IMIESA September 2019 by 3S Media

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

i n f r a s t r u c t u r e d e v e lo p m e n t • B u i l d i n g • M a i n t e n a n c e • s e rv i c e d e l i v e ry

Shisalanga Construction Recycled plastic for South African roads Trenchless Technology

Creating trenchless opportunities

Geotechnical

A new East African pipeline route

ISSN 0257 1978

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HOW DOES UNRELIABLE WATER SUPPLY IMPACT YOUR PEACE OF MIND?

INSIDE

volume 44 no. 9 September 2019

Industry Opinion Founding the future

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

Regulars

I N F R A S T R U C T U R E D E V E LO P M E N T • B U I L D I N G • M A I N T E N A N C E • S E RV I C E D E L I V E RY

Africa round-up

Index to advertisers

Industry Opinion

Geotechnical

A new East African pipeline route

ISSN 0257 1978

Recycled plastic for South African roads 6

Recycled plastic for South African roads Creating trenchless opportunities

President’s comment

Cover Story

Shisalanga Construction Trenchless Technology

Editor’s comment

7 benefits of water quality testing

Malukazi scheme brings services to communities

Climate change impacts on water quality

SASTT Trenchless News Creating trenchless opportunities

Switching to trenchless techniques

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Founding the future

Waste Management

In a groundbreaking, market-leading initiative, Shisalanga Construction – a majority-owned subsidiary of Raubex Group Limited – has paved a South African road using a locally recycled plastic compound as part of the asphalt formula ingredient. P6

Roads & Bridges New roads to Polihali

New approaches to recycling

Forging precast links

Geotechnical Engineering Determining a new East African pipeline route

Consulting Engineering

CESA Awards honour the best in engineering

The changing landscape of surveying

The sewage plant of the future is already here From waste to resource

Cement & Concrete Concrete’s myriad advantages

Perfecting the cobble effect

Quarries and communities

Face brick is aesthetic

Clay Brick

Public delivery takes to the skies

Cavity walls and the thermal benefits

Transport, Logistics, Vehicles & Equipment

Water & Wastewater

Drones Public delivery takes to the skies

Developing Oranjemund’s future waste strategy

Social Housing

Drones

5 26

Water & Wastewater The sewage plant of the future is already here

Tough and connected

Hand-held tools perfected

Cement & Concrete Concrete’s myriad advantages

EDITOR’S COMMENT

Routes to investment

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

s we head into the final quarter of 2019, there are increasing expectations, and collective industr y lobbying, for an improvement in the fortunes of the building and civil industry. Government spending remains a key driver in both cases, so that’s where the investment needs to start at personnel level, to ensure that public sector decision-makers are equipped for the task. Every district in South Africa can and must act as a change agent, but this needs the full support of each and every one of us to make it work. That includes payment for services rendered, like electricity and water. Foreign direct investment, combined with local funding commitments, is the key to unlocking the value in major growth sectors like agriculture, manufacturing, mining and tourism – all areas where South Africa is rich in potential. These are also areas where the civil and building industries play an enabling role. For all countries, roads remain a critical route for getting goods to market. However, road maintenance and construction has been significantly subdued over the past 18 months in South Africa, and definitely needs a cash injection. Sanral’s recent announcement that it plans to invest more than R40 billion over the next two to three years is, therefore, welcome news for the roads industry and the economy. It’s also going to be a major opportunity for new market entrants, since Sanral is committed to using this opportunity to effect lasting transformation. That’s an important step in creating capacity within our municipal districts. From August 2019, Sanral has stated that smaller work package maintenance tenders will start being released across all provinces. The industry should also be excited about the prospect of bidding on major N3 tenders valued at around R8.3 billion for upgrades on the heavily trafficked N3 route between Pietermaritzburg and Durban. According to Sanral, these tenders will be released during the current financial year.

Advertising Sales key account manager Joanne Lawrie Tel: +27 (0)11 233 2600 / +27 (0)82 346 5338 Email: joanne@3smedia.co.za ___________________________________________________

Publisher Jacques Breytenbach Novus Print (Pty) Ltd t/a 3S Media 46 Milkyway Avenue, Frankenwald, 2090 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 www.3smedia.co.za Annual subscription: R600.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2019. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Email: imesakzn@imesa.org.za NORTHERN PROVINCES Secretary: Ollah Mthembu Tel: +27 (0)82 823 7104 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Email: imesafsnc@imesa.org.za 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. _____________________________________________

District delivery model Improving service delivery is a priority for government and proactive steps are being taken in many areas to overcome bottlenecks. A recent example is the proposed Khawuleza District Coordination Service Delivery Model unveiled at the inaugural President’s Coordinating Council meeting in August. Khawuleza means “hurry up” in isiXhosa, underscoring the need for rapid change and improvement where it’s needed. The plan is to pilot the model at O.R. Tambo District Municipality; however, even the best model can only work if it is steered by experienced and dedicated people. It’s common knowledge that technical and financial skills gaps remain a key challenge for municipalities and this is supported by National Treasury’s State of Local Government and Financial Management Report for the 2017/18 period. Things are changing for the better, albeit too slowly for most. On a positive note, though, significant improvements have been made in terms of stabilising senior leadership structures within municipalities. The number of acting CFOs was down to 62, compared to 85 in 2016/17. In turn, the number of acting municipal managers fell from 88 to 42 during 2017/18. But that still highlights the serious gaps that must be filled soonest. Going forward, and as we continue to embrace local and global change, it remains heartening to see that South Africa is still regarded as a vital catalyst for Africa’s renaissance. This was underscored by President Cyril Ramaphosa’s invitation to attend the 45th G7 Summit in August 2019. Other African representatives were Burkina Faso, Egypt, Rwanda and Senegal. We hope that more African countries will be included at future G7 events.

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

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

INFRASTR

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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 Joanne Lawrie on +27 (0)82 346 5338. IMIESA September 2019

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President’s comment

IMESA

Building sustainable local authorities

he theme for our 83rd IMESA Conference is ‘Conquering Municipal Challenges’, which underscores the current need to address a number of critical issues that face local government across South Africa. These are both technical and financial: the two are interlinked. Non-revenue water (NRW) losses, for example, place a major burden on municipalities in terms of service delivery and from a revenue perspective. NRW statistics for South Africa currently average around 39%, but can be higher depending on the municipality and the condition of its pipeline and related infrastructure. Losses currently run into the billions, while the cost of processing this water remains fairly constant. We have to ensure that our local authorities are sustainable, since they are responsible for creating an enabling environment for investment. That can only happen if all infrastructure services run efficiently and towns have working water and wastewater treatment facilities. Research shows that NRW reduction projects typically have relatively short payback periods, say around three to four years. However, few municipalities have the internal capacity at present to develop bankable project proposals to leverage offbalance-sheet funding. Investors also want the assurance that authorities have the ability to comply with and enforce NRW turnaround strategies. Fixing the problem depends on a myriad of factors, but upskilling and better equipping our municipal engineers is definitely one of them. For this reason, IMESA continues to invest in the development of CPD-accredited training courses to this end, working with external stakeholders like academic institutions, research entities, industry experts and Salga. These courses are free for IMESA members.

We currently have four projects in progress, entitled: - Capacity Building in Urban and Regional Planning - Small Coastal Stormwater Outlets - Water Reclamation and Reuse Guidelines, which is being compiled under an MoU with the Water Research Commission - Water Demand Management (WDM) Tool programme.

WDM pre-feasibility tool Initiated in 2017/18, the WDM Tool project is now at an advanced stage of completion, following a seven-month development phase. The project, entitled ‘Refinement of a Water Conservation (WC) and Water Demand Management (WDM) Pre-Feasibility Tool’ was initiated by GreenCape with funding support provided by IMESA. Key input was provided

by experts from the Department of Water and Sanitation, WRP and Salga Western Cape. The draft tool was first piloted at Laingsburg Municipality. The ultimate objective is to create a practical tool that can be applied by a broad range of municipalities and water services authorities. Once all inputs have been refined and approved, we will begin rolling out a dedicated training workshop for municipal engineers at centres around the country during 2020. Water and wastewater treatment continues to be a pressing concern. We ran two successful courses in 2018 and the one we held in February 2019 was equally well received. Running over three days, the February programme was entitled ‘New developments in water and wastewater treatment for municipal engineering personnel’.

Small Coastal Stormwater Outlets

Randeer Kasserchun, president, IMESA

Our ‘Small Coastal Stormwater Outlets’ one-day course will be held for the first time on 1 October 2019, ahead of our annual conference, which will run between 2 and 4 October at the Durban International Convention Centre. Professor Koos Schoonees and Dr Andre Theron, both from Stellenbosch University, will be facilitating this course on behalf of IMESA. Key aspects covered include: coastal processes, design methods, beach usages, aesthetics and location, shoreline changes and scour, outlet protection, and water quality. Recommendations on the construction of small stormwater outlets will also be made. To those attending our 83rd IMESA Conference, we look forward to welcoming you. Alongside a range of other essential infrastructure interventions, water and wastewater are recurrent themes on the presentation agenda.

IMIESA September 2019

CoVEr Story

Delegates from Sanral, eThekwini Municipality and the Department of Transport attended the South African recycled plastic road paving trial, which was successfully completed in Cliffdale, KwaZulu-Natal, on Friday, 2 August 2019

In a groundbreaking, market-leading initiative, Shisalanga Construction â&#x20AC;&#x201C; a majority owned subsidiar y of Raubex Group Limited â&#x20AC;&#x201C; has paved a South African road using a locally recycled plastic compound as par t of the asphalt formula ingredient.

IMIESA September 2019

Recycled plastic for South African roads

Cover Story

Shisalanga is the first South African company to successfully complete an application of recycled plastic road by utilising a binding agent that has unique properties

A perfect mat finish

n Friday, 2 August 2019, the South African recycled plastic road paving trial was successfully completed in Cliffdale, KwaZulu-Natal, in the presence of representatives from Sanral, the Department of Transport and eThekwini Municipality, who witnessed this watershed occasion. Two critical challenges exist in South Africa, one being an abundance of plastic waste and the other, damaged roads. Shisalanga has combined these two challenges to produce the maiden recycled plastic paved road in Africa. “We have been working on this project for some years now and while the technology is in use in India, parts of Europe and in the USA, no one has successfully applied the solution in our country, until now,” says Deane Koekemoer, managing director, Shisalanga Construction. “This process is not an easy one. I am incredibly proud of our team for achieving this milestone with limited international support,” he continues. “We are proudly South African and part of one of the largest road construction companies in the country. The successful completion of this trial is a forerunner of great things to come from Shisalanga and we expect to extend this product throughout the country.”

Africa to minimise waste to landfill and reduce other environmental threats. Wynand Nortje, technical manager, Shisalanga, confirms: “Shisalanga is the first South African company to successfully complete an application of recycled plastic road by utilising a binding agent that has unique properties and, through this, creating a usable and durable solution for the road construction industry.” The type and quality of the recycled HDPE plastic is critical to ensuring that the binding process is successful. The recycled plastic is readily available from South African recyclers and provides an appropriate use in this road construction application – ensuring locally generated waste, and not an imported material, is used. Shisalanga has a proven track record of innovation, leading the way with the introduction of steel slag manufactured asphalt – also a first in South Africa. A cost-competitive solution to conventional UTFC (ultra thin friction course), this product is the preferred choice for asphalt manufacture on the N3, one of the busiest road corridors in South Africa. “The introduction of our plastic asphalt solution is yet another incredible South African success story!” Koekemoer concludes.

Finding sustainable solutions

The successful completion of this trial is a forerunner of great things to come.”

The extremely poor condition of many of South Africa’s primary and secondary roads demands an immediate and long-lasting solution. Local communities use these roads to get to market, work, clinics and school every day, and deserve roads that are safe and well maintained. On the other end of the scale, there is a pressing need to recycle plastic waste in South

www.shisalanga.com

IMIESA September 2019

Industry Opinion

Founding the future Investor confidence and building sector performance are intertwined, both from a public and private perspective. IMIESA speaks to Roy Mnisi, executive director, Master Builders South Africa, about the unprecedented slump in activity and possible resolutions – a key one being the need to fix government procurement and supply chain issues. How would you describe the current state of the industry and construction in general? RM Our industry is in a very bad state. We have been seeing constant decline since 2010. There are lots of challenges. Top of the list include a lack of construction work both in the private and public sector, late and non-payment of contractors for work done, and illegal invasions of construction sites by local business forums. These are key causes for business closures, and the loss of employment.

Which are the best and worst performing regions? According to the cidb Construction Monitor released in April this year, construction activity is concentrated in Gauteng, which accounted for 26% (R18 billion); the Western Cape, which accounted for 21% (R14 billion); KwaZulu-Natal,

IMIESA September 2019

which accounted for 15% (R10 billion); and the Eastern Cape, accounting for 15% (R10 billion). The lowest are the Free State, sitting at R2.6 billion, and Northern Cape, with only R1.5 billion. This is in line with the economic capability and investment dynamics in the provinces.

Is Master Builders South Africa (MBSA) working with other key stakeholders to find solutions? MBSA has been consistently working with all key industry stakeholders including government, other voluntary associations and professional bodies. There are constant engagements aimed at developing solutions to various challenges facing the industry. MBSA took a decision to call an industry congress on 9 September 2019 to discuss and propose solutions. Leaders of various construction industry

bodies form part of the debate aimed at developing a collective approach to save our ailing industry. At the time of going to press, President Cyril Ramaphosa had been invited as a keynote speaker to share his views and plans for a collapsing industry.

Does MBSA see a turnaround in fortunes any time soon? MBSA believes that there are things to be done in order to turn the corner. For example, we are of the view that if government were to immediately spend half of the infrastructure budget across all spheres and SOEs, such a move would ignite construction investment and improve the current status of the sector. Sub-Saharan Africa’s construction growth is currently sitting at around 6.8% year-onyear; so, from a South African perspective, there’s definite scope for improvement above the anticipated 2% mark forecast for 2019. Our industry is generally an indicator of a country’s macroeconomic performance: if the building market improves, it’s a sure sign that South Africa is on the road to recovery and sustained growth.

What percentage of MBSA members work in the public sector? A high percentage of our members do public sector projects. We don’t have recent stats of the exact split between public and private work, as that changes dependent on the pipeline of infrastructure spend available.

Has the public sector traditionally been a strong market? Yes – in fact, government is the biggest procurer of goods and services in South Africa. According to the recent cidb report, the public sector dominates the projects awarded in most provinces (eight out of nine provinces). It has the largest proportion of projects awarded in the following provinces: Limpopo (93% or R5 billion); Eastern Cape (90% or R9 billion); North West (90% or R1.9 billion); KwaZulu-Natal

Roy Mnisi, executive director, Master Builders South Africa

Industry Opinion

4 000 (78% or R7.8 billion); Free State (76% or R2 billion); Northern Cape (73% or R1 billion); Mpumalanga (72% or R3 billion); and Western Cape (53% or R7.6 billion). The private sector has the largest proportion of projects awarded in only one province, namely Gauteng (69% or R12.6 billion). Most companies rely on government work to sustain their businesses. For this reason, if government is not paying contractors on time or at all, that has far-reaching consequences for the sector.

Please comment on the current tender environment and government payment time frames. The current tender system requires some serious reform. It is mired in red tape and inefficiencies, and it is costly for contractors. In some instances, there’s a lack of consistency in terms of the tender processes and requirements. Corruption has been found to have its permanent home in infrastructure procurement processes. Late and non-payment of contractors by the state has been one of the industry’s bugbears for a while now. A lot of government departments are not complying with the 30-day payment requirement.

Our members are owed billions of rand; unfortunately, some have had to be liquidated as they could not pay suppliers of goods used to build government infrastructure. This is one of the huge challenges faced by the industry now.

Can training help build capacity? MBSA has always prioritised skills/SMME development, and this is in alignment with government’s economic transformation initiatives. However, targeted public sector procurement spend on SMME development requires a coherent support framework between the construction industry and government to ensure its sustainability. MBSA used to run its own National Development Funds aimed at promoting and developing skills in the built environment before the establishment of the SETAs. It continued to play a significant role in various skills development initiatives, such as awarding and managing bursary programmes at a regional level across the country. MBSA is currently embarking on a National Apprenticeship Programme and is one of the implementers of the Construction Sector Training Authority skills development programmes. There are various contractor development programmes aimed

MBSA is a federation of employers in the construction sector with a combined contractor membership of approximately 4 000

at SMME development and these have been in place for many years. The Federation has developed the Small Builders Manual, a step-by-step guide that covers all aspects of running a small-to-medium-sized contracting business, meant to assist emerging contractors with information on how to professionalise and grow their businesses.

What are the advantages of being an MBSA member? Joining Master Builders South Africa offers a range of benefits. These include: • Contractual and legal: members get quality support and assistance on contractual, regulatory or building-related legal issues. • Members are listed and their services are promoted to the public, as well as to other members, on their behalf. • Health and safety advice and assistance. • Networking: members can attend meetings, workshops, events and functions throughout the year. • Lobbying: members are represented by a recognised body at national and regional levels when lobbying government and industry stakeholders on pressing issues affecting the building and construction industry. • MBSA has a dedicated training

manager who is able to assist with any training-related queries. We offer a range of industry and contractor development training courses. • Information: members receive online and offline communication on relevant information they need to run their business efficiently and effectively. This may include tender notices, regulation updates, and other relevant industry information.

And in closing? Historically, the construction sector has accounted for around 4% of South Africa’s GDP, or approximately R108 billion annually, and has been one of the country’s biggest employers. That picture is changing and, according to Statistics SA’s latest Quarterly Labour Force Survey, the construction sector is now the biggest loser of employees of any sector. We have to work together to avoid the total collapse of the industry and the loss of our capability to carry out infrastructure development programmes and projects. This can be achieved through quick wins, simply by correctly spending the money that is allocated annually for public works, and immediately eradicating irregular and wasteful expenditure. Re-establishing trust will also unlock meaningful PPP roll-outs in all sectors.

IMIESA September 2019

INFRASTRUCTURE NEWS

FROM AROUND THE CONTINENT

37%

Only around 37% of Luanda’s population is connected to a formal water network

Angola

with a production capacity of 3 m3/s, 72 km of Bringing water to Luanda gravity transmission pipelines Angola has received a towards Luanda, and storage package worth US$1.32 billion and distribution systems in the suburban (R20.32 billion) from the International districts of Bita, Cabolombo, Mundial Bank for Reconstruction and Development and Ramiros. to support its efforts to promote more The Bita Project will initially bring new inclusive growth, improve water services, or improved piped water service to an and strengthen the national social estimated 1 million people in the fastprotection system. growing, unserved urban and peri-urban belts Among the projects that will receive of south Luanda, with capacity to serve up to financing is the Luanda Bita Water Supply two million people in the coming years. Project, which will improve access to clean Only about 37% of Luanda’s seven million water service in selected areas of Luanda. people currently benefit from connected The $500 million (R7.96 billion) Bita service from the network, while another Water Supply Project Guarantee will improve 22% get water from public standpipes. access to clean water service by mobilising The rest rely on unregulated and extremely commercial financing for the government. costly private tanker truck services (25%), The first phase consists of investments in or consume water drawn from illegal water production, transmission, storage and connections or from untreated river distribution, including a water treatment plant sources (16%).

The Gambia Digitising municipalities for sustainable development The Republic of The Gambia will soon be implementing the Greater Banjul Area: Sustainable Urban Development Programme 2020-40 in an attempt to achieve sustainable urban development of the greater Banjul area. A number of activities will be rolled out under the programme, including capacity

building and the formulation of a master plan for urban development using digital technologies, which are intended to greatly improve the operational efficiency of the municipalities of Banjul, Kanifing and Brikama, and also provide support to the Banjul port expansion. The UN Office for Projects Services in The Gambia is implementing the project and already carried out a

workshop during which local stakeholders provided inputs to the master plan and the launch of the project. Stakeholder consultations are still ongoing and more data is being captured to assure the successful development of an integrated and well-informed greater Banjul area digital master plan. The programme will serve as a pilot with implications for a country-wide roll-out.

Somalia Boosting resilience with infrastructure The African Development Bank has approved grants of US$28.86 million (R492.72 million) for water and sanitation and roads projects designed to improve livelihoods in Somalia and boost the country’s resilience. The Kismayo-Baidoa water supply and sanitation project will boost access to potable water, improved sanitation and strengthen capacity for related delivery services in Somalia’s Jubbaland and South West State. It is hoped that this project will propel Somalia towards meeting the Sustainable Development Goals on universal access to water and sanitation. It will benefit around 200 000 urban and peri-urban people living in Kismayo and Baidoa, which are experiencing a high influx of internally displaced persons, resulting in high youth unemployment, leading to increased fragility. The Road Infrastructure Project is expected to enhance connectivity through the rehabilitation of some 247 km of roads, in addition to the construction of a new 100 km feeder road. The European Commission is also providing a grant of $47.11 million (R804.3 million) for the road infrastructure project, giving a total $63.97 million (R1.09 billion) that will be invested under this programme. Poverty levels in Somalia are extremely high, with about 50% of the population living below the poverty line. It is aggravated by widespread insecurity and natural disasters, like floods and droughts. The grants are expected to help improve quality of life, inclusiveness and engender resilience in the communities, especially in Kismayo and Baidoa, where an estimated 65% of the population lives below the poverty line, and 70% is younger than 30 years and unemployed.

247 km

Roughly 247 km of roads will be rehabilitated in Somalia

IMIESA September 2019

Roads & Bridges

New roads to Polihali The Lesotho Highlands Water Project (LHWP) Phase II advance infrastructure works prepare the groundwork for the construction of one of the largest dams built locally in decades.

onstruction is now under way on two major road contracts forming part of Phase II of the LHWP. Running in parallel, the projects commenced in July 2019 for scheduled completion in June 2021. These works comprise the Polihali Western Access Road (PWAR) West, and the PWAR East, awarded to the HSPY JV and Rumdel/AC JV, respectively, at a contract value of M410 million (R414 million) and M562 million (R568 million). They are the fifth and sixth of approximately a dozen advance infrastructure contracts awarded to date by the Lesotho Highlands Development

The site location for the new Polihali Dam. The dam will create a reservoir on the Senqu and Khubelu rivers with a surface area of 5 053 hectares and a full supply storage capacity of 2 325 million cubic metres

Authority (LHDA) ahead of the construction of the Polihali Dam and gravity transfer tunnel. This will connect the reservoir at Polihali with the Katse reservoir built during Phase I. Polihali’s embankment will stand 165 m high, have a crest length of 921 m and a crest width of 9 m. At its base, the embankment will be 470 m wide. Over 13 million cubic metres of rock quarried locally within the dam basin will be compacted to form the embankment. The HSPY JV comprises Hillary Construction, Polokwane Surfacing and Ya Rena Civils, from South Africa, and Lesotho-based Structuretone Construction; while the Rumdel/AC JV comprises South African company Rumdel Construction (Cape) and A&C Holdings from Lesotho. The PWAR West section is a 21.44 km long road stretching between Ha Seshote and Semenanyane River, with the 32.86 km East section travelling between Semenanyane River and the Polihali Dam site. The East section will terminate where it ties with the Polihali North Eastern Access Road, currently being constructed under a separate contract awarded to the Lesotho-based Nthane Brothers and South African Sinohydro JV in October 2018.

PWAR and NAR link The PWAR route will tie into the Northern Access Road (NAR) at Ha Seshote. The NAR provides access to the Katse Dam basin from Pitseng to Katse village. The NAR, scheduled to be upgraded as part of the Phase II advance infrastructure works, and the PWAR will form the major access corridor for construction equipment, materials

Tente Tente, acting chief executive, LHDA

and tunnel boring machine components for the Polihali Dam and transfer tunnel. When completed, the PWAR will comprise a two-lane surfaced road with surfaced shoulders and passing lanes. Some sections of the road follow an existing gravel track that will be upgraded to an engineered surfaced standard. Other sections of the road follow a new route to improve the vertical and horizontal alignments. Along the way, three new bridges will be established, including a new bridge at the Matsoku River. Stormwater drainage system and road ancillaries also form part of the PWAR contract. “The quality roads constructed under Phase II will not only provide access to the Polihali Dam construction site, but will also significantly influence sustainable economic growth through tourism and industrial development,” states Tente Tente, acting chief executive, LHDA. AECOM SA, working with AECOM Lesotho and Lesotho-based RWB Consulting Engineers, designed the PWAR phases, as well as the rehabilitation of the NAR, and will supervise construction. Phase II of the LHWP builds on the successful completion of Phase I in 2003. It supplies water to the Gauteng region of South Africa, in addition to utilising the delivery system to generate hydro-electricity for Lesotho. Phase II will increase the current water supply rate of 780 million cubic metres per annum incrementally to more than 1 270 million cubic metres annually. At the same time, it will increase the quantity of electricity generated in Lesotho and is a further step in the process of securing an independent power supply for the country. Feasibility studies have confirmed that conventional hydropower is the preferred option for Phase II.

IMIESA September 2019

Roads & Bridges

Wirtgen’s WR 240 soil stabiliser

New approaches to recycling The Wirtgen Group is redefining how flexible pavements can be rebuilt using cold asphalt recycling techniques. Waylon Kukard, sales manager, Wirtgen South Africa, expands on product developments that provide contractors with the latest cutting-edge equipment. By Alastair Currie

irtgen has led the world with its milling series, and the introduction of the multipurpose CR cold-in place recycling range extends this leadership. It’s a purpose-built line-up catering for in situ road milling and subsequent resurfacing seamlessly: essentially a cold recycler in a milling machine body. Popular in major markets like the USA, its imminent introduction will be a first for South Africa. With the CR series, Wirtgen has perfected the ‘in-place method’. In operation, the existing asphalt surface layer is removed across the full lane width in a single pass. During this process, it is directly mixed with a specified binding agent, like bitumen emulsion. The recycled asphalt formulation is then immediately transferred via the CR’s conveyor into a following paver for spreading, levelling and subsequent roller compaction. Once resurfacing has taken place, all that’s required is a final seal and/or wearing course, after which the rehabilitated road can be opened for traffic, often the same day. “CR units apply the cut-down process during cold asphalt recycling operations,” Kukard explains. “This makes it possible to systematically vary the size of the granulated pieces milled depending on the age and condition of the asphalt. “The overall benefit is that up to 100% of the existing asphalt material can be reused, greatly reducing the overall maintenance costs,” he expands.

IMIESA September 2019

W 240 CR, W 240 CRi, W 380 CR and W 380 CRi models cater for 2.35 m or 3.8 m lane widths, as indicated by their nomenclature, and can be equipped with an optional integrated screed. An added advantage is that the CR range can also be deployed solely for standard milling applications using Wirtgen’s up-cut process.

Soil stabilisation Alongside the CR series are Wirtgen’s WR soil stabilisation machines, designed to produce a homogeneous subgrade when combined with binding agents that include cement, foamed bitumen, lime and water. Cement, for example, increases the bearing capacity. Wirtgen’s soil stabilisers meet the need for a diverse range of soil improvement and strengthening applications. In addition to roads, these include industrial facilities and runways. They are also well-suited for the construction of embankments and slopes, while more specialist roles extend to the production of linings in landfill establishment. The five model line-up includes the WR 240 and WR 250 units. South Africa remains one of the world’s largest markets for Wirtgen soil stabilisers, with around 120 units currently operational nationally. During soil stabilisation, the machine’s milling and mixing rotor mixes the existing soil, plus the specified quantities of prespread binder, e.g. cement. Water is injected via an interconnected leading tanker.

WR machines are also well suited for cold recycling tasks. Here, the WR’s rotor granulates the asphalt and base layer, and injects the binder during the mixing process, together with water, to achieve the mix design. Two tankers, one transporting water and the other bitumen, form part of the integrated road train. Wirtgen designs and develops its own water and/or bitumen spray injection systems in-house. Another key feature compared to competitors is the optimal machine set-up. On the WR series, for example, approximately 50% of the overall weight is positioned over the rotary cutting drum for the best sub-base material remixing result. “In situ sub-base stabilisation remains the preferred method adopted locally by Sanral and other roads agencies for both maintenance and new construction,” Kukard explains. “It’s a highly cost-effective and environmentally sound method, since it minimises the need for the importation of additional materials to construct the road.”

The cold recycled mixing plant Mobility is a key factor in delivering road rehabilitation projects. In response, Wirtgen has developed its KMA 220 (220 t/h) cold recycling mixing plant. The entire plant is mounted on a three-axle flatbed semi-trailer, interlinked and hauled via a truck tractor. It’s a revolutionary invention that’s ready to deploy on-site within minutes, with mixing performance outputs that comfortably exceed

Roads & Bridges

Road train: a Wirtgen W 380 CRi feeds reconstituted asphalt to a paver as part of a seamless road resurfacing operation

many stationary hot mix plants. The KM 220 can produce cold mixes from a large variety of new aggregate mixes, reclaimed recycled materials and binding agents. Since it’s driven to the site, long-distance truck haulage requirements are negated, together with the ensuing logistics costs. Feeding the standby trucks on-site with processed material is an onboard discharge conveyor that can be slewed by 55 degrees. At an output of 200 t/h, one 20 t truckload of cold recycling mix can be produced at approximately six-minute intervals, which underscores the rapid resurfacing capabilities. That translates into a 150 m long, 4 m wide and 150 mm base layer paved per hour.

Wirtgen’s iNOVA continuous mobile asphalt plant series now comprises four models. The iNOVA 2000 was the first model to be introduced to South Africa

iNOVA series from Brazil Alongside cold mix developments, Wirtgen continues to gain ground globally with its CIBER continuous mobile asphalt plants. The iNOVA line features unique technologies that minimise the energy required to dry and heat aggregates. There are now four units in the range, comprising the iNOVA 1000, 1500, 1502 and 2000 models. The iNOVA 2000, with its 100 t/h to 200 t/h capacity, was the first

model to be introduced to South Africa back in 2018. The next machine identified for introduction to the South African market is the iNOVA 1502 model, catering for 75 t/h to 150 t/h outputs. Both the iNOVA 1502 and 2000 models are road legal, which passes on substantial savings in terms of transport costs when compared to static plants. Another significant feature is their proven fuel efficiency. “The South African roads market has been flat for well over a year; however, we are positive

that 2020 will see a major resurgence in new construction and maintenance projects,” says Kukard. “This view is supported by Sanral’s recent announcement of an approximately R40 billion package, to be allocated over the next three years, which is a welcome development for the local roads market. “As capacity builds, we will continue to support the SMME and top-tier contractor market with product developments, training and advice on the best road-train configuration for their specific project and technology requirements, whether it’s a cold or hot application,” he concludes.

IMIESA September 2019

Roads & Bridges

The bridge will help authorities evacuate residents during flood conditions, while also significantly improving overall mobility

The in situ works, including the sides of the structure, make provision for labour-intensive construction techniques

Forging precast links

aking a precast approach provided a fast and practical solution for the establishment of a pedestrian bridge crossing a stream in Kaalfontein, Gauteng. Valued at around R13 million, this 100 m long by 3.5 m wide structure forms part of a series of pedestrian infrastructure projects being rolled out by the Johannesburg Roads Agency. CoreCivils proposed the use of hollow-core slabs as opposed to rib-and-block sections between the precast concrete beams to provide a quicker and more accurate means of constructing the superstructure. These modifications to the original design were accepted by the design engineer, BMK Consulting Engineers.

CoreCivils’ system comprises conventionally reinforced precast concrete beams and hollow-core slabs that are supported by two in situ concrete piers. For this project, 14 precast concrete beams – two per span – were installed. Each beam weighs 4 t and measures 15 m in length. “The hollow-core slabs were manufactured and cut to size at our factory and were placed directly on top of the precast concrete beams,” says Jaco de Bruin, managing director, CoreCivils. “This eliminated the need to first install extensive propping before being able to cast the riband-block slabs.” Once positioned, the hollow-core slabs were first covered with polystyrene moulds

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with voids, to reduce the load of the 150 mm thick final concrete slab resting on the precast concrete beams. Services were installed on top of the polystyrene moulds and covered with a steel mesh to reinforce the slab. The in situ phases, including the sides of the structure, promoted labour-intensive components and about 17 members of the community worked alongside the contractor, Axton Matrix, on this project. Meanwhile, an additional 20 people will be employed to work on the extended work scope, which includes the construction of about 70 m of asphalt roads and sidewalks. This is in addition to the installation of stormwater drainage, kerbing and wing walls.

Geotechnical Engineering

Determining a new East African pipeline route Geomechanics won an award for Best Safety Performance 2017 at the Total World Day for Safety awards for contractors in April 2018

The extensive works undertaken by GeoGroup for Total’s Lake Albert Development Project Tilenga and East African Crude Oil Pipeline underscore the depth of expertise fielded by this South Africa-based geotechnical contractor. IMIESA speaks to Grant Rijsmus, works director, GeoGroup, about the key phases.

eoGroup’s geotechnical investigations for a central processing facility (CPF) in Bullisa, Western Uganda, and a pipeline to transport crude oil from the CPF to the 1 443 km pipeline to Tanga on the coast of Tanzania successfully put its skills to the test. As testimony to its commitment to project excellence, GeoGroup subsidiar y Geomechanics recorded zero safety incidents during 120 000 man hours for the CPF portion of the project. “Right from preparation phase for the geotechnical surveys contract, which included a number of HSE workshops, Geomechanics always demonstrated a willingness to meet the stringent Total HSE requirements,” says Tumwesigye Justus, H3SE/Safety Operations (2018), Total E&P Uganda. “Even during operations, Geomechanics continued to comply with the Total HSE requirements, as demonstrated by a score of 74% during the Operations HSE Audit for Geotechnical Operations,” he continues. “As a result, Geomechanics was invited to present its

Geomechanics’ barge positioned for drilling operations

ABOVE LEFT A CPTu drill rig being loaded on to Geomechanics’ barge on Lake Albert ABOVE Installing a piezometer in a test pit

‘HSE Journey’ at the Total Contractor Forum for the year 2017. In April 2018, Geomechanics won the award for Best Safety Performance 2017 at the Total World Day for Safety awards for contractors.” This was a multiphased project divided into a series of work packages. The nearshore investigations entailed drilling and testing in river beds, lake floors and on land. Six rotary core holes and five CPTu tests were conducted in the Nile River and another 12 holes and 10 CPTu tests in Lake Albert. Land-based drilling included 49 rotary core holes and 135 CPTu tests. The pipeline investigations from the CPF to the coast of Tanzania required 21 rotary core holes, 41 CPTu tests and 94 trial pits in Uganda, and 37 rotary core holes, 70 CPTu tests and 165 test pits in Tanzania. The logistics required to successfully complete this project were substantial: more than 400 people needed to be housed in 19 different locations over a period of seven months. At any one time, there were three full camps in operation – one for the advance team, one for the

acquisition team and another being set up for the advance team to move into. The advance camp moved to a new location every 10 to 14 days.

Project location The Tilenga project is located within Total’s Exploration Area 1 (Block 1) on the eastern shore of Lake Albert and Exploration Area 2 (Block 2), covering the districts of Nwoya and Bulisa. The northern part of the project is split by the Victoria Nile River. The scope of the investigation included the CPF, a pipeline section crossing under the Victoria River, well pads, and the lake water abstraction (LWA) site. The objectives of the geotechnical investigations were to: • characterise the nature of the ground and groundwater • confirm lithology and thickness of subsurface layers, based on geophysical surveys previously conducted by Geomechanics • provide physical and geomechanical properties of soils required for the CPF, Nile River pipe crossing, well pads and flow lines, and LWA

IMIESA September 2019

Geotechnical Engineering • locate and characterise potential hazards along the planned project route • provide recommendations for the future CPF’s foundations, site preparation, and the Nile River pipe crossing using horizontal directional drilling techniques.

Work Package 1: CPF Geomechanics personnel mobilised at Bugungu Camp, some 20 km from the CPF site. Work The pipeline route

began with the CPTu rig on 17 September 2017, followed by five drill rigs in a phased approach from 18 to 25 September 2017. In total, 2 298.09 m of drilling was completed. Tests completed indicate the complexity of the work on these and other phases: • borehole logs, core photographs and driller’s logs • standard penetration tests, pocket penetrometer tests, pressuremeter

tests and cross-hole and downhole geophysics surveys • collection of undisturbed Shelby and intact core sub-samples • schematic drawings of the piezometer installations • cone penetration tests • groundwater level readings and in situ water testing • trial pitting and DPL tests

Geotechnical Engineering • in situ tests in trial pits: soil temperature, electrical conductivity, vane shear testing and soil infiltration tests • as-built survey • laboratory testing. Throughout Geomechanics’ various investigations, all samples taken from boreholes and trial pits were kept in a temperaturecontrolled environment. That began with airconditioned tents on-site, to sample transfer

via refrigerated trucks to a climate-regulated laboratory. Each drill rig and test pitting team also had a permanently stationed and qualified geologist.

Work Package 2: Nile crossing The proposed Nile crossing pipeline spans a length of approximately 1.45 km in a north-south orientation, traversing below the Victoria Nile River. An alternative Nile crossing alignment, spanning approximately 1.3 km, was later proposed approximately 4 km downstream, with both sites investigated. Geomechanics’ barge and associated equipment arrived on 11 November 2017 and were then transported to the Nile crossing survey area. Modifications were subsequently made to the barge to meet Total’s HSE requirements. All land-based and offshore drilling and CPTs were completed by 21 April 2018. Guar gum (a biodegradable and non-toxic hydrophilic polysaccharide from the seed of the guar plant) and water were used as a drilling fluid medium. This improved hole stability and enhanced the lubricity of the equipment to minimise mechanical breakdowns and facilitate recovery in troublesome formations such as clay zones. Guar gum was also used on other phases.

Work Package 3: Well pads, feeder line and flow lines The geotechnical fieldwork for the well pads was carried out from 4 October to 19 December 2017. After the December shutdown, fieldwork recommenced on 8 January 2018 and was completed on 18 March 2018.

Lake water abstraction Geomechanics completed one onshore CPT within the proposed LWA site boundary on 3 December 2017 prior to the December shutdown. Proceeding to the next stage, Geomechanics’ barge was

moved to Lake Albert via the Victoria Nile River on 27 April and commenced offshore testing two days later. “We negotiated our jack-up barge down the Victoria Nile River, at times through 0.8 m of water, to reach Lake Albert, instead of having to disassemble the barge and transport it, resulting in a roughly three-week saving,” Rijsmus explains. “GeoGroup also upgraded the barge prior to mobilisation to suit the site conditions,” he expands. “The pontoons were lengthened by 1.8 m to increase buoyancy and decrease the vessel’s draft. The diameter of the 11.8 m long legs was also increased from 168 mm to 350 mm to meet drilling depths down to 17 m.” At Lake Albert, a combination of inclement weather and high swells caused some downtime on production. The remainder of the land-based CPTs were conducted from 17 to 20 May 2018 and the single onshore borehole commenced drilling on 24 June 2018.

East African Crude Oil Pipeline (EACOP) project: Tanzania and Uganda Alongside the CPF and allied work packages in Uganda, Geomechanics was responsible for executing the investigative work for the interrelated EACOP project on behalf of Total East Africa Midstream. This prepares the way for the design and construction of the 1 443 km pipeline. Geomechanics’ fieldwork in Tanzania commenced in October 2018 and ended in May 2019. In turn, works in Uganda started in February 2019 and also ended in May 2019 The investigation sites in Tanzania and Uganda were spread across the entire pipeline route, crossing a variety of terrain. In general, the investigation sites were selected to be at river and infrastructure crossings, where faults are identified and where the pipeline route has particularly steep slopes. The detailed investigation points were refined on the basis of preliminary results and the preceding geophysical survey. “Technically, the EACOP investigations were relatively straightforward due to the shallow depth of the boreholes,” says Rijsmus. “The key challenge was the linear nature of the investigation and the extensive distances involved. “However, the CPF and allied works for the Lake Albert Development were certainly among our most technically involved and intricate projects to date,” he continues. “Overall, the enormous scale makes it a true milestone project for GeoGroup, which celebrates its 30th anniversary in 2019,” Rijsmus concludes.

IMIESA September 2019

Consulting Engineering

CESA Awards honour the best in engineering The country’s leading built environment professionals recently gathered for the 2019 CESA Aon Engineering Excellence Awards to celebrate South Africa’s excellence in engineering.

his year’s awards, hosted by Consulting Engineers South Africa (CESA) and sponsored by Aon South Africa, celebrated 25 years of democracy in the quest for engineering excellence. “Given the pivotal role that infrastructure development plays in the South African economy in achieving the goals of the National Development Plan and Vision 2030, as stated in President Cyril Ramaphosa’s recent State of the Nation Address, these awards highlight the role that consulting engineers and their clients play in providing excellence in engineering for economic development and job creation,” said Chris Campbell, CEO, CESA. The project entries and winners are as follows:

Projects with a value greater than R250 million Winner: Growthpoint New Lakeside Offices | AECOM The new Lakeside office development is a ninestorey commercial office development in the Centurion CBD with a Green Star Design rating. Built on Inherent Hazard Class 8 dolomite, the site posed significant geotechnical challenges. A key component for the success of the project was cross-disciplinary collaboration to devise a holistic approach in which engineering systems effectively worked together rather than being approached in isolation. The successfully completed offices are evidence that, with sufficient site information and knowledgeable experts, a cost-effective solution can be found to overcome severe challenges while addressing client needs. Aurecon won the award for the best project with a value between R50 million and R250 million

IMIESA September 2019

Commendation: Discovery Headquarters | Aurecon Other entries: • Improvements to the Mount Edgecombe Interchange on National Route 2 Section 26 | SMEC • Design and Construction of the 1 400 MVA Sebenza Substation | PSW Nyeleti JV • Mokolo Crocodile Water Augmentation Project | Mokolo Crocodile Consultants, a JV between Aurecon, Hatch Africa, iX engineers, Mott MacDonald and SMEC

Projects with a value between R50 million and R250 million Winner: The Docklands – 70 Prestwich Street Apartments | Aurecon The Docklands is a nine-level, mixed-use building that consists of 200 m2 of retail, 134 apartments and 160 parking bays, located within walking distance of Cape Town’s V&A Waterfront. The site housed an existing office building with one level of semi-basement parking, ground-level parking and three levels of offices above that. The proposed new development required three levels of parking and six levels of apartments over the full footprint of the property.

AECOM won the award for best project with a value greater than R250 million

A tight budget and time constraints meant the programme had to be fast-tracked, which negated the option of building from scratch. In response, the project team came up with an innovative conceptual design that incorporated the existing building. Commendation: Rosslyn Brewery Cogeneration Plant | Hatch Africa Other entries: • New Mechanised Stercus Facility, Cape Town | JG Afrika • Resurfacing of the National Route R503 Section 2 | Knight Piésold • Loeriesfontein Bulk Water Supply Project | BVi Consulting Engineers • Reconstruction of Two Flood Damaged Bridges at Ga-Ntata | Nyeleti Consulting • Mpact – Fully Automated Paper Roll Storage Facility | LNW Consulting Engineers & Project Managers • Upgrading of Selby Msimango Road km 5.5 to km 6.2 | Vumesa • Cornubia Boulevard Overpass Bridge | Royal HaskoningDHV

Consulting Engineering

Knight Piésold won the award for the best international project

The power generated at the pump-as-turbine (PAT) station is fed back into the municipal grid, offsetting the electricity consumed during pumping, producing an estimated 320 MWh annually, which equates to 44 days of free pumping. By using the same set of pumps to pump water and generate electricity, the PAT station is considered a first of its kind in South Africa.

Projects with a value less than R50 million Winner: Leliefontein Pump-As-Turbine Station | Aurecon Originally intended to be a booster station, Leliefontein’s location within Drakenstein Municipality’s bulk water network proved ideal for the establishment of a mini hydro-electric power station. The project team designed a novel solution that uniquely utilised the same set of pumps to pump water and generate electricity by reversing flow through the pumps.

Commendation: Sani Pass Phase 2A Structures | Royal HaskoningDHV/ SFC Engineers/Ndizani Civil Works JV Other entries: • Houghton Heritage Wall Pedestrian Bridge | Royal HaskoningDHV • Malukazi Pump Station Project | Bosch Projects • Sky City Mega Housing Development | Infraconsult Engineering

Best International Project Winner: Azambi Hydropower Project | Knight Piésold

Young Engineer of the Year Winner: Jeshika Ramchund, Bosch Projects Commendation: Dr Tony Igboamalu, Aurecon Other entries: • Malope Sabata | Nyeleti Consulting • Valize Scholtz | Nyeleti Consulting • Darren Pillay | Knight Piésold • Trevor Mathabatha | Knight Piésold

Mentor of the Year Winner: Kim Timm | Aurecon Other entry: Rajan Padavattan | Nyeleti Consulting

Mentoring Company of the Year Winner: Knight Piésold Other entry: Zitholele Consulting Business Excellence: BVi Consulting Engineers

Small Company of the Year: ADA Consulting CESA Lifetime Industry Achievement Award: Graham Burrows

Visionary Client of the Year: Black Mountain Mining, a subsidiary of Vedanta Zinc International

CESA Branch of the Year: Western Cape Job Shadow and Poster Initiative Award: Mariswe

Located in the remote Orientale province of the DRC, the 11 MW Azambi Hydropower Project was developed to support the increasing power demands of Kibali Gold Mine, one of the largest gold mining operations in Africa. Knight Piésold worked closely with the client to develop the purpose-built, low-impact and cost-effective run-of-river hydro-electric project. Local communities were consulted to ensure a positive legacy, and construction and development strategies placed an emphasis on uplifting the local region through skills transfer and local employment. Producing approximately 64 GWh of renewable, reliable electricity each year, the project has decreased the mine’s reliance of diesel fuel and reduced the overall energy cost by around 75% – a saving equivalent to US$19.2 million (R295 million) per year. Commendation: Construction of Main Road 118 between Oranjemund and Rosh Pinah | SMEC Other entries: • Antarctica: SANAE IV Research Base: Refurbishment of the Base for the Department of Public Works | Royal HaskoningDHV

Drones

Public delivery takes to the skies The commitment of the Gauteng Department of Infrastructure Development (DID) to service excellence includes the deployment of drone technology to ensure that each of its projects is executed on time and within budget. By Alastair Currie

longside a host of interrelated technological advances in IT and artificial intelligence, the advent of the drone has become a permanent and rapidly growing feature within the world of construction.

Moloisane Moloi, senior business analyst at the DID, proudly displays his commercial drone licence. He is the first drone pilot to qualify within the Gauteng Provincial Government

The private sector was an early adopter, recognising the advantages of these remotely piloted aircraft systems (RPAS) for a range of applications that include cadastral sur veying, general security sur veillance, quantity sur veying, design, project and programme management. Now the public sector is following suit, with the DID leading the way with the adoption of these and other smart technologies. In this respect, the department recently celebrated a major milestone when Moloisane Moloi, senior business analyst, DID, qualified as its first licensed remote drone pilot through the South African Civil Aviation Authority. The path to qualification is a rigorous one that, in addition to medical tests, covers aviation law, navigation, flight planning, and practical flight training. The DID currently owns a number of drones and plans to add further pilots over time. The one flown by Moloi is a DJI Mavic Pro enterprise version, configured for commercial and industrial operation. In preparation for its entr y into the RPAS field, the DID concluded a memorandum

of understanding with the University of Johannesburgâ&#x20AC;&#x2122;s Centre of Applied Research and Innovation in the Built Environment, in July 2018, to test the viability of going this route. The custodian for public facilities, barring human settlements and roads, the DID is responsible for implementing developments that include clinics, hospitals, libraries and schools. Key ongoing projects include a new R500 million forensic pathology laborator y for the Department of Health on the Helen Joseph Hospital site in Johannesburg. This five-storey building is now at an advanced stage of construction and expected to be fully commissioned by June 2020, with drone sur veying forming a core part of the building process.

3D mapping Using specialised 3D photogrammetr y via drones, combined with project management and costing software, the DID will now be able to precisely and visually monitor all stages of construction â&#x20AC;&#x201C; from start to finish. The plan is to integrate processed

The use of drones has revolutionised how we execute projects, providing the DID with a new way of interpreting and/or verifying construction data.â&#x20AC;? 20

IMIESA September 2019

Drones

data into a building information modelling platform for both new construction and maintenance. “The use of drones has revolutionised how we track and execute projects, providing the DID with a new way of interpreting and/ or verifying construction progress, and providing near real-time opportunities for process improvements,” explains Moloi. “Flight metadata information recorded is compared against plans and the reports can be shared online with the professional team and contractors. Working in sync, projects will be delivered quicker and more cost-effectively.” Each aerial sur vey starts with a flight plan, with preset GPS grid coordinates to ensure automated and pinpoint accuracy of the areas of the site being photographed by the drone. From there, the images

captured are downloaded and collated into a 2D map using purposedesigned software. This map can then be superimposed over the original design plan. In that way, the DID can check for variations, and validate progress. More importantly, the DID will be able to pick up anomalies quickly, rather than having a snag list at the end and ensuing project delays and cost overruns. In the near future, the DID also plans to expand its technology suite to include 3D laser scanning to execute high-definition sur veys. In addition to works in progress, this will enable the DID to carr y out detailed condition assessments and maintenance

planning on existing buildings within its R12 billion plus portfolio. “We are excited about the use of drones within the public infrastructure deliver y environment and, moving for ward, the bigger picture could see the DID establishing a business unit that specifically manages drone operations,” adds Moloi. “The power of analysis depends on the accuracy of the data, and the advent of drone mapping has definitely taken this to new heights,” he concludes.

Drones

The changing landscape of surveying Although aerial mapping is nothing new, drones have provided a far more efficient way to capture topography for use in land surveying. By Danielle Petterson

erial imagery can offer great value to engineers, planners and even those in the field of social science; however, putting a plane in the air to collect data can be prohibitively expensive, particularly for smaller pieces of land. Remotely piloted aircraft systems (RPAS), or drones, not only offer a considerably more cost-effective method than planes, but they also provide a significantly more efficient method of topography capturing than measuring discreet points on the ground. Chris Kirchhoff, partner at 5D Survey, recalls the days of large film cameras and stereoscopic plotters being used to stitch negatives together. This was a highly manual, time-consuming process of creating maps

IMIESA September 2019

using the technology available at the time. The rise of robotics, GPS, computing power and digital photography have revolutionised this process, making it quicker and easier to collect imagery from the air. “It is now so much easier to collect imagery from the air. And the beauty of capturing imagery from the air is that we not only know where things are, but we can determine the RGB values, which allows us to recognise and differentiate between various types of infrastructure and land, such as roads, fields and even informal settlements. For example, we can teach a computer what the edge of a road looks like and programme the drone to automatically follow it,” explains Kirchhoff.

“We can collect an immense amount of knowledge about the earth’s surface and convert it into digital information that can be used in a broad number of applications, such as upgrading services or understanding future demand by mapping growth patterns,” he says. RPAS also offer municipalities the ability to regularly survey and monitor change in key areas, even if they are small areas.

Broad applications The mapping data that surveyors can provide based on drone footage has a broad range of applications. For example, regular mapping of a road construction project can provide a better understanding of the earthwork required based on the ground conditions,

Drones

contractors’ progress can be monitored, and better quality control can be ensured. “You can quickly and easily monitor progress to ensure better cost and time control, avoid overruns and ensure work is done correctly,” explains Kirchhoff. Similarly, the data can be very useful for infrastructure upgrades and installations. Kirchhoff recently completed a mapping project of London Road in Alexandra, Gauteng. Using drone photography, a map was created showing all existing infrastructure, contours, sizes, housing density and more. This will be used to inform the municipality’s planned upgrade of the road. “With this one picture, you can understand what you need to consider – from pedestrians to schools, informal settlements and factories – for a road upgrade. And because there is elevation and contours, the engineers can understand the drainage and flow down towards the river,” says Kirchhoff. “A day of mapping has allowed them to do much more detailed planning than they would have been able to achieve with a traditional discreet survey. The big advantage is that this is a very busy road and instead of having surveyors on the ground for five or

six days, which could have necessitated closure of the road, we have provided a much safer option.” Similarly, Kirchhoff undertook a mapping project in a small town in the Northern Cape, where the municipality wanted to install potable water connections and waterborne sewerage. The map allows the municipality to determine the topography, number of houses, where the town is growing, the best layout for reticulation and sewer systems, as well as identify space for a treatment works. With around 40 minutes of drone flying and a day of traditional surveying to position the topography, Kirchhoff and his team were able to supply the municipality with more than double the information that could have been collected on foot over a week. “We have so much more information available now. And if the municipality shares this internally, there are so many people who can benefit. The more we share the information we collect, the more we realise how many people can benefit from having the understanding it provides. It is particularly relevant in the social sciences space to understand social forces and drivers at work,” he adds.

The digital revolution Because technology has made it so much simpler to collect data, Kirchhoff believes land sur veyors are moving away from data collection into a data analysis and interpretation role, in order to support good decision-making. As professionals become more spatially aware, they will be asking increasingly complex questions of surveyors, and technology will allow surveyors to provide the answers. “The next big step is machine learning for the analysis of data. We can now collect data very efficiently, and machine learning will allow us to analyse vast amounts of data and extract meaningful information. Big data is nothing without meaningful analysis to support decision-making,” says Kirchhoff. However, Kirchhoff cautions that the technology itself is not enough. It comes down to providing accurate, actionable information. “Taking a picture with a drone is not a map. The skill and understanding of the maths required to conver t a picture into something that is an accurate representation of reality and a map with good and correct knowledge is the real skill of a surveyor.”

IMIESA September 2019

CELEBRATING 100 YEARS OF INNOVATION

Water & Wastewater T PARK in Hong Kong is an example of the circular economy serving economic development and the environment

The technology already exists to build wastewater treatment plants that are 100% water and energy autonomous.

The sewage plant of the future is already here

water and energy self-sufficient plant that serves as a prime example of the circular economy by turning waste into worth is already operating in Hong Kong. The Veolia-built and -operated T PARK sludge treatment facility processes 1 200 tonnes of sludge per day from 11 sewage treatment works in a region of over 7 million inhabitants, with a total design capacity of 2 000 t/day – making it the world’s largest sludge treatment plant. At the heart of the plant, fluidised bed incineration technology incinerates the sludge at 850°C for two seconds, reducing the volume of waste to be landfilled by 90%, and the emission of greenhouse gases by up to 237 000 t per year. The heat generated during this process is recovered and transformed into electricity. The 14 MW that is produced is able to supply the entire site, including a 600 m3/day desalination plant that meets the plant’s process water requirements, with the remainder fed into the public power grid. At full capacity, the plant can produce up to 2 MW of surplus electricity, which is enough to light up 4 000 homes. The facility achieves zero effluent discharge via a wastewater treatment plant that collects, treats and reuses the wastewater produced

on-site for various uses such as irrigation and cleaning. Furthermore, the low footprint and efficient design of the plant equipment are integrated within a remarkable architectural feat that is environmentally harmonious with its surrounding landscape between sea and mountains, with approximately 70% of the 7 ha site being green space and water. In addition, the facility has a 2 800 m² interactive exhibition centre focusing on sludge treatment, which plays an invaluable educational role in creating greater knowledge and support for the circular economy transition. On completion of the plant, Veolia assumed a 15-year operations and maintenance contract. In addition to ensuring the plant meets the most stringent ecological performance standards, Veolia will also ensure continual technologydriven optimisation to ensure the plant remains a landmark of sustainable waste management strategy long into the future.

Circular approaches in SA Veolia Water Technologies South Africa brings these technologies and expertise to subSaharan Africa’s municipalities and industries. One such example is South Africa’s first Biobulk® wastewater treatment facility, which Veolia installed at Distell’s distillation facilities in Stellenbosch to lower the chemical oxygen

Veolia is helping to bring the circular economy to life, as we ramp up our fight against the challenges of climate change demand load in the outfall to the municipality and harvest the energy in the wastewater. This highly efficient treatment plant treats 1 000 m3 of effluent per day containing a daily COD load of 8.6 t, which it reduced by approximately 94%, while harvesting the biogas generated during anaerobic digestion – now used as a fuel for the plant’s boilers. In one of the largest evaporation and crystallisation plants in the world, the Veoliadesigned and -built Ambatovy Mine treatment plant treats mine water while recovering up to 210 000 t of ammonium sulfate per annum, which makes an ideal fertiliser. What was once a hazardous waste product has been transformed into a useful agricultural product that is sold as a secondary revenue stream by the mine. By extracting and recycling useful resources contained in our waste, Veolia is helping bring the circular economy to life, as we ramp up our fight against the challenges of climate change.

IMIESA September 2019

Water & Wastewater

From waste to resource

CHP plant at the Northern Wastewater Treatment Works

Wastewater treatment plants are typically seen as a way to treat and dispose of unwanted waste. However, the opportunity exists to transform these plants into resource factories that generate an income while promoting a circular economy approach. By Danielle Petterson

he sludge produced from the wastewater treatment process is considered a problem for most utilities. Many only partially treat their sludge due to ailing infrastructure, limited budgets, and poor operations and processes. As a result, sludge does not always conform to the sludge guidelines and water-use licence requirements, and utilities pay for it to be transported and disposed of at landfills or on agricultural land, at significant cost. The costs of disposing of this unwanted sludge can amount to tens of millions of rand every year, says Karl Juncker, owner, WEC Projects. However, if process controllers

can ensure a well-performing sludge process using anaerobic digestion and the resulting benefits thereof, wastewater treatment works (WWTWs) can transform into resource recovery plants that create valuable by-products from their sludge and nutrient-rich final water.

Enhanced sludge process In order to transform WWTWs into resource recovery centres, all aspects of good sludge treatment must be considered to achieve optimal resource beneficiation and nutrient recovery. These include: • adequate upstream sludge treatment • good sludge conditioning

• maximising gas production for combined heat and power (CHP) • nutrient recovery • biosolids production. “It’s not about treating water; it’s really about treating sludge. Sludge should be a valuable source of revenue, not a cost,” says Juncker. The aim is to stabilise and disinfect the sludge to A1a requirements (as per Volume 2 of the Guidelines for the Utilisation and Disposal of Wastewater Sludge), so that it becomes a biosolid suitable for agricultural use. According to Juncker, the best way to achieve this in large-volume WWTWs is through optimised anaerobic digestion, which

Biosolids

Thermal hydrolysis plant

IMIESA September 2019

Water & Wastewater

Struvite

A Guideline for Anaerobic Digestion of Municipal Wastewater Sludge (Van der Merwe-Botha et al., 2019), adapted from The Capable Plant Model (AWWA)

will result in the production of methane gas and stable sludge.

Sludge conditioning The first step is to optimally pre-treat your sludge prior to anaerobic digestion. This can be done via thickening, process optimisation and hydrolysis. Juncker advocates for thermal hydrolysis due to the many benefits it offers, namely: • increased sludge bio-degradability and digestibility • increased gas production • kills pathogens (class A sludge) using heat • results in drier sludge and therefore reduced volumes and lower handling costs.

Biogas-to-energy or CHP A well-operated anaerobic digestion process produces large quantities of methanerich biogas. Unfortunately, this methane is often released straight into the atmosphere,

where it is 21 times more harmful than CO2. Many WWTWs flare off their methane, converting it to CO2, without using the energy potential of the gas. Although less harmful, this still poses environmental problems and the gas could be utilised to benefit the municipality, given the new Carbon Tax Act (No. 15 of 2019). Ideally, WWTWs should be harnessing this biogas for CHP. The heat can be returned to the anaerobic digesters, while the electricity can be used as an energy source to run the plant. This process is optimised by implementing thermal hydrolysis pre-treatment, which will produce more methane-rich biogas and, therefore, more energy. Typical municipal WWTWs (activated sludge) are extremely energy intensive to run, requiring around 1.3 MW per 100 MLD. Juncker argues that, with good processes in place, plants can produce 60% to 80% of their energy requirements via CHP from the sludge treatment process at the plant. This

will result in significant cost savings, together with reducing reliance on Eskom and mitigating greenhouse gas (GHG) emissions. When taking into account offsetting the GHG emissions from the treatment process and dependency from Eskom’s electricity production, CHP could generate hundreds of millions of rand per year in carbon credits for the utilities.

Biosolids production If performed correctly, enhanced anaerobic digestion should produce an A1a class sludge, or biosolids. These biosolids contain residual nitrates and phosphates, making excellent fertilisers that can be sold for over R300 per tonne to the agricultural industry, says Juncker. Unfortunately, many utilities are currently sending non-compliant sludge to farmers for agricultural purposes, while others send their sludge to landfill. “Instead of being a problem, sludge can be a resource. Right now,

Clarifiers at a WWTW

IMIESA September 2019

Water & Wastewater

Cape Town leads the way The City of Cape Town will soon be implementing a biosolids beneficiation facility (BBF) at its Cape Flats WWTW. This will be one of two centralised BBFs already approved by the municipality, with the aim to establish a third facility in the future. Establishing centralised anaerobic digestion facilities rather than installing digesters at individual treatment plants will allow the city to harness economies of scale at both capital and operational levels, explains Sven Sötemann, head: Development and Infrastructure Planning for the Wastewater Branch, City of Cape Town. The centralised facilities are being designed to accommodate the ultimate sludge production capacities of the surrounding WWTWs, and have been positioned to minimise travelling distance from the donor plants. The municipality currently disposes of its dewatered primary sludge at a hazardous landfill, while dewatered waste-activated (secondary) sludge is applied to ‘sacrificial’ farmland – agricultural land that is used to grow animal feed. The Southern BBF, located at the Cape Flats WWTW, will be constructed on a brownfield site, making use of the three existing 1 800 m3 anaerobic digesters. At an estimated project cost of R650 million, this facility is expected to be completed by 2023.

utilities are paying transportation costs to give their sludge away. Instead, they could be selling biosolids and making an income to supplement operating costs,” he says.

Nutrient recovery Nutrient recovery can be undertaken via controlled struvite precipitation. The resultant struvite is a valuable fertiliser that can be sold at around R3 000 to R5 000 per tonne. By removing nutrients, you also prevent the formation of struvite in downstream pipes, where it can cause blockages and increase maintenance costs.

Key considerations Digester operation and optimisation remain critical to the process, cautions Juncker. Digesters need to be regularly

IMIESA September 2019

checked, cleaned and maintained, and a process control regime put in place. The efficiency of digesters can be evaluated by monitoring the biogas production. Additional gas (and power) production can be achieved by co-digestion, namely adding an additional external carbon source (high-organic matter) to the digesters. Unfortunately, inadequate infrastructure and the poor operation and monitoring of WWTWs, especially anaerobic digesters, is a prohibiting factor preventing the uptake of these processes in South Africa. According to Marlene van der Merwe-Botha, director, WaterGroup, this is coupled with a lack of expertise and finance. There is also an absence of incentives and pricing structures that promote electricity production from biogas and the reuse of nutrients and biosolids, as well as an absence of a conducive legislative and procurement framework. However, the potential is huge. There are currently 108 verified active anaerobic digesters in South Africa at municipal WWTWs, and even more at works owned by the Department of Public Works. The South African-German Energy Programme (Sagen) has funded the development of a decision-making tool by WEC Projects in cooperation with Salga and GiZ to assist municipalities in assessing the potential of their WWTWs. GiZ-Sagen has also supported the development of a practical guideline called Anaerobic Digestion of Municipal Wastewater Sludge, compiled by Van der Merwe-Botha, which demonstrates the relationship between maintenance, design, operation and business processes, and how they should work together to ensure that an anaerobic digester is capable of producing biogas and biosolids of the highest quality. Van der Merwe-Botha notes that not all plants are financially feasible for co-generation, but that options of co-digestion and reducing the impact of GHGs offer significant benefits to WWTW owners. Although the initial investment costs for establishing a resource recovery plant are high, Juncker argues that the payback period can be less than seven years in certain cases. “There is a very strong business case. If we treat sludge as a resource, plants can potentially make or save enough money to run the entire sludge process and still have some change. Moreover, by getting the sludge treatment process optimised, the water treatment process will inherently operate well,” says Juncker.

“In this way, we can adopt a circular approach in which our WWTWs become resource recovery centres that provide valuable resources, which create worth instead of waste.” Van der Merwe-Botha confirms that South Africa will, in future, refer to wastewater treatment plants as resource recovery plants, noting the commercial value of finite resources such as nutrients, organics, energy and first-to-second-grade water from WWTWs. She stresses that public-private partnerships and a conducive, incentivised, regulatory environment would be the most beneficial way to unlock resources, stimulate investment and propel South Africa forward towards achieving its SDG Goal 6.3 objectives.

City of Tshwane kicks off co-generation project The City of Tshwane will soon be implementing a small-scale CHP system at its Zeekoegat WWTW to transform the biogas produced via anaerobic digestion into energy. According to Kerneels Esterhuyse, acting deputy director: Technical Support and Compliance Management, City of Tshwane, the Zeekoegat WWTW was identified as a highly favourable and suitable plant for CHP because it is relatively new and has good infrastructure and processes in place. Having been commissioned as recently as 2016, the plant doesn’t require any civils upgrades, making the capital requirements for CHP much lower. The aim is to install a small-scale, modular CHP plant at Zeekoegat that can be scaled up and replicated where needed. “This is a learning curve for us. We have no in-house knowledge on the running of CHP plants, so we want to build capacity and then explore expansion possibilities once we have a successful plant in place,” explains Esterhuyse. With this in mind, Tshwane plans to enter into a three-year build, operate and transfer contract to ensure skills and knowledge transfer. The project is expected to produce enough energy to cover roughly 20% of the plant’s energy needs. Construction is expected to begin by January 2020, with the CHP plant up and running by the end of the city’s financial year.

Water & Wastewater

7 benefits of

water quality testing Access to safe drinking water is a basic human right and vital to human health. NOSA Testing’s ISO 17025 accredited laboratory offers a range of tests to ensure that water outputs meet the national standards.

he SANS 241 Drinking Water Specification states the minimum requirements for potable water to be considered safe for human consumption, including the microbiological, chemical and physical properties of the water. This includes effluent water generated in multiple operations, in myriad industries, including mining, food and industrial processes. Performing water quality testing with an accredited laboratory offers a number of benefits, including: • It protects human health: Nothing is more important than health. Individuals who make use of their own water source for drinking need to have it regularly tested. Drinking water should not contain any harmful concentrations of chemicals or pathogens. Ideally, it should be aesthetically pleasing in its appearance, taste and odour. • It protects livestock health: If livestock looks poor or malnourished, it is important to get their water checked, to ensure its suitability. The water may have an unacceptable chemical composition (e.g. too acidic or alkaline, or contain high concentrations of certain elements), or be physically unsuitable (e.g. a toxic blue-green algae species is present). • It protects plant, nursery and crop health: Plant nutrition can be significantly affected by the quality of the water you apply to plants. It is important to know the quality of the water, and whether it can effectively

dissolve fertiliser. If this is ignored, plant growth could be inhibited. • It protects pipes and equipment: Irrigation and hot water systems are expensive to replace. Calcium salts in the water can form a white crust of calcium carbonate. These deposits will accelerate the formation of milk-stone (a combination of calcium deposits, proteins, and phosphates) on dairy equipment, and will eventually block irrigation equipment and affect hot water systems. Conversely, some water is corrosive, and will strip metals (such as aluminium, and copper and its alloys (bronze and brass)). Dissolved copper shows up as green stains on washbasins and baths when the water encounters soap or other alkaline materials.

Aesthetics Pay attention to the way borehole or tank water looks, smells or tastes. Be on the lookout for unexplained particulates floating around or a peculiar smell. Whether it is pollen, black rubber or insect nymphs, diagnosing aesthetic water quality is important. The problem may be about more than just the water’s appearance.

Future investment With current water sources under enormous pressure through climate change, and increased demand and pollution numbers, it is vital to monitor and protect alternative and future water sources. To offset the declining inflow to dams, the future will see increased

NOSA Testing’s ISO 17025 accredited laboratory’s expertise includes: • Heavy metals via ICP-MS and ICP-OES • Microbiological (pathogens and bacteria) • Total organic compounds • Chemical oxygen demand • Testing for trihalomethanes • Groundwater analysis • Borehole water analysis • Treated water analysis • Mining discharge water analysis • Wastewater analysis • SANS 241 chemistry, microbiology, somatic coliphages and protozoan parasites rainwater yields and deeper aquifer withdrawals, the replenishment of deep aquifers with recycled water, and the expansion of seawater desalination capacity. Monitoring water quality will enable us to better understand and protect our aquatic ecosystems into the future.

Avoid outbreaks in pools Swimming pools and spas, particularly public ones, are sensitive to outbreaks of infectious diseases. Swimming pools should be regularly tested for heterotrophic plate count, E. coli and Pseudomonas aeruginosa. Indications of poor pool health are measured by the incidences of diarrhoea, nausea, vomiting, abdominal cramps and fever. This organism is responsible for skin and mucous membrane infections and ear infections, particularly in children. Avoid outbreaks by regularly having the water professionally tested.

IMIESA September 2019

Water & Wastewater

he Malukazi Bulk Sewer Infrastructure Scheme included the construction of bulk sewer gravity mains, a sewer pump station, sewer rising main and 20 communal ablution facilities, with associated water and sewer reticulation, connecting into the adjacent Lower Malukazi Phase 1 catchment. Bosch Projects was appointed to carry out multidisciplinary designs, implementation and construction management for the project. “Apart from the civil design and electrical and mechanical components, Bosch Projects was also responsible for the important coordination management of subspecialists, including mechanical, ventilation, fire, geotechnical, electrical, roads and earthing contractors,” says Manditha Jamuna, project manager, Bosch Projects. The project, which commenced in August 2016, created employment within the community and now provides a basic level of service of sanitation and water to the previously unserviced community. “Despite numerous challenges affecting the continuity of work, including business forums,

Malukazi scheme brings services to communities community unrest and political pressure in the area, the project was completed within budget and to the highest-quality standards,” continues Jamuna.

Project design Civil design for this project encompassed the pump station design review, the design of a temporary pump station, bulk and reticulation sewer infrastructure, roads and stormwater rehabilitation, and the environmental management of the water course. Electrical and mechanical components included pump and associated pipework design, ventilation design,

lighting and electrical supply, lightning protection and telemetry. Another challenge of this project included the construction of the pump station in excessive groundwater conditions. Geotechnical intervention was required, to ensure stability of the excavated area. The complexity of the project was increased, as a temporary pump station – designed to service communal ablution facilities in the interim – was operational during the construction of the main pump station. The temporary pump station was then converted into the overflow chamber of the pump station.

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Climate change impacts on water quality More attention needs to be paid to the causes and responses to declining water quality and its management.

mong the impacts of climate change will be an aggravation of water quality in South Africa’s rivers and dams; this may in turn lead water authorities to raise the bar for water discharged by industry and mines. “Variable rainfall patterns occasioned by climate change are already being seen in more frequent high-intensity downpours in parts of the country,” says Manda Hinsch, partner and principal water and environmental scientist, SRK Consulting. Global research confirms that more intense precipitation and increased run-off result in increased levels of pollution entering waterways in the form of sediments, nitrogen from agriculture, disease pathogens, pesticides and herbicides. One of the more dramatic consequences can be blooms of harmful algae and bacteria. “The steady and ongoing enrichment of water with nutrients gradually reduces its quality, with significant implications for the environment and downstream use,” Hinsch explains. Where these heavy rainfall events are interspersed with hot, dry periods, high levels of evaporation could further increase the concentration of nutrients.

Manda Hinsch, partner and principal water and environmental scientist, SRK Consulting

Low-quality discharge On the other hand, water quality is also likely to be compromised in areas where climate change is leading to less rainfall. These negative impacts on water quality will exacerbate an already problematic situation, where the widespread malfunctioning of municipal wastewater treatment works is contributing to low-quality discharge into rivers and dams. Hinsch points out that many of the concerns expressed by government and industry about climate change relate to the future changes in our water quantities, with insufficient attention paid to how the quality will change. “In response to the declining quality of water, the relevant authorities may well have to take further policy and regulatory steps,” she stresses. “Water legislation already governs the acceptable or target levels of contaminants the receiving water environment can sustain in order to be suitable for downstream water users. Mines and industry should not be caught unaware if water quality standards become more stringent in future.” Hinsch emphasises the integral connection between water quantity and quality when developing water management plans, be they for local government or private enterprises. While these plans need to be multifaceted and focused on local conditions, there is growing appreciation of the role of wetlands in water management. They play a vital role in controlling the flow of surface water and reducing run-off, while also trapping sediments and removing pollutants to help purify water. “We will hopefully see greater use of attenuation ponds and constructed wetlands as part of our national response to climate change and more variable rainfall patterns. The strategy can also be applied by mines and even certain industries,” she concludes.

IMIESA September 2019

SAST T Trenchless News

Many of South Africaâ&#x20AC;&#x2122;s municipalities engage in ongoing pipe replacement and rehabilitation based on their asset management programmes. These often provide ideal opportunities to employ trenchless technologies.

Creating trenchless opportunities

he Prasa Park Station Sewer and Stormwater Upgrade is a perfect example of how trenchless technology can be used to rehabilitate old, dilapidated infrastructure in an area that cannot be shut down to accommodate open trenching. The existing infrastructure beneath the commuter station had become deteriorated significantly, and constant blockages required daily over-pumping from manhole to manhole to maintain sewer flows. At platform level, there were constant sewer overflows. The existing 150 mm diameter clay sewer outfall had become severely overloaded and was also positioned below a superimposed stormwater system located in a largely inaccessible position between busy railway tracks, making it extremely difficult to inspect, clean and maintain. Servicing over 180 000 passengers daily, Johannesburgâ&#x20AC;&#x2122;s Park Station could not be shut down to accommodate repairs.

A trenchless solution Consultant SMEC South Africa, together with contractor Trenchless Technologies, undertook investigations and developed a trenchless solution for the rehabilitation of the main sewer pipeline and stormwater reticulation system. CCTV pipeline investigations together with ground-penetrating radar surveys were used to establish the location and condition of existing infrastructure in relation to the site. Investigations confirmed that ground conditions were soft and homogeneous, free of rock and boulders, and therefore suitable for the use of horizontal directional drilling (HDD) to install a new 250 mm diameter sewer pipeline. These were also essential to locating a feasible drill path through the maze of old buried infrastructure, which included many obstructions such as obsolete post office tunnels, concrete beams and slabs, various unknown old structures, cables and old pipes.

IMIESA September 2019

SAST T Trenchless News

Drilling was successfully undertaken at minimum falls of 1%, from 14 access pits up to 6 m deep. The access pits required very small footprints to fit within extremely contested platforms and rail areas, and in some cases no access was available on the surface to allow for surfacemounted drilling. Instead, HDD rigs crawled down constructed ramps or were lowered into the access pits to drill from within the access pits. Using HDD, Trenchless Technologies successfully installed the following:

• 300 m of 250 mm Ø HDPE pipeline installed beneath operational railway tracks to create a new outfall pipeline • 47 m of 250 mm Ø HDPE connecting pipeline installed underneath the railway tracks • 132 m of 250 mm Ø HDPE pipeline installed diagonally, underneath the railway tracks, to connect to the new outfall pipeline. According to Meghan Brinkley, section manager: Management Services, SMEC South Africa, the project highlights the ability of trenchless technology to solve many urban infrastructure challenges, even in extremely congested and populated areas. SMEC South Africa has been involved in a broad range of trenchless projects, particularly ongoing sewer rehabilitation projects for some of the large metros. According to Rowan Griffioen, function manager: Management Services, SMEC South Africa, trenchless technology is well suited to sewer rehabilitation, particularly in old installations that combine sewerage and stormwater. The combination and age of the installation often result in pipes being undersized for current needs and trenchless technology provides an opportunity

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to split these services and increase capacity. The pipe materials best suited to trenchless applications are also more acceptable to sewers than water reticulation pipes. Griffioen explains that projects are often advertised as rehabilitation projects and not specifically trenchless projects; however, contractors can still employ trenchless techniques for rehabilitation where appropriate. “We often have no choice in Johannesburg because it is too densely populated,” adds Brinkley. Most large municipalities have asset replacement programmes in place, prioritising sewers that are over capacity. As part of these programmes, SMEC is currently involved in several rehabilitation projects. “Many of these areas are densely populated, so we have to go with a trenchless solution or roads and driveways will have to be dug up and people would not be able to access their properties,” says Brinkley.

A question of economics

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The decision of open cut versus trenchless is often a question of economics. Sometimes, it is cheaper to dig, but open trenching proves too disruptive or costly in many cases. According to Brinkley, resurfacing roads is a major cost factor and trenchless solutions will almost always be more cost-effective than digging up a road when this aspect is taken into consideration. “The client is always looking for the most cost-effective solution, but we must take job creation and SMME employment into account,” she adds. SMME inclusion can make employing trenchless technologies more challenging because it requires specialised equipment. Open cut is therefore easier when promoting SMME inclusion and labourbased construction, although limitations on the depth to which you are allowed to trench by hand can make this a challenge, she explains. Finding contractors who are comfortable with trenchless technology is another challenge. When opting for trenchless, it is also important to select the most appropriate technique. Brinkley and Griffioen agree that pipe bursting is often the best method when rehabilitating or replacing sewer pipelines, as it allows you to upsize by replacing the pipe while following the original gradient. If the pipe is encased in concrete, pipe bursting becomes problematic and HDD is more preferable. “CIPP (cured-in-place pipe) is not the ideal choice for rehabilitating smaller-diameter domestic connections, as it will reduce the capacity; however, it is a good option or solution for bulk pipelines of 250 mm Ø and up because the reduction in diameter has a lesser effect on capacity,” says Griffioen. “Trenchless and open cut both have their place. It is important to take each project on a case by case basis and ensure that the right method is used for the job at hand,” concludes Brinkley.

SAST T Trenchless News

Switching to trenchless techniques

Trenchless equipment supplier ELB Equipment has developed unique structures within the company to easily assist municipalities and municipal contractors to find solutions to piping infrastructure needs.

Dezil Arends (left), area sales manager, ELB Equipment, with Paul Minnaar, director, Last Mile

ABOVE Ditch Witch directional drills can drill long spans underneath existing structures like roads, canals, buildings and other valuableÂ infrastructure

or quicker and easier identification of equipment requirements, tendering assistance and access to finance, ELB Equipment has put in place special departments that are focused entirely on dealing with local government requirements, with specialists who are trained and well versed in government business. According to Desmond van Heerden, divisional director, ELB Equipment, the idea is to ease the burden on officials and technical staff in order to streamline the process and ensure the right equipment is available to do the unique jobs

IMIESA September 2019

SAST T Trenchless News

Jan Bouwer (left), owner, Gokor Construction, and ELB Equipment’s Phillip McCallum inspect the company’s well-used HammerHead HG 12 pipe-bursting system

Over the years, Last Mile has gained considerable experience in a wide array of drilling applications to support fibreoptic installations, pipelines and other infrastructure. During this time, it has become a leader in the use of trenchless technologies using ear th drills, moles and related equipment to burrow beneath obstacles such as roads and other infrastructure, to minimise disruptions and save on the costs of restoring infrastructure to its original condition.

Versatile solutions

required within the boundaries of each town and region. “We have a 100-year history of service within South Africa, during which time we have customised our services and products to become an integral supplier to all spheres of government. We have also made sure that our products are listed on the central procurement RT57 tender system to ensure that officials have quick and easy access to our equipment when required,” Van Heerden explains. “Our easy-to-access offerings put the equipment in reach of emerging contractors as well, which means that we are actively developing these contractors through skills development and training, as well as providing easier access to finance and ongoing advice and support for their equipment. “We are also actively encouraging our emerging contractors to adopt trenchless technologies in their service offering as a relatively untapped market with massive scope for growth. Many of our existing towns and cities have complex buried infrastructure; trenchless techniques are

IMIESA September 2019

the only viable means of replacing aged infrastructure in these circumstances,” Van Heerden continues.

Urban necessity He further explains that pipelines placed by means of trenchless technologies are naturally founded in the surrounding earth and are, therefore, less likely to fail due to load stresses that may other wise be caused through trenching and filling. In certain circumstances, where soil conditions are varied or poor, trenchless techniques can actually minimise the maintenance associated with constant failures in these with poor founding conditions. This is especially true in coastal areas such as Cape Town and the Cape Flats. Cape Town City Council’s strict guidelines for trenching with minimal disruptions to residents and traffic have provided a considerable advantage to ELB Equipment’s customer Last Mile, which has won a number of contracts based on its workmanship and the capabilities of its equipment.

Paul Minnaar, director, Last Mile, says the company is currently engaged in a large number of drilling contracts in the Western Cape and Free State, mainly for the installation of fibre networks. These require manual trenching up to driveways and roads where the company’s latest tool, the Ditch Witch JT10 directional drill, provides the reach to drill across even the largest of obstacles. “In order for us to be effective, we under took a thorough investigation of equipment and best practices a number of years ago, to identify the right equipment for urban inner-city and suburban environments,” explains Minnaar. “We wanted to meet the strictest of municipal requirements and provide the fastest and most effective tools to get in and out of an area with the least disruption and happy customers.” “This led us to the advanced range of Ditch Witch products that met the criteria. In operation, these machines are also proving to be ver y reliable and well supported by the national supplier, ELB Equipment, which has a large stockholding of accessories, spares and par ts that we need to meet our ser vicing and maintenance requirements,” he continues.

Old favourite “This is important because any disruption as a result of breakdowns can infuriate residents and slow the progress of fibre installation on behalf of fibre bandwidth suppliers. It also costs us tens of thousands of rand in operational costs, so the importance of equipment reliability cannot be overemphasised,” he stresses. He says the company’s original Ditch Witch JT 922 machines have been ser ving the City of Cape Town for a number of years and drilling an average of 60 m

SAST T Trenchless News

HammerHead pipe bursting in action

per day for the installation of underground infrastructure. During this time, they have also saved the infrastructure owners and residents of the city many millions of rand in permissions to uproot infrastructure and return it to its original condition thereafter. For example, the City of Cape Town charges contractors a fee of more than R4 000 per metre to manually trench across secondary roads. Long delays for permits and permissions would otherwise also cost installers many days in waiting, which clearly shows why directional drilling has found favour among city officials.

Pipe bursting In other instances where large amounts of infrastructure are required to be replaced, pipe bursting is considered the best and most cost-effective means of replacing pipes quickly and efficiently with minimal disruption to infrastructure and sur face traf fic. Another of ELB Equipment’s customers, Gokor Construction, is assisting cities throughout Gauteng to stem the loss of millions of litres of potable water daily, while preventing sewerage leaks from silently contaminating our water ways and groundwater. With thousands of pipelines already well over the 50-year mark and equally as many over 100 years old, failures are becoming commonplace and specialised pipe-laying companies like Brakpan-based Gokor Construction are increasingly being called on to find ways of replacing the pipes under layers of underground infrastructure and below houses, hospitals, roadways and buildings. The contractor is one of the only specialised pipe-laying companies in the region that can under take large-scale pipe replacements using pipe-bursting technology, which allows special tooling to be passed through and burst existing pipelines, while simultaneously pulling in a new (often larger-diameter) pipe behind it. In this way, up to 170 m of pipeline can be replaced in two hours, without digging trenches or interfering with above-ground or buried infrastructure.

Tembisa record According to Jan Bouwer, owner, Gokor Construction, the company purchased a

purpose-built HammerHead HG12 and Hydroguide pipe-bursting system from ELB Equipment precisely to undertake this type of specialised pipe replacement work for Gauteng’s municipalities. “Throughout Gauteng, we have built our towns and suburbs over these buried pipelines and now it is mostly impossible to manually dig trenches and repair or replace pipes. As a result, a complete pipeline failure means that either the area gets dug up or the place floods in water or sewage. With our solution, that does not have to happen, as we simply dig entry, exit and inspection pits, and pull new pipes through without unsettling the ground,” Bouwer explains. “In places like Tembisa, we were even able to replace a 70 m stretch in 38 minutes and the entire 170 m pipeline in just two hours. In cases like this, it ensures the municipality is able to effect speedy upgrades and it saves residents the inconvenience of digging up their properties. It provides a quick replacement service for water and sanitation,” he expands.

Contractors required Phillip McCallum, product manager, ELB Equipment, explains that the HammerHead solution is most suited to urban work and allows crews to work in confined and heavily built-up areas. Also, with round-the-clock support from ELB Equipment, as well as the manufacturer, no underground challenge is insurmountable. The high level of support also means the machine is able to work for protracted periods of time reliably and with minimum disruption, which is especially important on urgent pipeline replacement projects. Good news for emerging contractors is that companies like Gokor Construction have replaced thousands of metres of pipelines and provided essential services

in Ekurhuleni, Johannesburg and a host of smaller municipalities, as well as in industrial sites and mines. There is plenty of room for other contractors to specialise in other types of piping or in one of the many areas not already serviced by dedicated contractors. “Municipalities and private proper ty owners need to be made aware of the fact that they no longer need to dig up and disrupt properties or infrastructure, nor disrupt road traffic, to replace pipelines. Due to the speed of operation of the HammerHead system, we are able to assist with most pipe replacements in confined areas, quickly,” says Bouwer.

Supporting government Van Heerden reiterates that the market for trenchless technologies is in its infancy and growing rapidly. Municipalities and contractors should adopt these technologies as a means of providing underground services without damaging and disrupting surrounding infrastructure. With the assistance lent to municipalities and contractors, ELB Equipment is making it easier than ever before to identify and procure the right equipment for the job at hand and it pays to contact the company’s specialists in order to speed up service delivery. The company also provides full training on the operation of the equipment and assists contractors to establish profitable practices to ensure their ongoing success. ELB also offers specialised telematics to assist with fleet management.

www.elbequipment.co.za

IMIESA September 2019

Waste Management

Developing Oranjemund’s future waste strategy Challenging geology, shifting desert sands and a remote location required creative solutions during the design of a new landfill site for an old mining town transitioning to new commercial ventures that include agriculture. By Stan Jewaskiewitz*

he town of Oranjemund is located in a remote corner of Namibia, at the mouth of the Orange River, which feeds into the Atlantic Ocean. The town of Alexander Bay can be seen on the opposite bank of the river, on the South African side. Oranjemund has an interesting history and was originally developed as a town in 1936 for workers on the diamond mines that stretched from the Orange River mouth northwards along the coastline towards Lüderitz. The town was built by mining company Consolidated Diamond Mines (now known as Namdeb) and was closed to visitors until as recently as October 2017. Non-residents and family members had to apply for visitor’s permits if they wanted to visit. Namdeb has for some time been winding down its mining operations: in order to enhance the economic sustainability of the town, it was decided to reduce the interdependence of the two. Oranjemund was officially proclaimed a town on 21 October 2011 and the first town council was appointed a year later. Thereafter, the town was declared ‘open’ and anybody was free to visit. The town is full of surprises, including signs warning of gemsbok, ostriches, bicycles and wind – more on the latter later! The gemsbok can be seen openly grazing and walking through the town. Some services, such as water supply and refuse removal, are now the responsibility of

IMIESA September 2019

the municipality. The next step is the transfer of private and commercial property. In the meantime, the town management is a team effort between the town council, Namdeb, the government, business owners, investors and residents. The town currently has some 12 000 residents and ongoing township development is taking place. The Oranjemund Town Council plans to develop a new landfill site and close the existing waste dump and rehabilitate it. The existing waste dump is unlined and uncontrolled, and poses a potential pollution risk to the environment. The new landfill will include both general and hazardous waste cells, designed and lined as per the Waste Classification and Management Regulations in South Africa as published in Government Gazette No. 36784. The site infrastructure will include internal haul roads, perimeter fencing, security facilities, a weighbridge, leachate management infrastructure, a materials recycling facility, a composting facility, and site offices and ablutions. In association with Rent-a-Drum Namibia, a large Namibian waste management company, Envitech Consulting was appointed to carry out the required site investigations and detail design of the proposed new landfill site facility.

Site geology and topography The proposed site is relatively flat with a gentle slope; however, the topography is constantly

changing due to the non-cohesive Aeolian sands that overlay the site and are blown in different directions by the prevailing winds. The landscape is classified as being in the Namib Plain region, an area with sand drifts and prominent inselbergs largely of the midPalaeozoic Age. The site is located within the catchments of the Orange River, a perennial river, draining in a westerly direction. The surface geology in the area is mainly dune sand and gravel. The subsurface geology of the area consists of alluvium and sand of the Namib Desert from the Quaternary Age. Groundwater flow would be mostly through primary porosity in the alluvium sands of the Namib Desert, and through secondary porosity along fractures, faults and other geological structures present within the underlying hard rock formations. The natural ground level ranges from approximately 69 m above mean sea level at the north of the site to approximately 45 m on the south-western boundary of the site.

Climatic conditions and design criteria The area is classified as semi-arid, with an average rainfall of approximately 100 mm per annum and an average evaporation rate of approximately 2 800 mm per annum. The site is therefore in a negative-water-balance area. The wind direction is predominantly northwesterly, bringing hot air in from the desert,

Waste Management

while the south-westerly winds bring cold air in from the Atlantic Ocean. These climatic conditions have a significant impact on the design of the landfill site. With the population size of approximately 12 000 people and using the international norm of approximately 1 kg of waste generated per person per day, the town will generate approximately 12 tonnes of municipal solid waste per day.

Groundwater Local groundwater flow from the proposed site can be expected in a southerly direction. According to the Department of Water Affairs (DWA) database, no boreholes exist within a 10 km radius of the site. Water supply boreholes supplying Oranjemund town are, however, present along the Orange River, but well upstream of the Oranjemund town CBD (approximately 8 km east).

Geotechnical investigation A geotechnical investigation was carried out to assess the in situ soil conditions. Due to the nature of the in situ material, it being a cohesionless fine-grained Aeolian sand, it proved nearly impossible to excavate the test pits, as the side walls continuously caved in. Another factor that soon became apparent was that as soon as the sand was excavated, the wind blew it away! Due to the nature of the in situ soil, it was immediately ruled out as an option for the construction of the landfill cells. Therefore, appropriate material would need to be imported from other sources to construct the on-site roads and landfill cells. During the site investigations, two potential borrow pits were identified. The first borrow pit (an existing open excavation) was identified near the gun club on the outskirts of the town,

approximately 5 km from the new landfill site; a second borrow pit was identified within the Namdeb mining area, courtesy of Namdeb staff. Material from the Namdeb mine borrow pit was being placed on some of the existing gravel roads within the town. Soil samples were obtained from both borrow pits and sent to a commercial laboratory in Windhoek for permeability and indicator testing. The results of the tests showed that both the materials are silty clayey sands and have permeabilities in the order of 1 x 10-9 cm/s and would therefore be suitable for the construction of the landfill cells. The maximum permeability required is 1 x 10-7 cm/s.

and geosynthetic materials. The general waste landfill cells will be lined with a single composite liner comprising compacted clayey soil and a 1.5 mm HDPE geomembrane liner, with a geotextile protection layer and a stone leachate drainage layer. The hazardous waste landfill cells will be lined with a double composite liner system comprising compacted clayey soil and a 1.5 mm HDPE geomembrane liner with a geotextile protection layer, a stone leak detection layer, a geosynthetic clay liner, a 2 mm HDPE geomembrane liner with a geotextile protection layer, and a stone leachate drainage layer.

Landfill site infrastructure Landfill cell construction The landfill will be constructed in phases comprising some 15 cells, including two cells for hazardous wastes. The cells will be constructed by excavating into the natural ground to achieve the design elevation of the basal area of the cell. The cell floor, edge containment berms, separation berms and leachate dam embankments will be constructed using the silty clayey sand material from the borrow pit. Each cell will have a composite lining system and a leachate collection system. The containment berms will be a minimum of 1.5Â m high and the basal area will have a fall in the south-westerly direction of a minimum of 2%, to allow for leachate drainage into the leachate collection system. The earthworks for the side slopes of the cells will be constructed at 1 horizontal to 4 vertical for the lined surface, and 1 horizontal to 3 vertical for the outer unlined surface.

The site infrastructure will include a single weighbridge for monitoring types and volumes of wastes, administration offices including ablutions, a materials recycling facility (steel portal framed building) and a composting area. A security gate with boom control will also be provided, with the perimeter fencing consisting of treated timber poles and plastic-coated mesh fencing.

Conclusion This project has proved to be both interesting and challenging, considering the remoteness of the site, the site conditions in terms of lack of suitable construction soils, and the impact of strong winds in the area, which are likely to hamper construction â&#x20AC;&#x201C; in particular the installation of the geosynthetic liners. The development of this new landfill site will certainly provide the basis for future waste management and waste disposal practices in Oranjemund and aid in the sustainable economic development of the town.

Landfill liner system The landfill cells will have engineered composite liners comprising both clayey soils

*Stan Jewaskiewitz is the technical director at Envitech Consulting.

IMIESA September 2019

83 RD IMESA CONFERENCE

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Cement & Concrete

Concrete is changing the face of South Africa’s landscape, with cuttingedge architects and engineers increasingly making this their material of choice. Here, Bryan Perrie, MD of The Concrete Institute, deals with the benefits of the world’s oldest and most popular building material. The range of designs, colours and textured finishes available in concrete is limited only by a designer’s imagination

Concrete’s myriad advantages

ue to its longevity and ease of construction, concrete is often the most economical choice for engineered structures. Load-bearing concrete, exterior precast or tilt-up walls ser ve not only to enclose the buildings, but to carr y roof and wind loads, eliminating the need to erect separate cladding and structural systems. Concrete construction can minimise the overall building height to shorten vertical runs of mechanical and electrical systems and reduce the exterior sur face area to be enclosed and insulated. Additionally, thin concrete floor structures facilitate the use of raised floor systems used where the wiring is run in the space below.

Faster turnaround Once the design has been selected, there is generally pressure to get a project started. More and more organisations are making speed a priority, particularly hightechnology companies and rapidly growing firms. When such businesses decide to construct a new facility, they are often

overburdened and already behind schedule. With concrete designs, there is no delay in getting started, as concrete is readily available from many locations across South Concrete is the most economical choice for engineered structures, says Bryan Perrie, managing director of TCI

Concrete textures can resemble smooth, highpolished granite or gutsy, exposed aggregates with a rugged feel. Other possibilities include tumbled cobblestone, brick, cultured limestone, slate, flagstone or river rock

IMIESA September 2019

Cement & Concrete

From multibillion-rand dams to simple low-cost housing schemes, concrete is the logical choice

Africa. A concrete structure can be well under way using in situ concrete before final plans are complete. Precast/pre-stressed concrete can also help reduce construction time and on-site labour costs, by taking advantage of pre-fabrication of standard and custom structure segments. Advanced construction techniques such as flying formwork systems increase the speed of floor construction. As a concrete frame progresses upward, workers on the completed floors below can proceed with interior partitions, exterior finishing, electrical, mechanical and plumbing systems. Faster construction means reduced carr ying costs and faster revenue generation. This facilitates the more timely payback of financing charges and faster revenue generation for the developer/owner. A further advantage is design flexibility: concrete allows the contractor to accommodate design changes after the process has begun.

Stamping and scoring As natural stone becomes inaccessible or the costs rise prohibitively, concrete is also a natural alternative for recreating traditional finishes in a cost-effective way. Besides being widely available and less expensive than quarried stone, cement-based cultured stone is easier to match and install. This makes it popular even in places where quantities of quarried stone are available. Reduced sound transmission is another factor. Containing sound within the walls of a structure is critical in todayâ&#x20AC;&#x2122;s highly competitive environment. Should the tenant requirements include sound transmission control, the natural mass of concrete floor and wall systems provides both acoustical resistance and vibration control.

More floors per structure Shallower floor systems are an important structural advantage of concrete. On average, the construction of concrete buildings will allow one additional floor to be created for each 10 storeys of traditional building height, resulting in more rentable space for buildings of similar size. When faced with height restrictions, concrete construction is a key

IMIESA September 2019

consideration and could represent initial cost savings and additional income generation. Post-tensioning reinforced concrete beams and slabs further allow for longer floor spans with fewer columns to plan around. This offers flexibility in architectural layout and even more usable space. Increasingly, concrete is setting the standard for space planning and utility infrastructure. Concrete is also often left exposed on interior walls due to its aesthetic appeal, durability and inherent fire-resistance.

Ideal for strict specifications Another major advantage of concrete construction for engineered structures is the materialâ&#x20AC;&#x2122;s properties of density and mass. Lateral stiffness, or resistance to horizontal movement, make concrete the product of choice when constructing tall buildings where high winds or seismic conditions are considerations. This lateral stiffness also means that occupants of concrete towers are less able to perceive building motion.

Energy efficiency and recycling Most concrete is produced locally, minimising fuel requirements for handling and transportation. Once in place, concrete offers significant energy savings over the lifetime of the structure. The mass of a concrete structure makes it a significant thermal reser voir with the ability to store large amounts of energy. In hot months, concrete walls and floors absorb the interior heat during the day, then radiate warmth back into the space at night. The same principle holds true for cooling. This thermal inertia allows concrete to help maintain a relatively steady interior temperature. Concrete is also an inert material that is easily recyclable. Old concrete that has reached the end of its ser vice life can be reused as aggregate for new concrete mixtures. The addition of industrial byproducts such as fly ash, silica fume and blast furnace slag make concrete less permeable while incorporating materials that would other wise be deposited in landfill sites. Therefore, in all respects, concrete is a highly sustainable building solution.

Perfecting the cobble effect

eminiscent of ancient city streets and roads, Technicrete’s bevelled Cobble Bond paving can create a similarly attractive effect for those developers wanting to install a high-class finish to commercial, municipal or residential projects. The pavers can be applied in various pattern formations, such as stretcher bond, herringbone and basket weave. Each paving block has a strong interlock capacity. The cobble look is created by a central groove, which is bevelled across the middle of the block. Pavers are available in thickness and length widths of 50 mm 200 x 100 and 60 mm 200 x 100. Sizes such as 80 mm and 100 mm are available upon request. The Cobble Bond paver is designed specifically to withstand vehicle and foot traffic in applications that include driveways, municipal parking areas, pavements and pathways, and commercial developments. It is a durable yet cost-effective paver option, with a wide range of colour options ensuring a smart finish to any project. Technicrete’s Cobble Bond pavers are available in Terracotta, Plum, Grey, Slate, Tan and Autumn

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83 RD IMESA CONFERENCE

02-04 October 2019 DURBAN INTERNATIONAL CONVENTION CENTRE CONFERENCE SOCIAL ACTIVITIES

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Quarries and communities

iscussions between traditional leaders, communities, and local and national government departments are urgently needed to resolve challenges in the quarr ying industr y. This is according to sur face mining industr y association Aspasa. At a recent Aspasa member meeting in KwaZulu-Natal, it was resolved that the Department of Cooperative Governance and Traditional Affairs (Cogta) should be the link between government and the industr y in meeting set objectives in the province. These include coordinated stakeholder engagement and assisting with Integrated Development Plans (IDPs) and Social and Labour Plans (SLPs). Nico Pienaar, director, Aspasa, says major emphasis needs to be placed on skills development and job creation. “Communities should understand and benefit from the SLP focus areas. In this regard, Cogta must also handle and resolve conflicts. Many of the IDPs were developed in 2011 and few are working well,” says Pienaar, adding that the IDP focus has been on macro projects, which is problematic. Complicating matters were requirements and ‘demands’ from local councillors, municipalities and the Department of Mineral Resources (DMR) on small quarries, which cannot comply in terms of time and financial resources. Pienaar suggests that an ideal scenario would be greater collaboration between larger and smaller mines to achieve the best impact possible for communities. “It will be essential in future to ensure that other businesses and industries (apart from quarries) work together in an area and do something big,” Pienaar adds. At the Aspasa meeting, other challenges highlighted included the payment of royalties to traditional leaders, as well as in-fighting among chiefs and communities. To prevent any misuse of funds, Aspasa asserts that the DMR should develop a guideline that is practical and clear, preventing double dipping. Illegal mining needs to be clamped down on as well. Going for ward, the Aspasa-led Cooperative Forum for Quarries has been established to set out priorities and formulate documents Nico Pienaar, director, Aspasa and guidelines.

Social Housing

Face brick is aesthetic

A section of Joshco’s recently built Turffontein social housing development, showcasing its distinctive face brick exterior

ohannesburg’s housing backlog continues to grow exponentially, as a constant flow of migrants enters the province in search of employment. In response, the Johannesburg Social Housing Company (Joshco) is mandated by the city to provide and manage affordable rental housing for the lower-income market. Working with the Social Housing Regulator y Authority (SHRA), a recent example is the construction of Joshco’s Tur ffontein development, comprising

525 units, 21 of which are for transitional housing. “Corobrik’s range was chosen for the outer skin of the building as it is very low maintenance – the dust and dirt of everyday living will not show up against the brickwork, retaining a clean look for longer,” explains Nico Killian, contracts manager, Joshco. Anca Szalavicz of ASA Architects comments: “We used two different face bricks – Montana Light and Protea Travertine – to create some form of contrast within the design; because of the high number of units, the design

hinged on creating small, manageable, semiprivate courtyards. Some of the blocks have vaulted roofs, which gives the development quite a unique appearance.” The end result is an affordable and durable solution, as Musa Shangase, commercial director, Corobrik, explains: “Our extensive face brick range ensures costs are kept down because there is no future plastering or painting maintenance needed, but the aesthetics are in no way compromised. It’s important that people feel proud of their homes.”

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Clay Brick

About a third of all the heat lost in an uninsulated home or building escapes through the walls. But this can be countered with the installation of thermally efficient cavity walls that, in addition to temperature regulation, lower sound transmission.

Cavity walls and the thermal benefits

modern cavity wall is a water tight, energyefficient masonr y structure appropriate for external load-bearing walls. It’s also air tight. The cavity prevents dampness from the outer leaf penetrating into the inner leaf. Additionally, if walls are made of a highdensity masonr y material, like clay brick, then cavity walls will also help to keep buildings cooler during the summer and warmer in winter. “Cavity walls were originally introduced in the early 1900s to stop rain seeping through single solid brick walls,” explains Mariana Lamont, executive director, Clay Brick Association. “However, waterproofing aside, no matter how thick the wall or what it is made from, condensation will always be a problem if there is only a single walling layer or leaf.” Any solid, single-leaf wall – even one made from thick concrete – will experience condensation. The same is true for cavity walls. The key difference is that it gathers in the cavity behind the first wall and never reaches the second interior wall. The home or building remains warm and dr y.

The outer leaf provides visual appeal and, here, clay face brick (FBA, FBS and FBX) offers a wide range of aesthetic options. In turn, the inner leaf is usually constructed of NFP or NFX clay plaster bricks. The two singleleaf walls are linked to each other with metal or plastic wall ties that are permanently fixed into the mortar of both brick leaves,

crossing the cavity. These ties strengthen the cavity wall. As with any building system, the benefits can only be achieved if the correct methodologies are applied: even the simplest of details cannot be overlooked. That’s an impor tant consideration for construction and project managers when it comes to final quality control on public

Load-bearing cavity walls must be laid on a level, stable concrete foundation. The foundation trench width and depth need to conform to the requirements of the local authority

IMIESA September 2019

Energy standards revision imminent An important revision to SABS 10400 XA Energy Efficiency in Buildings of the National Building Regulations is expected to be published in 2019. Key changes for external walls include: - An energy zone map will be used to set minimum total R-value requirements for external walls. - Cavity walls will be mandatory for external masonry in most areas of the country (Zones 1, 2, 4, 6 and 7). The minimum R-value requirements for walls with a surface density greater than or equal to 270 kg/m2 will be 0.5. Cities and towns here include Bloemfontein, Cape Town, Johannesburg, Kimberley, Port Elizabeth and Witbank. - T raditional solid double-skin masonry for external walls will only be permitted in Energy Zones 3, 5A and 5B. The minimum R-value requirements here for walls with a surface density greater than or equal to 270 kg/m2 will be 0.35. Cities in these zones include Durban, East London, Margate, Nelspruit and Mahikeng,

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Wall ties should be used every 450 mm (every fifth course of brickwork vertically), with a maximum horizontal spacing of 600 mm (every second brick)

Weep holes must be provided in the external leaf immediately above the damp-proof course at intervals of 100 cm (or about every fourth brick horizontally)

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from the interior wall, across the cavity and through the outer wall. Its purpose is to drain away any water in the cavity towards the weep holes and discharge it outside.

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“The standard gap between the two masonr y leaves makes provision for a 50 mm cavity,” Lamont explains. “This gap should be consistent from the bottom to the top of the wall. Another important consideration is that the cavity must be kept free of mortar. Other wise, this could block water from draining away, leading to damp and mould.” For optimum results, the wall cavity needs to extend to 150 mm below the damp-proof course (DPC) level. Then beneath this, the cavity must be filled with fine concrete. For additional thermal per formance, the cavity can be partially filled with insulation attached to the inner leaf. The DPC level usually comprises a PVC sheet extending with a downward cur ve

IMIESA September 2019

Bonding patterns “Although there are several bonding patterns in modern construction, the stretcher bond is recommended to simplify the construction of a cavity wall,” says Lamont. With the stretcher bond design, each vertical joint is located in the centre of the bricks above and below it. This ensures a strong and stable wall that is able to withstand both ver tical and horizontal loading. The mortar sand used should be free of clay and comply with SANS 1090. “Overall, achieving the right mortar mix is essential. Mortar may account for as little as 7% of the volume of the wall, but it has a significant effect on the final strength,” Lamont concludes.

Transport, Logstics, Vehicles & Equipment

Tough and connected

oosan’s latest-generation DX300LCA hydraulic excavators come to market equipped with the OEM’s e-EPOS system. This is connected to the engine electronic control via a data transfer link to synchronise the operation of the engine and hydraulics. The end result is improved productivity, higher operating capacity and lower fuel consumption. These machines also feature Doosan’s advanced telematics and tracking technology – DoosanConnect – designed to maximise equipment utilisation, machine health and life-cycle costs. “The proactive service of this system encompasses automatic gauge monitoring, alerts in the event of an antenna disconnection, alarms for equipment malfunction symptoms, as well as geo/time fence alerts,” explains says Darrel Holton, managing director, DISA Equipment T/A Doosan. A telematics terminal, which is simply connected to the machine, is enhanced by a dual-mode cellular or satellite communication system and the DoosanConnect web service, which allows users to monitor the machine’s status. According to Doosan customers, these machines have exceeded performance expectations in tough environments. Operational highlights include a bucket digging force of 18 t and notable gains provided by an improved drawbar pull of 25.2 t.

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Transport, Logstics, Vehicles & Equipment

Hand-held tools perfected Atlas Copco’s extensive por tfolio of hand-held pneumatic, hydraulic and petrol-driven products is purpose-designed for extended per formance and durability.

he HAPS™ (Hand and Arm Protection Systems) innovation on the pneumatic and petrol-driven tool range minimises vibration impacts. “This innovation can extend daily working hours by as much as six times, giving an unmatched boost to productivity,” notes David Stanford, business line manager: Portable Products, Atlas Copco Power Technique. The trademarked two-step, soft-start trigger on the Atlas Copco pneumatic breaker range gives the operator full control when starting a cut, even under difficult conditions. Thanks to the solid body design, the single-cast one-piece pneumatic breakers and rock drill series contain fewer parts, for increased reliability and a

low centre of gravity for good balance. Moreover, the pneumatic range’s highly efficient silencer reduces noise levels by 75% while the air-cushioned piston lowers vibration and wear. Stanford also points out that several pneumatic tools can be powered by a single compressor, delivering the benefit of lowest total cost of ownership to customers. The pneumatic tools range is supported by a professional service portfolio that includes highquality air-line accessories, such as air hoses and hose nipples. The offering also extends to couplings, water separators and oil-air lubricants for drills and breakers. Atlas Copco’s completely autonomous, easyto-service Cobra petrol drills and breakers are easy to transport and provide rapid set-up times.

Atlas Copco fields an extensive portfolio of handheld pneumatic, hydraulic and petrol-driven products

Applications are diverse and include concrete breaking, asphalt cutting, tamping, compacting, driving (spikes, tubes, poles, ground rods and probes), as well as digging (ditches and holes) in remote locations and hard-to-reach areas. Turning to Atlas Copco’s hydraulic tool range, Stanford says, “We’ve packed a lot of power into these small machines.” Their smart design extends service life through a closed-loop system that prevents dirt and moisture ingress, and includes fewer moving parts that reduce wear and maintenance. These compact multifunctional hydraulic breakers, core drills and cut-off saws are ideal for operation in applications where space is limited, such as indoors and even underwater areas.

INDEX TO ADVERTISERS

agru Kunststofftechnik

Old Mutual

APE Pumps

Rocla 43

Aspasa 45 Dynapac 14 ELB Equipment

Shisalanga Construction

OFC

Sizabantu Piping Systems

IBC

Southern Pipeline Contractors

2, 35, 48

GeoGroup 21 Grundfos IFC IMESA 40, 44, 52

Technicrete 46 Trenchless Technologies

Macsteel Fluid Control

OBC

Victaulic 24

Model Maker Systems

Wirtgen 49

IMIESA September 2019

I M E S A A F F I L I AT E M E M B E R S

IMESA

PROFESSIONAL AFFILIATES AECOM siphokuhle.dlamini@aecom.com Afri-Infra Group (Pty) Ltd banie@afri-infra.com ALULA (Pty) Ltd info@alulawater.co.za AQUADAM (Pty) Ltd sales@aquadam.co.za Aurecon Fani.Xaba@aurecongroup.com Aveng Manufacturing Infraset werner.booyens@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 Farhana@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering Leonardus.Basson@honeywell.com ERWAT mail@erwat.co.za GIBB marketing@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 Herrenknecht schiewe.helene@herrenknecht.de Huber Technology cs@hubersa.com Hydro-comp Enterprises info@edams.co.za I@Consulting info@iaconsulting.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 ccherry@ctokamteys.co.za Kitso Botlhale Consulting Engineers info@kitsobce.co.za Lektratek Water general@lwt.co.za Lithon Project Consultants (Pty) Ltd info@lithon.com Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za 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 Mariswe (Pty) Ltd neshniec@mariswe.com Martin & East gbyron@martin-east.co.za Mhiduve adminpotch@mhiduve.co.za Mogoba Maphuthi & Associates (Pty) Ltd admin@mmaholdings.co.za

Moedi Wa Batho Consulting Engineers (Pty) Ltd info@wabatho.co.za Much Asphalt bennie.greyling@muchasphalt.com NAKO ILISO lyn.adams@nakogroup.com Nyeleti Consulting merasmus@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za Pumptron randall@gormanrupp.co.za Ribicon Consulting Group (Pty) Ltd info@ribicon.co.za Royal HaskoningDHV francisg@rhdv.com SABITA info@sabita.co.za SAFRIPOL mberry@safripol.com SALGA info@salga.org.za SAPPMA admin@sappma.co.za / willem@sappma.co.za SARF administrator@sarf.org.za.co.za SBS Water Systems mava@sbstanks.co.za Sembcorp Siza Water info-sizawater@sembcorp.com Sigodi Marah Martin Management Support lansanam@sigodimarah.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 Southern Pipeline Contractors (Pty) Ltd spc@vinci-construction.com SRK Consulting jomar@srk.co.za Star Of Life Emergency Trading CC admin@staroflife.co.za Syntell julia@syntell.co.za TECROVEER (Pty) Ltd info@tecroveer.co.za TPA Consulting roger@tpa.co.za Ulozolo Engineers CC admin@ulozolo.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 Wam Technology CC support@wamsys.co.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 WSP Group Africa ansia.meyer@wsp.com

Treat your water-energy like gold Unmet efficiency with up to 10%-20% energy cost reduction Super high flow rate Designed for superior cavitation resistance High regulation capabilities

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