IMIESA September 2020 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 • R O A D S • B U I L D I N G • M A I N T E N A N C E • S E R V I C E D E L I V E R Y

PEXMART Leaders in the manufacture, supply and installation of HDPE pipes and fittings

Alternative Building Systems

Light, strong and sustainable in steel

Drone Surveys

New geospatial possibilities explored

Roads & Bridges

A road investment prioritisation model for SA

IN THE HOT SEAT Our decision-making authority is strongly decentralised, enabling managers to make operational decisions and execute projects without red tape. We believe this structure is the key to our success and differentiates us from other larger engineering firms.” David Leukes Managing Director, BVi Consulting Engineers ISSN 0257 1978

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INSIDE

VOLUME 45 NO. 09 SEPTEMBER 2020

www.infrastructurenews.co.za

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 • R O A D S • B U I L D I N G • M A I N T E N A N C E • S E R V I C E D E L I V E R Y

PEXMART Leaders in the manufacture, supply and installation of HDPE pipes and fittings

Alternative Building Systems

Light, strong and sustainable in steel

SASTT Trenchless Technology

Regulars Editor’s comment

A look inside your pipes

President’s comment

Index to advertisers

Trenchless equipment demand keeps growing

Facilities Management

Cover Story The plastic pipe innovators

Drone Surveys

New geospatial possibilities explored

Roads & Bridges

A road investment prioritisation model for SA

Our decision-making authority is strongly decentralised, enabling managers to make operational decisions and execute projects without red tape. We believe this structure is the key to our success and differentiates us from other larger engineering firms.” David Leukes, Managing Director, BVi Consulting Engineers ISSN 0257 1978

For over three decades, Pexmart has led the way as a manufacturer, OEM supplier and turnkey installer of HDPE, LDPE and PVC plastic pipe systems in South Africa, and across Africa. P6

IN THE HOT SEAT Investing in infrastructure presents exciting new possibilities. David Leukes, managing director, BVi Consulting Engineers, talks about what it takes to spearhead change within South Africa’s current and future built environment. P10

A better world with BVi

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ON THE COVER

ROADS & BRIDGES Pampoennek route open for business

Geosynthetics

Hot Seat

IN THE HOT SEAT

State hospitals benefit from FM

Roads & Bridges A road investment prioritisation model for South Africa

Pampoennek route open for business

Plastic Pipes A legacy of quality and trust

Pushing the limits

Extrusion line investment adds value

Mighty oaks from little acorns grow

HDPE through the decades

Combating ground contamination with 4IR

Drone aerial mapping presents new geospatial possibilities

Social & Affordable Housing A new addition to Joburg’s inner city 42 Kigali’s city vision unfolds

Banking on housing

New housing opportunities for Bellville

Building Systems Light, strong and sustainable in steel

Cement & Concrete M2 restoration

Water & Wastewater

Fibres in the mix

Performance-based contracts: An important part of a utility’s toolkit 26

Pavers take the traffic load

Forming slabs without steel reinforcement

Non-revenue water: Its impact and how to manage it

Pressure management basics

Water restrictions loom for Gauteng 32 Certified water meters provide higher levels of trust

PLASTIC PIPES Pushing the limits

Vehicles & Equipment Mobile asphalt quality and automation

Intelligent excavation

BUILDING SYSTEMS Light, strong and sustainable in steel

IMIESA September 2020

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EDITOR’S COMMENT MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson HEAD OF DESIGN Beren Bauermeister CHIEF SUB-EDITOR Tristan Snijders CONTRIBUTORS Randeer Kasserchun, Chris Kirchhoff, Ntuthuko Ngcamu, Don Ross, Mike Smart, Bryan Perrie, Matthew Townshend PRODUCTION & CLIENT LIAISON MANAGER Antois-Leigh Nepgen PRODUCTION COORDINATOR Jacqueline Modise GROUP SALES MANAGER Chilomia Van Wijk FINANCIAL MANAGER Andrew Lobban BOOKKEEPER Tonya Hebenton DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za PRINTERS Novus Print Montague Gardens ___________________________________________________

Nothing works in isolation

s we enter Q3 2020, it’s clear that public and private sector stakeholders need to agree on a workable strategy for Q1 2021. This especially applies to construction, which continues to contract and was the worst performing sector for Q2 2020, according to Statistics South Africa. Even factoring in the lockdown, construction experienced its eighth consecutive quarter-onquarter decline, indicating a lack of adequate investment by public entities. Within the infrastructure space, municipalities remain the key interface with the construction industry and getting their houses in order is vital. Essentially, it comes down to how the available funds are managed and executed, especially as government’s stimulus packages kick in. To eradicate fruitless and wasteful expenditure requires central and real-time oversight of municipal performance, as well as structural reforms that enable rather than debilitate.

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 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 2020. 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

Local Government Week These topics formed part of the discussions at the National Council of Provinces’ Local Government Week in September 2020. The theme was ‘Ensuring capable and financially sound municipalities’. As in all parts of the world, Covid-19 has placed unprecedented pressure on government and industry. In South Africa’s case, the outcomes have been particularly severe. In the case of our municipalities, some R127.7 billion was owed by householders when the past financial year closed in June 2020. A further R28.9 billion was owed by businesses and R18.1 billion by government. In turn, municipalities owed more than R53 billion to various creditors – two of the largest being Eskom (approximately R11.3 billion) and water boards (some R6.24 billion). To revitalise municipalities, the District Development Model (DDM) steered by the

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. _____________________________________________

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Best practice solutions In the end, the best solutions are hybrid ones that incorporate public and private sector expertise. A case in point is the 2019 South Africa Investment Conference, where leading companies and countries wholehear tedly demonstrated their support, pledging around R363 billion across key industry sectors. The market is willing and quick to respond: the pandemic-inspired Solidarity Fund formed in March 2020 being another great example. Demonstrating how ‘Unity in Action’ works in practice, the fund has since approved around R2 448 billion to be spent on inventions and projects in the fields of health, humanitarian relief and behavioural change. The fact that the Solidarity Fund is an independent entity is significant. Contributions received from private and public donors are strictly audited and allocated in a transparent manner. Rather than getting bogged down by master plans and rhetoric, those quick wins are exactly what our economy needs right now. Hopefully the Infrastructure Fund is among them.

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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Depar tment of Cooperative Governance and Traditional Affairs (Cogta) is a practical response – a shift away from “silo planning, budgeting and implementation” across the three spheres of government. Cogta’s strategy includes the formation of district hubs, incorporating scarce skills, such as engineers, ICT specialists, planners and administrators that will help facilitate intergovernmental planning and project deliver y. A recent example is Waterberg District Municipality in Limpopo, one of three DDM pilot projects – the other two being OR Tambo and eThekwini.

ENT R E D E V E LO P M

TENANCE LDING • MAIN • ROADS • BUI

PEXMART

manufacture, Leaders in the lation of supply and instal fittings HDPE pipes and

Cover opportunity

IVERY • SERVICE DEL

Alternative Building Systems

Light, strong and sustaina ble in steel

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.

Drone Surveys

New geospatia l possibilit ies explored

Roads & Bridges

A road investme nt for SA prioritisa tion model

IMIESA September 2020

managers IN THE HOT SEATing authority is strongly decentralised, enabling red tape. We

projects without Our decision-mak us from other decisions and execute success and differentiates Engineers to make operational is the key to our BVi Consulting believe this structure Managing Director, firms.” David Leukes, 5.00 larger engineering er 2020 • R5 09 • Septemb 8 ISSN 0257 197

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Tracking water consumption is made easy by Water Wise

The Department of Water and Sanitation (DWS) aims to reduce water demand and increase supply to our growing population and economy to ensure water security by 2030. Currently, our waterstressed country faces economic water scarcity due to issues with the country’s water infrastructure, an ever-increasing demand on a limited supply and other environmental factors.

leaks, which can be easily detected if households monitor their water use by taking regular water meter readings. To assist people with this, Rand Water’s environmental brand, Water Wise, has developed a Water Wise calculator, which serves as a simple tool to estimate household water use and assist people in detecting high water-use activities and even leaks. The calculator, through a question–answer system, generates a water usage chart and an estimated cost (R) of the household’s water bill in a month. This estimated value should not be used to dispute municipal bills, however, as the value generated is based on general South African water use statistics. This calculator aims to assist the end-users to be responsible in ensuring optimal use of the water they receive.

Keeping track of water usage through the Water Footprint Assessment, founded by Arjen Hoekstra, is a step in the right direction that shines light on water use patterns in different aspects of society. With a deeper understanding of water consumption patterns and water balance, water utilities and municipalities can work towards improving their existing water-supply models, as well as addressing Achieving this will contribute to the bigger picture water wastage such as non-revenue water, and excessive use and leakages, in order to reduce of reduced water demand, ensuring a sustainable supply water losses in large distribution networks. of water for South Africa. End-users such as homeowners also encounter

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PRESIDENT’S COMMENT

IMESA

investments made to date on the latest generation plants like Kusile and Medupi.

IPPs

It’s been a very challenging year so far, but there are positive signs that we’re winning the war against Covid-19. However, while that threat starts to diminish, the single biggest risk remains the impact of manmade climate change.

The shift to low carbon infrastructure

he world continues to get warmer and extreme weather events more frequent. Examples include more prolonged droughts, the steady increase and severity of forest fires, and the progressive melting of the polar ice caps, contributing to rising sea levels, major storm events and floods. The period between 2016 and 2020 is believed to be the warmest on record, according to the United in Science 2020 report, a multi-agency study coordinated by the World Meteorological Organization. It states unequivocally that unless we accelerate the transition to a greener society, the fight against rising CO2 emissions could be lost, and some climate change trends irreversible. As can be expected, emissions levels did drop during the hard lockdowns imposed globally, but only marginally. By early June 2020, CO2 levels had already started returning to 2019 levels, according to the report. Speaking recently, UN Secretary General António Guterres said, “Never before has it been so clear that we need long-term, inclusive, clean transitions to tackle the climate crisis and achieve sustainable development. We

must turn the recovery from the pandemic into a real opportunity to build a better future.”

Energy as a change agent One of the key challenges is the world’s rapidly growing population and the pressure it brings to bear on natural resources, especially water. It also inevitably increases the demand for energy, the most attractive being renewable power from wind and solar. As new storage technology is developed, renewable energy will become the dominant power source, and its implementation needs to happen far more rapidly. The big question for many countries is what to do with their existing coal-fired power plants. Now there could be a solution, thanks to the pioneering work of Australian company MGA Thermal and the invention of a miscibility gap alloy (MGA) that stores energy in the form of heat for extended periods. This stored energy is provided by allied solar or wind plants. Coal-fired power plants could be converted to run purely on MGA or similar technologies, with some of the heat being used to generate the steam needed to run existing turbines. That would be good news for South Africa, and Eskom’s future, given the substantial

South Africa’s Independent Power Producer (IPP) Programme holds huge potential. It is also an essential infrastructure intervention to counter our constant outages. The immediate public sector opportunities are presented by the Department of Mineral Resources and Energy’s Risk Mitigation IPP Procurement Programme. This sets out to purchase an additional 2 000 MW from the open market to meet short-term distribution gaps. The plan is for approved projects to connect to the grid by 2022.

Transportation and e-bikes Extending storage windows is the key to unlocking the full potential of renewable energy. In this respect, it will be exciting to see how battery technology evolves in all areas – transportation being a prime example. Electric-powered vehicles are the future, but at this stage too expensive for mainstream consumers. However, that’s certainly not the case for electric bicycles (e-bikes), which have become far more affordable. Today’s e-bikes can comfortably cover in excess of 150 km on a single charge, depending on factors like a mix of assisted (e-power) and unassisted normal pedalling, rider weight and hills. But the potential is massive; if mobilised and funded on a national scale, this would significantly improve mobility for millions of people across South Africa. Renewable and clean power resources provide us with immediate opportunities to combat climate change. As engineers, it also presents exciting opportunities to reimagine our current and future infrastructure landscape.

Randeer Kasserchun, president, IMESA

IMIESA September 2020

COVER STORY

The plastic pipe innovators For over three decades, Pexmart has led the way as a manufacturer, OEM supplier and turnkey installer of HDPE, LDPE and PVC plastic pipe systems in South Africa, and across Africa. Expertise in detailing, costing, construction and project management, delivery and installation meet the exacting specifications of the agricultural, building, commercial, industrial, mining and municipal sectors.

eading through technology and a winning team approach, Pexmart continues to build on its reputation as a multifaceted specialist providing tailored solutions for the local and international markets. Irrespective of the project scale, the focus is on efficient and cost-effective execution in the fields of manufacturing, installation and maintenance. Growth is being sustained by a dual-pronged focus on public and private sector clients. Forming part of its expansion strategy, Pexmart concluded the acquisition of Spiral HDPE Pipe’s operations in 2018. This was followed in 2019 by the acquisition of Marley Pipe Systems’ HDPE and FLEX plant in Rosslyn, Gauteng. A member of the Southern African Plastic Pipe Manufacturers Association (SAPPMA), Pexmart adheres to and fully supports SABS and SAPPMA’s Quality Assurance Programme. Products are manufactured to meet highand low-pressure ratings. Alongside pipe systems, these include the PEX-FLEX range of

IMIESA September 2020

flexible hoses specially developed for a wide range of applications, including domestic, firefighting, irrigation, industrial and mining. “HDPE solid wall pipe has been used in potable water, sewer and mining for many decades and is rapidly growing as the preferred material for pipe lining and relining, slurry applications and for use in dolomitic areas,” explains Andre Janse van Rensburg, CEO, Pexmart. “HDPE is also increasingly the preferred choice for municipal water and wastewater projects.” We can manufacture pipe sizes ranging from 16 mm to 1 000 mm (HDPE) and 300 mm to 3 500 mm for spiral structured wall pipe that can be welded.

Spiral HDPE pipe The key advantage of the spiral range is that the corrugated design provides superior ring stiffness and rigidity while using less material in the manufacturing process compared to sold wall pipes. Providing a more cost-effective solution, they are well

suited to applications like culvert stormwater management and gravity trunk sewer mains. Other custom fabricated spiral HDPE products include manifolds, manholes, tees and reducing fittings.

Mining and municipal The ability to fabricate to demanding production timelines and specifications is underscored by the fact that Pexmart has ongoing supply and installation contracts in place within the mining sector. These include a five-year contract with Debswana Diamond Company, plus contracts with Royal Bafokeng Resources, and Anglo American Platinum.

SPIRAL WOUND STRUCTURED WALL PIPE Key benefits - Resistance to chemical attack, abrasion, scale, sediment build-up and UV degradation - No electrolytic or galvanic corrosion - Lightweight - Long lengths - High impact strength - Superior flow characteristics - Flexibility - Variety of jointing methods - Comprehensive range of fittings - Cost savings in transportation, handling and installation

COVER STORY Project: Fraser Alexander/Royal Bafokeng – Rasimone Platinum Mine. Pexmart manufactured the 750 NB pipe closures and fittings for 6 mm carbon steel pipe sections. This included an internal and external epoxy coating

“Our lined pipe systems have successfully passed all ASTM F1545 requirements,” says Marina van der Walt, sales and marketing manager, Pexmart, adding that, prior to installation, HDPE lined fittings are pressure tested at 1.5 times more than the client’s service pressure threshold, to ensure exacting compliance. “In addition to reducing friction, our liners lower operating pressures, provide a substantial cost saving on flanges and energy bills, in addition to extending the longerterm replacement of carbon steel pipeline systems,” she continues. “Our liner systems also reduce risks associated with leaks and environmental impacts.” Liners are custom extruded to the exact internal diameter of the steel pipe. After the liner is installed, HDPE sealing stubs are welded to the ends of the liner and then covered with blowing flanges. On-site pipeline lengths ranging from 100 m to 1 000 m can also be lined in situ by Pexmart’s installation team, depending on the pipeline route and terrain contours.

HDPE continuous butt-welding Project: Majuba Power Station. Here, Pexmart manufactured and supplied 355 mm x 18 m PN 12.5 PE 100 HDPE pipe

Within the municipal market, Pexmart has provided specific solutions for various municipalities and metros over the years, an example being the City of Tshwane’s Water & Sanitation Department, plus various rural development initiatives. Other key public sector clients include Eskom and Gautrain. “What sets Pexmart apart is our commitment to our staff. We strive to attract and retain experienced personnel to facilitate balanced growth and promote a culture of continuous improvement. As a result, we have a strong core team of loyal, highly skilled employees who have a ‘can do’ attitude and are focused on achieving successful outcomes for our customers,” says Janse van Rensburg.

Lined pipe systems Alongside its solid wall offerings, Pexmart develops custom HDPE lining systems for the carbon steel pipe sector. It’s a proven fact that HDPE liners provide new or older steel pipes with greater strength and protection from erosion and corrosion in more aggressive environments – a key consideration in extending asset life. The interior walls of the HDPE liner are also very smooth, resulting in superior fluid flow due to a reduction in resistance and friction. Applications include the fluid transfer of acid water, crude oil, slurry, wet gas, raffinate and effluent.

PEX-FLEX flexible hoses are specially developed for a wide range of applications, including mining, irrigation, industrial and domestic

The most important event during the continuous lining process is the thermal buttfusion method employed. Thermal butt-fusion provides an economical and fast method of delivering a complete, long continuous length of HDPE pipe. The fused joints are as strong as the pipe itself, providing a continuous leakproof system. Pexmart’s expert technicians use high-tech welding machines for enhanced efficiency, productivity and safety. Their general mantra

Successful pipeline projects have one thing in common – successful pipeline people.”

COVER STORY

INSTALLATION SERVICES - Materials management and procurement - Civils - Steel pipeline construction and welding - HDPE continuous butt-welding - Continuous HDPE lining systems - Pipeline pre-commissioning and commissioning

is: “For every metre of steel pipe welded, there’s a metre of HDPE liner butt-welded.” The welding quality and internal seam lineup in pipeline welding are crucial to avoid defects during the HDPE lining process. For this reason, Pexmart ensures that that correct internal line-up pipe clamp is used for welding preparation. This avoids edge misalignment and provides full alignment to the weld seam during the entire welding process.

PLASTIC PIPE & FITTINGS SERVICES Manufacturing • HDPE plastic pipes and fittings • Optic fibre duct • PEX-FLEX: flexible hoses specially developed for a wide range of applications, including domestic, firefighting, irrigation, industrial and mining Specialist suppliers • PVC, HDPE and LDPE pipes and fittings Installation • HDPE, PVC, LDPE plastic pipelines and fittings Welding • Butt-welding, electrofusion, branch, socket and extrusion welding of plastic pipes

Pexmart offers a flame-retardant HDPE piping system (this system is safe for underground mining)

Pipeline pre-commissioning and commissioning “After a pipeline is constructed, and before it is put into service, key activities are required in order to ensure the pipeline meets the requirements of its owner or operators,” says Van der Walt. Pipeline pre-commissioning is used for bolt-up cleaning and commissioning of the pipeline and carrying out inspections using torque converters with the correct torque settings, CCTV camera inspection and pressure testing (hydro or pneumatic).

Optic fibre duct In addition to the fluid transfer market, Pexmart designs and produces corrugated pipe for the electrical and telecommunications sector: 110 mm diameter pipes are manufactured in 6 m and 50 m lengths and supplied with seal and coupler. Additionally, micro ducting options can be produced to meet specific project requirements. Designed for slots and micro-trenches, a key feature of the PEXMICRO duct range is their robust construction, making them highly resistant to crushing. They are also UV resistant.

Pexmart designs and produces corrugated pipe for the electrical and telecommunications sector. Inner ducts/ subducts (with 32 mm and 40 mm outer diameter) provide a means of mechanical protection for fibre-optic cable and are installed in outer ducts or directburial application

IMIESA September 2020

HDPE lined pipe and fittings for a 650 NB carbon steel pipe. Pexmart designs and manufactures a complete HDPE liner system, which includes bends, tees, concentric, eccentric and laterals

Inner ducts/subducts (with 32 mm and 40 mm outer diameter) provide a means of mechanical protection for fibre-optic cable and are installed in outer ducts or directburial application. The fibre-optic ducting series comprises the 8/5, 12/10, 14/10 (with 1-way, 2-way, 4-way, 7-way enclosures). Various colour options are available on request. The standard lengths supplied are 500 m, 1 000 m and 2 000 m.

Turnkey integrity As a recognised leader, Pexmart meets the challenges and demands of the pipeline industry by providing the best products and systems available, as part of their turnkey approach to projects. Company specialists provide advice on regulations and compliance, design and installation, backing this up with input from respected consulting engineering experts in pipeline integrity and management. In this way, Pexmart delivers the right solution. “We maintain our leading-edge approach by continually gaining new insights and knowledge utilising the latest technology available, supported by our ongoing research and development programmes,” Janse van Rensburg concludes.

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HOT SEAT

A better world with BVi Investing in infrastructure presents exciting new possibilities. IMIESA speaks to David Leukes, managing director, BVi Consulting Engineers, about what it takes to spearhead change within South Africa’s current and future built environment. What does transformation mean for BVi? DL At BVi, we believe transformation must be actioned through structured programmes. In this way, it remains dynamic, driven with intent and part of our vision, ensuring that everyone has ownership. Our Level 1 BBBEE status bears witness to this. Transformation is about empowering our staff, especially our young graduates, and our black, woman and young professionals to reach their full potential. As part of our Education and Training Programme, we provide bursary opportunities for aspiring built environment students to achieve their dreams. Through the years, we’ve also noticed that it’s becoming challenging for young graduates to gain access to career opportunities in our industry. This motivated us to establish our BVi Academy for engineering graduates to participate in a structured, well-mentored internship programme. We also established a BBBEE Employee Trust for our young black professionals to enable them to develop into future leaders in our company and industry. As a business, BVi is 54% black owned, David Leukes, managing director, BVi Consulting Engineers

IMIESA September 2020

with more than 50% of its shareholding owned by professional engineers and technologists. All BVi shares are owned by South African citizens. With a minimum of 50% black representation at management level, we are also one of the few larger firms that are black managed. By applying a strict equity policy to recruitment, 70% of all new recruits in the last year were black. In time, this will further improve BVi’s equity ratios to reflect a fair representation on all levels. We also procure from BBBEE companies and have assisted a number of smaller firms to learn the essential skills needed to operate in the consulting engineering environment. Furthermore, every BVi branch is involved in social corporate responsibility projects. In 2017, in celebration of our 50th anniversary, we launched the successful BVi Visionaries project. Seven winners nationally became ‘BVi Visionaries’ – each of them qualifying for a bursary and educational support for the duration of their studies. These visionaries are now in their second year of study. At BVi, we are passionate about education and committed to the growth and personal development of our entire workforce, with 15% of our shareholding sold to the BVi BBBEE Employee Trust. These and other initiatives all ensure that our transformation goals become achievable actions owned by all BVi Group employees. How have traditional consulting services evolved in the past decade?

I’ve been in the consulting engineering industry for the last 26 years. Over time, services have diversified, with many companies becoming multidisciplinary in response to client demand. Innovation and technology have also played a huge role in the way we design and share ideas with clients. I have seen our industry going from producing contour surveys, designs and drawings on draughting tables to developing and implementing computeraided design programs. Clients are now able to view 3D models ahead of construction and visualise the impact it will have. Construction materials and their application have also greatly improved thanks to ongoing research and development initiatives, providing further value for clients. In recent years, our industry has been affected by key factors like economic downgrades, recessions and high interest rates. I’m sure we will face yet more challenges in the future. The upside is that this has motivated us to adapt. At BVi, we’ve learnt to embrace change and focus on providing improved solutions. This has assisted in shaping our industry for the better. What’s different about BVi’s management approach? BVi’s unique structure ensures that senior management members actively participate daily in our projects, which means they are easily accessible to clients, staff and communities. Personal attention on a project level ensures superior quality and service. Furthermore, our decision-making authority is strongly decentralised, enabling managers to make operational decisions and execute projects without red tape. We believe this structure is the key to our success

HOT SEAT and differentiates us from other larger engineering firms. How does your business integrity management system work? As a member of Consulting Engineers South Africa (CESA), BVi embraces CESA’s Business Integrity Management System (BIMS). BIMS defines how we engage with clients and is reinforced by the core values that define our company culture, namely: • value for money • quality • build and maintain trust • innovation • high level of personal attention • sustainable support • health and safety • respect for deadlines • resource-sensitive solutions • employee personal empowerment. Is information and communications technology (ICT) redefining engineering as we know it? ICT is growing at an explosive rate, so businesses must have systems in place that are flexible, adaptable and embrace new or improved technologies. At BVi, we stay current by investing in technology that enables our services to evolve in innovative ways. Face-to-face communication can never be replaced; the value of human interaction cannot be downplayed. ICT has, however, improved efficiencies in the way we communicate remotely. There is a reduction in travel time and the carbon footprint has been reduced. Where do you see the growth post Covid-19? Covid-19 is a tragic event and BVi would like to offer its sincerest condolences to the many in our nation that have experienced the loss of loved ones. We are also well aware of the financial hardship caused by the pandemic. As South Africans, our resilience will indeed be tested in the current disruptive environment. But we have survived worse situations and we will prevail. Economic conditions were already challenging before Covid-19. The pandemic presents new ones, but as management we have chosen to deal with all of them in a positive and productive manner.

I am confident that Team BVi will continue to deliver on our vision of ‘Providing professional services in identifying and implementing engineering projects for medium to large corporations, in South Africa and internationally’.” David Leukes, managing director Based on lessons learnt in previous years, we’d already modernised and right-sized our business prior to the lockdown. We remain confident that continuous improvement in our operational and business systems now positions us well to seize future opportunities. We know that socioeconomic growth will be led by investment in infrastructure, underscored by recent events like government’s Sustainable Infrastructure Development Symposium of South Africa (Sidssa). Are the big roads developments coming back? Over the past few months, clients like Sanral have started to advertise new bids in most parts of our country. The agency also plans to roll out more than 200 additional road infrastructure projects across all nine provinces of South Africa. We remain optimistic that provincial road departments will follow suit. Sidssa also identified key routes for construction and, yes, we believe that these projects will be awarded and implemented soon. How can consulting engineers help to improve municipal delivery? As a multidisciplinary service provider, with years of municipal engineering experience, we can and do add tremendous value and sound advice. Municipalities face many challenges when it comes to service delivery. We

accept that challenge and must continue to present innovative, labour-intensive and cost-effective solutions. We look forward to further engagement with municipalities across South Africa. What is BVi’s outlook for the balance of 2020 and going into 2021? At BVi, we believe that we must and will play a key part in defining not just our own future, but also the future of the built environment. As a business, we will continue to streamline our operations and business model, while building on our established network of strategic relationships with key public and private sector stakeholders. We have a stable order book, which can only improve, and we will redouble our efforts to engineer the best value for our clients, staff, communities and the environment.

Big enough to make a difference, small enough to care www.bvi.co.za

IMIESA September 2020

ROADS & BRIDGES

A road investment prioritisation model for South Africa Faced with pressing financial constraints and fragmented strategies, there is an urgent need for a fresh approach to funding and executing road projects. The following in-depth economic analysis presents the case for a new model that has practical benefits. By Professor Don Ross and Dr Matthew Townshend

ll South African road departments face five core policy challenges: deterioration in road network conditions; shortfalls with respect to their obligations to satisfy citizensâ&#x20AC;&#x2122; constitutional rights of transportation access to basic services; inconsistent prioritisation of roads that best promote the general economy; an excessive rural road network; and application of inefficient road surfaces that do not optimise road maintenance and road-user costs, and fail to take advantage of the low shadow price of unskilled labour. Road departments must respond to these challenges within the context of tight fiscal constraints, considering that the road maintenance backlog has reached an extent where it is now out of the question that it could be eliminated through national transfers and subsidies. To assist road departments in managing these core policy challenges, we have developed a road investment prioritisation model that offers principled advice to optimally allocate

IMIESA September 2020

any given budget in a way that conforms to the roads sector mandate. Given the spotty history of successful implementation of national-scale economic plans in democratic South Africa, the prioritisation method is insensitive to scale above the threshold of local municipalities and can be implemented first by those departments best able to mobilise will and capacity. The prioritisation model was developed to complement the existing road asset management systems and human resource capacities within road departments, which makes it immediately operational at a municipal, provincial or national scale. The normative basis for allocating available resources is the official mandate assigned to the roads sector in the 1996 White Paper on National Transport Policy and reaffirmed in the 2018 Draft Roads Policy for South Africa. This mandate stipulates that the roads sector must: (i) satisfy citizensâ&#x20AC;&#x2122; right of access to constitutionally protected basic services, and (ii) maximally contribute to economic growth. The Bill of Rights establishes the nonnegotiable basic entitlements that the 1996

Dr Matthew Townshend

Professor Don Ross

White Paper on National Transport Policy mandates the road network to support. In particular, citizens have the right to have efficient and effective access to healthcare services and basic education. All official macroeconomic and industrial policies adopted by the government since 1994 and in current policy frameworks, such as the National Development Plan, specify mandate element (ii) more precisely as the promotion of export-led growth. The urgent need to develop a South Africaspecific road investment prioritisation model stems from the fact that none of the alternative international and local road investment prioritisation models respect basic access provision as an obligation, nor privilege an export-led growth strategy. This criticism extends to common cost-benefit-analysis-based prioritisation models, such as the Highway Development and Management (HDM) Tool and the Deighton Total Infrastructure Management System (dTIMS).

CEA-based classification system The first stage in the development of the road

ROADS & BRIDGES

investment prioritisation model was to ensure that roads are classified according to whether their value lies in their service to provision of basic access, or their potential to promote economic growth, or both. To achieve this, we developed a costeffectiveness analysis-based (CEA-based) road classification system that accounts for the type and relative value of the economic service provided by a road. This system includes five road classes: Basic Access Roads, Strategic Roads, Tactical Roads, Multi-functional Roads, and Surplus Roads. Basic Access Roads provide the only viable means for communities to access basic service centres and in their absence, citizens fall outside the prescribed norms and standards for access to primary and secondary schools and/or healthcare facilities. Strategic Roads support high volumes of growth-promoting economic activity that persists through all stages of business cycles. Tactical Roads support economic activity that promotes growth only near the top of South Africaâ&#x20AC;&#x2122;s productivity frontier. Multi-functional Roads are classified as roads essential for basic access that also consistently contribute to economic growth. Surplus Roads fulfil no basic access function and make a negative economic contribution, as the cost to maintain these roads exceeds the value of the economic activity they facilitate. Road departments are advised to unproclaim Surplus Roads to protect against the misdirection of scarce resources and deadweight losses that can result from other public departments, which operate in isolation of road departments, locating service centres along these roads. The remaining road classes are prioritised according to a normative framework that puts basic access as the first lexical priority. This approach conforms with the institutional constraint on road planners to treat basic access as a protected universal right.

Key findings Fortunately, our analysis shows that potential Basic Access Roads account for approximately 8.2% of the total road network maintenance cost. Moreover, potential Basic Access Roads in regions in the lowest gross value added

quintile account for less than 5.0% of the total road network, which suggests that most of the demand for access to basic services can be satisfied by Multi-functional Roads. Thus, departments can maintain Basic Access Roads within current budget parameters with significant budget still available to maintain and upgrade many Strategic and Tactical Roads. Conversely, were departments to adopt the opposite approach to that set for the CEA-based road classification system and prioritise Strategic Roads and Tactical Roads before Basic Access Roads, it is unlikely that sufficient budget would remain to maintain the Basic Access Roads on which the poorest citizens rely to access constitutionally protected basic services. Given the severe fiscal constraints, it is essential that road departments minimise the cost of fully guaranteeing basic access in order to maximise the budget available for the maintenance of growth-promoting roads. The first mechanism we explored in this regard is the optimal configuration of roads, schools and clinics to ensure the highest feasible degree of access is provided by Multi-functional Roads, allowing for the conversion of some Basic Access Roads to Surplus status by rendering their basic access function redundant. To rationalise the Basic Access Road Network, we applied a two-step floating catchment area method to measure spatial accessibility to primary and secondary schools, healthcare facilities and jobs. This information was combined into a 16-level Multivariate Road Index, with the lowest weighting assigned to roads in the furthest feeder zones and with the highest levels of unemployment. We identified 45 757 km of roads in the lowest priority class. We then compared the life-cycle cost of these low-priority roads with the alternative cost of relocating or constructing new schools and healthcare facilities closer to isolated communities. Bearing in mind the road lengths at which life-cycle road maintenance costs break even with the respective costs to establish or relocate the different school and clinic types, every 1.0% reduction in this 45 757 km road network could release between R1.5 billion and R2.0 billion for the maintenance of growthpromoting roads.

Optimal road surface portfolio The second mechanism we explored to minimise the cost of fully guaranteeing basic access was an optimal road surface portfolio. A total of 73.6% of the road network was unsealed in 2017, with the majority carrying fewer than 100 vehicles per day and classified as Basic Access or Multi-functional Roads. In the absence of a national road surfacing policy, departments have based their strategy on the HDM-4 derived guideline that annual average daily traffic must exceed 200 vehicles to justify upgrading an unsealed road to a surfaced standard. This threshold is economically arbitrary. We therefore developed a more principled alternative using life-cycle cost analysis to compare 11 road surfaces. The analysis accounts for the relative labour versus capital intensity involved in providing and maintaining each road surface, which is critical given the abundance of underemployed, unskilled labour across the country and the relative expense of imported capital equipment. Our results support a policy to seal all lowvolume roads worth maintaining at all, at a rate possible within the exogenous fiscal constraints. In addition to freeing up resources over the long term for the maintenance of roads that promote economic growth, the proposed surfacing policy would mobilise a significant proportion of currently wasted unskilled labour assets in areas with the highest unemployment rates, and would generate an economically meaningful reduction in the current fiscal burden of social transfers in the seven poorer provinces. Having specified the policy that minimises the cost to fully guarantee basic access, we continued the application of CEA to develop and test a model of road maintenance prioritisation that exploits the remaining given roads budget allocation to optimise the sectorâ&#x20AC;&#x2122;s contribution to national economic growth through export promotion. Given this prioritisation objective, we specified export-related heavy vehicle kilometres as an effectiveness proxy and applied a standard gravity model to estimate and rank the relative contribution of road maintenance projects to potential export growth. To demonstrate the potential benefits of the road maintenance prioritisation model, we applied it to the Mpumalanga provincial

IMIESA September 2020

ROADS & BRIDGES

road network as a pilot exercise. The costeffectiveness approach, which supports preventative maintenance, generated an efficiency gain relative to the current method, with substantially more roads and, importantly, roads that support export transportation maintained from the same available budget.

CEA versus CBA In contrast to the pavement engineering models that use cost-benefit analysis (CBA) for project evaluation, we promote CEA as the second best alternative, given that full CBA is precluded until key data limitations are resolved, which are at best medium- to long-

term prospects. We also argue that CEA is the first best project evaluation alternative as and when reformed political and institutional constraints on road planners shift their focus from maximising the net present value of road projects, for which CBA is best suited, to efficiently allocating the fixed budget among alternative road projects based on the investment priorities. The South African Office of the Presidency has identified expanded investment in road networks as a core component of a new fiscal stimulus programme intended to address the country’s extreme failure to engage its relatively low-skilled labour pool, to increase

the growth rate of GDP, to promote new selfsustaining productive activity, and to mitigate the recessionary effects of the recent international downgrading of South Africa’s sovereign debt quality. To this list of policy targets for fiscal stimulus has now been added cushioning the reduction in economic activity caused by the Covid-19 pandemic and the demand shock generated by temporary suppression of the retail, services and tourism sectors to flatten the transmission curve of the virus. Road departments are therefore advised to apply the road investment prioritisation model to ensure that the available budgets are targeted at the highest-priority road projects, and that they realise their full potential contribution to national economic recovery and renewal. *Professor Don Ross lectures at the School of Economics, University of Cape Town, and Dr Matthew Townshend is an economics consultant at Cornerstone Economic Research.

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ROADS & BRIDGES

Pampoennek route open for business

uilt at a cost of around R377 million, the R512-PWV3 Pampoennek Road in Brits, North West, forms part of Sanral’s Horizon 2030 initiative. The new road stretches from the R512 to the west of Hartbeespoort Dam and connects directly to the N4 to Rustenburg through Pampoennek, greatly improving transport flows in the region. Consulting engineering firm Zutari was responsible for the design and construction supervision (project management and quality control) during this 30-month project, with the works led by main contractor Grinaker-LTA. The project brief was the construction of National Route 4 Section 12 (PWV3) from km 69.985 at the interchange with Road 980 to the interchange between the project road and Road P123-1 and to km 76.170.

ABOVE The road stretches from the R512 to the west of Hartbeespoort Dam and connects directly to the N4 to Rustenburg RIGHT Traversing through the cutting

Passing through mountainous terrain, the route follows a north-westerly to southeasterly direction. This resulted in a vertical alignment with a subsection in deep cut and other sub-sections on high fills. The cut had a maximum depth of about 19 m, while the fill reached a maximum height of 18 m. Included within the construction mix is 6 km of undivided dual carriageway, with interchanges at P123-1 and 980, a 75.8 m long bridge structure at the interchange with Road P123-1, plus a game underpass south of the cutting.

The project was officially opened by Minister of Transport Fikile Mbalula (third from left), in partnership with Sanral and Madibeng Local Municipality, on 3 September 2020. Zutari, responsible for the design and construction supervision, was represented at the official opening by Hendrik Louw (left), engineer’s representative; Phil Hendrik (holding the commemorative plaque), client director: Transport; and Joe Ndala (second from left), CFO

Perfecting the alignment The mountainous terrain and the limited width in the cutting through Pampoennek made the optimal vertical alignment quite a challenge, notes engineer’s representative Hendrik Louw. The consulting team and contractor carried out investigations in the cutting in a grid pattern (just over 60 blocks in total per horizon) in 3 m deep horizons to ensure optimal utilisation of the on-site materials. To cater for the dual carriageway, the cutting has a total roadway width of 41 m. Various designs were considered, with the final choice being vertical retaining walls on the left-hand side of the cutting and a contiguous piled wall on the right-hand side. Local labour and subcontractors received both on-site and accredited training. The training provided was for NQF levels 3 and 4. Additional contractor development training was also provided to 15 identified local SMME contractors. A total of 209 full-time local labourers were employed on-site. A certain percentage of the expenditure for local SMME contractors was allocated to womanowned enterprises.

IMIESA September 2020

PLASTIC PIPES

A legacy of quality and trust

IMIESA September 2020

Formed in 2004, the Southern African Plastic Pipe Manufacturers Association (SAPPMA) is committed to advancing the benefits of high-quality plastic pipe systems. IMIESA talks to CEO Jan Venter about key trends since the first products started to become available in the 1960s.

PLASTIC PIPES

What are some of the major R&D milestones? JV There are many, of which the following are of great significance: − The quality of polymers has increased greatly. In HDPE, the popular pipe grade has gone from PE 50 to PE 100. This has resulted in an increase in design stress and a consequent reduction in design wall thickness, which in turn has meant a reduction in cost. Furthermore, it enabled the extrusion of much larger diameters than before. More recently, solid-wall HDPE of 3 500 mm in diameter has been achieved. − In the PVC arena, the development of OPVC is of great significance, enabling higher pressure capability in large diameters. − Similar improvements have been made in equipment. The output of extruders has greatly improved, with better-designed screws and extrusion heads, and electronic control systems. An output of 2 000 kg per hour is not unusual anymore, which creates quite a logistical challenge! How has SAPPMA helped to change perceptions about plastic pipe? For the past 16 years, SAPPMA has been promoting the benefits and use of plastic pipe. This has been done through personal contact with design engineers and contractors, as well as making available useful and objective design information. We’ve been constantly familiarising the market with these materials. How does South Africa compare with the world in terms of plastic pipe specifications? Pipe specifications in South Africa are based on ISO standards and hence on par with most developed countries. Theoretically, the quality of a specific pipe in South Africa should be equivalent to one made in Europe. Where we fall short is in terms of production volumes and hence profitability. In turn, this has a negative effect on capital expenditure.

Do engineers understand the benefits of plastic pipe? Generally, yes; however, there remains a gap in the curricula of engineering students in terms of plastic pipe materials. We have recently engaged with the Department of Civil Engineering at the University of Pretoria by providing some basic technical info, to be presented to third-year students. Can plastic pipes be recycled and reused? Indeed yes, and it is done to a great extent, given the high price of polymers.

information, marketing and training. We will continue to interact with all role players in this crucial industry and fulfil a much-needed role of watchdog and coordinator.

Are some plastics superior to others? Horses for courses: the two most popular materials in South Africa are HDPE and PVC, each of which fulfils very specific needs. What assurances do specifiers have? If the design of the pipeline is correct, and if the specifiers ensure their tender documents cover the required product standards, the certification of the manufacturer and an acceptable quality assurance plan, they can rest assured the product will meet the design life, which can easily exceed 50 years.

Jan Venter, CEO, SAPPMA

What are SAPPMA’s plans for 2021? Much of the same – with a focus on product standards, quality, technical

Are there any limitations when it comes to infrastructure services? I’m not aware of any limitation in terms of product range. Our limitation is linked to the lack of required expenditure in water and sewage systems.

IMIESA September 2020

Pushing the limits A specialist in applying molecular orientation to pipeline solutions, Molecor is continuing to push the limits with its new PVC-O DN 1 000 pipe and the technology for DN 1 200.

ounded in 2006, Molecor began it business focusing on Oriented PVC pipes and fittings for pressured water conveyance. But the company’s true differentiating factor is its ability to manufacture large-diameter PVC-O pipes, offering product ranges not previously available on the market. TOM® pipes cover nominal diameters from 90 mm to 1 200 mm in 12.5, 16, 20 and 25 bar pressure. Moreover, they are certified in more than 10 countries and are 100% recyclable. These points have also facilitated their expansion worldwide when Molecor offered these products to the market.

Technology evolution In 2010, Molecor designed the M-OR-P 3163 system. Before this design, some tests were done with the M-OR-P 1640 machine, manufacturing a 500 mm diameter pipe. Thereafter, the 630 mm diameter in Oriented PVC was born, and still maintains the highest quality – Class 500 – without losing its best mechanical and physical properties.

IMIESA September 2020

In 2013, the next technological development, the M-OR-P 3180 system, went hand in hand with the DN 800. Molecor extended its product range one more time, making the largest PVC-O pipe in the world to date, positioning with this achievement in this way Molecor as the largest Oriented PVC pipe manufacturer globally. The M-OR-P 5012 system is now a reality, bringing a new machine for high-quality PVC-O pipe manufacture to the market with never before seen diameters. The pipeline market receives the widest range of pipe diameters, up to 1 200 mm. Molecor has now expanded its offering, with a wider choice of pressurised water solutions. The first DN 1 000 pipes are now being manufactured in Madrid and the DN 1 200 are expected to be available at the beginning of next year.

Large diameters with the highest quality It is well known that large-size pipes are usually heavy and difficult to handle. But the full range of PVC-O TOM pipes has become the best choice for the pressurised

Molecor's DN 1 000 and M-OR-P 5012 mold under operation at the company's Madrid factory

conveyance of water due to their physical and mechanical proper ties, which are improved during the manufacturing process. PVC-O pipes are lighter and more ductile, allowing superior installation performance. TOM PVC-O pipes are less than half the weight of PVC and PE pipes, and between 6 and 12 times less per linear metre than cast iron pipes of an equivalent nominal outside diameter. This, together with their ease of connection and watertight joints, ensures the highest-speed installation performance in the market. TOM pipes also have an extremely high resistance to impacts. Moreover, the material creep behaviour is very low, ensuring the durability of the pipe working at nominal pressure for over 100 years. They offer lower celerity than other piping systems, which means less water hammer is caused by sudden variations in water volume and pressure. Thanks to molecular orientation, TOM pipes come with a higher internal diameter and greater flow section, contributing to their hydraulic capacity, which is about 15% to 40% more than pipes made from other materials. Additionally, they have a maximum ductility that allows the pipes to bear big deformations of their internal diameter. These products have also proved to be highly chemically and mechanically resistant to degradation and corrosion. The full range of TOM PVC-O pipes manufactured by Molecor run from DN 110

PLASTIC PIPES to DN 1 200 and can reach pressures from PN 12.5 to PN 25. This includes the ecoFITTOM® PVC-O fittings, providing a full solution that covers all the medium- and high-pressure needs of the market. All pipes and fittings can be used in numerous applications, including potable and non-potable water transport, irrigation, sewerage, fire protection and even industrial applications. Ultimately, TOM pipes and the ecoFITTOM fittings provide the best solution to pressurised water conveyance.

Molecor's first DN 1 000 pipes are now being manufactured in Madrid

Molecor mold DN 1 000 under operation at its Madrid factory

THE SIZABANTU DIFFERENCE Sizabantu Piping Systems is the official distributor of Molecor products in South Africa. Sizabantu’s Sean Harmse offers some insights into local market conditions: What are some of the pressing infrastructure gaps/shortfalls in SA’s water and sewer networks? SH The current major hurdle in the water industry is implementation backed by political will. Because South Africa is a water-scare country, we need to protect our valuable water resources. However, a recent survey found that up to 60% of potable water conveyed in aged and damaged infrastructure is being lost and does not reach the end-user. If we can replace and upgrade existing networks, we will address a major part of the water availability to the citizens of South Africa. How can plastic pipes help? The pure fact that a well-laid plastic pipe has a maintenance-free work life of more than 50 years, and in some cases 100 years, highlights that plastic pipes

are the ultimate future for water and sewer infrastructure. Can you tell us about the use of PVC-O locally? Since the introduction of PVC-O to the South African market in 2012, we have seen a massive swing towards its use in nearly every municipality and water board in the country. This is a clear indication of the confidence that PVC-O has instilled through the hundreds of projects it has been supplied for. Our export into Africa has also seen massive growth and countries like Zambia, Botswana and Madagascar are now insisting on PVC-O. Memorable projects include the City of Polokwane’s Sterkloop Wellfields Infrastructure where 450 mm PN 25/20 was installed, as well as the Mutshedzi Bulk Water Network in Venda, which used 630 mm and 450 mm PN 20.

What are the benefits of being a SAPPMA member? Being part of the SAPPMA family provides massive support. SAPPMA ensures that quality pipes are produced for the market by reputable manufacturers. Through continuous discussions and interactions, SAPPMA drives quality and ensures all members adhere to the various standards. What role does Sizabantu see itself playing in South Africa’s long-term water security and supply? Sizabantu Piping Systems has now been in the water industry for more than 17 years and we continue to grow. By bringing new technology and products to the market, we will form an integrated part of South Africa’s water security and supply. Our industry relies heavily on stable and reputable manufacturers to lead it into the next decades.

Molecor TOM PVC-O largediameter pipes on the field

IMIESA September 2020

PLASTIC PIPES

Established in 2014, Inkulu Plastic Pipes' team combines years of industr y experience with the application of cuttingedge technology to target niche market expansion. The company’s motto, ‘Dare to commit’, underscores its confidence in meeting just-in-time deliver y and strict quality assurance standards, says Gabriel Reddy, founder and CEO.

Supplied by Zhangjiagang City Yili Machinery, Inkulu’s 38D Series pipe extrusion machine sets a new manufacturing benchmark for the company, as well as the local market, enabling pipes of up to 1 200 mm to be produced

Extrusion line investment adds value

uring Januar y 2020, Inkulu commissioned its 1 200 mm pipe extrusion line at its Hammarsdale factory in Durban. Supplied by Zhangjiagang City Yili Machinery (Yili), this 38D Series machine sets a new production benchmark for the company, as well as the local market, for the extrusion of high-density polyethylene (HDPE) solid wall pipe in nominal diameters from 500 mm to 1 200 mm. This specialist extrusion line is set up for a maximum output capacity of 1 600 kg/h. Yili’s relationship with Inkulu started in 2015, when the company began its initial capex investments. To date, Yili equipment installed at the Hammarsdale facility includes various extrusion machines, shredders, granulators and pelletisers. Virgin-grade materials are used to form all products. The company currently operates seven pipe extrusion lines, with an overall monthly production output capacity of more than 900 t. Depending on the application,

Installation of an HDPE bulk water line

IMIESA September 2020

products are supplied in three different materials, namely HDPE, low-density polyethylene (LDPE) and polypropylene (PP). HDPE solid wall pipes are now manufactured in a range from 16 mm through to 1 200 mm according to specified pressure ranges to meet small-, mediumand large-bore requirements in South Africa, as well as further afield in Africa in countries such as Botswana, the DRC and Zambia. A hose line is also produced in 16 mm to 40 mm diameters in 500 m coils. In addition, Inkulu produces spiral structured wall pipe from 300 mm to 1500 mm applications that include stormwater and sewer systems. “Our multimillion-rand investment in this automated 38D Series line has positioned Inkulu as a major player in the bulk water and sewer line segments,” says Reddy, who has more than 30 years’ experience in the HDPE piping industry. Inkulu is a Level 2 BBBEE contributor with a dedicated focus on transformation, technical training and skills transfer.

An extruded pipe section coming off the production line at Inkulu’s Hammarsdale factory

“Prior to the acquisition, our research showed that high-speed machines are far more efficient, significantly reducing the cost per kilogramme to produce plastic pipe. Faster output times now make us more competitive from a price perspective, as well as in terms of our turnkey installation and commissioning services,” he continues. Standard industr y material tests are conducted at Inkulu’s on-site laboratory according to SANS ISO 4427/ISO 4437. Inkulu is also ISO 9001, ISO 14001 and ISO 45001 certified, and is a member of the Southern African Plastic Pipe Manufacturers Association.

Gas market gains Alongside its focus on the water and wastewater markets, Inkulu has identified growth opportunities for the fluid transfer of

PLASTIC PIPES

liquid gas in an HDPE pipe range from 16 mm to 630 mm. Sectors supplied to date include the industrial, mining, municipal and residential markets. The latter includes the Steyn City mixed-use precinct in Gauteng, where Inkulu supplied and installed a residential gas reticulation network in 2017. “Switching to gas as an alternative energy source holds huge potential,” says Reddy. “In this respect, HDPE lines – combined with electrofusion fittings – are ideally suited to this application.” Manufactured in accordance with ISO 4437 standards, Inkulu’s gas pipe and fittings are quality tested throughout the entire production process to ensure safety and reliability. Available in coils and lengths, these gas pipes are specifically designed for buried installations and, like all HDPE products, they are maintenance free over their lifetime, corrosion resistant, easy to install and flexible, with high impact strength. A fur ther advantage of HDPE pipe is its suitability for trenchless construction.

The material of choice Within its operating range, plastic pipe has become the preferred material for all industrial sectors, including the rigorous demands of the mining industry, where corrosive fluid transfer is common. Within Inkulu’s truck fleet ensures on-time delivery. Purpose-designed trailers cater for pipe lengths up to 24 m

PRODUCTION CAPABILITIES Materials Depending on the application, pipe products can be supplied in three different materials, namely: • HDPE • LDPE • PP Products • Coiled: HDPE pipes 16 mm to 110 mm • Lengths: HDPE pipes 125 mm to 1 200 mm • Perforated: HDPE pipes 63 mm to 1 200 mm • Plumbing hot water pipes, manufactured using PP • Telecommunication optic fibre HDPE ducting • PE100 HDPE gas pipe • Manufactured fittings up to 630 mm • Moulded HDPE butt-welding and electrofusion fittings

the infrastructure space, Inkulu is experiencing growing demand for water, wastewater and stormwater applications as municipalities recognise the cost benefits compared to traditional pipeline systems manufactured from ductile iron and concrete. Alongside its extrusion line acquisitions, Inkulu has responded to client requirements for turnkey solutions by investing in fabricated fittings equipment. A wide range of bends, tees, stubs, flanges, and reducers cater for pipe systems up to 630 mm. “Through our ongoing research and development (R&D) programme, we’ve met the need for more complex and costefficient pipeline designs by means of HDPE fabricated fittings to solve installation situations where common fittings fail,” Reddy explains, adding that Inkulu also

To support its turnkey installation and commissioning services, Inkulu has invested in a wide range of welding technologies. These include butt-welding machines, socket fusion machines and electrofusion welding machines

supplies and manufactures moulded HDPE butt-welding and electrofusion fittings. Keeping pace with the market, Inkulu’s ongoing R&D initiatives continue to tap into new niche markets. The latest developments include the production of PP plumbing hot water pipes, as well as telecommunication optic fibre HDPE ducting. “Inkulu has established a well-proven track record for supplying quality pipes on time, focusing on establishing and building partnerships with suppliers and customers. Our recent capex investments now place us at the forefront of the plastic pipe manufacturing sector and we’re excited about the possibilities as more infrastructure projects come online in 2021,” Reddy concludes.

www.inkuluplastics.co.za

IMIESA September 2020

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PLASTIC PIPES

Mighty oaks from little acorns grow Eighty-five years ago, the first PVC pressure pipes were being installed in the Olympic Stadium area in Berlin for the 1936 Olympic Games. Today, they are widely used. By Mike Smart*

hen first introduced to South Africa 60 years ago, PVC pipes were not enthusiastically received. Initially, heavy-duty PVC was only specified for 150 mm diameter pipes laid at grades flatter than 1:5. Now, more than 95% of domestic sewer reticulation pipes are PVC. Similarly, HDPE SANS 4427 remains the preferred material for slurry pipeline applications and dominates water supply house connections.

12.5 MPa for larger pipes – 110 mm to 630 mm in diameter. In the 1970s, the PVC industry wanted its pipes used for underground mining services. But the brittle failure characteristic of PVC-U first had to be eliminated. A project, led by Dr Ken Hart, produced a high-impact pipe, PVC-HI SANS 1283, which satisfied mining industry conditions and enabled PVC pipes to be used underground. As a result of this development, in the mid1990s, PVC-M (modified polyvinyl chloride) SANS 966-2 was developed in a project led by Mike Osry by adding impact modifiers, commonly CPE (chlorinated polyethylene), or rubber toughened acrylics, or a combination thereof, to the material to increase its impact strength – thereby enabling the material to exhibit ‘tough’ characteristics. This facilitated the reduction of the design coefficient (C) from 2 to 1.4, which increased the σ-value from 12.5 MPa to 18 MPa.

Thermoplastic evolution Thermoplastics are continuously improving, thanks to scientists, polymer technologists and processing engineers. The allowable design stress (σ) for HDPE, since its introduction into South Africa, has increased from 5 MPa to 8 MPa – a substantial 60% increase, unknown in other materials. The increase in PVC’s strength is even more substantial. The σ-value of PVC has increased from 10 MPa to 36 MPa – an incredible 260% increase. The first PVC-U (unplasticised polyvinyl chloride) SANS 966-1 pipes had an σ-value of 10 MPa that increased to

Introducing PVC-O About 40 years ago, the PVC industry developed PVC-O (oriented unplasticised polyvinyl chloride) SANS 16422. This uses molecular

orientation, which results in the improvement of physical and mechanical properties. In the intervening 40 years, there have been improvements in PVC-O material itself, from classification 315 to 500 – based on the minimum required strength (MRS). The latest PVC-O material, classification 500, has an MRS of 50 MPa and a C-value of 1.4, giving a σ-value of 36 MPa, where σ = MRS/C. This is a substantial improvement – twice the allowable design stress of PVC-M – made possible by improved in-line production technology. Sizabantu Piping Systems’ technology partner Molecor excels at this. Molecor has increased the range of PVC-O pipes from the previous limit of 315 mm diameter class 16, to 630 mm class 25, to 800 mm class 20 in 2015, then to 1 000 mm class 16 in 2020 and now to 1 200 mm class 16, which will be available in 2021. For the thermoplastic pipe industry, these are exciting developments that have made the previously inaccessible large-diameter, high-pressure pipe market an arena industry members can compete in.

Continuous improvement PVC DEVELOPMENT TIMELINE PVC pipes used in the Olympic Stadium complex in Berlin

1936

PVC-HI MRS = 25 MPa C = 2.5 and 2.0 σ =10 and 12.5 MPa 50-year design life 1970

1960 PVC-U MRS = 25 MPa C = 2.0 σ =12.5 MPa 50-year design life

PVC-M MRS = 25 MPa C = 1.4 σ =18 MPa 50-year design life 1990

1980 PVC-O MRS = 31.5 MPa C = 2.0 σ =16 MPa 50-year design life

1996 PVC-O MRS = 50 MPa C = 1.4 σ =36 MPa 100-year design life

The ISO protocol specifies that the design service life of thermoplastic pipes shall not be less than 50 years. However, with the latest high-technology polymers, the service life of thermoplastic pipes is not less than 100 years. PVC technology has improved substantially, and continues to do so, giving the pipeline industry proven materials to use for large-diameter, high-pressure, bulk supply pipelines historically dominated by steel and ductile iron. *Mike Smart is the owner of Genesis Consulting. He is currently a member of SAPPMA, chairperson of IFPA, and a specialist consultant for Sizabantu Piping Systems.

IMIESA September 2020

PLASTIC PIPES

HDPE through the decades HDPE has come a long way since its invention in 1955, with characteristics that offer an ideal solution for pressurised water pipelines.

DPE was first introduced to the world at the 1955 Hanover Fair (now K-Fair) by German chemicals company Hoechst. By 1959, the results of the first hydrostatic testing to determine minimum required strength (MRS) and lifetime were already available, and HDPE pipes had been used in numerous German projects. These PE 50 pipes were manufactured by the Ziegler process, which used Hostalen bi-modal technology in order to balance the material characteristics and build in longer molecular chains for improved toughness. “It was recognised early on how important this is when developing plastics for long-term use and toughness,” says George Diliyannis, technical service leader, Safripol.

Local HDPE development Safripol, the second largest polymer producer in sub-Saharan Africa and only producer of HDPE, was established in South Africa in 1969 as a joint venture between Hoechst and Sentrachem. Safripol commenced production of HDPE in 1972 using Hostalen bi-modal technology at its Sasolburg plant. At the time, Safripol was producing PE 63 materials and plastic pipes were relatively new to the local market and viewed with some scepticism. However, this view quickly changed and developments in materials and technology ushered in PE 80 in the late 1970s and PE 100 in the early 1990s. As the material evolved, pipe wall thicknesses could be reduced while ensuring the same pressure capabilities. This resulted in a lower cost per metre and improved the pipe’s properties, specifically MRS and long-

IMIESA September 2020

term crack resistance. It has also allowed for HDPE to be used in tougher applications, such as horizontal directional drilling and pipe lining.

Changing standards Changes to the global standard ISO 4427: Plastic piping systems in 2007 ushered in major changes, placing far more onerous demands on raw materials. The ISO standard, which was adopted as a SANS standard in 2008, required a far greater stress crack resistance, which required there to be no knee formed during hydrostatic testing at 80°C before 5 000 hours. “This necessitated a major change in the molecular make-up of the material and was a game changer – not only in determining the pressure resistance of the material but also its lifespan. While the pressure capabilities remained the same, the PE 100 from the 1990s and early 2000s is completely different from the PE 100 produced after 2007,” explains Diliyannis. To rapidly meet the new standards, Safripol signed a technology agreement in 2008 with Australian polymer producer Qenos, which already had years of experience in developing and marketing the new-generation, highperformance PE 100 pipe material. ISO 4427 was updated again in 2019, imposing more stringent requirements around measuring and testing raw materials, and Safripol is working hard to ensure compliance to the new standard, even before its possible local adoption by the SABS. Today, Safripol’s flagship HDPE PE 100 pipe resin, iMPACT100®, provides a single, world-class solution to the local water and wastewater transfer markets.

Local adoption Since the introduction of iMPACT100 10 years ago, Safripol has tripled its production output of PE 100 pipe material. “This highlights the fact that people are well aware of HDPE and its many benefits. However, more awareness is needed around the negative effects associated with taking shortcuts in the pipe manufacturing process,” cautions Diliyannis. A study conducted by Safripol showed that including even a small percentage of non-PE 100 materials in the manufacture of HDPE pipes results in a significant decrease in the pipe’s resistance to cracking and subsequent lifespan. However, when produced correctly, in line with ISO standards, modern HDPE pipes exhibit excellent toughness, sag resistance and a long lifespan. They require little to no maintenance and are resistant to corrosion, as well as bacterial and microbial growth. “The life-cycle costing of polyethylene is highly favourable and, when paired with its good carbon footprint, HDPE beats the alternatives in many aspects,” concludes Diliyannis.

George Diliyannis, technical service leader, Safripol

QUALITY CONNECTIONS CREATING ABSOLUTE CUSTOMER CONFIDENCE IN THE PLASTIC PIPE INDUSTRY The Southern African Plastic Pipe Manufacturers Association (SAPPMA) is a voluntary, self-regulating association incorporated under Section 21 as a company not for gain, which was launched in 2004 to represent the interests of the well-developed plastic pipe business in South Africa and surrounding countries.

use of high quality plastic pipes and pipe systems. SAPPMA members contribute towards the long term well-being of the plastic pipe industry by way of research, technical discussion, analysis and problemsolving. Being a non-proﬁt organisation, it is solely aimed at protecting the customer and the infrastructure of the country.

Pipes produced by member companies carry the registered SAPPMA logo for clear identification. SAPPMA members are allowed to use the association’s logo on their products only after they have been able to successfully demonstrate that their plastic pipes and fittings comply with the association’s quality and manufacturing requirements and that they are fully compliant with all relevant local and international standards and specifications. This includes: • Ensuring they are ISO 9001:2015 quality management system compliant (or alternatively, they have passed a SAPPMA systems audit) and as such strive towards successful maintenance and improvement of these systems. • Agreeing to be independently audited on a regular basis (announced or unannounced), including sampling and testing of products. • Conforming to additional SAPPMA ‘Minimum Standards’ to further differentiate members from non-members.

All SAPPMA members are committed to a strict Code of Conduct whereby they agree to comply with various requirements for national product standards, internal standards and pay due regard to trade mark, copyright, patent ownership and all other intellectual property in order to maintain the industry body’s highest ethical standards.

THE SAPPMA MARK: A GUARANTEE OF QUALITY The purpose of SAPPMA is to create consumer conﬁdence within the plastic pipe industry and to promote the production and the

By signing SAPPMA’s Code of Conduct, members undertake not to supply counterfeit products, refrain from negative marketing and any form of corruption with customers, suppliers, competitors, legal authorities and any other persons, desist from any anticompetitive behaviour (including the ﬁxing of prices or other trading conditions), the division of markets through the allocation of customers, suppliers, territories or types of goods, or collusive tendering. IT’S WHAT’S ON THE INSIDE THAT COUNTS SAPPMA members only use virgin grade approved polymers and in terms of the relevant product standards no third party regrind PE-HD material. They do not use any ﬁllers, nor heavy metal additives in the production of PVC pipe.

PLEASE SUPPORT THE FOLLOWING SAPPMA MEMBERS WITH CONFIDENCE:

emeraude-international.com

amanzistarway.co.za

chemsystems.co.za

aenor.com

flo-tek.net

gradcosa.co.za

hultec.co.za

inkuluplastics.co.za

borealisgroup.com

bsigroup.com/en-ZA

macneil.co.za

marleypipesystems.co.za

mrstubman.com

nsf.org

pexmart.com

pipeflo.co.za

pipe-tech.co.za

plasco.co.tz

plastrading.com

polyflo@mweb.co.za

proplastics.co.zw

rare.co.za

safripol.com

sasol.com

satas.co.za

sinvac.co.za

sizabantupipingsystems.com

spc.co.za

sunace.co.za

swanplastics.co.za

vanrynrubber.co.za

WATER & WASTEWATER | UTILITIES

Performance-based contracts An important part of a utility’s toolkit

As cities continue to grow at rapid rates, water utilities are under increasing pressure to provide services. Performance-based contracts offer utilities the opportunity to harness the skills and resources of the private sector to improve performance. By Danielle Petterson

apid rates of urbanisation in sub-Saharan Africa have meant that the percentage of the urban population receiving access to safe drinking water has been declining for decades. Added to this, many peri-urban and informal areas must contend with intermittent ser vices or none at all, says David Ehrhardt, chief executive, Castalia.

IMIESA September 2020

In many cases, utilities are not generating enough income to maintain infrastructure or raise finance for new infrastructure roll-out. Instead, they must rely on their national governments to provide them with grants – a challenge at a time when many governments have increasingly less money available. Poor revenue collection, coupled with increasing water losses, declining infrastructure and a lack of incentives for per formance means that successful water utilities are usually the exception and not the rule. However, some African water utilities are per forming well above average in providing good water ser vice for the poor, even in rapidly growing cities with arid climates. Ehrhardt participated in a World Bank study that examined the utilities succeeding in providing water ser vices and the methods they employed. Many of them have made use of per formance-based contracts (PBCs) at some point in the past. “The use of PBCs has been a key tool in the toolkit of some of the best per forming utilities in Africa,” he notes.

Performance-based contracts PBCs allow public water utilities to contract the ser vices of a private company to provide a specified level of ser vice in the management of the utility. They include predetermined per formance targets that could be linked to several areas across the utility’s operations and reward the contractor financially for meeting those targets. Importantly, there are several types of PBCs, allowing for increasing risk transfer and private sector responsibility. These include ser vice contracts, management contracts, lease contracts and concession contracts.

Service contracts Ser vice contracts typically focus on one component of a utility’s operations, such as revenue collection, metering management or non-revenue water reduction, and have no influence of the management of the utility. In Burkina Faso, for example, Ouagadougou’s utility brought in one of France’s international water operators to

WATER & WASTEWATER | UTILITIES

run their commercial function – billing, collections and metering – as part of the utility’s transformation to become one of the best per forming utilities in Africa.

Management contracts These contracts involve the government or board of a utility hiring an outside team to take over the management of the utility for a specified period. The contract will be linked to per formance indicators with associated per formancerelated bonuses. “These contracts can often pay for themselves. For example, if some of the targets are to increase revenue collections and reduce costs, a good management team should be able to generate a lot more cash than what they earn in their fixed and per formance fees,” explains Ehrhardt. However, he cautions that management contracts can be met with resistance from the existing utility managers who are being replaced or sidelined. The contracted managers – often foreigners – are also not required to provide any financing or take any risks and will continue to receive their base fee even if they do not make improvements. “It is a tool that has its place but that also has some serious drawbacks,” he notes. Uganda’s National Water and Sewerage Corporation presents an encouraging example. It successfully used management contracts to bring in foreign management contractors for ser vice in Kampala. Drawing on the experience and enhanced capacity created by these contracts, it developed Internally Delegated Management Contracts in which it applied the principles of incentivised management to the utility’s area managers with great success.

Lease contracts Lease contracts are usually entered into with an international water specialist company. Similar to a management contract, the company is given the right to run the public utility and make management decisions, but this time they take on risk, explains Erhardt. Instead of being paid a fixed fee, the operator receives the utility’s operating

profits, but is also responsible for all expenses, including salaries and bills. This gives the most complete incentive on operations, as the contractor will want to maximise revenue while minimising costs. However, the contract must contain ver y strict provisions about the ser vices that must be achieved. Furthermore, a component of the tariff will go to the government or a publicowned company that holds the assets of the utility, in order to cover the financing of new infrastructure, which remains the responsibility of the government under this model. “This is a good model and produced ver y good results in Dakar, Senegal, but it still doesn’t solve the problem of the government having to finance infrastructure when there is no money available,” notes Ehrhardt.

Concession contracts The concession contract tries to solve the infrastructure funding challenge by giving a private company full operational responsibility of the utility for a predefined period (typically 20 to 30 years). These contracts often have far more ambitious ser vice targets because, in addition to running the utility, the contractor must provide funding for new infrastructure and ser vice expansion. “This model can work, and Ivor y Coast is a good example of this in Africa, but it has mainly been used in Europe. There have also been some high-profile failures,” notes Ehrhardt. “It is ver y close to privatising a water utility, and can therefore be politically unpopular, but it is also the only model that brings in capital. However, to attract that capital, the utility must generate sufficient revenue, which often leads to an increase in tariffs – although higher tariffs may be the only way to provide adequate infrastructure,” he adds. Mozambique is currently exploring this model with the assistance of Castalia. The countr y has had lease contracts in place in many of its small towns, which have worked relatively well. However, the infrastructure in these towns is generally quite poor and

limited funds for infrastructure upgrades have resulted in a ver y slow rate of improving ser vices. Concession contracts present the only realistic solution. However, attracting investment in small towns with limited revenue generation presents a challenge. Castalia is therefore investigating a hybrid option, which involves co-financing of infrastructure by both the public and private sectors. “We think this could be a viable solution for cities and towns in Africa because it is possible to attract some level of private investment, and we need to attract as much of that as possible to keep up with population growth,” says Ehrhardt.

Designing PBCs Ehrhardt stresses the importance of well-designed PBCs. “There are many of these contracts that have gone wrong because they are not well designed,” he says. The rights and responsibilities of the contractor must be ver y clear to avoid conflict between the contractor and utility management. This is especially the case in concession contracts where private companies are being asked to sink money into infrastructure that they cannot recoup if the contract fails. For long-term contracts, it is advisable to include regulator y-like provisions for periodic reviews of tariffs as costs change, according to specific rules. Contract models do exist and should be used where relevant. By studying what did and didn’t work in 10 different management contracts, Castalia developed management contract models for the World Bank. The company also explored provisions in long-term contracts to develop key provisions and term definitions. While PBCs have received some resistance in the past, Ehrhardt stresses that they are an important and useful tool available to African utilities. “PBCs offer a solution that has worked, and utilities need to look practically at the tools available to solve their problems – PBCs are one of those tools.”

IMIESA September 2020

WATER & WASTEWATER | UTILITIES

Non-revenue water:

its impact and how to manage it The ability of water services authorities (WSAs) to sustainably supply potable water is hampered by poor and ageing infrastructure. This is compounded by technology gaps and the shortage of the vital skills needed to effectively manage non-revenue water (NRW). Left unchecked, NRW undermines the ability of WSAs to effectively finance and meet service delivery demands. By Ntuthuko Ngcamu, Pr Tech Eng*

mgeni Water has been mandated by the Minister of Human Settlements, Water and Sanitation to provide support to all WSAs in KwaZulu-Natal, thereby ensuring that sustainable improvements are made in their water supply services. This assistance will be provided through the Department of Water and Sanitation's (DWS's) regional office. Studies commissioned by Umgeni Water’s Water Demand Management Unit have provided a clear indication of the state of water conservation and water demand management (WC/WDM) within the province. For the first time, the true magnitude of the problem, from a water efficiency, NRW and economic perspective, has been identified.

Umgeni Water assistance and reporting The four areas of the framework support provided by Umgeni Water’s WDM Unit are: (i) Strategic – preparation/updating of WC/ WDM master plans (ii) Tactical – provision of specialist technical assistance and engineering advice for WC/WDM or NRW reduction implementation (iii) Regulatory – provision of assistance and support for No Drop assessments, monthly reporting to the DWS (e.g. WSAs’ submission of water balance and water saving reports to the DWS in compliance with regulatory

IMIESA September 2020

requirements) and training for WSAs to ensure sustainability (iv) Financial – not direct funding support, but assistance in preparation of business plans and funding applications, among others. Umgeni Water is supporting the KZN WC/WDM programme on an ongoing basis, with further improvements based on lessons learnt from previous projects and through the requests of WSAs. In support of the programme’s overall objectives, six key support areas (KSAs) have been identified. These are summarised as follows and were part of the 2019/20 financial year project: • KSA 1: WC/WDM Master Plans (updating where necessary) • KSA 2: Development of Revenue Improvement Strategies (identifying and conceptualising revenue enhancement projects) • KSA 3: Determination of True Cost of Water (which will ultimately assist with tariff modelling) • KSA 4: DWS IWA (International Water Association) Water Balance Reporting Assistance (Umgeni Water actively participates in and facilitates the KZN WC/WDM quarterly forum) • KSA 5: WSA WC/WDM mentorship and training • KSA 6: Programme Support.

Bulk metering needs In the 2014/15 financial year, the Department of

Water and Sanitation conducted and ACIP funded a WC/WDM project that identified the scope and costs required for meter improvements on a WSA basis. Bulk metering ensures that water balances (to the IWA modified standard and with 95% confidence limits) can be produced regularly on a WSA, town and water supply system basis. It also ensures that each WSA has sufficient bulk water metering in place to accurately record system input volume and it helps improve monitoring and reporting on WC/WDM activities and quantification of water demand reduction across all WSAs. A total of 216 water schemes were visited and 2 833 bulk meters audited. From the meters audited, it was further discovered that a total of 522 meters needed to be replaced, 1 759 new meter installations were needed and only 552 meters were in good working condition. An estimated R189 000 000 is required to address metering needs across the province.

State of NRW in KwaZulu-Natal A report on the state of NRW in KwaZulu-Natal was prepared during the middle of the recent drought and focused on the 2016/17 financial year. This report provided comprehensive water balances for each of the 14 WSAs in the province. In addition, KPMs, economic analysis and an institutional assessment of the capacity and capability of the WSAs to plan, deliver and monitor WC/WDM projects were also defined. The drought has since ended in the province, and an update of the NRW situation for the 2017/18 and 2018/19 financial years was prepared to determine any changes in water supply conditions. The figures used in the report for the 2018/19 financial year were based on information provided by WSAs and related to their regular reporting to the DWS. Monthly reporting is mainly done using the IWA water balance template.

WATER & WASTEWATER | UTILITIES

The IWA developed the standard water balance to benchmark and evaluate the performance of water distribution systems (bulk and reticulation) and it is being promoted across the world as best practice. The IWA standard water balance was slightly modified for South Africa to allow for free basic water.

Key findings The following are some of the key findings from the study conducted by Umgeni Water in the 2018/19 financial year: - The average NRW by volume % in the province is 44.5%. - Conservatively, approximately 1 958 Mℓ/day is supplied to the province’s served population, with only 1 087 Mℓ/day of that being billed to consumers. That means that 871 Mℓ/day is being lost to NRW, of which 560 Mℓ/day is lost to leaks. - The average infrastructure leakage index (ILI) in the province is 5.8, which means that leakage is, on average, 5.8 times higher than the theoretical best it could be. - The cost of NRW in the 2018/19 financial year was R2 266 792 728, of which R1 456 429 094 was directly lost to leaks. - If the relevant components of NRW had been sold to consumers, this would have amounted to an equivalent revenue of R4 243 912 062 in the 2018/19 financial year. - Unbilled consumption (not illegal/unauthorised consumption) amounted to an equivalent lost revenue of R870 960 233. NRW by volume percentage regressed over the three-year period 2016-2019 and is presented in Figure 1. This indicates that the overall percentage of NRW has regressed from 42.1% to 44.5%. Although this illustrates a concerning trend, it must also be highlighted that bulk water metering is deficient in many areas in the province. As a result, much of the information presented must be assumed from estimated production volumes. One of the main recommendations arising from the studies is for adequate bulk water metering to be implemented in both systems and zones throughout each WSA.

WC/WDM-funded projects in KwaZulu-Natal The DWS listed 13 WSAs as beneficiaries from the Water Services Infrastructure Grant (WSIG) for the 2019/20 financial year. A total of R872 374 000 was allocated for water and sanitation projects. It is encouraging to see that seven WSAs were allocated more than R250 000 000 to undertake WC/WDM-related projects. It is

90,00% 80,00% 70,00% 60,00% 50,00% 40,00% 30,00% 20,00% 10,00% 0,00%

Non-Revenue Water (%) 2016/2017

Non-Revenue Water (%) 2017/2018

Non-Revenue Water (%) 2018/2019

FIGURE 1 WSA non-revenue water by percentage (Bigen/Joat 2019)

hoped that this investment will bear fruit through a reduction in NRW across the province. Umgeni Water, together with the DWS, has developed the WC/WDM Business Plan Assessment Tool to be used for monitoring/ evaluating project success. Development of this tool/checklist assists the DWS in determining ‘value for money’ when receiving funding applications for WC/WDM projects from WSAs. The tool includes WC/WDM norms and standards, ROIs, project checklists, motivations/justifications, and measurement and verification processes.

NRW economics At this stage, the following high-level, provisional assessment of the economics of NRW reduction within KwaZulu-Natal can be presented (numbers quoted exclude VAT): - The total five-year investment required for reduction of NRW is R9 496 329 776 of which R6 387 642 262 is capex and R3 108 687 514 is opex. - The total five-year investment required for billing improvement is R1 873 935 964. - The total five-year investment required for leakage reduction is R7 622 393 812. - The current cost of NRW in the province is R1 709 545 400, which would provide an ROI of 5.6 years on the total required NRW investment budget. - The current cost of leakage in the province is R1 023 509 220, which would provide an ROI of 7.4 years on the total required leakage reduction budget. - The current cost of equivalent lost revenue (unbilled authorised consumption, illegal connections and meter under-registration) in the province is R1 380 627 154, which

would provide an ROI of 1.4 years on the total required leakage reduction budget.

Conclusion Considering the unacceptably high water losses and NRW, the WSAs cannot afford to continue with new capital works without replacing old AC pipes, resolving illegal connections and metering all customers with individual connections. Bulk metering is also a key priority in order to accurately calculate the water balance in each scheme. It should also be remembered that the water demand model utilised for the water master plans of WSAs includes the assumption that water loss percentages will decrease over time, as it plans for good business, not management deficiencies. If the WSAs do not intervene and reduce water losses, the demands predicted for various schemes will almost certainly exceed the resource yield, leading to reduced supply to consumers. For effective implementation, a common vision on water efficiency is required, driven by strong and informed leadership. *Ntuthuko Ngcamu, Pr Tech Eng, is the head of the Water Demand Management Unit at Umgeni Water.

Think water, think Umgeni Water www.umgeni.co.za

IMIESA September 2020

WATER & WASTEWATER

Pressure management basics Pressure management can be one of the most cost-effective and important water demand management interventions in driving down water losses from municipal water supply systems.

hile pr essur e management is not appropriate in ever y situation, the savings are often very significant and worthwhile where it can be applied. However, there appears to be a general lack of understanding in many municipalities that

IMIESA September 2020

operating their systems at unnecessarily high water pressures is a poor strategy that leads to excessive leakage, says Ronnie McKenzie, former chairman of the IWA Water Loss Specialist Group. It is well known that leakage is driven by pressure and that high water pressures will often result in very high levels of leakage. Where appropriate, pressure management is often one of the most cost-effective measures to reduce leakage and wastage, particularly given that many of South Africa’s municipal water supply systems are operated at unusually high pressures. McKenzie notes that pressure management can take many forms – from the basic fixed outlet pressure control to some form of more sophisticated hydraulic or electronic control, often referred to as ‘smart control’ or ‘advanced pressure control’. He has written a guide to the reduction of water losses from municipal water supply systems, which is available freely from

the Water Research Commission. Many of the issues discussed below have been summarised from his report*.

Getting pressure zones right Water pressure reduction can be achieved through a wide range of measures, ranging from standard fixed outlet control valves to various more complicated control involving some form of advanced electronic or hydraulic controllers that offer greater control and may even involve the use of artificial intelligence. “Most of the savings achieved through pressure management originate from the basic fixed outlet pressure-reducing valve (PRV),” says McKenzie. He indicates that additional savings can often be achieved from the use of more sophisticated control but stresses that the capital costs and maintenance issues associated with the additional control equipment must be considered carefully before deciding to use such technology.

WATER & WASTEWATER

He highlights that the most appropriate technology to suit a specific situation is often the most basic, and robust, equipment – especially in many parts of Africa, where technical capacity may be limited. Selecting the most appropriate pressure management equipment for each zone is vital and will depend on a variety of factors, including cost, technical expertise within the water utility, technical backup for the equipment, topography, leakage levels, as well as the main source of leakage. However, McKenzie also stresses that no piece of equipment, regardless of the level of sophistication, can replace the importance of a properly designed, wellmanaged and well-maintained network. For example, ensuring that the appropriate boundary valves are closed and all internal network valves are open is of greater importance than any form of pressure management, with or without a pressure controller. Moreover, a PRV will not operate properly if the pressure management zone has been compromised by the unauthorised opening or closing of boundary valves. “Pressure management can produce huge savings, but the key to success rests not with the valves or the associated hightech add-ons but rather with sorting out the pressure zones. From experience, the most important issue when trying to introduce any form of pressure management is ensuring that the zone being considered is and remains discrete,” says McKenzie. If the zones are not discrete and are interlinked in any way, then pressure management is unlikely to function properly and should not even be considered until the underlying zone problems have been resolved. Sectorising and operating the pressure management zones is often the most difficult and time-consuming part of any large pressure management installation; for this reason, it is also the issue that is most often neglected. McKenzie believes that one of the most serious issues facing municipalities in South Africa (and elsewhere worldwide) is ensuring that the pressure zones are operating properly and have not been compromised through an unauthorised opening or closing of valves. He suggests that municipalities introduce some form of monitoring system that will pick up such problems soon after they occur.

The monitoring and maintenance of the zones is a continuous process and should always be part of any overall pressure management strategy. Unfortunately, despite being the key to any successful pressure management installation, sorting out the zones is often tedious and thankless work that attracts little attention.

The common factor Various models are available for cost-benefit analyses, which can help to determine whether pressure management is likely to be viable in a specific situation. These will also help identify which form of pressure control is likely to provide the best return on investment. McKenzie points out that selecting the form of pressure control to use will often be decided by both the costbenefit analysis and the preferences of the reticulation managers, who must be comfortable in and capable of implementing the chosen solution. “The common factor in every system is the fact that leakage is driven by pressure; if the pressure is increased, the leakage will also increase. If the water pressure in a system can be reduced, even for a short period during times of low demand, the water leakage from the system will be reduced,” says McKenzie. However, he stresses that while pressure management will lower the rate at which new leaks develop and, in many cases, the incidence of new bursts, existing leaks in the system will remain and should ultimately be addressed. That being said, pressure management will usually provide very attractive payback on the initial investment, and the financial benefits of prolonging the life of the system through reducing bursts should always be considered. Delaying the necessity of large-scale pipe replacement through some form of pressure management can result in huge savings to the municipality, as pipe replacement is often the most expensive water loss intervention and should be the option of last resort. *McKenzie, R. Guidelines for Reducing Water Losses in South African Municipalities Report TT 595/14 to the Water Research Commission, ISBN 978-1-4312-0565-3, August 2014

41% of municipal water does not generate revenue

35% of municipal water is lost through leakage

1 660 million m³ Municipalities lose ≈1 660 million m³ per year through NRW

R9.9 billion NRW amounts to R9.9 billion annually (at a unit cost of R6/m³)

IMIESA September 2020

WATER & WASTEWATER

Water restrictions loom for Gauteng

FOR MORE INFORMATION ON HOW TO BECOME WATER WISE, VISIT: facebook.com/WaterWiseRSA

As the county’s dam levels continue to decline in many areas, Rand Water has warned that it plans to curb water demand from August 2020 until January 2021. This means that it is essential that water users start implementing water-wise principles in their homes, gardens and offices.

ouseholds, businesses and industries in Gauteng and surrounds are being urged to reduce water consumption as Rand Water moves to impose various levels of restrictions on its bulk supply meters in agreement with municipal customers. This comes as the Vaal Dam level continues its steep fall, plummeting to levels unseen since the beginning of 2017, when large parts of the country were in the grip of a devastating drought. While the overall level of the Integrated Vaal River System remains stable, present levels hover at around 60%. This is influenced by the levels of both the Mohale and Katse dams in Lesotho, which sit at around 6% and 27% respectively (at the time of writing).

Water restrictions Rand Water has issued notices to municipalities that restrictions will likely be imposed until January 2021. It intends to keep water consumption within the licence target level, which requires an overall reduction of 8% by municipalities. The City of Ekurhuleni has already urged consumers to ensure that no water goes to waste and that efforts to reuse water are applied and rainwater harvested where possible. However, it is hoped that dam levels will rise as the country’s inland provinces move into the summer rainfall season.

IMIESA September 2020

twitter.com/water_wise www.waterwise.co.za/site/home.html

Use water wisely Through its Water Wise brand, Rand Water continues to urge consumers to use water wisely and sparingly. Most water systems in South Africa are already at the point of overutilisation. Current predictions are that the demand for water, at current use rates, will outstrip supply by 2030. Only through changing behaviour and attitudes can this be addressed. Rand Water encourages households to use its Water Wise calculator (calculator. waterwise.co.za:92) to identify areas of high water use in order to implement savings. Users are also urged to regularly read their water meters and perform leak tests to help save both water and money. All water users – from bulk customers to business, the hospitality industry, local authorities and individual households – are encouraged to: Protect the environment by removing invasive alien plants, conser ving rivers and wetlands, curbing deteriorating water quality, controlling erosion, protecting ecosystems, conser ving water and mitigating the effects of climate change. Apply sustainable development principles by following a ‘catchmentto-tap’ approach in managing water quality. Explore alternative sources of water, such as rainwater and stormwater harvesting, underground sources of water,

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and the reuse of household greywater or treated wastewater; however, water should always be used sparingly, no matter the source. Design and maintain landscapes according to Water Wise principles, such as using endemic, water-wise plants and creating low-water-use urban gardens. Support responsible urban agriculture and food gardens by applying organic/permaculture practices in combination with Water Wise principles where possible. This helps produce food using minimal water. Design irrigation systems according to Water Wise principles and include water-saving technologies such as rain shut-off and automated irrigation systems. Address leaks, install water-efficient systems and encourage efficient water-use habits. Install water meters on all water take-off points and monitor water use regularly, as any spikes in water use could point to a leak.

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WATER & WASTEWATER

Certified water meters provide higher levels of trust In a bid to better assess and manage water losses in the country, the Water Research Commission is exploring the development of a water meter performance database for South Africa. Danielle Petterson speaks to Siphokazi Jozana, mechanical certification manager at the South African Bureau of Standards, about the role of product certification and the SABS Mark Scheme.

ll water meters, whether manufactured in or imported into South Africa, fall under jurisdiction of the Legal Metrology Act (No. 9 of 2014) and are governed by compulsory standards set by the National Regulator for Compulsory Specifications (NRCS). In line with this, the NRCS requires ‘type testing’ on all water meters. This involves the examination and testing of water meters to ensure that they meet the legal, technical and accuracy requirements with regard to the relevant specifications, after which the equipment will be issued with a Type Approval Certificate. While type approval is mandatory and aims to ensure the credibility of water measurements related to a prescribed device, product certification, in turn, is an entirely voluntary process.

“The water industry and consumers need to understand the difference between ‘type approval’ and ‘product certification’ in order to help them make informed purchasing decisions. While product certification remains a voluntary process, there are major commercial advantages to having the product certified by a reputable and accredited testing house, such as the SABS, and consideration should be made for making this a mandatory process,” says Jozana. Product certification provides consumers with a quality assurance that the products they are using have been independently tested, verified and certified. This provides a guarantee that the product meets quality standards and that its performance will be maintained. Jozana adds that the SABS test is conducted over a three-year period and includes yearly audits of the manufacturing facility. Type testing is only required every 10 years.

Challenges and recommendations The SABS recently conducted a controlled factfinding investigation with several metros and municipalities around some of the challenges in the water metering space. The results showed that many of the challenges faced by the municipalities include political, economic, social, technological and environmental external forces. Notably, the installation of water meters is often conducted by junior and unskilled local workers who have not had adequate installation training. Furthermore, various water meters have differing nominal bore sizes and there are challenges to find laboratories with the capacity to test these various bore sizes. Currently, challenges remain with bore sizes larger than 30 mm. The price of the SABS testing is also sometimes considered too expensive.

“We need further investigations into what the challenges are, and a greater collaboration between industry stakeholders, the SABS, the NRCS, and the Department of Trade Industry and Competition. We need to go back to the drawing board in an effort to address these challenges and the gaps in the testing space,” says Jozana. Jozana proposes that municipalities consider making product certification mandatory in their procurement process and enforce compliance to the relevant national standards regarding water meters. Manufacturers should also understand that they can acquire both type approval from NRCS and the SABS Mark for product specification – one does not depend on the other. For years, the SABS has been offering both product certification and installation compliance certificates to customers. The SABS has developed a checklist for installers of water meters to ensure compliance with regulation and includes the following segments: • SANS 1529-1:2019 – Water meters for cold potable water Part 1: Metrological characteristics of mechanical water meters of nominal bore not exceeding 100 mm. • SANS 1529-9:2019 – Water meters for cold potable water Part 9: Requirements for electronic indicators used with mechanical water meters, electronic water meters and electronic prepayment water measuring systems. • Water supply and drainage for buildings Part 1: Water supply installations for buildings. The SABS says that it is ready to collaborate with role players and would like to see wider participation in the SABS technical committees process to help resolve challenges and ensure best practice and compliance in the future.

IMIESA August 2020

TRENCHLESS TECHNOLOGY

Customers demand effective service delivery at the lowest cost. Johann Wessels, consulting engineer and former SASTT president, believes it is important for municipalities to understand the capabilities of the available trenchless techniques for pipeline and sewer condition assessment and rehabilitation in order to achieve this. By Danielle Petterson

A look inside your pipes

outh Africa sometimes finds itself faced with overflowing sewers due to a lack of capacity and stormwater ingress. However, the overall situation is made worse by the poor physical condition of the pipe network, fat build-up, tree root infiltration, including extreme axial root intrusion, which can cause blockages and cavities. This makes condition assessment vital to ensure that pipelines and sewer networks are maintained and rehabilitated as needed to ensure optimal service delivery.

Pipe network inspections CCTV inspections aim to provide visual coverage of 100% of the pipe network under inspection. Wessels believes that, with repetitions and contract incentives, coverage of >90% is

achievable. Flow analysis, maintenance and stormwater transgression data, as well as any complaints for the public or ward councillors must also be considered alongside CCTV inspections. CCTV footage should be used to grade any incidents (problems or defects) detected in the pipe. This includes the incident value, severity value and structural graded value. These incidents and values should all be plotted on a grading plan (as shown in Figure 1). Pipes with a grading weight of over 600 – that means more than 10 grading points per metre over an average of 60 m – should be prioritised for rehabilitation or replacement. A sewer rehabilitation summary plan can be compiled for the overall control of the rehabilitation of the sewer network.

FIGURE 1 Example of a grading plan with six different cases

IMIESA September 2020

Figure 2 shows such a plan, where the red indicates where CCTV and cleaning has been done and green means rehabilitation has been conducted. The bars on each suburb indicate GIS length (black), CCTV done (blue), replacement/rehabilitation still to be done (yellow), and replacement/rehabilitation completed (white). At the end of the contract period, blockages before, during and after the contract should be plotted in order to control the effectiveness of the selection and the quality of the contractor’s work.

Outfall sewer assessment Wessels highlights that the cost of outfall sewer failure is huge, presenting a very high risk. “Condition assessment and prioritisation on outfall sewers is even more important than on networks, but the technology is different,” he explains. Here, multisensor inspections using laser above the water line and sonar below the water line, augmented by a digital camera, are conducted. Most of the time, a floater containing all three is used, but numerous equipment options are available depending on the diameter and condition of the sewer during inspection. For example, if the pipe is close to or completely surcharged at the time of inspection, submersible floaters containing only the sonar equipment can be used. If the water levels are low, a trawler with only the laser and digital camera can be used. The laser, sonar and digital camera take continuous readings. Together, this equipment provides a 3D view of the pipeline, making it easier to identify abnormalities such as protrusions and corrosion.

TRENCHLESS TECHNOLOGY

determined with digital CCTV, which can be manipulated from various angles to present a recognisable picture. “Importantly, the remaining useful life of the sewer should be monitored using the inspection data and the as-built drawings, so that rehabilitation can be planned in good time. The budget for major rehabilitation can therefore be determined and scheduled,” explains Wessels.

Trenchless pipe rehabilitation

FIGURE 2 Example of a sewer rehabilitation summary plan

Having digital CCTV to augment the sonar and laser observations offers many benefits. Certain incidents can be hard to identify with sonar or laser but can be very accurately

Wessels advocates for the use of trenchless technology for pipeline and sewer rehabilitation and replacement because of the many benefits it offers. “Studies have found that open excavation can cost up to seven times as much as trenchless replacement. And that does not even include the cost of blockage removal and the disruption open trenching causes,” he points out.

There are several trenchless rehabilitation methods available, including: - pipe bursting - cured-in-place (CIPP) relining - segmented slip lining - close-fit slip lining - spirally wound lining - localised point repair - flood grouting. The choice of method will depend on a variety of factors. However, Wessels cautions that there is a window of opportunity for replacing pipelines and sewers using trenchless methods. If left too long, the pipeline might collapse, forcing the use of open excavation, likely at far greater cost.

Examples of sonar/laser equipment for outfall sewer assessment

TRENCHLESS TECHNOLOGY

TRENCHLESS EQUIPMENT DEMAND KEEPS GROWING Upgrading ageing infrastructure and the installation of high-speed fibre solutions throughout the country has dramatically increased the requirement for all types of trenchless technologies.

ith its extensive Southern African footprint and world-leading plant, ELB Equipment is at the forefront of supplying the contractors who are responsible for the installation of these utilities. Whether the requirement is to drill servitudes underneath the span of a major highway, send a small piercing tool below a residential driveway or undertake major pipe replacement projects without disrupting surface activities, the equipment distributor has it all. Keith Smith, national sales manager: Ditch Witch, ELB Equipment, says the company has the technical expertise to assist municipalities and contractors to find viable trenchless solutions for infrastructure delivery headaches. With operations across the region, even the smallest and most remote municipalities should have access and support nearby.

Safe option “Trenchless technologies represent the safest and easiest means of placing utilities such

IMIESA September 2020

as water, electricity and data infrastructure in urban areas, especially where blueprints are inaccurate, in sensitive areas or where high volumes of surface traffic are encountered,” Smith explains. “The popularity of our trenchless equipment in recent times is due to the rapidly growing demand in our major centres, but also demand from contractors in outlying areas where our branch and dealer network gives us the unique ability to service clients countrywide and across borders. In addition, our field service technicians are on the ground and provide coverage for most regions to ensure proper support for our equipment,” he continues. Commonly purchased equipment includes Ditch Witch’s range of Hammerhead piercing tools, or moles as they are referred to in the industry, which are commonly used in fibre installations. They are also increasingly being used to minimise disruptions in the installation of electricity and water infrastructure. These tools are mainly used under roads, driveways and other obstacles and range from 50 mm to 145 mm in diameter. Models with reciprocating heads and no moving parts are becoming the tools of choice due to their efficiency and reliability.

Precise work “Similarly, among larger contractors, horizontal directional drills are fast becoming a mainstay for larger-scale applications where drills like our powerful Ditch Witch JT 10 and 20 are being used to drill under obstacles, whether it be a large road, building, dam or river. The ability to guide the drilling head around other buried infrastructure is also invaluable when installing utilities such as gas, electricity, telecommunications, water or any other requirement,” says Smith. He adds that ageing water and sewage infrastructure at many of our municipalities has also given rise to the popularity of another trenchless tool in the form of pipe-bursting equipment. The Hammerhead range is already extensively used in most municipalities, where it is used to simultaneously burst ageing pipes and pull new HDPE piping in behind it. The Hammerhead range is easily able to deal with steel, clay, concrete, asbestos and other pipe material types with the addition of different fittings. Both static and pneumatic models are available depending on individual contractor requirements. Ground-penetrating radar and locators from Subsite Electronics, as well as other equipment to assist trenchless contractors, are also available.

FACILITIES MANAGEMENT

State hospitals benefit from FM

raditionally, hospitals used to operate with their own in-house facilities management (FM) or maintenance teams. Progressive hospitals, however, are changing this approach by outsourcing this service. “The stakes and expectations are high for public hospitals who have to comply with legislation such as government’s Immovable Asset Management Act (No. 19 of 2007) and the Public Finance Management Act (No. 1 of 1999), which regulate the management of state assets,” says Lydia Hendricks, business development director of the AFMS Group and its subsidiary FM Solutions.

In 2014, FM Solutions assisted the Eastern Cape Department of Health with condition audits, provided maintenance solutions and introduced SMME development initiatives at 343 of its provincial medical facilities. Recently, FM Solutions formed a joint venture company, Lentegeur Facilities Management Solutions, specifically for the on-site management of certain FM services at the Lentegeur Psychiatric Hospital and Western Cape Rehabilitation Centre situated in Mitchells Plain, Cape Town. In addition, FM Solutions took over the management of certain facilities at the Hospital of Hope – the temporary hospital constructed at the CTICC.

It was believed to be the largest Covid-19 field hospital in Africa. Because transparency and accountability are vital, FM Solutions uses state-of-the-art technology to track and manage expenditure, prolong asset life and ensure overall efficiency. “The turnaround time for repairs is reduced and the entire management process on the ground just becomes much smoother and quicker. I believe the future for hospitals in our country shines brightly and that public hospitals will be able to dispel the stigma of being rundown and ineffectively run if they accept the helping hand that is offered to them,” Hendricks concludes.

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GEOSYNTHETICS

Combating ground contamination with 4IR Geosynthetics are the key to sustainability, with 4IR (Four th Industrial Revolution) developments spearheading a revolutionar y shift in how environmentally engineered projects are designed and executed, says specialist contractor GAST. Covid-19 has been an influencing factor.

roduce, consume, discard and repeat. This has been humans’ pattern since the dawn of time. We have become more sophisticated in what we produce and how we consume it. But the discarding, fundamentally, remains unchanged, with tonnes of waste often ending up in landfills or water sources. Whether it is in dams, mines or landfills, without the proper measures and

tools in place, our actions risk contaminating the planet. As Africa’s oldest and largest geosynthetic installer, GAST understands how effective and efficient having the correct geosynthetics service provider can be. This has been GAST’s niche since 1961 and the company has constantly installed an array of quality geosynthetics to meet the requirements of varying terrains and project needs. GAST not only supplies but installs numerous geosynthetic products. These include geomembranes, which have the primary function of preventing the migration of contaminated leachate to surrounding soil in landfills, tailings storage facilities, coal stockyards, pollution control dams, and/or return water dams. Another core area is geotextiles, which play an integral role in various construction and civil applications due to their versatility and robustness. GAST also provides a range of other geosynthetic-related products and services.

As Africa’s oldest and largest geosynthetics installer, GAST understands how effective and efficient having the correct geosynthetics service provider can be

Leading through innovation GAST has always been synonymous with innovation and progressive methods, stemming back to the 1980s when the company patented the first ‘dam’ linings, perfected through GAST’s ingenuity, which made the ‘plasticisation’ of soil possible for the first time in the world. GAST is always adapting to the changing landscape, innovating not only to meet the needs of the industry, but to consistently deliver quality products and services to its clients. It is believed that the geosynthetic industry is experiencing a 4IR boom, with entities across the globe adapting sophisticated equipment and tools to push innovation and improve quality. GAST is seen as a leader and pioneer in its 4IR endeavours, currently developing fully automated deployment machines that utilise state-of-the-art Artificial Intelligence (AI) and other deep learning AI technologies to provide a more cost-effective and higherquality service to its clients. Kevin Gast, CEO and President of GAST Global, states, “Globally, we have seen a tremendous shift in geosynthetics over the last two years and Covid-19 has exacerbated the need for more innovative and cost-effective solutions, forcing geosynthetics installers and manufacturers to find 4IR-driven technologies.” “GAST has recently appointed a new Chief Technology Officer and is at the forefront of autonomy and AI within the industry,” he explains. “Our clients come first and utilising technology provides them with a cheaper, higher-quality and safer product.” GAST has completed over 13 000 projects, boasts accreditation from the United Nations and World Bank, and is seen as a world leader in geosynthetics. A proven track record for project excellence confirms this.

IMIESA September 2020

GEOMATICS

Drone aerial mapping presents new geospatial possibilities Accurate data collection and precision mapping will always be among the core skills required for sur veyors. However, the rapid rise in drone technology is reshaping the geomatics profession in new and exciting ways. Rather than being pure data providers, sur veyors are transitioning to become intelligence gatherers and exper t information analysts. By Chris Kirchhoff*

ver the last 10 years, the ability to create accurate 3D representations of the earth’s surface using unmanned aerial vehicles has gone from being a sought-after, but occasionally used, speciality to a standard tool integrated into nearly all work processes. Photogrammetry and lidar data collection and processing capabilities, combined with big data analytics and machine learning, have so improved in efficacy and cost-efficiencies that the concept of a 3D digital twin is the expected norm. The global unmanned aerial vehicle (UAV) market is forecast to grow from the current US$17 billion (R284 billion) to

IMIESA September 2020

$40.6 billion (R677 billion) by 2028. There is not a single industr y that does not believe that the integration of UAVs and their use in geospatial data collection will play an increasingly important role in optimising work practices. We can now debate more realistically about the viability of human-free functionality, automation and advanced artificial intelligence (AI). We can envisage a not-too-distant future where drones are in the air constantly, scanning construction sites, inspecting the work and using the data collected to predict and solve problems before they arise. In turn, earthmoving and allied plant operate remotely. But, of course, it’s not actually humanfree – it’s just our roles that are changing from doing to managing. As I continually chide my children when they fall behind with their schoolwork: “Do you want to work for a robot, or do you want robots working for you?” This question has the same bearing for the geospatial and land surveying community. We must grow from being the collectors of spatial information to the interpreters, the analysers and the providers of actionable location intelligence. Within this context, the drone is an invaluable tool that takes us on this new journey.

Time for change We don’t have a spreadsheet department, we don’t have typing pools anymore… so, why do we have a UAV mapping department? Why do we describe ourselves as mapmakers when we should be calling ourselves

location-based intelligence analysts, given the massive advances in software and hardware? To loosely quote Adam Carnow, if we describe ourselves purely as drone pilots and map-makers, then the response will be, “Thanks. When I need a map, I’ll get back to you.”

Reality capture To further emphasise why this change of mindset from tool operator to data analyst is so important, it’s important to consider the significance of reality capture and location intelligence. (Location intelligence being defined as the capacity to convert the spatial component of business data into business understandings and visions.) Jürgen Mayer, president: Reality Capture Division of Hexagon Geosystems, suggests, “Rapid changes in technology and computing power are affecting almost every aspect of our lives – from democratisation and information access to communication and how we visualise the world around us. As technology becomes smaller, more affordable, and more automated, 3D reality capture is becoming more accessible to a wide range of applications and everyday users – not just specialists.” He suggests that the reasons for this include the fact that: - 3D reality capture solutions form the bridge to transform the real world into mirrored digital realities that can be used for all kinds of applications. - 3D reality capture enables you to replicate the physical world and turn it into a virtual

GEOMATICS

environment, using software to derive valuable and useful information, such as in building construction, where users can monitor the progress of a project and quickly compare as-built to design-intent models, ensuring quality control and highlighting any issues. - 3D reality capture provides a rich documentation data set so that users can always go back to the site in a digital environment and check asbuilt documentation. Sometimes, the site might not be available anymore, as in the case of a crime scene or car collision. Here, 3D reality capture enables investigators to capture the evidence and clear scenes quickly. Furthermore, these digital environments can be used to test scenarios and create simulations for training purposes. - 3D reality capture is a key enabler in digitising business processes across all kinds of industries, putting data to work to boost efficiency and productivity. As BIM (building information modelling) processes are more widely adopted, they will heavily rely on an up-to-date 3D model that people can work on collaboratively. - 3D reality capture improves workflows and operations. People working on complex projects benefit from one single 3D model that can be visualised to make decisions from remote places, bringing work functions closer together to improve workflows. - 3D reality capture can be integrated with other new technologies, such as virtual and augmented reality.

point where the future described above is the new normal. This is thanks to crucial software and hardware advances. The mainstream software available today greatly improves our processing power and analytical capabilities, as the quality and size of data files steadily increase. Cloud developments further improve information sharing over secure networks. Other advances include the use of web-based visualisation tools to analyse and interpret data through machine learning and AI.

UAV developments: software and hardware

Trilateration improvements

If I were asked to summarise the advances in UAV aerial mapping techniques, my answer would be that we have reached a

VTOL One of the major drone breakthroughs is vertical take-off and landing (VTOL). The ability of combining the efficiency and safety of vertical take-off, as used by multirotor drones, with the flight efficiencies of fixedwing drones makes a huge difference in terms of aerial data collection. The major drawbacks of fixed-wing drones are that they either need to be ‘thrown’ into the air or catapulted using a mechanical launch platform. Their ‘belly flop’ landing style also increases the chances of mechanical failure, camera damage, and shortened operating life. The major drawback to multicopter drones is that flying operations are inherently inefficient. Flight times and resultant mapping areas are therefore considerably reduced. However, by combining the ability to take off and land in a vertical configuration, and then flip into a horizontal flying mode, the VTOL drone overcomes all the above inefficiencies.

Traditionally, drones have used onboard GPS receivers that utilise the C/A code on the L1 carrier of the GPS signal structure. Based on this, the receiver calculates its position

by trilateration – measuring the distances to four more satellites and establishing the unique intersection of the resultant spheres. Due to atmospheric variations, the accuracy is between 7 m and 20 m. This is sufficient to create a photo mosaic and establish where the photographs were taken. Then, based on mapping techniques and pixel recognition, an orthophoto map is created. If we add ground control points to the processing, we can then mathematically ‘stretch and fit’ the pixels into a real-world representation with an accurate geospatial aspect. Traditionally, sur veys have used GPS receivers capable of monitoring both the L1 and L2 frequency. The errors resulting from satellite perturbations, ionosphere and troposphere modelling can be removed by comparing the wavelength of variations in these two frequencies in the trilateration process. The resultant accuracies are in the order of 20 mm to 30 mm. The big advance in drone mapping is that the UAV can now carr y L1 and L2 frequency receivers. This data can either be used in real-time or post-processing mode to accurately, within 30 mm, calculate the position from which each photograph was taken. When this is combined with dronemounted inertial measurement instrumentation, we can now solve the problems of calculating the camera position when GPS signals are not available, such as inside buildings or in mines. Thanks to these advances in technology, the tools of the geospatial trade are transporting us into a new world of realtime data proficiency and analysis that goes way beyond ‘making maps’.

*Chris Kirchhoff is a professional land sur veyor (PLS0962) at 5DGEO Professional Land Sur veyors. For more information, email chris@5dgeo.co.za.

IMIESA September 2020

SOCIAL & AFFORDABLE HOUSING

A new addition to Joburg’s inner city The refurbishment of Union Square, a 19-storey block at 80 Plein Street in the heart of Johannesburg’s original CBD, is well under way and scheduled for completion in the last quarter of 2020.

he project is being completed by Raubex Building, part of the Raubex Group’s infrastructure division, for the Johannesburg Social Housing Company (Joshco). While the ground floor at street level will be used as retail space, each floor from level 1 to 19 accommodates 18 residential units. These include 19 m2 bachelor flats, 35 m2 one-bedroom units, 43 m2 two-bedroom units measuring, and 94 m2 four-room communal cluster units. There are three basements for parking.

Renovation innovation Load-bearing

considerations

led

the

selection of the lightweight Imison walling system, achieving a significant weight reduction compared to bricks and mortar. The system is applied as a series of interlocking wall panels made from high-quality Neopor insulating material. A total of 15 500 m2 of Imison panels were used, along with 32 600 m2 of Fibrecote plaster. Some 33 000 ℓ of the specialised BASF MasterEmaco S 5410 CI – a fibre-reinforced structural repair mortar with active corrosion inhibition – was used in the repair of the building’s concrete façade. For safe façade refurbishment, scaffolding for the full height of the building had to be engineered and installed. In addition to being

Our REALITY CAPTURE DIVISION are experts in combining imagery & LIDAR from DRONE & ground-based systems to produce high-resolution datasets for large-scale infrastructure projects

surveys@geoafrika.co.za

Scaffolding the full height of the building had to be engineered and installed

tied into the building, the 350 t of scaffolding also had to be back-propped into the basements to accommodate its weight. Netting was also installed to eliminate the risk of any falling materials. There were several of these businesses from Johannesburg’s Ward 59 involved, as part of Raubex Building’s local participation programme, and this included PC Builders, a 30% QSE partner on this project.

SOCIAL & AFFORDABLE HOUSING

Kigali’s city vision unfolds The vision to develop Rwanda’s capital city into a centre of urban excellence is one step closer to reality following the City Council’s approval of an updated master plan.

ubbed ‘Kigali Yacu!’ meaning ‘Our Kigali!’, the Kigali Master Plan 2050 Vision will guide the rollout of a more equitable, flexible and incremental approach to city development, aligned with the UN-Habitat principles and the UN Sustainable Development Goals. The vision is to accommodate 3.8 million residents and provide 1.8 million jobs by 2050. Surbana Jurong and its member company SMEC worked together to update the city’s master plans, which incorporate key initiatives that include: • promoting mixed-use, affordable development with access to social infrastructure and facilities for all • promoting compact development for live-workplay in one place, with efficient use of land and infrastructure • introducing inclusionary zoning to upgrade unplanned settlements • introducing an incremental development model based on resource availability and requirements • integrating climate and disaster resiliency

into the planning and design of buildings, infrastructure and urban services • facilitating development of a transit-oriented city with more sustainable transport modes, such as mass public transport and nonmotorised transport • facilitating market access by small and microenterprises, thereby promoting the creation of more formal jobs. Various teams from across SMEC South Africa’s functions are involved in providing input to the city’s master plans. These include, but are not limited to, planning and traffic engineering, urban development and water supply. “Kigali Yacu is a multidisciplinary, collaborative initiative that is integral to Kigali’s future. Leveraging our understanding of the local needs and our experience with earlier master plans, we worked closely with the city and engaged the community in developing the vision of Kigali 2.0 towards what will essentially be a centre for innovative and inclusive living in Africa,” says Wong Heang Fine, group CEO, Surbana Jurong. Surbana Jurong and SMEC co-developed a methodology to update the previous Kigali master plan adopted in 2013.

Extensive community engagement Kigali’s residents were engaged through 16 focus groups, stakeholder meetings, plus codesign workshops. Comments from government officials and the public were incorporated into the review. “We supported the participatory process with a wide variety of communication channels, including meetings, planning displays, public announcements, social media and virtual messaging platforms to engage as many Rwandans as possible in the feedback and input process,” says Gabriella Robba, public engagement expert, SMEC. Surbana Jurong and SMEC also undertook additional socio-economic and demographic studies, which gathered new primary and secondary data to support the modelling for a city-wide transport plan. Adds Benon Rukundo, acting director: One Stop Centre, City of Kigali, “The revised Kigali master plan is a key milestone for a rapidly evolving city in a country that is experiencing significant change in social and economic dynamics. Our key objective is to develop a citizen-centred master plan that provides the City of Kigali with a solid base for future urbanisation. We are excited for the plan to be implemented.”

IMIESA September 2020

SOCIAL & AFFORDABLE HOUSING

The Department of Human Settlements, Water and Sanitation is readying itself to anchor human settlements as the biggest catalyst for reinvigorating the South African economy after the pandemic.

outh Africa’s housing backlog sits at an estimated at 2.6 million. Minister of Human Settlements, Water and Sanitation Lindiwe Sisulu believes that this, together with the Covid-19 pandemic, necessitates calls to redouble efforts and be bold and innovative in implementing the policies and decisions. “Our solutions must address persistent challenges that impede our delivery of human settlements in a way that spatially transforms our society and provides security of tenure on a broad level, and that ensures our people are living in safe and healthy environments, as we continue to battle to overcome the Covid-19 pandemic,” Sisulu said during the debate on the Human Settlements Budget Vote earlier this year.

Positive progress Sisulu reported that the National Housing Finance Corporation (NHFC) had exceeded targets set for the Finance Linked Individual Subsidy Programme (Flisp), which supports bank finance to first-time home buyers.

IMIESA September 2020

BANKING ON HOUSING developed more than 1 100 new settlements and neighbourhoods.

Bank support

Minister Lindiwe Sisulu

The new NHFC now has the benefit of a larger balance sheet to ensure the rapid mobilisation of capital and is currently involved in a funding mobilisation plan to raise the nearly R4 billion in debt finance from the private sector and other development finance institutions. “The potential for human settlements programmes to act as both a construction stimulus and economic lever should be noted,” said Sisulu. “Employing a combination of innovative and alternative construction technologies that are much quicker and more cost-effective than the conventional brick and mortar, the Housing Development Agency has implemented over 8 000 units in the major metropolitan areas of the country, with more still in the pipeline. This is part of our contribution to alleviate the impact of Covid-19 on our poor communities” With the budget allocated to human settlements last year, over 69 600 new houses and more than 51 000 serviced stands have been delivered, which, in the process,

Notably, Sisulu announced that the operating business model for the Human Settlements Development Bank (HSDB) has been approved by National Treasury. The HSDB is expected to become the preeminent development finance institution in human settlements and is expected to play the lead role in the financing of activities across the human settlements value chain. The department has also started a process of engagement with the Banking Association South Africa to strengthen partnerships within the banking sector. The banking sector has reportedly thrown support behind Flisp, as well as the Zenzeleni programme, which seeks to allow for more qualifying families to build their own homes. According to Sisulu, the banks will develop a new regime of building bonds for low-income earners. “With this programme, we aim to deliver billions of rand in home assets over the medium term. The Zenzeleni programme has the potential to deliver wealth of as much as R140 billion into the hands of beneficiaries,” she said.

Department priorities Sisulu noted several priorities for the year ahead, including: • incrementally upgrading over 300 informal settlements and improving living conditions of households • increasing the provision of Emergency Housing Assistance through alternative and affordable building technologies • introducing Covid-19 impact relief measures to enable the sector to survive the serious shocks and constraints brought about by the pandemic • delivering subsidy housing opportunities for serviced stands, houses, and selfbuild options using alternative building technologies • eradicating backlogs in registering title deeds • transforming the property sector as we enter the path of economic revival.

SOCIAL & AFFORDABLE HOUSING

New housing opportunities for Bellville The Glenhaven Social Housing Project is one of the latest efforts by the City of Cape Town (CoCT) to provide affordable and social housing opportunities on welllocated land that brings low-income households closer to economic opportunities and facilitates spatial and social integration.

he Glenhaven project comprises 512 social housing opportunities and 253 gap rental housing units. Located in Bellville, the project is being undertaken in partnership with the nonprofit social housing institution Urban Status Rentals. The CoCT has assisted Urban Status Rentals with all the funding and

Cllr Malusi Booi visits the Glenhaven Social Housing Project

statutory applications to enable the successful delivery of the housing units. The city has injected R67 million into the project for the earthworks and internal civil engineering services for the provision of water, sanitation and roads, electricity reticulation, street lighting and the units themselves. “Urban Status Rental has been successful in delivering good quality units that provide great value to tenants within constrained financial resources,” says Cllr Malusi Booi, MMC for Human Settlements, CoCT. Construction on the gap rental housing units was completed in February 2019 and these units are already tenanted. The CoCT’s gap housing market is made up of households that earn between R3 501 and R22 000 per month and do not qualify for a full housing subsidy. The completion of the social housing units, which was scheduled for April 2020, was delayed due to Covid-19 and the consequent national lockdown. After beginning construction in 2018, these units are expected to be tenanted by the end of this year.

A broader vision Glenhaven is one of 28 social housing projects located in urban centres across the metro in either the planning or construction phase currently under way by the CoCT and its partners. To date, five

social housing projects comprising over 2 000 units have been completed. In addition to state-subsidised Breaking New Ground projects, the city is increasingly focusing on affordable rental options, enhanced backyarder services provision and the upgrading of informal settlements. The CoCT “continues to assess city-owned land, including suitable land in and near the Cape Town CBD and other urban centres across the metro, to determine whether some of these properties could be developed for affordable housing opportunities,” says Booi. He adds that the city has been careful to manage expectations, as transforming the spatial patterns of Cape Town, as is the case across South Africa, will not happen overnight. “The housing economy is a complex sphere that must be approached with a focus on partnerships and innovation, while dealing with great demand and historical legacies of injustice and inequality,” Booi elaborates. “The city is committed to reversing the legacy of apartheid spatial planning by enabling the creation of affordable and inclusionary housing on well-located land close to public transport and job opportunities. This is part of the focus of enabling opportunities for a wide range of income groupings to respond to the increased demands of urbanisation, which is not a city government mandate alone.”

IMIESA September 2020

BUILDING SYSTEMS

Light, strong and sustainable Alternative building technologies (ABT) are becoming increasingly popular as fast and costcompetitive alternatives to conventional materials like brick and concrete. When it comes to durability and sustainability, light steel frame buildings (LSFBs) compete on an equal footing, says Mitchell Walker, director, Futurecon. By Alastair Currie

he Eiffel Tower, erected in 1889, measures 324 m in height and is composed of hot rolled wrought iron sections. It stands today as a classic example of the endless possibilities of constructing in steel and was a front runner for a host of classic buildings. These include the 102-storey Empire State Building, completed in 1931. Like many icons of its day, its heavy-duty structural steel frame enabled skyscrapers to reach unprecedented heights. At the other end of the scale, the development of far lighter and stronger cold rolled steels over the past decades have presented a host of new opportunities for residential, commercial and industrial developments, challenging other mediums as the construction material of choice. These LSFBs can be singleor multi-storey structures, with their designs in South Africa governed by the SANS 517 building code. Formed using structural trusses and walls made from cold formed thin gauge steel sections, their internal and external walls can be clad in a range of materials, including gypsum, timber and aluminium sheeting. LSFBs are faster to construct than conventional brick-and-mortar-type buildings. Since they are significantly lighter, LSFBs also An LSFB design schematic: schools, hospitals, libraries and commercial offices are just some of the possibilities

IMIESA September 2020

in steel

Before and after perspectives of a warehouse and office block development constructed using LSFB techniques

have less complex geotechnical requirements in terms of foundations. Futurecon uses 0.8 mm and 1 mm gauge steel as standard, with the option of using 1.2 mm and 1.4 mm thick sections. “Depending on the design requirements, building plans may be modular, or purpose built for each application,” says Walker. “Within the modular space, for example, we’ve recently developed a new product line under the ‘A warehouse in a box’ brand, which enables us to manufacture, replicate and supply LSFBs to customers worldwide. A warehouse building of approximately 1 200 m2 – essentially four walls and a roof – can be dispatched in a single shipping container.” Within the industrial market, recent completed projects include a 2 000 m2 warehouse with 1 000 m2 office block development for a client in Johannesburg. Meanwhile, in Cape Town, Futurecon is currently working on a renovation project, where the scope of works entails the supply of a 2 000 m2 roof plus 1 300 m2 of wall cladding for an existing building.

Unsupported spans Within the commercial and industrial space, LSFBs compete favourably with steel portal frame structures, typically composed of more robust horizontal beams or trusses that will need some measure of piling. Portal frames are designed with interspersed vertical I-beam columns to support the roof span. Being lighter, the roof load bearing capacity of LSFB systems allows for impressive unsupported spans of up to 48 m. Roofs can be assembled in complete sections on the ground and then lifted and positioned by crane. As a further plus, external walls are around 130 mm thick compared to up to 240 mm for brick. Additionally, since the bulk of the components is delivered in sections from the factory, there’s minimal – if any – wastage on-site, which translates into further cost savings. “In all respect, the foundations need to be perfectly level to the last millimetre to achieve flat walls with exact 90-degree corners,” says Walker. As an integrated system, LSFBs provide exceptional thermal efficiency, with Futurecon’s standard walls achieving R values

LSFB methods provide self-build and SMME opportunities in the human settlements sector, where there is a pressing need to address the housing backlog

ranging between 3.2 and 3.7. Insulation is chiefly provided by the woven glass wool filler in the frame cavities, plus the internal and external cladding specified. This greatly reduces the reliance on HVAC systems to regulate seasonal temperatures. Comparable with brick structures, standard external and internal walls have a one hour and a 30 minute fire rating, respectively. Typically, the heat of a fire needs to rise to around 396°C before the steel buckles.

Housing market “Interestingly, in warmer countries like Australia, steel frame homes have been one of the preferred construction methods for generations,” Walker continues. “And we’re starting to see this trend developing locally, including growing demand for high-rise rooftop conversions. “We’ve even filled orders for a few tiny homes – some trailer mounted – and mostly for the leisure market. However, it does underscore the fact that LSFBs are a good option for a broad spectrum of residential developments in South Africa. These include low-cost and affordable housing,” he expands. In more simplified forms, LSFBs are well suited for self-build programmes. Singlestorey homes can subsequently go up a level, as well as expand laterally. The same is true for any conventional property requiring modernisation or renovation, such as schools and hospitals, where the South

African government is placing major emphasis on ABTs to accelerate the roll-out of critical infrastructure. This makes a strong business case for LSFBs. A prime example is a current public hospital project in Gauteng where Futurecon is supplying some 10 000 m2 for a series of buildings.

Rust-proof Extending the life of building assets and lowering maintenance costs is a core concern for any property owner. In this respect, steel goes the distance since the sections are galvanised to prevent rust. The durability of LSFBs has been confirmed via various long-term case studies, including the Southern African Light Steel Frame Building Association’s Rust Report. This includes reference to a school in Cape Town where only minimal traces of rust were detected on screw connections after 10 years. The frames themselves were rust-free. “It’s important to stress here that specifying the correct components for every section is an essential part of ensuring the building’s long-term integrity,” adds Walker. Going forward, the design

Internal and external cladding systems being installed on a housing development

possibilities are endless and Futurecon continues to work with architects and property specialists to develop new model variants, including so-called hybrids. An example is a potential project that has ground-level concrete and basement structures topped by a multi-storey steel frame building, which combines I-beams with LSFB techniques. “Given the strength of steel and its proven durability, it’s an ABT that deserves far greater attention in South Africa,” Walker concludes. Compared to portal steel structures, LSFB designs make provision for larger unsupported roof spans

IMESA

IMESA AFFILIATE MEMBERS PROFESSIONAL AFFILIATES

A Miya Group Company

AECOM siphokuhle.dlamini@aecom.com AFI Consult banie@afri-infra.com lunga@alakeconsulting.com Alake Consulting Engineers ALULA (Pty) Ltd info@alulawater.co.za AQUADAM (Pty) Ltd sales@aquadam.co.za ARRB Systems info@arrbsystemssa.com Asla Construction (Pty) Ltd johanv@asla.co.za 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 mail@boschprojects.co.za Bosch Projects (Pty) Ltd 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 Dlamindlovu Consulting Engineers & Project Managers info@dlami-ndlovu.co.za DPI Plastics Farhana@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering Mark.Shamley@Honeywell.com ERWAT mail@erwat.co.za GIBB marketing@gibb.co.za GIGSA secretary@gigsa.org GLS Consulting nicky@gls.co.za Gorman Rupp Cordeiro@gormanrupp.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 info@edams.co.za Hydro-comp Enterprises I@Consulting info@iaconsulting.co.za Infrachamps Consulting info@infrachamps.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 general@lwt.co.za Lektratek Water 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 Maragela Consulting Engineers admin@maragelaconsulting.co.za Mariswe (Pty) Ltd neshniec@mariswe.com Martin & East gbyron@martin-east.co.za M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za Mhiduve adminpotch@mhiduve.co.za Mogoba Maphuthi & Associates (Pty) Ltd admin@mmaholdings.co.za info@wabatho.co.za Moedi Wa Batho Consulting Engineers (Pty) Ltd Much Asphalt bennie.greyling@muchasphalt.com Mvubu Consulting & Project Managers miranda@mvubu.net NAKO ILISO lyn.adams@nakogroup.com Nyeleti Consulting merasmus@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za amarunga@prociv.co.za Prociv Consulting & Projects Management Rainbow Reservoirs quin@rainbowres.com info@ribicon.co.za Ribicon Consulting Group (Pty) Ltd francisg@rhdv.com Royal HaskoningDHV info@sabita.co.za SABITA mberry@safripol.com SAFRIPOL info@salga.org.za SALGA 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 garths@sivest.co.za SiVEST SA Sizabantu Piping Systems (Pty) Ltd gregl@sizabantupipingsystems.com SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za capetown@smec.com SMEC gen@sobek.co.za Sobek Engineering director@sasst.org.za Southern African Society for Trenchless Technology spc@vinci-construction.com Southern Pipeline Contractors (Pty) Ltd jomar@srk.co.za SRK Consulting 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 VNA info@vnac.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 WRNA washy@wrnyabeze.com WRP ronniem@wrp.co.za WSP Group Africa ansia.meyer@wsp.com Zutari Rashree.Maharaj@Zutari.com

CEMENT & CONCRETE

M2 restoration A night-time view of a section of the M2

aking an increasingly heavy toll over the years, sections of the M2 recently required emergency repairs, partly due to a lack of maintenance and rising traffic volumes. These works were carried out by main contractor Stefanutti Stocks between February and October 2019 on behalf of the Johannesburg Roads Agency. Bordering the Johannesburg CBD, the M2 is an important conduit into and out of the city, as well as a vital link between the N1 and N3 freeways. Four of Sika’s products were used on the span of the road. Sikadur-32 Normal, a bonding agent, was used to bond the new concrete to the old. In turn, Sika MonoTop-412 NFG – the latest addition to the Sika mortar range – was used for road repairs. The product is suitable for restoration work, structural strengthening and for preserving passivity. Sika Ferrogard-903 Plus was applied to the concrete surface as a corrosion inhibitor. As a product that is based on organic compounds, it both delays the start and reduces the rate of corrosion. Finally, SikaTop Seal-107 ZA – a waterproofing, chloride and carbonation protective coating – was used for coating the barriers, finishing off a well-executed renovation.

Refurbishment of bridge sections forming part of the M2 bordering Johannesburg’s CBD

IMIESA September 2020

CEMENT & CONCRETE

Fibres

in the mix

Concrete properties can be altered and improved with the addition of fibres. Bryan Perrie discusses the role of synthetic fibres and their effects on concrete.

here are two basic types of synthetic fibres: stiff macrofibres such as carbon, and micro-fibres such as polypropylene. Generally, synthetic macro-fibres are used to impart improved properties to the hardened concrete, such as flexural strength (much as steel and glass fibres do), while the micro-fibres are generally used to improve crack resistance in plastic concrete. Synthetic fibres are man-made and developed by the petrochemical and textile industries. There are two different physical fibre forms: mono-filament fibres and fibres produced from fibrillated tape. Two different synthetic fibre volumes are generally used in application: low-volume percentage (0.1% to 0.3% by volume) and high-volume percentage (0.4% to 0.8% by volume). Most synthetic fibre applications are at the 0.1% by volume level, which generally do not affect the strength of the concrete.

IMIESA September 2020

Micro-fibres are used to improve crack resistance in plastic concrete (Credit: Chryso SA)

Key types Here are the main types of synthetic fibres used in concrete mixes: Acrylic fibres Acrylic fibres, used to replace asbestos fibre in many fibre-reinforced concrete products, are initially dispersed in a mixture of diluted water and cement. A composite thickness is then built up in layers, through pressure forming and vacuum dewatering. Acrylic

Bryan Perrie, managing director, TCI

fibres are usually added to conventional concrete at low volumes to reduce the effects of plastic-shrinkage cracking. Aramid fibres Aramid fibres are 2.5 times stronger than glass fibres and five times stronger than

When it comes to fabric and composite fibres, South African manufacturers have been extremely innovative in developing new versions of fibre for use with concrete.â&#x20AC;?

CEMENT & CONCRETE

steel fibres per unit mass. However, because of the relatively high cost of these fibres, they have been primarily used as an asbestos cement replacement in certain high-strength applications. Carbon fibres Carbon fibres are substantially more expensive than other fibre types, so their commercial use is limited. Manufactured by carbonising selected organic materials in fibrous forms at high temperatures, and then aligning the resultant graphite crystallites by hot stretching, these fibres can be produced as high modulus or high strength, depending on the material source and extent of hot stretching. Carbon fibres made from petroleum and coal pitch are cheaper than conventional carbon fibres produced from fibrous materials. They have high tensile strength and elasticity, and are not very brittle. However, the economic feasibility of carbon-fibre concrete is still uncertain and the fire-resistance proper ties of carbon fibre composites also need to be evaluated. Nylon fibres Nylon fibresâ&#x20AC;&#x2122; properties are created from the base polymers, addition of different levels of additives, manufacturing conditions and fibre dimensions. Currently, limited types of nylon fibre are marketed for concrete, but they are heat stable,

hydrophilic, relatively inert and resistant to a wide variety of materials. Nylon is particularly effective in imparting impact resistance and flexural toughness, and in sustaining and increasing the load-carrying capacity of concrete. Polyester fibres Polyester fibres are available in monofilament form and belong to the thermoplastic polyester group. They are temperature sensitive and somewhat hydrophobic, and have been used at low contents (0.1% by volume) to control plastic-shrinkage cracking in concrete. Concrete reinforced with polyethylene fibres at contents between 2% and 4% by volume exhibits a linear flexural load deflection behaviour, followed by an apparent transfer of load to the fibres, permitting an increase in load capacity. Polypropylene fibres Polypropylene fibres, first used to reinforce concrete in the 1960s, are made from synthetic hydrocarbon polymer using extrusion processes by hot drawing the material through a die. These fibres are hydrophobic and show poor bonding Concrete reinforced with polyethylene fibres at contents between 2% and 4% by volume exhibits a linear flexural load deflection behaviour, followed by an apparent transfer of load to the fibres, permitting an increase in load capacity

characteristics with cement matrix, a low melting point, high combustibility and a relatively low level of elasticity. Long polypropylene fibres can prove difficult to mix due to their flexibility and tendency to wrap around the leading edges of mixer blades. Mono-filament polypropylene fibres have an inherent weak bond with the cement matrix because of their relatively small specific surface area, while fibrillated polypropylene fibres are slit and expanded into an open network to offer a larger specific surface area with improved bonding. Fabric and composite When it comes to fabric and composite fibres, South African manufacturers have been extremely innovative in developing new versions of fibre for use with concrete. For example, to overcome the bond and elastic modulus problem of polypropylene fibres, one development has been that of a composite of a core fibre (which can be polypropylene or a stiffer material such as acrylic, Kevlar, glass or carbon fibres). This is then given a fluffy coating of polypropylene or cellulose, which can be bonded to the core at intervals to enhance the composite behaviour. These composite strands can be woven into a textile or cut into appropriate lengths for a range of applications, especially thin elements such as permanent forms and decorative cladding units.

For more information, contact The Concrete Institute on +27 (0)011 315 0300, send an email to info@theconcreteinstitute.org.za or download literature on fibres and many other concrete matters at www.theconcreteinstitute.org.za.

IMIESA September 2020

CEMENT & CONCRETE

Technicrete’s DZZ pavers provide a durable surface for Olifantsfontein Fire Station’s forecourt

Pavers take the traffic load

he City of Ekurhuleni’s new Olifantsfontein Fire Station replaces an older facility built in the 1940s and caters for current and future urban expansion in the area. The new station’s forecourt was paved with Technicrete’s Double Zig Zag (DZZ) pavers and Fig 3 kerbs, providing space for five fire trucks, three ambulances and a helipad. “The pavers we required needed to be able to withstand the harsh and frequent traffic load,” explains Zikhona Lukani, site agent,

Pmash Project Management. “We found these elements with Technicrete, who always met delivery scheduling and offered sound technical assistance.” Between February and March 2020, Technicrete supplied 4 400 m2 of grey 80 mm DZZ, 1 807 m2 of grey 60 mm DZZ and 1 000 mm of Fig 3 kerbs to the Olifantsfontein Fire Station project. “It is an economical paver, but still gives the project an impressive forecourt appearance and our Fig 3 kerbs added the finishing

touch,” says Luan van der Berg, sales consultant, Technicrete. Technicrete forms part of the Infrastructure Specialist Group of companies. Technicrete’s DZZ pavers are available in a variety of colour tones and sizes. Due to their durability and longevity, they are well suited for residential, commercial and industrial applications. Examples include petrol station forecourts, factory roads, suburban streets and areas used by forklifts and other yellow metal equipment.

SIKADUR-COMBIFLEX® SG BANDAGE SYSTEM HIGH PERFORMANCE JOINT SEALING SYSTEM Sikadur- Combiflex® SG Bandage is used for expansion, construction and connection joints. The system allows variable and high levels of movement in one or more directions, whilst maintaining a superior quality watertight seal.

Call us for more info: 010 823 5550 www.sika.co.za

CEMENT & CONCRETE

Forming slabs without

steel reinforcement

orking closely with contractor DM Bodenstein Projects & Construction, AfriSam supplied a purpose-designed readymix formulation for the construction of 300 mm thick sur face beds at an industrial development in Spartan, Kempton Park. DM Bodenstein Projects & Construction completed Phase 1 of the project in 2019, which comprised access and security structures. The balance of the work in Phase 2, 3 and 4 comprise the construction of three sur face beds in the storage yard, as well as the installation of fire hydrant lines plus sleeving for all ser vices and paved walkways. The challenge was to design and construct the concrete slabs to cater for forklifts carr ying up to 98.17 t on their front axle. The solution developed was a modified AfriSam Sur facebed mix with the addition of Oxyfibre, supplied by Chr yso Southern Africa. In consultation with the AfriSam Centre of Product Excellence and the technical team from Chr yso Southern Africa, a high dosage rate of 3 kg Oxyfibre per cubic metre of concrete was determined as the optimum application.

“The project specification called for a 40 MPa concrete, 125 mm slump, with a 22.4 mm aggregate. The addition of the Oxyfibre, with a strand length of 40 mm, required careful monitoring of the slump at all times,” says Dewet Bodenstein, director, Bodenstein Projects & Construction.

A thorough mix The high density of fibre in the mix necessitated ver y thorough mixing of the

Placement of fibrereinforced concrete using an AfriSam pump

The project specification called for a 40 MPa concrete, 125 mm slump, with a 22.4 mm aggregate

concrete to ensure that it was evenly dispersed. As AfriSam’s readymix plant in Spartan is less than 2 km from the construction site, the concrete trucks arriving on-site had to stand for another 10 minutes to complete the required mixing time. “Another major advantage of using fibre instead of steel mesh is that the fibre disperses throughout the concrete matrix, facilitating a multidirectional plastic shrinkage cracking reduction matrix,” Bodenstein explains. Seven-day cube results achieved 29 MPa and, with the appropriate curing, the required 40 MPA specified strength at 28 days was achieved.

IMIESA September 2020

VEHICLES & EQUIPMENT

Mobile asphalt quality and automation The quest for lower emissions and fuel burn costs has been a major focus for mobile asphalt equipment OEMs. CIBER Equipamentos Rodoviários has made major breakthroughs in these areas with proprietary innovations that include Total Air® burner technology. By Alastair Currie

ade in Brazil for the world market, CIBER is a Wirtgen Group company that celebrates 62 years of innovation in 2020. Leading from the front since 1958, CIBER pioneered the development of mobile counter flow asphalt plants and today fields the iNOVA series, available in four models. They come equipped with unique technologies that minimise the energy needed to dr y and heat aggregates – a key factor in ensuring a profit or loss in the asphalt business. The first machine to see ser vice in South Africa was the flagship iNOVA 2000 unit, sold to a local asphalt contractor some two and a half years ago. Since then, the iNOVA population in South Africa has steadily gained momentum despite low volume activity in the roads market over the past 24 months. This is largely due to constraints in government spending, combined with procurement bottlenecks; however, that position is changing for the better going into 2021.

“We’re definitely experiencing an increase in enquiries, as more Sanral and related roads department projects start being awarded,” says Waylon Kukard, sales manager, Wirtgen South Africa. “The need to transform the construction sector has also placed greater emphasis on creating opportunities for SMME subcontractors.” The iNOVA 2000 has a production capacity of 150 t/h to 200 t/h, positioning it as a top-tier machine for lead contractors. The next unit down is the iNOVA 1502, capable of producing 75 t/h to 150 t/h. “We believe the iNOVA 1502 is an exceptional choice, since its output capacity is more realistically aligned to the type of volumes experienced in our market,” Kukard continues. “This is especially the case for SMMEs awarded shorter-term work packages, where the emphasis is on delivering quickly and efficiently, and moving on to the next project.” The iNOVA 2000 and 1502 each comprise two separate sections that are joined to form one integrated production

platform. Each section is designed to be hooked up to a truck tractor for road-legal transportation. In contrast, the iNOVA 1500 (75-100 t/h) and 1000 (50-100 t/h) are self-contained units ready to ship out at a moment’s notice. For all plants, the 10 m3 aggregate feed bins are located on the first trailer. Their number can var y from four to five, depending on the customer specification. One will be a split bin (with two 5 m3 compartments) to cater for smallersized aggregates.

Technological edge Fuel efficiency and compliance to exacting environmental standards are distinguishing features of the iNOVA range, underpinned by CIBER’s Total Air closed burner technology. This is a self-generating closed-loop system, which means that air is not drawn in from the surrounding environment. The exact amount of air is produced internally to achieve optimum combustion, which makes the whole process far more fuel efficient. Delivered in two parts, CIBER’s iNOVA 2000 and 1502 units are road legal in Southern Africa

IMIESA September 2020

VEHICLES & EQUIPMENT

Plant assembly in progress in Porto Alegre, Brazil

If the air temperature were to drop below 100°C, moisture could develop on the filter membranes. This would cause clogging and correspondingly reduce filter per formance.

Remote control

“With the iNOVA system, you preset the temperature,” says Kukard. “The plant will then automatically maintain the exact drum speed required as the asphalt material curtain passes through.” Most OEM competitors still use openair burner systems, which are designed to suck in air from the outside. The challenge here is that too much air often gets sucked into the system. The whole process then needs to work harder during the aggregate dr ying process. Based on CIBER field studies, iNOVA plant owners can expect to break even on their investment within a shorter payback period compared to other OEM plants based on a lower fuel cost per tonne. Additionally, accurate dosing plays a key role, given that bitumen is one of the largest cost components in producing

asphalt. Typically, bitumen represents approximately 5% of the mix. CIBER claims an accuracy rate of 4.95% to 5.05%.

Best baghouse In addition to its Total Air technology, CIBER’s baghouse uses purpose-designed pleated filters that take up less space, but greatly increase the filtration sur face area, eradicating close to 100% of harmful gases. Only clean air is released back into the atmosphere. CIBER units also feature a smaller baghouse design compared to competitors, which keeps the overall plant profile as compact as possible. “CIBER’s ability to per fectly maintain air temperature is crucial – not just for combustion optimisation but also for 100% filtration efficiency,” Kukard continues. “These features are unique to CIBER.”

CIBER’s advances in intelligent automation ensure consistent product quality. This is backed by telemetr y systems that constantly monitor and report on system health. Business owners have full remote access via internet-enabled devices. Wirtgen technicians will also receive alerts where unscheduled maintenance inter ventions are required. That frees up the client’s operators to focus on asphalt deliver y, with the peace of mind that the iNOVA system is taking care of product quality control. “It’s a misconception that South Africa’s construction sector needs to shy away from high-tech processes. In fact, the opposite is true, especially when it comes to the proven savings in maintenance, running costs and best-in-class repeatable results. “Buying into the right technology is an invaluable investment, especially when it means contractors can work smarter and sustain their businesses over the longer term,” Kukard concludes.

A graphic representation of a CIBER iNOVA 1502 plant setup feeding asphalt product to an awaiting truck

IMIESA September 2020

VEHICLES & EQUIPMENT

Intelligent excavation The 25.2 t R260LC-9S hydraulic excavator is powered by a Hyundai HM5.9 engine delivering a net power of 121 kW

ompeting in the medium class, the Hyundai R260LC-9S excavator features a patented hydraulic system designed for improved controllability, enhanced efficiencies and smoother operation. A new auto boom and swing priority system provides optimum speed for each application,

while the new auto power boost feature delivers additional power when required. This series also boasts a new arm-in and boomdown flow regeneration system, for improved speed and operating efficiency. The engine and hydraulic horsepower work in unison through an advanced CAPO (computer-aided power optimisation) system.

At the touch of a button, operators can select their own preferences for boom or swing priority, power mode and optional work tools. The CAPO system also provides complete self-diagnostic features and digital gauges for critical information, including hydraulic oil temperature, water temperature and fuel level. The pump compartment encompasses power ful Kawasaki-designed variablevolume in-line axial piston pumps. The new compact solenoid block is equipped with four solenoid valves, an EPPR valve, a checkvalve accumulator and pilot filter to control two-speed travel, power boost, boom priority, and a safety lock. For improved stability, the Hyundai R260LC-9S comes standard with a long undercarriage design equipped with nine rollers on each side of the machine. Durable rail guards keep track links in place, while track adjustment is facilitated by grease-cylinder track adjusters and shockabsorbing springs. This is also a maintenance-friendly machine. Ground-line access to critical filters, lube fittings, fuses, machine computer components and wide-open compartments ensures easy serviceability and maximum uptime.

INDEX TO ADVERTISERS

African Utility Week / PowerGen

Inkulu Plastic Pipes

APE Pumps

KSB Pumps & Valves

BVi Consulting Engineers

Macsteel

20 IFC

SAPPMA

Sika

OBC Sizabantu Piping Systems

GAST South Africa

GeoAfrika Surveys

IMESA

IMIESA September 2020

2, 48

Pexmart Power & Electricity / The Solar Show Rand Water

IBC

OFC 37 4, 32

Technicrete

Umgeni Water

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IMIESA September 2020

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