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CONTENTS On the News Experiment underway to chart ecosystem restoration in the Coega IDZ
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On-Site Essentials Atlas Copco launches the Explorac 100 reverse circulation drilling rig
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EXPERIMENT UNDERWAY TO CHART ECOSYSTEM RESTORATION IN THE COEGA IDZ
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HE Coega Development Corporation (CDC), Uhambiso and WBHO Construction are launching a pioneering environmental experiment as a baseline study in the Industrial Development Zone (IDZ). The first ever Coega IDZ “ecosynthesis experiment” project started this month on a recently downgraded piece of virgin land adjacent to a site in Zone 2 of the Coega IDZ earmarked for Chinese car and truck manufacturer, First Automotive Works' (FAW) new plant, which WBHO is currently constructing.
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The environmental project will run for 12 months, with all costs covered by the Uhambiso/WBHO joint venture (JV). “The area, roughly 500 square meters, will undergo a natural restoration process and essentially we are allowing for the practice of ecosynthesis principles on this land,” said Johann Brink, C D C s a f e t y, h e a l t h a n d environmental project Manager.
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Ecosynthesis is a term used to describe the use of naturally introduced species to fill niches in a disrupted environment, with the aim of increasing the speed of natural ecological restoration. This method decreases the amount of physical damage to a disrupted and degraded landscape. Ecosynthesis is also the process of taking topsoil containing the natural seed bank of endemic plant species of the specific area and spreading it over a degraded area – then allowing “mother nature” to take its course. This deviates from the norm of hydroseeding, or direct human intervention in the rehabilitation process. “Essentially the hydro-seeding is replaced by the natural seed bank contained in the topsoil within that specific area. Thus, the 'import' of topsoil from outside the IDZ is not an option as we want to avoid introducing species not natural to that specific environment and
landscape.” “We will measure the rainfall over a 12 month period as well as germination of the natural seed bank – and then the identification of seedlings that have come up. Basically we want to see what mother nature gets up to so we can measure how to manage environmental support in an industrial zone and analyse how, without human intervention, the ecosystem will regenerate itself,” added Brink. Traditionally industrial areas, and those under construction, are not considered suitable for rehabilitation, for a range of reasons, including cost. However, legislative changes over the past 20 years have paved the way for better environmental rehabilitation methods. “The implication of not rehabilitating around a construction footprint is severely detrimental to the natural environment and ecosystems affecting both visual impact and
plant and animal species, which can possibly be lost,” said Arnie van Jaarsveld, site manager for the WBHO Construction of FAW's site. “We are highly interested in this baseline study as it could form the basis of future WBHO engagements with the environment on construction projects.” Environmental Authorisation for listed activities usually has standard conditions in terms of prescribing rehabilitation in or around the construction footprint. The more recent rehabilitation standards in the construction related environmenta degradation entails hydro-seeding which consists of either a summer or a winter seed mix and adds costs to the construction project. Brink says ecosynthesis – applied in two areas in the IDZ – has been successful at Coega but was never properly monitored, measured and recorded for future reference and application. Thus far these two areas, in Zone
“Both these areas underwent ecosynthesis rehabilitation seven and four years ago respectively which proves that the natural seed bank to that specific area is more resistant to drought and has a low mortality rate despite the lack of rain,” said Brink. The “experiment“ aims to prove amongst other things that with very little human intervention ecosystems in or around degraded areas can return to their original natural vegetated state and thereby heal the holistic ecosystem from being dysfunctional to functional.
“The focus of the ecosynthesis experiment is not on cost saving but rather natural environmental restoration in a holistic manner, restoring the intrinsic value which originally existed in the ecosystem landscape prior to degradation,” added Brink. As with all experiments, there will be a control in place – in the form of a piece of land where human intervention takes place to rehabilitate the land. On-going updates and results will be released by the CDC over the year-long period.
Experiment Underway to Chart Ecosystem Restoration in The Coega Idz
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10 (a construction footprint in the sand dune area) and Zone 5 (a historical degraded area of “borrow pits”) have both yielded positive but untested results.
COEGA DELIVERING ON JOBS PROMISE AND INVESTMENTS
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onstruction boom at Coega as projects under production amount to R1.2-billion, over 2500 jobs created BUILDING projects in the Coega Industrial Development Zone (IDZ) have injected over R1.2billion into the Nelson Mandela Bay construction industry over the past two quarters. Six major construction projects are currently underway in the Coega IDZ including erection of:
? Chinese car and truck manufacturer First Automobile Works' (FAW) plant;
? Famous Brands' cold storage plant;
? DCD Group's wind tower manufacturing plant;
? the addition of Coega Cheese onto the Coega Dairy outfit;
? Agni Steels' R400million smelter facility; and
? Rehau's extension
in the Nelson Mandela Bay Logistics Park (NMBLP).
Industrial gas company, Air Products South Africa, is also about to begin construction of its R300-million state-of-the-art air separation unit in Zone 3 in July, bringing the total number of projects being built to seven. “The global economic climate is still not stable, yet investment continues to flow into the Coega IDZ and is literally taking root in the construction projects underway,” said Ayanda Vilakazi, Coega Development Corporation (CDC) head of marketing and communications. “We currently have 20 operational investors, and
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once these seven construction projects are complete, we will be up to 27 operational investors by mid-2014.” Vilakazi said the activity meant major spinoffs not only for lead contractors, but also subcontractors, suppliers and the whole built environment supply chain: “At a time when there is industry malaise at a national level, the Coega IDZ is experiencing a construction boom to the value of R1.2-billion. “The unaudited results 2012/13 financial year also show that construction jobs in the Coega, IDZ and the NMBLP for April 2012 to March 2013 amount to 1722 and investor jobs created are at about 856 – so just over 2500 jobs created directly through activity in the Coega IDZ,” said Vilakazi, adding that it was through these major investments that the CDC was delivering on its mandate to create jobs. Famous Brands The Famous Brands project is nearest completion and the company was given access to the warehouse portion in the first week of May allowing its service provider to start with racking on the warehouse floor. The warehouse is operational and Famous Brands will move its stock into the cold storage unit on June 10.
SEALING THE DEAL: A worker on site at Chinese car and truck manufacturer First Automobile Works' (FAW) new plant in Zone 2 of the Coega Industrial Development Zone (IDZ).
SOLID FOUNDATIONS: The Famous Brands cold storage unit in Zone 1 of the Coega Industrial Development Zone is almost complete with the company scheduled to take occupation of the building next week.
“Everything is on track, with timeframes tight but on target to be met. The project is still well within original time, cost and quality parameters set – despite loss of a number of days due to inclement weather, mainly wind and rain,” said Bruno Ponzi, CDC senior project manager for infrastructure development. The company – which owns the likes of Steers and Debonairs – was also given access to the
SEALING THE DEAL: A worker on site at Chinese car and truck manufacturer First Automobile Works' (FAW) new plant in Zone 2 of the Coega Industrial Development Zone (IDZ).
ground floor of the office block portion this week, with the balance of the building due for hand over on June 21. Once delivered Famous Brands would become the newest operational tenant in the Coega IDZ. Vilakazi said Famous Brands was a prime example of the short conversion times investors experience from the point of signing a lease with the CDC to full operation. “The turnaround times are much quicker now than they were a couple of years ago and we are able to construct buildings for investors relatively quickly, meaning that they move to operational phase within about a year of signing, depending on this size of the project,” said Vilakazi. “This has implications for investors' bottom dollar as they are able to start production relatively quickly.”
A partnership between Famous Brands and Coega Dairy has also seen the dairy expanding its operations to supply cheese products to the group in a project dubbed 'Coega Cheese' with a joint valued investment of R45million pouring into the Coega IDZ as a result. FAW In addition, says Vilakazi, the construction activity is creating needed jobs on the city, particularly on the FAW site, with t h e R 2 0 0 - m i l l i o n FAW construction project well underway. To date about 304 construction jobs have been created on its site, a number that grows week to week. In total the construction phase will see about 2000 jobs generated over the year-long duration. In the operation phase of the truck assembling plant a
further 280 jobs will also be created. According to Arnie van Jaarsveldt, WBHO Construction Eastern Cape managing director and lead contractor on the FAW project, the highlight of the construction will be its architectural finesse. Van Jaarsveldt said Eastern Cape Architects Studio d'Arc wanted to make a statement with the Chinese automotive giants' building in Zone 2 of the IDZ. “Its prime position on the N2 means it will get heightened attention. FAW management loved Studio d'Arc's unique design on the office and reception area – particularly the exceptional use of concrete, so that's set to be the highlight of the building,” said van Jaarsveldt. “Otherwise, we are working hard
to keep to a strict timetable, and you will see the columns almost completed and some initial top structures going up over the factory portion. With a long way to go, the skeleton is definitely taking shape.” Van Jaarsveldt said construction is on-track for completion end December 2013, adding that there was significant collaboration between the Chinese engineers and their South African counterparts – a coup for skills development and mentorship. AGNI STEELS Agni Steels is also wrapping construction of its R400-million steel plant in Zone 6 of the 11500Ha IDZ. Agni Steels will operate in a high-tech smelting facility to produce mild steel billets from scrap metal. The plant at Coega will use 10 000 tons of scrap metal in phase 1 and 20 000 tons in phase 2.
LOCKING DOWN: A worker on site at the FAW plant in Zone 2 of the Coega industrial development zone.
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DCD GROUP DCD Group is also in the early phases of its R300million wind tower manufacture factory which when completed, is expected to employ 168 workers, and produce between 110 and 120 wind towers annually. “Coega is boldly delivering on our jobs promise through the attraction of investments,” said Vilakazi. “The construction boom is just a taste of things to come. Never before has it been so important to say: watch this space.”
INSIDERS VIEW: A snapshot of the inside of the Agni Steels plant in Zone 11 of the Coega Industrial Development Zone.
COEGA IN NUMBERS Investors
Numbers
Operational
20
Investors under construction
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First Automobile Works (FAW, China), Famous Brands (SA), Coega Cheese (SA), Agni Steels (India), Rehau (Germany) Extension in NMBLP, DCD (SA)
Investors due to start construction [pending construction company appointments in June]
1
Air Products SA
Investors in process of completing an Environmental Impact Assessment
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AfriSam (SA), AMG (China), Casa Steel (SA)
Signed term sheets
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Pipeline information
Comment Coega Concrete Product (Pty) Ltd, Dynamic Commodities (SA), UTI Couriers (SA), Cerebos (SA), MSC, PE Cold Storage (SA), Digistics (SA), Electrawinds, General Motors Part and Accessories Distribution Centre, Cape Concentrates, Universal Wind, Coega Dairy, AP Moeller South Africa, Discovery Holdings Pty Ltd. NMBLP: First tier suppliers: Faurecia (French), Rehau (German), Grupo Antolin (Spain), Benteler (German) and Inergy (French). Logistics: Kuehne and Nagel (Germany) One importer (Hella, Germany) and four SA linked service providers to the automotive sector are also located in the Central Hub of the NMBLP bringing the total tenants to 11 companies.
TBA when lease agreements are signed Projects in negotiation stage are valued at R8,1-billion and those under feasibility account for R116,3-billion.
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COROBRIK SPECIFIED FOR MINE HOUSING IN THE NORTHERN CAPE
Production volumes amongst the two biggest players in the region's mining sector - Assmang and Anglo American – continue to increase at a tremendous speed. To both cater for new employees and respond within the ambit of the revised mining charter published by government in late 2010, both mining giants are in the throes of creating new and upgrading existingaccommodation with a number of housing projects both on the drawing board and under construction. Gary Westwood, Sales Manager for the Free State and Northern Cape region said that Corobrik took pride in being a part of the progress of a sector that was the
greatest contributor to the country's gross domestic product.
three projects, namelyPostdene, Airfield and Boichoko,” he added.
For example, Anglo American's Kumba Iron Ore operation, which is located in Sishen near the town of Kathu, is believed to be one of the seven largest open pit mines in the world. It produced 38,9Mtpa in 2011. “Kumba is currently building 60 mine management houses with our Blue Barley Travertine and Roan Travertine face bricks. A contract for the construction of a further 479 50m2 houses has been awarded to Steffanuti Stocks and is scheduled to begin before year end,” he said.
Quoting the revised Mining Charter of 2010, GaryWestwood pointed out that during the apartheid era, the mining sector was known for the appalling living conditions under which its workers lived, which led to a myriad of social ills including the destruction of the social fabric of communities,substance abuse, as well as the contraction and spread of diseases.
In addition, production at the new Kolomela mine in Posmasburg came on stream in May this year (2012) and is expected to add additional production of 13Mtpa. “This Kolomela mine expansion saw Corobrik delivering some two million Corngold Satins for the building of 400 staff houses. This project has been divided into
“Review in 2009, prior to the amendment of the charter, indicated that many mines were making solid efforts to upgrade housing with many moving away from controversial hostel systems to create quality family homes. To build on this, new policy guidelines have since been put in place to ensure that accommodation was not only consistent with international best practices but also to help facilitate home ownership for all
mine employees by 2014. It is a stipulation that home ownership must be both affordable and sustainable,” he said. He said that, in meeting the objectives of the mining charter, the use of clay brick in housing projects went a long way to provide both affordable and sustainable housing. Very importantly, a clay brick house meets the aspirationalrequirements of the prospective homeowners to live in 'proper' houses and all the dignity associated with that. Miners keen to be housed may consider themselves fortunate that South Africa has not compromised and digressed from its well-entrenched masonry tradition and all the associated benefits that clay brick brings to house construction. “Brick fits all three dimensions of sustainability. At a social level nobody wants the stigma attached to living in a prefabricated box and there is no good reason that they should. Clay brick construction is
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South Africa has the largest known deposits of manganese ore in the world and is the largest producer of iron ore on the continent making mining operations in the arid Northern Cape critical to the national economy and the largest employers in the region.
proven economical as built and its record of performance, its robustness, its durability assures a low lifecycle cost. Add to that, that clay bricks have mineral properties that meet all necessary requirements for Healthy living, that clay bricks release no toxic fumes under both normal and fire conditions to impinge on air quality, that they have natural sound insulation properties to support quiet indoor environments and clay bricks sustainable value emerges in a unique holistic context.” He added that, in light of the fact that the region bordered the Kalahari desert and had some of the most acute temperature fluctuations in the country, the energy efficiency that resulted from the use of clay brick was particularly important. The real benefits of clay brick construction are to be realised in our long hot summer months when the natural thermal properties of clay brick help attenuate the impact of high outdoor temperatures indoors. “The value of thermal mass the clay brick walls provide, slows the
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heat flow to the inside by 6 to 8 hours over the hottest parts of the day, moderating internal conditions and providing target thermal comfort for longer, reducing artificial cooling interventions. Miners won't have the problem of overheating inside so widely associated with insulated lightweight walled Alternate Building Technologies such as Light Steel Frame Building. The use of clay brick in this instance well complements the priority being given to the use of solar power in these projects” he added. Gary Westwood said that one of the most critical housing projects in the Northern Cape – and one of the greatest challenges faced by the mining industry as a whole – was the resettlement of residents to facilitate the expansion of a mine. “Plans are currently being finalised to relocate the entire town of Dingleton situated 12 kilometres south west of Kathu to allow further expansion at the Sishen mine. This will require the building of more than 500
houses as well as schools, police stations and commercial properties.” Assmang owns both manganese and iron ore production facilities in the Northern Cape with their Iron Ore mines being located in Kathu and Posmasburg and their Manganese operations in the towns of Hotazel and Black Rock. “The recent fall in manganese prices has forced them to delay their capital projects in Black Rock and Hotazel. However, we believe these – which include 200 mine houses, a gym, a new guest house and accommodation for 40 students – is expected to go ahead towards the middle of 2013. In Posmasburg, they are currently busy with the construction of some 700 new houses. In Kuruman, 800 houses will be built. The first phase, which comprises 89 units, is expected to start in January 2013. A combination of Nevada Travertine, Nebraska Travertine,
Corngold Satin and Opal Satins has been specified by Assmang for these projects.” “In Kathu, there are plans to build 700 houses. Group 5 is already busy with the construction of 300 houses using our Sapphire Satin, Nevada Travertine, Montana Travertine, Nebraska Travertine and Opal Satin. VHB Developments is also busy with 60 houses which are being built with Sapphire Satin and Corngold Satin. Approximately 200 have already been completed and there are plans to extend the total number of houses to approximately 1000!” He understands that Assmang staff homes would be built by the mine with the intention to sell them onto the workers at subsidised rates. To help facilitate this staff receive a housing allowance of R2500 that can go towards bond repayments whilst they are in Assmang's employ.
BEATING POTHOLES: HOW THE REDP IS CHANGING EC ROADS ONE POTHOLE AT A TIME
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ASTERN Cape residents are no strangers to potholes – but an innovative programme by the Department of Roads and Public Works (DRPW) is set on making potholes in the province a thing of the past. The Road EnterpriseDevelopment Programme (REDP), launched in March 2010, has been rolling out various roads maintenance projects throughout the Eastern Cape, including everything from large scale reseals and bridge-building to potholes and road failure reliefs. “Soon it will be smooth sailing in the Eastern Cape for motorists and commuters. The Eastern Cape's roads have long needed attention and the REDP strategically aims to facilitate meeting these ends, in the process developing emergent and small construction firms to build roads under mentorship of established construction companies and engineers,” said Ayanda Vilakazi, Coega Development Corporation (CDC) head of marketing and communications. The CDC is the implementing agent for the programme. The broader community is also benefiting through better road links to health, education, amenities, food supplies and transport routes. In the past year over 25 685.7 cubic meters of potholes have been fixed throughout the province – either through the process of plugging or base and surface repair. The process of plugging is when a pothole is immediately patched with cold premix. Base and surface repair is when the road layer is removed and a new layer is laid with a new blacktop surface. The areas of concentration have been the Kouga District and the following Eastern Cape roads: R392, R410, R408, R409, R390,
R39, R349, R396; with many more earmarked for repair in the near future. The REDP sees the dual benefit of roads construction in the Eastern Cape and simultaneous training and development of small micro and medium enterprises (SMMEs). The enterprise development programme targets contractors, material suppliers, quarry operators, plant hires, consultants and mechanics on road infrastructure construction and maintenance in the region. “A simple approach to maintenance and infrastructure upgrade is seeing the creation of jobs and facilitation of skills development,” added Vilakazi. According to the CDC, 80% of the total roads construction projects have been awarded to small businesses over the past year. A Queenstown engineer working on the REDP, Lacier Wynne, said potholes were a perennial problem throughout the country and that only a complete overhaul of the roads system would address the problem, but added that the REDP initiative was a step in the right direction as an immediate solution. Participants on the project include engineers, contractors, grasscutters, flag bearers and safety officers. Wynne, who is contracted by M a r k M u c k l e P R Te c h Engineering, says roads are made up of various layers which can be damaged by water and general wear-and-tear causing potholes. “Cracks on the roads appear first and water seeps into the cracks and into the base characteristics of the materials used. These materials then have insufficient strength, and become weak under the wheels of heavy trucks – and that's where you get your potholes, which are quite easily formed.”
HOLE GONE: Workers on the Department of Roads and Public Works' Roads Enterprise Development Programme ensure that the Eastern Cape potholes are plugged or in some cases stripped and completely replaced and relayered.
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The alternative to black tar roads are concrete roads which are more expensive to lay, but last much longer before they require repair. “However, due to high costs, the black tarred roads are used in local communities and on all national roads,” said Wynne. The REDP engineers and construction workers repair potholes throughout the Eastern Cape and in the process document the sites of repair to ensure they are monitored. “When potholes are repaired, the date and time is recorded next to the pothole in visible road markings,” said Vilakazi. “We are essentially data-basing the state of the roads – but this process is not without its challenges. The reality is that while the repair jobs are well done, it is not long before a new pothole appears directly next to the very area that had been repaired. In time the capacitated SMMEs will be used for a complete overhaul of the Eastern Cape roads network, but for now this approach is the immediate solution.” The CDC believes in the power of the programme. “The REDP is an incredibly powerful, high-impact project which needs to be recognised as a pioneering initiative on behalf of government to deliver significant and lifechanging infrastructure to the people of the Eastern Cape and South Africa,” said Vilakazi. “The reality is that the Eastern Cape has many arterial routes which are used by heavy vehicles like trucks and the REDP is moving to mitigate immediate problems while creating a longterm solution in the form of enterprises which are empowered to provide the critical infrastructure needed in the province. This approach ensures delivery and high impact skills development.” The REDP in numbers 2012/13:
HOLE GONE: Workers on the Department of Roads and Public Works' Roads Enterprise Development Programme ensure that the Eastern Cape potholes are plugged or in some cases stripped and completely replaced and relayered.
? Base and Surface Repair: 25
458m3 ? Plugging: 227.7m3
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? Lane Marking: 850kms
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ON-SITE engineering & construction
“IS SA SELLING SUB-STANDARD CEMENT,” SAY’S MANUFACTURERS …
. A sample from an undisclosed manufacturer has been sent to the lab when its plant was found to be in breach of the standards. Though local companies are constantly appealing the regulator to investigate non-compliance with SA quality standards, the regulator believes the accusations are unfounded. It says the incidence of non-compliance of imported cement is between 7 percent and 8 percent. Underweight bags seem to be a bigger problem compared with the general failure rate of between 11 percent and 31 percent for all prepackaged products in SA though local producers remain adamant that standards are being breached . PPC's chief executive Ketso Gordhan says his firm has conducted its own tests and collected evidence of wrongdoing, which it will present to the regulator and also intends to file an antidumping charge against importers . The company has conducted random test on imported cement and a significant percentage of what it has tested is of inferior q u a l i t y, o r t h e b a g s a r e underweight, says Gordhan. Lafarge SA has also indicated that it would consider approaching the International Trade Administration Commission of SA (Itac) to protect the local market from cheap
imports . Imports Cement from countries like Vietnam and Pakistan gained about 6 percent of SA's market by the end of last year, giving established producers such as PPC and Lafarge something to worry about in an environment of already low demand . Imports mostly affect KwaZulu Natal because the biggest volume comes through Durban hence Port Elizabeth and Cape Town also receive small amounts of imported cement, but not enough to affect sales in those regions. . Though complaints from local manufacturers have increased s u b s t a n t i a l l y, t h e r e i s speculation that they are driven by the threat that imports will expose the market dominance of local players. . In the lead-up to the 2010 soccer World Cup, when cement demand soared, local manufacturers imported cement from the same manufacturers they now accuse of flouting local standards. Cement inspections Legal metrology is one of the two divisions of the regulator that conduct cement inspections. The chemicals, mechanical and materials division (CMM) is the other; it conducted 157 inspections between August and December 2012. These include proactive investigations by the division, as well as those
initiated when a complaint is filed. CMM acting inspection manager Rhoda Mbukwane says about five cases of non-compliance were uncovered. These are under further investigation.
sustainable in the long-term. Exchange rates and shipping costs (which are currently low) are volatile. In addition, domestic demand in or near the country of origin will determine the future availability of imports.
In one case, a complaint was lodged about the quality of two brands of cement imported from Vietnam. The case is awaiting a final test report, but the cement was confiscated based on evidence of a breach. The CMM also uncovered a case of non-compliant cement that entered SA through Port Elizabeth. Mbukwane says they are awaiting final test results. One batch of cement imported from India was found to be underweight, and Marneweck says the importer was prevented from selling the batch until the bags were refilled and retested. Another batch from Pakistan was treated similarly therefore, it has also worked with the SA Revenue Service to strengthen its enforcement at the Durban port. Despite the concern of established firms, newcomer Sephaku Cement, which will begin producing at the end of this year, is less pessimistic. Chief executive Pieter Fourie believes the inland region, where Sephaku's first plant is being built, offers good competition. Sephaku won't be as exposed to imports as other manufacturers, he says. He says imports are not
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ocal cement manufacturers maintain that importers are bringing sub-standard and underweight bags of cement into SA; however, the National Regulator for Compulsory Specifications' investigations into the quality of imported cement has revealed that the incidence of noncompliance is too low to be of concern
THE ROLE OF BUILT ENVIRONMENT IN THE INFRASTRUCTURE DELIVERY WITHIN THE AFRICAN CONTINENT
Minister of Public Works,Thulas Nxesi
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The Council for the Built environment (CBE) an entity of the Department of Public Works held its Built Indaba 2013 at Birchwood Hotel, Boksburg, Johannesburg, under the theme: “The Role of built environment professionals in the infrastructure delivery within the African continent”. CBE oversees six professional councils in the country including the architecture, engineering, landscape architecture, project and construction management, property evaluation and quantity surveying. In his address to the members of CBE professional members represented, delegates who included representatives from African countries such as Zambia, Ghana, Uganda, Kenya etc., on infrastructure development, the Minister of Public Works, Minister Thulas Nxesi, highlighted CBE's contribution towards the development of inter-regional understanding, networking and integration with the continent. He further highlighted the government's infrastructure development plans, and there are
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18 Strategic Infrastructure Projects (SIPS) some of which are set to reach our neighbouring countries, for instance SIP 1 deals centered on unlocking the north mineral belt. The Minister also touched on the National Development Plangovernment's long-term strategic vision that is set promote greater trade integration throughout South Africa; and mentioned the Programme for Infrastructure Development in Africa (PIDA) being driven by the African Union, and the Presidential Infrastructure Champions Initiative as some of the programmes that will spearhead growth in Africa. It was further stated that reliance on the west is not an option and Africans should be the drivers of their own destiny. Following is part of the Minister of Public Works, Thulas Nxesi's speech on the role of the built environment professionals. The Role of built environment professionals Turning to the theme of this Indaba- the role of built environment professionalsthere are so many areas- in the construction-that require that we cooperate so that we move forward together. CBE and the professional councils have an important role to play in this- and as the government we must be respective to your needs and ideas so that we create an enabling environment for development and growth to take
ON-SITE engineering & construction
place. Built environment professionals in the continent will be key in driving infrastructure investment through their skills and competence in planning, design, procurement, construction, maintenance and decommissioning of infrastructure. South Africa has 56 075 registered professionals and candidates across the 6 professions and a significant unregistered component. This provides a critical resource and a base to help drive continental infrastructure development. There is a deeper dimension to the built environment and its relation to development. The built environment we create must reflect the cultural, psychological and spiritual aspirations of our people and address their higher order needs of self –actualisation, psychological wellness and spiritual meaning. Our built environment professionals must embedded in the African context to design and build spaces and objects that reverberate with our cultural and spiritual ethos. It cannot be enough to just transplant technical solutions that are devoid of meaning and cultural context. Furthermore, the design of infrastructure needs to be not only fit for purpose, but also it must contribute to sustainable development. The design needs to take account of the anticipated results of climate change,
including increased incidence and severity of storms, floods, droughts, sea level rise, as well as impacts on structures over their life cycle- all of which effects sustainability and the quality of life. We have seen that the services of South African built environment professionals are in high demand for infrastructure projects across the continent. One of our aims must be to support and promote contracting and built environment professional skills and services across the continent. These efforts must also include measures to streamline and align the qualification requirements of the built environment professions across the continent so as to facilitate an easier exchange of built environment professional services. For example, quantity surveyors or engineer who may have qualified in Ghana or Zambia must be able to work on a big infrastructure projects in South Africa or Kenya- without having to go through too much red tape to obtain permits. In his closing remarks the, Minister of Public Works, said the Indaba provides an opportunity to strengthen and deepen the understanding and involvement of African built environment professions and is looking forward to receiving recommendations on potential areas of collaboration for the purposes of improving the continent.
SAFCEC URGES INDUSTRY TO ADOPT A BALANCED APPROACH TO CONSTRUCTION SECTOR FATALITIES
improvements that have been achieved by the industry to date,” comments James Flint, national SHERQ advisor for SAFCEC. When analysing construction related accidents and incidents one should bear in mind that the term “construction”encompasses both the building construction sector and the civil engineering construction sector. To this end, SAFCEC is proud of the emphasis placed on continuous improvement made within the civil engineering sector to ensure Health and Safety is paramount in its operations. SAFCEC continuously assists and guides its members in complying with legislation and good practice. The Federated Employer's Mutual Assurance Company (FEM) statistics indicate a drastic reduction in fatalities within the civil construction sector in the last ten years. It is worth noting that in 2008 with 23 603 employees, the Industry Accident Frequency Rate (IAFR)
established Health and Safety and Human Resources committees,” states Flint. The so-called “big five” contractors, as it is often referred to in mainstream publications, being Murray & Roberts, Group 5, WBHO, Aveng and Steffanuti Stocks – adhere to effective, high quality safety procedures and measures, aligned with International Standards of certification and far exceed the requirements as set out in legislation. SAFCEC would like to emphasise that it has a mutually beneficial relationship with the Department of Labour, which we are maintaining in the interests of occupational health and safety. On 24 August 2012 SAFCEC signed the Construction Health and Safety Accord – an agreement between Government, Organised Labour and Organised Business to improve the status of occupational health and safety in the construction sector. The agreement is proof of the value SAFCEC attaches to collective partnerships to reach a mutually desired outcome – Zero Harm in the construction sector. As an organisation, SAFCEC is also heartened by the growing relationship with key stakeholders such as the major Unions and other employer's organisations. “We believe that we are striving for a common objective and that with mutual help, support and understanding, outstanding levels of occupational health and safety can be reached in the South African construction industry,” Flint concludes.
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NEWS
JOHANNESBURG – The South African Federation of Civil Engineering Contractors (SAFCEC) appeals toGovernment, Unions, members of the media and industry players, to develop a fair, objective approach when evaluating and analysing safety statistics in the construction industry. SAFCEC and its member organisations wish to express its dedicated support to an uncompromised commitment to safety excellence in the construction sector and a zero tolerance approach to any injuries on site. SAFCEC would like to express its concern with recent media exposure and public debates providing a one-sided, unfair portrayal of the industry's safety performance and achievements. “Although we acknowledge the critical need for a continuous and persistent improvement in the industry's overall safety record – staying true to our commitment of Zero Harm – SAFCEC would like to emphasise the good work and
stood at 5.29. This has continuously declined and this year with 24 410 workers employed by the industry, the IAFR stands at 2.81. In the past, SAFCEC has, in partnership with FEM, made great strides in addressing the issues related to occupational health and safety in the civil engineering industry. SAFCEC has also committed to support various Industry launched initiatives such as Buildsafe South Africa, which is an industry lead initiative to try and improve health and safety within the sector. Furthermore SAFCEC has represented its members in the development, signing and commitment to the Construction Sector health and safety Accord. This Accord is the proof of SAFCEC's commitment to addressing health and safety within its sector in the context of a tripartite collaboration between Organised Business, Organised Labour and Government. To this avail, SAFCEC has a fully-fledged Safety, Health, Environmental, Risk and Quality department, staffed with qualified SHERQ professionals as part of its structure. Amongst other activities, the national SHERQ department and regional branches present or facilitate regular training sessions and workshops to improve skills, awareness and understanding. “Our members' levels of compliance are monitored by means of inspections and audits. Our member companies are actively involved in these activities by means of
ATLAS COPCO INTRODUCES COMPACT COMPRESSOR TECHNOLOGY WITH BREAKTHROUGH ENERGY-EFFICIENCY
Atlas Copco surprised the market with the launch of a new, very compact oil-injected rotary screw compressor range, the 737 GA VSD + , at Hannover Messe, in April 2013.
Essentials & Products
“Atlas Copco translated the most requested needs of our customers in this new type of compressor which include better performances, with less energy consumed, low noise levels and a compact footprint,” says Atlas Copco South Africa's Business Line Manager - Industrial Air, Charl Ackerman. In addition to a small footprint, the range offers a leap forward in Free Air Delivery with improvements of up to 12% and offers a breakthrough energyefficiency as it requires on average 50% less energy than a comparable idling compressor. This new type of compressor is available with a variable speed (frequency-controlled) which
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makes it ideally suitable for most industries. The GA VSD+ variable speed drive compressor, available from 7 to 37 kW, achieves better performances even at full load, than a comparable idling compressor. Koen Lauwers, Vice-President Marketing from the Industrial Air Division comments: “In 1994, Atlas Copco pioneered the Variable Speed Drive compressor and now we have launched an innovation that will once again set the benchmark in the compressor industry. The GA VSD+ has been completely inhouse developed and brings together all our expertise and know-how about energy-efficient compressor technology”. “The new type of compressor aims to contribute significantly to the green economy needs,” comments Ackerman and adds that this innovation will enable all
ON-SITE engineering & construction
compressor users to switch over to variable speed drive compressors, “an important step towards a more sustainable industry. ” According to Ackerman, Atlas Copco evaluated every part in this compressor: A more efficient fan, a robust air intake system, the elimination of all blow-off losses, and the best electronic components together with the new drive train, add up to energy savings of 50% on average compared to a traditional idling compressor of the same type. The new GA VSD+ is another 15% more efficient than Atlas Copco's current Variable Speed Drive compressor (the GA 7-37 VSD). A full feature version with an integrated dryer is optional. Several key components, including the drive train as well as components for the general design of the GA VSD+, are protected by Atlas Copco, with many patents on their way.
In addition to adapting its products, Atlas Copco has also adapted its production environment to the future: The GA VSD+ is currently built in Antwerp, Belgium, on a production line that is more efficient, more standardised and that takes less space. Regular maintenance and service by skilled technicians using the right tools and genuine parts are essential for ensuring optimum and reliable compressor performance and sustainable p r o d u c t i v i t y. A t l a s C o p c o Compressor Technique South Africa's four service branches in Johannesburg, Durban, Cape Town and Port Elizabeth, supported by ten authorised distributors, take care of customers' requirements across the country offering turnkey service solutions across the complete Compressor Technique product portfolio.
ATLAS COPCO'S INTRODUCES REVERSE CIRCULATION KIT FOR THE DM45 AND DML MID-RANGE BLASTHOLE DRILLS
A number of components are included with the optional kit, which can also be retrofitted on drills currently in the field. The cyclone arm allows for sampling from the ground or platform level, with a vertical raise and lowering function. A cyclone rotation of 160 degrees provides safe access for cleaning, maintenance, and attaching new sample hoses from ground level. The cyclone is a heavy duty system designed specifically with flexibility in mind. Some of the features of the cyclone assembly are: a hydraulic upper knife valve and pneumatic
lower knife valve for collecting and isolating the sample; a hydraulic hinge between the dump box and cone splitter that allows for easy cleaning; a fixed cone splitter with primary and duplicate sample chutes. All cyclone and sample functions are all easily controlled from the operator's cab. A 66 liter dump box, with a steep cone for limiting sample hang up is part of the sample collection feature. The primary and duplicate ports can easily be adjusted from 4-15%. The Reverse Circulation Carousel has four 4.5 inch rod cups and offers a 145 foot (44 meter) maximum on-board capacity.
head air swivel, and a fully integrated sample hose management system that has been designed with safety and practicality in mind. The DM45 and DML reverse circulation drills offer hole diameters ranging between 4 ½ inch – 5 ¾ inches (114 mm – 146 mm) with maximum hole depths of 145 feet (44 meters) based off on-board capacity.
Some other components included with the RC kit are a blast box/discharge, a blowdown valve that offers internal valving that does not require any external three-way valving or unnecessary hosing above or around the rotation head, an above head dual swivel that eliminates the need for a below
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Essentials & Products
Atlas Copco continues to expand its blasthole product offering with the addition of the reverse circulation (RC) kit for the DM45/50 mid-range blasthole drill. Based off proven systems, components, and technology the RC kit is designed to meet the demands of today's expanding mining market by offering the added dimension of in-pit grade control.
ATLAS COPCO LAUNCHES THE EXPLORAC 100 REVERSE CIRCULATION DRILLING RIG
Atlas Copco's new Explorac 100 is a reverse circulation drilling rig designed specifically for exploration drilling to depths of 100–200 meters. It combines a compact and robust design with the power necessary for fast collection of quality samples
Essentials & Products
The new reverse circulation rig is designed specifically for reverse circulation drilling and other downthe-hole drilling (DTH) applications. It is suitable for exploration drilling to depths of 100–200 meters and has a lifting capacity of 10.5 tons Reverse circulation is gaining ground as a preferred technology to collect quality samples in initial exploration, ore body development and in-pit grade control due to its cost efficiency and fast collection of dry, quality samples.
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“The launch of Explorac 100 is a firm response to increasing demand for personal safety and environmental care. It offers the efficiency and performance required by contractors, such as fast setup and drilling speeds, easy maintenance, reduced noise levels and minimum oil spillage, and enables the collection of high-quality samples requested by geologists,” says Martin Sommers, Vice President Marketing – Capital Equipment at Atlas Copco Geotechnical Drilling and Exploration division. “Following the launch earlier this spring of the Explorac 235 for mediumdepth drilling, this launch confirms our position in the reverse circulation segment”. The Explorac 100 is based on well-proven technology. It has a
ON-SITE engineering & construction
rugged and compact design, which makes it easy to move around even in rough terrain. Yet drillers will enjoy the power necessary to get more quality samples out of the ground faster. Atlas Copco can provide a complete solution for reverse circulation drilling, including drilling rig, compressor, booster and drill string. Highlighted features ? Rod handling as standard, including a 30-pipe rack ? A mechanized breakout table with two spanners ? The operator's panel is strategically placed on a tripod or carried on the operator's shoulder ? Low noise level for improved safety and work environment ? Tier III, Cummins power pack, 82 kW, ensuring
fuel efficient operations ? Hydraulic tank of cyclone type with 30 % oil volume compared to conventional tanks, reducing the rig's carbon footprint. For further information please contact: Graham Martin, General Manager – Atlas Copco Exploration Products Africa Tel: +27 (0)11 608 -1741 Fax: +27 (0)11 252 - 6999 Graham.martin@za.atlascopco.com
The new reverse circulation rig is designed specifically for reverse circulation drilling and other down-the-hole drilling (DTH) applications.
ATLAS COPCO LAUNCHES FIVE NEW UNDERGROUND PRODUCTS AT BAUMA IN MUNICH
COP 4038 Atlas Copco's new Boomer Eseries can be equipped with the strongest and fastest rock drill on the market, the new COP 4038. It's
20–30% faster than the nearest contender and optimized for hard rock conditions. The COP 4038 comes with a COP Care Pro service agreement that s a f e g u a r d s r e l i a b i l i t y, availability, and sustainable productivity. The COP 4038 is a super-fast 40 kW rock drill for 43–64 mm drifter holes. It utilizes Atlas Copco's high-frequency technology together with an efficient double damping system to absorb reflex shock waves – making it possible to drill exceptionally fast without increasing wear on the drill steel. COP 1800+ series The COP 1800+ series provides the same great performance as its predecessor, the standard COP 1800-series. However, the COP 1800+ series extends recommended service intervals by 50%. This provides great savings for your operation with increased equipment availability, and less time and money spent
on maintenance. It also means a reduction in costs associated with parts and safety risks posed while maintaining the machinery. The COP 1800+ series promotes environmental sustainability through reduced parts consumption. New Rig Control System During system development, Atlas Copco focused on creating an intuitive and easy-to-use operator system. All functions have been grouped in nine blocks under a new tree structure for easy navigation within the system. Together with the new touch screen display, operation is streamlined and training time is reduced for new operators. Göran Manell, Site Manager Rock Excavation NCC, says: “The new Boomer with its updated Rig Control System has as much better interface and a more user-friendly screen. It's
much faster for operators to work with than its predecessor. Göran adds, - “the new RHS Rod Handling System, has given us a big advantage. Everything works much smoother and we have a much safer working environment.” The new rig control system also includes two, new multifunctional joysticks with primary functions for drilling grouped in the top of the joystick. These highly functional joysticks allow the operator to focus on drilling instead of searching for functions on the keyboard or display. Underground Manager All over the world, demands for documentation and follow-up are on the rise. This prompted Atlas Copco to create its new Underground Manager, taking planning and evaluation to a higher level. The Underground Manager provides excellent support for all Atlas Copco underground machines. The user
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Essentials & Products
Atlas Copco is launching five new products for underground construction and mining applications at the Bauma 2013 exhibition. The new series of Boomer E rigs for underground face drilling features the new COP 4038, the fastest and most powerful rock drill on the market and also on display is the new COP 1800+ series. The new Boomer E-series also features a new Rig Control System and a new version of Atlas Copco´s advanced Underground Manager System with improved user interface that takes planning and evaluation to the next level in performance and efficiency. Last but not least, a new Dry Drilling System, providing totally water-free face drilling!
interface is new, modern, and easy to use. The system contains a new drill plan generator, complete 3D view of the tunnel, smart interpolation of contours, and an improved log and report function.
Essentials & Products
Dry drilling system A new dry drilling system is now available on the Boomer XE3 C. For the first time, Atlas Copco is able to deliver a three-boom face drilling rig that is totally water-free. The system uses compressed air for keeping the hole free from cuttings and a suction nozzle
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around the drill string to eliminate dust. The suction hose then returns the dust to a filter unit and a sealed container for simple dust logistics. The dry drilling system is ideal for projects where water is scarce or where it's not possible to use water due to rock conditions or surrounding temperatures. Comfortable and environmenta Operator comfort, safety, and environmental care are also in the spotlight. For example, all FOPS certified cabins are air-
ON-SITE engineering & construction
conditioned and ergonomically designed with the latest operator seat and controls. Atlas Copco knows that comfortable operators are efficient and productive operators. The large 3- and 4-boom rigs offer new operator chair that are more ergonomic and functional for the operator. Carbon emissions have also been reduced to a minimum. Diesel engines take care of tramming, but once on site‌electricity takes over for drilling. Stage 3B/Tier4i diesel engines are standard on the rig
and biodegradable hydraulic oils are available as well. Boomer rigs can be equipped with up to four booms providing a coverage area of 16–208 m2, and the most extensive range of high performance rock drills on the market (16-40 kW) designed to tackle all rock types and drilling conditions. All new products are available to order via Atlas Copco's worldwide sales organization and can of course outfit a rig with the features you need for all your mining applications as well.
P
an Mixers South Africa (PMSA) - the largest supplier of concrete, brick, block and paving making machinery and technology in Africa - is officially opening its cutting-edge showroom, following 18 months of tireless and dedicated work. The two-storey 700 m2 showroom - which will also house a sales and marketing office and training facility in order to fully highlight the endless creative possibilities that concrete offers in modern day construction - will officially open to the general public in April 2013. PMSA sales and marketing manager Quintin Booysen believes that the company is setting a trend in the local industry through the construction of the entire building which is, in itself, the most fundamental aspect of the showroom. "The modern, minimalistic and aestheticallypleasing building is constructed
almost entirely out of concrete, and in so doing, dispels the common misconception that concrete is a cold, grey and ugly material suited mostly for industrial purposes." The showroom flooring is completed with HTC Superfloor, which is an easy-to-maintain polished concrete flooring system that provides the highest shine to the floor surface, by making use of a range of HTC floor grinding machines and accessories. Booysen notes that PMSA has gone one step further by using HTC Superfloor to polish a number of concrete pullup structural concrete walling panels, which make up the showroom walls and main reception staircase. “A polishing and grinding machine weighs up to 300 kg and would be impossible to run against a wall. Another option
would be to use a hand-held grinding tool, however that would not ensure a precision finish. PMSA improvised by polishing the precast concrete panels using the HTC Superfloor system, before pulling them up by making use of a tilt-up method,” he continues. These panels are being used both for structural and display purposes to highlight the potential beauty of precast concrete, by simply polishing or adding colour aggregates to it. Booysen adds: “Our main objective is to show architects, engineers and contractors that a polished precast panel can serve as a stylish and modern finish in a home, office or shopping environment while being a structural element.” In addition to being aestheticallypleasing, Booysen points out that the PMSA showroom is also environmentally-friendly and
requires minimal maintenance and energy in its daily usage. "Polished concrete provides further benefits that include ease of cleaning due to a smooth surface, and a reduction in lighting bills, due to the fact that the panels reflect more light into the building." According to Booysen, concrete flooring can have a lower installation and lifetime cost, when compared to traditional products such as epoxy flooring and tiling. "What's more, the entire building is fitted with acoustic and thermal insulation ceiling to ensure that the structure is kept cool in the summer and warm in the winter, thereby further reducing energy costs and unnecessary energy wastage." Booysen adds that the showroom will also play a major role in highlighting the capabilities of PMSA's full range of quality concrete equipment and associated technology, as well as the technical support and after
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Essentials & Products
PMSA OFFICIALLY OPENS ITS INNOVATIVE CONCRETE SHOWROOM
sales service capabilities of the company as a whole. "Customers will also be provided with a value added service offering as they have the opportunity to touch and feel what is on offer, in addition to being able to directly interact with our various sales engineers, who are each specialists in their specific product lines," he continues. "By having all divisions centralised in one location, we can ensure that we provide a comprehensive customer service offering onsite, where clients and their employees will be trained in various fields, ranging from the application and usage of products, to operator safety and machine maintenance."
Essentials & Products
The concept of the showroom was first dreamt up by PMSA management in mid-2010, with construction beginning approximately one year later. "A lot
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of thought and effort was put into the concept of the showroom before construction began. Using a limited budget, we have created a magnificent structure that has been well and truly worth all of the effort that everybody has put in. Having finally achieved our goal, I am confident that we will inspire various contractors, engineers and architects to make more efficient use of coloured, decorative and polished concrete in the future," Booysen PMSA Contact Quintin Booysen PMSA Marketing and Sales Manager Phone: (011) 578 8700 Email:quintin@panmixers.co.za Web: www.pmsa.com
ON-SITE engineering & construction
105 CORLETT DRIVE; AN EYECATCHING OFFICE BUILDING Professional Team Architects
Paragon Architects
Structural Engineers
Sotiralis Consulting
Quantity Surveyors
Schoombie Hartman
Electrical engineering
Aftek Consulting Engineers
Wet Services Consultant
Ramsden Consulting
Mechanical Engineer
Adaptive Resource Engineering
Fire Protection Consultants Trevor Williams Consulting Engineers Baseline Project Management
Town Planner
Gavin Edwards
Landscape Architect
Insite Landscape Architects
Main Contractor
Tiber Bonvec Construction
Photography: Michelle Venter
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Projects
Project Managers
Photography: Michelle Venter
A
prominent A -Grade office building recently completed on Corlett Drive and overlooking the M1 highway, derived its conceptual design from a number of sources including its location and context, the choice of materials and the accommodation requirements and is characterised by wrapped gable-ended form floating above a two storey concrete podium.
Projects
The building comprises three levels of basement parking, a ground floor with a landscaped podium at highway level and three pods which are used for reception and waiting area, separate training room and a separate office upper ground with a mezzanine in one of the pods First and second floors house office space and the roof top cones provide an entertainment area and executive dining facility.
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The structure is designed to simulate the look of jewelry box supported on three glittering conical forms covered in reflective Caïman metal cladding with slot windows to highlight verticality of the cone forms. Computer software was used to generate a taut collection of forms that challenges traditionalexpressions of materials like concrete and glass and steel cladding. Generous landscaping on the podium softens the structure for the occupants. With a high visibility for passing motorists on the elevated freeway, the unique structure acts as a landmark. Carla Soudien project architect from Paragon Architects says, “The design is based on a glazed box which appears to float, supported by three conical forms
ON-SITE engineering & construction
clad in Caïman, supplied by Arcelor Mittal. On the north and south elevations, a reflective laminated Solarshield S30 has been specified and on east and west elevations a tinted Eclipse Grey Advantage glass has been specified as well. Ivan Lin assisted with glass specification and sound insulation. Steel columns clad in a layer of galvanized sheeting which form the weather line and the final layer of Caïman cladding on a special sub structure made up of 'omega Rails', which form a gap between cladding layers for ventilation. Steel structure workshopped between, 3D model of steel structure submitted by the steel subcontractor, overlaid onto the Revit model for co-ordination
and then approved (process of designing structure and approving shop drawings cut short to ensure information could reach site faster) - challenging to co-ordinate this process between steel, cladding and glazingsubcontractors, with each junction being unique because of the unusual forms. 3D technology played a large role in enabling the design to be co-ordinated and workshopped between the engineer, architect and steelwork sub-contractor. The interface between steel structure, cladding and glazing installation proved to be challenging due to the unique and unusual forms created.