from Mozambique, it will decrease power retail prices in Lesotho. The project will further support rural development by stabilising the grid in Mafeteng.

30%

The expected percentage of properly treated sewage in Tanzania by 2020

NAMIBIA Delivering low-cost housing Construction has begun on a mass housing programme at Otjiwarongo in the Otjozondjupa region. The programme involves the construction of 468 low-cost houses. According to Ismael Howoseb, CEO, Otjiwarongo Municipality, nine construction companies have been contracted to build five houses each within three months. The municipality will then evaluate their workmanship and the quality of the houses. The contract for the remaining houses will be awarded to the contractor that produces the best-quality work.

RWANDA New US$700 million airport Rwanda’s president, Paul Kagame, has laid the foundation stone of the country’s newest transportation hub, the Bugesera International Airport.

Dar es Salaam will increase its sewer and wastewater treatment capacity

Phase 1 of the Bugesera International Airport is expected to be complete by 2019

The government has successfully signed a concession agreement for the construction and operation of the new airport, positioning Kigali to become a nerve centre for business, travel and shipping in the sub-region. Estimated to cost $700 million, the airport project is designed to be executed across four phases. The first phase will involve approximately 27 months of construction – at an estimated cost of $400 million. It is expected to be completed by 2019, at which point the airport will be able to

accommodate 1.8 million passengers annually. “I am pleased to join you today to break ground for this important national project. We are as determined as you are to see this airport completed and operational,” Kagame said after laying the foundation stone. The president believes the new airport facility represents a critical element of ongoing national efforts to boost intra-African investment, trade and travel. The development of Bugesera Airport is aligned with Rwanda’s Vision 2020 – an ambitious strategy that aims to transform Rwanda into a knowledge-based, middleincome country by the end of the decade. The project also conforms to the country’s Economic Development and Poverty Reduction Strategy.

TANZANIA Major sewage works expansion The Dar es Salaam Water and Sewage Authority (Dawasa) has plans to increase the city’s sewer and wastewater treatment capacity, bringing relief

to residents and protecting the environment. Dawasa plans to embark on various projects to improve its sewage systems, increasing the rate of sewage transportation through proper channels from 10% to 30% by 2020. According to Dawasa acting CEO Remanus Mwang'ingo, three major sewage treatment plants will be built at Jangwani, Kurasini and Mbezi Beach, at an estimated cost of US$600 million. The plants are expected to generate power from biomass, while treated water from the plants will be used for cooling industrial parts and irrigation. There are also plans to divert the pipeline currently discharging effluent into the Indian Ocean to the Jangwani plant. Once completed, the Jangwani plant will have the capacity to treat 200 000 m3 of wastewater per day; however, Phase 1, which will see the diversion on the pipeline, will provide capacity to treat 25 000 m3 per day. While these projects are expected to commence at the end of the year, the water authority has raised less than half of the TSh2.8 trillion it needs to accomplish its goal.

IMIESA October 2017

Water value engineering Meeting the current and future potable and wastewater needs of South Africa’s rural and urban communities is a top priority, as are future drought countermeasures. IMIESA talks to Mava Gwagwa, new business and key accounts director, SBS Tanks®, about the company’s innovative responses. What is SBS Tanks’ current strategy for the municipal market? MG Our mission is to ensure that every municipality in South

In terms of cost impact and time, steel tanks are far faster to build when compared to concrete reservoirs, without compromising capacity.” Mava Gwagwa, new business and key accounts director, SBS Tanks

Africa understands the advantages of the SBS Tanks product line as a very flexible solution. At SBS, we offer a turnkey package that brings true value to the end user. Our tanks have been proven to last well beyond 60 years, with minimal maintenance. This means that municipal budgets are well spent. And this doesn’t just apply to South Africa. SBS exports globally and has an expanding presence in key public and private sector markets that include the USA.

What other fluids besides water can these tanks handle? Mining is one of the most aggressive environments and puts any product to the test. Our tanks meet the most exacting requirements in this area and that means that our products are field-proven for virtually every other application. SBS’s liners, which form an integral part of the tank system design, range from normal potable requirements to leachate and wastewater applications. Our tanks have also been widely used in the waste

IMIESA October 2017

management industry, because they can store leachate from dump runoffs and other waste management sites, assisting in the client’s requirements for stench control.

days, and then installed an additional 2.4 Mℓ and 3.3 Mℓ tank as per client requirements.

How does the wastewater segment fit into the business model?

Can you provide examples of how SBS works with municipal managers to find effective water storage solutions.

For the public sector market, we specialise in containing brackish water or wastewater for further processing. One of our flagship wastewater projects is the ongoing relationship we have with Sembcorp Siza Water in Ballito, KwaZulu-Natal. Sembcorp extracts water from two sources: the river system and processed wastewater. In November 2016, we provided a 2 Mℓ temporary storage solution to meet Sembcorp’s requirements over the December season, following a major tank failure on a non-SBS tank. Sembcorp sells its potable water to the local municipalities, so the implications were severe. SBS replaced the failed tank with the 2 Mℓ tank in just four

We advise on the best outcome for communities. Sometimes, this solution involves the interconnection of our tanks with existing supplies. At other times, it’s a standalone installation for rural communities outside the existing municipal grid. Often, the initial enquiry by municipalities is the starting point for a proactive discussion that ends with the final best outcome, after exploring all the other alternatives. Here, we pride ourselves on providing objective professional advice based on our value engineering philosophy. Our goal is to lower the cost for municipalities – e.g. by optimising gravity-fed systems, thereby reducing pump station and pipeline installations. Multiple smaller tanks can

HOT SEAT also be installed at higher elevations. To achieve this, SBS provides site assessment services to assist municipalities and consulting engineers with the best tank system location and layout. SBS also runs a series of annual roadshows at municipalities, which are also attended by contractors and consultants. Our smallest tank is 12.5 Kℓ (12 500 ℓ). But because we’re modular, the capacity can be incrementally expanded. In other words, we can customise the volume, scalable up to a 3.3 Mℓ capacity, given available construction footprints.

Steel tanks vs concrete reservoirs: how do they compare from a construction cost perspective? In terms of cost impact and time, steel tanks are far faster to build when compared to concrete reservoirs, without compromising capacity. A 3 Mℓ concrete reservoir would typically take around 18 months to complete; an SBS installation of the same capacity would be commissioned in approximately 40 days. When it comes to municipal strategy, this is obviously a very persuasive argument and we constantly reinforce the benefits through our national workshops. On another note, SBS is often appointed to remediate concrete reservoirs that experience major leakages. Here, we install the same PVC liner we employ in our own tanks.

South Africa has a major informal settlement challenge and a service delivery backlog in terms of water and sanitation. How can SBS assist? We are engaged with municipalities and they are aware of what we can do. After many similar successful installations, we’re positive that further opportunities will be forthcoming.

These systems can also be metered, whether powered by solar or the grid, via telematics that record elements like consumption, inflow, outflow, level and even water temperature – so there are definite benefits for community projects.

Can you expand on SBS’s solutions for rural communities, with project examples. Many of our municipal projects are incremental and ongoing. Examples include the Sol Plaatje District in Kimberley, as well as in Aliwal North, both in the Northern Cape. At Sol Plaatje, SBS’s installations comprised two 2.5 Mℓ tanks for potable water supply via municipal reticulation.

Can rainwater harvesting make a meaningful impact? Absolutely, and we’re proud to say that we have our own system installed at our Pinetown facility. The solution is highly sustainable and every building, public or private, should have a rainwater harvesting system. So far, we’ve installed systems at a number of companies and schools in KwaZulu-Natal, which obviously benefit from saving toilet water wastage.

Has the extended drought presented new opportunities for SBS? Without a doubt. Desalination, for instance, whether for seawater or inland brackish water, is a definite consideration now, despite its relatively high cost compared to conventional treatment. Cities like Cape Town have already started desalination projects as a critical drought inter vention. That presents opportunities for steel tank reser voirs (before and after treatment), especially given their speed of installation. And should a desalination plant go down for any reason, reser voir tanks always ensure a reser ve backup or, as we like to call it, ‘future water’.

What are your thoughts on the future in terms of balancing water supply and demand? We want to see our tanks filled, working and delivering water to the community. That comes down to building lasting partnerships with our public and private sector stakeholders. For SBS, we are proud to say that we deliver in terms of local and international quality and ISO standards and specifications.

www.sbstanks.co.za

IMIESA October 2017

MUNICIPAL FOCUS

EKURHULENI IMESA Conference HOST CITY

ince 2011, the City of Ekurhuleni has invested just over R25 billion in the acceleration of infrastructure development and maintenance, with a focus on energy, water and sanitation, transport, and information technology communication. To build on this progress, the City of Ekurhuleni will soon receive a share of R650 million towards infrastructure development. The money will be redirected from the Urban Settlements Development Grant to the country’s five

Executive Mayor Mzwandile Masina

Gibela site (Photo: Gibela)

ENERGY municipalities for the development of social housing, student accommodation, the upgrading of informal settlements and the acquisition of land for human settlements development as a response to rapid urbanisation. This is expected to build on Ekurhuleni’s emphasis on human settlements development and assist in dealing with the city’s housing challenges.

HOUSING

The City of Ekurhuleni made headlines earlier this year when it announced six mega housing projects in the pipeline to be rolled out over the next five years. The roll-out of these projects is expected to address the serious housing backlog across the city, with 8 000 housing units to be completed in the 2017/18 financial year. The city has secured, and is in the process of securing more, land to enable it to provide bulk services for housing settlements like Leeuwpoort, Clayville Ext 156, John Dube and Daggafontein. Housing will consist of rental stock for middle-income earners, as well as fully subsidised units for the poor. The notable Clayville/Tembisa Mega Housing Project is a large-scale mixed-landuse housing development that will produce approximately 14 320 mixed-tenure housing units. Earlier this year, the Gauteng Department of Human Settlements announced that it would spend R6 billion on the project in the coming years. On a smaller scale, the R2.9 billion Leeuwpoort Housing Project will deliver more than 19 000 housing opportunities over seven years. This will consist of social, FLISP, bonded and commercial housing opportunities. The houses will mainly benefit the people of Reiger Park, Boksburg and neighbouring informal settlements.

BUILDING A NEW UNIVERSITY As Ekurhuleni is the only metro in the country without a university, Executive Mayor Masina has repeatedly highlighted the need for one in the city, one of the county’s biggest metros and South Africa’s manufacturing capital. The city recently held a symposium to explore the establishment of a new university, which is envisaged to ensure the development of engineers, innovators and specialists in the fields of aviation, logistics and manufacturing within the metro, thereby contributing to the city’s economy. It is also expected to alleviate over-crowding at technical and training colleges, and provide greater educational opportunities for those within the region.

Ekurhuleni is expected to make massive investments into energy infrastructure as part of its efforts to secure local energy stability and pursue a renewable energy strategy. Speaking at the Manufacturing Indaba earlier this year, Ekurhuleni Executive Mayor Mzwandile Masina said the city had committed to invest R2.2 billion over the next three years. The renewable energy strategy calls for 10 MW of power to be generated renewably by 2021. The city also plans to install new electricity cables and build a small substation to help meet energy demand.

BUILDING TRAINS FOR THE NATION The manufacture of trains should go full steam ahead from the end of next year at the Gibela factory at Dunnottar in Ekurhuleni. Gibela – a partnership between international Alstom and local uBumbano Rail and New Africa Rail – was launched in 2014 to manufacture 600 state-of-the-art X’Trapolis Mega commuter trains over 10 years for Metrorail and supply technical services and spares for the trains over their first 19 years in service. The 85 ha Gibela site currently under construction will house a suite of 11 buildings covering 31 500 m2, a 4 000 m2 training centre, a 1.2 km test track for the new trains, and a dam to responsibly manage a pre-existing wetland. The Gibela initiative aims to build 62 trains a year, with the first scheduled to roll off the production line at the end of 2018.

IMIESA October 2017

Frikkie Oosthuizen, Executive: Contractual Affairs and Support Services, SAFCEC

IMIESA speaks to Frikkie Oosthuizen, Executive: Contractual Affairs and Support Services at SAFCEC, about key developments affecting the civil engineering industry.

rom its inception in 1939, the South African Forum of Civil Engineering Contractors (SAFCEC) has represented its member companies on key issues affecting the industry, ensuring fair practice and an enabling environment for a constantly evolving construction industry. More than 50% of SAFCEC’s members are emerging companies, supported by long-established medium and large enterprises. At the highest level, SAFCEC currently delivers for it members in two key areas, namely at the Bargaining Council and at the Construction Charter Council, particularly in terms of the proposed BBBEE scorecard. “Our key role in the formulation of the Construction Charter has been the springboard for many initiatives that are designed to ensure the sector transforms

IMIESA October 2017

Ensuring proactive representation and grows in a sustainable manner,” explains Oosthuizen. SAFCEC’s lobbying role with organs of state at the ministerial, provincial and local government level remains a critical one. For example, SAFCEC is currently participating, along with the Construction Industry Development Board (CIDB), in finalising the best practices for the Community Participation Goals. Preparations are also under way for the next round of negotiations at the Bargaining Council. These will start in the new year, ahead of the expiry of the current agreement in August 2018. SAFCEC, MBSA and the BBC-BE are also working towards the establishment of a Health and Safety Trust. The intention is to introduce additional self-monitoring and control measures that will assist the Department of Labour in overcoming skills shortages in this area. Additionally, SAFCEC is working with other industry organisations to establish best practice standards for prompt payment and construction adjudication provisions. As Oosthuizen points out, prompt payment is not purely a governmental issue; contractors also need to pay their subcontractors on time. “In the UK, studies show that during the 70s, 80s and early 90s, the country’s construction industry experienced a major slowdown, largely influenced by a ‘pay when paid’ approach where contractors were only paying subcontractors if they had sufficient funds. Obviously, this had a devastating ripple

effect. The same is true in present-day South Africa, where many emerging SMMEs face substantial business risks as a result,” he explains. In the UK scenario, when delayed payment procedures were corrected, industry growth followed. “We need a similar mind shift in our South African industry so that we can reschedule the sequence of payment applications between subcontractor, contractor and employer in a way that doesn’t constrain growth. We also need to factor in the implications of the new procurement provisions,” Oosthuizen adds.

Changing contractor landscape The Preferential Procurement Policy Framework Act (No. 5 of 2000) (PPPFA), coupled with the proposed BBBEE scorecard for the construction industry, has a couple of significant implications, particularly for predominately white-owned companies. Oosthuizen points out that the challenge faced by a Level 4 company when competing with a Level 1 organisation on the 80/20 principle for contracts above R50 million will be significant to overcome going forward. Coupled to that, 30% needs to be subcontracted in terms of the PPPFA. “I believe one of the most significant shifts we need to make is to replace the term ‘subcontractor’ with ‘fellow-contractor’, the emphasis being on fostering proactive partnerships,” says Oosthuizen. “We need to develop independent, selfsufficient companies that are efficient,

INDUSTRY INSIGHT

competitive and profitable, and not dependent on main contractors for their economic survival. Currently, I work extensively with black-owned SMME contractors who need assistance in overcoming challenges with larger companies in terms of payment and contractual issues, which underscores the point.” Currently, only 3% of 9CE contractors are at BBBEE Level 1 – clearly a low figure. However, some municipalities are only specifying Level 1. “At level 4, you cover 90% of all contractors, while a high percentage of black-owned construction companies are at Level 2. So the Level 1 stipulation excludes most players. My view is that BBBEE limitations will overheat the market for specific segments and will lead to tender price increases. So organs of state need to take these factors into account,” he asserts.

Economic pinch Major economic and political events during 2017 have severely impacted the civil engineering industry, with estimated tender values down by as much as 40% for the first two quarters. Tender activity is also subdued. For example, CIDB grade 9CE tenders per quarter have dropped to as low as 10 in 2017. Similar trends are being experienced across all CIDB levels. The CIDB recently undertook a Red Tape investigation and contractors surveyed identified five main constraints: • the payment process • access to work • access to credit (which has major considerations, since construction is a cash-flow-driven business)

• issues surrounding BBBEE • corruption. “As SAFCEC, we need to help members gain a fuller understanding of the underlying issues and take a delicate approach in seeking the right answers. There are tailor-made solutions to be found at the small, medium and large contractor level,” says Oosthuizen.

Price indices intervention Statistics South Africa (Stats SA) recently announced its decision to discontinue publishing the indices required for contract price adjustment escalation calculations. The reason, it says, is that the collection and management of the indices no longer complies with Stats SA’s quality requirements. At the same time, however, it does emphasise their importance for the industry. Currently, a working committee is undertaking the development of new civil engineering/construction-specific indices. There are a number of participants involved, including Sanral, SAFCEC and other organs of state. The goal is to find a resolution before the end of 2017, which is when Stats SA’s current set of indices expire. If not reapplied, Oosthuizen says the implications are potentially detrimental for business in general. “It boils down to the ability to accurately estimate price risk escalation for key commodities that include fuel, bitumen, steel and cement. South Africa has traditionally been exposed to price extremes in these and other key material groups. Therefore, maintaining this statistical forecasting mechanism is important.”

SIPDM The National Standard for Infrastructure Procurement and Delivery Management (SIPDM) has been welcomed by SAFCEC as it will improve information flow to contractors. The most prominent aspect is the differentiation between the different supply chain and procurement routes that organs of state can choose – i.e. general goods, general services, and products developed or altered on-site. Government wants to use the SIPDM to ensure value for money in infrastructure development. The fact that only registered built environment professionals can administer construction contracts has many advantages for public sector owners and clients. “No longer will construction language be lost in translation,” says Oosthuizen. The SIPDM’s philosophy emphasises the development of a relational model where contractors are appointed for terms rather than contracts. This moves away from the traditional ‘once-off project, once-off development of relationships’ approach, which is not sustainable for the future of South African construction. “That will foster the fellow-contractor approach, breaking down the barriers inhibiting industry growth. At SAFCEC, we will build value together,” concludes Oosthuizen.

www.safcec.org.za

IMIESA October 2017

CEMENT & CONCRETE

PPC turns IMIESA talks to Siobhan McCarthy, group manager: Corporate Affairs at PPC Africa, about the company’s business philosophy, footprint and commitment to sustainability. What is PPC’s unique selling proposition? SM PPC is a proudly South African company – a trusted brand that has been around for 125 years. We spend an average of 230 000 hours annually on testing and quality control to ensure that we provide premium products, on time, all the time. Achieving our 125-year milestone in 2017 was made possible by partnering with our customers. In doing so, we’ve been challenged to develop our products, find new holistic solutions, invest in a world-class laboratory that offers cutting-edge technical support, and build and grow generations of team

IMIESA October 2017

members committed to driving PPC’s vision for success. Our national footprint enables us to provide our products in bag or bulk anywhere across the country.

Does PPC plan to expand its operational footprint? PPC is a leading supplier of cement and related products in Southern Africa, with nine cement factories. These are situated in South Africa, Botswana, Zimbabwe and Rwanda. In 2016, PPC commissioned its fifth milling depot, located in Harare, Zimbabwe, bringing the company’s capacity to around nine million tonnes

of cement products annually. As part of its strategy and long-term vision, PPC has since further expanded its operations in the rest of Africa, through the recent commissioning of integrated cement plants in the DRC and Ethiopia. This has now increased PPC’s capacity to over 11 million tonnes of cement products per year. PPC’s Materials business – comprising Pronto readymix (including Ulula Ash) and the recently acquired 3Q Mahuma Concrete – forms part of the company’s channel management strategy for Southern Africa. As a result of these acquisitions, PPC’s footprint has grown to include 26 readymix batching plants across South Africa and Mozambique, with the capacity to produce half a million tonnes of fly ash. PPC’s Materials business also produces aggregates, with its Mooiplaas quarry

CEMENT & CONCRETE

in Gauteng having the largest aggregate production capacity in South Africa. PPC Lime, one of the largest lime producers in the southern hemisphere, produces metallurgical-grade lime, burnt dolomite and limestone.

PPC has developed a builder’s app. What are the key benefits? This innovative app allows consumers to accurately calculate product quantities and costs involved before starting a new project. This is a must-have for construction planning purposes: incorrect mixing calculations are an expensive waste of product and time. The app’s Project Centre functionality also helps contractors manage multiple projects, suppliers, contacts and tasks. You can save calculations, store project photos, and create/assign tasks to suppliers and contacts. You can also email a PDF of all project details to any email address. The app’s Knowledge Centre offers a comprehensive information glossary, answers to cement-related FAQs, DIY tips and video tutorials.

How are PPC’s procurement strategies helping to promote transformation? In the last financial year, PPC spent R4.8 billion with BBBEE suppliers in South Africa, representing over 85% of its total procurement. We focus on growing SMME enterprises in the construction industry.

What’s the motivation behind the Cement & Concrete Cube? Our commitment goes well beyond the sale and supply of cementitious materials: the Cement & Concrete Cube (C3) is a prime example. C3 is a unique information-sharing platform, providing a go-to resource for all things cement and

concrete. This forum is PPC’s commitment to educating and informing cement users on the latest developments and techniques in the building, construction, project management and architectural sectors. C3 members have access to the latest research, technical information, community discussion forums, as well as industry experts and thought leaders. This collaborative platform also enables information-sharing; by joining, group members can access the latest in international research and best practice in the cement and concrete industry.

PPC recently launched a mobile science lab programme. Could you provide more details about this? The mobile lab – an ideal alternative for underprivileged schools – incorporates both the technology and science equipment needed to conduct experiments covered in the high school science syllabus. The lab is a self-sufficient, portable structure on wheels. To date, we have donated 27 mobile labs to schools across the country, touching the lives of over 10 000 learners. Addressing educational needs remains one of Africa’s largest challenges. Access to education is characterised as a roadmap out of poverty, as it opens doors to better economic prospects. PPC sees investing in education as a need rather than a priority, as it is crucially linked to the development of future skills for the company and the resilience of the communities in which the company operates. In September, we handed over a mobile science lab, an IT lab, and an innovative container project to the King Senzangakhona High School in uLundi, KwaZulu-Natal.

Easy and cost-effective access to resources and materials is critical for the sustainable growth of any town or city. However, transportation is often one of the many challenges that rural communities face when it comes to accessing much-needed resources and materials. Having identified this as one of the problems faced by its rural customers, PPC donated the container to the King Senzangakhona High School. Communities in nearby villages can now purchase cement directly from the school, which also takes the profits.

Is PPC making a sustainable difference? PPC continues to make a sustainable contribution to the communities of the six countries in which we operate. Through our technical skills academies in South Africa and the DRC, we provide training to current and potential employees of PPC. Through our CSI programme, we run a series of initiatives within Botswana, the DRC, Rwanda, South Africa and Zimbabwe extending across the education, health and entrepreneurship sectors. Furthermore, PPC is dedicated to reducing the impact of its operations on the environment through water management programmes, the use of alternative fuels, and effective waste management. We continue to invest in the upgrading of our plants, in line with world-class standards, to minimise our impact on the environment.

www.ppc.co.za

IMIESA October 2017

For 125 years, PPC has gone above and beyond to deliver consistent quality. Every year we dedicate countless hours to testing and quality control, to ensure that our products always have the consistency and quality youâ&#x20AC;&#x2122;ve come to expect. Choose proven quality in every build. Choose PPC. Want to know more? Visit www.ppc.co.za

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IMIESA October 2017

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PARTNERS IN INFRASTRUCTURE

READ INSIDE Cracking the code Gabions and geotextiles work together

20 22

An industr y in focus

Building fire resistant structures

Successful EME trials

IMIESA October 2017

PARTNERS IN INFRASTRUCTURE

Cracking

the code

In cracking down on wastage and inefficiencies, the Gauteng Department of Infrastructure Development has developed a programme management tool with 162 compulsory steps that need to be followed for every project roll-out. THE PROJECT READINESS MATRIX

Jacob Mamabolo, MEC, Gauteng Department of Infrastructure Development

ooking back on the past 18 months of his current term of office, Gauteng Department of Infrastructure Development (GDID) MEC Jacob Mamabolo says that the key focus of his tenure has been to transform the department into an efficient project delivery machine and move away from a history of “crisis management and chasing shadows”. The GDID’s new Project Readiness Matrix (PRM) is a proprietary tool developed in-house to “monitor the 162 steps that a project takes from conception to completion”, and

IMIESA October 2017

• Promotes long-term collaborative planning • Ensures that risk is proactively managed • Ensures realistic expectations among stakeholders • Ensures delivery reliability and predictability • Ensures transparency • Ensures accountability • Minimises delays • Ensures value for money • Enables adherence and compliance to the IDMS as required by the Standard for Infrastructure Procurement and Delivery (SIPDM)

is a positive step in that direction. “With the ongoing migration of people into this province, it is absolutely imperative that we maximise the impact of infrastructure projects, and I believe we have now cracked the code on how to do this,” he explains. Mamabolo says the PRM is a tool of transparency, compliance and accountability. “It ensures no project goes into development until all the necessary steps have been taken to ensure the project is actually ready for implementation – and

then tracking every step in the process to completion thereafter.” The GDID currently has 152 projects, valued at R2.4 billion, in various stages of construction. All these have been subjected to rigorous due diligence analyses. That includes approved land use and adequate budget provision. Using the PRM in conjunction with Lutsinga Infrastructure House, the department’s state-of-the-ar t electronic monitoring ner ve centre, the GDID can now monitor each project’s implementation in near real time. This will prevent cost overruns and ensure quality construction, and ties in with the allied goals of National Treasur y’s Infrastructure Deliver y Management System. Comments Bethuel Netshiswinzhe, head of the GDID: “There have been very significant changes in the way we operate

and how we approach our mandate. We now speak of the ‘new GDID’. We have clearly defined business and delivery models, robust project management and clarity of purpose.” With the PRM in place, taking action against poorly performing suppliers and contractors is a top priority. “This is what stands between us and service delivery. Moving forward, we will only accept work signed off by registered professional service providers,” he stresses.

of Johannesburg. A similar initiative is planned for the City of Tshwane in 2018. The GDID is also in discussion with private sector investors regarding the viability of developing mixed-use mega projects, based on the precinct model, with a specific focus on revitalising township economies. “Thanks to the PRM, we now have the systems in place to achieve this and have identified a potential site in Soweto for our first project. Land planning is currently in progress,” he explains.

Portfolio management

Labour-intensive component

The GDID was formed in 2009 and now The Expanded Public Works Programme manages a property portfolio of approx(EPWP) is another focus area for the GDID imately R32 billion. The mandate is far in addressing pover ty alleviation and ranging and addresses historical backlogs unemployment within Gauteng and supports in areas like schools, sports facilities its back-to-school campaign. and hospitals. “In the future, we’d However, the GDID like to ensure that 50% The GDID also has a broader role of our projects include currently has to play in promoting capan EPWP component,” 152 projects, valued at adds ital formation via the Mamabolo. spatial development of “The department will R2.4 billion, in various vacant state land. The stages of construction.” also focus on skills depar tment is also development to ensure investigating the future use of a number sustainable employment and address of currently unused government buildings. the excessively high dropout rates in This recycling of assets will determine our schools. whether these buildings can be converted “We have been in consultation with the or, alternatively, should be sold off on the seven TVET colleges in Gauteng. We want open market. to enter into a partnership where the TVETs An example of a reuse initiative is the become the training centres for the skills Kopanong precinct, a R6 billion por trevolution we need to uplift communities. folio of government office buildings in We believe that the EPWP initiative can Johannesburg’s inner city. The GDID plans act as a catalyst for positive change, to convert some of these buildings into alongside the GDID’s vision for establishing student accommodation, working with the meaningful socio-economic transformation Department of Higher Education and terthrough building and maintenance projects,” tiary institutions that include the University he concludes.

IMIESA October 2017

PARTNERS IN INFRASTRUCTURE

Gabions and geotextiles work together Where there are soft soil conditions, geotextiles are an essential component of gabion installations; but with clay, the opposite is true. Then there’s the geotextile overlap. By Alastair Currie

abion walls constructed as freestanding structures are intended to serve as architectural features and not retaining systems. However, these walls still need a central steel support system and must be founded on concrete. “It illustrates the fact that gabions have a very diverse range of architectural and construction applications, and that each installation needs to be specifically designed and built to serve its intended purpose,” says Louis Cheyne, managing director of Gabion Baskets. If built well, gabion installations will last for decades. A more recent example that ticks all the right boxes is an approximately 80 m long contoured gabion retaining wall commissioned by the City of Cape Town. What makes this installation distinctive is that tubular gabions were installed, which require an extra level of proficiency from both the designer and contractor. This installation was erected in Cape Town’s northern suburb of Tygerberg. The 4 m high retaining wall is founded on a gabion mattress foundation. The wall runs alongside a river channel section that borders a multistorey building on

IMIESA October 2017

RIGHT Grey PVCcoated mesh was specified for this project. In addition to its enhanced aesthetic appeal (blending in well with the blue granite rock), PVC provides further protection to the underlying Galfan-treated doubletwisted hexagonal mesh. Galfan is a zinc-aluminium alloy coating that offers exceptional corrosion resistance

the one side and a paved road on the other. The primary purpose of the wall is to protect the building’s exposed pile foundations against erosion, while ensuring embankment stabilisation in case of flood events. Says Cheyne, “The tubular gabion effect has a strong aesthetic appeal since it reduces visible joins, which can sometimes look untidy, depending on the proficiency of the installation technique.”

Rounding the curves Essentially, tubular gabions are meshed frontfaced, elongated and diaphragm-segmented

ABOVE LEFT This contoured mass gravity retaining wall was constructed using tubular gabions for maximum design flexibility ABOVE The base width of the wall is approximately 2 m wide, with each steppedback section around 1.5 m high, with the exception of the final 1 m gabion tier

structures that have the flexibility to round curves in a way that cannot be matched by conventional square baskets. Gabion mesh rolls come in 50 m lengths. The mesh is then traditionally cut and shaped into 1 m3 rock-filled baskets. This traditional, modular approach differs when it comes to tubular gabions, where there’s extensive design flexibility to space the diaphragm panel intervals, especially when going around a corner. (The diaphragms provide structural stability.) In the Tygerberg example, the intervals were at 800 mm to create a more attractive front

PARTNERS IN INFRASTRUCTURE

ABOVE Examples of gabions used in an architectural application: a free-standing wall, complemented by gabionthemed pot plants MIDDLE A gabion and mattress system protects this pedestrian river bridge RIGHT Complex river training works, including weir systems built at the Glendower golf course in Johannesburg

face. Another advantage of gabions is that the width can also be varied according to the design, which is advantageous for the top baskets in particular. The speed of construction is also improved. For traditional square gabions, the rate is around one man per 1 m3 per day. However, with tubular gabions, the work rate can be up to 3 m3 per day because there’s less joining required.

“Those who think building gabions simply requires assembling a basket and throwing rocks into it could be in for an unhappy experience down the track,” adds Cheyne. “Gabions are engineered structures, which, if correctly packed and braced, are ver y stable and amazingly strong. For example, when designed as crash barriers or seawalls, they’ve proved to withstand tremendous forces. “But perhaps the best benefit for Africa is that gabion structures are affordable to construct, can use in situ materials, and are labour-intensive,” he concludes.

Permeability and soil retention In most mass-gravity gabion wall installations, non-woven needlepunched geotextiles are an integral part of the design and are placed behind and below the structure to hold the soil back. Gabions are intended to be porous, free-draining structures, essentially composed of 65% rock and 35% voids. For this reason, and in most instances, a soil-stabilising mechanism (a geotextile) needs to be present to allow the water to pass through, while preventing the passage of fine sands or silts. Progressive loss of soil materials will eventually undermine the structure. An exception is where there are cohesive soils present, like clayey materials. Cheyne says the recommendation then is not to use geotextiles (especially non-woven varieties), as these typically become clogged. The subsequent hydrostatic pressure build-up can lead to catastrophic wall failures. “The critical requirement for gabion retaining walls is to achieve the correct geotextile fit,” says Cheyne. The two main approaches for joining geotextiles are the overlap technique and the blanket-stitch method. In the first case, the overlap should be between 140 mm and 300 mm. Geotextile thickness is also important. A minimum 200 g/m2 is recommended behind the wall, as well as below the mattresses. For angular rockfills though – for example, where backfill materials are sourced from blasted rock – the geotextile needs to be thicker to minimise the risk of puncturing.

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

Erosion control blankets Gab - Bloc / Sandbag Gabion rock

Our Services Site assistance & advice Gabion structure design Price estimates

Technical support Practical site training Experienced installers

PARTNERS IN INFRASTRUCTURE

An industry in focus

The Concrete Conference brought together icons of industry to reflect on South Africa’s construction environment and the concrete industry. By Danielle Petterson

ith the construction industry suffering the effects of a poorly per forming economy and declining business confidence, trends suggest that the sector will remain under pressure for the foreseeable future. The effects of price cutting on quality are also of concern, while new legislation – such as the PPFA Regulations 2017 of the Preferential Procurement Policy Framework Act (No. 5 of 2000; PPPFA) further complicates things for the sector. “The state of our industry is not very positive at the moment; you have to look very carefully to find the positives. But it is not all that bad,” Frikkie Oosthuizen, executive: Contractual Affairs & Support

IMIESA October 2017

Services, SAFCEC, told delegates at the conference. One of these positives, according to Wally Mayne, manager: Contractual Affairs, Consulting Engineers South Africa (CESA), is National Treasury’s Standard for Infrastructure Procurement and Delivery Management (SIPDM), which requires that organs of state differentiate between the supply chains for infrastructure and those for general goods and services, in order to realise value for money and good-quality service delivery. The PPPFA is also a welcome introduction because it is aimed at enforcing transformation. However, it could put further pressures on an already struggling industry because it allows clients to

specify BBBEE levels in their tenders where there may be a limited number of firms with the requisite experience and expertise who qualify for the work. Mayne argued that the industry should be exploring opportunities to drive transformation as provided for in Chapter 13, Section 217 of the Constitution, subsections 2 and 3, which requires that all its tenets, namely fairness, equitable, transparent, competitive and cost effectiveness be upheld. It should therefore be a concern if appointments are made with little or no evidence of the requisite expertise such that the appointed company is unable to deliver the necessary professional service, leaving the public sector entity with the challenge of finding another suitable firm to complete the work. Such actions would be unconstitutional and contrary to the pursuit of sustainable transformation. “The onus to implement this responsibly is on the clients,” cautioned Mayne. “They need to balance BBBEE requirements with

PARTNERS IN INFRASTRUCTURE

If we don’t put efficiencies back into our industry, organisations, including government departments, will eventually be forced to call on the international market to build big projects in South Africa.”

As a South African civil engineer, I advocate African engineering solutions to African engineering problems. But we need to compete.” Manglin Pillay, CEO, Saice

Frikkie Oosthuizen,

If it is not possible to complete the project properly at the suggested price, you should not be awarded the contract. We need to be more critical in how we analyse the tender and to whom we give it.”

executive: Contractual Affairs &

Wally Mayne, manager:

Support Services, SAFCEC

Contractual Affairs, CESA

capacity and they need to go for value for money as far as they can to avoid wastage. If SIPDM is not implemented responsibly, you are going to get more instances of fronting and ‘tenderpreneurs’ who win bids and simply subcontract the work.” The cidb is currently working on best practices to guide organs of state on which projects BBBEE levels should be limited. According to Oosthuizen, only 3% of cidb Grade 9 contractors are registered at BBBEE Level 1. The result of the best practice guide will, therefore, likely be such that the lower the cidb level, the higher the BBBEE requirement. Nonetheless, Oosthuizen predicted that white ownership in construction companies will cease to exist. “Exclusively white-owned companies will not survive as they will not be able to compete on the 80:20 principle for projects above R50 million.” However, a level of white ownership will always be welcomed. To overcome these BEE challenges, CESA is encouraging member firms to consider more joint ventures where possible, and

has a list of member firms which may be able to form strategic alliances based on common strategic objectives.

A measure for quality In a country where accepting the lowest tender bid has become the norm, the new SIPDM should have a positive role to play in bringing quality back into construction projects. “If it is not possible to complete the project properly at the suggested price, you should not be awarded the contract. We need to be more critical in how we analyse the tender and to whom we give it, to ensure that there is no scope creep,” said Mayne. “If we revert to a system that allows you to score points for quality, you will get a much more balanced view. However, quality has unfortunately become a minimum hurdle in the tendering process.” Furthermore, companies still undergoing transformation within their management structures can only compete on price and not preference. The result is firms desperate for work slashing their prices,

and ultimately a drop in quality, causing the country to suffer as a result. To address this, organs of state need officials who understand what they are buying and the costing involved. Mayne believes the SIPDM will have a positive role to play in this space because it acknowledges that the lowest price is not always the best option. Furthermore, the standard is working to shift organs of state to Framework Agreement contracting, allowing companies to work for them on an ‘as and when required’ basis rather than once off. Manglin Pillay, CEO, Saice, believes industry associations have a role to play in independently pre-auditing submitted tenders to assist organs of state in determining whether a project can be executed within the suggested budget and skills level. On the positive side, Mayne reported that there has been a slight change in thinking, where more clients are insisting on bidders having CESA membership. This means clients don’t have to extensively vet

IMIESA October 2017

PARTNERS IN INFRASTRUCTURE

potential consultants because CESA has stringent membership eligibility criteria in place for its members, eliminating potential flyby-nights and tenderpreneurs.

Building efficiencies In trying to overcome unemployment, construction is seen as a vehicle for job creation; however, Oosthuizen argued that South Africa is developing a very inefficient construction industry as a result – something many international contractors do not tolerate. “If we don’t put efficiencies back into our industry, organisations, including government departments, will eventually be forced to call on the international market to build big projects in South Africa,”

said Oosthuizen. “The unintended consequences of developing so many small contractors in order to overcome unemployment and poverty may lead to greater inefficiencies driving up prices.” Things like legislation, labour relations, conditions of employment, employer attitudes and the cost of labour all restrict the way in which local firms deliver services and, ultimately, their efficiency levels, Pillay pointed out. While the validity of these is arguable, given the country’s history, they must be acknowledged. “As a South African civil engineer, I advocate African engineering solutions to African engineering problems. But we need to compete,” he adds. Adopting a more creative approach, such as off-site manufacturing, may provide a solution to overcoming some of these challenges and driving the economy forward. Oosthuizen used the example of hotels in the US, where whole hotel units are built off-site and later pieced together. This could be replicated in South Africa with structures like classrooms. “That is the kind of thinking that we should be driving to build efficiencies in the industry and overcome challenges.” In line with this, Pillay argued for more research and development (R&D), particularly in the cement and concrete sector. Cement production is one of the largest sectors in manufacturing, but the sector invests minimal amounts in R&D. In 2015, the world produced 4.6 billion tonnes of cement – the highest production levels in the manufacturing sector – but the industry invests, at most, 0.2% of turnover in R&D. “We need to be investing in R&D and skills,” said Pillay, who believes tough economic times are the best time to invest in innovative solutions. This kind of development may be of particular importance, given Oosthuizen’s future predictions for the sector. “I believe that your landscape in terms of your client-base will, in the foreseeable future, be completely different from what you are used to. You’re not going to have mega clients; I think they will disappear from our landscape to a large extent. Your client base is probably going to be dominated by a lot of medium-sized companies. So, for you to make profits, you will have to be a lot more efficient because you will have to deal with a lot more customers. That can, in itself, provide growth for the cement and concrete industry because you will need more resources.” But it is not all doom and gloom, according to Manglin. “Our industry is facing some seriously difficult times. But the kind of work our industry is doing, despite the stresses of the times, shows you can really be proud of being in the civil engineering and construction industry.”

IMIESA October 2017

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PARTNERS IN INFRASTRUCTURE

Building fire resistant structures More than 1 000 homes were destroyed by the fires that raged through Knysna in June this year. Brick masonr y has traditionally been used to provide superior fire resistance and safety.

emperatures of up to 1 000Â°C are reached in severe blazes, and the fires in Knysna were exacerbated by severe winddriven conditions, resulting in a travel rate of approximately 60 km/h or 1 km/minute. According to Chris Dickinson, technical consultant to the Clay Brick Association, solid clay brick masonry houses are at the lowest risk in terms of structural fire damage in these conditions. Clay bricks, being a fired product, are naturally highly resistant to fire. The eventual failure of a brick wall is likely to be caused by cracking or deformation due to thermal expansion, or insulation failure, rather than damage to the material itself. Small corrugated iron and wooden dwellings are at the highest risk of structural fire damage, followed by timber-frame houses and dwellings constructed of 140 mm hollow concrete blocks, while 220 mm solid clay brick masonry houses offer the lowest risk. The fire resistance rating of 220 mm external clay brick masonry is four hours. That means that

if a fire transit time of 10 to 15 minutes were to occur, with a fire travelling at 1 km/minute, the inherent high thermal resistance of clay brick and mortar masonry would significantly retard the flow of heat into the body of both bricks and mortar, with a reasonable probability of reducing the rate of temperature build-up to below that at which damage may occur. Most clay bricks are fired to at least 1 000Â°C, and even if higher external temperatures were to occur, the clay bricks

would not lose their integrity, says Dickinson. Consequently, it is unlikely that significant reductions in the structural strength of the clay brick masonry would have occurred. The reduced rate of heat penetration would also likely have prevented significant reductions in the strength of steel ties or brick force. Where there are visible signs of masonry cracking, wracking of the brick work or separation between adjoining wall elevations, however, the services of a structural engineer should be sought.

TABLE 1 Fire resistance and acoustic insulation values for clay brick walls

IMIESA October 2017

in partnership with

Enabling safer, faster, more efficient rural access in South Africa Permanent and temporary steel bridging solutions for vehicle and pedestrian applications

 Modular to enable rapid installation and

minimise on-site works

 Cost-effective vs traditional concrete to ensure

investment payback

 Pre-engineered to shorten project delivery

 Simple to transport and store for future use

 Full-scale tested to ensure product safety and durability

 Sustainable to protect the environment

 Hot-dip galvanised to minimise through-life maintenance

 Easily configurable for heavy vehicle access

To see how we can enhance your project, please contact: Tel: +27 (0) 12 329 4116 Fax: +27 (0) 12 329 4120 Email: sales@ecmtech.co.za 18 Eighteenth Street, Hazelwood, Pretoria, Gauteng, South Africa www.ecmtech.co.za www.mabey.com

Providing fast, safe and efficient access for communities in South Africa One of the biggest constraints facing people in rural communities is a lack of connectivity. While improved digital communications have improved this, many people still find themselves isolated by an underdeveloped physical infrastructure. A lack of access to major road networks not only impacts people’s ability to maintain jobs, but means local children suffer a choice they should not need to face: risk all trying to cross fast-flowing rivers or miss school. This lack of access also impacts patients who may be unable to access the healthcare they need. Bridging the gap between people and their local communities is imperative. We have been working closely with local communities in Africa for over 50 years, and have seen first-hand the societal and economic benefits of developing critical infrastructure. A new bridge brings new employment and market opportunities, not to mention new cultural benefits. At this year’s IMESA conference, we’re celebrating how Mabey works with local people, businesses and communities. Not only do we provide fast, safe and efficient bridging solutions, but we train local people with the skills they need to continue bridging the connectivity gap in the future.

A history in innovation Our work in South Africa began in the 1970s and, since then, every project we have worked on in the region has seen enhancements in the design and installation methods used. You only have to look at today’s easy-toinstall Mabey Compact 200™ (C200™) bridge system to see how quickly things have evolved. Key to this evolution are the materials used. In a country which relies heavily on concrete, the short-span nature of most of South Africa’s rural bridges means that they can be quickly damaged by environmental factors and become impassable. With a life-span extending to well over 100 years, a pre-fabricated steel bridge can be built in less than a quarter of the time. A lightweight steel bridge is also more sustainable; it only needs a small construction site and nearly 100% of structural steel is recyclable. Traditionally, concrete has been seen as the permanent material in South Africa, however, we’re seeing a change in this mindset across the continent, with steel being recognised as a superior material.

Empowering local communities Perhaps the most important aspect of our work in South Africa is the training and employment of local communities. Where local people are employed on Mabey bridging projects, many technical and creative skills are transferred and are transferable to other disciplines.

Above left: Bengu, South Africa

Above right: Thabane, South Africa

Mabey Bridging Solutions • Modular pre-engineered design with standard interchangeable connections • Suitable for both rural and main highway applications • Clear spans of up to 100m plus multi-span configurations available • Single, 2 and 3 lane carriageway formats • Full highway load-carrying capability • Full training and site support services • Optional outside or inside walkways for safe pedestrian use • Various deck options available • Choice of concrete abutments constructed locally, or pre-fabricated modular steel abutments delivered to site

Take the construction of the Tsomo Bridge in the Eastern Cape of South Africa. After this initial development, the local installation team in the area used their knowledge and expertise to build an additional bridge in Bengu safely and efficiently in just six days. These programmes empower the local community to take a more active role in the governance of their region and their livelihoods.

IMESA 2017 We’re extremely proud of our work in South Africa. We have reduced the cost of rural bridges – so it’s possible for a higher number to be supplied and maintained – and we have reduced construction times so the benefits can be felt more quickly. To celebrate this ongoing mission to develop critical infrastructure and connect rural communities across the region, we will be working with our South African partners, ECM Technologies, to demonstrate two exciting innovations at this year’s IMESA event. These include a Virtual Reality (VR) system that will allow attendees to virtually explore our bridges in situ. We will also display our bridge configurator, which demonstrates how customers can adapt bridges to suit their own specifications and virtually explore the site from a 360-degree perspective. This is the first time we have demonstrated these capabilities internationally, and these innovative solutions will no doubt lead to faster and more efficient modes of design and installation in the future. Visit Mabey and ECM at Stand 63-64 at IMESA to find out more. Darren Keep, Regional Sales Manager, Mabey

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PARTNERS IN INFRASTRUCTURE

Sabita listing Title Initials

Last Name

Company

Postal Address

City

Pelser

ACTOPHAMBILI ROADS (PTY) LTD

PO Box 16661

Atlasville

Postal Code 1465

Agenbag

ADVANCED POLYMERS (PTY) LTD

PO Box 742

Gallo Manor

2052

JJS

Weidemann AECOM SA (PTY) LTD

PO Box 3173

Pretoria

0001

Bonser

AFRISAM SA (PTY) LTD

PO Box 6367

Weltevreden Park

1715

Broom

AJ BROOM ROAD PRODUCTS CC

PO Box 16421

Dowerglen

1612

Pegge

AMANDLAGCF CONSTRUCTION CC

PO Box 6064

Welgemoed

7534

Lehman

AMMANN CONSTRUCTION MACHINERY SA

Suite 253, Private Bag X43

Rynfield Benoni

1500

Browne

ANTON PAAR SOUTHERN AFRICA

PO box 50471

Randjiesfontein

1683

JPJ

Webb

AQUA TRANSPORT & PLANT HIRE (PTY) LTD

Private Bag X11

Ashwood

3605

Grindley

ASTEC TECHNOLOGY (PTY) LTD

PO Box 140

Rothdene

1964

van der Walt AURECON

PO Box 1347

Cape Town

8000

Nelson

BITUGUARD SA

Cambridge Street 32

Bethlehem

9701

Botha

BITUMEN SUPPLIES & SERVICES (PTY) LTD

PO Box 1028

Sunninghill

2157

Smith

BITUMEN WORLD (PVT) LTD

PO Box AY 20

van Niekerk

BSM LABORATORIES (PTY) LTD

PO Box 15318

Amby, Harare, Zimbabwe Westmead

3608

Greyling

BVI CONSULTING ENG. WC (PTY) LTD

PO Box, 86

Century City

7446

Neal

CAPE PENINSULA UNIV OF TECHNOLOGY

ABC Building, 1st Floor, Symphony Way Bellville

7530

Ballantyne

CIM CHEMICALS (PTY) LTD

Postnet Suite 479 P/Bag X29

Gallo Manor

2052

Monnet

COLAS SOUTHERN AFRICA

20 Georgian Cres East Fulham Hse

Bryanston

2192

Wise

CRUZE (PTY) LTD

PO Box 742

Gallo Manor

2052

King

DICK KING LAB SUPPLIES (PTY) LTD

PO Box 82138

Southdale

2135

WAG

Venter

DMV HARRISMITH (PTY) LTD

PO Box 912

Harrismith

9880

Ntombela

DUPONT DE NEMOURS INT SA

PO Box 3332

Halfway House

1635

McKune

DURBAN UNIVERSITY OF TECHNOLOGY

PO Box 101112

Pietermaritzburg

3209

La Grange

EFG ENGINEERS (PTY) LTD

PO Box 3800

Durbanville

7551

Williams

EMERGECO TRADING (PTY) LTD

PO Box 635

uMhlanga Rocks

4320

Brown

GAVIN BROWN & ASSOCIATES

24 Botanic Grove

Berea

4001

Moffett

GIBB (PTY) LTD

PO Box 3965

Cape Town

8000

Derbyshire

PO Box 3893

Cape Town

8000

Hattingh

GLADAFRICA CONSULTING ENGINEERS (PTY) LTD GMH /TSWELELO CONSULTING ENGINEERS

PO Box 2201

Randburg

2125

Henning

GT DESIGNS & TECHNOLOGIES

137 Jan Hofmeyr Road

Westville

3630

Bradley

HATCH GOBA (PTY) LTD

PO Box 25401

Gateway Durban

4321

Laatz

HHO AFRICA

PO Box 6503

Roggebaai

8012

Clunnie

IMESA

PO Box 2190

Westville

3630

Continued on page 34

IMIESA October 2017

PARTNERS IN INFRASTRUCTURE

Sabita listing Title Initials

Last Name

Company

Postal Address

City

Postal Code

Bechan

IMPACT CHEMICALS (PTY) LTD

PO Box 30792

Kyalami

1684

Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr

S E J PA GR GM AD M MC MA N SRM W B

Tinarwo Mukandila Van Niekerk Olivier Tyndall James Wills Fynn Barnard Van Reenen Berning Adande Reusch Burger

PO Box 17219 PO Box 22 PO Box 28041 PO Box 1109 PO Box 3132 PO Box 116 PO Box 201636 Private Bag X26 PO Box 32798 PO Box 739 24 Tees Lodge, 107 Hope Street 214 9th Avenue PO Box 779 PO Box 40158

Norkem Park Menlyn Malvern Sunninghill Cape Town Pinetown Durban North Gallo Manor Totiusdal White River Cape Town Morningside, Durban Gillits Faerie Glen

1631 0063 4055 2157 8000 3600 4016 2052 0135 1240 8000 4001 3603 0043

Mr Mr Mr Mr Mr Mr Mr

O JR BC B DS F M

Peringuey Uys Greyling Theron Judd Samaai Manicum

INSTANT TAR SURFACES IX ENGINEERS (PTY) LTD JAVSEAL (PTY) LTD JEFFARES AND GREEN (PTY) LTD KANTEY AND TEMPLER (PTY) LTD KAYMAC (PTY) LTD T/A KAYTECH KRATON POLYMERS NEDERLAND BV LAFARGE INDUSTRIES SA (PTY) LTD LEO CONSULTING LETABA LAB (PTY) LTD LIESEN BITUMEN (PTY) LTD MDUBANE ENERGY SERVICES (PTY) LTD MILLING TECHNIKS (PTY) LTD MMILA CIVILS & TRAFFIC SERVICES (PTY) LTD MORE ASPHALT (PTY) LTD MOTT MACDONALD AFRICA (PTY) LTD MUCH ASPHALT (PTY) LTD MURRAY AND ROBERTS INFRASTRUCTURE N3 TOLL CONCESSION (PTY) LTD NADESON CONSULTING SERVICES NAIDU CONSULTING (PTY) LTD

PO Box 2180 PO Box 7786 PO Box 49 PO Box 585 PO Box 67166 PO Box 51121 PO Box 2796

Durbanville Roggebaai Eersterivier Bedfordview Highveld Park V&A Waterfront Westway Office Park

7550 8012 7103 2008 0169 8002 3635

Continued on page 66 IMIESA October 2017

PARTNERS IN INFRASTRUCTURE

Successful EME trials An update on the shor t-term per formance of enrobé à élevé (EME) on the N1. By Imraan Amien, Bernhard Botes and Dirk Immelman*

pproximately two years have passed since the successful construction of the first EME asphalt base in the Western Cape. Located north-east of Paarl along the N1 truck crawler lane between the Huguenot Tunnel west portal and the toll plaza, the EME was constructed along a route that has become accustomed to experimental and developmental pavement structures since 2009. During 2015, Royal HaskoningDHV (consultant) and Martin and East (contractor) successfully constructed a 120 mm EME asphalt base, as well as 70 mm and 100 mm ultra-thin continuously reinforced concrete (UTCRC) pavements along one of the most heavily trafficked routes in South Africa.

Project location and specifications The special maintenance of the truck crawler lane on National Route 1 Section 1 comprised four different pavement design strategies, as shown in Table 1.

EME base layer A total of 3 100 t of EME was placed in 2 mm x 60 mm layer lifts to yield a final base layer thickness of 120 mm. Due to the uncertainty surrounding the product at the time, the contractor sensibly opted to place the EME at a conservative rate of 240 t per day. However, despite these precautionary measures, the production rates of the EME remained far superior to all other pavement strategies during the project. The general industry consensus around EME at the time of the project was that a very

ABOVE EME along the crawler lane (outer LHS lane only) BELOW Isolated bleeding spots on the EME

small compaction window existed in which the desired compaction densities could be achieved before the asphalt mat “locked up” due to the stiffness of the 10/20 binder. This initial fear was compounded further by the relatively long haul distances between the asphalt plant and the site. In order to allow for sufficient time to compact the mix before this supposed phenomenon occurred, it was decided to mix the asphalt at temperatures in excess of 180°C during the construction of the trial section; despite industry best practices calling for asphalt to be mixed at temperatures between 160°C and 180°C (Sabita, 2013). Unfortunately, as a result of these elevated mix temperatures, the mat behaved tenderly during compaction, even after cooling. This presented difficulty in compacting the mix, ironically, in an opposite fashion to what was initially expected from the EME’s supposed locking-up potential. Subsequently, it was decided to reduce the mixing temperature to within industry norms (170°C) for the remainder of the project. Thereafter, the mix began to behave like a typical asphalt

mix, as the required compaction densities were easily achieved and no locking-up of the asphalt was experienced.

Performance of the EME to date A visual assessment was conducted in June 2017 (18 months after construction) to evaluate the current in-service performance of the EME. The site conditions in which the EME was constructed may be considered as extreme due to the combination of steep grades, high ambient temperatures and slow-moving heavy vehicles. However, during the visual assessment, the only observable defect recorded was bleeding at minor isolated sections along the left-sided wheel path. This defect was confined to the UTFC and did not originate in the EME. Minor mechanical deformation was also observed at isolated sections along the UTFC. However, this was not related to the performance of the EME. This section of road will be continuously monitored over the coming years to assess the long-term performance of the EME technology in South Africa. *Imraan Amien and Bernhard Botes are engineers at Royal HaskoningDHV and Dirk Immelman is an engineer at the Western Cape Government.

TABLE 1 Four different pavement design strategies

PAVEMENT STRATEGY

START CHAINAGE END CHAINAGE PRODUCTION RATE

SECTION LENGTH

Continuously reinforced concrete pavement (CRCP) 160 mm/190 mm EME asphalt base 120 mm + 20 mm UTFC

km 61.0

km 60.4

85 m/day

600 m

km 59.6

km 57.4

170 m/day

2 520 m

Ultra-thin continuously reinforced concrete pavement 70 mm

km 57.4

km 56.9

35 m/day

500 m

Ultra-thin continuously reinforced concrete pavement 100 mm

km 56.9

km 56.4

30 m/day

500 m

IMIESA October 2017

ROADS & BRIDGES

Building SA’s

mega bridges d you know? i D

The long-awaited N2 Wild Coast road project is under way and work on the initial bridge, which will mark a first for South Africa, will begin shortly.

he multibillionrand N2 Wild Coast tollroad project (N2WC) involves the construction of a 410 km road between East London and Mtamvuna, as well as nine bridges, two of which will be mega bridges spanning extensive river gorges. The highway aims to provide an improved, shorter and safer road link between Eastern Cape, Western Cape and KwaZulu-Natal. A shorter, more efficient transport route is viewed as an improvement to the national road network and is considered to be of strategic importance to the region and the country as a whole. The project has been over a decade in the making, with the agreement for the bridge designs signed by Sanral in 2003. Construction of one of the mega bridges on the route, the Mtentu Bridge, is now set to start in early November 2017, and is scheduled to last approximately 40 months. Sanral has awarded the tender for the bridge to the Aveng Strabag Joint Venture, consisting of major South Africa-based construction company Aveng Grinaker-LTA and Strabag, a leading construction company in Europe with extensive experience in major balanced cantilever methodology bridge construction. As the first of its magnitude in South Africa, the 1.1 km long Mtentu Bridge will be one of the longest main-span balanced-cantilever bridges in the

world and will reach heights of approximately 220 m.

Msikaba Bridge Meanwhile, Sanral has announced that the tender for the Msikaba Bridge – the other mega bridge along the route – will be retendered due to the fact that the agency received no fully responsive tenders. Set for construction near Lusikisiki, the Msikaba Bridge will be a 210 m high, 500 m span structure. The cable-stayed bridge will feature imposing inverted Y-shaped towers, which will be a distinctive architectural feature. This will become the biggest cable-stay bridge ever constructed in South Africa. Because of the height and wind conditions associated with the construction of the bridges, both have been put through wind-tunnel tests in London and Ontario.

Uplifting the Eastern Cape The bridges form the backbone of the greenfield portion of the N2WC road project, which will play a vital role in improving travel time, connecting previously divided communities in the region, and opening up opportunities in business and community-based tourism for the Wild Coast. “By improving the travel time between Durban and East London by up to three hours for heavy

The Wild Coast region has been identified as an area for strategic economic development in accordance with government’s Spatial Development Initiative strategy

ABOVE Msikaba Bridge BELOW Mtentu Bridge

freight and by providing a high-mobility route through an extremely isolated area underserved by road infrastructure, the route will have significant social and economic benefits and will act as a catalyst for local and regional development,” says Vusi Mona, communications manager, Sanral. The project is expected to be a growth engine for the Eastern Cape both during and post construction, creating employment and business opportunities in an area with an extremely high unemployment rate. Sanral’s direct job creation forecast is 1.8 million man-days or 8 000 full-time equivalent jobs over the construction period of four to five years. More than R400 million will be allocated to wages for unskilled, semi-skilled and skilled workers employed directly on the N2WC road project. A further R1.5 billion is destined for local SMMEs comprising local contractors and local suppliers of goods and services to road and bridge construction projects. “Sanral’s R120 million community development and SMME training programme project, which is currently underway, is providing local labour and local SMMEs with the necessary skills to optimally participate in this and other forthcoming N2WC road projects,” states Mona.

IMIESA October 2017

ROADS & BRIDGES

Designing Mtentu Bridge

anral recently announced that construction of the Mtentu Bridge was awarded to the Aveng Strabag Joint Venture (JV), with work to begin later this year. Designed by an extensive collection of engineers, the bridge will span one of two major gorges on the Greenfields section of the N2 Wild Coast route between Mtamvuna and Lusikisiki. The mammoth design task was undertaken by the HVA JV â&#x20AC;&#x201C; a JV of Halcrow (now part of CH2M), VKE (now part of SMEC) and Axis. Subconsultants include Dissing+Weitling (international bridge architects), Melis and Du Plessis (geotechnical), Nyeleti (BBBEE design and detailing), and Dynacon (BBBEE design and detailing). Specialised investigations were commissioned from the Department of Geoscience (seismic loading), CSIR (wind

FIGURE 1 Elevation of Mtentu Bridge

IMIESA October 2017

Once complete, Mtentu Bridge, a mega bridge on the N2 Wild Coast Toll Road, will be one of the longest main-span, balanced-cantilever bridges in the world. climate assessment), and UK-based BMT Fluid Mechanics (wind tunnel testing).

Design challenges During the concept and preliminary design stage of the Mtentu Bridge, the challenge was to find a short bridge on a simple alignment that would minimise the environmental impact, while still being an aesthetic and cost-effective solution. The first hurdle was to find a suitable geometric alignment. Several horizontal alignments were considered. As the bridge sits in a valley with relatively steep sides, various vertical grades were considered for the approach roads, ranging from 4% to 6%, in order to optimise the alignment and minimise the bridge length. More than seven alternatives were costed, all optimised to lower wind and seismic loading, reduce foundation size â&#x20AC;&#x201C; and requiring proven, uncomplicated design and construction

methods. The optimisation process considered cost, programme, visual impact, environmental impact, and design and construction risk. The position of the piers adjacent to the river presented the largest challenge in terms of geotechnically sound foundations, shorter main spans and reduced environmental impacts. A degree of compromise was required, as it was determined that putting one foundation near the edge in a forested area significantly decreased the cost of the main span. The contractor will take great effort in minimising the impact on the forest and revegetating on completion. Structural forms considered included longspan, cable-stayed spans with main spans of 480 m; a balanced-cantilever, five-span deck; and a combination of a balanced-cantilever main span, with incrementally launched approach spans (the latter being the structural form that went forward to detailed design).

ROADS & BRIDGES

Wind-tunnel testing of a model of the balancedcantilever spans under construction

Deck cross section to the balancedcantilever spans at the front face of the main piers

Typical deck cross-section at the incrementally launched approach spans

Winning design The final structural form consists of three balanced-cantilever spans with a main span of 260 m. The approach spans are incrementally launched on spans of 66 m, giving a total deck length of 1 133 m. The deck supports four traffic lanes, with shoulders and two separate 1.4 m wide sidewalks. The horizontal alignment of the bridge is straight, while the approach spans are on vertical sag curves, requiring the incrementally launched spans to be launched on a vertical circle. The main spans are on a constant grade and all foundations are spread-

footings on rock with 148 m high piers to the main spans and piers up to 80 m high on the approach spans. The deck is continuous, with expansion joints only at the abutments. This required the main piers to carry very large loads during construction and under seismic loading, while still being able to deflect with temperature variation. This was achieved by making these monolithic piers twin-bladed hollow box sections. The approach

spans are supported on bearings with these piers being hollow box sections. The deck cross-section to the main spans vary from 15 m deep at the piers to 5 m deep at mid-span, while the approach spans are 5 m deep. Extensive wind-tunnel testing was done to determine the wind loading on the completed structure as well as the wind loading on the balanced cantilever during construction. The wind-tunnel testing revealed that the irregular terrain produced highly turbulent wind with a significant vertical component, this being one of the more critical load cases for the balanced cantilever during construction. Taking the project forward, the challenges during construction will include excavating very large foundations, some on steep slopes in an environmentally sensitive area; constructing very tall piers with complex cross sections using climbing formwork; constructing one of the worldâ&#x20AC;&#x2122;s longest span balanced cantilevers with a main span of 260 m; and constructing large incrementally launched decks with very long main spans of 66 m. All those involved in the construction will have a challenging and exciting four years ahead of them.

IMIESA October 2017

ROADS & BRIDGES

Hydro demolition used in M1 bridge repair

ommissioned by WBHO Construction in partnership with Sanral, the wider project included the complete rehabilitation of the bridges in Rosebank, involving major structural repairs. Hydro demolition technology was employed to remove deteriorated concrete from the structures without damaging the existing steel reinforcement. Hydro demolition involves the use of highpressure pumps, water and robotics to break down and remove cement-based materials in situ. According to Bradley Storer, director, Total Blasting,

Major structural repairs to the M1 northbound highway bridges over Oxford and Federation roads in Johannesburg required the removal of superfluous concrete from the bridges. the high-volume, special demolition technique can target specific demolition areas with relative precision, supporting a cleaner demolition site. And unlike conventional demolition methods such as jackhammering, hydro demolition does not damage the rebar or surrounding structure. The technology for the project, supplied by Total Blasting, was imported from Europe and the USA, and specifically developed for concrete demolition. While there were challenges to the hydro demolition aspect of the project, such as limited site access and channelling sufficient water

to site in order to feed the pumps, the bridge rehabilitation project was completed on time. A total of three Total Blasting employees, with specialised skills in water jetting and hydro demolition, were deployed to this project for its duration. â&#x20AC;&#x153;Hydro demolition is in its infancy in Africa; the success of this project does not only represent a well-respected client that is highly satisfied with the work we have done, but opens up opportunities for hydro demolition and water jetting in the Southern African concrete repair sector,â&#x20AC;? concludes Storer.

ROADS & BRIDGES

Taking a multi-axial approach

he application of a geotextile inter vention for a subgrade stabilisation project has passed on substantial savings for the Moretele Local Municipality. The municipality, lying to the north-west of Hammanskraal, consists of 26 wards, each comprising 74 villages and plots that are connected by a low-bearing road network. When a new road was under construction between the villages of Mathibestad and Makapanstad, CV Chabane & Associates concluded that it was not financially feasible to apply conventional methods, namely the placing and compacting of dump rock, typically to a depth of more than 1.5 m, over the challenging clayey subgrade material. Seeking an alternative design, the engineer consulted with Kaytech’s Danie Herbst who, with the assistance of Tensar, recommended the installation of TriAx TX 160 as a stabilisation geogrid, and bidim A2 as the geotextile separation below. “Per formance trials have shown that a mechanically stabilised layer using TriAx reduces the thickness of the sub-base layers required and increases the design life of the road,” Herbst explains. Kaytech is South Africa’s leading manufacturer of nonwoven geotextiles. TriAx is produced from an extruded sheet of polypropylene that is punched with an array of holes and stretched to create its unique triangular structure. As a multi-axial geogrid, TriAx incorporates several characteristics that combine to create an optimised structure. “By providing near-uniform stiffness through 360 degrees, TriAx is a truly multidirectional product with near isotropic properties,” Herbst explains. “Through aggregate confinement and interlock, TriAx produces a mechanically stabilised layer with exceptional per formance.”

Bidim A2 laid over the compacted clayey subgrade

The first layer of TriAx laid over the bidim as subgrade stabilisation

Bidim separation layer An initial separation layer of bidim A2 was laid on to the clay subgrade and then covered with TriAx TX 160, which, through its unique mechanically stabilising function, effectively reduces the amount of rockfill required to provide adequate load support. The rockfill layer was then overlaid with bidim A2 to separate the rockfill and selected layers above, in the process creating a drainage layer: water can pass through the rockfill without influencing the selected layers. Manufactured in Kaytech’s ISO 9001-accredited facility in Atlantis, Cape Town, bidim is a continuous-filament, nonwoven, needle-punched geotextile that meets the most stringent civil engineering and industrial specifications. This A-grade bidim is produced from high-grade polyester made from 100% recycled material. In total, 8 568 m2 of bidim A2 and 9 520 m2 of TriAx TX 160 was installed during the course of the project to provide Moretele Local Municipality with an economical and durable solution.

IMIESA October 2017

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ROADS & BRIDGES

Connecting the Eastern Cape Asphalt paving near the Jeffreys Bay interchange on the N2

uch Asphalt supplied the bitumen-treated base (BTB) asphalt for patching, as well as 49 000 t of semi-gap A-E2 asphalt with rolled-in chips for the surface paving for the project from its Port Elizabeth plant.

The project, awarded to Concor Infrastructure (formerly Murray & Roberts Infrastructure) by Sanral, was completed within schedule this year with minimal disruption, despite heavy traffic loads on the N2. Good communication and planning were essential due to the distance between the

asphalt plant and the site, coupled with unpredictable weather, explains Joe Nell, contracts director, Concor Infrastructure. “The asphalt received from Much was consistent and of excellent quality, which is key on such a high-production contract.” Nathan Jacobs, branch manager: Port Elizabeth, Much Asphalt, adds, “Constant communication between the contractor, consultant and all suppliers ensured the success of this project. Everyone worked together towards the common goal – from the bitumen and aggregate suppliers to the paving crew.”

R75 Uitenhage Also in the Eastern Cape, Much Asphalt is currently supplying another Sanral project for the rehabilitation of 16.5 km of the IMIESA October 2017

IMIESA October 2017

ROADS & BRIDGES

R75 route from Despatch to Uitenhage, and 15 km of the R336 between Kirkwood and the R75. Much is supplying BTB and wearing course patching, as well as 50 000 t of semigap A-E2 with rolled-in chips. Completion is expected in November 2017. On the back of these

Compaction during asphalt paving near Uitenhage on the R75

successful projects, the asphalt supplier has also been awarded the supply of 60 000 t of BTB A-E2 and 37 000 t of semi-gap A-E2 with rolled-in chips for the rehabilitation of another 13 km of the R75 between Port Elizabeth and Despatch. Concor Infrastructure is also the main contractor on this project, which will commence in October 2017.

N2 supply contract Meanwhile, East Coast Asphalt, in which Much Asphalt is the majority shareholder, recently completed the supply of 22 000 t of a special high-modulus asphalt mix (EME), for another Sanral contract on the N2 freeway from Buffalo River to the Breidbach Interchange in the Eastern Cape. About 60% of the EME base course was paved

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on the N2 sections that carry high traffic volumes through the King Williamstown CBD, with the remaining 40% placed on the periphery of the town. The product was then overlaid with an AE2 modified mediumgrade asphalt. EME, manufactured with the hard 10/20 bitumen grade, offers a superior bitumen-treated base solution due to excellent rut-resistant properties. The risk of running out of the scarce 10/20 binder from the Shell refinery was mitigated during the supply period through access to Much Asphalt’s strategic additional bitumen storage capacity off-site. Francois Meyerhoff, branch manager: East London, East Coast Asphalt , and the site staff successfully managed the binder supply logistics for the haul distance of almost 600 km. “It was our first opportunity to supply this sensitive product from our East London drum-mix plant,” says Brian Mchunu, MD of East Coast Asphalt. “We are very excited to have delivered the final product to the client, Roadspan, to specification and with an impeccable zero reject rate.”

ROADS & BRIDGES

Calculating the financial benefits of road projects is a complex but essential task, which ensures that the future use of roads translates into positive socio-economic gains that exceed the initial infrastructure investment. By Wessel Pienaar*

Cost-benefit analysis

uring the planning process to construct or physically improve a public road, the relevant road authority needs to ensure that the proposed project is technically feasible and financially viable. In addition, an environmental impact assessment is required in terms of the Environment Conser vation Act (No. 73 of 1989). It is not yet mandator y to conduct an economic or social cost-benefit analysis of a proposed road nor assess its expected impact on the economic welfare of the South African society. However, steps are presently being taken to introduce the execution of

t c e j o r f road p

cost-benefit analysis in a standardised manner in the planning process. From an allocative efficiency point of view, the strength lies in its potential to: • save economic resources through significantly lowering the social cost of transport • d ivert (attract) traffic • i nduce traffic. A large saving in social transport cost is an indication of efficient national resource allocation; good traffic diversion is an indication of the project’s ability to help distribute wealth; and good traffic induction is an indication of its ability to help create wealth through economic growth and development.

A public road construction project is regarded as economically justified when the present worth of future reductions in road-user, road maintenance and external cost (to nonroad-users) is in excess of its investment expenditure. The term social cost-benefit analysis is used interchangeably with costbenefit analysis and economic evaluation. It does not include financial evaluation.

Cost-benefit analysis techniques Various techniques, all based on the principle of discounted cash flows, can be used for cost-benefit analysis. The individual evaluation techniques ascertain the economic

IMIESA October 2017

ROADS & BRIDGES

viability of prospective projects on the basis of: minimum total transport costs, which can be determined through the present worth of cost (PWOC) technique; net absolute benefit, which is determined by the net present value (NPV) technique; or relative benefit, which is usually determined either by the benefit/ cost ratio (B/C) or the internal rate of return (IRR) technique. These techniques can be classified into two groups on the basis of their underlying philosophy. For the first group, only the cost of each alternative to achieve a specific objective is calculated: the argument being that the alternative with the least cost – i.e. being the most cost-effective – would be superior. The PWOC technique falls in this group. In working with the next group of techniques, namely NPV, B/C and IRR, both benefits and investment costs of alternatives are calculated. The total cost of road infrastructure supply and usage comprises once-off and recurring costs. Once-off costs comprise the investment or initial costs. Collectively, the once-off costs represent the cost component in social costbenefit analysis. Recurring costs are incurred continuously throughout the service life of a facility and consist of the facility user costs, maintenance costs and external costs imposed on the community stemming from road operation. Recurring costs form the basis of determining the benefit component in social cost-benefit analysis. An increase in once-off costs (i.e. greater investment) generally gives rise to

IMIESA October 2017

a decrease in recurring costs, and vice versa. Minimisation of total societal cost per trip undertaken can, therefore, be achieved by determining the optimum trade off between investment costs and recurring costs.

The cost component The cost of an investment in road infrastructure includes the following components: • cost of direct planning and design such as traffic surveys, studies of use and establishing a facility, environmental impact studies, compilation and recording of the construction details, etc. • the land reserve and preparation of the site for development, including demolishing, levelling, reinforcement, etc. • the construction of the facility, including the construction of access links, installation of traffic control devices and other appurtenances, and landscaping. In their totality, they are often referred to as project implementation costs: the actual scarcity value of all inputs that are needed to create the facility and to link it to the existing road network and places to which it provides access (that is, to supply it complete and ready for use).

The benefit component

improvements other than those related to routine, periodic and emergency maintenance in order to keep the road passable to traffic. Recurring costs are then determined for the improved road and the benefits determined as the saving in recurring costs resulting from the improvement.

PWOC technique This technique selects the lowest-cost alternative among mutually exclusive projects. All economic costs (i.e. the social opportunity costs) associated with the provision, maintenance, and use of each possible alternative project are discounted to their present worth. Given the objective of economic efficiency, the alternative that yields the lowest PWOC is regarded as the most beneficial proposal. When a proposed project will, due to lower user cost, induce additional traffic over and above normal-growth traffic, the above-mentioned criterion of lowest total transport cost presents a contradiction in terms. Any diverted or induced traffic will increase the facility’s PWOC, thus defeating the objective of minimum cost. However, use of the PWOC technique is appropriate in project selection when a chosen alternative will not induce additional usage – for example, when the most cost-effective alignment or design of a facility needs to be determined, and the demand volume will remain the same regardless of the chosen alternative.

“An increase in once-off costs (i.e. greater investment) generally gives rise to a decrease in recurring costs, and vice versa.”

The benefits of a road project are estimated by means of a ‘with or without’ comparison. Recurring costs are first projected for a continuation of the existing situation (the null alternative) in which no expenditure will be incurred on

ROADS & BRIDGES

IRR technique

Examples of the latter situation are when the construction of a new airport on vacant land is being contemplated or when the establishment of a new seaport at a presently inaccessible location on the coastline is being considered, and the most cost-effective ways of linking these facilities to an adjacent urban region have to be evaluated. Under these circumstances, the PWOC of the link (using different alignments and designs) may be used, as the complication that occurs with the treatment of induced traffic is not present.

NPV technique The NPV technique provides an economic performance measure that is used to select the best alternative among mutually exclusive projects. In this method, the present worth of investment cost is subtracted from the present worth of all future project benefits relative to the null alternative. All projects reflecting a positive NPV are economically viable. The NPV method can, therefore, be used to establish whether projects are economically justified. Those with a negative NPV are considered not to be economically justified. When mutually exclusive projects are analysed for a specific purpose, and where the projects are not compared with other independent projects aimed at other purposes,

the mutually exclusive project with the highest NPV is most suitable for implementation. The method cannot be used to compare independent projects. While the NPV technique determines the economic viability of a project on the basis of net benefit as an absolute amount, another important use of the NPV technique is that it can be used as input for a regional economic impact analysis.

B/C ratio technique The B/C ratio is determined by dividing the present worth of the future project benefits by the present worth of the project investment costs. All proposals with a B/C ratio greater than 1 are economically viable and can be selected for implementation when an unlimited budget is available. Budgets, however, are usually limited so the benefit-cost ratio method must be applied as follows: • Independent projects: when independent projects (ones that fulfil different functions) are compared, the one with the highest B/C ratio is economically the most advantageous in relative terms. The B/C ratio can be used to rank independent projects from the most to least advantageous. • Mutually exclusive alternatives: the B/C ratio cannot be used to compare mutually exclusive alternatives of different sizes, but the incremental B/C technique can be used to identify the best alternative.

The distinctive feature of the IRR technique is that its application does not entail a singular discounting procedure with one official rate only. Future benefits (returns) for the period under review are discounted to the beginning of the period. (Each year’s benefit is calculated in the same manner as is done with the NPV and B/C techniques.) The sum of these discounted amounts is compared with the discounted project investment cost. Different rates of discount are selected iteratively and applied until, at a certain rate, the sum of the annual discounted returns equals discounted investment costs. This rate is then referred to as the internal rate of return. When independent projects (ones that fulfil different functions) are compared, the project with the highest internal rate of return can be regarded as the most advantageous in relative terms, although the actual criterion is to compare the rate, thus obtained, with the official social discount rate. If it exceeds the prevailing social discount rate, the alternative is economically viable. However, if two or more mutually exclusive projects of different sizes cannot be compared, incremental analysis must be used to identify the best alternative. *Wessel Pienaar is a faculty member of the Department of Industrial Engineering at Stellenbosch University.

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CONSULTING TO LOCAL GOVERNMENT

Engineering Excellence Awards Consulting Engineers South Africa (CESA), supported by Aon South Africa, brought together the consulting engineering community once again for a celebration of innovation, quality, outstanding workmanship and professionalism in the industry.

he CESA Aon Engineering Excellence Awards ser ve to showcase the extent to which local built-environment professionals provide the best in engineering expertise, as the 2017 awards proved to be better than ever, with over 47 submissions received. Outstanding performance across a wide range of categories was celebrated. These include large and small, as well as local and international projects, as well as future leaders in the industry. Speaking at this year’s event, CESA president Lynne Pretorius noted, “Consulting engineers are at the forefront of infrastructure development and these awards bear witness to the pivotal role that consulting engineers, as trusted advisors and partners to our clients, play in the delivery of services to the people of South Africa and the African continent.” Pretorius went on to highlight the importance of young engineers, mentorship and transformation, noting that, in addition to creating innovative infrastructure solutions for the people of South

Africa and Africa, consulting engineers play an important part in the country’s transformation agenda. The 2017 instalment of the Engineering Excellence Awards took place on 16 August in Midrand, with major players in the consulting engineering industry present. The project entries and winners are as follows:

Projects with a value greater than R250 million Winner: Mall of Africa – Aurecon The Mall of Africa, located in Waterfall City,

Midrand, is the largest shopping mall ever built in a single phase in South Africa, with over 130 000 m2 of retail space, and a gross building area of 485 000 m2. The massive project had a main construction period of only 32 months. This necessitated meticulous planning, innovative design solutions and ongoing collaboration between all stakeholders to keep meeting deadlines and resolving challenges to reach the key milestones of the programme. Construction for bulk earthworks commenced in October 2012, with main

Projects with a value greater than R250 million winner Aurecon

WINNER IMIESA October 2017

CONSULTING TO LOCAL GOVERNMENT

construction starting in September 2013 and reaching completion in April 2016. The Mall of Africa opened on time to over 120 000 people on 28 April 2016. Commendation: Witwatersrand Goldfields Acid Mine Drainage Project, Eastern Basin – AECOM In the Eastern Basin, the Blesbokspruit and Suikerbosrand rivers that feed into the Vaal River below the barrage faced a serious pollution threat from some 82 million litres of acid mine drainage (AMD) that would flow out of low-lying mine shafts near Nigel each day. AECOM SA was appointed to implement urgent short-term intervention. The timely design and construction of the 110 Mℓ/day Eastern Basin AMD Treatment Plant – one of largest of its kind in the world – successfully arrested the rising acid mine water in the Eastern Basin, averting an environmental disaster. Following a trouble-free startup of the plant, a drawdown of 100 mm per day in the AMD water level was observed across the whole basin within two weeks of commencement. Commendation: Provincial Main Road 577 & BRT Corridor C3 – Royal HaskoningDHV Main Road 577 was developed to provide critical access for residents of Inanda, KwaMashu and Ntuzuma to jobs and economic activity in the New Germany and Pinetown areas of Durban, south of the uMngeni River. The addition of the first dedicated bus rapid transit (BRT) lanes in Durban to the design and construction process, part-way through the contract, added a challenging element. With a difference of up to 6.5 m in the level of the two carriageways, the decision was taken to provide a four-lane:two-lane splitlevel dual carriageway. The redesign had to be

carried out while the contractor was busy with the MR577 project. Public traffic lanes on the MR577 through to New Germany opened in late July 2017. The BRT lanes on Corridor C3 Pinetown to Bridge City are expected to be opened in mid-2018. Other entries: • Namakwa Regional Water Supply Scheme – BVi Consulting Engineers • Medupi Non-process Buildings – Nyeleti Consulting • Rustenburg Integrated Rapid Public Transport System, NE-Corridor – Bigen Africa and Lotshephe Development Engineers, as Lotshephe Africa JV • Upgrading of N2 Section 13 & 14 between Grahamstown and Fish River – Bosch Projects and Mott MacDonald JV

Projects with a value between R50 million and R250 million Winner: L’Ormarins Hydro Power Project – Neil Lyners & Associates The L’Ormarins Hydro Power Project, located on the L’Ormarins Estate in Franschhoek, required the design and construction of a pipeline from an environmentally sensitive, high and inaccessible part in the mountain to enable the generation of 2.3 MW of green electricity. A small portion of a stream is abstracted to generate electricity. The pipeline conveys the water at a maximum flow rate of 700 ℓ/s to two turbine stations before the water is returned to the lower part of the stream. The remote location of the site posed a significant challenge. More than 1 650 helicopter return flights were undertaken to construct the pipeline in the mountain. The project was commissioned in June 2016, with the civil and structural engineering

WINNER

construction having been completed within budget and prior to the client’s deadline for readiness. Commendation: Stortemelk Hydropower Plant – Aurecon The Stortemelk Hydropower Plant, with a single 4.4 MW vertical Kaplan turbine, was installed adjacent to the spillway basin of the Botterkloof Dam on the Ash River, near Clarens. The plant uses the water being released into the Ash River from the Lesotho Highlands Water Project to generate approximately 28 GWh of electricity per annum, and is the first fully grid-compliant hydropower plant in South Africa in terms of the latest Renewable Energy Grid Code. The power station had to be constructed between two existing dams – the Botterkloof Dam and the Boston A Dam – without affecting their operations and stability. This required deep excavations in geological conditions not ideal for load-bearing foundations. The plant now contributes to South Africa’s power grid, as well as the local economy of Dithlabeng Municipality through employment and local procurement. Commendation: Special Maintenance of N2 Section 11 between Bramlin and Soutwerke – Bosch Projects National Route N2 Section 11 between the Bramlin Interchange and Soutwerke at Coega is a dual-carriageway freeway (700 000 m² surface) that carries not only through traffic, but also large volumes of commuter traffic. Bosch Projects was appointed by Sanral for the special maintenance of the route. Bosch Projects utilised all available technology to design a custom approach, taking into account a range of repair and resurfacing options that met the client’s requirements in the most cost-effective and pragmatic manner. A detailed assessment of different surfacing types and asphalt mix

Projects with a value between R50 million and R250 million winner Neil Lyners & Associates

IMIESA October 2017

CONSULTING TO LOCAL GOVERNMENT

options, and their suitability for use on this project, resulted in six different asphalt mixes being utilised. The works contract was completed in November 2016, more than two months ahead of the scheduled completion date, and within budget. Other entries: • Bruma Lake Rehabilitation Project – cba • Watervalspruit Proper and Ext 9 Affordable Residential Development – Infraconsult Engineering • South32 Desalination Plant at the Hillside Aluminium Smelter Project – JG Afrika • Tshwane UTC System – ITS • City Deep Kazerne Freight Hub Roads Upgrade Programme – Knight Piésold • Mafenya Reservoir – Moedi Wa Batho • BMW Building 50 H-EMS Roof Lift – Nyeleti Consulting • Reseal of Sections of MR201, DR1118, DR1388 and DR1152 in the Drakenstein Area – UWP Consulting • Rehabilitation of N7 Section 8 between Okiep and Steinkopf, Northern Cape – UWP Consulting

Projects with a value less than R50 million winner Fellows Consulting

WINNER

Projects with a value of less than R50 million Winner: Malapa Fossil Site Cover and Visitors’ Centre – Fellows Consulting Malapa, located in the Cradle of Humankind UNESCO World Heritage Site, is one of the world’s most important fossil sites. The steel structure that comprises the Visitors’ Centre is over 10 m high and shaped like a beetle with eight legs. It is made up entirely of circular hollow sections, apart from the cold-rolled, lipped channels supporting the aluminium roofing tiles and the lower legs. It covers an area of 250 m2 and the

tourist viewing platform caters for 48 people. Suspended below the platform is a 1 t capacity crawl beam to lift rocks out of the excavation. Inspired by the opportunities for reflecting the bones of the fossils, the structure expresses the “unusual beauty of skeletal structures”. Commendation: Water Reclamation Plant at the Bafokeng Rasimone Platinum Mine (BRPM) – Bigen Africa BRPM commissioned Bigen Africa to conduct a study to investigate the problems experienced by its water reclamation circuit and to develop a sustainable solution for its optimal utilisation. A water reclamation plant was proposed to enable reuse of the water from the return water dam in mining operations. This water reclamation plant is the first dissolved air flotation reclamation system used on a platinum mine to reduce the potable water consumption for gland service water. Potable water use has since reduced by 50% and, based on actual water savings and operating cost savings, the capital invested is projected to be paid back in less than four years. The water security of the mine has improved significantly.

Commendation: Plankenbrug Main Outfall Sewer & Associated Works Phase 1 – AECOM Ageing and under-capacity sewers serving Stellenbosch necessitated the upgrading of the sewer network by replacing three existing outfall sewers with one new sewer. A new 1.8 km long, 1 200 mm diameter concrete gravity sewer was installed at depths ranging from 1.8 m to 11.8 m. A length of 240 m was pipe-jacked in three sections, to limit open-cut excavation to a depth of 7 m. The three existing outfall sewers had to remain live while the new sewer was constructed. However, clashes with the existing sewers necessitated the construction of specially designed manholes to allow the existing sewers to protrude through the new manholes and remain live. The new sewer will efficiently accommodate all future developments as anticipated in the Stellenbosch sewer master plan. Other entries: •G a Seleka Roads Project – Aurecon • Reseal of Sections of MR201 and MR305, Wolseley – UWP Consulting • Construction of Nick Toomey Road and Stormwater – Knight Piésold

Best International Project Winner: Mizingani Sea Wall – Aurecon The Mizingani sea wall project focuses on the

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CONSULTING TO LOCAL GOVERNMENT Visionary Client of the Year winner Tongaat Hulett

WINNER rehabilitation of 340 m of the remaining sea wall adjacent to Stone Town along Mizingani Road in Zanzibar. Mizingani Road boasts some of the oldest buildings in Stone Town, and is a UNESCO World Heritage Site. In line with this, the project team collaborated with the local community, which saw the incorporation of a boat slipway into the sea wall design to give boat owners easier access to the beach. The project serves as a world-class example of successfully preserving the old, while integrating it with the new through innovative use of materials and construction techniques – capturing the intangible qualities and spirit of the historic site.

Young Engineer of the Year Winner: Jabulile Msiza, Jones & Wagener

Commendation: Catherine Blersch, Aurecon Commendation: Dr Pieter Crous, SMEC Other entries: • Werner Küsel, Bosch Projects • Sarisha Harrychund, Hatch • Robert Greyling, Knight Piésold • Disele Mathabatha, Nyeleti Consulting • Gina Skinner, Nyeleti Consulting • Sizwe Mchunu, MCPM

Mentor of the Year Winner: Corrie van der Wath, Matleng Energy Solutions Other entries: • Jeremia Jesaja (Mias) van der Walt, Bigen Africa • Leon Furstenburg, Knight Piésold

Young Company of the Year Winner: Matleng Energy Solutions Other entries: Phunga Consulting Engineers

Business Excellence Winner: Nyeleti Consulting Commendation: Knight Piésold Other entries: • Bigen Africa • BVi Consulting Engineers • Matleng Energy Solutions

Publisher of the Year Winner Trade Publications: 3S Media Winner Daily Newspapers: Independent Newspapers

CESA Branch of the Year Mentoring Company of the Year

Winner: Port Elizabeth

Winner: Bigen Africa Other entries: Knight Piésold

Visionary Client of the Year Winner: Tongaat Hulett

CONSULTING TO LOCAL GOVERNMENT

Municipalities and parastatal organisations need specialised insurance solutions that take care of many complex risks.

Rian van Dyk, manager: Municipality, Parastatal and Commercial Business at Aon South Africa

Managing emerging risks

or government, these risks can range from assets such as buildings, equipment, facilities and fleets, to infrastructure, liabilities arising from employees, communities and contractors, as well as new and emerging risks such as cybercrime, civil and political unrest. “Protecting municipal and parastatal organisations is a highly specialised field. It demands an enterprise-wide risk management strategy that takes care of every facet of the public sector environment. This ensures transactional insurance broking is enhanced with tailored risk management advisory services, covering areas such as risk finance, assets, liability, business continuity, legal and professional risks – through to new and emerging threats,” explains Rian van Dyk, manager: Municipality, Parastatal and Commercial Business at Aon South Africa. Aon’s 2017 Global Risk Management Survey points to an era of unprecedented volatility where trends in economics, demographics and geopolitics, combined with the exponential pace of technology change, are converging to create a challenging new reality for organisations around the world. While these forces create new and sometimes

unforeseen opportunities, they also create new risks that must be managed in new and innovative ways never before considered. State-owned enterprises are not immune to any of these dynamics or threats, as has been highlighted by Kenya’s recent elections. South Africa has also seen many violent strikes and protests that have left the country and many municipal precincts reeling from the destruction of property and assets. Service delivery and politically motivated riots have become far more common, and councillors and municipal managers face very serious threats to their lives over these periods, such as in Ditsobotla Local Municipality in Lichtenburg, where the mayor was taken hostage by disgruntled community members. “Municipalities face a barrage of complex risks and interlinked challenges. Their ability to traverse these risks successfully varies dramatically from municipality to municipality – some have well-evolved risk programmes in place, while others are in dire straits, pressured by a lack of skilled human resources, risk and financial management,” says Van Dyk.

“Staff turnover is often high in the public sector, presenting a breakdown of legacy knowledge and continuity from a risk management point of view. Risk and insurance are sometimes viewed as pure balance sheet items to be managed by the finance department, which can leave the municipality at significant risk of underinsurance when cost-cutting is prioritised ahead of prudent risk mitigation.”

A tailored approach Budgets are under enormous pressure, leading to resistance to the higher cost of insurance as a result of market conditions. This, in turn, impacts risk management and mitigation measures, which further exposes public organisations to the financial implications of uninsured losses. The slowdown in the economy equates to less investment in risk management programmes, both in physical risk control and engineering and risk finance programmes. There is also a lack of investment in risk planning and the mitigation of evolving risks, such as cybercrime. Instead of selecting the optimal solution, many municipalities simply comply with the minimum requirements in order to tick the box, Van Dyk reveals. Aon works with insurers to structure suitable insurance programmes that will offer long-term

IMIESA October 2017

CONSULTING TO LOCAL GOVERNMENT

agreements that can save municipalities money. “If municipalities are able to diligently manage their claims and risk exposure, they could enjoy a further saving on their annual premiums without exposing themselves to the risk of underinsurance,” he explains.

Risk assessment through needs analysis In conjunction with in-house municipal resources and the insurer, Aon conducts a comprehensive needs analysis, looking

for areas to improve the municipality’s risk profile. In some instances, this may involve some measure of alternative risk transfer for the metros, although this is not feasible for smaller municipalities with weaker balance sheets. “Taking care of the risk and insurance management for over 70 municipalities countrywide, Aon’s long-held emphasis is on a thorough needs assessment that takes into account the conditions of responsibility, emergency safeguards and other factors influencing a public organisation’s acceptable risk-bearing capacity, with a view to better risk

understanding and possible premium savings. The objective is to correctly formulate covers, neither under- nor over-insuring in the process, taking into account the realities of the times, the changing environment, evolving technology and emerging threats,” explains Van Dyk. By drawing from global capabilities, reach and expertise, Aon is positioned to advise municipal or governmental parastatals on the best approach to protect civil servants, assets, data integrity prescribed by the PoPI Act, and reputation by highlighting emerging risks and underscoring these with risk preparedness.

IMIESA October 2017

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The directors of Sikhumba Construction have been in the civil construction industry respectively for 47 and 22 years and they have a vast amount of experience. We pride ourselves therein that we have a hands-on management system. This allows for timeous and quality completion of contracts. SOCIAL RESPONSIBILITY

We involve previously disadvantaged people in our contracts. We believe in promoting people from within, training able people and involving SMME sub-contractors.

Creators of infrastructure through design, construction and maintenance

012 802 1166/7

Plot 113 â&#x20AC;˘ Mooiplaats â&#x20AC;˘ Pretoria

086 659 6201

info@sikhumba.co.za

Infraconsult Engineering’s experience in designing and installing municipal infrastructure, as well as structures founded on dolomite formations, provides a lasting solution for a major Gauteng affordable housing and allied commercial development that includes environmentally engineered attenuation. Municipal infrastructure ser vices have been installed in Phase 1 for 2 118 affordable residential units, with Phase 2 now under way.

gainst the backdrop of a huge housing backlog in Gauteng and, more specifically, the Ekurhuleni region, Cosmopolitan Projects launched mega housing development Watervalspruit in June 2016. The conceptual and town planning, as well as the preliminary designs, started as early as 2005, with Germiston-based firm Infraconsult Engineering being part of the project (as lead consultant) from inception. It was appointed initially for Phase 1 and now for Phase 2. Renamed as the Sky City Housing project, the entire Watervalspruit development will consist of 15 358 residential units, which will be developed and completed within phases over a period of eight to ten years. Sky City will provide housing to a group of people normally referred to as the ‘missing gap’ – i.e. households with a combined monthly income of more than R3 000 that do not qualify for RDP housing grants, plus those who cannot afford higher-end houses, in this segment, of above R500 000. This combined segment typically earns at least R10 500 per month. Housing packages from less than R400 000 will be made available to these beneficiaries. Additionally, beneficiaries who qualify in terms of the Finance Linked Individual Subsidy Programme will also be catered for at Sky City.

CONSULTING TO LOCAL GOVERNMENT

Fit-for-purpose

engineering

Watervalspruit’s gabion-designed attenuation system under construction alongside Rand Water pipeline installation works

Watervalspruit and Ext 9 Infraconsult’s scope in Phase 1 (Water valspruit proper and Extension 9) comprised the provision of bulk and internal engineering services to 1 693 stands and 425 high-density stands, a shopping centre, filling station, taxi rank, two schools and three social node stands for community facilities, at a cost of around R160 million. The main contractor was Sikhumba Construction. This site is underlain by dolomite of the Chuniespoort Group, which was a major design consideration from the onset. “The dolomite hazard risk for this phase ranges from Hazard Zone 2 (low risk of sinkhole and subsidence formation) to Hazard Zone 4 (high risk of sinkhole and subsidence formation),” comments Monro Jansen, managing director, Infraconsult. Thus, the design of all engineering and infrastructure services had to be done in strict accordance with the stipulations set out in: • SANS 1936 (2012) Part 3 and 4: ‘Design and construction of buildings, structures and infrastructure in dolomite risk areas’ •S ABS 1200 • F idic Red Book specifications. “Developers have bottom-line costing requirements, so the key is to ensure

“The total infrastructure project cost of the entire development will be close to R1.3 billion, so meticulous detail was given to planning and technical design to cater for all future phases.”

that projects are not over-designed, but optimally meet the future construction programme in a safe, efficient and sustainable manner,” Jansen explains. “When it comes to dolomite, we have extensive and proven experience, which includes similar housing projects, like Protea Glen, situated south of Johannesburg, where approximately 18 000 houses with services were constructed; so, for Sky City, we were able to provide an optimal solution for the client.” At Watervalspruit, the geotechnical considerations were always going to introduce an added cost implication compared to conventional servicing. By virtue of the dolomitic conditions of the underlying substrata, strict emphasis was placed on the installation of wet services. Trenches were excavated slightly

IMIESA October 2017

CONSULTING TO LOCAL GOVERNMENT

wider, with more effort required in the jointing of pipes (to ensure water-tightness). Standard ogee precast pipes were ruled out due to the dolomite Hazard Zone 3 category. Instead, spigot and socket pipes were installed. “That’s a jump in costing, but an essential requirement. It also demonstrates the commitment by the developer to ensure lasting infrastructure.” Exper t environmental management consultant Dr Gwen Theron, from LEAP Consultants, and her team ensured compliance to conditions of the EIA and specifications as set out in the EMP. Contractors were strictly monitored to ensure damaged areas were rehabilitated to their original state or better.

Stormwater and attenuation Ekurhuleni Metropolitan Municipality (EMM) indicated its requirement for attenuation facilities as part of the overall stormwater management requirements. Infraconsult investigated various options of attenuation and its recommendation entailed utilising and upgrading old existing farm irrigation dams and dam walls inside the Kliprivierspruit, which flows north-south along the western boundary of the development.

SOCIAL AND ECONOMIC SUSTAINABILITY • Approximately 2 118 families will be provided with decent homes, schools, social nodes and allied developments in Phase 1 • Some 15 358 families will benefit over the estimated 8- to 10-year duration of the project • Over 22 000 man-days of local jobs were created during Phase 1 • This job creation trend will increase during housing construction and further phases, and will be sustained over the entire project period and beyond as a result of further economic activities spurred by the complete development • Sustainable economic and business opportunities for small SMMEs in construction, retail, transport and allied sectors will be boosted by this project By making use of this innovative option, the client will save millions on the construction of lined, watertight attenuation dams across the entire development. In the process, more land has been made available for residential and other purposes.

Consultation FROM TOP TO BOTTOM An integrated stormwater outfall and Reno mattress system An aerial view with construction of structures at an early stage The development’s stormwater outlet channel shown here nearing completion Homes built to a high standard at Sky City

IMIESA October 2017

Consultation and coordination with numerous players was a key factor during the planning and design phases: • EMM technical departments were consulted on the minimum specifications and guidelines • ERWAT had to give its approval for the huge sewer inflow expected to be catered for at the Waterval Wastewater Treatment Plant • the Council for Geoscience was consulted • Gautrans is affected • Rand Water, Transnet, Sasol Gas and others are affected and were consulted. Much care was given throughout the conceptual and preliminary design phases regarding the eventual impacts and possible damage to the local environment. A number of sensitive areas, such as wetlands, were identified during the EIA processes. As such, Reno mattress and gabion stormwater outlet structures were opted for rather than conventional concrete or masonry systems. This will allow for the eventual natural integration of the built infrastructure and surrounding natural development. Commercially, the project has been a great sales success for Cosmopolitan Projects, and work on Phase 2 has now begun.

CALL FOR ENTRIES

TUESDAY 30TH OCTOBER PORT ELIZABETH

IMESA/CESA BIENNIAL PROJECT EXCELLENCE AWARDS

CATEGORIES

EXPLANATION

1. STRUCTURES AND BUILDINGS

Giving recognition to well-engineered civil engineering projects for infrastructure

2. WATER/WASTEWATER

Portraying the art and science of civil engineering for infrastructure to the general public and indicating how the profession finds answers to challenging. The project must be in southern africa.

3. ROADS/STORMWATER 4. ENVIRONMENTAL 5. COMMUNITY UPLIFTMENT

CLOSING DATE FOR SUBMISSIONS: 18 JUNE 2018 Projects completed by 30 June 2018 will be accepted for the Awards

ENTRY FORMS AND AWARD CRITERIA are available for download www.imesa.org.za QUESTIONS Debbie Anderson – IMESA – 031 266 3263 • conference@imesa.org.za IMESA: t +27 (0)31 266 3263 f +27 (0)31 266 5094 www.imesa.org.za CESA: t +27 (0)11 463 2022 f +27 (0)11 463 7383 www.cesa.co.za

IMESA THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA)

INTELLIGENT INFRASTRUCTURE

Transforming business

through technology

IMIESA October 2017

INTELLIGENT INFRASTRUCTURE

A collection

of excellence

OH’s umbrella of companies has grown to represent a fleet of municipal infrastructure specialists, providing an end-to-end offering across the infrastructure value chain. By acquiring companies with a proven track record, the JSE-listed group is able to provide a comprehensive range of reliable services to over 5 000 clients across the globe, explains Leon Geustyn, business development director: Municipal Infrastructure, EOH.

EOH, a leader in technology and business solutions, has spent years acquiring specialist companies with proven capabilities, creating a collection of centres of excellence within the EOH Group.

This time-tested growth strategy has paid off, ensuring a growth rate of approximately 40% per year over the past two decades, comprising 50% organic growth and 50% acquisitions. The group is now present in 134 locations in South Africa and over 50 countries, both within Africa and abroad. EOH attributes this growth to a culture of remaining prudent and not just meeting, but exceeding, customer expectations. The group’s operations are centred on key business areas and industry verticals, offering

end-to-end solutions via a simple design, build, operate formula. Within the infrastructure environment, EOH offers public and private sector technology services to improve business and operational efficiencies in the fields of civil, electrical and mechanical engineering, with a focus on water, energy and transport. By focusing on industry-specific solutions, EOH is able to provide insights into future business trends and drivers, giving it the skills and capacity to deliver end-to-end knowledge services.

Transport infrastructure Transportation infrastructure is essential to economic growth and development, making the quality management and maintenance of this infrastructure vital. Urban infrastructure in South African is under pressure, and peak period congestion is the order of the day in South African urban areas. EOH’s Transportation Division provides leading technology and solutions to allow for the

IMIESA October 2017

INTELLIGENT INFRASTRUCTURE

WELCOMING A NEW CEO

management and maintenance of transport infrastructure, while EOH Roads & Highways works to develop South Africa’s infrastructure. The Roads & Highways Division has played a crucial role in developing South Africa’s highways, having assisted Platinum Corridor Concessionaire Bakwena to ensure minimum service levels on its network, particularly in the implementation of a diverging diamond interchange (DDI) at Sefako Makgatho Drive in Pretoria North. Although the concept of a DDI is not new internationally, only one has ever been implemented in South Africa – at the KwaMashu Interchange along the N2 freeway in KwaZulu-Natal. The implementation of the DDI solution, as well as innovative traffic and geometric engineering solutions, meant the minimum

service levels could be satisfied in terms of agreements for the remainder of the concession period ending in 2031. EOH has also assisted Bakwena with improvements to the N1 between Proefplaas Interchange and Pumulani, and rehabilitation of the N4 between Swartruggens and Zeerust and the P35 Interchange. Key to ensuring quality management and maintenance of not only transport infrastructure, but all infrastructure, is asset management. EOH subsidiary V&V Consulting Engineers specialises in road asset management systems (RAMS). The consultancy also offers the design of new roads, upgrading, maintenance and rehabilitation of existing roads as well as the design, implementation and upgrading of municipal infrastructure.

Earlier this year, Zunaid Mayet took over as CEO of the EOH Group. Prior to this appointment, Mayet served as CEO of the EOH Industrial Technologies Division, a business he started six years ago. He joined EOH eight years ago after spending many years with a global technology and engineering group, fulfilling various leadership and executive leadership roles in Europe, Asia and South Africa. Mayet has an education in software engineering, business administration and executive development, and has a solid track record of leading and growing businesses internationally.

Building on this is IMQS, which has provided solutions to over 100 government and private organisations across the country and internationally for over a decade. The company develops specialised, GIS-centric software for the infrastructure asset management market and offers a modular set of solutions to address various problems that infrastructure asset management presents. The software products can operate independently, in combination

IMIESA October 2017

INTELLIGENT INFRASTRUCTURE

with each other or as part of an integrated solution with one of IMQS’s expert partner companies’ services.

Water and wastewater The effective management and utilisation of water resources, maintenance of infrastructure and minimisation of losses is crucial to ensuring long-term sustainability of supply. Complementary to this is a need to find new water sources to cope with the current and future demand. Within this field, EOH has acquired a large number of subsidiaries, all leading experts within the industry, covering the entire spectrum of the water value chain – from simple water infrastructure data collection to very large water and wastewater treatment plants. The most recent addition to this is WRP, a specialist engineering consultancy for water resources engineering, water conservation and

IMIESA October 2017

water demand management, including non-revenue water (NRW) reduction. WRP was the first company to introduce advanced pressure control to South Africa in the mid-1990s and it designed, commissioned and operated three of the largest and most successful advanced pressure control installations in the world. Building on this is JOAT, which has spent the past 15 years focused on NRW reduction through a winning combination of leading expertise, reliable world-class products, in-depth knowledge and partnerships with global experts. With the cost of water losses estimated to be R7.2 billion per annum, JOAT is able to effectively deliver NRW-reduction strategies through a range of services. Specialist GLS Consulting provides an extensive service related to the optimal analysis, planning and management of water distribution, and sewer and electricity reticulation systems. The company has been performing

hydraulic modelling and master planning of water and sewer systems for more than 25 years for the Ekurhuleni, Johannesburg, Tshwane and Cape Town metros, as well as all municipalities in the Western Cape and several others across the country. GLS offers a high level of expertise and experience supported by the latest technological developments and cutting-edge technology software developed by associated companies such as IMQS. Similarly, EOH subsidiary CSVwater Consulting Engineers focuses its attention on water and wastewater treatment and infrastructure projects. The company offers full civil, mechanical, electrical, control and instrumentation consulting engineering services in its focus areas and is able to assist its clients with the development of Blue Drop- and Green Drop-related plans and documents. Rounding out the offering is PCI Africa, a 64-year-old company specialising in water and wastewater treatment. The company offers a variety of services from process design, plant design, project management, equipment manufacture, materials supply and installation to commissioning and, where appropriate, operation and maintenance. On the environmental side of the water industry is Exigo, which offers environmental, environmental monitoring and hydrogeology services to add value to clients’ environmental and water-related projects. Exigo has established a strong network of partners across the industry and is trusted to deliver the most innovative, flexible solutions, while mitigating risks and optimising economic benefits. The company has a list of well-known clients, including

INTELLIGENT INFRASTRUCTURE

many large mining houses. Notable projects include the Sishen Western Waste Dump EMPR amendment and mine dewatering design and costing for KOV and Kamoto Copper-Cobalt Mines. Exigo has also assisted with integrated water-use licence applications for Gautrain, Platinum Australia Phokathaba Mine, Xstrata Alloys Thorncliffe, Mototolo, Helena, Flotation Plant, Kumba’s Sishen Mine, and Magareng Mining Developments.

Energy Trends such as urbanisation, digitalisation, converged connectivity, climate change and renewable energy are just some of the challenges Africa is facing. These challenges demand solutions that meet the requirements of an ever-evolving and increasingly complex energy environment. Meeting these complex energy requirements

necessitates a service provider that is highly aware of the impact of its technologies, solutions and services. EOH Energy Infrastructure and Services strives to provide appropriate, holistically integrated energy solutions and services. EOH offers leading energy infrastructure, energy management and optimisation solutions, through turnkey energy services and projects based on a thorough understanding of the unique requirements of customers’ needs and the industry in which they operate. EOH recently expanded its energy-related offering through the acquisition of Powertech Systems Integrators, enhancing the group’s geographical reach and energy portfolio of integrated and smart, resilient energy solutions. Powertech generates over R300 million per annum from an active customer base of over 250 companies across South Africa and sub-Saharan Africa, including large energy users and power utilities. This builds on the capabilities of Dihlase Consulting Engineers, an award-winning, professional consulting engineering practice specialising in electrical, mechanical and electronic engineering. The majority black-owned firm strives to be the industry leader, offering cost-effective, innovative and practical solutions without any compromise in quality. Dihlase also features shareholders who are all electrical or mechanical engineers or technologists, building the company’s knowledge pool and ability to provide high-quality engineering, energy and project management services to the industry.

previously disadvantaged. As a contributor to South Africa's drive for transformation, EOH has achieved the BBBEE status of a Large Enterprise Level 2 contributor, with 156% BEE procurement recognition. The group has also placed a large emphasis on job creation. Aside from a highly successful internal internship programme, which trains 700 to 1 000 people per year, the group has partnered with 702 and is on track to creating 100 000 jobs for unemployed youth by 2020. Every year, the pair host a Youth Job Creation Challenge, challenging South Africa to improve work experience skills for many of the unemployed youth across the country by taking on more learners and interns. Since 2012, over 35 000 learners and graduates have benefitted from the initiative, with 14 500 of them completing learnerships or internships. Of the individuals taken through the programme, 83% have been placed in full-time employment within EOH and its partner networks. By building not only infrastructure but also opportunities for those who need it most, EOH is working towards building a prosperous South Africa.

A truly South African company In delivering solutions to South Africa’s needs, EOH is committed to sustainable transformation and the empowerment of those who have been economically marginalised and

IMIESA October 2017

PARTNERS IN INFRASTRUCTURE

Sabita listing

Continued from page 34

Title Initials

Last Name

Company

Postal Address

City

Mr Mr Mr Mr Mrs

LC J N S B

Raman Strydom Nathoo Pretorius van der Wat

NAKO ILISO CONSULTING (PTY) LTD NAMIBIA TECHNICAL SERVICES CC NATHOO MBENYANE ENGINEERS NATIONAL ASPHALT NELSON MANDELA METROPLITAN UNIV

PO Box 686 PO Box 30623, Pioneers Park PO Box 47595 PO Box 1657 Dept Civil Eng. Block C, Room C210

Mr Mr Mr Mr Mr Mr Mr Mr Ms Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr

N L T N W J J L S KG G T D G PB JB BI J A RL C JL

Govender Heathcote Freestone Burger Venter Seima Nicholson Cochrane Rattray Rocher Catin Saks Weldrick Joffe Joubert Lansdell Jonsson van Heerden Marais Hornsey Botha Walstrand

PO Box 28617 PO Box 3186 PO Box 288 PO Box 129 3 Van Eyck Crescent Postnet Suite 190, P/Bag X31 1550 Tiburon Boulevard, Suite B1 Cnr Jurgens Street & Jet Park Road PO Box 50566 PO Box 10302 PO Box 10302 PO Box 911-489 Bldg 4, Quodrum Office Park PO Box 84513 PO Box 867 PO Box 234 PO Box 8379 PO box 1 The Marine Building, 22 Gardner Str 6 Ipivi Road PO Box 72927 PO Box 15324

NOLANS EARTHWORKS & PLANT CC OUTENIQUA LAB (PTY) LTD POLOKWANE SURFACING (PTY) LTD POWER GROUP (PTY) LTD PRIDE LAB EQUIPMENT (PTY) LTD PUMA ENERGY SERVICES SA (PTY) LTD RAETEX INDUSTRIES RAND ROADS (A DIV GRINAKER-LTA) LTD RANKIN ENGINEERING CONSULTANTS RAUBEX (PTY) LTD RAUBEX KZN (PTY) LTD RELIANCE LAB EQUIP (PTY) LTD RETTENMAIER SOUTH AFRICA (PTY) LTD ROAD MATERIAL STABILISERS (PTY) LTD ROYAL HASKONINGDHV SALPHALT (PTY) LTD SARF SASOL CHEMICALS (DIV OF SASOL SA) SASOL WAX (PTY)LTD SHELL SA DOWNSTREAM (PTY) LTD SMEC SOUTH AFRICA (PTY) LTD SPECIALISED ROAD TECHNOLOGIES (PTY) LTD SPRAYPAVE (PTY) LTD

Gillits Windhoek Greyville Hillcrest Summerstrand Campus Haymarket George Industria Ladanna Blackheath De La Haye, Bellville Saxonwold Tiburon, Ca Jet Park, Boksburg Lusaka Ashwood Ashwood Rosslyn Johannesburg Greenside Gallo Manor Isando Birchleigh Sasolburg Durban Kloof Lynnwood Ridge Westmead

PO Box 674

Alberton

0009

TAU PELE CONSTRUCTION (PTY) LTD TOSAS (PTY) LTD TOTAL SA (PTY) LTD TPA CONSULTING (PTY) LTD TSHEPEGA ENGINEERING (PTY) LTD UNIVERSITY OF PRETORA, DEPT CIVIL ENG UNIVERSITY OF STELLENBOSCH WORLDWIDE TANKS ON HIRE CC WSP TRANSPORT & INFRASTRUCTURE ZEBRA SURFACING (PTY) LTD ZIMILE CONSULTING ENGINEERS ZYDEX INDUSTRIES PVT LTD

PO Box 13125 PO Box 14159 PO Box 579 PO Box 1575 PO Box 33783 Lynnwood Road, Private Bag X1 PO Box 2250 33 Sloane street PO Box 14335 Postnet Suite 252, P/Bag X11 G1 Gotri Sevsai Rd, Sevasi Vadudara

Noordstad Wadeville Saxonwold Westville Glenstantia Hatfield Matieland Durban Bryanston Kenwyn Halfway House Gujarat

9302 1422 2132 3630 0010 0002 7602 4001 2192 7790 1685 39021

Jansen van Vuuren Mr MP Prinsloo Mr D Pagel Mr D Mtshali Mr RB Purchase Prof GJ Jordaan Prof WJVDM Steyn Prof KJ Jenkins Ms R Ganga Mr M Muthen Mr JM Pearce Mr S Gama Mr P Sreedhar

IMIESA October 2017

Postal Code 3603 4023 3650 6001 3200 6536 0704 7581 7530 2132 94920 1459 3605 3605 0200 2034 2146 1600 1621 1947 4001 3610 0040 3608

WATER & WASTEWATER

READ INSIDE Changing lives through Umgeni flagship projects

Flexible water solutions

Ending Cape water crises

Revitalising a corroded station

Securing Amajubaâ&#x20AC;&#x2122;s water

Water reuse, the smar t way Effective, alternative water treatment

IMIESA October 2017

ERWAT

Consistent quality requires consistent excellence ...

EXCELLENCE IN WASTEWATER

... in every area of wastewater management. Serving both the public and private sectors, ERWAT promotes a healthy environment by providing cost-effective wastewater treatment solutions through innovative technologies. It specialises in sustainable, quality wastewater services, backed by focused technical, maintenance and engineering services. An ISO/IEC 17025 accredited laboratory renders a wide variety of specialised analyses, while industrial wastewater quality management assessments and advice are also offered.

East Rand Water

Reg. No. 1992/005753/08 (Association incorporated in terms of section 21)

GPS Co-ordinates: S 26° 01’ 25.8” and E 28° 17’ 10.0” Address: Hartebeestfontein Office Park, R25, Bapsfontein/Bronkhorstspruit, Kempton Park. Tel: +27 11 929 7000 E-mail: mail@erwat.co.za

uppe marketing A13900

www.erwat.co.za

WATER & WASTEWATER

Revitalising a

corroded station The City of Cape Town’s Macassar sewage pump station was brought back to life following extensive remediation works to badly deteriorated concrete sections. Exeo Kholeka was awarded the fourmonth contract, with Aurecon appointed as consulting engineer.

he refurbishment programme made extensive use of Sika proprietary products, a key one being FerroGard-903 Plus, a surface-applied corrosion inhibitor based on organic compounds. FerroGard-903 Plus penetrates concrete to form a protective monomolecular layer on the surface of reinforcing steel. This serves to re-passivate the existing steel in the structure. Protection of the cathodic and anodic zones delays the onset of corrosion and reduces its rate: service and maintenance life cycles can be

increased by up to 15 years. In addition, FerroGard-903 Plus doesn’t alter concrete’s water vapour diffusion properties. SikaTop Armatec-110 EpoCem was applied as a bonding primer for reinforcement corrosion protection to all the badly corroded steel and concrete surfaces on the inside of this >14 m deep pump station. These surfaces were completely exposed. Product benefits include extended open times for repair mortars, excellent adhesion to concrete and steel, good resistance to water and chloride penetration, and high shear strength. For thick layer concrete repairs to the pump station, the entire inside had to be re-profiled with Sika MonoTop-615 HB. This product can be applied using the wet spray method and offers good mechanical strength, good freeze/ thaw resistance, and good resistance to water and chloride penetration. Sika MonoTop-615 HB provides outstanding workability characteristics, including adjustable consistency and excellent thixotropic behaviour. Sikagard-720 EpoCem – a three-part, epoxy-modified, cementitious, fine-textured mortar – was used for levelling and finishing the concrete surfaces to cover all the MonoTop 615 areas. With better chemical resistance than a PCC mortar, it provides

FROM TOP TO BOTTOM Inside the Macassar sewage pump station: completely restored concrete surfaces These completely exposed sections of steel reinforcement provide an example of the severity of the corrosion problem Refurbishment works at the Macassar pump station in Cape Town

excellent concrete protection in aggressive environments and is suitable for vertical or horizontal applications on green or hardened concrete, whether wet or dry. The final product used to complete the coating was Sikalastic-844 XT, a two-part, elastic, modified polyuria, spray-applied membrane with high acidic and alkaline chemical resistance. Providing extremely fast reactivity and curing times, it allows for almost immediate return-to-service time. Sikalastic-844 XT’s high resistance to microbial waste and biogenic sulfuric acid also made it the ideal waterproofing and anti-corrosion coating for the Macassar project.

IMIESA October 2017

WATER & WASTEWATER

Securing Amajuba’s water Long-term water solutions through collaboration – this has been the guiding philosophy of the working relationship between the Amajuba District Municipality (ADM) area in northern KwaZulu-Natal and SRK Consulting, a global group of engineers and scientists.

Raven Kisten, partner and project manager, SRK Consulting

he par tnership is delivering results, with over 19 500 rural dwellers in 3 256 households expected to benefit from turnkey projects in 2017/18. According to Thanda Zulu, technical director at ADM, the area is characterised by a range of settlement types from very scattered and remote to densely populated areas – many of which are challenged by backlogs in water infrastructure. “There is particular difficulty in getting water services to rural inhabitants in mountainous areas where settlements are located some distance from each other,” said Zulu. “Our strategic objective as a Water Services Authority is – like many municipalities – to address the provision of potable water and sanitation services to communities in need.”

IMIESA October 2017

Drilling of a high-yielding borehole in Ingogo

KwaLembe spring development project

Alignment He highlighted that any proposed water interventions also had to align with the priorities of the municipality – to conform to its Integrated Development Plan (IDP) and Water Services Development Plan (WSDP). Water provision by means of tanker services has proved to be an expensive and unsustainable option to the ADM, leading to the partnership with SRK Consulting. “Since 2012, the ADM has been working with SRK on a number of projects that provide integrated, longer-term and economically feasible solutions to address water demands in the rural communities,” says Raven Kisten, partner and project manager based at SRK Consulting’s Durban office. “Our wide range of in-house disciplines – from surface and groundwater to stakeholder engagement

and civil engineering – allowed us to plan and implement these interventions costeffectively in a highly integrated way.”

Data-driven approach Initially, options like bulk water pipelines to remote areas were considered. Instead, the decision to begin the process with desktop assessments, taking into account previous work by consultants in the area, was taken. “SRK gathered the baseline data for the district, including groundwater characterisations based on geophysical investigations, borehole drilling and yield testing, ascertaining yields of springs and a water demand verification of all households and water infrastructure,” says Zulu. The adopted approach was to formulate a dynamic plan that could be updated

WATER & WASTEWATER

as information was added. An important aspect of this phase included groundwater characterisations based on geophysical investigations, borehole drilling and ascertaining yields of springs and boreholes. A water demand verification of all households was also conducted. This allowed SRK to put a foundation of knowledge in place that would set the scene for longer-term, systematic interventions, subsequently facilitating better continuity in terms of service delivery, leading to specific strategies to address the water backlog, explains Kisten.

High-yielding boreholes On the strength of the baseline work, SRK identified high-yielding boreholes that met the standards for potable water supply, and which could be used to target surrounding communities. This allowed the impact from each intervention to be optimised. The work already done by other consultants and contractors over the years was leveraged and included the drilling of boreholes, and the rehabilitation of windmill and hand-pump projects. “Much of this infrastructure was in disrepair, but some of it could be returned to service relatively quickly,” Kisten says. “Once we retested the yields and ensured that the water quality was compliant with minimum standards, some of the boreholes tested were escalated to bigger reticulation schemes.” Another strategy that suited the situation was that of spring developments with gravity-fed water systems. This allowed existing water resources to be harnessed without expensive drilling, construction or sophisticated equipment. The source needed to be protected and livestock kept away to avoid contamination.

“In some cases, the springs were the water sources around which communities had originally settled,” he adds. “We then had to formalise these by installing storage units and designing gravity-fed reticulation to the extremities of the community. We use isolation and air-valve chambers for the purposes of checking and problem-solving, but the system is robust and straightforward.” The remote location of many sites created several challenges. Many communities are too far from Eskom’s main electricity grid to enable power connections for pumping purposes, for instance. “We installed solar-powered schemes where feasible, along with some protection to address the issue of theft and vandalism. We also worked closely with communities to ensure they took ownership of these assets and collaborated in protecting them,” he explains. To facilitate easier monitoring, solar panels were installed within the boundaries of a property where possible, and where there is human traffic. According to Kisten, the approach has proved successful in reducing theft; he emphasises that community buyin is important in helping to apply this kind of technology.

Open communication The dilapidated state of some equipment used in the existing water schemes, he points out, was usually the result of a lack of community training and capacity building in the monitoring and maintenance of mechanical items.

Rehabilitation of a hand pump

“Often in the past, there have not been formal communication channels with the municipality to alert it to any breakdowns that need repair. In a more effective handover process, community members can now be made aware of what to do when something goes wrong – so that the system can be quickly returned to use,” explains Kisten. He opines that the collaborative partnership between the ADM and SRK has proved the value of a flexible and dynamic approach in addressing water security. “Our practical and integrated solutions, combined with ongoing engagement with community structures, are expected to ensure better protection and longer life for public assets,” concludes Kisten.

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WATER & WASTEWATER

Water reuse, the smart way As South Africa faces increasing pressure to maintain the quality of its water supply, there is a greater need to understand, treat and reuse new types of liquid waste.

or more than two decades, QFS has treated both potable water and wastewater for municipalities, building up a wealth of experience and ser vices including design, installation, commissioning and aftersales training. QFS has invested significantly in advanced technologies, which have a direct link to more sustainable solutions, reducing energy

requirements and footprints, and allowing QFS to offer efficient but cost-effective decentralised water reuse systems. With quality as the key focus on any technology or installation, QFS also places a great deal of emphasis on the reduction of long-term life-cycle costing, largely associated with the implementation of advanced technologies. Linked to this, QFS per forms a risk analysis to reduce downtime during

the evaluated operational period, resulting in risk management by automation, preventative maintenance and continuous operator training. The company also has experience in plant assessment, providing clients with detailed recommendations to enable plant upgrades and augmentation to achieve set objectives, such as process enhancement, capacity upgrade and nutrient removal.

DE DOORNS

BALLITO

Project description: Municipal wastewater reuse @ 1.5 Mℓ/day (upgradable to 2.5 Mℓ/day) Process configuration: Ultrafiltration, UV and GAC Product water quality: Irrigation water Year completed: 2017

Project description: Municipal wastewater reuse @ 3 Mℓ/day Process configuration: Ultrafiltration and reverse osmosis Product water quality: Potable water Year completed: 2016

BEAUFORT WEST

MOSSEL BAY

Project description: 2.3 Mℓ/day direct reclamation plant Process configuration: Memcor ultrafiltration to remove all TSS, two-stage reverse osmosis, permeate water treated by ultraviolet light and hydrogen peroxide as an advanced oxidation step. Product water quality: SANS Class I drinking water Year completed: December 2010

Project description: 5 Mℓ/day desalination reuse plant Process configuration: Final effluent from WWTW, Memcor ultrafiltration membranes as protection for the reverse osmosis membranes Product water quality: UF permeate NTU < 1 Year completed: June 2010

IMIESA October 2017

Treatment capabilities As the cost of buying raw water and discharging untreated effluent rises, increasing opportunities for recycling industrial waste streams present themselves. These opportunities are being converted into treatment plants by companies such as QFS, who can deliver the required technologies at realistic prices. QFS can provide semi- or fully automated and remotely monitored wastewater treatment plants, improving fault detection and reducing costs by eliminating the need for a fulltime operator. Based on experience in membrane treatment processes, QFS is also capable of seawater desalination and can design facilities for the treatment of bore water or water from rivers and streams, which require colloidal particle removal and disinfection.

Operation and maintenance QFS provides an operation and maintenance optimisation ser vice to industr y through the experience of its engineers and technical officers who have commissioned, operated and maintained water and wastewater treatment plants. It can assess the design capability of a plant and check this against a per formance assessment by visual and instrument checks, as well as monitoring and collating available data. Comprehensive reports provide a breakdown of the plant’s capability, per formance and the steps needed to tune or modify the plant to produce effluent at the statuar y standards or provide cost-saving in disposal charges.

Training and management Both initial and ongoing training for operators and staff have become essential ser vices and a viable alternative to infrastructure investment. With the need to make the most of scarce capital resources, it has become necessar y to place increased stress on facility operation, which requires a higher degree of operator knowledge and skills.

Project management QFS’s project managers appreciate the need for compromise in the project development process by a multidisciplinar y team and are capable of driving the project on the correct course within defined constraints. They are familiar with Microsoft Project and ensure the client has an understanding of current tasks under way. The industr y shift towards 'turnkey' project management has been recognised by QFS as an important factor in cost and risk minimisation.

ARCELOR MITTAL Project description: 5 Mℓ/day wastewater treatment plant Process configuration: Water is fed to the plant through a high-rate clarifier, which acts as a high-turbidity protection step, two ultrafiltration skids and three twostage reverse osmosis skids, which are fed from a common manifold Product water quality: Conductivity < 200 µS/cm Year completed: August 2012

WATER & WASTEWATER

Effective, alternative water treatment MIOX Mixed Oxidant Solution (MOS) for water treatment was first discovered by scientists at Los Alamos National Laboratory, USA, in 1982.

lthough the electrolytic technology used today by MIOX to create MOS was developed for the US military in 2003, the first patent for MIOX electrolytic technology was issued in 1988, and the first field unit was installed in 1992. Years of subsequent research and development show that MIOX technology offers a very safe and extremely effective water disinfectant capable of eliminating dangerous microorganisms, including bacteria, viruses and protozoan cysts. Today, MIOX holds 55 total patents on electrolytic expertise with thousands of equipment installations in over 50 countries.

Why use hazardous chemicals When you can use the mioX on-site chemical generator? mioX systems are used in multiple applications through a wide range of products, cost-effectively producing disinfection chemistry from 1 to 906 kg per day Fac (free available chlorine) utilizing a single on-site chemical generator. multiple on-site generators can be used in series to provide higher free available chlorine capacities based on the application requirements. With this flexibility, mioX on-site chemical generators can be utilized in many applications including: • drinking water treatment for small communities to cities of 10 million people • Wastewater treatment for municipalities and industrial processes • large industrial cooling towers and district cooling buildings • oil & gas water treatment including frac and produced water recycling • Food and beverage applications including clean-in-place and process water

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Cape Town: Tel: +27 21 702 0979 | Johannesburg: Tel: +27 11 608 1734 info@filconfilters.co.za • www.filconfilters.co.za

MIOX on-site chemical generator The electrolytic cell of a MIOX on-site chemical generator uses salt combined with water and electricity to generate disinfectant at the point of use. This allows water treatment facilities to do away with hazardous chemicals such as chlorine gas or bulk bleach. MIOX offers two types of on-site chemical generators: mixed-oxidant and hypochlorite. MIOX’s sodium hypochlorite (HYPO) systems are engineered to provide the absolute cheapest and most reliable bleach available on the market, while the MIOX MOS systems are engineered for maximum disinfection efficacy through proprietary cell design, control of power and cell geometry.

Four key benefits 1. Improved operator safety Chlorine and industrial-strength bleach traditionally used in water disinfection pose a variety of hazards to the operator. On-site generator (OSG) systems use only water and salt, and produce non-hazardous oxidant solutions with a chlorine content that typically contains less than 0.8% free available chlorine. Treatment plants that use OSG systems, therefore, typically face less oversight from state health agencies, provide less safety training for operators, and have less of an insurance issue. 2. Higher-quality chemicals Storage issues mount in areas that are required to have 30 days’ or more supply of disinfectant chemicals on hand. In addition, recent research indicates that older hypochlorite will contain less and less free available chlorine and more degradation products. MIOX OSG systems typically produce only a two- to three-day supply of chlorine at a time, thus providing a potent disinfectant. Salt does not decompose, so long-term requirements can be met by storing enough salt to comply with regulations. 3. Greener application In addition to the reduction in use and potential accidental release of toxic chemicals, transportation of chemicals from factories to the water plant is reduced with OSGs. This, in turn, lessens the plant’s carbon footprint. 4. Cost savings Although OSG systems usually present a large upfront capital equipment cost, most water plants realise a return on their investment within two to three years. OSGs typically produce chlorine at a much lower cost than traditional delivery methods, primarily by eliminating the need to continuously purchase expensive chlorine chemicals, particularly for systems using calcium hypochlorite. Additional savings come from decreased transportation- and safety-related costs, and lower insurance premiums. MIOX systems cost-effectively produce disinfection chemistry from 1 kg to 906 kg per day FAC (free available chlorine) utilising a single on-site chemical generator. Multiple on-site generators can be used in series to provide higher FAC capacities. With this flexibility, MIOX on-site chemical generators can be utilised in many applications, including: • drinking water treatment for communities and cities of up to 10 million people • wastewater treatment for municipalities and industrial processes • l arge industrial cooling towers and district cooling buildings • oil and gas water treatment including frac and produced water recycling • food and beverage applications including clean-in-place and process water • legionella prevention at hotels, casinos, universities, and hospitals. In addition, MIOX’s on-site chemical generators have a more compact design compared to the competition, offering a small footprint, ease of installation and reduced labour and materials needed on-site. IMIESA October 2017

WATER & WASTEWATER

CHANGING LIVES THROUGH UMGENI WATER FLAGSHIP PROJECTS

The cur

Phase S Phase 1 2 3

• Strong Black economic enterprise development through Contract Participation Goals • Learnership and skills transfer • Temporary jobs created for youth, women and men DARVILL WASTEWATER PLANT UPGRADE

TREATMENT

The Darvill WWTW Upgrade is the construction and installation of civil, structural, mechanical, electrical and control & instrumentation to upgrade the existing Wastewater Treatment Works in Pietermaritzburg from 65 Ml/day to 100 Ml/ day. A further upgrade to 120Ml/day has been accommodated in the design and included in part into the current construction component. The project value is R961 million and the design work commenced in August 2012. Construction work commenced in August 2014 and is currently 85% complete and expected to be complete in December 2017 or early 2018. The design of the upgrade was completed by Hatch Goba and the contractor carrying out the work is Group Five Coastal. Egg-Shaped Digesters The most unusual structures on the project are the Egg-Shaped Digesters. The contract includes the construction of two 36m high, 18m diameter Egg-Shaped Digesters. These ‘Concrete Eggs’ are the 3rd and 4th of their kind in South Africa, their predecessors being the existing two built in 1975. The Digesters are post tensioned and being constructed using specialist formwork brought in from Europe.

Fine Bubble Diffused Aeration The largest concrete structure on the project is the construction of a 112m long by 70m wide, 8m deep aeration reactor basin. The reactor consists of +/-7,200m3 of concrete and is a water retaining structure. The basin houses a Fine Bubble Diffused Aeration specialist mechanically installation as part of the treatment process. A key project driver is increased energy savings in the wastewater treatment plant, which is why the fine-bubble diffused aerator was the suggested and preferred solution. The fine-bubble diffused aeration system supplies oxygen to the metabolising microorganisms, enabling them to come into contact with the dissolved and suspended organic matter. Pilot Effluent Reuse Project Incorporated into the design of the wastewater treatment works is a 2 Mℓ/d high pressure water system for plant operations which will double up as demonstration effluent reuse plant to showcase the efficiency of effluent reuse to a potable standard. The demonstration plant will incorporate several advanced technologies – such as oxidation and biologically activated filters, including ultrafiltration membranes – thereby providing breakthrough barriers against bacteria, viruses or other endocrinedisruptor contaminants. Expenditure to date on the project has been R844 million and job creation peaked at 105 temporary employees and there has been more than 57000 person days of employment.

Egg-Shaped Digesters

UMSHWATHI REGIONAL BULK WATER SUPPLY SCHEME The purpose of this project is to provide a safe and reliable bulk potable water supply to communities previously serviced by boreholes and / or small package plants which have become unreliable and, in the main, dysfunctional.

Aerial photo of Darvill WWTW

IMIESA October 2017

The existing Wartburg System, which supplies bulk potable water from DV Harris Water Works to Wartburg and surrounds is operating at maximum capacity. In order to meet the projected demands for both

4 5 6

Phase 1 Pipe Lay

*Subjec

The est includin and VAT 61% or grant fu

A total o being e work, w 2017 an workers

LOWER SCHEM Phase 2 Reservoir Reinforcing

existing consumers as well as the areas of greater Efaye, Ozwathini and Central Ndwedwe, new infrastructure will have to be constructed. The six phases of the Umshwathi Regional Bulk Water Supply Schemes are: 1. Claridge to Wartburg Pipeline (27km x 850ND), pump station (1.35MW) and storage reservoir (8Ml); 2. Wartburg to Dalton Pipeline (14.5km x 700ND), pump station (1.25MW) and storage reservoir (10Ml); 3. Dalton to Efaye (29 km of 750ND, 700ND, 400ND ) and Ozwathini (18km x 700ND) Pipelines, pump station (0.15MW) and reservoir (12Ml); 4.Southern Ndwedwe, reservoirs, and pipelines; 5. Ozwathini / Maphumalo, reservoirs and pipelines; and 6. Supply from Bruyns Hill Reservoir into the Wosiyane Scheme within Southern Ndwedwe. Design of Phases 1 and 4 were undertaken in-house whilst Phase 2, 3, 5 and 6 have been designed by Professional Service Providers. According to census 2011 figures the population served by the regional scheme is nearly 270 000, which is estimated to reach over 385 000 by 2045. The system design capacity of the regional scheme is 74Ml/d.

Introdu The LTB construc operatio electrica for a Mℓ/d Wa Thukela of Durb billion a in Febru and the Commu from the

Technic The pr infrastru Thukela the exis water to in the iL the uTh then no phase.

The prin the proje

a) A w integra uThuk and ul now e works across (171 m abstra b) A 5

WATER & WASTEWATER The current status of each Phase is shown below: Phase Stage Start of Construction Planned Completion Stage

Start of Construction

Planned Completion

Commissioning

Feb 2014

Completed

Substantially complete, Commissioning to follow

Mar 2015

Completed

Substantially complete except for 12Ml Ozwathini reservoir

July 2015

Nov 2018

Detailed Design

Nov 2018

Nov 2021

Planning

Feb 2019

Jun 2021

Planning

Feb 2019*

Jun 2020

*Subject to securing grant funding The estimated total budget is R2.3 billion including contingencies, capitalized interest and VAT, of which the social component of 61% or R1.4 billion will be co-funded from grant funding. A total of 1 231 decent temporary jobs, each being equivalent to 100 person days of work, were created from the start until July 2017 and wages totaling R26m paid to the workers. LOWER THUKELA BULK WATER SUPPLY SCHEME

the areas nd Central have to be

hi Regional :

line (27km 35MW) and

ne (14.5km 25MW) and

ND, 700ND, m x 700ND) 5MW) and

voirs,

Phase

and

ervoirs and

servoir into n Southern

undertaken nd 6 have al Service

figures the l scheme is ed to reach tem design s 74Ml/d.

Introduction The LTBWSS includes the planning, design, construction, commissioning and trial operation of civil, structural, mechanical, electrical and control & instrumentation for a new 110 Mℓ/d abstraction and 55 Mℓ/d Water Treatment Works on the Lower Thukela River near Mandini 100km North of Durban. The total project value is R1.6 billion and construction work commenced in February 2013. The plant is in operation and the defects liability has commenced. Communities have been receiving water from the scheme since July 2017. Technical Description The project comprises the provision of infrastructure to abstract raw water from the Thukela River, treat and then distribute it into the existing bulk supply network to provide water to the various surrounding communities in the iLembe District Municipality south of the uThukela River from its first phase and then northwards from a future 55Mℓ/d, 2nd phase.

ii.Contractors: Steffanutti Stocks (WTW), Group Five Coastal (Weir), Veolia Water (M&E), Esor (Gravity Main) and Consolidated Power Projects (CONCO) (Power Supply). iii.CPG - Contractors: All contractors and service providers achieved a minimum 35% Contract Participation Goal (CPG) target. This includes a total number of 24 CPG Contractors on the project, realising approximately 35% or R 476.7 million paid to CPG Partners/small contractors.

with high-rise pump station (with certain components constructed for the future and ultimate capacity of 110 Mℓ/d, but now equipped for 55Mℓ/d). Gatehouse, Administration Building, Chemical Dosing Building, Chlorination Building, Centrifuge Building, Inlet Works, Clarifloculators, Pulsators, Filter Block, Machine Room, Reservoir, High Lift Pump Station, Backwash Recovery Tank, Thin Sludge Holding Tank, Gravity Thickener, Thick Sludge Holding Tank. c) Access roads; to the abstraction works and to the Water Treatment Works (i.e. a road on either side of the river). d) An approximately 3.65 km x 900 mm diameter rising main pipeline. e) A 30 Mℓ reservoir (command reservoir). f) An approximately 30km gravity main pipeline to link up with Umgeni Water’s existing water distribution network at their Mvoti Reservoir with several offtakes to iLembe DM along the way. g) Substation and power supply from Eskom. Project Service Providers The works was undertaken by the following primary role players: i. Professional Service Providers: Aurecon (Design & Procurement); Bigen Africa/MSA (Quality Assurance, Contract Admin and Construction Monitoring) and Henwood & Nxumalo (Environmentalist).

Programme and Progress Planning commenced in 2011 and construction work on the first contract awarded commenced in February 2013, and the trial operation of the final O&M contract is expected to be completed in October 2017. Beneficiaries and Job Creation The 55Mℓ plant can serve between 28 000 and 45 000 households (230 000 people). A total of 23,106.75 local labour days for local labour was achieved on the project with a large number of permanent job opportunities with the operation and maintenance of the scheme. State of the art Hydro Cyclone and Inlet Works with an Analyser Station in front Filter Block and Chemical dosing building

Budget and Expenditure to Date

The principle components constructed under the project include the following: a) A weir and abstraction works with an integrated low-lift pump station in the uThukela River (constructed for the future and ultimate capacity of 110 Mℓ/d, but now equipped for 55 Mℓ/d). Abstraction works with sediment traps (110 Mℓ/d). Weir across the river to manage water levels (171 m wide). Low lift pump station at abstraction works (60 Mℓ/d) b) A 55 Mℓ/d Water Treatment Works

310 Burger Street, Pietermaritzburg, 3201, Republic of South Africa P.O Box 9, Pietermaritzburg, 3200, Republic of South Africa Tel: +27 (33) 341 1111 | Fax: +27 (33) 341 1167 | Toll free: 0800 331 820 Email: info@umgeni.co.za | Web: www.umgeni.co.za

/umgeniwater

@umgeniwater

/uwa1974

Improving Quality of Life and Enhancing Sustainable Economic Development

IMIESA October 2017

Structa Technologyâ&#x20AC;&#x2122;s Prestanks are hygienically safe, cost effective and a reliable way to store water for commercial sectors, private sectors and even for personalized storage. Choose from temporary or permanent erection at mines, powerstations, building sites, hospitals, water affairs,municipalities, rural communities and agriculture.

Pressed Steel Sectional Water Tanks Specialists in the manufacturing of domestic and industrial water storage

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STORAGE

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Robust steel tanks specifically intended for rural, domestic, industrial and agricultural water storage needs. Roddy tank capacities range from 3900 - 10,000 litres and stands 5m and 10m high. Designs are based on SANS 10160 and our Hot Dipped Galvanised units are made according to SANS 121 (ISO 1461) standards. MEYERTON | 0861 STRUCT (787828) Sales & Marketing: Chris Evans tanks@structatech.co.za +27 (0)82 739 9031 Director: Rodney Cory rodney@structatech.co.za

www.prestank.co.za Manufactured in SOUTH AFRICA Structa Technology is a Level 3 BBBEE contributor and is 51% Black Owned of which 34% is Owned by Black Women (Designated)

WATER STORAGE

Flexible water solutions The development of a new, smaller-capacity water tank series meets community requirements for lower volume storage of up to 10 000 ℓ.

s a member of the Structa Group, Structa Technology proudly ser vices the public sector by assisting in the provision of much-needed water storage to rural communities throughout South Africa. “Over the years, our 40-year-old proprietary product, Prestank, has proved to be a hygienically safe, cost-effective and reliable water-storage solution for communities, the commercial and private sectors, and even for personalised storage,” says Rodney Cory, director: Prestank, Structa Technology. “We are one of the preferred suppliers of water storage tanks for municipal authorities and mines, and are known as a supplier that always strives to deliver on time and within

The Roddy tank is a sectional, round, galvanised water storage unit that offers 3 900 ℓ, 7 200 ℓ as well as 10 000 ℓ capacities. As community needs grow, the original tank capacity can be incrementally extended

budget, adhering to the best quality standards,” says Cory, adding that Prestank water storage solutions are ideal for large volumes of water – 10 000 ℓ and up. Prestanks can be used for various water storage applications, including temporary or permanent installations at mines, power stations, building sites, hospitals, water utilities, municipalities, rural communities and farms.

Improved service offering The company has now improved its basket of services to municipalities by introducing its newly patented water storage tank series. “We’ve responded to community storage requirements for lower volumes of water of up to 10 000 ℓ,” says Cory. Known as the Roddy tank, this product is ideally suited for smaller villages, schools, and clinics situated in rural areas. The Roddy tank is a sectional, round, galvanised water storage system that offers either 3 900 ℓ, 7 200 ℓ or 10 000 ℓ capacities. However, if the client requires more than 10 000 ℓ – for example, if a village population grows and requires a bigger water storage tank – this patented system makes provision for further incremental capacity expansion. “There is, therefore, no need to replace the original water storage tank with a bigger one,” says Cory. The Roddy tank can remain on ground level or on a stand of 5 m or 10 m.

company’s philosophy is to partner with local contractors in the area to provide the foundations for tank construction installations, as well as erection, thereby supporting the respective municipality’s localisation policy and assisting with much-needed job creation.

Durability Structa’s customisable, high-quality, pressedsteel sectional tanks are hot-dip galvanised for corrosion control in accordance with SANS 121 (or ISO 1461) galvanising standards. The thickness of the hot-dip galvanised coat is applied within a range of 80 μm to 100 μm – more than five times that of zinc on pre-galvanised corrugated steel cylindrical tanks. This ensures an extended maintenance-free life. A Prestank installation: 1 Mℓ capacity tank supported on a multicolumn support structure

Partnerships that improve service delivery Structa Technology provides municipalities with cost-effective and durable products. The

Structa Technology offers local water utilities and municipalities two durable and costeffective water storage products for either low- or higher-volume requirements.” IMIESA IMIESA October October 2017 2017 79 79

WATER & WASTEWATER

Ending Cape water crises Current water scarcity is set to increase, particularly in Cape Town. As the city is bordered by two oceans, desalination seems the best answer, especially if rolled out in packaged form where turnaround times are minimal. But is seawater use the sole answer? By Frances Ringwood

t a round-table discussion hosted by engineering firm Gibb South Africa on 13 July this year, experts from government, industry and the built environment gathered to discuss the feasibility of using desalination to ease Cape Town’s water crisis.

Siting a desalination plant on the coast and near a power station can significantly reduce costs

Panellists included Leonardo Manus, chief director of infrastructure operations and maintenance: National Water Resources Infrastructure Unit, Department of Water and Sanitation (DWS); Jacques Laubscher, business development manager and technical executive, Gibb; and Margaret Wolf, project manager for the Unilever Centre for Environmental Water Quality and the Rhodes Institute for Water Research.

“The topic of desalination actually gained traction some years back when scientists realised humanity is growing at a rate beyond its means. Our resources are being depleted in inverse proportion to population growth, and we don’t have the ability to make water. Yes, it shifts forms but we don’t have the ability to actually create new water for the earth, so we need to look at how we manage resources more critically,” Manus began.

Wastewater alternative

“People’s attitude to water – the way that we potentially waste or save it – has to be targeted for interventions at a much earlier stage, when people are younger.”

IMIESA October 2017

He pointed out that desalination is only really viable for drinking water supply for those South Africans living in coastal areas, highlighting the need to improve the cultural acceptability of direct wastewater reuse. “As much as desalination is a viable option, the same technology is required to clean water that has already been used, and the salinity level of that water is much lower, which means energy consumption and membrane filters may not be as intense. This makes wastewater a more economically viable option as a water source,” he said, while also acknowledging the need to invest in the country’s wastewater treatment plants.

WATER & WASTEWATER

Free basic water Manus plays an instrumental role in determining raw water tariffs for the DWS. For years, water experts have questioned whether free basic water, part of the tariff structures of almost all municipalities in South Africa, can continue. There is no simple answer to this question. On the one hand, freshwater demand is tipped to increase by 50% by 2030. This will have severe consequences for South Africa, a country already over-reliant on surface water and one that has fully utilised its existing surface water resources. On the other hand, as Manus points out, doing away with free basic water is not a feasible option at this time because the economic reality of the country is such that the poor cannot afford to pay for water and it is guaranteed to them as a right.

Coastal desalination Laubscher kicked off his discussion with some frightening statistics: “Only about 0.08% of the world’s water is accessible for direct human use, which means that 2.5 billion people worldwide live in waterstressed areas. Our national water resource strategy says that the national water deficit will be more than 240 000 Mℓ per year by 2025. This is the shortage that desalination seeks to fill. A decrease of only 1% in quality and the usability of water in South Africa may cost 200 000 jobs, nearly 6% in disposable income per capita and 5% – or R1.8 billion – in government spending.” Given the facts, Laubscher pointed out that it’s not a question of whether South Africa could afford to desalinate but whether it could afford not to, while also acknowledging the high costs associated with the technology. “At the moment, South Africa treats surface water at a cost of about R5 to R10 per m3. When you desalinate water, the costs more than double, even when using reverse osmosis (RO), which is the preferred desalination technology in South Africa because it is more affordable than thermal desalination. In total, the cost of RO seawater desalination, including transportation and environmental cost, is about R11 to R16 per m3.” “Unfortunately, technology has not yet caught up with demand, despite significant investments in research and development around RO technology. I trust that science will be able to develop a viable solution,

though. Then it will be up to the policy experts to come up with a crosssubsidisation model that makes water affordable to all.”

Mixed approach Like Manus, Laubscher believes in a mixed model incorporating direct wastewater reuse. However, when rolling out any technology, the unique geographic and site conditions need to be examined before deciding on the best solution. For example, one of the biggest costs involved with desalination is energy. A few years ago, the City of Cape Town mothballed a desalination plant at its Koeberg nuclear power plant. Now, the city is reconsidering building a new plant on the site, which could eventually provide up to two thirds of Cape Town’s daily water needs – anything from 150 Mℓ/day to 450 Mℓ/day. The site’s location near a power plant could considerably reduce costs.

Behavioural change Wolf added that climate change has resulted in old hydrological models no longer being reliable enough to give an accurate picture of the type of rainfall people can expect in future. She also pointed out that technology would not solve the problem of water scarcity on its own and that people’s attitude would have to change to enable South Africa to manage water effectively for the future. “Technology is quite easy to work with, but changing the way people think about water is much trickier. People’s attitude to water – the way that we potentially waste or save it – has to be targeted for interventions at a much earlier stage, when people are younger.” She also explained how Unilever and Rhodes University are pursuing a model where they encourage catchment management agencies to work with the relevant municipalities to ensure that people come first when it comes to water rights. This marriage between technology and behavioural change is something that needs buy-in from all South Africans in order to create a culture that values water as a scarce resource. This is a prerequisite for the country’s future water security, as well as its economic and environmental health.

Freshwater demand is tipped to increase by 50% by 2030

Only about 0.08% of the world’s water is accessible for direct human use

By 2025, South Africa’s water deficit will be more than 240 000 Mℓ per year IMIESA October 2017

PIPES, PUMPS & VALVES

I disagree that Trump has a total disregard for the environment; that’s a perception generated through the poor coverage the president gets through the national media. It’s ‘fake news’.” Tony Radozewski, Plastic Pipe Institute, USA

t ol i T he p

n 4 and 5 September this year, South Africa’s plastic pipe fraternity gathered at Emperors Palace in Ekurhuleni for PIPES XI – a two-day conference where design engineers, plastic pipe manufacturers, regulators and other stakeholders met to discuss the latest innovations and industry trends. Held annually, the Southern African Plastic Pipe Manufacturers Association (SAPPMA) conference has always drawn a respectable number of leading industry experts from all over the world. In his welcoming address, SAPPMA CEO Jan Venter noted, “This year sees even more international speakers, as the conference is being hosted jointly with the Plastic Pipes Conference Association (PPCA).” The PPCA is the global organisation advancing technical skills and expertise in the effective and sustainable use of plastic pipes. “This partnership has resulted in a twoday event, rather than just one, necessitating a larger venue, making this a landmark conference for SAPPMA,” Venter added. Pipelines are one of the most important elements of a developed country’s infrastructure. As Venter pointed out, “There can be no civilised life without the underground piping that many take for granted. “Over the years, SAPPMA has worked hard to maintain quality and standards in South Africa and to dispense useful technical information. That is one of the main reasons we hold this conference every year: to get technical information to the people who are interested in it and those who need it.” Venter’s ultimate takeaway was that, in spite of the difficult economic conditions

Demonstrating a more international flavour than ever before, this year’s annual SAPPMA PIPES conference saw presenters tackling more controversial topics, including infrastructure spend in Trump’s USA and the proposed South African Mining Charter. By Frances Ringwood

f piping

over the past few years, the importance of what the plastic pipes community does is undiminished. “Therefore, we will continue doing what we can to maintain the integrity of this industry, the quality and all the other good things that will sustain the industry over the long term,” he said.

Inventing for sustainability Also delivering his welcoming address was Zoran Davidovski,

vice-president: Marketing and Innovation at the Pipelife Group, Pipelife representative of the European Plastics Pipes and Fittings Association and PPCA organising member. In his address, he noted that PIPES XI is also the sixth PPCA spin-off conference undertaken in conjunction with a local plastics pipe association or organisation, with previous iterations being held in China and Russia, among others. “As you know, the Cradle of Mankind lies but a few kilometres from today’s venue. Perhaps the connection between the Australopithecus discovered there two years ago and today’s ‘Homo plasticus’

IMIESA October 2017

is not fully obvious, but what is apparent is the fact that, for sur vival, we need inventions: the axe, the plough, the wheel, etc. “Not only do we need inventions, we also need sustainability. We need to take care of our communities, water supplies and arable farmlands. During this conference, the two major topics being discussed are invention and sustainability,” Davidovski pointed out. He also noted that last year marked the 80th anniversary of the first polyvinyl chloride (PVC) pipe and how, during the talks presented at PIPES XI, the audience would hear about the latest innovations in PVC-O – a type of PVC oriented at high temperatures so as to be as strong as any steel pipe yet more economical.

International guests and ‘fake news’ Presenters flew in from Australia, Austria, Belgium, Germany, India, the Netherlands, Norway, Spain and the USA to join local plastic pipe experts in mapping the global plastic pipes market and determining how local trends impact upon the bigger picture. One of the more controversial presentations came from native Texan Tony Radozewski, from the Plastic Pipe Institute (PPI) in the US, who argued that, from the point of view of GDP growth and infrastructure development, US President Donald Trump is actually doing a good job. “Mr Trump said he was going to make America energy dominant. A headline on Investor’s Business Daily on 3 July was ‘Trump Launched An Energy Revolution While Everyone Was Obsessing On (sic) His Tweets’. Radozewski then went on to criticise the previous Obama administration for cancelling the XL Keystone pipeline and congratulate Trump for opening the Arctic for drilling. The presentation was ultimately about how the manufacturers of Middle America were benefitting considerably from deregulation. South Africa is a developing nation with different stakes and commitments in global clean energy and carbon debates. Naturally, members of the audience wanted to know how Radozewski could possibly support Trump’s environmental position.

IMIESA October 2017

PIPES, PUMPS & VALVES

ABOVE Ian Plaatjes, corporate services executive at SABS ABOVE RIGHT SAPPMA annual conference attendees this year reached higher numbers than ever before

He responded, “I disagree that Trump has a total disregard for the environment; that’s a perception generated through the poor coverage the president gets through the national media. It’s ‘fake news’.” Not wanting to be outdone on his the home turf, award-winning South African economist and now three-time SAPPMA conference veteran Roelof Botha delivered an equally controversial presentation, rubbishing South Africa’s proposed Mining Charter, which will

put 51% of mining shares in the hands of BBBEE partners as benefitting “people from India and Dubai or anybody else who gets fast naturalisation thanks to Malusi Gigaba”. He then went a step further by interrogating BBBEE more generally, asking “what the hell does the pigmentation level of your skin have to do with your character, your intellect and your approach towards life in general?” While both of these presentations featured some charry content, they did ultimately have a bearing on the important issue of the need for manufacturing support and infrastructure spend, and their role in GDP growth.

Good-news economics Botha’s presentation was part of a mainstay of SAPPMA conferences, where an economist provides an overview so that attendees can situate themselves and their businesses within a broader

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context. He started by lashing the Reserve Bank’s failure to drop interest rates, saying: “Without wanting to agree with the new Public Protector, who is clueless, the Reserve Bank is not playing its part regarding the interest rate.” Botha took this opportunity to remind the audience that he is self-employed. “The Reserve Bank has a mandate broad enough to decide if it wants to increase or decrease interest rates. If it were to lower the interest rates, this would lower the cost of credit, making it easier for businesses to invest in new productive capacity, and making it easier for consumers to go buy things. In South Africa, what we’ve experienced of late is declining capital formation and declining endurable consumption because of political uncertainty and high interest rates. “The plastic piping industry is, ultimately, involved in infrastructure. Infrastructure creation is also a function of interest rates – of the capital costs because infrastructure is expensive. There are a host of indicators that should have signalled the Reserve Bank to lower interest rates but it has not woken up to these as yet,” said Botha. In spite of this issue, Botha says South Africans have reason to be more optimistic as the year progresses. “The good news is that inflation is dropping like a stone. The Consumer Price Index has come down since December by 220 basis points and it is a certainty that interest rates will continue dropping. That is going to lower the capital costs in South Africa and, with a little luck, we will see relatively modest growth in the second half of this year, rising in 2018, especially after the electoral conference in December. This is because, no matter who wins, there will more certainty than there is right now.” Exactly one day after the conference, Statistics South Africa announced that the economy had grown by 2.5%, moving the country out of a technical recession.

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As the 11th PIPES conference drew to a close, audience participants went away with new clarity on important issues affecting the industry. This year also saw higher participant numbers than ever before, ushering in what looks to be a new decade where cooperation will foster even higher standards of technical excellence for plastic pipe manufacturing, design, installation and innovation.

IMIESA October 2017

PIPES, PUMPS & VALVES

“Results can be emailed directly to the end user. In addition, the user is able to email our technical department directly from the app itself in the event of any further queries,” explains Renier Snyman, technical and product manager, DPI Plastics.

Expanded production capabilities

Pipeline app launched

he DPI FlowCalc app, recently unveiled by PVC and HDPE pipeline manufacturer DPI Plastics, follows the global trend towards conducting business via smartphones. The app is now available for free download from Google Play and Apple's App store and makes it easier for customers to obtain critical information on their pipeline requirements and specifications. A first for the South African industry, the app includes a calculator that can be used to determine friction loss, flow resistance, pipe size, and water delivery for pipelines under pressure.

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Commissioned in March 2017, DPI’s new factory, located adjacent to the existing Roodekop facility in Johannesburg, has 14 extrusion lines, and an installed capacity of 2 200 t a month. This facility is set up to produce HDPE pipe up to 1 000 mm in diameter, and up to PN25 pressure class. The Durothene-branded series is produced in ranges from 16 mm up to 1 000 mm, in pressure classes from PN3 to PN25. Smaller pipes up to a diameter of 110 mm are coiled in up to 100 m lengths. “Our laboratory has melt flow indexing and oxidation induction time testers to perform critical quality tests on our HDPE pipes,” Snyman explains. DPI Plastics also has a recycling facility where internal scrap is reworked into pellets that are tested and reused. The latest addition enhances the manufacturing capabilities of DPI Plastics, which already boasts the largest PVC pipe production capability in Africa. Commissioned in 1980, the existing Roodekop factory has 15 extrusion lines, and an installed capacity of 2 700 t a month. It produces PVC pipe in diameters from 50 mm up to 630 mm, and pressure classes from 4 bar to 25 bar. “This is the only factory in Africa that produces 630 mm diameter PVC-m pipe,” Snyman confirms.

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PIPES, PUMPS & VALVES

An end to pump corrosion A new coating formulation that combats aggressive fluids and passes on major savings in power consumption has been developed.

s part of APE Pumps/Mather+Platt’s (APE’s) ongoing R&D programme, APE commissioned a specialist chemical formulation company to create a unique product that meets its stringent requirements. The end result is an advanced polyurethane UV-protected coating called Roc-Anode, which APE now applies to the inside surfaces of its pumps, in specific applications, to protect the metal from abrasive and corrosive liquids. “This coating also has an added benefit: it significantly improves flow efficiencies and, in the process, lowers the operating power amps, reducing the amount of energy needed,”

explains Richard Harper from APE. Roc-Anode meets the requirements of a diverse range of industries. In mining, one of the toughest applications, this advanced coating has gained

major traction in areas that include pipework, structural steel, process plants and storage tanks. The same is true in general industry and the municipal wastewater and sewerage BELOW LEFT Roc-Anode can be applied via brush, roller or specialised spray systems BELOW Roc-Anode coatings meet the requirements of a diverse range of industries

IMIESA October 2017

APE pumps - Pumps at the heart of africa Mining

Waste Water processing

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

Power Generation

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

Petrochemicals

Vertical sump pumps API 610 pumps

PIPES, PUMPS & VALVES

ABOVE Test sample: two galvanised steel bolts were partially coated in Roc-Anode and immersed in 30% sulfuric acid. The trial was terminated after 72 hours, at which time the steel was still being dissolved by the acid; the only effect on the Roc-Anode was a colour change due to staining from the oxidised steel On the left is a section of cured Roc-Anode, which was immersed for 30 days in a jar containing 30% sulfuric acid, with no measurable effect on the coating

pipeline markets, and other instances requiring corrosion prevention as a top priority. “When used correctly, Roc-Anode provides many years of internal protection against corrosion caused by condensation and moisture penetration of hollow steel products,” he continues. “Externally, Roc-Anode counters environmental impacts on structural steel work, with product operational life expectancy in excess of 10 years.” In industrial settings, Roc-Anode coatings are able to withstand attack from 30% dilute sulfuric acid and 10% hydrochloric acid – among the most corrosive substances commonly used in industry.

Trials During one of many laboratory trials, a section of cured Roc-Anode was immersed in a jar containing 30% sulfuric acid for 30 days, with no measurable effect on the coating. In another test, two galvanised steel bolts were partially coated in Roc-Anode and also immersed in 30% sulfuric acid. The experiment was terminated after 72 hours, at which time the steel was still being dissolved by the acid; however, the only effect on the Roc-Anode was a colour change due to brown staining from the oxidised steel.

APE recently commissioned SGS Metlab to conduct adhesion tests, in accordance with the ASTM D4542:2002 methodology, for a client in the Western Cape, by applying Roc-Anode to galvanised steel plates. The product did not separate from the steel at more than 8.30 MPa after having cured for 28 days. “This was an independent test and the result is a major achievement, considering the industry standard is around 3 MPa,” Harper points out. The trial was conducted to evaluate RocAnode’s suitability as a coating on the inside surfaces of APE pump casings to protect the metal from corrosion and abrasion caused by entrained solid matter in the pumped media. “We can say, with confidence, that RocAnode has extended the intervals between services and, therefore, offers a significant reduction in the cost of ownership of our pump products,” Harper proudly states. Based on the field-proven success of the Roc-Anode coating system, APE/Mather+Platt has created a new business unit dedicated to rolling out this solution. Headed by Harper, this division is available to consult with customers on issues related to corrosion protection on an industrial scale. IMIESA October 2017

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The newgeneration Etabloc close-coupled pump range offers an energy-efficient solution to a wide range of industries including industrial and municipal water pumping.

he newly enhanced series from KSB Pumps and Valves comprises 43 pump sizes, which can be driven by either two- or four-pole motors. With further additions to the selection chart, the pump size can now be selected even closer to the best efficiency point. Designed for greater versatility, the range offers a large variety of nozzle positions and installation options for maximum flexibility. The discharge nozzles are fitted with more connection options for pressure gauges as standard, so several measurements can be conducted at the same time, and the flanges of suction and discharge nozzles are optionally drilled to EN1092 or ASME dimensions, for all materials. Another feature of the updated type series is its service-friendly design, says David Jones, regional sales manager, KSB. The conical seal chamber, for example, allows for easy access and provides more space for maintenance work.

Energy efficient The drive lantern comes in standardised mating dimensions, offering the operator maximum choice in selecting an electric motor. Every pump is supplied to the customer with the impeller diameter trimmed exactly to the duty point. This, combined with the large range of pump sizes available, is the only way of keeping the pump set’s energy consumption to the necessary minimum. The latest generation of the Etabloc-type series meets strict global standards including the EU requirements of Commission Regulation 547/2012/EU for water pumps.

IMIESA October 2017

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TRANSPORT, LOGISTICS,VEHICLES & EQUIPMENT

READ INSIDE 102

Taking an integrated approach

A mobile breakthrough for asphalt

Moving the ear th with LeeBoy

The latest in pothole repairs 105

Building routes with Roadtec

New backhoe brand

Leading in mechanised demolition

101

107

IMIESA talks to Reyan Fortune, Technical Advisor, Associated Asphalt Equipment (AAE), about the company’s history to date and its future expansion plans as a leading supplier of asphalt equipment, bitumen handling and earthmoving solutions in sub-Saharan Africa.

Taking an integrated approach What was the motivation for the formation of AAE? RF AAE identified a gap in the market for price-competitive products that meet the needs of a diverse range of potential users, from major contractors to SMMEs. The products we distribute and support are world class, and we are proud to represent the following OEMs, namely Roadtec, Romanelli and LeeBoy. LeeBoy is a VT Systems company with factories in the USA, Brazil and India. Roadtec is a USA-based manufacturer, while Romanelli is headquartered in Brazil. In some cases, we will be supplying the full OEM range from each of these manufacturers; in other

IMIESA October 2017

instances, we will be importing specific product lines that we’ve identified for either niche market expansion, or mainstream applications. In each instance, we’ve selected the best machine for the job. Roadtec is a leader in roadbuilding and asphalt paving equipment and has a longestablished reputation locally, so we’re excited about this recent addition to our offering. VT LeeBoy, Inc. is a massive global player and produces a very comprehensive range that includes asphalt pavers, motor graders, compaction rollers, asphalt distributors, brooms, pothole patchers and chip spreaders. In addition to LeeBoy’s earthmoving range,

other key LeeBoy brands sold in South Africa comprise LeeBoy Ticel asphalt plants and LeeBoy Rosco brooms and chip spreaders. Rounding out the extensive line-up are the products from Romanelli, the definitive choice when it comes to slurry pavers, bitumen distributors and cold mix asphalt plants. All our OEM products have proved themselves for decades in key markets that include Europe, South America, the USA and Asia.

What is AAE’s marketing strategy? Our goal is to progressively expand our range for the roads construction and maintenance

market, while at the same time ensuring that these brands are aligned in terms of current and future client fleet requirements. We identified the SMME contractor market as a major opportunity since this is a key focus area for National Treasury, provincial governments and all municipalities in terms of procurement strategies. AAE is a BBBEE Level 1 contributor and 100% blackfemale-owned company, with its head office in Durban. Since its inception in 2013, the company has made significant strides in capturing market share based on its business philosophy of 'premium products backed up by premium service’.

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

LeeBoy

What is the key differentiating factor for the asphalt market? We want to provide turnkey solutions. For asphalt plant owners, in particular, we’d like to assist them in terms of their infrastructure design requirements, plant set-up, weighbridge establishment, as well as assigning AAE personnel to provide on-site technical advice – especially for new-start-up companies.

LeeBoy Rosco

LeeBoy Ticel

RoadTec

We want to make sure that we sell bitumen and asphalt plants that succeed.

maintenance and inventories. Parts are housed at our warehouse facility in Durban.

How does AAE support its brands?

And, in closing, what future innovations are in store from AAE?

We have in-house engineering expertise. That extends from professional ser vices to parts backup, and artisan field service. There is also a high degree of parts commonality across our brands, which simplifies both

We will be unveiling a number of new products at Bauma Africa 2018 in March. These include cold-mix asphalt plants, new earthmoving machines, and a distributor that is

Romanelli

designed to apply crumbed rubber bitumen. We understand that the right equipment and technology are vital for the efficient operation of any construction business. We also appreciate that the best solution for the job doesn’t have to come at the highest price. To this end, the equipment we supply has been tried and tested to deliver best-in-class results.

www.asphalt-equipment.co.za

IMIESA October 2017

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

Moving the earth with The first choice for emerging and developing markets.

AE is gaining ground in the South African market for the LeeBoy range of earthmoving machines and pavers, with a number of new product introductions planned for early 2018. On the earthmoving front, these comprise the LeeBoy 995 motor grader, the 525 hydraulic excavator and the 528-D crawler-mounted drill rig, which are being showcased at Excon in India during December 2017. “We have focused on supplying products that are ideally suited to the SMME contractor and municipal segments,” says Fortune. The current LeeBoy earthmoving line-up supplied locally comprises the 699 backhoe loader, 523E excavator (which will

THE NEW LEEBOY 525 HYDRAULIC EXCAVATOR This 24t machine features a modern design and comes equipped with industryleading ergonomic features. The lever-type mechanical throttle adjustment on the previous generation 523E model has been eliminated and replaced with an ergonomic knob-type throttle control.

IMIESA October 2017

be replaced by the 525) and two grader models, namely the 12t LeeBoy 785 and 15.5t LeeBoy 985 units. These will be joined by the 23.5t LeeBoy 995 grader in January 2018. The sole hydraulic excavator unit available is the 24t 525 machine, which comes standard with hammer lines. This is a very robust machine fitted with a Berco heavy-duty undercarriage system and powered by a Cummins engine.

LEEBOY 528-D CRAWLER

LeeBoy has entered a new product segment with the launch of the 278t LeeBoy 528-D drill rig

LEEBOY PAVER 1000G

Pavers One of LeeBoy’s major research and development successes has been the refinement of its pavers. The series starts with the 1000G mini paver; this particular model presently dominates in North America, where it enjoys an approximately 65% market share. The 1000G is a highly flexible product designed to meet smaller works, as well as the paving of onelane road widths. At the other end of the scale is the local addition of the LeeBoy 8816B paver. AAE sold its first unit in September this year. The 8816B has an approximate operating weight of 11.3t (with screed fitted) and can pave widths of up to 6 m. Strong interest is also being generated for the LeeBoy 1200B Maintainer, which is fitted with a milling drum and can pave in a 0.965 m to 1.57 m width range, making it ideal for applications that include edge-break repairs. This machine is ideal for municipalities and road maintenance contractors. A product that has its own unique niche is the approximately 2t LeeBoy 420D mini pneumatic roller, ideal for smaller jobs and when working in confined areas.

LEEBOY BACKHOE LOADER The LeeBoy 699 has a 74 kW output and is a new generation machine designed to deliver. LeeBoy has been manufacturing earthmoving solutions since 1964

LEEBOY PAVER 8816B

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

ROSCO A WHOLLY OWNED LeeBoy brand, the Rosco range is equally renowned for premium quality. For the South African market, AAE has appointed Macnay as a subdealer to supply and support the Rosco broom and chip spreader lines. The key focus for the self-propelled broom range will be the RB50 unit, while the CSH and CSV chip spreader models will both be supplied. The CSH is the static version, while the SCV has a hydraulic hopper. All CSH units come with the option of a 10, 12 or 14 foot hopper. The CSV’s variable-width-spread hopper and smaller overall footprint provide

TICEL

Brooms and chip spreaders. flexibility, which enables chipping within confined areas. Given the raw power of these units, the quality of the finished product remains the same even in areas with rough and steep terrain. On the CSH hydrostatic chip spreader, superior automation allows the operator to place materials precisely using a computer-controlled system. To ensure coverage is consistently smooth, immediate adjustments can be made by the operator using the daylight-readable ergonomic computer screen.

ROSCO CSV CHIP SPREADER

ROSCO RB50 BROOM

Redefining the future of mobile asphalt plant technology.

THE TICEL CF120 THE LEEBOY TICEL mobile asphalt plant range is manufactured in Brazil. The three models selected for South Africa are the CF80, CF120 and CF160. The number indicates output capacity in tonnes per hour. Larger models are also

ROMANELLI

available on request from 200 tph up to 260 tph. All models are equipped with recycling collars for recycling of reclaimed asphalt pavement at various percentages. The first plant sold to date is a CF120 unit, which was supplied and commissioned in

January 2017. The key benefit of the CF120, which is a common characteristic across the range, is the plant’s simplicity and low cost-per-tonne operation. Ticel has set a new standard for practical design and that was a key factor in AAE’s decision to distribute this range locally. The range targets SMME and larger contractors and provides the flexibility to set up the plant within close proximity to a specific project, greatly reducing asphalt haulage distances. Hot-mix asphalt can be supplied on rehabilitation and upgrade contracts, irrespective of their location – something not possible with static commercial plants.

Made in Brazil and surfacing the world.

ROMANELLI EHR 15 FORMING PART OF AAE’s integrated solutions is a selected range from Romanelli’s product line. The key products distributed locally comprise the: • UHR 700 and UHR 900 slurry pavers with 9 m3 and 18 m3 capacities, respectively, designed for microsurfacing using modified emulsions • UPMR 40/60 cold-mix plant • EHR 15 crumb rubber bitumen distributor. AAE recently sold a UPMR 40/60 plant to the Johannesburg Roads Agency. These coldmix plants are designed for manufacturing

cold-mix asphalt as well as precoating aggregates used in chip and spray applications. Sanral has stipulated that precoating procedures must be carried out through static plants, as opposed to previous stockpile mixing practices. AAE has now taken the decision to import a mobile version. Romanelli’s EHR 15 is specially designed to meet the increasing demands for new paving techniques on rubber-modified seals. This unit is recommended for applications requiring superior performance, high elasticity and resistance to ageing from asphalt binders. IMIESA October 2017

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

Building routes with Roadtec pioneered the development of the material transfer vehicle in 1989 and, since then, has continued to refine the optimum techniques for asphalt pavement contruction.

ROADTEC PRODUCT LINE MATERIAL TRANSFER VEHICLES MTV-1100E SB-1500E/EX SB-2500E/EX MILLING MACHINES RX-100E RX-300E/EX RX-600E/EX RX-700E/EX RX-900E/EX COLD-IN-PLACE RECYCLING Both the RX-700e/ex and RX-900e/ex milling machines can be equipped with bolt-on packages that allow them to be used for cold-in-place recycling

ssociated Asphalt Equipment was appointed as the Roadtec distributor in September 2017 and this exciting development enhances the product range that AAE provides to the roads maintenance and construction market in terms of its one-stop-solution approach. Roadtec machine categories supplied locally comprise the material transfer vehicle range, the milling machine series, and the soil stabiliser and reclaimer product lines. Based in Chattanooga, Tennessee, USA, Roadtec was founded in 1981 and forms part of Astec Industries, a corporation famed worldwide as a leader in asphalt paving equipment since the 1970s. Roadtec was the first manufacturer in the industry to install an FXS fume extraction system as standard equipment on all its pavers and Shuttle Buggy material transfer vehicles. In turn, Roadtecâ&#x20AC;&#x2122;s new Comfort

IMIESA October 2017

ROADTEC STABILISER Drive operator system embodies the latest in ergonomic design, providing greater visibility and low-effort fingertip control.

MTVs When it comes to material transfer vehicles (MTVs), Roadtec is at the forefront of development and its machines are a common sight on construction projects across the globe. MTVs are among the most critical interfaces in the paving train and are designed to lower operating costs, facilitating continuous paving while reducing asphalt haulage vehicle congestion on-site. Contractors can choose from a three-model line-up to address the needs of most hot- or warm-mix asphalt applications. The baseline model is the MTV-1100e, which allows simple entry into non-contact paving. This is followed by the mid-range SB-1500 Roadtec Shuttle Buggy, which is one of the mainstream choices. The SB-1500 can store up to 13.6t of asphalt

STABILISERS/RECLAIMERS SX-2E SX-6E SX-8E

mix and is fitted with an end dump hopper or an optional windrow pickup head. It also features the patented anti-segregation auger, which remixes materials for the control of aggregate and temperature segregation. Leading the range is the SB-2500e/ex Shuttle Buggy, which has a 25t surge capacity and can store and transfer hot-mix asphalt material from a truck to a paver for continuous paving. An optional windrow pickup head is available.

Road milling machines The cold planer series offers solid design features, systems that are simple to troubleshoot, and low-cost operation. The extensive range in this category meets every requirement â&#x20AC;&#x201C; from small suburban jobs to major highways. Specific models are available in three- and four-track configurations, and each Roadtec machine is compatible with the exclusive Guardian remote telematics system.

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

ROADTEC MTV Key models in the planer line-up include Roadtec’s RX-300 compact milling machine, which combines manoeuvrability with high performance to easily operate in a wide range of applications. With a base cutting width of 1.2 m and the capability of cutting up to 305 mm deep, the RX-300 is excellent for both commercial applications and narrow milling projects. A 100-degree load-out conveyor swing capability enables the machine to easily discharge material in a wider range of environments. Moving up the range, the larger RX-700e/ex milling machine is available with either three- or four-track assemblies. Built with the Roadtec focus on balanced weight distribution, the RX-700e/ex is a heavy-duty unit that is user-friendly in both operation and maintenance. The machine cuts up to a depth of 35.6 cm and standard widths are 201 cm, 218 cm, 249 cm and 305 cm. Like all Roadtec planers,

this model features a 60-degree front loadout conveyor swing. The Roadtec RX-700e/ex and the range-topping RX-900e/ex milling machines are available with bolt-on packages that equip them for cold-in-place recycling projects. With bidirectional functionality, these machines make it easy to down-cut for better sizing. Providing the ultimate in versatility, Roadtec’s niche RT-500 unit can be paired with the RX-900 to create a cold-in-place recycling machine, or it can function on its own as a mixing plant, allowing for more efficient processing of reclaimed asphalt pavement.

Stabilisers/reclaimers Whether employed for new or reconstruction, Roadtec’s soil stabilisers and road reclaimers are designed to perform a wide variety of tasks. Each machine is well balanced and constructed with a sealed box frame to make them as durable and versatile as possible. Roadtec’s SX-2e is a task-specific

soil stabiliser with a rear-mounted cutter designed for small to medium-sized projects. Next in line is the mid-size SX-6e/ex soil stabiliser/reclaimer, equipped with four cutting speeds and designed for stabilising, pulverising or cold recycling projects. With an operating weight of 37 195 kg, the SX-8e/ex is the largest in the series and capable of cutting down to a depth of 50.8 cm and a width of 254 cm. The machine’s weight is evenly distributed between the two axles, which results in power being applied more efficiently. With weight balanced over the cutter, the machine is designed to handle the most challenging surface and ground conditions. When combined on-site, the Roadtec range functions as an interrelated system to tackle all road construction phases – from layer works to final riding surfaces. It’s a complete solutions approach.

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Leading in mechanised demolition One of Forte’s Hyundai R300LC9S excavators fitted with a hydraulic shearing tool

Expanding its niche, Fochville-based Forte Demolition Services is working across South Africa on key projects, supported by a Hyundai earthmoving fleet.

LEFT Marolize (director) and Edward Gibbens (CEO) from Forte Demolition Services

ince 2012, For te Demolition Ser vices has been involved in various demolition fields, including asbestos abatement, mechanical and technical demolition (including industrial plants and structures), as well as rehabilitation. “Now we mainly pursue two avenues – namely asbestos abatement and full mechanical specialised demolition,” explains Edward Gibbens, CEO, Forte. To date, Forte has completed some of the largest clean-up projects in South Africa in key sectors that include the mining and petrochemical industries. Spearheading Forte’s mechanised requirements is a dedicated Hyundai earthmoving fleet, supplied and supported by High Power Equipment Africa (HPE Africa), sole distributor of Hyundai construction equipment and Doosan hydraulic breakers in Southern Africa.

“Through trial and error, we’ve found a partner in HPE Africa that lives up to our standards and can produce genuine 24/7 backup service and parts availability,” says Gibbens, adding that expert advice from HPE Africa has ensured an optimum machine/application match.

Fleet expansion Forte currently operates a fleet of about 25 machines, and has an ongoing replacement programme in place to ensure high availability. Recent acquisitions include Hyundai R220LC9S and R300LC-9S tracked excavator units, an HSL850-7 skidsteer, an HL760-9S wheel loader and two H940-S backhoe loaders. The excavators and wheel loaders are fitted with Cummins engines, while the backhoe and skidsteer come equipped with a Perkins and Kubota power plant, respectively. Hyundai’s R220LC-9S and R300LC-9S crawler excavators are fitted with Tier II Cummins B5.9-C

and C8.3-C power plants, respectively. These engines have been designed with 40% fewer parts than competitor units. This feature provides an exceptional power-to-weight ratio, and promotes simpler maintenance. For load and carry applications, the HL760-9S is a leader in the medium class. With an operating weight of 17.9 t, a maximum bucket capacity of 4.1 m³, and a maximum digging force of 159 kN, it is ideally suited for any project calling for productivity, reliability and low operating costs. The same applies to the H940-S backhoe loader, which has a 7.6 t operating weight and a maximum backhoe digging depth of 4 220 mm. The maximum dumping height is 3 450 mm for the 0.90 m³ loader bucket and 5 665 mm for the 0.17 m³ backhoe. Forte’s smallest Hyundai, the HSL850-7 skidsteer, is a versatile workhorse weighing in at 3.2 t and fitted with a 0.37 m³ bucket. “We’re impressed with all our Hyundai machines. They deliver the operator comfort, productivity and reliability we expect from a leading OEM. We believe this is going to be a long-standing relationship we’ve built with HPE Africa,” Gibbens concludes. IMIESA October 2017

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Our services include: Turnkey Asbestos Abatement Projects, Demolition of Industrial Plants and Structures. Specialising within the Mining, Industrial and Petro Chemical Industry Nationwide. Contact Details: Head Ofﬁce: +27 81 470 0965 Email: info@fdeng.co.za Website: www.fortedemolition.co.za

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

A mobile breakthrough for asphalt

he South African introduction of the CiberiNOVA 2000 continuous asphalt plant, in October 2017, truly redefines the concept of mobility in this field. That’s because this is the first two-section trailer-mounted unit in its class that can be directly connected and towed via a truck. The iNOVA 2000 is homologated and licensed to run at a moment’s notice on public roads. Most competitor models depend on low-beds to meet South African transport laws, and since they cannot be immediately hooked up, their disassembly and crane-assisted loading come at a much higher cost.

iNOVA 2000 MAJOR BREAKTHROUGHS:

Automatic control and consistent throughput have reached new levels of refinement with the development of a revolutionary, trailer-mounted solution. By Alastair Currie

“Wirtgen refers to the Ciber iNOVA 2000 as a ‘two mobility’ solution,” points out Waylon Kukard, sales manager, Wirtgen South Africa. A wholly owned Wirtgen Group company, Ciber is an original equipment manufacturer based in Brazil. So far, more than 1 800 Ciber plants have been sold worldwide. Production capacities on the iNOVA 2000 range from 100 tph to 200 tph, depending on whether the plant is at sea level or higher altitude. In Johannesburg, which is approximately 1 753 m above sea level, the anticipated output is 170 tph, while the volumes in Cape Town would be closer to 200 tph. This plant can comfortably handle an approximately 20% reclaimed asphalt (RA) mix, which has been proven on global sites. Higher RA capacities are also achievable.

Control over aggregates Mobility is a key factor for contractors, drying time but so too is the technology, and here A true appreciation of the iNOVA the iNOVA 2000 excels with three 2000’s capabilities begins with a major breakthroughs: more detailed explanation of its three •M ore advanced control over the main technological advantages. Let’s aggregate drying time start with the aggregates drying process. • Significantly improved fuel and As Kukard explains, for the production of energy economy, thanks to a new hot asphalt mixes, the aggregates must be combustion system completely dry and heated to the optimum • Precision control of the mixing time temperature to obtain adhesiveness with the for the aggregates and asphalt binder bitumen binder. This ensures the cohesive

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Ciber’s iNOVA 2000 has two interconnecting units that form the asphalt process chain

mix properties required, as determined by the design specification. Traditional plants dry and heat the aggregates in a rotating drum, driven by motors with a fixed speed. That means the drying time is also fixed, so its does not factor in variables such as aggregate moisture content or their adhesiveness characteristics with the asphalt binder. More porous aggregates need to remain in the drying environment for longer until the presence of moisture has been entirely eliminated. However, those aggregates that dry out faster should be released. Fixed systems cannot regulate variable aggregate mixes effectively. To address this requirement, Ciber invented a new drying system for the iNOVA 2000. This adjusts the aggregate drying time according to the characteristics of the inputs mentioned above. A frequency inverter automatically regulates the rotation speed on the drying drum. The more porous aggregates are subjected to the burner for longer, while less porous aggregates go through the dryer faster. The iNOVA 2000 is the only asphalt plant on the market that offers this technology in standard configuration.

TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

Drying time control means that more porous aggregates spend more time receiving heat from the flame of the burner for complete drying, while less porous aggregates go through the dryer faster, without altering the plant's production

Intelligent combustion Traditional burners employed in asphalt plants use the air from the environment (sucked in by an exhaust fan with constant turning speed) and a mechanical fan (called a blower) to provide the amount of air needed for combustion inside the dryer drum. The control over the airflow is regulated via a component called a damper. The optimum combustion ratio is 13:1 (13 volumes of air for one volume of fuel) and the airflow variation is dependent on the position of the damper, since the exhaust flow is constant. The development of iNOVA’s proprietary Total Air system perfects this by accurately and automatically controlling the air-to-fuel ratio. All the combustion air is mechanically supplied by the plant (without air suction from the environment) through two fans (a blower and an axial fan). Total Air works in a closed loop: only the air used for combustion is heated, resulting in major fuel economy. This can realistically translate into a saving of one litre per tonne.

the material throughput at the outlet area between the mixer and the drag elevator. When this outlet area is reduced, the blend is trapped within the mixer, increasing the material volume and the mixing time, and keeping the production of the plant constant. If the outlet area is open, the asphalt mix leaves the mixer more freely, decreasing the volume of material in the mixer and decreasing mixing time, while still maintaining constant production. “The iNOVA 2000 always ensures optimum homogenisation of the aggregates prior to the injection and dispersion of the bitumen binding agent, and comfortably handles special mix designs that use additives,” adds

Kukard. “And it all comes together in a highly mobile package.” The Ciber brand has been in South Africa for more than 10 years and there are currently 11 continuous mix units in operation. Ten are Ciber 120 tph UACF 17 P2 plants, and the other is a 50 tph Kompakt KP500 unit. The iNOVA now becomes the third option in the mobile range. Alongside its on-road series, Wirtgen also fields the Benninghoven asphalt batch plant range, widely regarded as the global class leader. To date, a Benninghoven plant has not been set up in South Africa. However, Kukard says Wirtgen has received a number of positive enquiries.

The first truck is transporting the 1:4 feeding bins, contol panel and electrical panel. The second truck is connected to the dryer drum with burner, bag house and pug-mill mixer

Control over mixing time The iNOVA 2000 features a newly developed external pug-mill mixer designed to prevent early ageing of the bitumen. The pug mill automatically controls the mixing time according to

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TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

The latest in pothole repairs

he Pavijet MG7’s low cost, compact dimensions and high paving speed make it ideal for South African operating conditions. Extremely versatile, the new paver is capable of laying both hot and cold asphalt, as well as cement, sand and even crushed stone. This allows it to perform a range of tough maintenance jobs, such as patching roads, sidewalks, pavements and parking lots. According to Andre Steenkamp, national sales manager, Bobcat Equipment South Africa, the internationally patented machine features a retractable screed, allowing it to bypass any obstacles such as advertising signs and trees. A central auger brings the material to the screed, with the speed of the auger determined by the loader motor. All functions – from the auger, screed lifting/lowering and telescopic screed to hopper opening and closing – are hydraulic for increased efficiency. The Pavijet MG7 can be controlled from a skidsteer loader and/or wireless remote control.

The Pavijet MG7 can be controlled from a skidsteer loader and/or wireless remote control for added flexibility

Representing the latest in asphaltfinishing technology, Bobcat Equipment South Africa – part of the Goscor Group – has launched the ‘pothole-busting’ Pavijet MG7 paver.

Paving width: 0.2 m to 1.9 m Paving height: -5 cm to 25 cm Paving speed: 25 m/min Hopper capacity: 1.4 m3 Hydraulic pressure: 180 bar Machine weight: 711 kg

Goscor to represent SANY GOSCOR EARTH MOVING (GEM) will now represent the SANY brand, making an entrance to the larger excavator and roadworks equipment market. This augments GEM’s total product offering, providing customers with a single option for both smaller and larger equipment. Part of the Goscor Group, GEM offers SANY excavators, motor graders, and rollers for the construction, mining, agriculture, sand and stone, forestry, roadworks, and plant hire sectors. Technical expert Simon Zhu highlights that SANY is the number one heavy-equipment

brand in China, with 500 000 units supplied in 180 countries. “We expect SANY’s market share in South Africa to increase significantly as a result of the distribution agreement concluded with GEM,” says Barry Owen, managing director, GEM. He adds that the main differentiator for SANY in the local market will be highly competitive pricing for a world-class product, supplemented

by increased parts-holding and full in-field service and technical backup through GEM’s national branch structure. “We hold about R8 million worth of SANY spares at any one time, and replenish this stock on a weekly basis,” he reveals. In addition, SANY equipment has been engineered specifically for African operating conditions, including features such as shorter sticks and stronger booms on its excavators for enhanced durability. Major benefits for customers are fuel savings, efficiency, user-friendly design, and reliability. Commenting on GEM’s strategy to entrench SANY in the local market, Owen highlights that the initial focus will be multiple client reference points. “Of course, one only gets these good references if one has the aftersales service to support the machines. Hence our strategy is to cultivate 10 to 20 customers as strong advocates of the SANY brand.” IMIESA October 2017

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TRANSPORT, LOGISTICS, VEHICLES & EQUIPMENT

New backhoe brand The new Dezzi CMI 883 backhoe loader has an operating weight range of 7 800 kg to 8 750 kg

new backhoe brand has entered the South African market following a joint venture between Port Shepstone-based OEM Desmond Equipment SA (Dezzi) and Turkish manufacturer Cukurova Machine Industry (CMI). The 883 Dezzi CMI backhoe is fitted with a ZF rear and front axle. Power is delivered by a 74.5 kW Tier II Perkins engine coupled to a ZF transmission offering four forward gears and four reverse gears, with a maximum travelling speed of 40 km/h. The backhoe boom, arm and loader are controlled by mechanical levers. However, the Dezzi CMI can be customised according to customers’ needs with the option of a hydraulic joystick for loader control. A 1.1 m3 loader bucket is fitted as standard, while the backhoe attachment has a 0.2 m3 capacity.

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HPE Africa placed an R200LC-9S demonstration unit on site with the largest fleet owners of earth moving equipment in KwaZulu Natal, South Africa. The machine built gravel stockpiles and loaded this material into tipper trucks for 14 days. Fuel consumption was carefully monitored by HPE Africa’s technical staff and was verified by the client. At the end of the 14 day period the R200LC-9S achieved an average fuel consumption significantly below the expected IMIESA October 2017 107 nine litres per hour.

TECHNICAL PAPER

Women mixing concrete (Bloemfontein)

Engineering and labour-intensive construction

evels of unemployment are extremely high in South Africa and this is compounded by the fact that job opportunities have to be created for large numbers of people who often have little or no education and very few formal skills. This is due to historically imposed inequalities. Economic growth is widely postulated as the solution. However, even where economic growth does take place, it’s widely argued that the benefits accrue more to the rich than the poor, who get left behind. So, while we wait for economic growth, what do we do in the interim? Just accept that the poor are always with us? Or, advocate a universal income benefit? This is certainly the quickest route to providing some poverty alleviation, but alone it cannot provide the necessary skills required for personal development and productive employment. Large amounts of public funds are spent on the construction and maintenance of public building and infrastructure. Could this funding be allocated in a way that it

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Modern labour-intensive construction methods applied in South Africa during the 1980s and 1990s are still valid today. In fact, labour-intensive promotes both skills development and employment construction – in its true engineering creation? The answer is sense – should receive far more a resounding yes, and it focus in terms of the Expanded can be achieved by applying modern labour-intensive Public Works Programme. methods of construction and By Robert McCutcheon* maintenance that definitely compare favourably with conventional techniques. Modern labour-intensive construction has a sound intellectual basis. In the August 2017 issue of IMIESA, I defined it and provided an outline of some principles and practices, citing examples in Kenya, Botswana, Lesotho and Malawi, where large-scale, longterm programmes have been successfully applied. Well over 10 000 km of high-quality, low-cost rural roads were constructed and maintained. And this was achieved without compromising time, cost or quality. In South Africa, there are numerous examples of modern labour-intensive construction practices carried out during the 1980s and 1990s. Of particular note is the work

carried out under the auspices of the Valley Trust in KwaZulu-Natal (Mann and Little), at Ilinge in the Eastern Cape (Croswell), and at Mohlaletse in Greater Sekhukhune (Donaldson Trust and the universities of the Witwatersrand and Twente, in the Netherlands).

Ilinge, Eastern Cape At Ilinge, James Croswell designed and supervised the construction of a range of municipal services using highly labourintensive methods. These included roads, water supply and reticulation, small-bore

TECHNICAL PAPER

Patented Spinning Beam (Hattingh)

sanitation and 54 000 m3 maturation ponds (primary, secondary and tertiary). One of his criteria for design and specification was that all items had to be constructed by hand. Where it was deemed that the rock had to be removed by mechanical means, a compressor was brought on-site. The example of the ‘drum’ for the small-bore sanitation system applied on this project is particularly stimulating. Instead of importing concrete or plastic tubs from far away, concentric rings were made on-site, which could be manhandled by four people, slid into the hole and sealed with mastic. Implementation was carried out by selected small contractors who were trained by Croswell.

Thokoza Road, KwaZulu-Natal During 1983, Rob Little visited the labour-intensive construction programme under way in Botswana. At that time, he was a consultant to the Valley Trust – an NGO located in the Valley of a Thousand Hills. The trust was run by Chris Mann. Although logistically close to the economic powerhouse of Durban, the valley was beset by high levels of unemployment and poverty. On returning from Botswana, Little persuaded the Trust to use highly labour-intensive methods to construct a 13 km stretch of road. The road was constructed in mountainous terrain.

Accredited qualification and training material Successful construction operations require a range of operatives and skilled site supervisors. This applies to both equipment- and labour-intensive construction. In the IMIESA August article, we saw that trained hands-on site supervisors are absolutely crucial for modern labour-intensive work. During the early 2000s, an accredited NQF 4 level qualification for this category of person was developed for CETA. The training material was based on unit standards. There were three categories of construction: Roads and Stormwater, Water and Sanitation, and Structures. A candidate specialised in one of the three categories; additional study and experience enabled

a candidate to be competent in two or three categories. The qualification was titled ‘construction processes site supervisor’. The courses were structured so that the unit standards chosen meant that the same title of the qualification was valid for either equipment- or labour-intensive construction. The specifics have been defined in terms of class learning and mentored experience. In sum, about 18 months’ training is required to achieve the NQF 4 qualification. Although the format of the training is allowed to vary, I am convinced that it is essential for the class instruction to be closely related – in time – to the field experience. At the time of the formulation of the NQF 4 qualification, an NQF 2 qualification was established for a contractor. It has since been raised to NQF 4. This initial setting of the level at 2 displayed an ignorance of various aspects of running a contract, particularly regarding the technical essentials. Unfortunately, although we have seen the crucial importance of the hands-on site supervisor for effective modern labour-intensive construction, very little systematic training of construction processes site supervisors has actually taken place.

Mohlaletse, Limpopo Starting in 1996, and funded by a grant from the Donaldson Trust, a development programme was established at Mohlaletse

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in Greater Sekhukhune. It was organised by the WORK Research Centre in the School of Civil and Environmental Engineering at the University of the Witwatersrand and by students from the University of Twente in the Netherlands. Between 2002 and 2005, the Umsobomvu Youth Fund ran two successful accredited NQF 4 level courses for a construction processes site supervisor. Trainees had to have a matric. The rigorous selection process was followed by a month’s refined selection, which led to a cohort of 60 trainees. The 18-month course consisted of two nine-month components. The 60 trainees were separated into two groups of 30. During the first nine months, classroom instruction alternated with site-training: one week in class, the next on-site. Thus, there were always 30 trainees in class and 30 on-site. Construction proceeded slowly and steadily, without hiatus. During the second nine-month component, additional site training and intensive mentoring experience were carried out. Each course trained about 60 people to become accredited. Several of the more enterprising trainees proceeded to further training as independent contractors. Interestingly, during a mid-term review of the Free State’s Expanded Public Works Programme (EPWP) (2007), one analyst – not known to the author – stated that the training in Sekhukhune should be the model for the national EPWP. The recommendation was not heeded.

High-standard infrastructure As mentioned above, large-scale, long-term implementation took place elsewhere in Africa in relation to the construction and maintenance of rural roads. The author’s initial emphasis focused solely upon the substitution of labour for (non-essential) equipment in a rural environment in South Africa. However, starting in 1989, research and field implementation at and in association with the University of the Witwatersrand were carried out upon three other avenues for increasing the generation of employment per unit of expenditure. The four avenues of investigation are categorised as follows: • s ubstitution of labour for non-essential equipment • labour-intensive materials (and their related techniques and technologies) that have been used in the past but have been replaced (and thus obscured from professional view) by the use of materials that are more amenable to the use of capital-intensive methods; e.g. water-bound Macadam. • modification of existing materials in such a way as to enable the use of labour-intensive methods and lower the need for imported equipment; e.g. a bitumen with a modified chemistry • new materials that would increase the proportion of labour and decrease that of imported equipment; e.g. ionic stabilisers, such as sulfonated petroleum products.

In all four approaches, it is essential to understand that in order to generate significantly more employment per unit of expenditure, it is imperative that this objective be incorporated into the design and contract documentation, including conditions of contract, specifications and bill of quantities. The labour-intensive technology thus becomes the ‘design driver’, requiring that the designers think through the processes long before site implementation. Labour-intensive methods cannot be effectively tacked on during the construction phase alone. In all four approaches to labour-intensive construction, research and prototype development have been necessary. This research and field implementation in South Africa demonstrated that the potential and scope for modern labour-intensive construction encompasses far more than low-cost, low-volume roads. Research and practical implementation, here, have reconfirmed the findings of the World Bank and ILO research (1971 to 1987). It is, indeed, technically feasible across a wide range of civil construction and can result in the same quality of product. Under cer tain circumstances, it can be economically efficient and even cost competitive with conventional construction. High-standard, highcost civil construction can be provided using modern labour-intensive methods and contractors could play a greater role in implementation. Work provides an income and contributes to personal and communal dignity. Where are there similar oppor tunities in the national economy to generate skills and employment opportunities for the poor and unskilled, using money that has already been allocated for expenditure? So much for the innovative projects and research carried out prior to the EPWP. In the next issue, we will provide an introduction to the role of modern labour-intensive construction in relation to the potential and assessment of the South African PWPs.

*Robert McCutcheon is a professor emeritus and honorary professor in the School of Civil and Environmental Engineering at the University of the Witwatersrand. He is also an employment creation and development specialist at MPA Consulting Civil and Structural Engineers.

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CEMENT & CONCRETE

Forming infrastructure for 83 years

L A visit to the Ulco Cement operation with AfriSam’s executive team showcases a rich history of evolutionary development and points to a possible merger. By Alastair Currie

ocated some 80 km from Kimberley, AfriSam’s Ulco Cement operation has been part of the Northern Cape landscape since 1936, when it was originally established to supply manufactured lime to regional gold mines, as well as the agricultural market. Its original name was the Union Lime Company. In 1984, Ulco’s cement kiln was commissioned, adding a new product stream and positioning this plant as a major regional producer, alongside AfriSam’s second cement-producing operation at Dudfield in Lichtenberg, North West. Ulco is uniquely placed as the primary producer in the Northern Cape and its reach by rail and road is extensive, extending as far as the East and Western Cape. The brand has gone through various name changes and ownership over time. The Alpha brand is probably the best remembered in recent years and was introduced in 1996, followed by the Holcim trademark from 2004. Both quickly became household names, bolstered by previous market representation. Holcim became AfriSam in 2008 when the new group identity was established. Today’s AfriSam logo retains an Alpha element in its current brand identification: linking the more immediate past with the future, backed by continuous research and development initiatives across its proprietary products. “In the past 83 years, the corporate ownership has changed, but we are still fundamentally the same company, with a continued commitment to quality and customer service,” comments Rob Wessels, acting CEO at AfriSam. AfriSam’s contribution to infrastructure projects is endless. Past examples include Eskom’s 1 332 MW Ingula Pumped Storage Scheme, KwaZulu-Natal’s

Global cement demand & production • China currently ranks as the world’s largest producer. India, USA, Brazil, Iran, Vietnam, Russia and Turkey are the next biggest players • South Africa has an installed cement production capacity of 20 million tonnes annually • Global annual cement demand is estimated at around 5 billion tonnes. China accounts for around 2.8 billion tonnes, compared to Africa at approximately 0.24 billion tonnes (an estimated 4.8% of total demand) • South African annual demand is around 13 million tonnes • Consumption of cement per capita in sub-Saharan Africa is 82 kg, significantly below the world average of 513 kg • Sub-Saharan Africa is expected to grow by an average of 3.44% between 2017 and 2021, leaving the region with surplus capacity in excess of 25% for the foreseeable future • Strong economic growth is forecast for East Africa and West Africa

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CEMENT & CONCRETE

Spring Grove Dam, the iconic Katse Dam development in Lesotho, the Gauteng Freeway Improvement Project, the Durban harbour mouth widening and port expansion, the Gauteng Rapid Rail System, and extensive public and private building projects. These include the Newtown mall, which opened in 2014 and forms part of the Johannesburg urban renewal project, said to be the largest inner-city development since the construction of the Carlton Centre in 1973.

The current market AfriSam is currently Southern Africa’s largest producer of aggregates, and the second largest producer of cement and readymix concrete, and thus has a strategic role to play in serving public infrastructure and allied private sector expansion. “This includes a dedicated focus on SMME development, backed by training support, where applicable, since this is absolutely essential for meaningful transformation in the local construction industry,” says Wessels. AfriSam’s South African roots, experience and expertise also extend beyond the country’s border. In addition to operations in Lesotho and Swaziland, AfriSam has a 68% shareholding in Tanga Cement Company in Tanzania, which is listed on the local exchange. Tanga Cement Company’s manufacturing facility recently completed a major kiln expansion to meet longerterm growth projections. AfriSam has also established export markets into countries like Burundi, the DRC, Malawi and Rwanda. The distance from AfriSam’s Dudfield plant to Gaborone is just under 170 km, meaning this closely accessible cross-border market is constantly supplied.

capacity in excess of 4 million m³. This currently represents around 23% of estimated demand nationally. “We’re well known for providing complex design requirements, particularly when it comes to high-strength concrete,” Wessels explains. It is estimated that the South African readymix industr y consumes 1.8 million tonnes of cement and in excess of 7 million tonnes of aggregate per annum. According to AfriSam, as at the end of 2016, there were 341 readymix plants belonging to 131 companies producing approximately 6.5 million m³ per annum. The market remains highly fragmented, with new entrants emerging, but often not subscribing to industry standards set by the Southern African Readymix Association, an industry body to which reputable readymix concrete producers, such as AfriSam, belong.

African competition: threats and opportunities The African continent remains dominated by leading multinationals, a number of which have further strengthened their market position and territorial footprint by concluding strategic mergers. Africa is gaining more intensive focus as cementitious consumption trends in developed nations continue to decline or, at best, remain stagnant. This has implications for home-grown African players, who now also need to respond if their strategy is to pursue regional rather than purely home-based growth. Otherwise, smaller African players could be displaced by the global giants. There are three dominant European companies that currently operate within Africa, alongside competition from China in terms of cement imports.

Bulk services “On the cement side of the business, we have a strong focus on the bulk market, where we offer specialised services in terms of quality and mix design support to customers, helping them to optimise their processes ,” says Wessels. AfriSam’s South African operations have the capacity to produce over 4.5 million tonnes of cement annually. In turn, the annual aggregate production capacity is in excess of 10 million tonnes.

Readymix In terms of readymix, AfriSam has 40 operations in major business centres across South Africa, with a combined annual production

Rob Wessels, acting CEO of AfriSam, on-site at Ulco Cement

Possible merger AfriSam is currently in discussions with PPC Limited to join forces in South Africa and Africa. The revised merger proposal, as at September 2017, includes a R4 billion recapitalisation of AfriSam by Fairfax Africa Investments prior to the proposed merger with PPC. As Michael Wilkerson, CEO of Fairfax Africa, states, “We are excited about this opportunity and we strongly support the underlying strategic rationale for the merger, including the potential to create a black-empowered national champion for South Africa that is better positioned to compete in a challenging market environment.”

AfriSam was extensively involved in the supply of cement and aggregates during the construction of the iconic Katse Dam project, which formed part of Phase I of the Lesotho Highlands Water Project

Were they to merge, their combined penetration in Africa would still be small compared to the global players, but it would help to establish a more equitable share of the market and form a base for future expansion. “We believe the combined company will be well positioned to capitalise on higher growth in Africa, building on the foundation already laid by the two companies and, over time, will become a pre-eminent and leading African player in cement,” adds Wessels. Either way, infrastructure spending and its roll-out remain key to stimulating domestic and international investment in South Africa. A stronger South Africa will also have a positive role to play on the continent in fostering the NEPAD vision.

IMIESA October 2017

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CEMENT & CONCRETE

RMC is a job creator The labour-intensive nature of rubble masonry construction promotes sustainable opportunities while addressing pressing infrastructure requirements. By John Roxburgh*

ubble masonr y concrete (RMC) is a building material has been used throughout the world for thousands of years – as far back as AD 122 when Hadrian’s Wall was built in Britain, and more recently and locally in 1679 when Cape Town’s Castle of Good Hope was constructed. Although RMC has been used extensively over the centuries, very little was known about the properties of the material. In-depth pioneering research work by Dr Rod Rankine, when employed by TCI’s forerunner, the Portland Cement Institute, and released in his doctoral thesis in 2000, has led to a much greater understanding of RMC’s mechanical properties.

Pretoria consulting engineering firm ARQ has been involved in the design of several RMC dams in Southern Africa. ARQ has reported that the performance of these structures during several significant floods bears testimony to the durability and effectiveness of RMC for the construction of major dams. A lesser-known but very useful application for RMC is the construction of culverts and small arch bridges. Another important advantage is the cost benefit. Financially, savings of between 30% and 60% can be realised when compared to other dam building techniques.

Mndwaka Dam RMC is a composite material, derived from placing uncut stone randomly in a bed of

mortar. It is often used in mass gravity and arch buttress dam construction. The recent completion of the 30 m high multiple-arch buttress Mndwaka Dam in the Eastern Cape is a typical and noteworthy example. This impressive dam, which won an Infrastructure Commendation in the Concrete Society of Southern Africa’s 2017 Fulton Awards, was built to supply the basic water needs of about 40 000 people living in 63 villages along the Eastern Cape’s Wild Coast. Situated in a particularly remote location close to the landmark Hole in the Wall, between Elliotdale and Coffee Bay, construction of the 30 000 m3 dam – the largest of its kind yet built in Southern Africa – called for careful planning in terms

Construction of rubble masonry concrete dams and bridges is very labour-intensive (Photo: Dr Rod Rankine)

IMIESA October 2017

115

82ND IMESA CONFERENCE

PORT ELIZABETH

31ST OCTOBER - 2ND NOVEMBER 2018

2018

CALL FOR ABSTRACTS OUR THEME

INNOVATIVE INFRASTRUCTURE SOLUTIONS

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

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

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

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

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IMESA ORGANISER

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

2018

CEMENT & CONCRETE

of design, construction and materials procurement. In their submission for the Fulton Awards, the contractors, Zana Manzi Joint Venture, stated that the construction of the dam provided abundant employment for residents living in the surrounding villages. Back in 1995, the Bakubung multiple-arch RMC dam in the Pilanesberg National Park was also a very labour-intensive project, calling for 9 000 person-days of employment during its construction.

Building method The typical construction method for RMC involves spreading a layer of mortar between 100 mm and 200 mm thick. Rocks are then pushed into the mortar until bedded against underlying rocks. The largest possible rocks – ranging in size from 10 kg to 40 kg – are

placed first and packed as closely together as possible to reduce the amount of mortar required. Smaller stones (spalls) are then pushed into the gaps between the large stones to reduce the mortar volumes even further. When this is complete, the next layer of mortar is placed. The construction material is self-suppor ting, so there is no need for pressure-resisting shutters. Formwork is sometimes used to shape the structure, but the outer leaves of masonry are generally built by more skilled masons, using stiffer mortar. These leaves contain the layer of more workable mortar laid by less-skilled labourers who can be employed to build the inner section. The cost savings are due to locally sourced sand and rock: either naturally occurring boulders or

The construction of the RMC Mndwaka Dam provided abundant employment for residents of the isolated Wild Coast villages surrounding the dam (Photo: CSSA)

quarried rock. Without a need for formwork, cement is the only imported material and, with careful construction, its content can be reduced to well below 300 kg/m3. In more rural areas, this cost saving would be even higher. The massive advantage offered by RMC is the use of unskilled labour. Any municipality looking to increase the labour content on civic infrastructural development should consider using RMC where possible. Experience has shown that, for a given structure, the person-days for construction using RMC are between five to nine times higher compared to using alternative construction methods and materials. *John Roxburgh is a lecturer at The Concrete Institute’s School of Concrete Technology. IMIESA October 2017

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CEMENT & CONCRETE

Precast student blocks

precast approach proved to be the optimum construction method for the extension of the male and female residences on the University of Venda’s campus in Thohoyandou. Corestruc and sister company Coreslab were consulted during the initial design phase to provide technical input on the use of hollow-core slabs and precast beams to accelerate the building programme in time for the new 2018 student intake. This extensive upfront work was undertaken together with Lemeg Architects and structural engineer Thiko Consulting, ahead

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IMIESA October 2017

of the arrival of main contractor Base Major, in 2016, to commence construction of the eight female and eight male residence blocks. Located behind the main faculty, these are three-storey structures with each level accommodating about 14 rooms. The structures’ foundations also consist of hollow-core slabs, a decision that has helped to accelerate the construction works by up to six months. This solution was proposed by Jaco de Bruin, managing director, Coreslab, to overcome delays experienced during the piling operations, which commenced early in 2016. Other changes to the original design that have helped fast-track the programme

include a decision to incorporate precast concrete internal stairs and fire escapes. This has proved to be more cost-effective than steel alternatives. These precast items have been batched with a special selfcompacting concrete mix and complement the residences’ striking clay-brick façade. Just under 10 000 t of precast items, covering a surface area of about 34 000 m2 have been supplied and are being installed on campus. By July, the Corestruc team had already started installing the third and last floor on the remaining female blocks with the intention of completing all of these units during October 2017.

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

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IMESA

Malani Padayachee & Associates (Pty) Ltd admin@mpa.co.za M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za Maragela Consulting Engineers admin@maragelaconsulting.co.za Marley Pipe Systems info@marleypipesystems.co.za Martin & East gbyron@martin-east.co.za Masithu Consulting & Project Management info@mcpm.co.za Mhiduve adminpotch@mhiduve.co.za Moedi Wa Batho Consulting Engineers (Pty) Ltd info@wabatho.co.za Mott Macdonald Africa (Pty) Ltd mahomed.soobader@mottmac.com Much Asphalt bennie.greyling@muchasphalt.com NAKO ILISO hans.hartung@nakogroup.com Nyeleti Consulting ppienaar@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za PMA Consulting pragasen@pmaconsultingsa.co.za Pumptron info@pumptron.co.za francisg@rhdv.com Royal HaskoningDHV SABITA info@sabita.co.za SAFRIPOL mberry@safripol.com SALGA info@salga.org.za SARF administrator@sarf.org.za.co.za SBS Water Systems desere@sbstanks.co.za Sembcorp Siza Water info-sizawater@sembcorp.com Servotech (Pty) Ltd finance@servotech.co.za SiVEST SA garths@sivest.co.za Sizabantu Piping Systems (Pty) Ltd gregl@sizabantupipingsystems.com SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za SMEC capetown@smec.com SNA stolz.j@sna.co.za Sobek Engineering gen@sobek.co.za Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Syntell julia@syntell.co.za TPA Consulting roger@tpa.co.za Ulozolo Engineers CC admin@ulozolo.co.za UWP Consulting nonkululekos@uwp.co.za V3 Consulting Engineers (Pty) Ltd info@v3consulting.co.za Vetasi south-africa@vetasi.com VIP Consulting Engineers esme@vipconsulting.co.za VUKA Africa Consulting Engineers info@vukaafrica.co.za Water Institute of Southern Africa wisa@wisa.org.za Water Solutions Southern Africa ecoetzer@wssa.co.za Wilo South Africa marketingsa@wilo.co.za WRP ronniem@wrp.co.za WRNA washy@wrnyabeze.com IMIESA October 2017 WSP Group Africa sam.herman@wspgroup.co.za

119

INDEX TO ADVERTISERS

African Mining Indaba

110

ERWAT

Quality Filtration Systems

Rainbow Reservoirs

AfriSam South Africa

Filcon Filters

Amanzi Meters

Forte Demolition

Ammann APE Aquadam Associated Asphalt Equipment

IFC 88&89 75 94-99

Astore Keymak

Barloworld SEM Barloworld Logistics

G&W Mineral Resources Gabion Baskets High Power Equipment Africa IMESA

101 54 22&23 107 42, 60, 116

Incledon

106

Jaguar Land Rover

100

Kaytech

Sabita SAFCEC Sanral SBS Water Systems Sensus SIKA Sikhumba Construction Sizabantu Piping Systems

BTW & Associates BVi Consulting

52 OBC

Kemach JCB

Clay Brick Association of SA

KSB Pumps & Valves

Colas

Model Maker Systems

DPI Plastics

Much Asphalt

ECM Technology

30&31

ELB Equipment

104

EOH Mthombo

61-65

National Asphalt OdorCure Portia Portland Cement

OFC, 6&7 59 16-18

71 33, 34, 66 14&15 4 10-12 87 117 56 IBC

SMEC South Africa

SRK Consulting

Krohne

72&73

Structa Group The Concrete Institute

78&79 114

Tosas

TT Innovations

Umgeni Water

76&77

UWP Consulting

Veolia Water Technologies

dl rou

Pro

udl

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