IMIESA September 2015 by 3S Media

www.infrastructurene.ws

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

MERCEDES-BENZ TRUCKS INDUSTRY

INSIGHT ROB REIN, PPC Cementing industry innovation

Driving the sustainable mobility movement

ECSA

Upholding the engineering profession

Rural Road Asset Management A foundation for service delivery improvement

Municipal Focus Unlocking the power of wastewater

IN THE HOT SEAT “As a leading supplier of hydraulic machines (pumps and turbines), we are proficient in the technology needed for power stations, water supply facilities, and for pulp and paper mills.” Molefe Seth Phalatse Chairman: RITZ Pumps South Africa ISSN 0257 1978

V o l u m e 4 0 N o . 9 • S e p t e m b e r 2 0 1 5 • R 5 0 . 0 0 ( i n c l . VAT )

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CONTENTS www.infrastruc

turene.ws

IMESA The officia l magaz ine of the Institu te of Munici pal Engine ering rn Africa Southe of

INFRASTRUCTURE

MAIN DEVELOPMENT •

TENANCE • SERVI

CE DELIVERY

-BENZ TRUCKS MERCEDESthe sustainable Driving ent mobility movem

INDUSTRY

T INSIGH , PPC ROB REIN try Cementing indus innovation

VOLUME 40 NO. 9 SEPTEMBER 2015

Rob Rein, sales and marketing executive at PPC, speaks to IMIESA about PPC’s pivotal role in the industry. P18

PIPES Park Station sewer upgrade

INDUSTRY INSIGHT Regulars

ECSA

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

Upholding the engineering profession

Rural Road t Asset Managemen ce A foundation for servi nt delivery improveme

Municipal Focus Unlocking the powe of wastewater

IN THE HOT SEA

es), we are nes (pumps and turbin facilities, er of hydraulic machi “As a leading suppli stations, water supply logy needed for power Pumps South Africa proficient in the techno se Chairman: RITZ Molefe Seth Phalat 0 mills.” paper 2015 • R50.0 and 9 • September and for pulp olume 40 No. 8 ISSN 0257 197

Roads 3 5 8 96

Cover Story ( i n c l . VAT )

From the company’s earliest days, the development of fundamental technologies for particularly efficient, environmentally compatible vehicles has been a recurring theme in the history of the Mercedes-Benz brand. P6

Mercedes-Benz Trucks – Driving the sustainable mobility movement

Municipal Feature Unlocking the power of wastewater 10

Hot Seat Ritz Pumps – Pump it up

Professional Development Upholding the engineering profession

Industry Insight PPC – Cementing industry innovation 18

Pipes & Pipelines

HOT SEAT In this month’s Hot Seat, Molefe Seth Phalatse, chairman of RITZ Pumps South Africa, shows how this small company – with only eight employees – is able to maximise its resources to create value and supply high-quality pumps. P14

ROADS Leave it to Lafarge

The future for plastic pipes Gaining ground in Africa Park Station sewer upgrade Divisional Hot Seat: In the trenches Dynamic new flow transmitter with 3D flow profile from NIVUS Small industry, massive impact Asset management at the click of a button Significant milestone for Western Aqueduct Phase 2 NuWater's African expansion continues Sustainable solutions for a greener future

23 24 26 30 32 33 38 40

Rural road asset management Leave it to Lafarge

Bauma Conexpo Africa 2015 African opportunities Showcasing a full offering Extreme hoisting 101 Diverse applications for a diverse audience Off-road fleet acquisitions Quarrying industry to push for autonomy A multilingual approach to concrete education Quality concrete at reduced operating costs Emoyeni Mall on stable ground Celebrating one year of industry innovation Hydro cutting for improved road surfaces Creating learning possibilities Energy efficiency – More than an R-value

57 59 61 65 67 69 70 73 74 76 77 78 81

Human Settlements First Sibaya land parcels released

SHEQ Drugs in the workplace Caution: Health and safety under construction

CESA Aon Engineering Excellence Awards

Celebrating engineering excellence

Technology & Innovations

South African infrastructure competition goes international

BAUMA | VEHICLES & EQUIPMENT Extreme hoisting 101

49 55

87 89

BAUMA | CEMENT & CONCRETE Emoyeni Mall on stable ground

EDITOR’S COMMENT

Change, technology, and elections – IMESA 2015

PUBLISHER Elizabeth Shorten EDITOR & ASSOCIATE PUBLISHER Nicholas McDiarmid SENIOR JOURNALIST Beatrix Knopjes JOURNALISTS Liesl Frankson, Frances Ringwood HEAD OF DESIGN Beren Bauermeister DESIGNER Ramon Chinian CHIEF SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter CONTRIBUTORS Siva Chetty, Rob Dyer, Rhys Evans, Albie Hanekom, Priska Myburgh, Henk Oosterdijk CLIENT SERVICES & PRODUCTION MANAGER Antois-Leigh Botma PRODUCTION COORDINATOR Jacqueline Modise FINANCIAL MANAGER Andrew Lobban MARKETING & DIGITAL MANAGER Esther Le Roux MARKETING SPECIALIST Philip Rosenberg ADMINISTRATION Tonya Hebenton DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za PRINTERS United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________

ITH ONLY A month to go to the IMESA 2015 Conference, being held in Cape Town from 28 to 30 October, the many voices and dynamics of the people, institutions, and organisations involved in public infrastructure come to mind. And, this year, I have definitely heard a common thread; when obstacles endure, change becomes necessary – and that change begins at home. The theme of this year’s conference is ‘Changing the face of the Municipal Engineer’; to quote IMESA: “With all the challenges facing our industry today – whether economic, social, environmental, or political – we need to adapt and be innovative. This starts with the local authorities, where most of us perform some function to serve our communities. But it goes beyond the government corridors – it stretches into the ideas and solutions created by each engineer in South Africa.” IMESA conferences are always landmark events, and they continue to be the gathering point for all stakeholders with a vested interest. I have observed, especially while attending other industry conferences, a great interest from companies who previously have not seen themselves as stakeholders. Notably, the role of the municipal engineer in utility services seems to be gaining attention; companies providing technology solutions for asset management, energy management, as well as those who facilitate those technologies, are seeing the value and market potential of local government. Noting the theme of change, what technical changes does the municipal engineer face today? Noting IMESA’s roll-out of its asset management registry and management programme, the role of information technology in designing, implementing, building, monitoring, managing, maintaining, and replacing public infrastructure assets is central, and has come a long way since we all adopted email as the ‘next big thing’.

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

PUBLISHER: MEDIA No. 9, 3rd Avenue, Rivonia 2056 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: nicholas@3smedia.co.za www.3smedia.co.za ANNUAL SUBSCRIPTION: R550.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2015. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: King Singh P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Fax: +27 (0)43 743 5266 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Fax: +27 (0)41 585 1066 Email: imesa.easterncape@gmail.com KWAZULU-NATAL Secretary: Penny Pietersen Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: imesakzn@imesa.org.za NORTHERN PROVINCE Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 Email: imesanorth@vodamail.co.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesa.southcape@gmail.com WESTERN CAPE Secretary: Erica Albertse Tel: +27 (0)21 444 7114 Fax: +27 (0)21 444 9470 Email: Erica.albertse@capetown.gov.za FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Fax: +27 (0)86 628 0468 Email: imesa.fsnc@gmail.com

Nicholas McDiarmid

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

@infrastructure4

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

With many systems on the market, and almost unlimited potential for development, choosing the right system for the right infrastructure can seem like quite a crazy jungle of choices. As part of IMIESA magazine’s ongoing development of focus, we began our focus on information technology some time back now, and it has been particularly heartening to be covering the actual implementation and use of these systems – most recently that of the City Power’s use of load management technology through smart metering. This theme will be developed through all applications and, by this time next year, we will have a library of information for all engineers working in the public infrastructure space to draw from. Following on from that, 3S Media has been hard at work developing content and a platform for its recently acquired continuing professional development product, CPD on Demand. An indispensable tool for all engineers, it is convenient and practical to ensure ongoing ECSA registration, while keeping up to date with the latest in engineering technical, regulatory, and practical information. Visit www.infrastructurene.ws/cpdondemand to discover a practical and affordable solution that fits right in with today’s busy schedule. Next year is a local government election year, and there is no doubt that more new build and maintenance projects are to be rolled out, leading up to these elections. There is a general sense that this may be one of the most contested elections we have yet seen in South Africa, for many reasons. There can be no doubt that the more capacitated the municipal sector, the better off we all are, and it would be good to see this as a general driving principle. I look forward to seeing you all in Cape Town and hearing about what is happening in your part of the world.

frastruc

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INFRASTRUC

IMESA

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• MAINT

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

ber the rub d Where the roa meets

MERCEDES-BENZ TRUCKS INDUSTRY

INSIGHT ROB REIN, PPC Cementing industry innovation

Driving the sustainable mobility movement

ECSA

Upholding the engineering profession

ggles Power Struy engineering African energ

ussion Panel Discruction,

Rural Road Asset Management

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

A foundation for service delivery improvement

Municipal Focus

Road constce, and equipment maintenan

Unlocking the power of wastewater

l Focus Municipa Bay

Mandela ipality Nelson n Munic Metropolita

Infrastructure News

IMESA

The official magaz ine e of the Institut pal of Munici Engine ering rn Africa of Southe

IN THE HOT SEAT

that are lt products sive T SEAT ffective aspha cing labour-inten Asphalt THE HO Much er of cost-e al, ut sacrifi a numb roads, witho Director: Plant & Technic “We have st to these • Augu ideally suited ds.” Herman Marais 8 V o l u m e 4 0 N o . 8 7 metho 257 19 ISSN 0 construction

2015

“As a leading supplier of hydraulic machines (pumps and turbines), we are proficient in the technology needed for power stations, water supply facilities, and for pulp) and paper mills.” Molefe Seth Phalatse Chairman: RITZ Pumps South Africa

.00 • R50

( i n c l . VAT

ISSN 0257 1978

V o l u m e 4 0 N o . 9 • S e p t e m b e r 2 0 1 5 • R 5 0 . 0 0 ( i n c l . VAT )

IMIESA September 2015

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PRESIDENT’S COMMENT

IMESA

Countrywide optic fibre roll-out

Duncan Daries, IMESA president

One of the biggest challenges currently facing municipalities and road authorities is the roll-out of optic fibre cabling.

HAT THE COUNTRY has prioritised this is a given, as it is vital in maintaining a competitive edge in attracting investment and for a thriving economy.

Why is this an issue? Within municipal areas, road reserves primarily have to accommodate the actual road for vehicular and pedestrian access purposes. Secondary, but equally important, road reserves have to accommodate: • basic services such as water, foul sewer, stormwater, electricity, and street lights – including their supporting infrastructure such as manholes, valves, fire hydrants, and control boxes • telecommunications infrastructure. The road reserve width is, therefore, a constraint when it comes to accommodating all these services and, for proper governance, it is necessary that the road authority is the final arbiter of where these services are located within the road reserve to ensure that all these services can be rendered. Most authorities, therefore, prescribe where these services are located when areas are developed or services are retrofitted. In the era when there was only one telecommunications service provider/authority (Telkom), the accommodation of its cables was never a problem, other than excessively large manholes that were constructed in some

locations. However, this has since changed with over 400 ECNIS licenses issued by Independent Communications Authority of South Africa (Icasa) in terms of the Electronic Communications Act of 2005. In Cape Town, we are aware of at least 14 ECNIS license holders who can install and own telecommunications infrastructure. The lead up to the 2010 World Cup and the rapid implementation of telecommunications infrastructure to support the event was a great learning experience for municipalities. As each telecommunications infrastructure service wanted to install their own service, the cities soon ran out of space. Roads and road verges were constantly being trenched and post-trench reinstatement failures were difficult to apportion blame to. The City of Cape Town began an initiative to create a coordinating body consisting of the known role players in the telecommunications industry. From this initiative, they developed a policy and guidelines to the issuing of wayleaves to telecommunication infrastructure applicants.

Management and wayleave process – City of Cape Town • a two-stage process comprising a wayleave and a construction permit • tariffs for wayleaves, permits, and damages deposit • one trench principle, accommodating multiple service providers

• regular district engineer office coordination meetings • a registered civil engineering practitioner must be appointed by the service provider to oversee and sign-off on construction and reinstatement work in the road reserve • a master plan of each ECNIS licence holder network must be submitted and made available on GIS for coordination purposes – not only the core network but also the secondary and FTTX networks • the built information, with coordinates, must be submitted at sign-off of completion certificate. The approach to exercising road authority duties and responsibilities, in terms of national and provincial legislation as well as municipal by-laws, has been challenged in court by service providers in terms of the Electronic Communications Act. It is, therefore, worthwhile for readers to familiarise themselves with the following 2 cases: • Sanral vs Telkom in the KZN High Court – Oct 2010 • Msunduzi Municipality vs Dark Fibre Africa (RF)(Pty) Limited in the Supreme Court of Appeal, Bloemfontein – Oct 2014 The City of Cape Town tasked its official, Ian McDonald PrEng, to make presentations to both Salga and the Roads Coordinating Body concerning this issue. I can report that the National Depar tment of Transport has successfully been engaging with Icasa and that the following proposals have been

accepted as a starting point for onward discussions: • Establish and agree on a common approach in managing service applications including alignment with TRH 27 proposals. • Set up standard application and approval processes, including placement position within road reserve prism. • Develop and obtain approval for tariffs to be levied for wayleave and permit process as well as rates for damages deposits in terms of the MFMA – section 17(3)(a)(ii). • Prohibit trenching across roads – service providers must make use of trenchless technology methods – penalty rate included in schedule of tariffs. • Ensure that all new developments – including low-income housing – make provisions for ducting to be installed at construction stage. • Develop a rental tariff for the existence of optic fibre cables – rate per metre or per line speed or other. Other than this conventional trenching and laying of cables, another service provider is currently pursuing the placement of communications cables within sewer and stormwater conduits. This service provider wants its primary network located within these conduits but will still require traditional trenching for its secondary network, which links up its clients. The governance and practicality around this initiative is of great concern to municipal engineers.

IMIESA September 2015

COVER STORY

From the companyâ€™s earliest days, the development of fundamental technologies for particularly efficient, environmentally compatible vehicles has been a recurring theme in the history of the Mercedes-Benz brand.

Mercedes-Benz Trucks

ERCEDES-BENZ TRUCKS has been the first to bring numerous relevant technologies to production and market maturity, and continues to develop them further, even to the level of alternative technologies such as hybrids and fuel-cell drive systems. Outstanding innovations have been regarded as milestones in the development of more efficient and environmentally compatible commercial vehicles. The Mercedes-Benz powertrain strategy not only offers an impressively wide range of available technologies, but also the greatest possible flexibility in their use. Even within all the conceivable transitional scenarios, it optimally meets the varied requirements of different customers and markets. Keeping in line with Mercedes-Benzâ€™s innovative technology, fuel economy in vehicles can be improved in many ways, including increasing engine efficiency, reducing aerodynamic drag, rolling friction, and improving fuel consumption.

New efficiency and safety enhancements Following on the success of the hypoid rear axle for the current Actros range, Mercedes-Benz

IMIESA September 2015

Driving the sustainable mobility movement engineers have come forward with new efficiency and safety enhancements on the Actros on-highway truck tractors that focus on driveline optimisation and safety. Many of these enhancements, such as Telligent Stability Control and the driver airbag, have been incorporated as standard on the model range for 2015, from the Actros 1844LS/36 DD 4x2 to the flagship Actros 2658LS/33. Two new additions to the range, with varied horsepower, are the Actros 2641LS/33DD, for applications within the medium- to longhaul segment, and the Actros 2646LS/33, which replaces the 2644LS/33. The increased power and torque in these upgraded models are now more accessible and useable due to the optimised directdrive transmission driveline. The introduction of this transmission (on the 410 hp, 460 hp, and 540 hp engines),

on the 6x4 tractor, further optimises the driveline, which is a welcome innovation to complement the hypoid axle previously introduced. The G281-12, with 12 forward and 4 reverse gears, is a direct-drive, powershift, constant-mesh automated manual transmission with integrated engine, transmission, and clutch control for improved shifting times and high/shift comfort.

Intelligent solutions The Telligent Stability Control feature, which is now standard on 4x2 and 6x4 airsuspended prime movers, is a complete package of systems covering all aspects of operation in the Actros. Intelligent systems monitor and regulate the vehicleâ€™s functions, giving drivers a safer, smoother ride, prolonging the life of the vehicle. One of the significant features of the Telligent technology is the braking system,

COVER STORY

which is a standard specification. It comprises a dual-circuit brake system, with internally ventilated disc brakes all round, ABS, ASR, and auxiliary brakes such as the engine brake and retarder. The system relays each signal at lightning speed, much quicker than any mechanical system could. It allows braking power to be applied more sensitively, as in passenger cars. The braking force is optimally distributed between tractor and trailer according to the load. The Telligent brake system also ensures that the brake pads on the different axles do not wear at significantly different rates. Telligent Stability Control also recognises potential instability, such as skidding or swer ving, and counteracts it where possible. Systematic adjustment of engine torque, precisely measured tractor braking, and control of the trailer brake system helps the driver to avoid tricky situations. The enhanced, additional safety feature inherent in the airbag integrated in the steering wheel is linked to a control unit that ignites several propellants within a period of 30 milliseconds as from a precisely defined minimum deceleration in the event of an impact.

One propellant deploys the airbag and a fur ther propellant activates the pretension device and draws the safety belt as close as possible to the driverâ€™s body. In the event of an accident, kinetic energy is absorbed, preventing direct contact between the upper body and steering wheel. With the optional Telligent Safety Pack, Mercedes-Benz Trucks offers the ultimate in safety, with active protection that no other manufacturer can currently offer in the local market. The pack consists of Telligent Distance Control and Active Brake Assist II. The Telligent Distance Control system consists of a radar sensor and control unit, which controls the vehicle speed and supports the driver in automatically maintaining the distance from a vehicle detected in front of it.

Putting the brakes on road accidents

Brake Assist II evaluates the traffic situation in front of the vehicle up to a distance of 200 metres. The system uses vehicle data for this purpose and also monitors the distance from vehicles ahead, as well as their speed. If the system detects the risk of a potential rear-end collision with a vehicle ahead, the driver is informed by means of a three-stage escalating warning system, corresponding to the actual situation. This warning gives the driver sufficient time to react. If there is no reaction from the driver to the collision warning, Active Brake Assist II automatically initiates emergency braking (full braking application) if there is a vehicle ahead. The warning concept for Active Brake Assist II is designed to allow drivers to take action themselves to avert critical situations. Mercedes-Benz Trucks continues to be the driving force for sustainable mobility in the future and is working intensively on further developments in all areas.

Active Brake Assist II uses the existing radar system of the Telligent Distance Control system, which assists the driver when an accident hazard is detected and reduces the vehicle speed by staged braking intervention. During driving, Active

IMIESA offers advertisers an ideal platform to ensure maximum exposure of their brand. Companies are afforded the opportunity of publishing a two-page cover story and a cover picture to promote their products to an appropriate audience. Please call Jenny Miller on +27 (0)11 467 6223 to secure your booking.

www.mercedes-benz.co.za

IMIESA September 2015

AFRICA ROUND-UP

INFRASTRUCTURE NEWS FROM AROUND THE CONTINENT were substandard, while some were based on the low capital provided for construction. According to him, the Ministry of Public Works has several infrastructure projects lined up, including the connection of roads to county capitals as well as other major trade hubs.

ETHIOPIA CCECC to construct Hawassa Industrial Park for $246 million China Civil Engineering Corporation (CCECC) concluded a $246 million deal for the construction of the Hawassa Industrial Park. The project, with MH Engineers as consultant, will be completed in nine months, with a focus on garment manufacture and agro-industry. Construction of the Hawassa Industrial Park includes 35 factory sheds and 19 buildings, which will be used as exhibition halls, food courts, dormitories, and for other purposes in the first phase. This phase will cover 100 ha, while the remaining phase will add 200 ha more. "The number of factories intended to be included in the first cycle of the Industrial Park project is 35. Nevertheless, the government requires the construction of more buildings in the park," says Kalkidan Betre, CCECC engineer: Quality & Safety.

KENYA

NIGERIA China to partner with Yobe on infrastructure China Civil Engineering Corporation (CCECC) concluded a $246 million deal for the construction of the Hawassa Industrial Park

director Flora Okoth said work is expected to be complete in 18 months from the contract signing date, on 1 July 2014. Lebanon-based firm Zakhem International won the contract. The six local and international banks are CFC Stanbic, Citibank, Commercial Bank of Africa, Co-operative Bank, Rand Merchant Bank (a division of FirstRand Bank Limited London Branch), and Standard Chartered Bank. The loan is one of the largest commercial bank financing ventures ever entered into by a Kenyan parastatal without government guarantee.

LIBERIA $1.99 billion needed for infrastructure development Liberia is looking at a bill of nearly $2 billion for infrastructure development, which includes the rehabilitation and construction of roads and bridges. This is according to William Gyude Moore, Liberia's Minister of Public Works. Speaking at the House of Representatives recently, he told plenary that, since 2006, more than $700 million has been spent on the development of roads in the country. Minister Moore admitted that most of the roads constructed

$350 million secured for new Mombasa-Nairobi pipeline Kenya Pipeline Company (KPC) has secured a $350 million loan to finance the construction of a new 450 km oil pipeline from Mombasa to Nairobi. The state-owned oil distributor will upgrade to a 20 inch ultramodern, multiproduct oil pipeline to replace the more than 30-year-old 14 inch pipeline currently in use. Speaking during the loan signing with a consortium of six banks, KPC acting managing

IMIESA September 2015

Kenya Pipeline Company (KPC) has secured a $350 million loan to finance the construction of a new 450 km oil pipeline from Mombasa to Nairobi

The Chinese government will partner with the Yobe State government in the areas of agriculture and infrastructure development, Chinese ambassador to Nigeria Gu Xian Jie has said. â€œThe Chinese government is interested in partnering with Yobe to develop infrastructure and agriculture and to work with it to develop education. These are key areas of sustainable economic development,â€? he said. The ambassador noted the effort of the Yobe State government in improving the living conditions of the people of the state, especially in the areas of road construction and education, despite prevailing security challenges and the threats of Boko Haram. Gu asked governor Ibrahim Gaidam to continue to provide security to Chinese companies working in the state even as he pledged to make the Chinese firms working in the state more conscious of their corporate social responsibility. On his part, governor Ibrahim Gaidam, who thanked the Chinese ambassador for his government's support to Nigeria in general and Yobe in particular, said the state government will continue to work with the security agencies in the state to ensure that the environment is safe for the Chinese and other nationals working in Yobe State.

AFRICA ROUND-UP

Liberia is looking at a bill of nearly $2 billion for infrastructure development, which includes the rehabilitation and construction of roads and bridges

RWANDA Rwanda, Burundi, and Tanzania plan joint railway project Rwanda, Burundi, and Tanzania are looking for investors to participate in the building of a new 1 661 km standard-gauge railway, expected to cost about $7.6 billion. The partners, through the Rwanda Transport Development Agency (RTDA), are seeking expressions of interest from firms to finance, design, construct, operate, and maintain the railway under a publicprivate partnership. RTDA director general Guy Kalisa said interested firms will be evaluated, to shortlist potential private partners, prior to issuing the request for proposal documents for the project. The new standard gauge railway line is to be constructed from Dar es Salaam to Isaka, in northern Tanzania, and Kigali, in Rwanda, with a link to Burundi running from Keza to Musongati, through Gitega.

TANZANIA Experts call for firm slum infrastructure support Dar es Salaam's population is growing at an average of 8% per annum, with most people residing in slums with no tap water,

sewerage systems, or solid waste facilities. Visiting Professor David Hulme, from Brooks World Poverty Institute in Manchester, said the problems of infrastructure and service delivery in slums are so complex that government alone cannot solve them. "These problems can only be solved by collective community action involving the civil society and private sector," Prof Hulme said during an EcoPoor Dialogue held in Dar es Salaam recently. He advised that private investment is required in supplying slum dwellers with water, sewerage systems, and garbage treatment plants to support government investments. Over 70% of Dar es Salaam settlements are unplanned, while less than 5% of the population has access to formal sewerage system. Currently, about 60% of the city's residents have access to clean tap water, while the

40 % without access are mainly slum-dwellers.

UGANDA Uganda seeks $145 million World Bank loan for oil roads Uganda's parliament has recommended a loan request of $145 million from International Development Association (IDA) of the World Bank Group to be approved to finance the Albertine region districts road connectivity development project. The project will focus on improving the connectivity of the region, providing basic infrastructure and planning at local government level, and investing in institutions and people to prepare them for potential employment opportunities that are anticipated to Dar es Salaam's population is growing at an average of 8% per annum, with most people residing in slums with no tap water, sewerage systems, or solid waste facilities

result from growth and development of the region. The loan will finance the upgrading of a 100 km stretch of road. The total project financing will be $153.89 million; comprising an IDA credit of $145 million and an $8.89 million contribution from the government of Uganda, to be implemented over a period of five years.

ZAMBIA Eurobonds â€“ result of investor confidence Zambia has successfully issued the targeted amount of $1.25 billion on a Eurobond, reportedly for infrastructure development. The Eurobond, with a coupon rate of 8.97%, has an eleven-year average life, with repayments in 2025, 2026, and 2027. The latest $1.25 billion, therefore, brings the total Eurobond debt to $3 billion. Speaking to the media, Deputy Finance Minister Christopher Mvunga says the funds will be used in infrastructure-related projects in the road, energy, education, health, water, and transport sectors in order to better the lives of the Zambian people. Amid loan repayment obligations, the government will still need to continue constructing roads, building hospitals and schools, and providing other public goods as well as ser vices. Any default by the country, in terms of the loan repayment, would greatly dent the country's credit-worthiness, which the government administrations, past and present, have worked hard to attain.

IMIESA September 2015

MUNICIPAL FEATURE

Unlocking the power BY SIVA CHETTY, ROB DYER, AND HENK OOSTERDIJK*

of wastewater

The eThekwini Municipality has several wastewater treatment works (WWTWs). The WWTWs treat domestic and a small amount of industrial effluent, through the aerobic treatment of the liquid fraction and the anaerobic digestion of the solids fraction.

HE ANAEROBIC DIGESTER produces biogas, which has about 65 % combustible methane. Some of the biogas is used to heat the digester so that it operates optimally and the rest, about 65%, is flared. eThekwini Water and Sanitation intends to use the biogas more beneficially, in a combined heat and power (CHP) system, to gain advantage from a renewable energy source. The CHP plant will generate ‘green’ electricity. In this way, the works can reduce the consumption of coal used to produce electricity at Eskom. The Northern Wastewater Treatment Works (NWWTW) has been selected as an appropriate works, with a current treatment capacity of 56 Mℓ/day, as a potential site to implement a methane-gas-to-electricity project, using the CHP system. The NWWTW is located in the northern area of Durban. It has an installed capacity of 70 Mℓ/day, with current average dry weather flow of 60 Mℓ/day. The NWWTW consists of primary sedimentation, activated sludge treatment, and anaerobic digestion. The secondary effluent is clarified in a system of secondary clarifiers and then discharged into the environment, after chlorination. The waste-activated sludge, from the aerobic process, and the primary sludge are anaerobically digested in three anaerobic digesters (Figure 1). The digesters are heated to mesophillic temperature (37OC) using about 40% of the biogas generated. The remaining biogas, comprising approximately 65% CH4 and 25% CO2, is flared into the atmosphere. The digested sludge is dewatered and transpor ted to land application. Electricity is primarily used in the aeration plant and pumping equipment throughout the works. The activated sludge plant’s power consumption is about

IMIESA September 2015

480 000 kWhr per month, which is about 70% of the treatment works’ total consumption.

*The authors: Siva Chetty, principal water technology consultant, Royal HaskoningDHV; Rob Dyer, senior planning engineer, eThekwini Water and Sanitation; and Henk Oosterdijk,

Scope of feasibility study

senior consultant: Waste Management &

A feasibility study was undertaken, from September 2013 to April 2014, to investigate the following: • undertake sludge production study • undertake process configuration investigation to maximise biogas production • undertake gas-to-energy study • u nder take technical evaluation of possible options • undertake economic evaluation of possible options.

Energy Technology, Royal HaskoningDHV

Project benefits The project is the first of its kind in the eThekwini Municipality and will have several benefits, such as: • stopping the release of global warming gases, such as methane and nitrous oxides – methane and nitrous oxides respectively have 23 and 296 times the global warming potential compared to carbon dioxide • increasing the use of non-renewable energy sources such as from biosolids • increasing energy efficiency • transferring waste heat from generator sets to heat up digester to mesophillic temperature of 37OC • anaerobic digester technology is a good example of appropriate technology in the green economy and sustainable green energy production • affording the possibility of future registration with the clean development mechanism in the future • aligning to the new regulations on carbon tax. The utilisation of biogas represents a shift

Figure 1 Anaerobic digestion plant at the NWWTW

from non-renewable, fossil-fuel-based energy towards renewable, bio-based energy. It will lay the foundation to view wastewater treatment as a green energy factory. It has been reported (Guo, Koornneef and Lue, 2009) that as much as 25% of the cost of treatment is attributable to energy costs, primarily in the form of electricity. The use of electricity consumption from a non-renewable resource, such as coal, is a problem in terms of climate change impact. It will lower the carbon footprint of the WWTWs, as the green electricity generated from the biogas will offset the need for nonrenewable, coal-based electricity. Although

MUNICIPAL FEATURE

CO2 is also released in the course of biogas combustion and COD reduction, the CO2 released is not taken into account, as it is considered biogenic (Gupta et al., 2012). The project intent is also to investigate the potential to enhance the operation of the digesters in order to maximise gas production and transform the secondary sludge (waste-activated sludge). Transforming the sludge makes it more amenable to anaerobic digestion and gas production. The on-site power generation will assist the treatment works in operating even where there are mains power supply outages. This will ensure full treatment is achieved, which will ensure compliance with the discharge permit and protection of the environment.

Figure 2 Combined sludge feed to anaerobic digesters in series

Figure 3 Gas conditioning system (Source: Northern WWTW in Johannesburg)

Maximisation of biogas production Several options were considered to maximise biogas production so that more green electricity can be generated. Considered options are outlined in Table 1. After an in-depth consideration of the technical and economic evaluation (Visser, 2014) of the different scenarios in Table 1, the alternative configuration 2 (Number 7) resulted in the best value-for-money option. This option is shown in Figure 2. This mode represents a close to plug flow configuration with resultant higher biogas production by about 8% to 10%.

Technical options investigated for biogas utilisation Several biogas utilisation options were investigated. The possible options are: • boiler • gas-engine-based combined heat and power unit •m icro gas turbine • f uel cell. The description, advantages, and disadvantages for the biogas system are summarised in Table 2. From the screening level economic evaluation, the option of the gas-engine-based CHP unit offered the most favourable economic return. Based on this screening exercise, the CHP option was explored in more detail in terms of its technical capability and economic viability.

Technical description of the CHP solution The biogas produced from the three digesters goes through a conditioning system, and

is then fed into the biogas-fired engines, to be wholly consumed. The purpose of gas conditioning is to remove hydrogen sulfide and siloxanes. These chemicals would cause damage to the gas engines if not removed. The gas conditioning system is shown in Figure 3. After conditioning, the gas is pumped into the generator. The generator has two outputs: heat and electrical energy. The excess heat generated from the generator engine block and exhaust is transferred into a cooling water circuit, through a system of heat exchangers. The heated water is used to heat up the digesters. The electrical energy produced undergoes voltage transformation and is then synchronised into the NWWTWs electrical grid. The CHP system is shown in Figure 4.

Technical data and CHP equipment sizing The design basis is the size of the works, as determined by the works inflow capacity and the settleable solids in the primary sedimentation process. The amount of biogas production is based on the sludge TABLE 1 Scenarios considered for maximisation of biogas production

Scenario Existing situation

Number 1

Description In this scenario, the existing situation is continued. The only difference is that an operating temperature of 37°C is assumed; this is the optimal temperature for mesophilic digestion.

Thermophilic digestion 2

The existing configuration is used. The operating digester temperature is 55°C.

Thermal treatment 1

3 (a) or 3 (b)

The existing configuration is used. WAS is pretreated thermally prior to digestion. The treatment type is based on the Cambi or a similar system. The digesters are operated at 37°C (option a) or 55°C (option b).

Thermal treatment 2

Same as scenario 3 a/b, but with another thermal treatment method based on the Thermocrack system developed by Royal HaskoningDHV.

Plug flow digestion

One digester is revamped to a plug flow digester consisting of three or four compartments with internal recycle. From this digester, the sludge is fed to the two remaining digesters operating in parallel mode. Again, digestion temperature can be 37°C (option a) or 55°C (option b).

Alternative configuration 1

Raw sludge and WAS are mixed and fed to the three digesters, which are operated as mesophilic (option a) or thermophilic (option b) parallel-operated digesters.

Alternative configuration 2

Raw sludge and WAS are mixed and fed to the three digesters, which are operated as mesophillic (option a) or thermophilic (option b) series-operated digesters. This way, a more plug-flow-type of operation is achieved.

IMIESA September 2015

MUNICIPAL FEATURE

loading into the primar y digesters, its volatile solids content, and the temperature and residence time in the digesters. The methane content of the biogas is based on actual sampling and analysis of the biogas stream. The methane content is used to estimate the calorific value of the biogas. The electrical efficiency is a function of generator size. The key technical data for the CHP system is presented in Table 3.

Figure 4 Combined heat and power system

Capital investment The capital investment is required for: • biogas conditioning • heat distribution system • digester reconfiguration • reciprocating gas engine • electrical connectivity • control and instrumentation. The estimated value is about R25 million. The applicable rate of exchange was €1.00 = R14.50. The operating costs are made up of maintenance (15c/kWh), labour, capital charges, and gas conditioning, and would amount to R2 million per annum. The savings would be due to reduced consumption of electricity from the Eskom grid. Figure 5 indicates the differential between expenses versus income from savings in electricity generated.

TABLE 2 Biogas utilisation options

System Boiler

Description The biogas is the main fuel supply to the boiler. The boiler can generate medium pressure.

Advantages High energy conversion efficiencies can be achieved. Hot water can be used for digester heating and local use.

Disadvantages Apart from digester heating, there has to be a demand for hot water in the plant or nearby.

CHP

Combined heat and power (CHP) is the simultaneous generation of usable heat and power (usually electricity) in a single process. Reciprocating gas engines are used to drive an alternatorgenerator system.

Suitable for WWTWs, as both the heat and electricity can be consumed on-site. High energy conversion and use efficiency; reduces carbon footprint of the works.

High initial capital investment and ongoing operating and maintenance costs.

Micro gas turbines Micro turbines (30–500 kWe) are increasingly being applied for generating power from biogas.

Variable speed, highspeed operation, compact size, simple operability, easy installation, low maintenance. Can accept relatively high levels of hydrogen sulphide (H2S) up to 5 000 ppm.

The noise levels are high. The electrical efficiencies are lower than for reciprocating engines by about 10%. The smaller systems (< 1 000 kWe) are more expensive than CHP equivalent.

Fuel cells

Fuel cells cleanly and efficiently convert chemical energy from hydrogen-rich fuels into electrical power and heat. The electrochemical process is virtually absent of pollutants.

The use of fuel cell technology for commercial operations is still in the development phase. Several types of fuel cells exist but all require extensive purification of the biogas.

Economic analysis There is a net gain in the investment taken over the 20-year analytical period. The NPVbased economic analysis clearly shows that the payback period is strongly influenced by the revenue from electricity saved, which is determined by the annual rate of increase in electricity charges. The current electricity increase is 8% per annum as set by the National Energy Regulator of South Africa (Nersa). However the increase over the last five years has been 60%, which is equivalent to an annual average increase of 12% per annum. In a recent media article (Mercury, May 2014) Eskom applied for a tariff increase of 16% per annum to sustain its electricity generation and supply mandate. Hence the increase of 12% and 16% per annum is a likely scenario. On the basis of a 12% electricity increase per annum, and investment of R25 million, the payback is expected to be less than 10 years with an internal rate of return (IRR) of 18%. Over a 20-year investment period, the net gain will be about R52 million.

IMIESA September 2015

Fuel cells produce energy electrochemically — without combusting the fuel. When a hydrogen-rich fuel, such as clean natural gas or renewable biogas, enters the fuel cell stack, it reacts electrochemically with oxygen (i.e. ambient air) to produce an electric current, heat, and water.

MUNICIPAL FEATURE

Operating and maintenance strategy One gas engine/generator is capable of 8 059 continuous operating hours per year. This provides an equipment availability of 92%, which shall also be guaranteed by the operator. The remaining 701 hours per year are used for scheduled maintenance. It is recommended that the major engine overhaul (rebuild) is under taken ever y 60 000 operating hours, which is equivalent to six to eight years. Maintenance can be distinguished as scheduled and unscheduled maintenance. Scheduled maintenance, like oil and filter and spark plug changes, can be planned in advance. This shall be planned in off-peak hours in order to minimise lost revenue. Unscheduled maintenance (breakdowns and consequent repairs) cannot be planned and, as such, can happen at any moment. The maintenance contract shall cover the whole 60 000 operating hour cycle, including the large overhaul (at 60 000 to 64 000 operating hours). Thereafter, the gas engine/generator set can be considered as new, and the maintenance schedule cycle starts again. It is recommended that the supply contractor be engaged for a sufficiently long time (say, 10 years) so that it is responsible for the major ser vice and maintenance requirements. If this does not happen, the municipality may inherit the economic risk of having to undertake the repairs itself at exorbitant costs. Further, a new operator may impose severe cost penalties as

it may doubt the previous operating and maintenance coverage. The following reasons are provided why the contractor shall have an extended (10-year) operating and maintenance contract: • The eThekwini Water Ser vices Unit does not have the experience and WWTW-level mechanical, electrical, and power engineering technical skills to operate and maintain the CHP. As can be seen, the maintenance programme can be onerous and it is not the core business activity of the EWS. • A maintenance contract for a shorter period is possible but has an associated risk that another contractor may not be willing to take over the contract due to a poor maintenance record or will only take over at high costs. • A contract covering only the first three years of operating shall have a lower specific price than a contract that covers years four to eight. • A long-term contract ensures the contracted operator operates the plant optimally by ensuring the scheduled maintenance occurs as planned. If the factor y-scheduled maintenance is not carried out, it could be possible for the genset to incur greater costs sooner, thereby having a negative effect on the financial returns.

Value-for-money assessment The economic analysis has shown that the savings from the generated electricity covers the operational and maintenance expenses for the CHP plant. In addition,

Figure 5 NWWTW: differential between expenses vs income from savings in electricity generated

TABLE 3 Key technical data for the proposed CHP system

Average works inflow

50 000 m3/day

Biogas production Methane content Maximum electrical output Electrical efficiency

5 500 m3/day 65% 690 kWe

Thermal efficiency

45%

39%

Annual works generation 5 092 MWh/y Annual works consumption

7 920 MWh/y

Generation/consumption 64% Carbon footprint reduction

4 665 t/y

there are some savings to pay off the capital investment in less than 10 years.

Conclusion The feasibility study into the use of biogas from the NWWTW for green electricity production has been an exciting development. It has generated a new body of knowledge in areas such as enhanced biogas production, carbon footprint reduction, the notion of WWTWs as renewable energy factories, economics of renewable energy systems, and operating and maintenance strategies for CHP systems. The study has highlighted that the economics of CHP systems as applicable in a medium-sized WWTW can be marginal at lower power price increases. This is true in the context of South Africa, where electricity has been ver y affordable compared to global prices for electricity. Further, the lack of subsidies for greener and more sustainable fuels, and the weakening of the South African rand have also contributed to making such projects marginal, in terms of return on investment. The positive news is that a CHP system is a ver y appropriate choice of technology for a WWTW, as both the heat and power can be locally consumed, thereby increasing the overall use efficiency to over 80%. In addition, the renewable energy generated can have a substantial reduction in the carbon footprint of the WWTW, by as much as 35%. Finally, the consideration of biogas for power generation is the first step in positioning the WWTW as an energy factor y. For a full list of references, please contact the editor.

IMIESA September 2015

HOT SEAT

RITZ PUMPS SOUTH AFRICA

Pump it up RITZ Pumps South Africa supplies a wide range of pumps from German company Andritz. In this month’s Hot Seat, Molefe Seth Phalatse, chairman of RITZ Pumps South Africa, shows how this small company – with only eight employees – is able to maximise its resources to create value and supply these high-quality pumps.

Can you sum up RITZ Pumps South Africa’s history and its current structure? MSP RITZ Pumps South Africa was formed in 2006 as a joint venture with Andritz RITZ. 23% is owned by Andritz RITZ, and 77% is South African owned – of which 67% is black-owned and a substantial portion of this is owned by women.

What are the stand-out applications of RITZ Pumps’ products? Our capacity to pump acid mine drainage (AMD) as well as dewater flooded mines from surface, while we and ensure that acceptable levels are maintained so that there is no over flooding, is unparalleled. AMD poses a significant risk to the environment and our pumps are uniquely suited to deal with the issue. This is because they are double suction

IMIESA September 2015

ABOUT

Molefe Seth Phalatse, chairman of RITZ Pumps South Africa, brings a wealth of experience and business acumen to the company. He has more than 20 years’ service with BMW, and recently retired off the board. He is currently the president of the Southern African-German Chamber of Commerce and Industry in South Africa. He has served, and is still serving, on the board of companies such as Ithuba Holdings, Emerson Network Power, Bosch, International Ferro Metals, and, previously, Da Vinci Holdings. He is a trustee of the South African Democratic Education Trust and has been involved in a number of charity programmes. Phalatse is also a classic car enthusiast and avid collector of Chevrolet Impalas. pumps, each capable of pumping 1 500 m3/hour. We are currently pumping up to 84 million litres of AMD out of the Central Basin every day. We have two of these pumps – 1 500 m3/ hour (combined 3 000 m3/hour) – installed in Central Basin, two more pumps – 1 500 m3/hour (combined 3 000 m3/hour) – onsite for the Western Basin, and will install three more pumps – 1 500 m3/hour (combined

4 500 m3/hour) – in the Eastern Basin this year.

As a leader in Conduit Hydropower, please tell us about your recently completed Annlin Reservoir project in the City of Tshwane? In the City of Tshwane (CoT), water is distributed through a large water system which includes 165 reservoirs, 39 water towers,

ABOVE Molefe Seth Phalatse, chairman of RITZ Pumps South Africa

10 863 km of pipes, and more than 280 pressure reducing stations (PRS). As the water enters the CoT area, the excess pressures need to be dissipated. Instead of using PRSs, turbines (or pumps acting as turbines) were installed, generating electricity as a by-product of an existing process. The capacity of hydroelectric installations can vary to suit the application for the amount of power to be generated or needed.

How is the generated electricity used? The generated power will be compatible with the CoT’s existing electricity supply system. The frequency will be 50 Hz and the designed control equipment will ensure the delivery of 420 V

HOT SEAT

The specific benefits for developing conduit hydropower in the CoT’s water distribution network include:

• conduit hydropower uses the available water distribution infrastructure and, thus, as long as there is a demand for water, hydroelectric energy can be generated • the operational life of the existing pressure reducing valves is extended • conduit hydropower ‘piggy backs’ onto existing water infrastructure, resulting in a minimal environmental impact • the feasibility studies indicate short payback periods.

three-phase power. The speed of the generator/alternator will be 1 500 rpm, to ensure a 50 Hz frequency. A 420 V to 11 kV step-up transformer or miniature substation will be installed to connect to the local network. This will be metered at the grid connection.

What is the potential of conduit hydropower in South Africa? Hydropower represents a nexus of water and energy and, in municipalities and water utilities, there are several locations where a feasible conduit-hydropower scheme could be implemented. A technically feasible scheme assists in reducing high operating costs – mainly caused by energy increases – and provides a sustainable solution while having a positive environmental impact. A number of water utilities have started taking the initiative in developing this type of hydropower and it is believed that there is significant potential in South Africa. It is also believed that conduit hydropower is the ‘low hanging fruit’ in terms of viable renewable energy that could be developed. The CoT is in the advantageous position where excess energy is currently being dissipated and this could be utilised to generate clean sustainable energy instead. The municipality has further taken a bold step to making a council resolution that no new reservoirs or PRSs can be built without investigating the potential opportunity to use the site to generate hydroelectric power.

How does form meet function in the design of RITZ’s pumps? The pumps have various proper ties, depending on the medium concerned. That is why the choice of material and suitable finishing are the determining factors in the functioning and stability of the pump. Different materials are used depending on the service conditions and customer requirements, including: • c ast iron, cast steel, non-alloyed • and low-alloy steel grades, stainless • CRNI steel grades, duplex and super-duplex • steel grades.

What are the key market segments targeted by the pumps RITZ South Africa distributes? As a leading supplier of hydraulic machines (pumps and turbines), we are proficient in the technology needed for power stations, water supply facilities, and for pulp and paper mills. This enables us to lay the foundation for successful further development of pumps and turbines. Centrifugal pumps and pump turbines from Andritz are operating successfully all around the world. They offer robustness and wear resistance, thus fulfilling high customer expectations in terms of efficiency, life cycle, ease of maintenance, and economic efficiency. By using standard

components, the units have excellent operating availability and can use tried and tested components. The pumps can be used for drinking water, residual and waste water, and pulp suspensions in the pulp and paper industry. It can be used as recovery turbines – e.g. in pulp and paper mills; and in small hydropower plants to supply energy, such as to mountain refuges and forest lodges.

What applications does the Andritz Vertical Line Shaft Pump have? The Vertical Line Shaft Pump has applications in water transport for irrigation and drainage, and drinking and industrial water supplies. It can be used in power supply as cooling water pumps for power stations and flue gas desulfurisation pumps. It also has applications in seawater desalination as seawater intake pumps.

How does the Andritz Atro Hydrodynamic Screw work and what advantages does it have? The Archimedean screw made water flow uphill. The hydrodynamic screw turns that principle around and uses the position and energy difference of falling water to generate power. Ever y kilowatt-hour generated by a hydrodynamic screw means around 1 kg less CO2 polluting the environment. Fish, other creatures, and floating particles pass through the hydrodynamic screw unharmed. It can be used as a substitute for waterwheels, as residual water screw in an existing spillway or in a weir system in place of small, antiquated turbines, at former irrigation weirs, and at the clear water outlet from sewage treatment plants. It is efficient, rugged, and environmentally friendly.

Where are the pumps tested and manufactured? Product testing is conducted in Germany, and our pumps and motor adhere to strict international quality standards. They are currently manufactured in Germany, although we are looking into expanding our premises to facilitate local sub-assembly. At this stage, we have a fully equipped workshop, to service the pumps here, and are expanding that to make room for a subassembly plant. This will adhere to local content regulation, as well as create jobs.

How would you define the full value of offering RITZ, beyond being a supplier of product? We do not just install the pumps and leave, we sell clients a managed solution and we maintain the pumps for the client if they require this service from us. We are able to install smart monitoring devices in systems that provide live monitoring of the pumping equipment. This way, we are able to pick up issues or downtime on the pumps, often before the client is even aware of it.

What is RITZ Pumps South Africa’s vision for the future? We firmly believe that successful companies recognise people as their greatest asset. Wherever possible, we endeavour to identify potential and dedication in individual employees and assist them with training to help them realise their ambitions. This is the key to staff retention and one of the reasons we have sent people to Germany for training to expand our skills base.

www.ritzpumps.co.za

IMIESA September 2015

PROFESSIONAL DEVELOPMENT

Upholding the

engineering profession

HE ENGINEERING COUNCIL of South Africa (ECSA) is a statutor y body established in terms of the Engineering Profession Act (EPA), 46 of 2000. ECSA's primar y role is the regulation of the engineering profession in terms of this Act. Its core functions are the accreditation of engineering programmes, registration of persons as professionals in specified categories, and the regulation of the practice of registered persons.

competent by his peers; so it should be with the engineering profession. When building public infrastructure, in particular, the people employed should be beyond reproach.” In the case of a director of a company, in compliance with King III, most CEOs and CFOs are also appointed as executive directors of companies. The legal role of a director is less about the description and is, rather, determined by the role that an individual plays in the company. The same should apply to an engineer.

Registering professionals

The prevalence of socalled ‘acting positions’ in senior roles within South African state-owned entities misleadingly suggests a lack of accountability. BEATRIX KNOPJES speaks to ECSA CEO Sipho Madonsela about the importance of professional registration in engineering, and the legislative changes that need to take place to safeguard the reputation of the profession.

IMIESA September 2015

ECSA is the only body in South Africa that is authorised to register engineering professionals who have met the requisite professional registration criteria. According to ECSA CEO Sipho Madonsela, “Registration with ECSA is not compulsor y; but, rather, it is incumbent on employers to ensure that engineers are properly registered, especially when working on public infrastructure.” In law, the fact that one is only acting in a position is inconsequential and the appointee to a position, even on an interim basis, assumes all the legal responsibilities associated with that position. The same accountability holds for whether or not a working engineer is registered with ECSA. Says Madonsela, “While we cannot compel engineers to register with us, we feel that it should be made compulsor y, as it is with the health profession. You would not see a doctor who was not qualified and recognised as

ABOVE Sipho Madonsela, CEO of ECSA

Rigorous competence testing ECSA’s registration is thorough, as Madonsela explains: “ECSA conducts rigorous competence testing. Our mandate is to ensure that whoever practices in the engineering profession is properly qualified and has the necessar y experience. “Our vigorous process of testing relies on peer judgement and, as such, we depend on industr y participation and voluntar y associations to assist in this regard. Their availability has an impact on the frequency of our meetings and, therefore, on the expediency of the registration process. We go through extensive lengths to verify qualifications to prevent fraud.”

Advantageous for tendering While ECSA registration is not compulsor y, many state-owned enterprises insist on it for the awarding of tenders. “For tendering processes and so forth, the majority of infrastructure-focused government entities demand ECSA registration. This is because an ECSA-registered engineer can be vetted as competent. Thus, the product is assured and credible,” emphasises Madonsela.

PROFESSIONAL DEVELOPMENT

“You would not see a doctor who was not qualified and recognised as competent by his peers; so it should be with the engineering profession.”

Africa with international best practice. Madonsela explains: “We use the IEA as a benchmark to review our standards and policies.

Transforming the profession

This does not limit parastatals’ choices when choosing an engineer, however, as Madonsela emphatically states, “We have 46 000 registered engineers.” If a senior executive or manager in a company assumes a role in an acting or on an interim basis, the temporary nature of their appointment will not serve as a legal defence if they fail to execute their responsibilities with care, skill, diligence, and in accordance with the law. It is, therefore, incumbent upon all those who assume managerial and executive positions, on an acting or interim basis, to be fully conversant with what is required of them, legally and otherwise. Likewise, it is imperative that an engineer responsible for a public infrastructure project be held to book for that project.

Regulatory authority ECSA has regulator y authority over its members. “We work to develop standards and regulate the industr y as much as we are able. If disciplinar y action needs to be taken, we are able to implement conduct management and sanction the engineer, if found guilty,” says Madonsela. “We make use of continuing professional development to keep registration valid. This way, engineers are encouraged to keep abreast of trends in the industr y,” says Madonsela. This ensures that its members remain up to date with trends in the profession in order to retain their membership. They also adhere to international standards to align the profession in South

“ECSA wants to transform the engineering profession in South Africa. We want to review the legislation and make registration compulsor y for all engineering professionals. This way, fly-by-night engineers will hopefully be eradicated. “We are seeking to have more influence over entities who employ engineers. We would like to have more authority to oversee them and penalise non-compliance. In this way, we will be in a better position to add value to the profession,” says Madonsela. “We would like to appeal to the profession and the voluntar y associations to assist us in executing our mandate. Together, we will uphold the reputation of the engineering profession and, through our collaboration, make engineering a profession of choice.” IMIESA September 2015

INDUSTRY INSIGHT

PPC

Cementing industry innovation PPC’s sponsorship of the Master Builders Association’s (MBSA) conference and awards, collocated with this year’s Bauma Conexpo, is another in a long list of industry-supporting sponsorships by PPC. Rob Rein, sales and marketing executive at PPC, speaks to IMIESA about PPC’s pivotal role in the industry.

Why are sponsorships like these important to PPC? RR An industr y conference, like the MBSA conference, contributes immensely to infrastructure development by providing a space for knowledge sharing and hosting discussions on the latest trends within the industr y. Industr y leaders and affiliated bodies are gathered with the common aim of addressing issues such as transformation, skills, and sustainability within the building and construction industr y. The prime role of the MBSA congress is to improve industry standards, provide a networking platform with key stakeholders, and form partnerships that will contribute to industry, development and further engage with government and legislative bodies on national policies that affect the industry for the purpose of creating a sustainable building industry in South Africa. The conference has made tremendous strides in terms of setting an agenda that speaks to current issues and providing

IMIESA September 2015

a forum for the industry. It is important for PPC to support conferences of this nature, as they drive relevant topical issues. We see our involvement in the conference as a means of enabling collaboration so as to advance our sector. This makes it so much more than a ‘sponsorship'. PPC believes in leading innovation, ensuring that the latest trends are top of mind in the industry and that we engage with them appropriately. To this end, we have developed the Cement & Concrete Cube (C3), a dynamic information sharing and collaboration platform that enables development in the sector. The C3 platform was designed to drive dialogue, encourage conversation, and share academic and industry content, as well as the latest international research in the field of cement. Expert members of the platform are also able to share their insights and advice. PPC calls on this year’s conference delegates to help shape these critical conversations by registering with C3.

How does PPC view its role in the construction sector? Cement and concrete play critical roles in construction. As a leading supplier of cement in Southern Africa, PPC is committed to offering innovative, industry-first, quality products, solutions, and services that will add value to the construction industry.

What does PPC view as the most important issue facing the sector at the moment? Africa is growing and its people are urbanising rapidly – as a result, infrastructure construction is taking centre stage. But, an opportunity of this scale also represents a massive challenge for us as an industry: we will need to think creatively about new ways of manufacturing, designing, and financing our projects if we are to succeed. According to the 2014 International Monetar y Fund World Economic Outlook, six of the world’s ten fastest-growing economies are in Africa, and the

continent is expected to continue growing at 6% per annum in 2015. Activity in large infrastructure projects has grown by 46%. However, African markets are extremely diverse; solutions will have to be developed that are appropriate to each specific market. Overall, a shortage of engineering and technical skills means that traditional construction methods and design practices will have to be rethought, to meet the demand for housing in particular. Meeting Africa’s needs will require innovation across the entire construction life cycle. Dynamic, new approaches will be required to overcome a range of challenges, which include affordability, sustainability, and long implementation time frames. Affordability is a critical issue when it comes to overcoming the realities of economic inequality and high unemployment. For example, innovative thinking by Mexico’s Cemex company has enabled it to harness the power of traditional savings schemes

INDUSTRY INSIGHT

part of their journey, from start to finish.

How does PPC assess opportunities for expansion, both in South Africa and north of its borders? PPC currently operates in emerging markets, where 70% of the world’s cement is produced. PPC typically enters markets with higher population growth, GDP, and cement demand. The selected markets need to offer new opportunities and deliver higher returns for a producer of cement and related products.

Is the recent expansion into Zimbabwe a sign of PPC’s confidence in the SADC market? TOP PPC team members at the Totally Concrete Expo LEFT PPC stand at the Totally Concrete Expo ABOVE Guests exploring the portal at the C3 launch; (left to right) Dr Elsabé van Aswegen from Jeffares & Green, Silvio Ferraris from ReMaCon, and January Sethibe from PPC

(which resemble local stokvels) to give people the wherewithal to expand their living quarters one room at a time. Similarly, 3D printing is already proving itself as a way to construct buildings, potentially allowing the industry to overcome the skills shortage, as well as existing quality issues. Other new materials and processes are being developed that are easier to use or more energy efficient than traditional ones. An example here is selfcompacting concrete, which is suitable for difficult conditions, reduces noise levels during construction, and is quicker to lay. The material is already being used in South Africa. Using innovative materials is only part of the solution. While manufacturers will have to look at ways of producing products

like cement more sustainably, traditional design approaches will also need rethinking. For instance, the construction phase of any building accounts for around 15% of its total energy footprint, while 85% is produced during the life of the building. By designing for energy efficiency, however, the 15% contributed by construction can be more than offset by savings during the building’s useful life.

What is PPC doing, operationally, to support its customers in managing today’s challenges? Our customers are the reason for our existence, and all our efforts are focused on good relationships, understanding, and meeting their needs consistently.

At PPC, we pride ourselves on being more than simply cement producers. We see ourselves as solutions-driven project partners – committed to offering ‘strength beyond the bag'. We help our customers shape their success through our superior products, efficient delivery, technical support, and our Builders’ App. The Builders’ App for smartphones provides a wealth of knowledge, quantity calculators, product information, store locations, and much more. This app is geared towards helping you get the most out of your budget and is only one of the ways PPC is adding strength beyond the bag. PPC also constantly looks for innovative ways to add value to our customers. We strive to understand our customers’ needs and are involved in every

PPC has a cement plant in Bulawayo and it has positioned us well in Matabeleland, but it’s clear that much of Zimbabwe’s future growth centres around Harare and northern Zimbabwe. PPC’s Msasa factory is being built in direct response to the opportunity we see in – and beyond – this region.

What other industrysupporting initiatives is PPC engaged in? The South African Forum of Civil Engineering Contractors (SAFCEC) Conference, the Southern Africa Readymix Association (SARMA) conference, and Concrete Society roadshows, to name a few.

As we enter the last quarter of 2015, what is PPC’s vision for 2016? To grow PPC into a leading emerging-market business.

www.ppc.co.za

IMIESA September 2015

IMESA conference 2015 social events

Grand West Casino and Hotel 27 OCTOBER 2015

28 - 30 OCTOBER 2015

OPENING FUNCTION

COMPANION PROGRAMME

• Grand West Casino and Hotel: networking with exhibitors, other delegates and colleagues

• Wed 28 Oct to Fri 30 Oct – for spouses to enjoy while partners are at the conference – Kalk Bay with lunch at Brass Bell – Rhodes Memorial – Franschhoek – Chocolate factory – Shopping

GOLF DAY • Bellville Golf Club – Shotgun start four ball alliance Starts at 11:30 // prizes

29 OCTOBER 2015 GALA EVENING – SHIMMY’S BEACH CLUB • Ocean front dining, with its breath taking backdrop of Cape Town’s iconic Table Mountain; join us for a spectacular fun filled evening of delicious food and entertainment.

Delegates attending full conference: Opening Function and Gala evening included in full delegate fee. To book any of these social events call Debbie 031 266 3263 or email: conference@imesa.org.za

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

t +27 (031) 266 3263 email conference@imesa.org.za

INSIGHT

PIPES & PIPELINES

POLYPIPE Water Management Solutions

POLYPIPE – GAINING GROUND IN AFRICA

ASSET MANAGEMENT AT THE CLICK OF A BUTTON

PARK STATION SEWER UPGRADE

NUWATER'S AFRICAN EXPANSION CONTINUES

MEASUREMENT CONTROL INSTRUMENTATION

SUSTAINABLE SOLUTIONS FOR A GREENER FUTURE

Swen Weiner, area sales executive (Business Unit Utility Tunnelling), takes this Hot Seat to discuss Herrenknecht’s unique trenchless technology capabilities in South Africa.

HOT SEAT

IMIESA September 2015

Visit us at IFAT Environmental Technology Forum Africa.

15 - 18 September 2015 at the Johannesburg Expo Centre, stand. no D19.

PIPES & PIPELINES

The future for plastic pipes

ROJECTIONS ESTIMATE that global demand for polyvinyl chloride (PVC) pipes is set to rise by nearly 7% over the next five years, reaching a staggering 19.3 billion metres installed by 2019. PVC pipe has gained incredible traction as a reliable, safe, durable, and costeffective product in its own right – no longer a mere alternative. The construction sector, including civils, remains the dominant user of the PCV pipes. In Africa, however, housing and public infrastructure are currently, and will remain, the strongest consumers of the product, driven by the incredible demand for potable bulk water and reticulation, and the lower cost and ease of installation inherent to PVC pipes.

Resource efficient While the word ‘plastic’ is not synonymous with environmental friendliness, this is not a misconception suffered by engineering and

construction professionals. Recent South African data clearly supports the idea that PVC pipes have some serious advantages – environmentally – particularly in terms of more sustainable energy practices. This special Pipes & Pipelines Division coincides with the South African Plastic Pipe Manufacturers Association’s (SAPPMA) ninth annual conference, of which IMIESA is once again the proud media partner. With challenges currently facing so many areas of the construction and infrastructure sectors in South Africa, the ongoing commitment of SAPPMA and its members, and the essential support of the conference sponsors – PipeFlow, DPI Plastics, Protea Chemicals, and Marley Pipes – speaks to a tenacious and strong business community. This endurance is ultimately to the benefit of the country as a whole, and IMIESA acknowledges the importance of its contribution, and will continue supporting it through the sharing of knowledge and skills.

Pipes and pipelines are the metaphorical veins and arteries of a nation’s lifesupporting infrastructure and, as with the human body, breakages and blockages threaten its survival. New data coming out of tests and studies suggest that plastic pipes have some serious advantages for South Africa’s ageing system.

IMIESA September 2015

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Our pipes are used in: South Africa Zambia Zimbabwe Angola DRC Tanzania Namibia

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PIPES & PIPELINES | DIVISIONAL COVER

Gaining ground in Africa With just two years’ presence in the African mining market, Polypipe’s water management solutions have surged in popularity, winning praise at several prestigious projects. Bart Malan, Mining Business Development Manager, Polypipe, looks at what makes its products inherently suited to mining applications, and how Polypipe adds value to mine operators.

IMIESA September 2015

OLYPIPE IS A global organisation with a British manufacturing operation recognised for delivering technical excellence. With over 20 000 product lines, Polypipe boasts the broadest range of plastic pipework systems available from a single manufacturer and, with the introduction of its portfolio to the African mining industry, it has brought a new perspective on plastic pipework. Mining is the second largest industrial user of water in the world, with only power generation being responsible for higher water consumption. Globally, around 7 to 9 billion litres of water are used for mining purposes each year, which is as much as a country like Nigeria uses, in total in, a year.

road or rail transport but increase the amount of water used by a mine. Arid climates often lead to dusty conditions, particularly on service roads, and water is used to damp down and control dust. Finally, but no less importantly, high-quality water is also required to meet the drinking, cooking, and washing needs of workers throughout the life of the mine. In an industry typically dominated by concrete or ductile iron pipework, polyethylene (PE) and high-density PE (HDPE) pipes now have a proven track record in some of the world’s toughest mining environments – covering a variety of vital mine processes including tailings management, heap leaching operations, process slurry pipelines, and potable water.

Rigidrain range Water use in mines The uses of water in mining operations are varied and substantial. It is employed to recover mineral ores from chemical solutions, to cool equipment such as rock cutters, and to wash minerals once extracted. Ores can also be transported away from the site through pipelines in slurry, which can cut the costs associated with

At the Marampa Mine, a brownfield haematite iron ore mine in Sierra Leone, a project to drain and stabilise a tailings dam saw Polypipe’s HDPE Ridgidrain range deployed to manage water decanting from the tailings. Ideally suited to rugged terrain and offering superior corrosion and chemical resistance, Ridgidrain is a complete, lightweight solution for non-pressurised

PIPES & PIPELINES | DIVISIONAL COVER

OPPOSITE PAGE Bart Malan, Polypipe Mining Business Development Manager ABOVE Rigidrain pipe TOP RIGHT Mine dewatering by Polypipe

surface and sub-surface drainage applications. With an easy push-fit installation, it delivers time and cost savings over traditional systems and requires no heavy lifting equipment on-site. Normally manufactured in 6 m lengths, the consignment was made to 5.8 m lengths to allow for the internal dimensions of the shipping containers and to maximise their capacity – all supplied against a tight pre-booked shipping date. Ridgidrain has also been successfully installed at another high-profile Sierra Leone mining project, providing surface drainage of the rail marshalling yard. Tonkolili mine represents one of the largest iron ore resources in the world, contributing substantial economic benefits to Sierra Leone, and operator African Minerals recently refurbished and replaced 74 km of its port and rail infrastructure, which links the mine and the port facility at Pepel, 200 km away. Specifying HDPE as a sustainable solution for the surface drainage at the new rail marshalling yard, African Minerals selected Polypipe through a competitive tender process. Ridgidrain benefits from a structured wall design that provides high ring stiffness and strength while maintaining a lighter weight than traditional pipe materials, enabling it to withstand the ground movement and differential settlement typical of transport infrastructure and working mine sites as well as providing excellent abrasion resistance both inside and out. The longer pipe lengths available reduce the number of joints required, significantly reducing the risk of leakage, while its extremely smooth bore resists blockage and makes the pipework system easier to maintain. The product supplied for the Tonkolili project was fully perforated to allow for effective subsoil drainage. In Central Africa, Ridgidrain has established a track record for excellent performance in substantial tailings management facilities through its installation at the Namoya mine in the Democratic Republic of Congo. Situated at the

south-western end of the Twangiza-Namoya gold belt, the mine selected Ridgidrain to provide effective subsoil drainage as part of its tailings dam. Tailings management facilities are essential in ensuring the mine operates in an environmentally-conscious manner, and the Ridgidrain system allows for the controlled seepage of treated water. The system can also deal with unpredictable fluctuations, due to factors including stormwater, and is a crucial element of an effective water management system.

Namoya mine Polypipe supplied the Namoya mine with 1 386 m of 500 mm diameter and 190 m of 600 mm diameter Ridgidrain twinwall pipe, shipped via eight 40 ft sea containers, which required close coordination between Polypipe’s UK manufacturing operation and the shipping agent in order to meet deadlines and ensure the full order was dispatched as one shipment. Ridgidrain is, however, just one of Polypipe’s products that is ideally suited to the operating conditions typical of mines, with PE100 also bringing considerable benefits to the mining industry, wherever a medium-pressure pipe is required. Able to handle up to 25 bar pressure, PE100 is also resistant to thermal shock and will stand up to the harshest of environmental conditions, operating between -40°C and +60°C – ideal for mines at high altitudes where temperatures can drop well below freezing, and also for mines in arid, hot climates. It also offers the same resistance to chemical corrosion or rock and metal abrasion that has made Ridgidrain so popular with mine operators.

Above-ground applications For above-ground applications, black PE100 systems have the additional benefit of being UV-stabilised and, therefore, do not need to be buried or covered, as they are inherently resistant to weathering. Additionally, PE is naturally non-conductive and is, therefore, not at risk of electrolytic corrosion, subject to taking the correct precautions to avoid the build-up of static discharge – however, should there be a

requirement, electrically-conductive systems can be produced. An issue that many modern mine operators have to factor into their development strategies is sustainability, which can not only influence the mining operations themselves, but also the choice of materials for infrastructure work. Both HDPE and PE have the advantage of excellent environmental credentials. With ongoing technological innovation, they have become thinner, lighter, and more robust than most rigid materials, and typically weigh 94% less than their concrete equivalent – delivering excellent benefits in terms of reduced transportation costs, manoeuvrability, ease of installation, and also the possibility of reuse. Additionally, the interior surfaces of PE pipes resist bacterial growth, an attribute which is essential for the supply of drinking water to remote mines, where no mains supply is available. Concrete and metal pipes, meanwhile, can be badly damaged by both bacterium sediment build-up and galvanic corrosion, to which PE is resistant.

Conclusion Polypipe’s water management solutions address many of the issues faced by mine operators – from transporting the pipes to remote sites easily and safely, to resisting degradation from the chemicals used in mineral extraction. Where Polypipe adds considerable value is through its world-class manufacturing capability that delivers pipework systems designed to perform to a consistently high standard. Every product made is governed by stringent British and international standards to ensure Polypipe systems, including PE100, are fit for purpose and capable of being easily assembled and installed to ensure that the performance of the system is never compromised.

www.polypipe.com

IMIESA September 2015

PIPES & PIPELINES

Park Station in Johannesburg recently underwent a major sewer upgrade to facilitate a forthcoming upgrade and expansion – without disrupting the trains. Trenchless technology was seen as the ideal solution. BY BEATRIX KNOPJES

COMBINATION OF high traffic volumes through the station and aging infrastructure meant that the station was in dire need of sewer and stormwater upgrades. The train terminus was experiencing regular blockages in the sewer system and these urgently needed to be dealt with. The station will be undergoing a massive upgrade, to the tune of R1.5 billion, over the next three years. “The station is a hive of activity, with buses, taxis, and trains all congregating here as the 300 000 daily commuters move in and out of the city. Over the past year or so, we have expanded our food court and a number of banks have set up operations within our mall. Our sewerage could not handle the current capacity; it certainly would not handle future capacity. Thus, we needed to intervene before we moved forward with our upgrades to ensure all necessary infrastructure was in place,” explains Tumisho Makofane, executive manager: Strategic Portfolio Programme Management of the Passenger Rail Association of South Africa’s Corporate Real Estate Solutions (Prasa Cres).

A living station The project, valued at R38 million, will allow Prasa Cres to expand its current floor space of 25 000 m2 to 40 000 m2. The expansion has just completed Phase 1, with Phase 2 expected to commence in April 2016. “Our biggest problem is that this is a live station – we cannot stop the trains. Thus, innovative solutions for the sewer upgrade were required. This is why we opted for trenchless technology,” states Makofane.

RIGHT A new sewer manhole in between the railway tracks at Park Station

IMIESA September 2015

Park Station sewer upgrade

PIPES & PIPELINES

The major overhauls of the station will make the commuter’s experience a more enjoyable and convenient one. Says Makofane: “We want Park Station to be a destination point, similar to an airport. We have a number of car hire services at the station, as well as food and clothing stores. We are building a clinic with doctors and dentists and introducing a mini Home Affairs office for commuter’s convenience.” “We have had to train our tenants, particularly in the fast food outlets, to not flush things into the sewer system unnecessarily such as oil, and to make proper use of their fat traps in order to assist with the maintenance of the new sewer system.” Consulting engineering firm SMEC South Africa, in partnership with contractor Trenchless Technologies, completed the project to rehabilitate sewer and stormwater reticulation systems at Park Station in Johannesburg on behalf of client Prasa Cres.

“The station is a hive of activity, with buses, taxis, and trains all congregating here as the 300 000 daily commuters move in and out of the city.” Tumisho Makofane, executive manager: Strategic Portfolio Programme Management of Prasa Cres.

RIGHT Manhole construction on the Park Station platforms. Railway lines had to be operational at all times IMIESA September 2015

+27 (0)86 006 6344 info@trenchless.co.za www.trenchless.co.za

WE ARE IN THIS TOGETHER Our customers wanted more power to perform all functions at once. They wanted a heavy-duty stakedown system for greater stability when boring and backreaming. They wanted greater horsepower, a higher-capacity pump, advanced electronics - and, of course, they wanted all of it to be easy to operate. Our engineers love a challenge, and you’ll love the JT30 All Terrain directional drill.

The Ditch Witch TK Series HDD Guidance System: You can cut through noise and complete bores with an unprecedented level of confidence, thanks to the TK Series’ dual locating methods (peak and null), four-frequency beacon, depth range of up to 33.5 m, high-contrast graphics, and much more.

Tri-Hawk Down-hole tooling for soft to medium rock, fractured and chunk rock

The JT9 combines the simplicity and easy operation of smaller horizontal directional drills with the advanced features of bigger drilling machines.

We don’t just sell equipment. We pledge to be there when you need us. After all, we’re in this together. Authorised Distributor

ELB HEAD OFFICE: 14 Atlas Road Anderbolt Boksburg (011) 306-0700 • e-mail: Elb@elbquip.co.za • www.elbequipment.com DEALERS & BRANCHES - RSA AND EAST AFRICA: BRITS: (012) 250-1565 • CAPE TOWN: (021) 933-2383 • DURBAN: (031) 464-6522 • EAST LONDON: (083) 427-0993 GEORGE: (044) 878-0874 • KIMBERLEY: (053) 841-0040 • MIDDELBURG: (013) 246-2312 • NAIROBI: (00254) 20 807 0728 • POLOKWANE (015) 293-1978 PORT ELIZABETH: (041) 451-0232 DEALERS - SOUTHERN AFRICA: BOTSWANA: (00267) 390-9972 • LESOTHO: (00266) 2831 3926 • MOZAMBIQUE: (00258) 214-460094 • NAMIBIA: (00264) 61-234-052 SWAZILAND: (00268) 518-5348 • ZAMBIA: (00260) 212-210-642 • ZIMBABWE: (00263) 4 485 771/2/3/4

PIPES & PIPELINES

According to a press release issued by the company, the project was an important showcase of consulting engineer SMEC South Africa’s total solutions package, from initial investigation to preliminary design report, construction drawings, and overseeing the entire construction process.

“Conventional trenching techniques were not an option, as the line that had to be replaced ran underneath the railway lines at Park Station.”

Horizontal directional drilling

Meghan Brinkley, professional engineer: Asset

“We opted for horizontal directional drilling (HDD) for the refurbishment of the Park Station sewer network. This is a steerable trenchless method of installing underground pipes whenever trenching or excavating is not practical,” explains Meghan Brinkley, professional engineer: Asset Management and Advisory Services, SMEC South Africa. “Conventional trenching techniques were not an option, as the line that had to be replaced ran underneath the railway lines at Park Station. HDD has a minimal impact on the surrounding area, making it ideal for a range of applications and soil conditions,” notes Brinkley. Makofane confirms: “The old cast-iron sewerage pipes run in line with the tracks. If those pipes get blocked, the overflow is rather unpleasant and, of course, people complain. We had to pump the sewerage on a weekly basis to keep it under control. Our maintenance cost will now go down considerably.”

The process The HDD process involves three main stages: drilling a pilot hole, enlarging (pre-reaming) the pilot hole and, finally, the pull-back installation of the carrier pipe. Uncontrolled or unguided drilling can result in damage or unforeseen complications, meaning it is vital to track the drilling head when drilling the pilot hole on the designed path. “Another important consideration is to maintain the designed slopes along the drilled path. The contractor utilised the iTrack system from Radiodetection to locate the bore head and keep it on track, providing the operator with accurate data on tilt angle, roll position, depth, remote left/ right steering, and alarm conditions,” elaborates Brinkley. The borehole is supported by a bentonite drilling fluid that prevents it from collapsing. Soil conditions are critical, as voids or incomplete rock layers can render HDD impractical. It also affects the type of heads used in the pilot-hole process. “During the geotechnical investigation, GPR (ground penetrating radar) revealed no anomalies along the designed path,” confirms Brinkley. HDD was used to drill a new 160 mm diameter HDPE pipeline diagonally underneath the train tracks at Park Station, in order to connect existing manholes with the new main-line manhole constructed on PF11 (Platform) and PF12. A new 250 mm diameter HDPE line was also drilled from the new manhole on PF11 to PF12 then to the municipal connection manhole under Harrison Avenue Bridge.

Maintenance In order to prioritise effective maintenance, the new reticulation network was structured for easy accessibility. SMEC South Africa’s investigation called for repairs on existing sewer pipes inside sewer ducts. In addition, inspection eyes had to be installed and joints adequately sealed. “The driving factor behind the use of trenchless technology was to have minimal disturbance in the station. In fact, most people did not know we were doing the upgrades at all,” explains Makofane. All sewerage flowing from the above-ground shopping outlets and toilets between PF1 to PF10 is now collected by four 110 mm diameter uPVC pipelines, supported by a service tray for easy access and visible inspection.

IMIESA September 2015

Management and Advisory Services, SMEC South Africa

“It is important that these pipelines run parallel to the train tracks and do not cross the train power lines at any point,” stresses Brinkley. Four 110 mm diameter uPVC pipelines drop vertically and offload sewerage into platform manholes, as well as a new manhole constructed on PF9 to PF10. “Going forward, continued maintenance will ensure effective operation of the sewer network for years to come,” states Brinkley. “We are upgrading all of our stations, with Cape Town already complete. It is a delicate balance of creating a modern, functioning station and, at the same time, preserving the heritage of our old stations, particularly in the case of the Pretoria Station. However, we are determined to change the commuter experience and make public transport, particularly rail transport, an attractive alternative,” concludes Makofane.

Horizontal Trenchless & Vertical Drilling (Pty) LTD

PIPES & PIPELINES | HOT SEAT

HERRENKNECHT

German tunnel-boring machine (TBM) manufacturer Herrenknecht is the leading provider of holistic, technical solutions in mechanised tunnelling. Swen Weiner, area sales executive (Business Unit Utility Tunnelling), takes this Hot Seat to discuss Herrenknecht’s unique trenchless technology capabilities in South Africa.

In the trenches How would you define trenchless technology? SW The name says it all: underground construction without a trench! Trenchless technology is the collective term for all kinds of trenchless construction methods to excavate utility tunnels for sewage, water, cables, oil, and gas. In microtunnelling, a remotecontrolled tunnelling machine is used to construct a tunnel. Depending on the geology, different machines are available, like slurr y shields, earthpressure balance shields, or auger boring machines, which are used for pipe-jacked or segmentally lined tunnels. Another well-known trenchless technology used for steel pipeline installation is horizontal directional drilling (HDD).

Under what conditions is trenchless technology generally used? Generally, trenchless technology is used whenever conditions on the sur face are restricted or where ecological and economic reasons require an environmentally friendly installation method. Trenchless technology is often carried out in urban areas or in places where natural barriers have

IMIESA September 2015

to be overcome with minimal disruption. For crossing obstacles like rivers, for example, it is usually the only choice. The high flexibility of the different technologies available provides trenchless solutions for all ground conditions, even under groundwater.

Is trenchless technology accepted on a global scale? Acceptance and the level of utilisation depend strongly on the region. In Europe, for example, Herrenknecht has built a ver y good reputation for both the equipment we supply and trenchless technology in general. Having started in Germany in the early 1980s, the technology is well established today. Contractors are quite independent, and engineers and consultants are familiar with the basics of trenchless methods. In other regions of the world, we’ve had to start almost from scratch, explaining the functional principle of tunnelling machines and the possibilities the technology offers with regard to tunnel alignment, installation depth, and ground conditions. In some of these regions, we still continue our

educational effor ts to make clients and consultants more aware of the benefits of ‘going trenchless’.

Swen Weiner, area sales executive (Business Unit Utility Tunnelling), Herrenknecht

Where is South Africa on the scale of trenchless technology adoption?

What can be done to improve acceptance?

The technology is on the move locally, but still in an early stage. Although the basics of the technology are known, mechanised tunnelling is not yet used much.

Why do you think this is the case? Project owners mostly go for open-trench methods when they tender a project. Unfortunately, even consultants and engineers do not intend to change this right now. At first glance, open-trench solutions often seem cheaper than investing in tunnelling equipment; however, the indirect cost savings of using trenchless technology (e.g. less traffic disruption, earth movement and restoration, and speedy completion) are usually not considered. In addition, man is a creature of habit. People tend to trust in technologies they know well, even if there are more reasonable and beneficial alternatives.

Our mission is to train and convince all involved parties. Therefore, we have visited many project owners, municipalities, consultants, and engineers to present trenchless solutions, highlighting the benefits and ever-growing range of applications. Thousands of reference projects worldwide speak for themselves. Our presence at conferences and shows is obligatory. In addition, we have organised, and will continue to organise, roadshows and workshops promoting trenchless methods.

Which application fields could benefit from trenchless technology in South Africa? Currently, the focus is to convert sewage projects in urban areas from open-trench to trenchless. There is, however, another ideal application: since the surf zone of South African beaches often extends 200 m to 300 m into the sea, costly coffer dams are needed when open-trench

PIPES & PIPELINES | HOT SEAT

"Generally, trenchless technology is used whenever conditions on the surface are restricted or where ecological and economic reasons require an environmentally friendly installation method."

methods are used for installing marine outfall lines. Here, the use of trenchless technology would prove beneficial in terms of costs, time, and environmental impact. Based on 35 years of experience in trenchless technology, Herrenknecht is the technologyâ€™s global leader. Contractors around the world use our equipment to install hundreds of kilometres of tunnels and pipelines every year, while many also extend the range of application possibilities. Long-distance pipe jacking, the possibility of curved alignments, and great installation depths offer new perspectives to consider, especially

from a budgetary standpoint. And cost is what counts for municipalities!

What kinds of technologies are usually considered for sewerage and water networks? Generally, we think of remotecontrolled microtunnelling, in diameters up to 3 m. Globally, there is a rising demand for highcapacity, large-diameter tunnels, like the 3.5 m diameter water transmission line that will cross the mountains in East London. Here, segmentally lined tunnels may be a good alternative, due to the possibility of relatively long drive lengths.

And what technologies are used for pipeline crossings? When considering pipeline construction, we think of steel pipeline installations for oil and gas. However, Herrenknecht has proven, in various cases, that equipment solutions can be flexibly adapted to other areas of application. Herrenknecht HDD rigs have been used, in the past, to install water pipelines under rivers or out to sea. The installation is the same, whatever the final purpose is. With new developments, like our trademarked Direct Pipe method to install pipeline crossings in one step, Herrenknecht

ABOVE Based on 35 years of experience in trenchless technology, Herrenknecht is the technologyâ€™s global leader â€“ as seen here at the breakthrough of the Mahatma Gandhi Road sewer in Durban

uses its experience and engineering capacity to come up with innovative, optimised solutions that adhere to project requirements.

www.herrenknecht.com

IMIESA September 2015

PIPES & PIPELINES

Dynamic new flow transmitter

with 3D flow profile from NIVUS

HE NIVUFLOW 750 features new numeric discharge models saved in the transmitter’s internal memory, which allow more accurate and reliable determination of flow rates, even under difficult measurement conditions. Based on the ultrasonic cross correlation method, the system detects single velocities at different levels of the flow profile wherefrom the real 3D flow profile is computed. Several factors having an influence, such as channel shape, discharge behaviour, and wall roughness, are accordingly considered while calculating the flow. The ultrasonic flow meters visualise the 3D flow profile in real time. The compact dimensions of the new transmitter allow for installation on DIN rails and in switching cabinets, even under confined conditions. The connecting options, using plug-in terminals, on the transmitter front ensure quick and reliable wiring as well as allowing for quick exchange of the transmitter without tools. The modern menu-based operation with rotary-push button and colour display allows quick and easy commissioning of the measurement system on-site. Additional input devices or software are not required. The internal memory contains all common channel shapes and pipe geometries so that only the dimensions need to be entered. This additionally facilitates and expedites commissioning. Comprehensive diagnostic functions support users during the commissioning procedure as well as with maintenance, hence saving more time and costs.

NIVUS OFR radar The NIVUS product range now also features a non-contacting flow metering system for open channels and part-filled geometries.

NIVUS OFR radar

IMIESA September 2015

NivuFlow 750 transmitter

The NIVUS group, a leading developer, manufacturer and supplier of measurement instruments for the water industry, presents a new generation of intelligent transmitters for wastewater flow measurement. Visit us at IFAT Environmental Technology Forum Africa 15–18 September 2015 at the Johannesburg Expo Centre, Stand D19 The new OFR radar-based velocity measurement system shows its strengths particularly in combination with known ultrasonic measurement methods. Supplementing Doppler, transit time, or the cross correlation method patented by NIVUS, the system provides added value to accuracy and reliability of flow measurement covering the entire measurement range. Due to radar technology, OFR is well-suited as an individual system for flow measurements in aggressive or abrasive media. Moreover, it can be used for measuring in areas difficult to access, where processes cannot be shut down, or where it is not allowed for medium-contacting measurement systems to be installed. For flow calculation, the OFR system determines surface velocity as well as the level of the medium. NIVUS’ latest hydraulic calculation algorithms ensure reliable flow metering even under very

difficult conditions. Further benefits of the measurement system are the very low maintenance expenses. The system consists of an impulse-radar, for surface velocity detection, and an ultrasonic level measurement. The minimum distance to the surface is being measured 30 cm. Flexible holder brackets allow quick and easy installation on-site. Due to its versatility, OFR is a good choice, even for exposed measurement situations such as irrigation channels, mountain streams, and problematic media – e.g. coolants or contaminated media.

www.nivus.com

PIPES & PIPELINES

The South African Plastic Pipe Manufacturers’ Association (SAPPMA) has warned that failure to replace and upgrade South Africa’s water infrastructure poses a severe risk to both the quality and quantity of the country’s water supply.

Small industry, massive impact

OMMENTING ON THE state of the country’s water supply, SAPPMA chairman Jan Venter says his association had grave concerns about the severe pollution in our water sources, water losses in distribution caused by water leaks and wastage, and the lacking water infrastructure that is expected to support the rapidly increasing demand. SAPPMA represents more than 80% of the plastic pipe produced in South Africa, and focuses its efforts on ensuring the delivery of pipe systems that are leak-free and durable for long-term use. It also focuses on the rehabilitation of old pipelines. “Our members are the ones who would be supplying and installing these pipes if there were any upgrades and would, therefore, have a very good idea of the amount of pipes ordered and installations completed by government. Saying that we are very worried about the state of our country’s water infrastructure would be an understatement”, Venter says.

The heart of SA’s infrastructure Water distribution, waste disposal, irrigation, and telecommunications all rely on pipelines to function. Pipelines lie at the heart of South Africa’s infrastructure and should be replaced before they fail. Although the South African plastic pipe industry is relatively small, it is of extreme importance to the development and maintenance of the country’s infrastructure. It is also one of the most demanding industries,

as plastic pipes and fittings are required to last in excess of a hundred years, as opposed to the old cement of asbestos pipelines that had a lifespan of no more than 50 years. “Two major causes of water loss are corrosion and poor jointing. For this reason, old steel or asbestos pipes, around the world, are being replaced with plastic pipes, because they do not corrode and the joints are leakproof if fitted correctly. High-density polyethylene (HDPE) and polyvinyl chloride (PVC) pipes answer these calls with distinction, as the materials are lightweight and easy to handle, easy to join, available in a range of sizes and pressure ratings, and have low frictional resistance, with hydraulic properties that remain virtually unchanged

TOP LEFT Jan Venter, SAPPMA chairman TOP RIGHT Kirtida Bhana, Plastics|SA ABOVE LEFT Economist Mike Schüssler ABOVE RIGHT Mike Smart, Genesis Consulting Engineers

over their useful life, which results in low pumping costs,” Venter explains.

Water supply at risk “The majority of the old steel and asbestos cement pipelines that were installed around South Africa, in the early 1960s, have undoubtedly been corroded by now and long since reached the end of their effective lifespan. Unless urgent attention is given to the replacement and maintenance of the water infrastructure, the country’s

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“We are already experiencing the first impacts of this catastrophic component failure, with bursts starting to occur on a daily basis, as well as the negative impact of regular and prolonged disruptions in service delivery.” water supply could soon be following in the footsteps of the country’s failing electricity supply. We are already experiencing the first impacts of this catastrophic component failure, with bursts starting to occur on a daily basis, as well as the negative impact of regular and prolonged disruptions in service delivery,” he says. According to the Water Research Commission, who recently completed a survey

of 132 municipalities in South Africa, ‘nonrevenue water’ averages around 37% (water lost through leakage, incorrect metering, and unauthorised consumption). Explains Venter: “This amounts to a financial loss of around R7.2 billion per year. Australia, another waterscarce country, loses less than 10%. South Africa simply cannot afford to continue losing so much treated water.”

Urgent call to action In 2012, it was being projected that the country could run out of water by 2025, and its economic hub, Gauteng, possibly by as early as this year. Indeed, since late last year through January this year, parts of the province were periodically without water due to low capacity and high demand, exacerbated by the country’s electricity crisis and acid mine drainage. Acid mine drainage is being diluted with good-quality water from the Vaal River, a main source of water for the province. “Not many people spare a thought for the thousands of kilometres of plastic pipes that supply rural communities across Africa with clean drinking water. Although the country is

only now waking up to the fact that water is fast becoming a critical problem, SAPPMA sees the water market as one of our most important areas of focus and has been calling on decision-makers to pay attention to the warning signs before it’s too late,” concludes Venter.

SAPPMA Conference 2015 – Pipes IX This September, 15 local and international experts in the field of plastic pipe manufacture and infrastructure will take to the stage when they present their papers at the Pipes IX Conference. Hosted by SAPPMA, at the Bytes Conference Centre in Midrand, the support of the four main sponsors – Protea Chemicals, DPI Plastics, Marley Pipe Systems, and PipeFlo – has been essential in making it happen. “We are anticipating that the ninth Pipes conference will play an important role in reigniting the passion and focus of our delegates as we highlight the important role and responsibility that pipes and related industries have to fulfil in our country’s future,” says Venter. IMIESA September 2015

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REAL BENEFITS, NO PIPE DREAMS PVC pipes are all around us, mostly invisible, but always present. It forms an indispensable part of our daily lives, transporting clean drinking water; drainage for the waste we produce, for surface water; and protection for our telecommunication systems. The performance of PVC piping is exceptional thanks to the key attributes of this type of plastic, which allow it to outperform traditional metal pipes. PVC pipes can be recycled over and over again without any degradation of its physical properties. PVC pipes are versatile and can be moulded into various forms, and an impressive longevity means that it can function for well over 100 years with minimal maintenance. Low-cost installation, outstanding recyclability and durability, excellent hydraulic performance and low maintenance costs all amount to a tremendously cost-efficient piping system. Even though we might not notice it, PVC pipe offers significant advantages to Southern Africa and we experience these benefits every day.

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The best in the business Well-known economist and keynote speaker Mike Schüssler will kick off the day’s discussion, followed by Prof Kobus van der Walt of the North West University, who will be discussing the country’s water crisis. Other speakers on the day include: • Willem Wegelin (WRP) – ‘Pressure management in water reticulation systems’ • Ulrich Schulte (Germany) – ‘PE100 a “must”…What is next? Polyethylene for pressure pipes with further increased resistance to crack’ • Dieter Mueller (Battenfeld, Cincinnati) – ‘New technology in HDPE pipe extrusion’ • Ian Venter (Marley Pipe Systems) – ‘The importance of HDPE and PVC SANS permit conditions to the specifier and end user’ • Marcus Hawerkamp (Bauku) – ‘Highstrength spirally wound pipe and fibrereinforced spirally wound pressure pipe and pipe fittings for large diameters’ • Kirtida Bhana (Plastics | SA) – ‘Innovate… before it’s too late’

• Dr Mark Webb (SSIS) – ‘Pipe behaviour, soil behaviour & soil-pipe interaction’ • Mike Smar t (Genesis Consulting Engineers) – ‘Trenchless technologies: a specifically engineered pipe’ • Rachid Zahidi (Unicor) – ‘High-speed corrugated pipe manufacture: properties and installation’ • Pranesh Maniraj (Marley Pipe Systems) – ‘Electrofusion: A suitable alternative to buttwelding’ • Alaster Goyns (Pipeline Installation & Professional Eng Services) – ‘Importance of assessing sewer condition before rehabilitation’. “There is no denial that the pipe industr y is under pressure and going through a tough time. However, we know, from experience, that tough times don’t last – tough people and companies do,” obser ves Venter. “Attending the Pipes IX Conference will expose delegates to the latest research and findings, and provide a rare opportunity for the sharing of relevant ideas and best practices that have been tried and

“Although the country is only now waking up to the fact that water is fast becoming a critical problem, SAPPMA sees the water market as one of our most important areas of focus.” tested by the leaders in the field. It is of vital importance for current and aspiring engineers, plastic pipe manufacturers, specifiers, and installers to attend the conference so that they can broaden their thinking and understanding of the issues at hand. “While we indeed need to learn from yesterday, live for today, and also hope for tomorrow, the most important thing is to never stop questioning and learning,” Venter concludes. IMIESA September 2015

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Asset management at the click of a button Successful water and waste management are key challenges for municipalities around the world, as is providing communities with safe and reliable access to clean water. As infrastructure ages and populations continue to grow, these challenges can become more difficult to manage effectively.

FFECTIVE INFORMATION management is another problem we often face. With pipelines, as with other assets, it is no different; we can often have the information but without easy access to it, its value is greatly reduced. Innovative pipeline asset management tools can provide valuable information on buried assets. Knowing what assets utilities have and when they will require rehabilitation is crucial for planning and fiscally responsible decision- making. The magic happens, however, when we integrate this information with the power of Geographic Information Systems (GIS), making the data obtained easily available at the click of a button. The information does not need to be collected at one time and in most instances historical data can be included in the intergration process. Data can also be easily updated so that the latest situation is always available to assist with decision-making and planning.

CoveGIS Camjet has, over many years, developed the CoveGIS software that will integrate the data, allowing you to enjoy the power of having information – literally at the click of a button. CoveGIS is an add-on to ArcGIS, developed specifically for the pipeline industr y,

IMIESA September 2015

which incorporates multiple labour-intensive functions into a fully automated, easyto-use, highly specialised pipeline asset management system that addresses both pre- and post-GIS processes. It is designed to save time and money, allowing users to obtain the maximum value out of future, current, and aged data. With this system – which seamlessly integrates GIS information, GPS sur veys, CCTV video, inspection images, and conditional databases – risk assessments can now be per formed at the click of a button, enabling better capital planning decisions with reliable dynamic information. Camjet can provide the complete answer by obtaining the information from trenchless conditional assessments and integrating it into a GIS mapping system, or by using your existing information and simply making it more accessible and usable.

Pipe identification CoveGIS will make it possible to identify the right pipe to be replaced or repaired; the use of a risk analysis will determine the right time required and engineering principles will determine the right material and standards. By making use of asset management principles in conjunction with geographic information systems, it is possible to incorporate

knowledge of pipeline conditions, risk assessments, and engineering principles into one comprehensive program for managing pipeline assets from one central location at the click of a button. The primar y objective of any asset management program is to provide utilities with guidance on how to effectively use conditional assessment information and techniques to improve both the long-term planning and day-to-day management of assets. It is, however, imperative that these tools are easy to use, quick, reliable, and accurate – minimising lengthy labourintensive processes. CoveGIS helps streamline planning and decision-making by establishing maintenance priorities, budgets, and the planning of future projects, as well as providing information on the condition and useful life of a utility’s infrastructure. The software moves utilities from reactive to proactive asset management and bridges the gap between operations, engineering, and finance. A number of recent reports have highlighted the need for better asset management practices in the water and wastewater industr y as existing infrastructure ages. The prevailing thought is that better understanding, planning, and efficiency can help utilities save money and provide better ser vice to customers as they renew these assets. As water and wastewater infrastructure reaches the end of its design life, combining condition assessment with an asset management strategy will help utilities overcome the financial burden of ageing infrastructure.

PIPES & PIPELINES

EAD OF ETHEKWINI: Water and Sanitation (EWS) Ednick Msweli said, in a release, that this important milestone indicated that the city’s largest ever bulk water pipeline project was on target for completion in 2017. The completed segment of pipeline took two years to complete, and comprises the first two contracts of the R1.8 billion second phase of the Western Aqueduct. The first phase of the Western Aqueduct, which measures 20 km and stretches from the Umlaas Road Reser voir to Inchanga, was commissioned at the end of 2012. The third contract, which will see the remaining 25 km of pipeline laid from Ashley Drive to Ntuzuma, is already well under way. “The contractor, Esor Construction, will be entering one of the more challenging parts of this project as it excavates the thoroughfare near the Kloof Station, in order to lay the pipeline,” says project manager Martin Bright.

Significant milestone for

Western Aqueduct Phase 2

The Western Aquaduct is on track for completion in 2017, with the 14 km Phase 2 stretch of water pipeline, extending from Inchanga Station to Alverstone Reservoir and then on to Ashley Drive in Kloof, recently completed. BY FRANCES RINGWOOD

On-site at the Western Aqueduct: the soil erosion prevention liner is pegged into place with wooden pegs

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Urgently needed branch line Another project milestone has been reached in the awarding of a fourth contract to Esor Construction for construction of an urgently needed branch line running along Haygar th Road and under the N3 to Tshelimnyama. This 16-month long contract, worth R88 million, is expected to relieve water shortages in the Tshelimnyama area. It will entail laying a pipeline with a diameter of 600 mm from the entrance of Makaranga Lodge to the Haygarth Road Reservoir. From there, a 500 mm diameter pipe will take water to the existing reservoir in Tshelimnyama. This contract entails laying 8 km of pipe, crossing under the N3 at the Mariannhill Toll Plaza. However, according to Bright, there will be no disruption to traffic or visible construction work affecting the N3. Esor Construction will construct a

IMIESA September 2015

pipe jack that will push a 90 m long concrete sleeve under the N3. The new water pipe will be inserted into this. He added that Icon Construction’s work on the Ashley Drive break pressure tank was progressing well. On completion, during the third quarter of 2015, it is expected to hold 20 Mℓ of water.

Soil management As the largest pipeline project ever commissioned by EWS, the Western Aqueduct has been designed to significantly increase the capacity of bulk water flowing from the KwaZuluNatal Midlands to the greater Durban area. As with any large project requiring earthworks, proper soil management was needed. Geosynthetic linings are usually employed for this purpose, with a couple of biodegradable options available in the local market. Knowing the benefits of each assists landscapers

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ABOVE Plans showing the diversions in Church Road and Old Main Road in Kloof

and contractors in making the best possible choice within the environmental and cost parameters of a given project. South African geosynthetic linings company Kaytech’s SoilSaver products have played an important role in minimising soil erosion on a number of legs of the Western Aqueduct, most recently the hilly 7 km stretch from Alverstone Nek Reservoir to Ashley Road in Hillcrest.

Contractor choice Paul Lombard, Kaytech technical sales representative working on the Western Aqueduct account, confirms some of the details of the project: “During the design of the Western Aqueduct, Naidu Consulting approached Kaytech regarding soil-erosion protection for the many steep gradients and delicate grasslands traversed by Phase II of the pipeline. “Specifying the liner was easy: environmentally-friendly SoilSaver was selected as the ideal solution to this challenging project. Supplied by Kaytech, from a biodegradable 100% jute yarn woven to form a 65% open-mesh structure, the product effectively traps sur face soil particles and prevents aqueous run-off – helping to prevent wind erosion, as well as soil erosion. Open spaces in the weave provide lacunae for plant propagation and growth,” explains Lombard.

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Environmental sustainability According to the National Environmental Management Act (Act 107 of 1998), areas vulnerable to soil erosion must be rehabilitated to their former states once construction has taken place. Having extensive experience with the installation of SoilSaver, Rietvlei Landscape was awarded the contract for this job. “Since commencement of the project in October 2013, the company has installed about 53 000 m2 of the product,” confirms Shaun Renton, director of Rietvlei Landscape. “I absolutely stand by this

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JUTE’S ROLE IN ENVIRONMENTAL REHABILITATION

Jute is a fibre that can be processed into coarse threads. It is the same raw material as that used to make burlap and hessian cloth. One of the most affordable natural fibres, Jute consists primarily of cellulose and lignin. Another biodegradable material used for making soil-stabilising liners is coconut husks. What puts natural products such as these ahead of the curve, when compared to synthetic liners, is that they are biodegradable and, after two to three years, disappear, leaving no trace. Liners like these are essential for ensuring that grasses regrow on land that has been dug up for construction. This stabilises soil in order to prevent environmentally negative impacts such as desertification and sedimentation in nearby rivers.

ABOVE Selecting a well-designed liner will add to the environmental sustainability of a given project, through proper ground rehabilitation

product; we install more than 50 000 square sections per year and we’ve been using it to stabilise topsoil on projects – from landfills to golf courses – for the last 10 years. “It is one of the most cost-effective ways of stabilising unstable slopes, too. In addition, the liner is also extremely easy to install, requiring no particularly special skills,” he adds. “Without the protection of the liner on these steep gradients, the increase in overall kinetic energy of the surface water runoff, especially during heavy precipitation, would quickly lead to severe erosion,” comments Lombard.

Ecological contribution Simple to install, the erosion protection liner is pegged down to the topsoil, creating a multidirectional path for surface water run-off. Within two to three years, during which time vegetation is re-established, SoilSaver biodegrades, leaving no pollution. Unlike many other natural materials that draw on the soil’s valuable nitrogenous reserves during decomposition, the fibres resulting from SoilSaver’s breaking down actually add nutrients to the topsoil. Ultimately, the product is economical and versatile, being suitable for use in numerous applications in any climatic conditions. It is supplied in compressed bales of about twelve 84 m2 laps – each of which can each be easily carried uphill by one person.

Once completed, EWS’s Western Aqueduct project is expected to supply Durban with up to 400 Mℓ per day – meeting the region’s needs for the next 30 years. A successful project, to date, the installation of SoilSaver has been problem-free and grasses have already been restored in some of the rehabilitated areas.

Traffic diversions Kloof residents have been urged to take note of road diversions, which will affect traffic travelling along Church Road from Abelia Road to the Church Road railway bridge, starting at the end of August. The pipeline will run along Willingdon Avenue and Church Road for about 1.7 km but, to ensure a constant flow of traffic, a temporary access into Old Main Road will be constructed to allow for the pipeline construction along Church Road.

IMIESA September 2015

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Years ago, a railway crossing was built behind Kloof Station linking to Old Main Road and Church Road, but it was decommissioned. The railway crossing will be resurrected so vehicles are able to travel along Church Road from Abelia Road, across the railway line and onto Old Main Road, behind Kloof Station. This will mean the section of Church road affected by the pipeline construction can be closed without a major impact on traffic flow. Unfortunately, Transnet has only allowed the railway crossing to be kept open temporarily while the pipeline construction is being undertaken. Construction of the railway crossing will begin during the first week of August and is expected to take about three weeks. During construction, traffic will continue to flow along the current routes. Once the temporary railway crossing has been constructed and traffic rerouted, construction of the pipeline on Church Road Bridge and Church Road will start towards the end of August. There will be adequate signage and road markings to warn road users about the construction and alternative route.

Road closures on Intengu Road in Kloof: patrols are in place to assist traffic where roads close due to the Western Aqueduct pipeline construction

Traffic control and construction of this section of the Western Aqueduct will take about six months. The advantage of this change to the original plan is that the extensive construction along Old Main Road, in the area of the Village Mall and Kloof Station, will not take place. This is a major advantage, as the traffic congestion here would have been immense, should construction have taken place in Old Main Road. Residents will be issued tags to identify themselves to the flag person, allowing them access to their properties at all times. The Umgeni Steam Railway, which passes through Kloof Station on the last Sunday of every month, will continue to run. It is a requirement of the Rail Authority that the level crossing be properly managed and traffic controlled on days when the train is

running. The temporary railway crossing will be blocked off at both access points until the train has passed. Traffic control officers will be present during that time, to ensure no traffic crosses over the railway crossing. The two phases of the Western Aqueduct are intended to replace and augment existing infrastructure that brings water into Durban from the Midmar and Spring Grove dams. The Western Aqueduct is expected to considerably strengthen the capacity of bulk water supply and meet eThekwiniâ€™s needs for the next 30 years. Msweli said EWS was extremely proud of the progress made on the second phase of the Western Aqueduct, adding that eThekwini Municipality had recognised the need to put in place critical infrastructure that would have a major impact on the future of one of South Africaâ€™s most rapidly growing cities. IMIESA September 2015

NUWATER

This year is proving to be another exciting one for NuWater, as it secures further landmark projects, expands its product offering, and enters into new strategic alliances with local and international companies. IMIESA caught up with John Holmes, NuWater’s CEO, to discuss the company’s status.

NuWater's African expansion continues

INCE THE BEGINNING of the year, NuWater has, among other projects, secured an expansion and term extension at its flagship mine wastewater treatment plant at Anglo American Thermal Coal’s New Vaal Colliery; won a new 20 MLD water treatment augmentation project based on ultrafiltration technology with the eMalahleni Local Municipality; and begun a major roll-out of modular sewage treatment plants with a leading waste management company.

Mine water Holmes explains the relationship with Anglo, “Anglo American has been a customer of strategic importance for us for a number of years now. We have invested heavily in our technology and plant to ensure we deliver industry-leading solutions for mine drainage wastewater reclamation and reuse. Our modular and mobile solution has proven to be incredibly flexible, allowing us to be responsive to the changing water chemistry at the New Vaal mine. “This responsiveness has been rewarded with project expansions and a further threeyear extension to our contract. We continue to own and operate this plant as a complete wastewater treatment solution for the mine, and the plant provides high-quality process water to Eskom’s neighbouring Lethabo power station – a great example of effective wastewater reclamation and reuse.

IMIESA September 2015

NuWater’s collaborative approach with Anglo and other mining customers has also helped these customers to identify new areas where water can be more effectively and economically recycled and reused. Holmes continues, “Our work at Anglo New Vaal serves as a blueprint for the solutions we are developing with other mining customers. We have already demonstrated that our modular solutions can be effective at other mines with different water treatment requirements and wastewater chemistries; for example, at Goldfields’ gold mines in Ghana.”

business model offer a highly reliable and costeffective solution to the growing service delivery challenges in South Africa. The flexibility of our solutions allows us to easily roll out similar plants to municipalities across the country, and the fact that we own and operate these plants means that these solutions are much more affordable and, therefore, more accessible to municipal customers. Our expertise in the use of advanced membrane technologies also offers a step change in the efficiency of the municipal water sector.”

Distributed wastewater solutions Public sector impact It is not just in the industrial sectors that NuWater is making waves. NuWater is commissioning the first large-scale ultrafiltrationbased plant in South Africa to be used in the public sector. Holmes explains, “We are, again, using our modular and mobile technology suite to rapidly deploy a solution that will have an immediate positive effect on the water treatment capacity of the eMalahleni Local Municipality. We have a three-year contract to augment the municipality’s existing conventional water treatment capacity. We believe our technology and

Just as exciting for NuWater is its move into the wastewater treatment sector. The delivery of efficient and effective sanitation services is an increasing challenge, not just in South Africa, but across sub-Saharan Africa. The company appears to be leveraging its leading position in modular and mobile water treatment plants to offer similar solutions for sewage treatment. This is confirmed by the strategic supply agreement the company has entered into with Sanitech, one of South Africa’s leading sanitation solution providers. Holmes confirms NuWater’s ambitions in wastewater treatment, “The delivery of

NUWATER

Off-grid solutions

wastewater treatment solutions across sub-Saharan Africa represents a major challenge for both central and local governments, as well as for the private sector. This challenge presents a significant opportunity for the company to expand its innovative solutions set. Our relationship with Sanitech is an important part of our strategy to deliver rapidly deployable and cost-effective decentralised wastewater treatment solutions across the region. Our track record in delivering truly modular and mobile solutions, which per form reliably in the toughest operating environments, means we have immediate credibility with potential customers as we look to expand into the sanitation and wastewater subsectors.” The company has also teamed up with Miranda, a leading international provider of biological wastewater treatment technology, to offer completely modular and rapidly deployable wastewater treatment solutions. The Rotating Biological Contactor (RBC) technology used in these package plants ensures the lowest possible energy consumption, together with the highest levels of reliability with minimal maintenance requirements.

Central to NuWater’s business model is its focus on decentralised water and wastewater treatment solutions that can be rapidly deployed and, where relevant, redeployed. However, in its target markets of Southern and sub-Saharan Africa, one of the biggest challenges to the delivery of water and sanitation solutions remains access to adequate and reliable electrical power. NuWater has, therefore, developed completely off-grid solutions using solar energy as an alternative. Holmes explains, “Water and wastewater treatment are energy-intensive processes. Historically, water and wastewater treatment infrastructure has been centralised and large in scale, relying on the supply of power from an established power grid. In addition, centralised infrastructure requires investment in conveyance and distribution pipelines and utilises significant energy moving water and wastewater to and from these centralised plants. The central premise at NuWater is that water and wastewater should be treated as close to where it is produced and consumed as possible, minimising investment in costly infrastructure and facilitating the local reuse of water. This requires a very different approach and mindset to solutions and service delivery. NuWater has, from the start, been built around offering these flexible decentralised solutions.” Holmes continues, “In order to maximise the relevance of our solutions and services to our target markets, we have had to also ensure that we offer suitable flexible power options. As our decentralised plants are, by definition, smaller than the conventional centralised plants, it is far more practical to use alternative renewable energy sources. We have chosen to focus on solar as the most practical power solution for our off-grid solutions. We

LEFT NuWater provides modular, rapidly deployable water and wastewater treatment and desalination plants and services ABOVE NuWater and Acciona's combined experience with reverse osmosis desalination covers small to very large plants

are seeing a steady uptick in demand for our completely off-grid solutions from both existing and new customers.”

Holistic approach Not content with its apparent leading position in decentralised water and wastewater treatment solutions in Southern Africa, NuWater has also recently entered into a strategic collaboration with Acciona Agua – a world leader in the design, construction, and operation of large-scale water and wastewater infrastructure – to target infrastructure projects in South Africa and neighbouring SADC countries. In conclusion, Holmes tackles this apparent contradiction in strategy for the company, “In Acciona, we have found a like-minded and dynamic team, with complementary skills and experience, that allows us to address the water and wastewater markets in South Africa holistically. We believe the combination of NuWater’s position as a dynamic leader in distributed, or decentralised, solutions, together with Acciona Agua’s skills and experience in engineering world-class large-scale infrastructure, will offer our customers a complete solution set, backed by the credibility and thought leadership of our combined companies.”

www.nuwaterglobal.com

IMIESA September 2015

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The Specialised Industrial Cleaning Division offers standard industrial vacuum cleaning services, as well as specialised services such as chemical cleaning, tank de-sludging, confined-space entry, asbestos removal and disposal, and automated bundle cleaning. It is supported by a highly specialised fleet of vehicles, plant, machinery, and equipment – which include a power lance, scissor lift, selfpropelled bundle extractor, and vacuum trucks – leading in technology, training, and safety.

Healthcare The Healthcare Division’s key asset is its health-care incinerator, based in Klerksdorp, North West. The incinerator typically incinerates third-party waste and is the only such facility in the North West province.

Wasteman Inland

Wasteman Inland is a fully integrated waste management service provider, specialising in the removal of general and industrial waste, recycling, and on-site management services. The division services a significant market of commercial shopping centres in Johannesburg, also providing demolition and site clean-up services. Wasteman Inland owns and operates its own baling facility, located at its H:H (hazardous waste) transfer station. In addition to its fleet-based offerings, Wasteman Inland has right of use of the Genesis Class B landfill site in Johannesburg. Genesis is open to receive waste from the industry and private contractors.

OUNDED OVER 30 years ago, Wasteman is a leading South African waste management company that provides fully integrated waste management solutions to a range of clients in the industrial, commercial, and domestic sectors. Wasteman ser vices over 4 000 clients, managing more than one million tonnes of waste annually. The company operates according to best available economic and environmental practice principles, to ensure that clients enjoy the benefits of constantly evolving best practice technologies and approaches.

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Recycling & Minimisation

Wasteman Automotive specialises in on-site total waste management, industrial cleaning, and specialised industrial cleaning, which ensures minimal staffing and detailed training on associated key functions. Quality systems and standard operating procedures ensure that segregation techniques are effective and maintained to reduce waste to landfill. With a national network of recyclers and end users of recyclable materials, Wasteman ensures that recyclable commodities are handled in a manner that ensures ethical adherence to all

The Vlakfontein joint venture is a new H:H landfill site being developed near Vereeniging, south of Johannesburg. Vlakfontein will be the second commercially available high hazardous waste landfill in the region. Vlakfontein is centrally located relative to the substantial industrial and mining operations in Gauteng, Mpumalanga, the North West, and the Free State. Vlakfontein is particularly well positioned to attract hazardous volumes from waste producers in the Vaal area – particularly the Sasolburg and Vanderbijlpark precincts.

Wasteman has extensive experience and expertise in the provision of customised waste management systems, including the recovery and recycling of suitable materials across the industrial, commercial, residential, and specialist facilities sectors. The applicable system can vary from a full sorting of recyclate, to the segregation and streaming of potential recyclate, with the removal of the ‘dry’ recyclate to a mechanised material recovery facility.

The Technical Division operates as a support function for the company on all technical aspects, providing a waste classification system and safety data sheet generation based on the Waste Classification and Management Regulations (GN 634), and full waste assessment. It manages the capping and postclosure management of the 100% owned Bulbul site in KwaZulu-Natal, the development of the Vlakfontein landfill, and operates two third-party landfill sites.

IMIESA September 2015

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Rural road asset management: A foundation for service delivery improvement Infrastructure has a direct impact on the quality of our living environment and creates opportunities for communities to prosper. As such, the Department of Transport has embarked on a drive to assist municipalities with skills shortages in the management of their road infrastructure. BY PRISKA MYBURGH & ALBIE HANEKOM

S PART OF THE S’Hamba Sonke programme, the Department of Transport (DoT) made grant funding available for the implementation of Road Asset Management Systems (RAMS), as set out in the framework for the Rural Road Asset Management Grant (RRAM), Division of Revenue Act (DoRA). The strategic goal of the RRAM Grant is to ensure efficient and effective investment in rural roads through the development of RAMS and the collection of associated road and bridge inventory data, condition assessments, and road-related assets such as road signage, pipes, stormwater channels, and traffic information. DoRA highlights and illustrates the interdependency in obtaining the ultimate goal of sustainable service delivery within all departments.

Objectives Improved data on rural roads will guide infrastructure investment and improve accessibility to, and mobility of, rural communities, as well as the prospect of future development. As this information is fully transparent, government will have a handle on it at all times, guiding proper planning on spending of infrastructure funds (from the MIG and elsewhere). This can be achieved by transparent monitoring of performance and monthly expenditure through a fully web-based system, which implies that management information on all projects is

accessible 24/7 – disjointed from infrastructure constrictions. Information is available per department, on portfolio, or per province or even at a lower level, should such information be required – providing essential information for network-level projects such as principal inspections, partial inspections, completed inspections, and visual assessments. Information can be drilled down for project-level inspections and maintenance programme implementation. It has been structured to respond to the prevailing statutory accounting compliance requirements, and recognised good practice pertaining to infrastructure asset management. In addition, good engineering best practice is encapsulated into the offering, which provides a professional and sustainable solution to national government. Obtaining adequate warning before serious structural failures occur, disrupting service delivery, due to extensive knowledge of the current state of infrastructure and historic records of spending, repairs, and strengthening, enables future budget forecasting through detailed and summarised reports. This supports ‘whole of life’ asset costs, ensuring that funds are to be allocated for the complete life cycle of assets, including the operation, maintenance, and replacement costs associated with assets. Benefits include knowing the location, condition, and usage of the available infrastructure while building human capacity,

economic empowerment, and community upliftment. Optimum efficiency enhancement of service delivery requires the implementation of an interrelated, transparent infrastructure monitoring and management system. This should harbour best practices, coaching, knowledge management, and human resource skills development. The primary aim of RRAMS is to integrate all relevant road asset information and improve maintenance planning and communication between municipalities, provinces, and the DoT, thereby substantiating decisions that will have an impact on one another. It is a cost-effective approach with a practical slant to road asset management and bridge management.

Approach/methodology This paper highlights how a holistic approach to the establishment of skills and support for provincial departments, districts, and local municipalities proves to be effective as a solution to eradicating service delivery challenges encountered in the past. Creating and establishing a transparent and accessible Asset Data Warehouse at the national programme management office requires the development of a deep business intelligence and data modeling solution, encompassing a unique institutional knowledge base of the governmental environments. All data pertaining to infrastructure and service delivery in the country,

IMIESA September 2015

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for all departments, is hosted here, guiding grant allocation and funding programmes based on justifiable facts void of intimidation and influence. RAMS comprises an interactive road asset management system for paved and unsurfaced roads, incorporating RISFSA (Road Infrastructure Strategic Framework for South Africa), now redefined as the Road Classification and Assessment Module (RCAM), and a Bridge Management Module incorporating the DER-rating system, as stipulated by TMH-19.

Key functions Interactive Road Location Reference System (IRLRS) The RISFSA/RCAM road dataset is geospatially referenced with a base reference system for all measurements of data. Road segments are uniquely identified by a unique road_id and this id can be used to reference all related road furniture data along with the kilometre position (TMH-18, 2013), for example, the blue marker boards on the Sanral toll routes.

This IRLRS usually has the following minimum attributes and is soon to be a national standard, enforced by TMH-18: road_id unique identifier across the entire authoritiesâ€™ network road_num a road number allocated to provincial and national roads only start_km indicating the start km position of this particular segment e.g. N1-22/37.8N end_km indicating the end km position of this particular segment e.g. N1-22/38N surface road surface types are flex (bituminous); gravel; concrete; block (concrete blocks); joint concrete; ultra-thin concrete reinforced pavement; earth; and undefined class the present RISFSA classification from 1 to 5a or 5b district district number length_km

the length of the road segment

Figure 1 Referencing of bridge loops

The minimum requirements for road network data are presently being finalised by the Committee of Road Authorities (COTO), through the publication of the new TMH-18. Road Asset Management System for Paved and Unsurfaced roads (RAMS) â€“ RISFSA and RCAM Road Asset Management may be defined as a systematic method of information

IMIESA September 2015

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collection, evaluation, and decision-making, which is necessary to permit the optimisation of resources for the maintenance, rehabilitation, and construction of pavements. The RRAMS prepares budgets and work programmes that will provide the optimum maintenance solutions for the limited funds available through identification, quantification, prioritisation, and budgeting for rural road networks.

Traffic control system (TCS) Through the purpose-specific grant allocation provided by DoRA, rural district municipalities should be assisted in collecting traffic data in line with the Road Infrastructure Strategic Framework for South Africa through manual counts of key road links. Meanwhile, the community is uplifted by using local unskilled labour, and obtaining traffic volume data not older than 3 years for RISFSA Class R1, R2 and R3 roads, and not older than 5 years for RISFSA Class R4 and R5 roads. Traffic information laying the foundation for (KZN-DOT, 2014) comprises: • r oad network planning for network improvements, alignment, surfacing, and paved width changes • traffic planning for the allocation of funds, modal splits, and land usage • traffic trends in terms of growth and mode changes • pavement management systems • accident and energy usage analysis

Bridge management system (BMS) All road authorities require some type of bridge or structural management system for keeping an inventory of bridge structures, culverts, and other structural assets. In addition, such systems should facilitate condition assessments in order to address any safety risks and required maintenance programmes. This is done by applying specialised functionality and generating useful maintenance management reports, including a GIS module wherefrom all structures are geographically available and coupled to the RLRS. A number of GIS themes are available to identify structures with different thematic properties. A BMS provides the functionality to serve as a master database, in which all relevant bridge and culvert data can be recorded, assessed, and managed.

In the past, not much attention was given by district municipalities to the condition of their bridges and culverts, with many bridge rehabilitation and maintenance projects being carried out on an ad hoc basis. A successful BMS is a valuable tool that can be used by district municipalities to manage all their structures, allowing for the prioritisation of all structures in terms of maintenance and rehabilitation requirements, which would lead to the optimisation of funding spent on structure maintenance and rehabilitation works. Thus, it is important to rate defects as opposed to giving the respective inspection items an overall condition rating. The rating system used for visual assessments of structures is called the DER-U rating system; this system helps the inspector to focus on the defects on a bridge or culvert (Struman, 2012). The degree (D) of the defect looks at how bad or severe the defect is. The extent (E) refers to how common the defect on the structure being inspected is, with relevancy (R) considering the consequences of this defect with regard to safety of the user and the structural integrity of the asset. The urgency (U) with which the remedial work should be carried out provides a way of applying time limits on the repair work. These time limits usually range from immediate for ‘make safe’ incidents to within the next 5 years, within the next 10 years, or during routine maintenance.

Integrated management reports and graphs Management reports and graphs are a direct result of integrated information

Figure 2 Integrated information management

management. One can see the whole picture within the current dispersed system, where inadequate or incompatible systems for managing information and communication can be amalgamated.

Integrated thematic map themes A thematic map focuses on a specific theme or subject area; it is specially designed to show a particular theme connected with a specific geographic area. These maps can portray any aspect of the geographical area that is available within the data. Examples may include the visual conditioning index of a specific road link; the structural priority index and location of infrastructure; and average daily traffic per road link. This increases the capability of hot spot analyses and visual reporting.

Spatial query facility on roads (geo-processing) This encompasses a user-friendly GIS-based, but GIS-independent, infrastructure and asset management solution (Hanekom et al., 2008). It enables the user to cut across functional areas in a data mining attempt, revealing information that would otherwise be hidden under layers of Decision Support System (DDS). DDS is fundamentally different to Management Information Systems (MIS) in that it is a computer-based information system providing sets of capabilities for non-routine decisions and suppor ts analysis and decision-making within the municipal environment or business sector.

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On the other hand, MIS primarily provides information on business unit performance to help stakeholders monitor and control the business. RRAMS is a data-driven DDS that supports decision-making by allowing users to extract and analyse useful information that was previously buried in large datasets collected in silos. Through knowledge discovery, one can identify novel and valuable patterns in large volumes of data through the selection, preparation, and evaluation of the contents, irrespective of which sector it originates from, providing cross-functional data analysis and pattern prediction capabilities.

Figure 3 Impact funding scenarios on paved conditions

Economic and human capacity building This initiative is aimed at addressing the ongoing deterioration of South Africa’s road network and has provided opportunities for small and emerging contractors aligned with the outputs stipulated by the S’Hamba Sonke programme. The S’Hamba Sonke programme seeks to empower young people to develop skills and enhance dignity and

human worth through constructive labour. It is supposed to target poverty stricken areas in the country and identify the special focus areas that deserve special intervention. Other objectives include building local capacity through skills development and mobilisation of resources to improve

community facilities like schools, clinics, and other social and economic opportunities by upgrading secondary roads networks, and fixing and repairing potholes. The DoT has, through the implementation of the RRAMS programme across seven provinces, created positions for around 150 civil engineering

IMIESA September 2015

Head Office: 12 Commercial Road, Wadeville, Germiston, 1422 Tel: 011 323 2000 / Fax: 011 902 1112 / Web: www.tosas.co.za Email: quotes@tosas.co.za / Branches: Spartan: 011 974 1971 Worcester: 023 342 0609 / Namibia: 0026 (46) 722 1942 Botswana: 00267 391 4957 / Bloemfontein: 051 435 0214 East London: 043 745 0595 / Hammersdale (KZN) – 082 492 3833

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• o ccupational health and safety (two days) • introduction to road building materials (three days) • practical road pavement engineering (three days) • design, construction, and maintenance of gravel roads (two days) • design, construction, and maintenance of low volume roads (three days) • bridge and culvert inspector’s visual assessment • i ntroduction to bridge management course (three days).

Conclusion

graduates. Most of these graduates obtained their diploma, with some being in their final year of registration with ECSA as professional technicians. Assistance provided through this training programme, among others, included visual condition assessment training and calibration using tablets and customdeveloped software. Further practical training included small group sessions where two or three graduates do visual condition assessments with an experienced assessor provided by the appointed service providers. All assessors were continuously monitored as part of the quality control measures. The graduates were required to pass a calibration test before they were allowed to work without the supervision of a senior road assessor; this incorporated a general standard for these opinion-based assessments. The accuracy of the visual assessment data depends largely on the knowledge, experience, and commitment of the assessors (TMH 9, 1992). Driver training was provided to graduates who possessed a learner’s licence. This was followed by an advanced driver training course, aimed specifically at travelling on gravel roads, which was undertaken in the vehicles that are used for the visual condition surveys (Zululand, 2014). All the graduates attended a Level 1 first aid course conducted by an accredited private emergency care training academy. General occupational health and safety induction, as well as a site health and safety induction, were provided to all the graduates by a professional site safety officer (Zululand, 2014).

Figure 4 Decision support system

Practical training towards national diplomas Graduates that have not obtained their civil engineering diplomas could use the current employment period as their practical year – this experience would then be signed off by their mentor at the end of the year. Graduates that have already obtained their diplomas have been registered with ECSA as technicians-in-training. Their logbooks will be signed off by their mentor after each phase of the project (e.g. after GIS centreline set development stage, and again after the visual assessments have been completed). Introduction to road building materials and practical road pavement engineering basic theory was provided by professionally registered engineers, with site visits depicting practical experience in placing of asphalt (A - E2) surface overlay with a 13 mm rolled in chippings. MobiCap user training sessions were conducted to aid in the use of road inventory data capturing software. In-house GIS training and support, provided by the service providers in conjunction with a formal classroom training session delivered by ESRI South Africa, in the use of Arc Map and non-accredited training in the use of QGIS open-source software were also offered. Graduates attended the following accredited courses (Zululand, 2014):

South Africa has infrastructure assets with a replacement value of several hundred billion rands. Limited skills are available for effectively managing this aging infrastructure. Principles to adhere to and of importance to remember are that ser vice deliver y does not end with the commissioning of the infrastructure. Effective management of infrastructure is required to ensure each facility reaches its designed life time and, with it, a balanced ser vice deliver y environment. Money saved on management of assets is not a saving, as it becomes a vicious circle once infrastructure is allowed to deteriorate. Expensive refurbishment becomes necessar y and there is even less money for ongoing maintenance. Deteriorating infrastructure leads to poor ser vice deliver y and reduced payment by consumers, exacerbating lack of cost recover y. In many cases, especially in South Africa, this leads to strikes and protests, which can become violent. Working together, we can establish a Balanced Ser vice Deliver y Centre to the benefit of all in the countr y. RRAMS is a combination of a condition-based system and a defects-based system, designed to find symmetr y in identifying and repairing defects that have a direct consequence on the integrity of ser vices and where the safety of users or the community are at risk. RRAMS aims to optimise and prioritise all remedial work activities required to repair or maintain specified ser vices, given a limited budget. For a full list of references, please contact the editor.

IMIESA September 2015

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Leave it to Lafarge

HE COMPANY FOCUSES strongly on the needs of its customers and their projects to develop innovative, holistic product supply solutions. The approach is proving to be highly effective, offering customers peace of mind and better value in a competitive marketplace. Lafarge South Africa is the local presence of the international Lafarge Group, a world leader in building materials. The Group’s brand baseline ‘Building better cities’ is founded on the huge global trend toward urbanisation and reflects Lafarge’s commitment to helping create cities that are desirable, sustainable environments for all people. This means contributing to better solutions that meet the needs of communities for decent housing, hospitals, schools and

offices, together with the associated infrastructure to connect and service cities, such as roads, airports, water, and power utilities.

Lafarge South Africa is in a unique position to provide the construction industry with building materials and solutions through having a strong presence in all of its construction-related business lines of cement, aggregates, readymixed concrete, fly ash, and gypsum plasterboard.

All-round support at Eteza A recent example of Lafarge South Africa’s efficient integrated service was on the Sanral contract to construct an overload control facility and full diamond interchange at Eteza, on the N2 in KwaZuluNatal. The main contractor was concerned about two main concrete issues. The driver of the project was the ability to place the Continuous Reinforced Concrete Pavement (CRCP) on time and within specification, when the closest commercial ready-mixed

concrete plant was 45 km from the project site. The second concern was ameliorating the heat of hydration (HOH) in the extremely hot, humid conditions. Lafarge’s successful offer to supply all main building materials, concrete, cement, fly ash, and 165 000 t of road aggregates, as well as 4 500 t of the company’s

IMIESA September 2015

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specialised cementitious roadbinder, RoadCem 32,5N, made it viable to provide a Lafarge mobile concrete batching plant on-site. This enabled the required combined total of 13 000 m³ of CRCP mix and other Conventionally Vibrated Concrete (CVC) to be supplied without compromising the quality or integrity of the concrete. The solution to assisting the contractor to control HOH was the supply of 6 500 t of Lafarge’s Powercrete Plus CEM II 42,5R premium technical cement. This unique product is not only a low heat cement with a typical HOH value of 227 J/g (compared with the EN 197-1 criterion of < 270 J/g at 41h), but it can also be extended further on-site with fly ash, to meet the various mix requirements.

Meeting a tight durability specification Similar support was provided to the main contractor on the Sanral contract to upgrade Section 14 of the N1 freeway between Trompsburg Interchange and Fonteintjie, a distance of 20.8 km. The site is some 120 km from the nearest fixed commercial ready-mixed concrete plant and this represented a potentially significant risk in terms of compliance with the tight durability specification.

IMIESA September 2015

Lafarge roadbinder RoadCem is being used in the rehabilitation of large sections of the R23 national road

The solution from Lafarge South Africa was to position a mobile concrete batching plant optimally on-site to service the major concrete pours and take on the durability risk. This was conditional on being awarded the full supply package of building materials. The successful outcome was the supply of 10 000 m³ CVC concrete, on specification, and on time. This involved the supply 3 500 t of Lafarge Powercrete Plus 42,5R cement, 7 000 t of aggregates, 1 000 t of fly ash, as well as 8 000 t of cementitious roadbinder, RoadCem. “Our construction contractor customers are appreciating the benefits of having their building materials supplied and managed from a single reliable source,” comments Lafarge South Africa’s Mike Fisher, development manager: Infrastructure Road & Rail. “By matching the extensive capabilities of Lafarge South Africa with the needs of the specific construction project and the individual construction company, we achieve consistent quality and better value all round for the stakeholders.”

BAUMA CONEXPO AFRICA 2015

African opportunities

SUPPORTING PROGRAMME will be introduced for the first time at the forthcoming Bauma Conexpo Africa. In addition to country specials and industry specials, Master Builders South Africa is holding its Annual Conference to coincide with the second edition of the international trade fair for construction machinery, building material machines, mining machines, and construction vehicles.

look at current technologies and trends within the construction machinery and mining market. The main focus is on the visions and challenges in the African market, as well as possible opportunities, and will include topics such as ‘Mining Cities’ presented by the University of Stellenbosch; ‘Changes to Import and Export Laws’ presented by the Bowman Gilfillan Africa Group; and ‘Doing Business in Africa’ presented by Nedbank and Intergest.

Country specials A key part of the supporting programme is the country specials, which will be held in the forum area, where various projects as well as selected African markets, with the opportunities and challenges that they offer, are presented in more detail. What is currently possible in the African market? Where does it make sense to invest and what needs to be borne in mind? The presentations which focus on South Africa as well as the Southern, Eastern, and Western Africa region, i.e. Ethiopia, Botswana, Kenya, Namibia, Nigeria, South Africa, and Zambia, provide answers to these questions. The country specials are organised together with partners and supporting associations.

Industry specials Industry specials will also be presented. Experts and associations from the industry

Annual Conference of the Master Builders South Africa A further highlight is the Annual Conference of Master Builders South Africa, which will take place, for the first time, during Bauma Conexpo Africa from 16 to 17 September. During the conference, members of the Master Builders Association and related industrial sectors from Southern Africa meet to encourage greater dialogue between members, decision-makers, and experts and to discuss current developments in the construction industry. The exhibitors at Bauma Conexpo Africa are also invited to present their products and services and establish contacts with participants and delegates. More detailed information regarding the theme blocks, organisers, and participants is available online at www.bcafrica. com/en/events

This year’s Bauma Conexpo Africa, which will take place at the Johannesburg Expo Centre from 15 to 18 September, is set to feature not only an impressive line-up of exhibitors, but also a number of firsts for this prestigious event.

IMIESA September 2015

BAUMA | VEHICLES & EQUIPMENT

Following the success of its debut, in 2013, high attendance is expected for Bauma Conexpo Africa 2015, with as many as 20 000 visitors – the majority coming from South Africa and other subSaharan African countries.

Showcasing a full offering

T THIS EVENT, Case Construction Equipment aims to raise its profile and create awareness of the comprehensive support it is able to provide customers in South Africa, and other markets in the region, through its strong dealer network. In collaboration with its distributor, CSE, Case will showcase its full line of equipment and complete solutions for construction businesses, which include retail financing, expert service support, and strong parts backup. “The African continent offers great opportunities for growth,” explains Andy Blandford, vice-president of CNH Industrial Construction Equipment for Europe, Africa, and the Middle East. “The Maghreb region and sub-Saharan Africa – South Africa in particular – are key markets for us. “Bauma Conexpo Africa provides us with the perfect platform to meet our customers and show them how we are able to help them get the job done and run their businesses effectively. Case has strong dealers in most of the larger African markets and offers the type of equipment that our customers need: robust, reliable machines able to operate in the toughest conditions and at the right cost of ownership,” he adds.

Meeting the specific needs of African construction businesses

FROM LEFT TO RIGHT Case CX210B, Case 821F, and Case 885B

The products that will be on display at the Case stand represent the brand’s wide offering and showcase its ability to offer customers a complete solution for their specific needs. On show will be the skid steer loaders and backhoe loaders, both trademark product lines in the brand’s offering in African markets. Among these will be the new 570T backhoe loader, which has been specifically designed and engineered to match the requirements of customers in the region who look for a reliable, high-performance machine and a fast return on their investment. This model shares the DNA of a long lineage of backhoe loaders, built on the company’s long history of industry firsts that include the world’s first factory-built tractor loader backhoe, introduced in 1957. More than 600 000 units later, Case backhoe loaders are synonymous with performance, high lifting capacity, best digging depth, and great breakout forces. The 570T runs a turbo-charged, four-cylinder FPT Industrial S8000 Series engine that delivers superior performance, high torque, and best-in-class fuel economy. The S-shaped boom has been designed for premium digging

and lifting performance, while its heavy-duty structure ensures strength and durability. The Case 570T reaches deeper than any other backhoe loader in this segment – up to 5.58 m with the Extendahoe dipper version. Customers looking for maximum flexibility can count on the lifting hook, welded to the bucket linkage, when they need the rear arm to lift and handle suspended objects – a unique feature by the manufacturer. The front axle is designed to handle heavy-duty applications, even in extreme conditions. This highly productive package comes with superior comfort; the largest cab in the industry is ergonomically designed to provide a comfortable workstation with excellent all-round visibility. The easy serviceability maximises uptime and productivity, while contributing to the low costs of operation. Also on display will be the 821F wheel loader, which is particularly appreciated in the mining and quarrying industries. The F Series wheel loader delivers fast acceleration, fast cycle times, high travel speeds and productivity, together with reduced fuel

IMIESA September 2015

BAUMA | VEHICLES & EQUIPMENT

consumption. The benefits that the F Series brings to construction businesses has led to these machinesâ€™ steadily growing success in the region. The B Series crawler excavators and graders have also been meeting with increasing success, as the demand for these product lines has grown, especially in the East African markets. The stand will show the CX210B and CX290B crawler excavators on steel tracks. These strong, rugged machines are built for durability and performance, while the exceptional fuel efficiency and long service intervals result in low operating costs. Also on the stand will be an 885B grader, featuring a powerful engine, rugged A-frame and

IMIESA September 2015

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moldboard design, best-in-class serviceability, and excellent visibility to deliver outstanding productivity on the hardest jobs.

Complete solutions to help construction businesses operate with success Case provides expert sales and service support through its network of strong dealers, which effectively covers most of the major African markets, and with the backing of the powerful resources and organisational skills of CNH Industrial. In South Africa, where the company has been active since 1960, the brand supports its customers in partnership with its distributor, CSE â€“ an established

FROM LEFT TO RIGHT Case 570T and Case CX290B

collaboration dating back to 1989. CSE covers the national territory through 5 branches and 24 dealers. Technical support it provided by its service network, which operates 15 service vehicles and a dedicated team of qualified technicians. Case customers in South Africa can also benefit from the tailored financing packages and extended warranty programmes offered by dealers and provided by CNH Industrial Capital, a specialist in financing for the construction industry with over 50 years worth of experience.

BAUMA | VEHICLES & EQUIPMENT

In January 2012, the engineering, procurement, and construction management services (EPCM) contract for the Shondoni Mining Project was awarded to a leading multidisciplinary engineering firm, as part of a R15.3 billion project by Sasol Mining to replace three of its ageing coal mines in the Secunda area.

Extreme hoisting

101

PON COMPLETION OF the upgrade, the three mines will be capable of supplying Sasol’s Synfuels complex with 42 million tonnes of coal per year, and transform the Secunda area into one of the largest underground coal complexes in the world. The Shondoni Mine is a strategic project for Sasol, replacing the Middelbult Mine and protecting the baseline feed stock for the Coal-to-Liquids (CTL) operations within Sasol Synfuels. Construction on the Shondoni Mine began in May 2013 and is expected to be completed by late 2016. The new Shondoni underground facility will be a fully operational and functional coal mine, complete with all infrastructure,

services and equipment, both surface and underground, to support 9.2 Mtpa of coal production, with an expected life of mine of 30 years. WorleyParsons’ scope of work over the 45-month EPCM contract includes design through to delivery of: an incline conveyor shaft, an underground equalising surge facility, a man and material shaft complete with winders, a ventilation shaft with three 350 m3 per second main fans, and allowance for underground capital infrastructure to support the mine. Other major packages are the main surface civil infrastructure, as well as an extensive materials handling system, which includes a 21 km overland conveyor.

TOP The hoisting and positioning of the winder house began early in the morning ABOVE LEFT AND MIDDLE The lifting and mounting of the winder house was a crucial stage in the surface infrastructure development ABOVE The massive winder house, including rigging, weighing 291 t, was moved 58 m across by crane and hoisted to a height of over 30 m

Groundbreaking progress Last month marked a critical and groundbreaking point in the project, with the strategic and highly technical lift and positioning of the mine’s winder house taking place. Malcolm Bentley, WorleyParsons’ project area manager for the Shondoni

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BAUMA | VEHICLES & EQUIPMENT

Mining packages, says that what made this particular portion of the operation so unique is that the Koepe winders were installed into the winder house on the ground, concurrent with sinking and equipment activities on the main shaft. This is something that has not happened before on any similar projects or designs. The original schedule and methodology allowed for the winder house to be lifted, in two parts, onto the top of the headgear, followed by the winder installation, which takes several months. Lifting the winder house as a fully installed unit, as opposed to moving it in two parts and only then installing the winders as is the norm, will recover at least three months of time that has been lost during the sinking of the main and decline shafts, which was mostly due to groundwater challenges and poor ground conditions. The lifting and mounting of the winder house was a crucial stage in the surface infrastructure development that required intricate planning, due to the high risk implications associated with this extreme hoist and the level of accuracy needed to align the winder house onto the existing headgear. The massive winder house, including rigging, weighing 291 tonnes, was moved by crane across 58 m and hoisted to a height of over 30 m before finally being positioned on top of the headgear. Sarens, a global leader in heavy lifting and engineering transport, undertook the lifting operations of the winder house. Bentley says that, while heavier crane lifts have been successfully achieved in South Africa, what made this process different and highly challenging is the size of the winder house, making it highly vulnerable to climatic conditions. “It was vital that there was minimal wind on the day of the hoist; moderate to strong winds could have created a force on the building, placing the lift at risk,” explains Bentley. Advanced weather forecasting technology was used and all risks identified and mitigated.

The hoisting The hoisting and positioning of the winder house began early in the morning, on Saturday 1 August, and took just an hour and a half from start of lift to commissioning position. Bentley goes on to explain that, once successfully positioned, the winder house was precisely surveyed before hydraulic rams were used to micro-shift the headgear around until the winders were perfectly aligned with the shaft and, finally, the unit was fastened to the headgear by the following day. The winder house is expected to be fully licenced and operational in early November, with the completed 11.7 m diameter main shaft system fully operational in January 2016, reaching a total shaft depth of 155 m. The shaft conveyance will be licenced to hold up to 200 people and carry a load of up to 65 tonnes.

IMIESA September 2015

BAUMA | VEHICLES & EQUIPMENT

Diverse applications

for a diverse audience With about 800 expected exhibitors, taking up 80 000 m2 of exhibition space, and nearly 20 000 expected visitors, the second edition of Bauma Conexpo Africa is well placed to confirm its role as the biggest industry event for the sector in Africa.

EW HOLLAND Construction, in collaboration with its South African distributor MB Plant SA, will be present at this years Bauma Conexpo Africa 2015 – the International Trade Fair for Construction Machiner y, Building Material Machines, Mining Machines and Construction Vehicles – that will be held from 15 to 18 September at the Johannesburg Expo Centre. “With 34 countries having participated in the first edition and the high expectations for this year’s show, we are sure that Bauma Conexpo Africa will ser ve as a prime opportunity for networking,” says Andy Blandford, vice-president: EAMA for CNH Industrial Construction Equipment. “We will be able to present New Holland

Construction’s latest innovations and technologies to our African customers and show how we are able to support them with our products and ser vices built around their needs.”

A line-up of innovative equipment solutions The event will offer the opportunity to see a rich selection of units from New Holland Construction’s equipment offering. The spotlight will be on its backhoe loaders and skid steer loaders, which are the company’s trademark product lines in African markets. Two entr y-level 97 hp B90B backhoe loaders will be on display to represent the company’s renowned range of backhoe loaders. Combining the power of a

wheel loader with the per formance of an excavator, the versatility and compact size of these machines make them the ideal solution for a wide variety of applications. The company’s backhoe loaders have been specifically designed to deliver impressive traction and per formance, together with exceptional fuel efficiency. The 200 Series skid steer loaders deliver huge per formance and manoeuvrability in a compact size, without compromising comfort or safety. For over 40 years, equipment operators around the world have trusted these machines to tackle even the toughest jobs in many diverse applications, including construction, landscaping, and agriculture. To date, more than 200 000 New Holland Construction skid steer loaders have been produced and have deser vedly become synonymous with best-in-class productivity, superior stability, and power ful hydraulic systems. The company will also showcase its heavy-duty C Series crawler excavators, including the 23 tonne E215C unit. The E215C crawler excavator is designed to deliver the ultimate in reliability and durability that customers expect. The long undercarriage provides dynamic stability and safe per formance on all terrains. This exceptional stability and optimal weight distribution enable the operator to make the most of the E215C’s superior

TOP New Holland 200B grader MIDDLE LEFT New Holland E215C MIDDLE RIGHT New Holland L213 BOTTOM New Holland W190C

IMIESA September 2015

BAUMA | VEHICLES & EQUIPMENT

No limits

New Holland L218

Integrated solution for leakage detection in drinking water networks? No problem with WATERFLUX. WATERFLUX electromagnetic water meter is now available with integrated pressure and temperature sensor as option. Thus it can be used for leak detection and quality monitoring in drinking water networks. The integrated solution eliminates the need for installation and wiring of external sensors, and presents pressure and temperature readings for each metering point. The integrated pressure sensor provides an alarm via a status output when the programmed upper or lower limit is reached. The integrated temperature sensor helps to monitor water quality. Adding the advantage of no straight inlet or outlet sections needed, the battery-powered meter can be installed even at remote monitoring points. GSM antenna (also battery powered) for remote transmission of readings is available as option as well as a protection class IP68 version. KROHNE – Water is our world. KROHNE South Africa 8 Bushbuck Close Corporate Park South Randtjiespark, Midrand Tel.: +27 113141391 Fax: +27 113141681 Cell: +27 825563934 John Alexander j.alexander@krohne.com www.za.krohne.com

breakout force and lifting capacity. Combining highly advanced electronic technology with a sophisticated hydraulic system, the E215C crawler excavator maximises performance and optimises fuel consumption according to the job requirements. The massive pushing power and high precision of New Holland Construction graders will also be represented on the stand by the top-of-the-range F200B motor grader. With a powerful and fuel-efficient engine, heavy-duty axles, and its unique design with the cab at the rear, the F200B provides impressive pushing power and is capable of tackling even the harshest conditions and the biggest jobs, when high power and a high traction capacity are needed. These wheel loaders are designed to give the biggest bucket payload in the industry and to get the job done with fewer loading cycles: with just three passes, the W190C can load a 19.2 tonne payload truck. Also on the stand will be the company’s telehandlers, masters of versatility that stand out for their performance, safety, and cost efficiency. Their outstanding stability and manoeuvrability, powerful traction, and breakout force drive productivity to new heights while the perfect visibility to the top of the fully raised arm allows for completely safe operation. African customers demand robust construction machinery to get the job done in the most extreme conditions. New Holland’s construction equipment solutions are built around the customers’ needs for productivity, reliability, safety, and fuel and cost efficiency. Its wide offering makes it the ideal choice for a variety of operational needs, including specific applications for key industry sectors such as infrastructure, residential building, and mining.

Comprehensive support from a trusted partner In partnership with MB Plant SA – its official distributor in South Africa, Lesotho, and Swaziland – New Holland Construction supports customers for the full life cycle of their equipment, from sales support and qualified product knowledge to after-sales services, technical trainings, and timely parts supply. “With regional offices located in Johannesburg and Durban, a new fully operational office in Cape Town, and a growing network of branches and dealers, MB Plant SA is able to provide comprehensive services and technical support to its highly diversified customer base throughout the country and Southern Africa,” states Franco Invernizzi, business director: Africa and Middle East. “In other African markets, we provide the same level of support through strong importers – for example, Rex Quip in Namibia; Ivecar in Angola; or Achelis in Kenya and Tanzania,” he concludes.

IMIESA September 2015

BAUMA | VEHICLES & EQUIPMENT

Off-road fleet

acquisitions

HESE ARE THE first Foton vehicles to be purchased by Bobcat SA, part of the Goscor Group of Companies, which, in turn, is part of the Imperial Group. “The Foton Tunland pick-ups were selected for use by our service teams after we had undertaken practical evaluations of both the double- and singlecab models,” explained acting managing director of Bobcat SA Andrew Lai. “The decision was based on our long relationship with the Imperial Group and the Tunland’s value-for-money proposition. The fact that it uses an engine from Cummins, one of the major players in the construction equipment industry with a reputation for reliability and durability, was another plus factor. “Our type of operation places heavy demands on the vehicles used by our field service personnel and that is why we selected the Tunland Off-Road model, which was introduced locally about a year ago. We dealt with Gareth van der Westhuizen, from the Imperial vehicle importers head office, and were pleased with the service we received,” added Lai.

Taking quality and costeffectiveness off-road The Tunland Off-Road models do not have four-wheel drive, but a limited slip differential and high riding body, with 220 mm of ground clearance, means they are well suited for operating in off-road conditions such as those found on farms, construction sites, and the like. Keen pricing makes the latest additions among the least expensive premium single-cab pick-ups on the local market, with the Comfort model, as selected by Bobcat for its fleet, coming with a comprehensive list of standard equipment including air conditioning, electric windows, a multifunction steering wheel with Bluetooth, an audio system with a

radio/CD/MP3 player and AUX and USB audio inputs, as well as attractively styled 16 inch aluminium alloy wheels. The Tunland is the first and only light commercial vehicle currently in South Africa to be equipped with the famous Cummins 2.8 ISF turbo diesel engine, which makes it particularly well suited for operating in rugged and demanding conditions. The engine in the single-cab models produces 96 kW of power and 280 N·m of torque. This 2.8 litre four-cylinder Cummins ISF turbo diesel, which complies with Euro IV emission requirements, is also very economical, returning 8 ℓ/100 km in the combined driving cycle, which ensures a very good range from the 75 ℓ fuel tank. Transmission of power to the rear wheels is handled by a five-speed manual gearbox. Not only can the single-cab Tunland OffRoad carry a payload of 1 130 kg in its spacious reinforced load body, but it can also tow a braked trailer weighing up to 2.5 tonnes.

International alliances The Tunland is made at Foton’s ultra-modern, multifunction manufacturing plant in Beijing and is exported in built-up form to these global destinations. Foton has made sure the Tunland will be able to take on the global opposition by working with major international component suppliers. For instance, Cummins, of the US, has a joint venture with Foton for an engine plant in China where it builds the turbointercooled Cummins diesel engine that powers the Tunland. Foton sales and service is available at 36 dealerships in South Africa, while the Tunland is covered by a three-year/100 000 km factory warranty, three-year anti-corrosion warranty, and three-year roadside assistance.

A leading construction equipment manufacturer and distributor recently took delivery of a fleet of 10 Foton Tunland Off-Road pick-ups to be used by its service teams located in Alrode, Rustenburg, and Witbank.

IMIESA September 2015

Three words which perfectly describe Sephaku Cement and what we as a company stand for. With tons of cement produced daily, our flawless delivery ethos, and unrivalled professionalism, at Sephaku Cement we ensure you receive a product that you can be proud of. So, no matter the building demand, be it bulk or bag, we always have the supply. Now thatâ€™s living up to our promise. Sephaku Cement.

Call us on 0861 32 42 52 www.sephakucement.co.za

BAUMA | CEMENT & CONCRETE

Quarrying industry to push for autonomy Aspasa chairman Gert Coffee

Small quarrying operations throughout the country are carrying the back-breaking burden of supplying the country’s entire building and construction industry with up to 70% of the building materials used to construct infrastructure and housing.

OWEVER, INDIVIDUAL quarrying operators in this key sector are not being nurtured by government. Instead, they are being over-regulated and are pushed to the point where smaller operations are becoming unviable and left with no choice but to close their gates. This often allows for illegal mining to escalate and become uncontrollable. The problem, says Aggregate and Sand Producers Association of Southern Africa (Aspasa) chairman Gert Coffee, is that the regulation of quarries is lumped into the same legislative framework as mining and, therefore, the same rules apply for small quarries as they do for large gold or platinum mines. The burden on the financial resources of small quarrying operations is enormous and can easily drive input costs beyond the price that is attainable for sand and stone.

Localised operation “For this reason, we want to be recognised as different from the mainstream mining industry and want to draw attention to the fact that the majority of members are smaller operations outside of towns that do not have the same resources that mainstream mines have. Without these small quarries, however, the construction industry in the area that it serves will be severely impacted, as materials will need to be shipped in, although road transport of aggregates beyond a 100 km radius is uneconomical and exceeds the attainable market price.

“Another problem is that input costs are pushing the price of sand and stone upwards and, as a result, building costs are rising to the point where illegal quarries and borrow pits are starting to thrive. With no regard for legislation, tax, royalties, or even the well-being of their workers, these unscrupulous operators can undercut their legal counterparts and drive them to closure,” says Gert. He explains that, in order to bring relief, Aspasa wants to work with the authorities to explore a separate sectorial classification that can be tailored to the industr y and govern it according to its own requirements. “It is not at all that we do not want to be regulated, but rather that we want regulations to be useful rather than counterproductive.

Construction materials “In a number of other countries, the industry is regarded as separate from mainstream mining and is defined rather as construction materials quarrying. It, therefore, takes into consideration the industry’s role as a key material supplier for the construction industry and acknowledges the materials’ importance in the building of roads, railways, infrastructure, and housing. “It also tackles legislation that is targeted at the types of equipment found on these sites; covers relevant health, safety, and environmental issues; as well as defines taxation, royalties, etc. in a different light compared with mainstream mining. With

our own set of rules and regulations, we can also begin addressing issues that affect our industry head-on, rather than adapting our response to an industry that is similar, but not the same. “For example, we can formulate sectorspecific skills development plans and work with government departments at all levels to eradicate illegal mining. More importantly, we can work in parallel with government and the construction industry to ensure the success of future construction and infrastructure projects on a national and local scale,” he says.

Toeing the line Gert concludes that, in the past two decades since the formation of Aspasa, the association has actively worked with all role players to establish acceptable working codes and best practices. It has also taken safety, health, and environmental ethics on its quarries to world-class standards and has implemented annual audits to ensure members comply with its strict guidelines, as well as with all legal and statutory requirements. “As a key role player in the mining industry, a member of the Chamber of Mines executive committee, and an active role player on various government and industry panels, we believe that the time has come for us to define our own sector, with rules designed to protect and promote companies and individuals within the quarrying industry.

IMIESA September 2015

A strong foundation for infrastructure success

BAUMA | CEMENT & CONCRETE

A multilingual approach to concrete education Matthews Magwaza has one important attribute that helps teach hundreds of South Africans how to correctly – and profitably – use concrete: he can speak five South African languages.

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AGWAZA, WHO HAS been associated with The Concrete Institute and its Midrand predecessors, the Cement & Concrete Institute (C&CI) and Portland Cement Institute (PCI), for a total of 18 years, says many previously disadvantaged South Africans are keen to pursue a concrete-related career. "But, the problem is that most of these people acquired all their concrete knowledge by watching friends or other people doing building work, so they end up being enthusiastic self-taught individuals, without the vital technical knowledge of how to use concrete correctly to create durable structures, or make quality bricks and blocks. This is why I enjoy my job so much – teaching these people how to enjoy their work and earn a living from even basic concrete technology," says the School of Concrete Technology lecturer. Another training obstacle many of these budding concrete businesspersons face is language. "For many years, South African concrete training was mainly conducted in English or Afrikaans, and a large percentage of black people, thirsty for concrete knowledge, could not properly understand the lecturers. In cases where they were illiterate, this was even more of a problem. The school's training is done in English but I am fortunate to be able to elaborate and answer students' queries in Afrikaans, Zulu, Xhosa, and the Sotho languages, if required," he adds.

A solid foundation Now 51, Johannesburg-born Magwaza, after leaving school, joined Cement Distributors of SA, which was closed down after the cement cartel was disbanded. Although familiar with the distribution and supply of cement, it was on a Cement Distributors site visit to a cement production plant that Magwaza, for the first time, saw how cement was actually made. "I was intrigued, and wanted to know more about the potential of the grey powder I had become so familiar with," he says. His hands-on days moved a little closer, location-wise in any event, when he joined the admin department of the SA Cement Producers' Association (SACPA), which operated from Portland Park in Midrand – the then headquarters of the School of Concrete Technology of PCI. When SACPA also closed doors, Magwaza joined PCI and was a jack of all trades initially, working in just about every department

IMIESA September 2015

BAUMA | CEMENT & CONCRETE

Matthews Magwaza, lecturer at The Concrete Institute's School of Concrete Technology, can answer students' queries – in five languages

– even the library – but never at the School of Concrete Technology. "But, I often popped into the school's lab during my lunch breaks and asked questions and watched how the lecturers mixed and tested concrete. I then asked PCI if I could enrol for a basic training course at the school; and, immediately, once I felt concrete in my hands, I knew I wanted to get my hands dirty with this material for the rest of my life," explains Magwaza. His big chance came when Rob du Preez, then education and training manager for PCI, decided to offer Magwaza a job as lab trainer when a position became vacant. "I was put through extensive training, but was never happier. And, to this day, I have never lost my love for concrete," he asserts.

Concrete can change your life Magwaza has provided training not only in the school's lecture rooms and laboratories in Midrand and other major South African cities, but also on building sites and in the veld and under trees all over South Africa and its neighbouring states. He has, in the process, seen men and women from all walks of life watch in amazement and delight as they mixed concrete properly for the first time in their lives – and marvelled at the products they finally produced during training. "Some of my students have become successful business people, running concrete brick and block production yards. Some are even erecting structural elements, while others have rapidly been promoted within their companies. Their backgrounds vary: most came from impoverished family backgrounds, but I have even taught a qualified medical doctor how to use concrete. She quit her job and opted for a career in concrete. That's concrete for you – it can change your life. It certainly did for me," he concludes.

IMIESA September 2015

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BAUMA | CEMENT & CONCRETE

Quality concrete at reduced operating costs Readymix wet batch plants – with capacities ranging from 30 m3 to over 240 m3 per hour – are a more cost-effective alternative to the traditional dr y ‘Karoo’ batch plants that currently dominate the local market.

AN MIXERS SOUTH Africa (PMSA) is the largest supplier of concrete brick, block, and paving making machinery in Africa. To maintain its competitive edge, the company recently entered into a local partnership with Italybased construction machinery manufacturer IMER. The partnership will see PMSA stock and distribute IMER wet batch plants to industries across Southern Africa. Globally, wet batch mixing plants are the standard for readymix and site batching. PMSA marketing and sales manager Quintin Booysen indicates there is a noticeable shift towards this trend in Southern Africa, where high-strength and high-quality concrete is required in minimal time. “There is a definitive trend among plant owners looking to move towards wet batching. PMSA and IMER have identified this as a major growth sector and, as a result, we recently received two orders for IMER wet batch plants to showcase to existing and potential clients,” he explains. The IMER wet batch plants are fitted with either a planetary or twin-shaft mixer,

depending on the capacity of the plant. Booysen points out that the aggregate is batched automatically from bulk aggregate storage bins onto a weighing conveyor belt. “The weighed aggregate is fed into the mixer, where cement and water are automatically added. The concrete is then mixed by the forced action of mixing paddles and arms before being discharged, fully mixed, into the transit truck or even directly into a pump, as may be required in the case of on-site batching. The plants have, on average, a 90-second cycle time between mixes,” he adds. In dry batch plants, aggregate is loaded into a weighing hopper by front-end loader until the correct weight is reached. The aggregate is then sent, via a conveyor belt, to the transit truck. Cement and water are then added and the constituents are free-fall mixed in the truck. Once sufficient time has passed, with the drum rotating at high speed, an appointed ‘batch man’, located on an inspection platform, typically inspects the consistency of the concrete in the truck and, if required, adds more water before giving approval for the truck to leave the yard. An experienced batchman is required to estimate when the concrete is homogenous. When the truck arrives on-site, the foreman may request several more minutes of highspeed, high-rev mixing before the concrete is discharged. Wet batch plants create fully mixed concrete, which ultimately reduces costs, as it eliminates the need for high-speed mixing in the truck prior to dispatch. “It also reduces wear and tear on the fleet of trucks, which is a readymix plant’s highest capital expense,” Booysen continues.

What’s more, there is also no need to manually check the truck before dispatch, as the mix is completely homogenous by the time it is discharged into the truck.

Proven wet batch plant performance When comparing the quality of concrete produced in dry versus wet batch plants, research conducted by the Italian Institute for Concrete found that wet mix plants produce concrete of an undoubtedly higher quality than a dry process. Various reasons were cited, including: lower permeability of the concrete produced; repeatability, which reduces the standard deviation; and a reduction in errors made by inexperienced or inattentive personnel. The research also found that, when using the same water:cement ratio, concrete produced in a wet batch plant had a higher workability. This ultimately results in a reduction of the water:cement ratio for a higher-strength concrete with the same cement content. Finally, the research showed that the mixing effect of wet concrete mixers facilitates total cement hydration, as confirmed by mix designs, with a higher strength class that, nevertheless, uses the same quantity of cement. Given these findings, Booysen is confident that PMSA and IMER can achieve measurable growth in sub-Saharan Africa through industry-specific wet batching plants. “IMER is an internationally recognised wet batching plant manufacturer and, bearing in mind PMSA’s excellent standing throughout Africa, I am confident this partnership will bring considerable value to our local market, which will lead to sustainable growth long into the foreseeable future,” he concludes.

IMIESA September 2015

BAUMA | CEMENT & CONCRETE

Five geosynthetic reinforced retaining walls, using precast concrete retaining blocks, have played a crucial role in creating stable terraces for the construction of Emoyeni Mall on the R538 between Nelspruit and Hazyview in Mpumalanga.

Emoyeni Mall

on stable ground

HE MALL WAS built by one of the country’s leading rural retail centre development specialists, McCormick Property Development – a company with a strong focus on the emerging markets of South Africa. Engineered Interlock Solutions (EIS), in conjunction with TMV Consulting Engineers, designed the geosynthetic reinforced concrete block retaining walls. The walls were built by EIS in close collaboration with the main earthworks contractor, Joubert en Seuns. EIS owner, Manie Troskie, says that EIS won the retaining wall tender on the basis of an alternative and more cost-effective design, which also offered better functionality. “There are substantial quantities of subsurface water on this site and our design had to make provision for extensive drainage. In fact, there were some embankment sections where one could actually see water oozing from the ground. “Three walls were open-face designs and were built with Aveng Infraset’s Terrace Blok TB 490 and TB 300 retaining wall blocks. The other two walls were closed-face and built with the Infrablok 350,” he explains.

Drainage The largest wall, some 200 m long, was built in an open-face configuration at an angle of 70 degrees. It was constructed on

IMIESA September 2015

the perimeter of the property to reinforce an embankment that rose to 12 m at its highest point from a service road below. Troskie details the installation, “We only had five to six metres to work with on this wall and the installation of extensive sub-surface drainage was required before construction of the wall could begin. Subsoil drains were installed on top of the foundations threeto-four blocks below kerb level. Fin drains, wrapped in A2 bidem, which go right back to the cut face, were laid to trap water at the top, sides, and bottom of the embankment. “We also installed 250 mm Kaytech wick drains, which were wrapped with bidem. And, in areas with the heaviest water flows, we positioned 100 mm slotted pipes covered with stone and Geomesh geotextile to trap the water at the cut face. All groundwater drains into a pipe at the bottom of the wall, which runs parallel to the foundation and feeds into the stormwater drainage system. “The foundation of the perimeter wall was steel-reinforced. At 1 m wide, it varied between 450 mm and 300 mm in depth, depending on the height of the wall. TB 490 retaining blocks were used to erect the lower section of the perimeter wall and the upper section was laid with lighter TB 300 blocks,” says Troskie. High-tenacity Paragrid reinforcing supplied by Maccaferri was used to reinforce the wall.

The material was specified due to its very low elongation properties. It also attains its tensile strength very quickly and has a stretch factor of less than 5%. The Paragrid reaches back to the cut face and was laid at a spacing of every second block on the lower half of the wall. Macgird WG4 was installed at every third block on the top half and extends 9 m into the fill.

Taking reinforcement to the basement The parking basement wall was also built as a geosynthetic-reinforced wall. Rising to 5.5 m, it takes a heavier loading than the perimeter wall, as it has to support a portion of the weight of the building that was built on a jockey slab, concrete columns, and normal foundations. Because of the heavier loading, the wall was built using the TB 490 blocks only. “Basement walls are normally built with solid concrete retaining walling; however, retaining block walls are more cost effective,” advises Troskie. Two closed-face walls were built using Aveng Infraset attractive Infrablok 350 at an angle of 85 degrees, due to limited space. The one wall that varies in height, between 1 m and 3.4 m, was built adjacent to a carpark feeder road and supports a building platform, on which a Cashbuild store was built.

BAUMA | CEMENT & CONCRETE

The walls were built around the concrete support columns and reinforced soil, and the retaining wall supports a portion of the building’s loading. Maccaferri Paragrid was used to reinforce this wall to prevent any soil movement under the building’s foundations. The second closed-face wall was built around a water reser voir situated on ground above the centre. This wall was constructed with Infrablok 350 blocks at a face angle of 75 degrees and Macgrid

WG4 was used for geosynthetic reinforcing. A combination of Macgrid WG4 and cement-stabilised backfill was deployed in areas where the space between the reservoir and the concrete block retaining wall was limited. Other members of the professional team included the main consultant, Endacon Consulting Engineers, and the main building contractor, Ikotwe Construction. Over the past 33 years, McCormick Property Development has completed 58

ABOVE LEFT One of the open-face retaining walls at Emoyeni Mall ABOVE LEFT One of the closedface walls, built with Aveng Infraset’s Infrablok 350

shopping centres, which have become the benchmark for rural retail development. They are now extending their reach into Africa with a number of large scale projects in the pipeline, most notably the Mall de Mozambique in Matola, Mozambique. IMIESA September 2015

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BAUMA | CEMENT & CONCRETE

Celebrating one year of industry innovation

IRST INTRODUCED TO the industr y in July 2014, PPC’s C3 continues to offer users a subjectspecific, neutral platform where they’re able to source and share information, and interact with like-minded people. “C3 was conceptualised to bridge some of the collaboration and communication gaps we had noted in the industry,” explains Hanlie Turner, specialist: Technical Information Services at PPC. “Its interactive interface speaks directly to the need for electronic information sharing and networking, driving practical conversations where groups can leverage collective experience and knowledge.” Industry uptake supports this assertion – with over 1 200 registered users on the platform. C3 has driven a number of key conversations over the past year, with posts around innovation and creativity generating the most engagement. “The trend is towards shorter, catchier content for day-to-day interaction, while more technical content is accessed when a specific need for in-depth information is identified,” notes Turner. The Cube has attracted members from across the sector, including the likes of John Sheath, CEO and director of the Concrete Society of Southern Africa, and Johan van Wyk, general manager of the Southern Africa Ready-mix Association. Both note C3’s ease of use as one of its key features.

IMIESA September 2015

“Contact with others in your sector is continually encouraged, as you receive alerts when new people have joined your group. This makes it the ideal platform to share new ideas as well as innovations affecting the wider built environment, including inspiration from architecture, art, and building,” says Sheath. Users are able to join multiple interest groups. This has seen the growth of groups around subject matter including innovation, architectural concrete, C3 A – Z, and energy. The ease of searching for content across the groups remains one of the strengths of C3. “The platform has also demonstrated that there are no limits in terms of what cement and concrete can be used for,” adds Sheath. Current, and future, users can look forward to the continued evolution of the Cube. “We’ve already received requests for an app that will facilitate greater interactivity, much like Twitter and Instagram,” says Turner. “We’re committed to updating and refining C3 to respond to this type of request, as well as to keep abreast of leading social and electronic media trends.” To celebrate C3’s one year anniversary, PPC will be running daily competitions to encourage users to access the platform, experience its functionality, and interact with fellow community members. Visit http://c3.ppc.co.za/ppc to be part of the celebration.

A year since its launch, in 2014, PPC’s Cement and Concrete Cube (C3) remains a true triumph for the industr y. Designed to facilitate greater collaboration and information sharing, C3’s interactive inter face speaks to user trends and needs – with many groups now communicating on a daily basis.

BAUMA | CEMENT & CONCRETE

Hydro cutting for improved road surfaces Sean Pretorius, managing director of National Asphalt, says that this cost-effective and environmentally friendly system for the repair and remediation of flushed bituminous pavements offers a number of significant advantages.

EAN PRETORIUS, managing director of National Asphalt, says that this cost-effective and environmentally friendly system for the repair and remediation of flushed bituminous pavements offers a number of significant advantages. “Hydro cutting restores the friction and texture of a pavement using high-pressure water blasting, and can be used to remove flushed seals including bitumen, asphalt, and concrete without reducing the structural life of the sur face,” he says. “This innovative technology improves the porosity of the asphalt, which significantly reduces the risk of aquaplaning, limits the road spray generated by vehicles by as much as 90%, and reduces the road noise factor by 50%,” Pretorius says. “All of this improves general road safety while extending the life of the road sur face as the stone chip matrix remains in place after the bitumen has been removed.” Pretorius says that, when it comes to multiple seal layers, seal stability is dramatically improved, with a reduction in the overall bitumen content ratio of up to one litre per square metre per single treatment and a substantial improvement of the micro and macro texture of the seal.

An all-weather solution The hydro cutter process, which is operable in all weather conditions, can also be used to clean open graded asphalt that has been clogged by debris. By simply changing the spray bar nozzles, spindle speed, cutting speed, and pressure to create a ‘washing’ action, the hydro cutter will revitalise the asphalt by removing all detritus. The water pressure can be

adjusted from 85 bar to 850 bar and, significantly, no chemicals are used in the process. The hydro cutter comprises a truckmounted high-pressure water pump and vacuum recover y system and offers the flexibility to treat widths from 0.75 m to 3.45 m. The high-velocity vacuum system allows the cutting pressure as well as the texture depth to be determined while the machine is in operation. Water energy is focused in fine streams at high speed via five rapidly rotating blasting heads. The water streams physically cut the binder from the stone with the energy of each ‘needle’ of water dissipated upon contact. Using only water, this method of remediation is environmentally friendly and safe.

Environmental benefits Another significant and environmentally important advantage is that the hydro cutter can capture and secure all spillages and waste material gathered for disposal at designated waste sites. 95% of all waste is recovered by the system. The unit has a 5 000 litre water tank and a 1 000 litre waste water storage capacity. Pretorius believes the company’s strong focus on innovation and the continued development of new technologies will bring further benefits to all stakeholders, including an enhanced road-user experience with maximised safety. “By employing one or a number of technology solutions that National Asphalt offers, customers will be able to drive down costs in an environmentally friendly and minimally invasive manner,” Pretorius concludes.

ABOVE FROM TOP TO BOTTOM National Asphalt's strategic investment in Shisalanga Construction last year saw the addition of hydro cutting technology to the company’s road surfacing solutions Hydro cutting restores the friction and texture of a pavement using highpressure water blasting The hydro cutter comprises a truckmounted high-pressure water pump and vacuum recovery system and offers the flexibility to treat widths from 0.75 m to 3.45 m

IMIESA September 2015

BAUMA | CEMENT & CONCRETE

Creating learning possibilities

HE HANDOVER OF the first phase of the multimillion-rand project was celebrated at a ceremony hosted at Hoofweg Primary School, attended by the Minister of Mineral Resources, Ngoako Ramatlhodi, education MEC Debbie Schafer, AfriSam dignitaries, and community members from Wesbank and surrounding communities. AfriSam’s relationship with the Western Cape Education Department goes back a number of years, and, in 2012, the company heeded the call to partner in the construction of the centre for under-resourced local and surrounding communities that face the challenge of accessing educational resources and training facilities.

Ideal location The centre is strategically located at Hoofweg Primary School to provide easy access to learners from neighbouring schools and the community. With three primary schools and one secondary school in the area, more than 4 000 learners are expected to benefit. The centre will offer e-learning (teaching through information and technology), literacy, numeracy, IT literacy, and library services. The library facility will serve as the mainstream teaching resource for grade four to seven learners, with the school using its existing media centre room for the foundation phase learners. The centre will be fully integrated into the Hoofweg Primar y School programme in the

One of South Africa’s leading construction materials groups – in par tnership with the Depar tment of Mineral Resources, the Western Cape Education Depar tment, and Airpor ts Company South Africa – is creating learning possibilities with the launch of the state-ofthe-ar t e-Learning and Resource Centre in Wesbank, Western Cape.

IMIESA September 2015

PAVE THE WAY Technicrete Double Zig-Zag inter-locking pavers form a continuous and hard-wearing surface overlay. Both economical and aesthetically appealing, any project using Technicrete Double Zig-Zag allows you to achieve an elegant and highly functional result, with cost-effective budgeting being met. Suitable for: • • • • •

Construction of heavy duty areas Industrial sites Roadways Depots Various commercial applications

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Tel: 011 674 6900 www.technicrete.co.za

BAUMA | CEMENT & CONCRETE

TOP Inside the e-Learning and Resource Centre sponsored by AfriSam and Airports Company South Africa, in partnership with the Department of Mineral Resources MIDDLE The e-Learning and Resource Centre, situated at Hoofweg Primary School in Wesbank, is a multimillion-rand project set to benefit the surrounding primary and secondary schools, and under-resourced communities ABOVE Minister of Mineral Resources Ngoako Ramatlhodi officially opens the e-Learning and Resource Centre in Wesbank, accompanied by Hoofweg Primary principal Allistair Sauer, ACSA acting communications manager Deborah Francis, and AfriSam CEO Stephan Olivier

mornings and open for surrounding schools and the community in the afternoons. AfriSam corporate social responsibility manager Tsholo Diale said, “We hope this facility motivates and encourages the learners and community members to invest in their education, with the vision of a better future for themselves and their communities. “Our role, as AfriSam, is to create possibilities and uphold our legacy of building communities by making it possible for our people to realise their dreams for the future benefit of our countr y.” AfriSam’s commitment to the project is in line with the company’s overall community involvement mission, which is to understand the needs of society and communities in areas where it does business, and make meaningful and sustainable contributions to their upliftment. AfriSam has committed to funding the second phase of the project, which is the construction of a full public librar y for the community.

IMIESA September 2015

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BAUMA | CLAY BRICK ASSOCIATION

ENERGY EFFICIENCY

More than an R-value Although South Africans think of their weather as mild in comparison to countries in the Northern Hemisphere, the reality is that our macroclimate has its own unique complications when it comes to construction.

UILDINGS IN EUROPE focus on dealing with extreme cold – most energy costs are used in keeping warm – so double glazing, insulated walls and roofs, and tight sealing of windows and doors are all critical. Here in South Africa, winter temperatures in the Highveld approach zero at night, but the following day can easily reach 25°C. In summer, nights are hot, but days are truly blistering with temperatures as high as 40°C at midday. We cannot design and build our homes and offices to keep heat inside because, for at least 6 months of the year, our biggest issue is keeping the heat out! In many countries, wall thermal resistance (R-value) is the sole determinant of energy efficiency. Because they are not designed for South African conditions, many Innovative Building Technologies (IBTs) such as lightweight walling panels cite their R-value measurement as proof of energy efficiency. However, R-values have shortcomings.

A real-world study Over a decade of empirical study, at the University of Newcastle in Australia, into the thermal performance of different wall construction materials gives statistics under ‘real-world’ conditions, in a climate that is very similar to South Africa. In the study, dwellings that were constructed of different walling materials yielded a wide range of thermal comfort levels, even though they all had the same R-values.

They were also shown to need very different energy levels for heating and cooling to maintain a feeling of comfort for inhabitants. The empirical research compared the following materials: • insulated lightweight walling in compliance with Australian building regulations • double clay brick cavity walls, with and without insulation in the cavity • brick veneer (an external skin of brick applied to lightweight interior walls) and reverse brick veneer (a clay brick skin applied to the internal skin of the external wall). Despite have a good R-value, the insulated lightweight external walled building was the worst performer – it showed significant temperature fluctuations with daily temperatures reaching an uncomfortable 30°C indoors during summer. Despite have a lower R-Value, the insulated clay brick was the best performer – the clay brick buffered internal temperature fluctuations in both summer and winter seasons. When clay brick walls were applied inside the building modules, the thermal comfort and energy-efficiency levels improved no matter the external wall construction type. When the insulated lightweight walled module was fitted with brick partition walls, energy efficiency was improved by 20%. This research adds further credence to clay brick’s undisputed status as the benchmark for energy-efficient house construction in South Africa.

IBT’s with lightweight concrete-fibre wall panels have no capacity to self-regulate and, in the South African climate, this leads to extreme discomfort akin to a ‘hotbox’. This forces property owners to waste money on air-conditioning – an expense that would be less necessary in a clay brick structure. In conclusion, thermal resistance, or a walls R-value, is an important thermal performance property in European climates, where temperatures average less than 7°C throughout long, drawn out winters. Here in South Africa, R-values are only one measurement to consider. South African buildings exposed to long, hot summer months require high thermal mass to achieve optimum warmth in winter, as well as cooling in summer.

THIS STUDY FOUND THAT:

• t he lightweight building (high R-value, but no thermal mass in the walls) was the worst performer in all seasons • brick veneer (one skin of brickwork on external walls) performed better than lightweight • insulated cavity brick performed the best. Notably, double skin clay brick walled modules with cavity insulation outperformed insulated lightweight-walled modules with the same R-value • in the case of building modules with lightweight external walling, internal brick partition walls enhanced energy efficiency by 20%.

IMIESA September 2015

N O I T A R T

S I G E R E N I L N O N O I T A R T S I G E R D E N E P O HAS

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28-30 OCTOBER 2015

THEME: Changing the face of the Municipal Engineer Earn 2.5 CPD points by attending The 2015 IMESA Conference will be hosted at the Grand West Hotel and Casino – Goodwood

• Late Registration for IMESA Members – R5100.00 • Late Registration for Non IMESA Members – R5700.00

• Last Minute Registration for IMESA Members – R5650.00 • Last Minute Registration for Non IMESA Members – R6250.00

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

t +27 (031) 266 3263 email conference@imesa.org.za

HUMAN SETTLEMENTS

First Sibaya land parcels released

OT ONLY IS THIS region attracting the attention of high net worth individuals from within South Africa but it is increasingly becoming the focus of wealthy individuals from Africa. Having identified the growing demand for new, sought-after coastal developments, Tongaat Hulett Developments has now released the first parcels of land for development within the much-awaited Sibaya precinct. The eastern component of the Sibaya precinct (Nodes 1 and 5) has full development rights, which will effectively pump R8 billion into the local economy, create 7 000 permanent jobs, and generate R100 million in annual rates. "There is a pent-up demand and serious appetite for investment on the North Coast and this release will most certainly meet the aspirations of the well heeled. Current developments like Izinga and Zimbali have been wholly sold out, leaving the market gasping for fresh investment opportunities," Tongaat Hulett Developments MD Mike Deighton said at the launch function, held at the Sibaya Casino and Enter tainment Kingdom, on 4 August.

Tongaat Hulett Developments fully endorses the confidence held in the broader Durban environment and adjoining coastal regions. Recent reports list uMhlanga and Zimbali as major investment areas for the ultrawealthy in South Africa.

Growth in KwaZulu-Natal The unprecedented growth of the KwaZuluNatal North Coast, specifically the region between uMhlanga and Ballito, has evolved into producing some of the most sought-after investment destinations in South Africa. The Sibaya precinct comprises 750 hectares, across five development nodes, with all the rights in

IMIESA September 2015

HUMAN SETTLEMENTS

LEFT Pictured at the Durban launch of nodes 1 and 5 of the Sibaya precinct are, from left to right, Rory Wilkinson, Michael Deighton, Sithembiso Mthembu, and Trenley Tilbrook

place for the nodes situated east of the M4 highway; thereby allowing an immediate start on development and construction. The launch saw the company release three investment packages out of the five available within Node 1, which abuts the coastal dune forest. Easy access – which is gained from the Sibaya Circle on the M4 and its close proximity to uMhlanga and King Shaka International Airport – certainly adds to the excitement of this new release to the market. "The vision is for a compact, mixed-use urban development, enhancing sustainability by reducing the spatial footprint of the overall development and reinforcing the natural landscape with generous open space," Deighton said. The development seeks to actively encourage a real integration of urban and natural environment, where each element

reinforces the other to provide an entirely new urban identity and way of life for future residents and visitors. The three pristine forests, which cover about 350 hectares, are some of the only coastal dune forests found outside the Isimangaliso Wetland Park in northern KwaZulu-Natal. "While developing land across the province, we remain committed to always adding value to our projects; Tongaat Hulett Developments will take responsibility for establishing a conservation trust for the long-term sustainability of the coastal dune forests," Deighton said.

Future development The three real estate packages being released will see the construction of 650 sectional title units and 28 exclusive halfacre stands (2 000 m2), for the creation of new homes ranging in size between

1 000 m2 and 1 500 m2. Provision has also been made to accommodate 9 000 m2 of commercial and retail space within the largest of the three packages. Equal provision has been made to accommodate future hotel developments, which could, ultimately, provide in excess of 900 hotel rooms – further underpinning the desirability of this becoming Durban’s future playground. Tongaat Hulett Developments would be responsible for the construction of the main boulevard access road to the three real estate packages heavily landscaping the surrounding areas, and will establish the management structures to enhance land and property values. The company would also be responsible for reticulating water, sewer, and electricity to the site boundaries for the developers. "Sibaya, quite simply, provides the platform for the last word in elegant, stylish, and sophisticated living. It is the promise of superior levels of privacy and unobtrusive security, coupled with extraordinary views of the ocean and Durban’s coastline," Deighton enthused. He explained that the development offered an opportunity for coexistence with the natural landscape, with generous open spaces. Discreet walkways through the forest offer access to the beaches below and the warm Indian Ocean, while still being within a few minutes' drive from uMhlanga's vibrant commercial and retail hub and King Shaka International Airport.

Conclusion Deighton concluded that the company had now formally released the real estate opportunities to developers and investors, inviting them to submit proposals that include their vision, development concept, track record, ability to deliver, role players involved – including BBBEE business participation – as well as deal structure, by the end of August. Judging by the interest already being shown, it is unlikely that there will be a shortage of proposal submissions.

IMIESA September 2015

SHEQ

Drugs

in the workplace Drug abuse in South Africa, as in many countries all over the world, has been an issue for years. However, the number of different types of drugs available has grown dramatically, at a variety of price points, and cheap recreational drugs are now easier to come by than ever before. BY RHYS EVANS

HE INCREASING AFFORDABILITY of drugs has given rise to growing levels of abuse and addiction. This can have serious negative consequences on businesses, as drug abuse not only affects home life but work performance as well, not to mention the negative impact on health and safety. Education is a vital component of helping to curb drug abuse, however, it is often not sufficient in isolation. Implementing stringent and fair drug testing policies and leveraging the latest equipment for testing, which is capable of detecting these new, cheaper drugs, is essential. This can help organisations to identify employees with problems and take the necessary action to assist them and ensure compliance with necessary health and safety regulations. The local drug industry is not new, yet it initially revolved mainly around cannabis – as this is accessible and easy to grow. It was only in the 1980s and 1990s that other drugs such as cocaine, methamphetamines, and heroin began to emerge. Cocaine usage, however, has always been limited to higher income groups, as it cannot be manufactured locally and must, therefore, be smuggled through customs, which significantly raises the price.

Amphetamines such as speed and ecstasy became popular in the 1990s among partygoers. Heroin also became more available in the 90s, however, it was almost always used intravenously and, therefore, never gained widespread use due to a prevalent fear of needles with many people. While all of these drugs are addictive and cause social problems and work-related issues such as illness, absenteeism, mood swings, and more, it is only recently, with the emergence of cheap street drugs, that drug abuse has become a real challenge for the majority of South Africans. Drugs such as mandrax and tik are commonly used in the Western Cape, while crystal meth is growing in popularity among party-goers in Gauteng, who snort it as a cheaper alternative to cocaine.

“A new drug, nicknamed nyaope or whoonga – a mixture of low-grade heroin, rat poison, detergents, and sometimes anti-retrovirals – is a growing problem.”

Drugs as a coping mechanism In addition, a new drug, nicknamed nyaope or whoonga – a mixture of low-grade heroin, rat poison, detergents, and sometimes anti-retrovirals – is a growing problem in the townships of South Africa. This drug is cheap and easy to make – as it is derived from readily available substances – is highly addictive, and the side effects are truly horrendous. This growing problem is affecting

IMIESA September 2015

SHEQ

â€œThese drugs are addictive and cause social problems and work-related issues such as illness, absenteeism, and mood swings.â€?

more and more South Africans at home and in their places of work. Drugs are often used as a coping mechanism for those who are stressed, unhappy, or not dealing with the pressure of their everyday lives. In addition, in industries such as farming and construction, drug usage can result from boredom and workers being away from their families for extended periods of time. Whatever the reason, the availability and low prices of recreational drugs present a challenge for many organisations. As people become increasingly addicted to a substance, they often spend a large portion of their income on it and cannot support themselves or their families. They also often stop eating and do not sleep, so they lose weight and their health and concentration levels decline. Their work performance usually suffers, absenteeism increases, and, ultimately, they are unable to perform their jobs effectively.

Ensuring a drug-free workplace Ensuring a drug-free workplace helps organisations to improve safety, decrease risk, comply with health and safety regulations, improve productivity and employee performance, and curb a growing problem in South Africa. Education is a large component of dealing with drug abuse. Many users of drugs are unaware of the implications and effects of drugs, as well as how to go about getting help once they realise they have a problem. However, organisations also need to implement drug policies, as well as testing procedures, to monitor employees for drug usage. This requires the use of the latest equipment to ensure fast, accurate, and minimally invasive testing.

IMIESA September 2015

RIGHT Rhys Evans, director, ALCO-Safe

With regard to testing equipment, a number of different solutions are available. Urine testing is a cost-effective option that comes in a number of different forms, including single and multi-panel dip tests; cassette tests, where a pipette is used to drop samples for testing onto the tests; and integrated cup tests, which incorporate the test panel into the sample cup. Urine testing, however, requires special consideration, such as the need for private bathrooms and the requirement for testers to be the same gender as those being tested. In environments where this is not possible, saliva drug testing may be preferable. Saliva testing uses a swab to produce results in a matter of minutes and can be used to screen for a panel of five common illegal substances including heroin, cocaine, marijuana, and methamphetamines. In addition to urine and saliva testing, test kits that enable the testing of solid substances for the presence of drugs also available. Using one of these testing options to enforce drug-free workplaces can benefit organisations. Drug abuse is a growing problem in South Africa and it affects both the work and home lives of those caught in its vicious cycle. Employers should implement educational practices, as well as testing policies and procedures, to help curb drug abuse in the workplace. Not only is this a health and safety requirement, it can also benefit businesses by improving productivity and employee health.

SHEQ

Caution: W

ITH THE NATIONAL Development Plan highlighting the growing importance of infrastructure development, the construction industr y has evolved substantially since the first construction regulations were promulgated in 2003. These regulations arose when the construction industr y, together with the Department of Labour, identified the need for sector-specific regulations, as the general safety regulations were inadequate in addressing matters of construction health and safety. Following the shocking incidents of structural collapse in recent years, the industr y again sought to update and amend the regulations. On 7 August

Health and safety under construction

The South African construction sector has come under the spotlight in the past two years, following the fatal collapse of the Tongaat Mall in 2013 and the collapse of a structure in Meyersdal, in Gauteng, last year. BY LIESL FRANKSON

2015, the Construction Work Permit of the Construction Regulation 2014 came into effect. The dispensation requires the registration of health and safety professionals in the construction industr y in order to address

the challenge of incompetency in the construction health and safety (CHS) industr y. The new Construction Regulations 2014 are intended to advance the ‘zero harm’ initiative in workplaces and promote a meaningful social dialogue in occupational health and safety matters. Ahead of the implementation of the regulations, the Department of Labour hosted an information session for the construction industr y comprised of a comprehensive training session targeted at departmental provincial inspectors, specialist inspectors, and principal inspectors. The inspector’s training focused on the elements of administering the new Construction Regulations 2014.

Low health and safety compliance in the construction industry During the session, it emerged that the construction industr y has a less than 50% rate of compliance to health and safety. Depar tment of Labour chief director: Occupational Health and Safety Tibor Szana said the construction industr y has been beset with incidents of fatalities for the past 15 years. “The level of incidents seemed to be repeating itself over and over again,” Szana said. He said the construction sector is surpassed by the iron and steel sector in terms of large volumes of claims lodged with the Compensation Fund – a workers' injur y and diseases claim fund.

IMIESA September 2015

SHEQ

“Registered persons must be certified as competent in order to work in the industry. Where registered CHS professionals default, we follow existing disciplinary processes to protect public interests.” Szana asked why the construction industry seemed to be failing to reverse the high levels of fatalities.

Partnerships imperative to safe working environments Szana said, while there were teething problems, these were surmountable. “Today marks the collaborative effort with the construction industry. The challenge is to step up inspection and enforcements,” he added. He said, going forward, the department wanted to spend less time with employers who do what the department expects of them, pointing out that the department wants to spend more time with those who do not comply. He reiterated that partnerships in the sector were imperative to healthy and safe working environments.

CHS professionals on the rise The South African Council for Project and Construction Management Professions (SACPCMP) is also playing a part in raising the awareness on CHS and the need for more

IMIESA September 2015

competent CHS professionals in the industry. “We are happy to announce that systems are in place and have been streamlined to professionalise the CHS discipline. “Our efforts to register competent CHS professionals will also contribute to the reduction of deaths, injuries, and other incidents on construction sites,” says Nomvula Rakolote, registrar of the SACPCMP. “It is shocking that South Africa sees almost two deaths a week on construction sites. This means loss of life, loss of breadwinners, and loss of family members,” she adds. “Registered persons must be certified as competent in order to work in the industry. Where registered CHS professionals default, we follow existing disciplinary processes to protect public interests. This includes deregistering them, a phenomenon that bars them from practicing for a period of time”, she said. Between January and March this year, the SACPCMP received between 300 and 400 applications per month. This is a significant increase from the 900 applications the SACPCMP had received since the

INTERNATIONAL HEALTH ISSUES IN CONSTRUCTION

• 337 million people are off work • 2.3 million people will die this year • 1.1 million people who work suffer from a work-related illness • 450 000 people are diagnosed annually • 12 000 people die from harmful substances at work

“It is shocking that South Africa sees almost two deaths a week on construction sites. This means loss of life, loss of breadwinners, and loss of family members.” Nomvula Rakolote, registrar of SACPCMP

opening of registration in June 2013 until December 2014 – an 18-month period. “This means that we have received close to 800 applications in two months. We currently have a total in excess of 1 700, some of which have been processed while others are still in the system,” continues Rakolote. The increase in registration has been boosted by the constant training and appointment of new assessors, which augmented an initial pool of 14 since the opening of registration. The increasing number of assessors assist the SACPCMP with preliminar y assessments of CHS applications; marking examinations, where necessar y; and conducting professional inter views, where applicable. The SACPCMP is also calling on all persons with relevant experience and/or qualifications to apply for registration as CHS professionals. “We are taking CHS into the boardroom. The work of CHS practitioners will now be a priority to senior executives to save life and limb on construction sites,” says Rakolote.

CESA AON ENGINEERING EXCELLENCE AWARDS

Celebrating engineering

excellence

The CESA Aon Engineering Excellence Awards, hosted by Consulting Engineers South Africa (CESA) and Aon South Africa, showcase the quality, innovation, outstanding workmanship, and professionalism of the consulting engineering industry.

HIS ANNUAL EVENT serves as a platform to showcase the outstanding achievements of the CESA member firms. The awards focus on consulting engineers and their clients, who initiate and fund projects that promote the advancement of our nation and the people of the continent. IMIESA magazine congratulates all winners.

The CESA Aon Awards overview 1 Project: The Point Category: Projects with a value greater than R250 million – Winner Professional Team: • Developers Berman Brothers and HCI • Project Manager Berman Brothers Group • Architect Louis Karol • Quantity Surveyor Aecom • Structural & Civil Engineers Moroff & Kühne Consulting Engineers • Electrical Engineers Louis & de Kroon Inc. • Mechanical Engineers WSP

• Wet Services Benatar Consulting • Contractor WBHO • Demolition L.O. Rall. To meet the client’s brief for the redevelopment of the old Galleria building on 76 Regent Road, Sea Point, into a 28 000 m2 shopping and lifestyle centre, innovative and out-of-the-box thinking was required by Moroff & Kühne’s structural team. The existing building – with a footprint of 4 940 m2 – was comprised of three levels of basement parking, with the ground and first floors being retail and office space. About 2 600 m2 of the ground floor was occupied by the anchor tenant, Checkers. Besides Checkers and some small line stores, the remainder of the building was vacant and was falling into a serious state of disrepair. This resulted in a challenging brief from the client – create an additional basement level over the full footprint of the building while keeping Checkers fully operational throughout the entire construction period. All the careful planning and hard work has paid off and the building has been totally transformed into a light and airy nine-storey

shopping and lifestyle centre, servicing all ages and incomes.

2 Project: Brandspruit Mine – Impumelelo Category: Projects with a value greater than R250 million – Commendation During August 2009, Sasol Mining appointed Hatch Goba and RSV ENCO (a linked enterprise of RSV), who formed the RSV ENCOHatch Goba Coal Joint Venture (JV), as the Engineering, Procurement and Construction Management (EPCM) Consultant for Impumelelo – a new 8.5 Mtpa replacement tonnage coal mine complex for the client’s Brandspruit Mine located in the Secunda area, Mpumalanga. The project scope entailed the design and development of the complete greenfield mine complex including the Shaft Systems (two vertical shafts, one decline shaft, and associated underground development), the Materials Handling System (underground conveyors, surface bunkers, and a 27 km single-flight surface overland conveying system – the longest in the southern hemisphere) and all supporting infrastructure (offices, change

IMIESA September 2015

CESA AON ENGINEERING EXCELLENCE AWARDS

houses, workshops, roads, power and water supply, as well as sewage treatment).

3 Project: Umgeni Road Interchange Category: Projects with a value greater than R250 million – Commendation In order to reduce the traffic congestion on the busiest section of the National Route 2, in Durban, the Umgeni Road Interchange required an upgrade. Sanral appointed Hatch Goba for the design and contract administration for this project. A unique feature of the project was that one of the bridge decks was constructed and launched from a 20 m high elevated casting yard. The elevated casting yard and the stunning sight of the two incremental launch bridges being constructed at the same time and crossing each other was a first in South Africa and attracted a lot of attention.

4 Project: Acid Mine Drainage Category: Projects with a value greater than R250 million – Commendation Cabinet appointed an Inter-Ministerial Committee (IMC), in 2010, to address the serious challenges posed by acid mine drainage (AMD) in the Witwatersrand Goldfields area. The Department of Water and Sanitation directed the Trans-Caledon Tunnel Authority (TCTA) to implement this emergency solution. TCTA commissioned Aecom to design and implement the short-term intervention solution for the AMD Project.

The key scope of Aecom’s project in the Central Basin included the construction of an abstraction pump station at ERPM South West Vertical shaft in Germiston; the utilisation of the High Density Sludge treatment process for neutralisation and metals removal; and the co-disposal of the sludge produced with gold tailings at the Brakpan tailings storage facility – Mega Dump.

5 Project: The Bronkhorstspruit Biogas Plant Category: Projects with a value of between R50 million and R250 million – Winner Professional Team: • Consulting Engineer Bosch Projects • Project Developer Bio2Watt – Sean Thomas • EPC Contractor Bosch Projects • Project Sponsor Butch Carr • Project Manager Steve Roux • Biogas Technology ComBigaS – Jens Jørn Helth • Operations & Maintenance Bosch Munitech Visionary Bio2Watt MD Sean Thomas appointed Bosch Projects to design, supply, install, and commission the Bronkhorstspruit Biogas Plant, after enduring a seven-year project development process, which ended with financial close in February 2014. The R150 million Bronkhorstspruit Biogas Plant is a unique biowaste-to-energy project located in the Bronkhorstspruit district of Gauteng. This facility converts multiple

IMIESA September 2015

streams of food, industrial, and agricultural waste to electricity for green manufacturing in an independent power producer (IPP) deal between Bio2Watt and BMW.

6 Project: Rehabilitation of Main Road between Muizenberg and Clovelly Road, Clovelly Phase 2 Category: Projects with a value of between R50 million and R250 million – Commendation The scenic 4.5 km stretch of coastal road between Muizenburg and Clovelly was last resurfaced in 1994, and was starting to show signs of distress. As a result, the City of Cape Town appointed Knight Piésold, as the consulting engineer, to undertake an initial assessment of the road’s condition in September 2006. It was subsequently determined that, in addition to the generally poor condition of the road pavement, the underground services (water mains, stormwater, and both gravity and pressure sewage pipes) were severely degraded and needed to be replaced urgently.

7 Project: Sundays River bridge Category: Projects with a value of between R50 million and R250 million – Commendation In 2005, the South African National Roads Agency Limited (Sanral) found signs of distress and extensive cracking in the 14.23 km, two-lane pavement of Section 11 of National Route 2, between Soutwerke and Colchester in Eastern Cape.

CESA AON ENGINEERING EXCELLENCE AWARDS

Concerned about the health and safety risk the damage posed to drivers, Sanral appointed the Semenya-Aurecon JV to rehabilitate the route, which runs northeast and ends at the intersection to Colchester. The appointment included detail assessment, detail design, and documentation.

8 Project: New microbiological laboratory Category: Projects with a value of less than R50 million – Winner Professional Team: • Royal HaskoningDHV Project Principal Cobus van Deventer • Project Manager and Cleanroom Design Adrian Kelfkens • Mechanical Design Andresh Naidoo • Electrical Design Kresan Moodley • BIM Shaleen Billson The National Bioproducts Institute (NBI) is the only company in South Africa that manufactures life-saving plasma-derived medicinal products. Royal HaskoningDHV is one of few companies who could provide NBI with specialised cleanroom services for the upgrade of its microbiology laboratory. The upgrade was required to improve the standard of pharmaceutical microbiology testing for priority medicines manufactured by the NBI. The R3.7 million project was started in October 2013 and successfully completed in July 2014.

9 Project: Kirstenbosch Centenary Tree Canopy Walkway – ‘Boomslang’ Category: Projects with a value of less than R50 million – Commendation In May 2012, the South African National Biodiversity Institute decided to invest in a tree canopy walkway for Kirstenbosch’s centenary celebration. The walkway was designed to blend unobtrusively into the forest, minimising both the visual impact on the area and the physical impact on the forest. To achieve this, a delicate structure, carefully located between the trees, and finished in colours that would blend in with its surroundings, was needed. Steel was clearly the material of choice, to satisfy these criteria. 10 Project: Izinga Phase 2A: the construction of roads and civil services Category: Projects with a value of less than R50 million – Commendation Located in the heart of uMhlanga’s rapidly growing residential, commercial, and retail environment, Izinga Phase 2A is one of many Tongaat Hulett Developments (THD) projects. This 246 unit phase forms part of the greater 2 000 unit Izinga development and comprises 32.5 hectares, of the total 210 hectares. The scope of works on the project includes the design and construction of local access roads, access loops, cul-desacs, traffic calming measures, sidewalks,

sewer, stormwater and water reticulation, installation of service ducts, a 50 m x 2.4 m box culvert, a 370 m x 11 m gabion watercourse, and infiltration manholes designed to attenuate excessive stormwater to prevent erosion.

11 Project: Botswana North South Carrier Water Transfer Scheme Category: Best International Project – Winner Due to significant and robust economic growth, Botswana developed a need for water augmentation by regional transfer from its water-rich northern resources. Bigen Africa was appointed by the Ministry of Minerals, Energy and Water Resources, in 2007, as its employer’s representative, for the conceptual design development, EPC tender documents, and construction supervision of the 360 km North South Carrier (NSC-2) regional water transfer system.

Winners from other categories Category: Business Excellence and Mentoring Company of the year Winner: Bigen Africa Category: Mentor of the year Winner: Colin Andrews of Royal HaskoningDHV Category: Young engineer of the year Winner: Geoff du Toit of Aurecon Category: Visionary client of the year Winner: Development Bank of Southern Africa

IMIESA September 2015

TECHNOLOGY & INNOVATIONS

South African infrastructure competition

goes international

HIS COMPETITION affords learners the opportunity of designing, constructing, and operating a water distribution network exactly the way civil engineering practitioners in local authorities and metros would do so. They encounter all the same challenges/problems that occur in real-life situations.

Very few interventions or career days have the advantage of practically illustrating what a career is all about. The finals of Aqualibrium, the exciting SAICE-Aecom Schools Water Competition 2015, do exactly that.

The competition Water distribution systems are important to supply safe and clean drinking water to people. The teams are tasked with designing a model water distribution network to distribute three litres of water equally between three points on the grid using two different diameter pipes and connection pieces. They are then judged on how well they execute the task – working on a penalty points system. The teams have a period of about an hour in which to design, build, and operate their network. This competition exposes learners to the practical application of processes that influence their daily lives, namely how water gets to their homes. They are made aware of the intricacies involved in the design of water distribution networks and the actual water delivery to households. The grid used for the water distribution network is on a background that depicts the entire water cycle. This grid intrigues learners, as well as educators, who find it a very helpful educational tool. The competition creates awareness regarding the issues surrounding water in South Africa. It spreads the message that water is a precious commodity, which should be recycled, reused, and respected, while the use of water should be reduced.

IMIESA September 2015

The 2015 winners Hoërskool Diamantveld from Kimberley came first, conceding only 45 penalty points. The team consisted of Frans Jacobs, Lourens van Niekerk, and Lohann Burger. In second place was Merrifield College in East London, represented by Kiam Venter, James Gibson, and Dominique Plaatjes, with 70 penalty points. The third place was taken by Mzilikazi High School from Bulawayo in Zimbabwe, participating for the first time ever, with 105 penalty points. Their team consisted of Anita Dube, Vusumuzi Ngwneya, and Freedom Mhondiwa. Regional winners from South Africa came to Johannesburg from as far as Bloemfontein, Cape Town, Dendron, East London, Harrismith, Kimberley, Pietermaritzburg, Port Elizabeth, and Richards Bay. Many of the teams were flown to Johannesburg and accommodated in a good hotel – an experience that these young people and some of the educators will never forget. For most, this was a first experience of the ‘big city’. Without the naming-rights sponsorship of Aecom, and other sponsors such as Bosch Stemele, Marley Pipe Systems, and DPI Plastics, this would not have been possible.

The three winners of 2014 are all currently studying civil engineering, underpinning the value of continuing with these kinds of projects in order to make a difference to the priority scarce-skills situation and the lives of many people.

Spreading the news Through this annual competition, SAICE and AECOM take the responsibility of spreading the news that water should be used wisely, that infrastructure should be maintained, and that new infrastructure should be developed to provide potable water to all in South Africa. In two consecutive years (2012/13 and 2013/14) the Aqualibrium initiative had the honour of being chosen as one of four finalists in the National Science and Technology Forum (NSTF)-BHP Billiton Awards, the oldest and most prestigious in South Africa, in the category of an individual or team being recognised for their outstanding contribution to science, engineering, technology, and innovation (SETI) through science communication and through creating science awareness.

PROFESSIONAL AFFILIATES AECOM vanessa.partington@aecom.com Afri-Infra Group (Pty) Ltd banie@afri-infra.com AJ Broom Road Products ajbroom@icon.co.za Arup SA rob.lamb@arup.com Aurecon danie.wium@aurecongroup.com Aveng Manufacturing Infraset cgroenewald@infraset.com Bigen Africa Group Holdings otto.scharfetter@bigenafrica.com BMK Consulting brian@bmkconsulting.co.za Bosch Munitech info@boschmunitech.co.za Bosch Stemele bsdbn@boschstemele.co.za Brubin Pumps sales@brubin.co.za BVI Consulting Engineers marketing@bviho.co.za Civilconsult Consulting Engineers mail@civilconsult.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za CSIR Built Environment rbapela@csir.co.za Development Bank of SA divb@dbsa.org.za DPI Plastics mgoodchild@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering leon.basson@elster.com Engcor Engineers masham@engcorengineers.co.za Fibertex South Africa (Pty) Ltd rcl@fibertex.com GIBB yvanrooyen@gibb.co.za GLS Consulting nicky@gls.co.za Gudunkomo Investments & Consulting info@gudunkomo.co.za Hatch Goba info@hatch.co.za Henwood & Nxumalo Consulting Engineers cc pmboffice@hn.co.za Herrenknecht schiewe.helene@herrenknecht.de Huber Technology cs@hubersa.com Hydro-comp Enterprises dan@edams.co.za I@Consulting louis_icon@mics.co.za ILISO Consulting hans@iliso.com INGEROP mravjee@ingerop.co.za Integrity Environment info@integrityafrica.co.za Jeffares and Green dennyc@jgi.co.za Johannesburg Water rtaljaard@jwater.co.za KABE Consulting Engineers info@kabe.co.za Kago Consulting Engineers kagocon@kago.co.za Kantey & Templer (K&T) Consulting Engineers info@kanteys.co.za Knowledge Base info@knowbase.co.za Lektratek Water general@lwt.co.za Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Malani Padayachee & Associates (Pty) Ltd admin@mpa.co.za Maragela Consulting Engineers admin@maragelaconsulting.co.za

Marley Pipe Systems info@marleypipesystems.co.za Martin & East gbyron@martin-east.co.za Mhiduve adminpotch@mhiduve.co.za Mott Macdonald PDNA mahomed.soobader@mottmac.com Much Asphalt leon.alberts@muchasphalt.com Namela Consulting (Pty) Ltd melissa@namela.co.za Nyeleti Consulting ppienaar@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za Pumptron info@pumptron.co.za Pragma nicojobe.mabaso@pragmaworld.net francisg@rhdv.com Royal HaskoningDHV SABITA info@sabita.co.za SALGA info@salga.org.za SARF administrator@sarf.org.za.co.za SBS Water Systems terri@sbstanks.co.za Sektor Consulting cradock@sektor.co.za Sight Lines sales@sightlines.co.za SiVEST SA garths@sivest.co.za Siza Water Company tionette.bates@sizawater.co.za SMEC capetown@smec.com SNA stolz.j@sna.co.za Sobek Engineering gen@sobek.co.za Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Sulzer Pumps Wastewater sales.abs.za@sulzer.com Syntell julia@syntell.co.za Thm Engineers East London thmel@mweb.co.za TPA Consulting roger@tpa.co.za UWP Consulting craign@uwp.co.za Vetasi south-africa@vetasi.com VIP Consulting Engineers esme@vipconsulting.co.za VOMM commerciale@vomm.it VUKA Africa Consulting Engineers info@vukaafrica.co.za Water Institute of Southern Africa wisa@wisa.org.za Water Solutions Southern Africa ecoetzer@wssa.co.za Wilo South Africa marketingsa@wilo.co.za WorleyParsons chris.brandsen@WorleyParsons.com WRP ronniem@wrp.co.za WRNA washy@wrnyabeze.com WSP Group Africa dirk.hattingh@mbs-wsp.co.za

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

IMESA

INDEX TO ADVERTISERS INDEX TO ADVERTISERS AfriSam 54

Krohne 66

ALCO-Safe 88

Marley Pipe Systems

Atlas Copco

MCI Measurement Control & Instrumentation

Aveng Infraset Bagshaw Footwear Barloworld Equipment

2 86 IFC

Builders 72 Camjet 39 Clay Brick Association of SA

Mr Stubman CC

National Asphalt

NuWater 44 Octopus Electronics

Sasol Polymers

STP Fittings

Sub Sahara Power Distributors

Technicrete 78 The Concrete Institute

Tosas 52

Corobrik 84

PipeFlo 23

ELB Equipment

PPC 18

Trenchless Technologies

Hall Longmore

Polypipe 24

TT Innovations

Rare Group

Ritz Pumps South Africa

Vermeer Equipment Suppliers

Herrenknecht 30 Horizontal Trenchless & Vertical Drilling 29

Robor 4

Vital Engineering

IMESA Online Registration

Rocla 70

Wasteman Sight Lines

IMESA Social Events

SA Readymix Association

Infrastructure Africa

Sephaku Cement

Hatch Goba

Komatsu 63

Mercedes-Benz OFC

Sizabantu Piping Systems

Sika 79

Water & Sanitation Services WRP Consulting Engineers

OBC IBC

IMIESA September 2015

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Water and Sanitation Services South Africa (Pty) Ltd (WSSA) is a specialised provider of sustainable water services in Southern Africa