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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

SIPHO MADONSELA, CEO OF ECSA Transforming the engineering profession

Panel Discussion Trenchless technology

Building

Municipal Focus Mogale City – An evolving landscape

Innovations in Construction:

Innovative approaches to infrastructure

IN THE HOT SEAT

enduring

roads

KPMM CONSTRUCTION

“South Africa is slowly embracing the advantages of the alternative delivery. AECOM is ready to meet the challenges and contribute based on our vast experience acquired from around the world” Dede Bukasa, Head of Civil Operations, AECOM ISSN 0257 1978

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CONTENTS

VOLUME 40 NO. 4 APRIL 2015

IMESA

ion Panel Discuss ology Trenchless techn

Municipal Focus Mogale City – An evolving landscape

Innovations in Construction:

es Innovative approach to infrastructure

Building enduring

roads

M KNSPTRM UCTION

INNOVATIONS IN CONSTRUCTION Printing your dream house

MUNICIPAL FEATURE Mogale City

Regulars

KPMM Construction has been specialising in the construction of roads and bridges, as well as the rehabilitation of asphalt paving, for nearly 15 years. The company's footprint is constantly expanding, as illustrated by its involvement in projects across South Africa. P6

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

Water & Wastewater 3 5 8 84

Cover Story 6

KPMM Construction

Municipal Feature Mogale City

Hot Seat AECOM - Dede Bukasa heads civil operations

Human Settlements

HOT SEAT With over 90 years on the African continent, born from legacy African businesses, AECOM’s footprint grows from project to project. Dede Bukasa, head of civil operations, takes this month’s Hot Seat to discuss AECOM’s vision for the future of construction in Africa. P14

Lifestyle friendly living spaces Building better houses Boomtowns demand sewage innovation

16 20 23

Innovations in Construction Printing your dream house Rise of the machines

31 36

Trenchless Technologies Spiral-wound technique comes of age Panel Discussion: Digging deeper, better, smarter

41 47

ROADS & BRIDGES New overpass bridge over N1 in Midrand

Water conservation and water demand management: Part 2 Clean bubbles

55 59

Roads & Bridges New overpass bridge over N1 in Midrand One death is one too many Partnering for growth Asphalt plants and the environment

60 64 67 69

Skills & Training ECSA – Transforming the engineering profession

Cement & Concrete Concrete training: Don’t be fooled Leave it to Lafarge Quarries need a champion in government

75 76 77

Construction Vehicles, Equipment & Logistics Deterring a dusty disaster

Technology & Innovations Advanced reality modelling Preventing soil erosion

81 83

TECHNOLOGY & INNOVATIONS Preventing soil erosion

IMIESA April 2015

INFR SET

PAVING

RAILWAY

Aveng Manufacturing Infraset produces a diverse range of precast concrete products to world-class quality standards and actively contributes to SADC infrastructure development. Our range includes concrete pipes, culverts, manholes, special precast products, various types of pre-stressed railway sleepers, turnouts, maintenance-free railway electrification masts and poles, paving blocks, retaining wall systems and roof tiles.

ROOF TILES

Aveng Manufacturing Infraset’s admired heritage is founded on innovation, technical and service excellence.

RETAINING WALLS

KERBS

SEVEN WAYS TO

LASTING INFRASTUCTURE Aveng Manufacturing House Tel: +27 (0)11 876 5500 Fax: +27 (0)11 872 1713 email: Infrasetinfo@infraset.com www.infraset.com

Pipes • Culverts • Manholes: Gauteng Tel: +27 (0)11 876 5100 Cape Town Tel: +27 (0)21 908 1156 Kwazulu Natal (Pietermaritzburg) Tel: +27 (0)33 387 2236

Railway Sleepers • Poles & Masts National Tel: +27 (0)11 813 2340

POLES & MASTS

INFRASTRUCTURE

Paving • Retaining Walls • Roof Tiles Rossway (Midrand) Tel: +27 (0)12 652 0000

International Branches Swaziland Tel: +2682 518 4236

Kwazulu Natal (Effingham) Tel: +27 (0)31 569 6900

Zambia Tel: +260 21 131 1838

EDITOR’S COMMENT

PUBLISHER Elizabeth Shorten EDITOR Nicholas McDiarmid EDITORIAL ASSISTANT Liesl Frankson JOURNALISTS Beatrix Knopjes, Frances Ringwood HEAD OF DESIGN Beren Bauermeister CHIEF SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter CONTRIBUTORS S Gibson, N Kranz, N Tandi 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 ___________________________________________________ ADVERTISING SALES Jenny Miller Tel: +27 (0)11 467 6223 ___________________________________________________

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 IMESA Administration Officer: Narisha Sogan 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 BRANCH Secretary: Melanie Matroos Tel: +27 (0)43 705 2401 Fax: +27 (0)43 743 5266 E-mail: melaniem@buffalocity.gov.za EAST CAPE BRANCH Clarine Coltman Tel: +27 (0)41 505 8019 Fax: +27 (0)41 585 3437 E-mail: clarinec@africoast.com KWAZULU-NATAL BRANCH Secretary: Rita Matthews Tel: +27 (0)31 311 6382 Fax: +27 (0)31 701 2935 NORTHERN PROVINCE BRANCH Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 E-mail: imesanorth@vodamail.co.za SOUTHERN CAPE KAROO BRANCH Secretary: Henrietta Oliver Tel: +27 (0)79 390 7536 Fax: 086 536 3725 E-mail: imesa.southcape@gmail.com WESTERN CAPE BRANCH Secretary: Erica van Jaarsveld Tel: +27 (0)21 938 8455 Fax: +27 (0)21 938 8457 E-mail: erica.van_jaarsveld@capetown.gov.za

Implementation Now!

S THE FIRST quarter of 2015 closes, the question of where this year is leading us remains somewhat obscured. There are distinct benefits to shortterm strategies, but it appears that there may be significantly more benefits in taking a longer-term view of the public sector infrastructure. Infrastructure remains at the core of South Africa’s economic growth path, and its very nature demands long-term views. While the construction industry, as a whole, has seen some decline – with some of the major construction companies posting significant losses – the positive indicators for most of them lie in their public sector project pipeline. This bolsters the most recent viewpoint of the National Treasury, which indicated that, despite the lags and the electricity crisis, national development is strong enough, and well-conceived enough, to see South Africa return to the 5% per annum growth last experienced in 2007. Much of this is based on the implementation of public sector infrastructure activity; however, rapid implementation remains the greatest constraint. Ironically, regulatory compliance is cited as one of the clear causes of this lag and, in this instance, surely the Economic Development Department and Presidential Infrastructure Coordinating Committee should be encouraged to intervene at the highest level. As editor of IMIESA, it is my privilege to speak regularly to the engineers and leaders in our municipalities, national departments and government agencies, and they are certainly singing from the same hymn sheet: implement with urgency. IMIESA will seek, in the coming months, to gain further insight into how the PICC intends to remove this final obstacle. Speaking of leaders, we are excited to announce the launch of a new annual publication entitled Leading Infrastructure. It is a first of its kind for this sector, and will also play a significant role in unlocking the bottlenecks. By including our various government departments, municipalities

FREE STATE AND NORTHERN CAPE BRANCH Secretary: Wilma Van Der Walt Tel: +27(0)83 457 4362 Fax: 086 628 0468 E-mail: imesa.fsnc@gmail.com

and stage agencies, alongside the private sector – including consulting and civil engineers, contractors, manufacturers, and suppliers to the industry – Leading Infrastructure will communicate across these organisations, through their leadership, and ultimately provide the direction and clarity needed at this time to make its contribution to South Africa. Due out later this year, this prestigious annual publication is set to define the ever-changing intricacies and demands of working in the public infrastructure sphere. It is also a platform to both encourage and recognise those leaders who are making a massive difference through their innovative, strategic approaches and incredible skill. This publication will make a difference by truly recognising the great pool of talent and skill that is so often left behind the scenes. Reflecting our true resources, talent and potential, Leading Infrastructure will be an important contribution to national development. In this edition of IMIESA, we have focused on trenchless technologies and other innovations that keep municipal engineering an ever-evolving profession. It is with sadness that we bid farewell to the late Joop van Wamelan, past president and honorary director of the South African Society for Trenchless Technologies (SASTT). Joop’s incredible career saw him in numerous high-profile roles, including assistant city engineer: Welkom; civil engineer at the CSIR’s Division of Building; manager and consultant to Agrément South Africa; as well as being instrumental in the establishment of SASTT. Joop passed away on 13 February 2015, and is survived by his wife, Diana, and his three sons, Paul, Arend and Riaan. IMIESA joins SASTT in extending our sincerest thanks and condolences to Joop’s family. We wish you well for the coming quarter and, again, perhaps a longer-term outlook will actually buoy a more optimistic view.

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

Infrastructure News

IMESA

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. Panel Discussion Trenchless technology

Municipal Focus Mogale City – An evolving landscape

Innovations in Construction:

Innovative approaches to infrastructure

Building

enduring

roads

KPMM CONSTRUCTION

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. IMIESA April 2015

PRESIDENT’S COMMENT

Potholes

IMESA

Duncan Daries, IMESA president

Having just seen the recent newsflash on eNCA regarding the pothole issue in Ekurhuleni, I needed to reflect on the perception of the general public and elected officials with regard to this issue.

THEREFORE STARTED to compile comments, explaining the reasons for pothole formation and the recommended reactive and preventative maintenance that should be implemented. While gathering information, one of my technical staff members provided me with two publications from the CSIR that cover the subject more comprehensively and are available for download at www.csir.co.za/ pothole_guides: • POTHOLES: A non-technical guide to their causes and prevention • POTHOLES: Technical guide to their causes, identification and repair. The first publication is targeted at people not involved in the technical aspects of road pavement engineering. These guides were produced in 2010 when the estimated asset value of South African roads was determined at R1 trillion, of which the paved road network amounted to R800 billion. Based on international best practice/World Bank standards, 2.5% to 3.0% of asset value should be set aside for road maintenance (40% capital expenditure for road rehabilitation and 60%

operational expenditure for resurfacing/reseals). Basically, this means if we use the lower 2.5% for a metro like the City of Cape Town, with an estimated road asset value of R42.3 billion and a network of 10 000 km (2010 figures), the maintenance budget should be in the order of R1.2 billion. The actual road pavement maintenance budget for Cape Town (2010) was only in the region of R450 million, which was less than 40% of the need. Other cities and municipalities are probably in a similar position, which effectively means that there is an increasing backlog in maintenance, which has resulted in the current state of the country’s road network. The CSIR study concludes, “It is unlikely that the formation of potholes will ever be totally prevented. However, with the judicious use of preventative and proactive maintenance, the incidence of potholes can be reduced significantly.” I couldn’t agree more with this statement. Fixing of potholes on its own is not going to bring about an overall improvement in the condition of our road assets. Preventative and proactive maintenance such as resurfacing, reseals, bitumen

rejuvenation and crack sealing is most important and a cheaper intervention to prevent an everincreasing and expensive rehabilitation backlog. Primarily, funding may be the problem but I would place greater emphasis on the technical skills within the client (road authority) bodies to strategically spend their limited budgets on those interventions that reduce the exposure to risk, thereby reducing user costs such as repairs and claims. The fixing of potholes is a primary function of the municipalities, and dedicated staff who have received specialist training must undertake these tasks. Whereas the latest technology can assist in removing the pothole backlogs, I do not advocate that this function be outsourced in its entirety.

Dedicated road maintenance funding stream Road infrastructure is not identified in the Constitution as a basic service and, presently, does not enjoy an allocation from the equitable share. Metros do receive an allocation from the fuel levy as an unconditional grant with the intention

that it should be spent on roads, but metros are responsible for allocating the fuel levy as they wish. USDG funds are available to do road rehabilitation work but allocations are done only where subsidised human settlements are direct beneficiaries. A dedicated road maintenance fund has been under discussion at both National Treasury and Department of Transport level and we await a positive outcome.

Asset management principles It still baffles me that, at this stage, only eThekwini, out of all the metropolitan municipalities, may have a fully functional asset management plan in place, that truly gives direction to where the prioritised infrastructure needs are and budget allocated accordingly. I need to give credit to our previous IMESA president, Jannie Pietersen, for the significant interventions that IMESA is undertaking on behalf of CoGTA in the Free State. Only once asset management principles are applied to municipal infrastructure as a whole, will the conditions of our roads improve.

IMIESA April 2015

COVER STORY

KPMM CONSTRUCTION

Building

enduring roads

KPMM's national infrastructure projects range from Pongola in KwaZulu-Natal to Giyani in Limpopo.

ROM THE ONSET of trading in June 2001, KPMM Construction’s (KPMM) core specialisation has been in roads and bridges, followed by an evolution into asphalt pavement rehabilitation. A number of major projects in progress are for the South African National Roads Agency Limited (Sanral), where KPMM is forging ahead on multifaceted infrastructure upgrades. KPMM is a Construction Industry Development Board (CIDB) 9CE contractor and holds a Level 3 BBBEE certificate. Historically, the initial focus was to the north of the country, working for what is now known as the Roads Agency Limpopo (RAL), which formed the springboard for further expansion. KPMM’s first major Sanral tender awards in this region were for

IMIESA April 2015

upgrades along the Polokwane to Vivo, and the Mooketsi to Tzaneen routes. KPMM then branched out into the Gauteng region, with a Sanral contract awarded for an upgrade to the R23 from Standerton to Balfour. This laid the groundwork for future growth in the province. In the meantime, various jobs have been ongoing for provincial authorities in Gauteng and Mpumalanga. Construction in the Northern Cape followed with three Sanral contracts awarded for road upgrades on sections of the N14 from Bladgrond to Pofadder and Pofadder to Witputs, and the R27 from Kenhardt to Keimoes over the 2012 to 2014 period. Three projects were completed in this time frame for an approximate contract value of R210 million.

Hibberdene milestone, Giyani gravel to tar conversion One of KPMM’s largest contracts to date entailed the construction of a north- and southbound dual carriageway on the N2 route in KwaZulu-Natal from the Hibberdene Interchange to Umzinto River. This 14 month project, valued at around R254 million, was completed in December 2014. The scope involved the milling out and replacing of the slow lane with 40% recycled asphalt, with a final layer of UTFC placed on top of the completed road surface. Meanwhile, a two-year contract in Giyani, Limpopo, is in progress. “We are now more than half way through this 23 km gravel to tar conversion, which includes a new bridge, as well as insitu culverts,” says Kevin Twiddy, managing director, KPMM. “The final riding surface will be chip and spray.” Rehabilitation on the N17 between Ermelo and Chrissiesmeer is also nearing completion.

COVER STORY

project, together with various 20 tonne and 30 tonne Cat hydraulic excavators, and Cat backhoe loaders. Three KPMM low-beds cater for site-to-site equipment transfers. “The 140K is driven by Cat’s proven C7 ACERT engine, with its 7.2 litre displacement, which, combined with an improved power management strategy and an advanced monitoring capability, significantly increases performance while keeping working costs to a minimum,” comments Barloworld Equipment Cat sales professional Molly Breton. Standard on all K-Series models, the variable horsepower feature increases machine productivity by matching power to ground speeds. In the lower gears where

November 2014; and an N12 dual carriage upgrade outside Lenasia and extending towards Carletonville over an approximately 35 km section for client, the Gauteng Provincial Administration, where two Cat 140K units form part of the construction mix. KPMM has also mobilised on the N11 Middelburg to Loskop Dam contract, an approximately R353 million Sanral award, the largest so far. The scope encompasses the rehabilitation and widening of the road, with mobile crushing and screening carried out on-site. Merafong Crushers, a division of KPMM, operates a commercial crushing and screening operation in Carltoneville, which produces the full spectrum of commercial

ABOVE A Roads Agency Limpopo contract for the upgrade of road D3756 from gravel to tar and the construction of a new river bridge

One of KPMM’s new Cat 140K motor graders deployed on a section of the N12 dual carriageway upgrade

Capital equipment investments To support these and other contracts, KPMM has been progressively expanding and modernising its plant capabilities. Recent acquisitions include latest-generation Cat 140K motor graders (replacing the previous H-Series), supplied and supported by Southern African Cat dealer Barloworld Equipment. As Twiddy points out, investing in the right equipment technologies, whether for paving or earthmoving, provides a critical competitive edge. This view is underscored by technological enhancements on the Cat 140K that translate into increased productivity and improved ser viceability. Three of these units are now deployed on the Giyani

the machine is traction-limited, engine horsepower is automatically reduced, lowering fuel consumption and minimising tyre slippage. Adds Breton: “On the move, Electronic Throttle Control provides easier and more precise throttle operation, and the addition of the Electronic Clutch Pressure Control system allows optimum inching modulation, providing better feel to the operator and smooth directional shifting. The end result is best-in-class, precision grading.”

New projects Moving for ward, new KPMM projects include rehabilitation works in Pongola, KwaZulu-Natal, which commenced in

aggregates for the civils, construction and mining sectors. Materials processed comprise previously blasted reef quartzite rock. Running alongside the civils programmes, KPMM’s Building Division also constructs structures such as mini factories, clinics and schools. A recent public sector example is a project for the Department of Education where KPMM built ablution blocks for six rural schools at an approximate contract value of R18 million. “Our strategy for roads going for ward into 2015 and 2016 is to continue targeting medium- to large-sized contracts on a national level, working across five to six projects in any given year,” concludes Twiddy.

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.

IMIESA April 2015

AFRICA ROUND-UP

INFRASTRUCTURE NEWS FROM AROUND THE CONTINENT A section of the Chinese-built standard gauge railway in Changamwe, Kenya Photo: Laban Walloga

EAST AFRICA Africans look to Chinese-built East Africa railway network African people are awaiting a Chinese-built standard gauge railway project set to run from Kenya's coastal city of Mombasa to Rwanda's capital Kigali, through Uganda – the latest in a spate of efforts to facilitate transportation and boost trade in the East African region. It is expected to cover a distance of about 2 935 km, featuring passenger trains with a speed of 120 km per hour and freight trains designed to move at 80 km per hour. China signed a deal, in May last year, to build a $3.8 billion rail link between Kenya's Mombasa and Nairobi, to be the first phase of a line that will eventually link the

countries of Uganda, Rwanda, Burundi and South Sudan. Under the deal, Exim Bank of China will provide 90% of the cost to replace the decades-old British colonial-era line with a 609.3 km standard gauge link while Kenya will fund the balance of 10%. Construction on the Kenyan side started in October and is expected to take three and a half years to complete, with China Communications Construction being the main contractor. By 23 January this year, about 500 m of the railway line has been already set in eastern Kenya.

ANGOLA Six railway stations to ease new airport access Six new multifunction railway stations and four fly-overs will

Addis Ababa Bole International Airport

IMIESA April 2015

be put in place to ease road traffic and facilitate the access to the new Luanda international airport. The information was released recently in Luanda by the Minister of Transports, Augusto da Silva Tomás, during a visit to the Luanda international airport construction site by the head of state, José Eduardo dos Santos, to learn about the pace of the works. According to the minister, an assessment of the new Luanda international airport works is underway, with a focus on the road and railway accesses to and from the site, including the airport city.

ETHIOPIA New international airport to be 'as big as Heathrow' Ethiopia is set to complete expansion work on Addis Ababa Bole International Airport in 2018 and is planning to commission a new facility to meet rising demand. According to Global Construction Review (GCR), less than a decade ago, Bole handled fewer than a million passengers a year, but that rose to 7 million in 2014. Passenger numbers are expected to continue increasing by 18% per year. China Communication Construction Company is currently working on the $300 million expansion to the airport, which started in September 2014. This will raise capacity to an estimated 20 million. Hailu Gebremariam, Ethiopian Airports Enterprise project manager for the expansion, told Reuters: "We did not

expect this growth to happen in eight years. That is why we are undertaking an expansion of the airport that will serve us for the next 15." Plans are being made to build another international airport in Ethiopia, one that could serve 70 million a year, which is about equivalent to London Heathrow.

GHANA Boost to local digital economy as fibre optic project comes alive

An 800 km fibre optic broadband backbone Infrastructure project has been completed by the government. The €38 million project, which was undertaken by Alcatel-Lucent of Denmark, covers 27 municipal and district assemblies and has been extended to the University of Health and Allied Sciences in Ho. President John Dramani Mahama, who announced this during his State of the Nation Address, explained: "The project will open up the Eastern Corridor to the information superhighway and offer not only teaching and learning opportunities but bring the digital economy closer to the area. "A growing telecommunications industry requires a dynamic regulatory framework, which ensures customer satisfaction, good return on investment, and adequate participation of Ghanaians in the sector", he told the nation.

AFRICA ROUND-UP

LIBERIA Bill introduced to create road engineering institute in Liberia A proposed law to establish the Liberia Institute of Road Engineering, Construction and Maintenance has been introduced in the House of Representatives in Liberia. The bill was introduced by Gabriel B Smith during the 16th day regular sitting of the House of Representatives. When enacted, the institute will make provision for the training of senior, middle- and low-level road engineers as well as construction workers. Smith is the Representative of Electoral District 3, Grand Bassa County, and also chairs the House's committee elections and inauguration. Following the reading, the plenary forwarded the proposed law to the committees on Education; Public Works; Ways, Means and Finance; and Good Governance to review and advise the honourable body within two weeks.

NIGERIA Development of $3.5 billion Abuja City Centre to begin soon Minister of the Federal Capital Territory (FCT) Bala Mohammed has disclosed that the development of the $3.5 billion Abuja City Centre will begin before 29 May 2015. Mohammed revealed that the Abuja City Centre would be a mixed-use development that has the capacity to generate about 10 000 jobs. The project will be executed by the Chicason Group in partnership with renowned international developer Eagle Hills. The FCT administration will enjoy 5% equity shareholding in the Abuja City Centre Development Company Limited, being a specialpurpose company incorporated

to own and operate the centre, while the Abuja Investment Company Limited would hold such shares in trust for the administration.

Lake Nyasa

TANZANIA 14 ports to be restored in Lake Nyasa Marine transportation structures that collapsed, in 2006, in three regions bordering Lake Nyasa are set for restoration, as the government plans to reestablish 14 ports in the area. Prime Minister Mizengo Pinda declared the government's commitment to improve marine services for the convenience of the population. According to a statement issued by the prime minister's office, the government has shifted the dry dock from Mwanza to the Songoro area, and a contractor from Songoro Marine Transport has already started the construction. "The significance of the project can be measured through its contribution to socio-economic activities. The dry dock will provide a workshop for the assemblage of a marine vessel, with the carrying capacity of 200 passengers and 200 tonnes of cargo," Pinda explained. "Farmers will be able to transport their crops in addition to 60 000 tonnes of coal, 72 000 tonnes of cement from Mbeya to Malawi and other neighbouring cities, 10 000 tonnes of fertiliser from Dar es Salaam, and iron from Liganga and Mchuchuma," he said.

Since October 2013, the city has only managed to install solar-powered traffic lights at four out of the proposed 16 intersections in the midlands city. Acting city director for engineering services Praymore Mhlanga said the Chinese contractor made it clear that they would not continue with the project until the outstanding amount is paid in full. "We have been facing financial challenges regarding funding this project and have an outstanding balance

of $46 000 that we owe the contractor," Mhlanga said at a MISA-Zimbabwe discussion on the state of service delivery by the midlands capital. He added: "The Zimbabwe National Road Authority is to settle the balance and they agreed to honour that part so that the project can be completed." The project, which is expected to cost about $500 000, would result in the reduction of traffic accidents caused by malfunctioning traffic lights due to power cuts.

Solar traffic lights

ZIMBABWE $46 000 debt stalls Gweru solar traffic lights project The city of Gweru has not completed its solar traffic lights project more than a year after it was launched because the council owes the contractor $46 000, a senior council official has said.

IMIESA April 2015

MUNICIPAL FEATURE

MOGALE CITY

An evolving

city

The executive mayor of Mogale City, Koketso Calvin Seerane, announced a bold threeyear infrastructure plan worth R685 million in his 2014 Budget Speech. IMIESA looks at some of the key projects the municipality is engagedÂ with. By Beatrix Knopjes

IMIESA April 2015

OGALE CITY is situated to the west of Johannesburg in Gauteng. It also forms part of the broader West Rand District Municipality, which consist of four local municipalities: Randfontein, Westonaria, Mogale City, and Merafong City. The plan includes a R34 million investment for Stage 1 construction of road and stormwater networks as well as bulk water and sewerage for the second phase of the Chief Mogale mixed housing development. The municipality will spend R120 million in rural development projects. Ga-Mohale

township will have new streetlights and new roads will be built in Tarlton, Magaliesburg, and Hekpoort. New traffic lights, streetlights and high mast lights will be installed on Beyers Naude towards Nooitgedacht, which is a site for a new development to be called Refentse township. The municipality will construct the Lindley water treatment works, at a cost of R50Â million, in order to unlock development potential of the Muldersdrift precinct where the R1.5 billion Cradlestone Mall is situated. Energy infrastructure, which includes smartmeter conversion in Munsieville, will cost the

MUNICIPAL FEATURE

Condale substation upgrade Condale substation forms the backbone of Mogale’s electrical reticulation ring network feeding the city’s commercial, residential, and industrial networks. The substation is 53 years old. Having reached the end of its designed life cycle, it threatened the city’s ability to supply secure, reliable and

Mogale City is exploring alternative offthe-grid energy provision for informal settlements across the city, while initiatives are underway to reduce the impact of conventional electricity generation on the environment, Seerane adds. “For example, a process of installing energy-efficient light fittings has started in

Mogale City is finalising its social housing policy, which aims to guide the establishment and promotion of a sustainable housing environment

municipality some R95 million. Its projects include completion of the Condale substation upgrade to improve firm electricity supply for the Chamdor and Boltonia industrial parks. “The municipality has set aside R68 million for the rehabilitation, refurbishment and upgrade of sports and recreation facilities in the next two years. This will see further work being done on the swimming pools of Kagiso, Azaadville, Krugersdorp West, and Coronation. The sports complexes of Ga-Mogale, Lusaka, Muldersdrift, Kagiso and others will benefit from this allocation,” said executive mayor Koketso Seerane.

safe energy to its industrial and residential consumers, which is of paramount importance. For this reason, the main intake substation is of strategic importance to Mogale City, which has ambitious plans to regenerate Krugersdorp’s business facilities, recreational spaces and living areas, following rapid residential, commercial and industrial growth over the last two decades. The rehabilitation and increased capacity of Condale is of utmost importance. According to Frikkie Erasmus, Energy Services Department manager, the substation currently receives capacity of 160 MVA from Eskom and the upgrade must increase capacity to 240 MVA. The project cost is in excess of R100 million and is expected to be completed in early 2015. The new substation will supply electricity to the entire Krugersdorp area, as well as new development areas such as the Pinehaven corridor and the Randfontein nodal corridor. Economic growth and employment opportunities are unachievable with a constrained electricity grid. It is for this reason that the municipality has made the upgrade of the Condale substation a top priority.

Electricity for Mogale Mogale City says that more than R200 million has been spent on upgrading the various substations and transmission lines to improve the city’s electrical supply capacity to accommodate new developments. The city also injected R5 million into the electrification of houses in Kagiso Extension 13 and Sinqobile, besides others, and provided for public lighting in informal settlements, including Pangoville, Tudor Shaft, Joe Slovo, and Makhulugama.

municipal buildings and on street lights, [while] a solar-geyser installation programme is [also] being rolled out. Currently, a wasteto-energy strategy is being developed to add impetus to an existing move towards alternative and renewable energy.” The city and the Department of Energy entered into a memorandum of understanding to pilot smart-metering and other renewable-energy projects in Munsieville, with the department contributing R10 million towards the project.

Chief Mogale integrated housing Executive mayor Koketso Seerane announced in his 2014 State of the City Address that Mogale City's central business district is set to get a facelift once the municipality implements its social housing policy. Mogale City is finalising this social housing policy, which aims to guide the establishment and promotion of a sustainable housing environment, after sourcing public comment in February. “Most business buildings in the CBD will be converted into residential apartments with varying occupation arrangements that include rental, rent-to-buy, and outright purchase,” says Seerane. The policy aims to accelerate the provision of housing to low- and middle-income residents as a way to “restructure and integrate” previously excluded groups in the area. According to the draft policy, low-income households are defined as those earning between R1 500 and R3 500 a month, and low-to-medium-income households are those earning between R3 501 and R10 000. Qualifying criteria for social housing include

IMIESA April 2015

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MUNICIPAL FEATURE

AREAS THAT MAKE UP MOGALE CITY: • Kagiso • Rietvallei • Azaadville • Krugersdorp and surrounds • Munsieville • Muldersdrift • Tarlton • Magaliesburg • Hekpoort South African citizenship and earnings of between R1 500 and R7 500.

Transport plans Meanwhile, as Mogale City recorded significant growth, a local integrated transport plan, which will see various transport hubs upgraded to meet the growing demand for an efficient public transport system, has been tabled. The mayor says development proposals are under consideration for the upgrade of the Krugersdorp railway station after the Passenger Rail Agency of South Africa (Prasa) budgeted R30 million for the project. “This project is part of a slew of interventions aimed at the regeneration of the Mogale City CBD,” said Seerane. “The city will work with the Gauteng Transport Commission to accelerate opportunities presented by the phased introduction of the bus service on the West Rand, as announced by Premier Nomvula Mokonyane in her State of the Province Address,” he adds. Efforts are also underway to conclude plans to upgrade the N14 between Mogale City and Tshwane, as part of the exportimport driven ‘Lanseria City’ development.

Water issues to be addressed The city’s provision of other basic services will also be boosted, as the municipality allocated R53.8 million to installing bulk water and sewer pipelines, and prepaid meters, besides other initiatives in areas such as Kromdraai, Lanwen, Munsieville, and Magaliesburg. New reservoirs will be constructed in Munsieville, Magaliesburg and Muldersdrift, while the Kenmare reservoir, sump and pump station will receive further attention. This emerged after the municipality said that, over the past few years, it had spent over R220 million on water and sanitation projects, including the resealing of reservoirs, maintenance, refurbishment, the installation of new water and sewer pump stations, upgrading three wastewater

ABOVE Krugersdorp is a central town in Mogale City, with a rich mining history and infrastructure development that will take it into the future RIGHT Map of Gauteng with Mogale City highlighted

treatment plants, and the extension of water reticulation to other areas of the city. “We also supply tankered water to informal settlements across the city,” Seerane added. A municipal priority for the year ahead would be a water pipeline replacement programme and the continuous installation of prepaid meters to reduce the volumes of unaccounted-for water. “Provision will also be made for bulk water supply to the Chief Mogale mixed housing development. All these water projects are expected to cost about R79 million,” the mayor said.

Rietvallei Ext. 2 roads and stormwater project Mogale City’s Roads and Stormwater Unit initiated the Rietvallei Ext. 2 roads and stormwater project in 2007. The project is funded by the Municipal Infrastructure Grant. Since the project started, 5 927 km of roads and 1 897 km of stormwater networks have been constructed, serving 3 010 households, with 15 050 people benefiting in wards 3 and 34. The Rietvallei Ext. 2 roads and stormwater project will benefit the community by: • promoting economic growth by providing job opportunities for the community and contributing to improvements in their quality of life; the project has already created jobs for 153 local people • upgrading the rocky, steep roads to provide better road networks for the Rietvallei community • installing stormwater systems to reduce soil erosion and flooding on properties, leading to reduced damage costs • reducing flooding by moving stormwater away from properties and roadways.

Lindley water treatment The municipality will spend R6 million over the next two years on the provision of water and sanitation services to rural areas, while working to build proper infrastructure in these areas as a long-term and sustainable solution for local communities. The budget will be allocated as follows: • R900 000 will be spent on bulk water and sewer projects at Dr Molefi Sefularo housing development. • R18.3 million has been set aside for construction of roads and stormwater networks in Muldersdrift. • R2 million will be committed to the installation of new traffic lights, streetlights and high mast lights in Muldersdrift along Beyers Naude and towards Nooitgedacht, which is the site of a new development to be called Refentse township. • A further R24 million will be spent in the three phases of construction of the new Muldersdrift reservoir. • R5.6 million will be spent on road construction in the western rural areas. • R3.5 million has been set aside for new streetlights in Ga-Mohale township and R3 million to reseal the Magaliesburg reservoir. • The municipality has budgeted close to R50 million for the construction of the Lindley water treatment works to unlock the development potential of the Muldersdrift precinct.

IMIESA April 2015

HOT SEAT

AECOM With over 90 years on the African continent, born from legacy African businesses, AECOM’s footprint grows from project to project. Dede Bukasa, senior executive and head: Civil Infrastructure, takes this month’s Hot Seat to discuss AECOM’s vision for the future of construction in South Africa.

Building a Legacy What is the extent of AECOM’s service offering locally and in Africa? DB AECOM is active in more than 40 African countries, with over 1 900 staff. The staff include award-winning engineers, planners, architects, environmental specialists, economists, scientists, consultants, cost managers, project managers, and programme managers who are committed to delivering projects that improve the quality of life for African communities. Locally, we have representation in all of South Africa's major cities.

Are you currently involved in any major projects that you would like to highlight? AECOM is privileged to be involved in most of the current major South African projects. I am personally involved in a range of AECOM projects, including providing EPCM services to Transnet on the manganese bulk terminal at Ngqura, the upgrade of the material handling and freight rail infrastructure for the tippler at the Port of Saldanha Bay, and 20 other infrastructure projects in the Cape region. Other notable projects include the design, construction monitoring, and commissioning of

IMIESA April 2015

TCTA’s acid mine drainage project; with the same services offered for Spring Grove Dam. On a greener note, AECOM has been appointed as either owner’s engineer or EPC contractor’s engineer on various renewable energy projects, including the 137 MW Jeffreys Bay Wind Farm project.

Describe your strategic outlook for medium-term development in South Africa. This hinges on a number of inter-related factors: it is generally the local political environment, the impact of the oil price on world economic growth prospects, and by extension the impact this has on the price and

What is your view on how South Africa can improve its infrastructure delivery within the constraints it faces? There exists the idea that there is never enough money to achieve the desired results. Added to this is a cumbersome procurement policy that acts as a hurdle to getting funding into the right hands. This needs to be addressed. What is most important is that government must seek value for money rather than focus on the lowest price when awarding work. I believe that a strong political will and an acceptance of an alternate way of doing business are required to benefit everyone in this country.

“We are proud of our socio-economic development scheme, which we propose to our clients on all of our projects.” demand for resource commodities such as coal and iron ore. We believe that a focused business strategy, based on doing what we do best, and ensuring that our current clients receive the best service available, is a cornerstone to maintaining and developing our position in the market – as both AECOM and the industry as a whole.

How is South Africa adapting to its delivery challenges and what role does AECOM play in developing alternative solutions and methodologies? South Africa is slowly embracing the advantages of alternative delivery methods like design-build, DBOT, PPP, and multiple hybrids of each. This process cannot be sped up until

the procurement engine (policies, etc.) is brought in line by government. The mindset change requires, to a large extent, handing over control of public infrastructure to private entities. AECOM is able to draw on a well-established body of knowledge and capability in all of the various delivery methods. AECOM is able to cofinance portions of the upfront project costs in order to develop a long-term option for the client. In addition, we are proud of our socio-economic development scheme, which we propose to our clients on all of our projects. It supports the government’s current objectives as set out in the NDP, and aims to upskill and empower South Africans on all of our projects.

In your view, what qualities does a project need to have in order to succeed as a PPP? In the project development process, a robust feasibility study that demonstrates the technical, legal and financial viability – including a demonstrable source of revenue to pay for the capital invested – of a project is critical to move forward to a bankable project that can achieve financial close.

HOT SEAT

AECOM PROJECTS

A stronger regulatory and legal framework for PPPs is required, based on the published guidance of international financial organisations, which directs infrastructure projects towards best practices during development. This includes mitigating environmental and social impacts, and leads to better outcomes for governments, developers, investors, and users alike. Other key success factors include: a strong consensus among public opinion and consistent support from key political leaders, early engagement with stakeholders, as well as an appropriate risk-allocation model to all relevant parties.

Please describe alternative delivery and its potential for alleviating service delivery backlogs in South Africa. The simple explanation of alternate delivery is any method other than the conventional way of delivering services. South Africans are demanding a higher quality of basic services, and the protests show discontent as these demands are not being met. South Africa’s policy and legislative frameworks limit our potential in this regard. Policies should enable, not restrict, advancements.

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sits with the delicate balance of an emerging ‘developed’ market, with a broad base that is still developing and expectations across the spectrum of developed service levels for all. This comes with a requirement for a concurrent payment commitment to fund the delivery of municipal services through the broader tax base, which overstretches an already compromised tax system. While there is no option but to recover these costs through utility rates and tariffs, there are multiple methods of cross-subsidisation and a blend of fixed and user-variable rates can be used to recover the costs. However, at the core of this would be a government about-turn on ‘free services’ for water, electricity, and other basics.

How do you develop strategic financing and funding strategies for complex infrastructure? Do you have partnerships with funding agencies? AECOM’s vision is to become the world’s premier integrated infrastructure delivery firm, capable of assembling and performing a broad range of services to provide a total solution to our clients. In developed markets, AECOM Capital, a subsidiary company,

provides strategic capital to get projects that utilise AECOM’s technical services (design, build, operate) off the ground. In less developed markets, AECOM can mobilise other sources of finance. When our clients seek to finance a project that meets preset criteria for its investment portfolio, AECOM is able to bring partners to the table, which helps with syndicating other investments and debt financing. AECOM is able to help clients finance projects in other ways, too, and maintains a network of strategic partnerships (including major banks and private equity firms, as well as key construction companies) that can directly or indirectly bring financing to the table.

How are you, as the private sector, engaging with the Presidential Infrastructure Coordinating Commission (PICC)? The governance of the PICC is well structured. One of its tiers is the PICC Task Team. This tier comprises parastatals and government representatives. We, as part of the private sector, engage with the PICC at this level through our involvement with parastatals – such as Transnet, TCTA, Eskom, Prasa, and Sanral – on our projects. We regularly interact with these role players, ensuring that, when we work with them on a

ABOVE LEFT Spring Grove Dam, KZN; Gibela project, Gauteng – architect’s rendition ABOVE Acid mine drainage project

project, we are aligned with their objectives as part of the PICC.

How does AECOM contribute to ensuring the success of South Africa’s NDP? We believe in continuously investing in our staff and, in particular, in young talent. This ensures a continuous transfer of skills, promoting equality across all levels of our business. We have a structured national mentorship programme called FutureNow, which signifies our investment in the future of young professional talent. This programme shares and transfers experiential wisdom and knowledge. AECOM also contributes extensively towards educational institutions, communities, welfare organisations, sports clubs, NGOs, and individuals for the upliftment and betterment of their environment and quality of life. We have representatives on various professional bodies, such as the CESA National Liaison Committee, where we engage with government stakeholders and other businesses in the industry to improve communications between the public and private sectors.

www.aecom.com

IMIESA April 2015

HUMAN SETTLEMENTS

Lifestyle-friendly

living spaces The fundamental core of human settlements is not just about building a roof over an individual’s head. It requires a multidisciplinary approach to overcome the shortfalls that housing delivery experienced in the past. Beatrix Knopjes looks at some key humansettlement projects to highlight their successes and what lessons can be learned from each.

ENTAL HOUSING is an effective method of alleviating South Africa’s housing shortage, and became part of the Breaking New Ground policy in 2004, which is an instrument for densification and urban restructuring, and an important option in the objective of making housing delivery more demandresponsive and providing a wide range of tenure and product choices. The process of providing rental housing, however, comes with challenges. From these challenges, lessons can be learnt to provide better human settlements and create sustainable communities with access to employment and social amenities. The aim is to create an integrated living space that meets the basic human need for shelter, but goes several steps further than that to provide bulk services, social amenities, commercial spaces and business opportunities, and environmental spaces.

Joe Slovo Social Housing project The Joe Slovo project is part of the bigger National N2 Gateway project involving the development of 25 750 affordable housing units, located in Langa, Cape Town. The site is situated directly north of the N2 and the adjacent stormwater canal, past the two power station cooling towers on the way to Cape Town International Airport.

IMIESA April 2015

The project was established to address the urgent housing and development needs of households in informal settlements adjacent to the N2 highway in Cape Town. The project gives a good indication of what Cape Town’s affordable housing may look like in the future. One of the objectives of the Joe Slovo project is to create a vibrant, medium-density residential area around a well-designed public spatial system. Owned by the City of Cape Town, the land was identified as a strategic site for urban medium-density housing. It is ideally located within the existing urban fabric of Cape Town and has easy access to a wide range of facilities and infrastructure. Multistorey housing units or apartment blocks that face on to public streets and squares are departures from more traditional approaches to affordable housing as they create medium-density urban environments. The semi-detached nature of the units and easy access to public spaces promote community development. The units all have bathrooms with showers and open-plan living, dining and kitchen areas. Energy-efficient plumbing, comprising a basin with a built-in geyser, provides instant hot water to both the kitchen and bathroom, ensuring minimal heat loss. A single, adjustable tap, serving both the basin and bath, reduces the need for

expensive plumbing pipework and connections. Units are built around central courtyards. Some units have both front and back entrances and others (first- and second-floor units) have access from the courtyards only. Certain upper-floor units are accessed through an external staircase along the front facade of the block. All these features add interest and variation to the building facades. Low-level walls define small front gardens and entrances to the ground-floor |units. Standard cavity walls were built, bagged and painted, and a variety of colours were applied to facades on the ground floor. Precast elements were designed to speed up construction and eliminate on-site shutter work. Precast hollow-core floor slabs were used for the floors, while precast concrete window and doorframes were built to house aluminium windows and standard timber doors. While glass-paned stable doors were proposed to allow for more light, standard wooden doors were installed to improve security. The mono-pitched roofs were covered with metal sheets. Energy efficiency was also considered and isotherm was used in the roofs to ensure interior climate control without energy wastage. Rainwater and grey water tanks were part of the original design to facilitate water conservation and to promote recycling, but

HUMAN SETTLEMENTS

these elements were later omitted because of prohibitive costs. The development was designed with integrated community living in mind. The City of Cape Town aims to integrate new and existing communities through innovative design interventions. Its intention was to create an appropriate urban environment that is close to employment, transportation, education and recreation facilities, as well as to create a medium-density setting to provide these benefits to as many people as possible. There are 705 units in total. The bachelor units are 27 m2 in size with the one- and twobedroomed units varying between 40 m2 and 48 m2. Orientation and building heights were carefully considered to maximise the living conditions within individual units located between existing power lines and freeways. The difference in height between the blocks ensures that the units in the lower blocks (positioned in front of the higher blocks) get adequate sunlight during the day.

Moshoeshoe Eco Village The Moshoeshoe Eco Village was built as a pilot project to the larger low- and middleincome Hull Street housing project, which was initiated by the Swedish International Development Cooperation Agency (Sida) and launched in cooperation with the Swedish and South African governments.

As sustainability issues are of the utmost importance to any building project, the aim was to place people and their environments at the very centre of the project. The character of the built environment influences how people live and how future generations will live. The Moshoeshoe Eco Village consists of 13 units and demonstrates a number of alternative or eco-technologies. These could

garden facing on to the street with its own entrance gate and low, diamond-mesh fencing. The back gardens have an opening onto a common green space that will be used for ecological and community recreation. The colourful units make for an attractive street frontage in Sol Plaatje. Energy efficiency was a ver y important aspect of the development and was

Cape Town aims to integrate communities through innovative design interventions to create an appropriate urban environment close to employment, transportation, education and recreation facilities turn out to be the ideal response measures for integration into future low-income housing projects. The Moshoeshoe Eco Village is situated within the municipality of Sol Plaatje, Kimberley. It is located in Galeshewe township, some 3 km from the city centre. The development is within a 500 m radius of schools, a church and economic nodes. The simple setting of the units along the street frontage offers an opportunity to demonstrate the various residential typologies: two-, three- and four-unit row modules. Single- and double-storey units are built side by side, achieving an interesting and varied streetscape. Each unit has a front

addressed in several ways. The use of renewable energy was integrated into the development through the installation of solar water heaters as well as photovoltaics. A back-up system of instantaneous gas water heaters was also installed. Although this system requires a higher capital outlay than an electric geyser, it is more energyand cost-efficient in the long term. All units were fitted with gas stoves and energyefficient light bulbs and appliances. The gas for heating and cooking lasts about four months but residents have found that they cannot bake in the gas stoves. Electricity is only used for lighting and to run appliances such as refrigerators.

IMIESA April 2015

HUMAN SETTLEMENTS

The unit blocks were constructed from traditional load-bearing brickwork with either timber or concrete first-floor slabs. Handmade bricks were tested but found to be unsuitable. Instead, the use of concrete bricks was adopted. The first-floor slabs are a type of rib-and-block construction. Firstfloor partition walls are lightweight drywalls, achieving minimal loading on slab and providing a cost-effective solution. Timber staircases were used for internal access in double-storey units. Roofs are formed of local-pine trusses supporting corrugatediron roof sheeting. A Rhinoboard ceiling, with insulative material, was used. Steel window- and doorframes, and timber doors were installed. The majority of the units

were plastered and painted internally and externally, but a few units were built from semi-face bricks.

Drommedaris On 16 November 2009, Communicare launched its first R75 million social housing project that will deliver 219 rental units and 20 units for purchase in the suburb of Brooklyn, Western Cape. Drommedaris is a collaboration between the Department of Human Settlements, the Social Housing

Foundation SA, the provincial government of the Western Cape, City of Cape Town, and Dutch International Guarantees for Housing (DIGH) and Communicare. Premier of the Western Cape, Helen Zille, officiated at the symbolic sod-turning event while other dignitaries included the MEC for Housing, Bonginkosi Madikizela; Dan Plato, mayor of Cape Town; and Brian Moholo from the Social Housing Foundation. The project will be financed to the tune of R28 million constituting a Restructuring Capital Grant, R22 million from the provincial government as allocated by the City of Cape Town, R20 million loan funding from the Dutch International Guarantees for Housing (DIGH) with Communicare funding the balance of the total project cost from its own equity. “Although Communicare has been providing affordable housing for the people of the Western Cape for the past 80 years, this is our first true social housing development,” explains Communicare chairman Herman Fourie. “The goal is to provide good-quality rental housing in well-located parts of the city, and Brooklyn is an ideal location. Excellent existing transport infrastructure and amenities are close by, and include hospitals, schools, and libraries – all of which meet the government’s criteria for quality social housing.”

“Although Communicare has been providing affordable housing for the past 80 years, this is our first true social housing development.” Herman Fourie, Communicare chairman, on the Drommedaris project

IMIESA April 2015

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HUMAN SETTLEMENTS

Building

better houses T

HE DRIVE TOWARDS sustainable construction has seen the building materials industry respond with innovative solutions and products to heed the call of the market. For the most part, many of the products used in high-performance building have been around for years, but manufacturers have either improved on them or repurposed them for different applications.

Something old, something new Expanded polystyrene (EPS) modules have been used in construction since the 1950s, mainly as a mainstream insulation material. Although EPS is still valued for its insulation properties, it has taken on a very different role today. BELOW Little Manhattan

IMIESA April 2015

Over time, we’ve seen trends in building materials move from natural to man-made products and back again. Today, the most popular building materials are those with ‘green’ advantages, which include being nontoxic, reusable, renewable, and recyclable. By Liesl Frankson

A 2013 market study by Ceresana, an international market research and consultancy company, predicted that the market value for EPS was likely to rise to more than $15 billion until 2020. In South Africa, we’ve seen evidence of the growing demand for EPS in the building industry with the rise of companies specialising in insulated concrete form (ICF) construction. ICFs are hollow EPS forms that are erected at the construction site, and then filled with five or six inches of reinforced concrete, according to the EPS industry alliance. Unlike traditional concrete forms, which are removed after the concrete cures, ICFs are left in place. Using ICF construction has numerous benefits for all stakeholders invested in a project. In the short term, project developers will see

upfront benefits because ICF buildings go up faster, which equates to financial savings. Contractors are also able to hire less skilled labour because the material is lightweight and easy to use. In the medium to long term, the financial benefit one receives from ICF construction is ongoing. The concrete core in ICF walls resists damage from wind, fire, earthquakes, termites, rot, mould and mildew, unlike other materials, which amounts to reduced maintenance and insurance costs. In terms of its environmental value, ICF’s insulation properties have major implications for energy efficiency because they are cooler in the winter and warmer in summer. This allows homeowners to lower their heating and cooling costs. The concrete-filled walls also provide improved sound insulation.

HUMAN SETTLEMENTS Wooden houses are growing in popularity

According to the National Ready Mixed Concrete Association of America, sound penetrates ICF walls only one-eighth to onequarter as much as conventional walls and, because an unbroken exterior envelope results in fewer cold spots and drafts, ICF structures provide a more comfortable interior environment.

The building blocks of sustainability Bricks are one of the oldest known building materials with evidence of their existence present almost 10 000 years ago. Initially used in the sun-dried mud form, brick makers soon discovered the benefits of fired bricks. These benefits, which are still as relevant today as they were 10 000 years ago, are what secured the place of bricks in the construction industry for years to come. The biggest benefit fired bricks provided is that they were more resistant to harsher weather conditions, which made them much more reliable for use in permanent buildings. Today, the construction industry is spoiled for choice when it comes to sourcing bricks, but with the current drive from government to deliver 1.5 million houses in five years, face brick has emerged as a favourite in entrylevel housing projects. A recent example where face brick proved to be a favourite with entry-level housing was the award-winning Little Manhattan apartment complex in Pretoria. Little Manhattan is being developed by Central Development Projects, which specialises in full-title, sectional and high- and low-density residential projects. South African brick manufacturer Corobrik supplied 2.4 million bricks for the project. Ockert van Heerden, Corobrik director of sales, believes that the success of projects such as Little Manhattan hinges on a good balance between aesthetics and practicality. Face brick has exactly this combination and is hard wearing, requires little maintenance, and still has aesthetic appeal, he adds. “Positive characteristics include affordability, longevity, structural strength, flexibility in design and application, natural soundproofing qualities, incombustibility, natural resistance to fire, solidity, and security. The enduring, natural earthy colours and textures of clay face brick walls significantly reduce maintenance costs,” he explains. He notes that five overseas and three South African studies have indicated that clay bricks promote healthy living, which is

“The inorganic qualities of fired clay deliver mineral content that guarantees a nearly pollution-free indoor air quality, which is particularly relevant in a home environment.” Ockert van Heerden, director of sales, Corobrik particularly important in an environment populated by young families. “The inorganic qualities of fired clay deliver mineral content that guarantees a nearly pollution-free indoor air quality, which is particularly relevant in a home environment. A natural propensity to absorb and release humidity from the atmosphere provides a good moisture balance inside apartments and protects against mould growth, which is widely recognised as a contributing factor to sick building syndrome.” Van Heerden adds that one of the most important attributes of clay brick is its good thermal performance. Scientific research has demonstrated that clay brick structures are warm in winter and cool in summer and, as a result, cut energy usage substantially. This is particularly important for families on tight budgets.

Constructing wooden wonderlands Wood is one of the oldest and most common building materials, but the construction industry has generally approached it with caution. For years, the industry has viewed wood as less sturdy and more prone to fire dangers in comparison to concrete and steel; however, this is fast changing. Confidence in wood as a building material has grown substantially over the last year, with many experts in architecture and construction marking wood as the next big thing in the construction of skyscrapers and apartment buildings. Cross-laminated timber (CLT) in particular has become very desirable. ReThink Wood, a North American initiative and online source for the use of wood in construction material and buildings, describes CLT as an engineered

wood panel typically consisting of three, five or seven layers of dimensional lumber. According to woodworks.org, CLT starts out as kiln-dried boards that are then layered perpendicular to one another and glued. This cross lamination provides dimensional stability, strength and rigidity. The boards are then face-glued and pressed, planed and sanded into panels. Using computerised numerical control machinery, the panels can be custom-fabricated to create openings, compound angles and unique features requiring complex geometry to meet specific end-use applications. ReThink adds that CLT offers high strength and the structural simplicity needed for cost-effective buildings, as well as a lighter environmental footprint than concrete or steel. It also provides numerous other benefits, including quicker installation, reduced waste, improved thermal performance, and design versatility. Insulated concrete form house

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IMIESA April 2015

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Boomtowns demand

sewage innovation

In President Jacob Zuma’s most recent State of the Nation Address, unlocking growth in mining towns and human settlements was placed high on the list of national priorities. Frances Ringwood asks: How is municipal wastewater treatment keeping up?

T’S A COMMON FEATURE of the postapartheid South African landscape to see human settlements and the development of safe, dignified housing stymied by inadequate wastewater treatment and related sanitation services. Worse still is when town planners go ahead and build with woefully under-capacitated facilities, resulting in polluted waterways and unhygienic living standards. Examples of such scenarios abound and the average engineer, scientist, city planner, contractor or environmentalist working in the field will have come across this state of affairs often enough. Recognising the problem and acting on research indicating the main challenges that occur when settlement growth outstrips supporting infrastructure, the national government has decided to act. The effect of government’s ‘back-to-basics’ approach is already being felt in mining towns (and cities) like Rustenburg, Ogies, Mogalakwena, and

Bloemfontein, where the public and private sectors are working together to implement smart strategies for creating towns that reflect South Africa’s good news stories.

Building houses is only the first step towards creating a better life for all; adequate infrastructure to service new communities is also essential

State of sanitation

with R290 million approved for informal settlement upgrades in Mpumalanga, North West, Gauteng, Northern Cape, Limpopo, and the Free State,” Zuma announced in his February 2015 SONA. In the same address, he informed the nation that 113 informal settlements are being assessed or prepared for upgrading through the National Upgrade Support Programme. Thirty-two settlements are being upgraded and 87 housing projects are being implemented across those mining towns identified for priority intervention. The banking sector and other organisations invested in South Africa’s future stability and wealth are in favour of the plan, with government, mining sector heads and Banking Association South Africa having

Since 2012’s Marikana massacre, the government has been forced to relook at what factors promote stability in mining – the country’s economic dynamo. As a result, a number of programmes under the Framework Agreement for a Sustainable Mining Industry were promulgated; these address violence and minimum wages first. A surprising third tier to the discussions was the need to revitalise mining towns for the purpose of creating better living standards and more hospitable living and working conditions. “We had also made a commitment in last year’s State of the Nation Address (SONA) to revitalise distressed mining towns and a lot of progress has been made. A total of R2.1 billion has been ring-fenced for this purpose,

IMIESA April 2015

HUMAN SETTLEMENTS

signed a contract for the development of sustainable human settlements, with mining priorities in mind. In addition, government has put about that it will be following a back-to-basics approach to municipal service delivery to support these interventions. What was not said was exactly how this would be followed through in terms of which infrastructure will be prioritised.

Electrification is something many human settlements desperately need – while proximity to mines aids municipalities to secure new connections, this doesn’t guarantee electrical supply. Solid waste management services are also of vital importance. Potable water, too, is a necessity and a human right. However, a real success story, and one that might read as a blueprint of sorts for bettering other types of service delivery, is when mines work with municipalities and communities to create complementary mechanisms for sewage handling.

Engineering a better tomorrow SRK Consulting’s principal director, and a hydrologist with more than 21 years of experience, Peter Shepherd, expresses enthusiasm for the environmental benefits South Africa’s platinum mines are leading the curve when it comes to adopting a new mindset where sewage is seen as a valuable asset, contributing towards environmental and business sustainability

of reusing municipal wastewater for specific mining applications. “It’s becoming standard practice in mining to reuse sewage from municipal wastewater treatment plants. Certain mines, such as the Kendal Coal Mine in Ogies, Mpumalanga, and Mogalakwena mine in Limpopo, run almost entirely on sewage for their processes, incorporating just a small fraction of potable water,” Shepherd explains. He adds that platinum mines are also particularly good at reuse and associated financing. “If you look at platinum mines like Impala in Rustenburg, it specifically set aside a capital contribution towards municipal wastewater treatment so as to have the best applicable quality of water possible for its processes,” says Shepherd. The reason sewage is better for certain processes in mines than a range of other waters is that sewage has an extremely low salt content, making it ideal for cooling and gland servicing. Low salinity means there is less sediment left in pipes and towers. Sediment in certain mine systems can cause

IMIESA April 2015

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damage to structures, which is costly to repair, and so there is a considerable cost benefit for mines using wastewater. Consultants such as Shepherd are experienced in calculating the environmental, legal and cost-benefit analyses of using different types of water for different processes on mines. For civil infrastructure development and assistance in creating suggested financing mechanisms, an experienced engineering consultant must be called upon.

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Focus on towns Bigen Africa has worked on several such projects in the last couple of years, and registered civil engineer Mias van der Walt talks passionately on the topic of how mines can work with municipalities for their mutual benefit, while simultaneously catalysing the development of mining towns. “In the past, people used to look at wastewater as a liability. In the last few years, we’ve witnessed a definite mindset shift towards seeing wastewater as an asset,” Van der Walt explains. “For example, in Rustenburg there was a moratorium placed on housing development because of inadequate sewage treatment. So Bigen Africa assisted in establishing the Rustenburg Water Services Trust and through this vehicle offered to sell treated effluent to mines for process water – in the process, Bigen Africa also managed the upgrading of the town’s defunct water treatment plant and were able to uplift the town. “At that point, the Rustenburg Water Services Trust was able to ring-fence finances from the project to offset some costs of the second phase of the much-needed water and wastewater treatment works upgrades in Rustenburg. These projects should commence in 2015.” explains Van der Walt. “A similar approach is being developed in Bloemfontein where a water reuse system is being developed to reduce the need for external bulk supply,” he adds, referring to another, similar project Bigen is involved in for the purposes of optimised water use in urban areas.

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Conclusion The above discussion outlines only the most basic aspects of using wastewater in mines for catalysing the development of mining towns. What needs to be understood is the complexity of each system that must be aligned when undertaking such projects – from having good legal, environmental and financial consulting in place, to bridging the gap between municipalities and mines, especially in the demanding field of engineering. National government, too, wants to be involved and ensure projects such as these – which promise substantial financial incentives – take off. However, the problem remains that residents in mining towns continue to feel inadequately serviced, as is evident from ongoing service delivery strikes in rural towns, reported in the news on an almost daily basis. What’s needed now is communication with disgruntled townsfolk who have not yet felt the benefits of conjunctive wastewater use: a way to impress upon them that, although the spatial and economic injustices of the past have set them back, both the public and private sectors are coming together to make things better. Furthermore, there is both a policy-aligned plan and funding to achieve these ends, providing a tangible thrust towards making better human settlement infrastructure a reality.

IMIESA April 2015

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HUMAN SETTLEMENTS

Bettering home energy use While there are a large number of impressive case studies where energyefficient technologies have been implemented in South African human settlements, there remains confusion over how these are funded and what methods to use for measuring success. By Frances Ringwood

OST SOUTH AFRICANS are familiar with the fact that the government is promoting energy efficiency in human settlements. Simply by looking at what has already been achieved reveals the extent and force of these efforts. Driving past Green Street in Cato Manor, Durban, a casual onlooker may be surprised to see there are solar water heaters (SWHs) on a large number of low-cost houses’ roofs. In addition, a vast number of Johannesburg Social Housing Company (Joshco) developments, particularly in the high-rise space, boast roof-top solar panels

Proper insulation is vital for maintaining the balance of a home’s ambient temperature; this applies to ceilings, walls and windows

IMIESA April 2015

and heating ventilation and air-conditioning (HVAC) systems. The private sector also hosts a number of trial technologies for a small sample of houses, such as SaintGobain Gyproc’s RhinoBoard test site in Diepsloot, showing off the strength, longevity and insulating properties of the product. These projects are being rolled out on an ongoing basis, and stakeholders are able to measure the results using faceto-face engagement as well as communication yielded by smart technology penetration, even among those who earn the least income. The problem, however, is that few people are really sure how funding incentives work, how exactly energy efficiency can be defined and what separates demand-side management from asking citizens to research and fund their own energy reduction strategies.

This confusion came to the fore at the recent African Energy Indaba, held at the Sandton Convention Centre in Gauteng, where a delegate from Ghana’s Water Company told panel discussion participants he was walking away from the conversation feeling disappointed and more confused than inspired – a sad fact given the tangible variety and extent of South Africa’s inroads into developing and implementing energy-efficiency technologies.

Projects Before discussing where generally held definitions and ideals are letting down South Africa’s energy-efficient human settlements, it bears noting relevant case studies and how these have been discussed in the past. Such an approach not only reveals the extent of South Africa’s investment in

HUMAN SETTLEMENTS

energy efficiency – through organisations ranging from Eskom, the CSIR and multiple private sector players – but also creates a lexicon of terms for discussing future development in a more productive way.

SWHs The extent and acceptance of SWHs in South Africa’s human settlements is truly astonishing. Cato Manor was a catalysing event for a broader roll-out, given that the project had to be finished in time for the COP 17 climate change talks, which were being held in the City of eThekwini in 2011. Surprisingly, while government played a major role in greenlighting this and other similar projects, foreign aid has been the driving force behind many local SWH rollouts. Led by the Green Building Council of South Africa, the 30 Green Street retrofits were almost entirely funded by the British High Commission. This particular case study forms a useful reference point, as the participants involved measured residents’ carbon footprint reduction while also looking at other positive spin-offs such as lowering paraffin and wood-burning use to generate heat (frequently a cause of fires and respiratory ailments). In addition, job creation through a green economy was incorporated into the study, along with complementary resource-conservation methods such as rainwater harvesting. Just a year later, a similar project was rolled out in Johannesburg, called the Solar Water Heater Programme (SWHP), which aimed to install SWHs at more than 110 000 houses over three years. This, the metropolitan said, would contribute 10% towards the national goal of 1 million SWHs to be installed by the end of last year. The SWHP looks to have been funded largely by government, with City Power identified as a major beneficiary. Still more SWHs have been installed through other programmes, with more than 500 families at the Joe Slovo housing project in Langa, Cape Town, having received SWHs towards the end of last year. The Joe Slovo SWHs were made possible after the Danish International Development Agency (DANIDA) environmental programme donated funds to South Africa’s Department of Human Settlements. These are just a few examples of South Africa’s SWH craze – a popular measure for securing energy efficiency in human

Other energy-reduction technologies that come part and parcel with the programme include pool timers, geyser timers, low-flow shower heads, flow restrictors, and geyser blankets

settlements with proven benefits, not only for families’ financial management but which also contribute towards better human and environmental health.

Lighting and other Eskom initiatives Say what you will about the national power utility, Eskom has been leading the way in promoting the adoption of energy-efficient lighting technologies among the country’s poorest communities for at least the last three years. Dubbed the Residential Mass Roll-out (RMR) programme, the utility has spearheaded two phases of a wider plan aimed to replace old-fashioned lighting technologies – such as incandescent globes – with compact fluorescent lamps (CFLs) and lightemitting diode down lighters. Other energy-reduction technologies that come part and parcel with the programme include pool timers, geyser timers, lowflow shower heads, flow restrictors, and geyser blankets. Eskom conscientiously designates the RMR as a demand-side management strategy and it is coupled with a system of rebate incentives for those households that install their own SWHs and heat pumps. Money allocated to the project amounts to R1.5 billion and detailed granular data for overall benefits can be accessed on Eskom’s website. Needless to say, the gains of the programme have been significant, with 56 819 630 CFLs having been installed countrywide by 2013.

Solar water heaters have been widely adopted in South Africa as one of those most impactful ways for human settlements to reduce energy consumption

Wonderbags One of the most innovative energy-efficiency interventions from the point of view of measurability is Wonderbag, which, in a pilot study undertaken in Newcastle Local Municipality in KwaZulu-Natal (funded by technology companies Microsoft and Frog), reduced energy used in cooking by 50%. Wonderbag is essentially a simple insulation solution for food preparation so that pots don’t lose heat throughout the day – without having to be left on a low-burning heat source. The idea was developed primarily with township environments in mind, where cooks and primary caregivers will have to leave the house most days to earn an income to contribute towards raising their families. The first part of the pilot comprised community engagement and enrichment through citizens’ participation. Electricity consumption and reduction was then tracked on recipient householders’ cell phones. Finally, carbon credits earned through the project were to be sold in order to fund infrastructure through the municipality. Four years on and Wonderbag is growing as a business, enjoying support from the likes of Sappi, Three Cities Group, T-Systems, Tsogo Sun, CSIR, uMhlathuze Municipality, Umjindi Local Municipality, Medi-clinic Group, AngloGold Ashanti, Anglo American,

IMIESA April 2015

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HUMAN SETTLEMENTS

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Building materials and methods Insulation, par ticularly the insulation of ceilings and windows, contributes enormously to the reduction of heating and cooling bills for homes, schools, community recreational centres, and other public buildings. Using good-quality, low-cost alternative building technologies, such as high-quality RhinoBoard, is one method to lower construction costs while insulating buildings. However, brick houses remain popular in human settlements, as they too have excellent thermodynamic properties. One of the most recent local technological breakthroughs in this area was pioneered by chemicals company BASF, which developed Styrofoam-based Neopor panels to maintain heat passively, lowering the amount of energy that would otherwise be used for heating and cooling. The CSIR has also published extensively on the advantages of ceiling insulation and its proper installation. Added to this is ensuring windows face the optimal direction to catch the maximum winter heat, while walls should be painted lighter colours in order to deflect excessive radiation in summer. Doubleglazing is, of course, another recommended measure for the proper insulation of buildings in areas subjected to more drastic weather. However, this measure can be prohibitively expensive.

power centres, such as cellular phone charging businesses. Global lighting company Royal Philips Electronics is, in fact, in the process of rolling out 100 lighting centres across Africa. Company representatives are taking the time to select particularly disadvantaged communities for the donation of solar centres including batteries to provide communities with shared recreational spaces at night. The €1.2 million project has already completed

don’t even begin to touch on the vagaries of advanced technologies in HVAC, a topic which, itself, could comprise material for an entirely different article.

Defining the problem Despite these widely known energy-efficiency innovations, even experts battle to define demand-side management, energy efficiency, or explain how these two concepts are related. A positive observation that did emerge from the African Energy Indaba panel on energyef ficient technologies was that measurement and monitoring methods are vital for achieving sustainable reduction and peak-time management goals. Moreover, consolidating government’s current national policies, incentives and funding methods to secure energy efficiency, for human settlements as well as other areas, is challenging. It may be the case that government’s overall carbon saving successes need to be accessible in a more universal way in order for their full force to be quantified and acknowledged. It appears that the private sector is enjoying greater public knowledge regarding its carbon and energy savings successes; but this too could stand to be better archived, monitored and measured for overall impact.

It appears that the private sector is enjoying greater public knowledge regarding its carbon and energy savings successes

Solar panels Solar panel installation can be one of the most cost-effective systems for the provision of electricity to communities remote from the grid. Photovoltaic modules convert the radiant energy of the sun into a direct current electrical source. When coupled with other energy storage devices such as batteries and power-management equipment, a system can be formed for either individual users or an entire community. In addition, spin-off business can be developed through the implementation of solar

light centres in Ghana, Morocco, Kenya, and South Africa.

Other innovations Signage and smart monitoring through intelligent technology looks set to be the next big thing in demand-side management. Verifiable data indicates that if users can see the amount of electricity being consumed and its cost, they naturally want to manage those figures. Without immediate access to such information, however, it’s a case of “out of sight, out of mind” and the incentive to actively manage energy usage is reduced. Smart meters, smart grids, liquid crystal displays, and smar t-device applications (apps) are just a small sample of the technologies and channels being developed to effect desirable changes in consumer behaviour. The above headings represent just a sample of the measures and case studies available for better energy efficiency and

Conclusion Despite recent loadshedding challenges, South Africa is a leader in energy-efficient human settlements in Africa. With that knowledge, South African companies, municipalities and other stakeholders have the responsibility to begin sharing energyefficiency innovations productively with the rest of the continent.

IMIESA April 2015

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INNOVATIONS IN CONSTRUCTION

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The advent of 3D printing has changed the way the world looks at fabricating products. Since the arrival of the 3D printer, and its rise in popularity, it has been used to make car parts, fashion accessories and equipment. More recently, its use in construction has been realised. By Liesl Frankson

N THE LAST three to four years, architects, universities and others with an interest in the field of 3D printing have taken on the challenge to print a 3D house.

The 3D Print Canal House The 3D Print Canal House is a three-year, publically accessible ‘R&D by doing’ project in which an international team of partners from various sectors works together on 3D printing a canal house in Amsterdam. The house is made of 13 rooms that each consist of several printed elements. Each room showcases a research update in shape, structure and material. The rooms are first assembled and tested separately before finally being constructed into the complete house. Thus, the expo site is experienced as ‘a growing village of rooms’. The project is initiated by DUS architects and shows that architecture can be a catalyst for cross-sectoral

ABOVE 3D Print Canal House – artist's impression Photo: DUS Architects

RIGHT Crug straight wall

innovation. It is collectively funded by all partners, who contribute to the project with knowledge and financial means.

Printing with plastic The house is printed using a large-scale version of the Ultimaker, a desktop 3D printer, known as the KamerMaker. The 3D Print Canal House site describes how it works: “The KamerMaker places a digital design in the ‘brain’ of the printer where it is translated into a G-code. This G-Code programs the printer to move along a path that is optimal for that design, layer by layer. The ‘control room’ of the printer also houses the material supply. The KamerMaker prints with plastic

IMIESA April 2015

INNOVATIONS IN CONSTRUCTION

ABOVE PB House – artist's impression ABOVE RIGHT The KamerMaker Photo: Martin de Bouter

in the form of granulate, which enters an extruder via a funnel. In the extruder, the granulate is heated and pressed together to form a homogeneous liquid. “This is brought to the printer head by a heated tube. The head extrudes the melted material along a programmed path on the X and Y axes and, when finished, moves up one step along the Z axis. This is similar to a normal printer with an additional axis, which allows objects to be printed layer by layer.”

According to the site, the materials used in the Kamermaker are bioplastics. “The granulate that goes into the KamerMaker is called Macromelt, a type of industrial glue (hot-melt) developed by Henkel. It is consists of 80% vegetable oil. It melts at 170˚C. “We aim to print with a sturdy, stable material that is sustainable, of biological origin, and melts at a relatively low temperature. Technically, the KamerMaker can print with any material that melts (at a temperature that isn’t too high) and then hardens again.” Most 3D printers use plastics for the construction of houses, however, there are examples where this plastic printing technique has been combined with a concrete-like material.

The Shanghai WinSun houses Last year, a group of 3D-printed houses, 200 m² each, were built in Shanghai, China, in under a day. These were created entirely out of concrete using a gigantic 3D printer. WinSun Decoration Design Engineering built the houses and had reportedly been working on developing the system and its materials for years, according to 3ders.org. WinSun’s 150 m (L) x 10 m (W) x 6.6 m (H) 3D printer is capable of printing an entire building within hours. The materials used are based on high-grade cement and glass fibre. In line with the project's development, the company owns 77 national patents of construction materials, such as glass-fibre-reinforced IMIESA April 2015

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INNOVATIONS IN CONSTRUCTION

gypsum and special glass-fibre-reinforced cement.

Dr Behrokh Khoshnevis, inventor of the Contour Crafting construction system

Contour Crafting

DISADVANTAGES OF 3D PRINTING IN CONSTRUCTION

Contour Crafting (CC) is a computer-automated construction technology, invented and developed at the University of Southern California. Dr Behrokh Khoshnevis, inventor of the system, says the system uses a combination of modern robotics and a construction tool used since ancient times – the trowel – to build a custom-designed house in a few hours. Khoshnevis describes the CC as a hybrid fabrication method that combines an extrusion process for forming object surfaces and a filling process to build the object core in a layered fashion. “CC will enable the construction of customdesigned, low-cost housing with a level of quality that has been unobtainable up until now,” says Khoshnevis.

ADVANTAGES OF 3D PRINTING IN CONSTRUCTION

• Faster and accurate construction – a 3D printer transfers the digital model into a physical one; errors that arise can only be due to faults in the digital model or the materials used • Reduced labour cost – a 3D printer does most of the work with minimal human effort • Reduced waste generation – components can be printed to order during the construction phase; those that are not used can be recycled • Reduced health and safety risks by replacing dangerous jobs on-site with printing processes • Environmentally friendly – recycled products can be used to produce the construction materials used in 3D printers • As much as 3D printing presents a breakthrough in the construction industry, there are still a number of challenges the technique presents, which first need to be overcome in order for it to be the construction technique of the future.

• Reduced employee numbers in the industry, since the 3D printer does most of the work • A limited number of materials can be used, since the same printer might not be able to print the required multiple materials • Transportation – getting the printers for large in situ components to and from the site • Storage of the printer on-site • Higher risks – any errors in the digital model can result in problematic issues on-site during the printing/ construction phase • Conventional product manufacturing companies and plant renting companies could suffer as their products are no longer required • Additional time may be required on-site if the components are created in situ.

IMIESA April 2015

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INNOVATIONS IN CONSTRUCTION

Rise of

the machines The rapid advancement of technology will undoubtedly have far-reaching, positive impacts on infrastructure and service delivery. Beatrix Knopjes looks at some of the most prominent technologies in infrastructure.

Information and communications technology (ICT) ICT is an umbrella term that includes any communication device or application – encompassing radio, television, cellular phones, computers and network hardware and software, satellite systems and so on – as well as the various services and applications associated with them. Breakthroughs in ICT are driving automation today. Increased computing power allows complex data to be processed from sensors in real time, making machines more responsive than ever. Currently, it is mostly large-scale manufacturing facilities that employ automation, as their scale is sufficient to offset the cost of implementing complex systems. Trends show an increase in machine complexity in parallel with their cost reduction, thus lowering the entry barriers for automation. We have moved from an age where basic machines did simple, repetitive tasks, to a time where sophisticated robots can undertake complex tasks.

IMIESA April 2015

The benefits of this kind of automation are potentially exponential. The ability of machines to perform entirely automated work creates the possibility of conducting operations in hostile or difficult terrains. Automation also brings with it a new level of perfection, as human error, exacerbated by factors such as fatigue, is greatly reduced. ICT improves the ability to access information, and provides a platform for advanced operations and improved performances. It increases efficiency and competitiveness, and promotes globalisation.

3D terrestrial laser scanning A 3D laser scanner is able to scan objects like buildings and environmental landscapes. It is able to collect data on the object’s shape and dimension. This data can then be used to create a 3D model of the object. This has a variety of applications, such as the production of video games, but has only recently become an economically viable method in civil engineering applications.

Creating a 3D model of an object allows an engineer to perform digital, non-destructive testing, quality control/inspection and documentation. The first commercial 3D scanners appeared on the market as early as 1998 and, while their use has become mainstream, it is the advancement of this technology and the expansion of its capabilities that has ignited imaginations. The reason for this is that constant advancement of this technology has produced laser scanners capable of producing more densely detailed scans of greater complexity, while reducing their cost of manufacture. Some of the most notable advancements in this field include: • an all-in-one design: scanner, power supply, control/display, data storage and digital camera in a single, compact, portable unit • standard sur vey workflow options: traverse, resection and back-sighting make scanning easier to learn, and more efficient

INNOVATIONS IN CONSTRUCTION

• r educed power consumption • faster scanning: scanning now often takes just a few minutes per scan and has shorter set-up times • increased accuracy at range and improved ability to capture dark and oblique surfaces • r eductions in scanner size, weight and price • i mproved accompanying digital imagery • many scanner accessories are now common items – survey controllers, total station batteries, tribrachs, iPads, etc.

Point cloud software for terrestrial scanning Large file sizes and an unfamiliarity of working with 3D models have, in some ways, made the adoption of this technology prohibitive. These factors have represented inherent challenges for transforming point cloud data into useful, actionable information. Software advances in this field have been advancing at lightning speed, making the adoption of 3D territorial scanning easier to use and applicable to more applications with greater detail: • emergence of ‘panoramic scan images’ as valuable, low-cost, scan-based client deliverables • quick-to-create or tho-images made of scan points • increased automation • 64-bit versions of point cloud software • new scan data formats that speed up working with large scan data files • more point cloud plug-ins for CAD • point cloud capabilities embedded directly within CAD applications.

separate graphics terminal. Civil engineering design software is used across a wide range of industries – by architects, project managers, engineers, designers, and other professionals.

Smart cities According to a report by Sylvester Samuel, senior strategic sales manager: Go 2 Market at T-Systems, the concept of the ‘smart city’ has emerged as a term to describe a city that uses technology to address service delivery challenges. Building a smart city is about more than just using technology – it is about ICT innovation and transformation that improves the quality of life for citizens. A smart city has defined processes, connected by innovative technologies that allow citizens to experience all public services with ease. This, in turn, fuels economic development to stimulate a high-quality life for all. From the provision of water and electricity to the ease of mobility within a

city across public and private transport, to the ability to provide quality health care and education to all citizens, smart cities are all about improving and simplifying the lives of citizens. The success of the smart city concept can be seen in T-City in Germany. The aim of T-City was to utilise technological innovation to achieve sustainable improvements in quality of life in the city. Broadband connectivity lay at the heart of the success of T-City. By connecting each and every citizen, they were able to access a wide variety of additional services online, including purchasing tickets, paying bills and so on. Internet-based learning and virtual classrooms were implemented and textbooks were made accessible online, extending education to all. An integrated emergency number ensured citizens could always get hold of the relevant services with ease. Through connectivity and connected smart devices, the government was also

Breakthroughs in ICT are driving automation today. Increased computing power allows complex data to be processed from sensors in real time, making machines more responsive than ever

Civil engineering design software Commercial software applications for 2D and 3D computer-aided design (CAD) and drafting, such as AutoCAD, have been available since 1982 as a desktop application and since 2010 as a mobile, web- and cloud-based app. This design software supports building information modelling (BIM) workflows. With it, infrastructure professionals can better understand project performance, maintain more consistent data and processes, and rapidly respond to change. Prior to the introduction of AutoCAD, most commercial CAD programs ran on mainframe computers or minicomputers, with each CAD operator working at a

IMIESA April 2015

INNOVATIONS IN CONSTRUCTION

able to gain feedback about the project. Smar t metering solutions enabled the monitoring of electricity consumption as well as more effective billing and processing. Public transpor t systems became more efficient, and a single ticketing system not only delivered valuable data to government, but was also highly convenient for citizens.

While T-City was conceptualised and demonstrated in a developed countr y in Europe, the lessons learnt from this project can be localised and made relevant for the South African market, according to Samuel. Connectivity is the foundation for the deliver y of smart ser vices – whether via mobile, wireless, fibre or satellite – and this fact remains the same

At the heart of the smart city is the ability to connect the dots between ICT and basic services, and use technology to deliver better services to citizens

IMIESA April 2015

Delivering key infrastructure projects, ‘TRUE’ & ‘FALSE Bridge Abutments’ from Cape to Cairo

National Tel: +27 87 742 2710 International Tel: +27 31 705 0500 Branches: Durban (HO), Johannesburg, Cape Town, East London, Tongaat (Factory)

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INNOVATIONS IN CONSTRUCTION

In order to succeed, smart cities need government commitment, engagement from citizens, and the collaboration of the private sector

regardless of location. The basic needs of people also remain the same, regardless of their location – access to water, electricity, education and health care are fundamental human needs that transcend cultural and geographical boundaries. These areas are all aspects that can be successfully addressed using the smart city concept. At the heart of the smart city is the ability to connect the dots between ICT and basic ser vices, and to innovate by using technology to deliver better ser vices to citizens. For example, a librar y in Johannesburg can become so much more than just a repositor y of old books – utilising technology, it can be transformed into a multimedia centre with computers that can be used to improve education, and also for a host of other areas such as paying municipal rates and accessing other ser vices. While ICT and broadband connectivity are critical components, technology is simply

IMIESA April 2015

the enabler of the smar t city ecosystem. Building a real smar t city requires a holistic view – one that includes changing cultures and behaviours alongside the introduction of enabling technology. Hand in hand with this is a requirement for collaboration between government and the private sector, and the need to incorporate innovative ways to fund development objectives to achieve economic transformation in South Africa. Private sector has the technology and process skills required, and needs to work with government to achieve a long-term, sustainable vision for the South African economy. In

addition, cities and municipalities need to stop working in isolated silos, but share processes and lessons learned to permeate success across the countr y, and create interconnected systems that can then add value to all citizens of South Africa. The smar t city is mutually beneficial to both the public and private sectors, as well as individual citizens. It promotes collaboration and transformation, which in turn stimulates economic growth, a more intelligent use of resources, access to up-to-date information, and the creation of jobs and skills. Citizens can access self-help ser vices to ensure effective collaboration between the public and the municipality. Enhanced information security and a cohesive system at government level reduces the chances of identity theft. Revenue can be assured, and ser vices can be cost-effectively delivered, benefiting all par ties.

TRENCHLESS TECHNOLOGIES

Spiral-wound technique

comes of age

Trenchless technologies have proven to be less disruptive and more environmentally sensitive than open-dig methods of pipe rehabilitation. The spiral-wound method is one of many trenchless applications, which stands out when it comes to improving urban reticulation. By Frances Ringwood

HE SOUTH AFRICAN Department of Water and Sanitation has declared War on Leaks, in order to mitigate the financial and resource losses resulting from aging and damaged portions of the country’s pipelines. Trenchless technologies offer a significantly superior option for repairing affected infrastructure, due to the numerous benefits, international acclaim and growing local acceptance. Benefits are generally similar but include certain specific pros and cons, depending on which method is used for a particular project. More widely known methods include pipe jacking, slip lining and horizontal directional drilling. A lesser known method in South Africa, which comes with its own raft of advantages, is spiral-wound pipe rehabilitation for repairing sewer lines.

Protecting water While cash strapped municipalities may be more inclined to focus their funding and planning on water pipes, maintaining sewer lines is equally important. Water that leaks from sewerage infrastructure may enter ground water, or worse, the storm water system, eventually contaminating lakes and rivers with E. coli and other nasty bugs carried in human faeces. The spiral-wound pipelining technique was first used in the 1970’s, with some of the most recent successful projects having been completed using this method being in Budapest, Hungary’s capital, and South

An example of the egg-shaped sewers that were rehabilitated using the spiralwound method in Budapest, Hungary [Source: SEKISUI SPR Group]

IMIESA April 2015

TRENCHLESS TECHNOLOGIES

LEFT Port Elizabeth sewer pipe with corroded invert, before repairs were undertaken ABOVE New lining in Port Elizabeth sewer pipe using spiral-wound method

Africa’s own Port Elizabeth in the Eastern Cape. In its latest iterations, this technology offers some of the most impressive solutions for sewer pipes with nominal to large diameters in circular, non-circular and custom shapes. Moreover, according to a recent South African Society of Trenchless Technology (SASTT) report, “The latest spiral-wound technology almost always yields a technically satisfying solution. It is not only costeffective but also offers greater production output.” The report also stressed the environmental friendliness of this solution given that, by not invasively overturning soil, carbon is locked into the ground. Another benefit is that because the method requires only one standard manhole entry, it is also unlikely to cause major disturbances to foot and road traffic, or noise, which might disturb nearby businesses or public institutions.

What and how The product used for the lining is extruded in a factory with the profile of a continuous plastic strip liner, demonstrating properties of versatility, durability, malleability and lightness. In general, the method is applied by feeding the liner through an existing manhole or access chamber into a winding machine below, forming a spirally-wound pipe inside an existing deteriorated pipe. By either pushing the spiral-wound pipe in or pulling the lining through, depending on the spiral-wound method used, the liner is then put into position. To secure the liner in place, the edges of the strip interlock to form a continuous watertight pipe inside the host pipe. Because of the product’s initial flatness, it can be made to fit virtually any diameter or structure. Tongue and groove locking is one of many profile designs available, which can be replaced with a welded-joint design where needed.

Some additional advantages specific to this method include the fact that it caters for all static loading conditions, causes minimal reduction of the pipe cross section and exhibits chemical, mechanical and thermal resistance to effluent. Some other, more general, benefits applicable to trenchless technology are that the service life of the liner is equivalent to that of a replacement pipe, and a shorter contractor period is achieved, lowering project costs.

Technology options The extrusion process produces liners for nominal widths of 200 mm to 5500 mm. These profile strips, which are PVC-U by standard, differ in their unique locking systems. Sekisui SPR, a German trenchless company, explains some of the available methods it uses, “the SPR PE method is unusual in that it uses an HDPE profile strip and the mechanical lock is replaced by a IMIESA April 2015

Trenchless Technology Specialist

Our range of services include: • Pipe Bursting • Horizontal Directional Drilling • Pipe Rehabilitation

• Pipe Ramming • CCTV Inspection • Dewatering

• HDPE Welding • Deep Excavation and Shoring • Underground Service Detection

• Slip Lining

• Industrial Pipe Cleaning

• Close-fit lining: COMPACT PIPE

For more information you can contact us: +27 (0)21 761 3474 F +27 (0)21 797 1151 E info@tt-innovations.co.za www.tt-innovations.co.za

TRENCHLESS TECHNOLOGIES

PE welding connection. Three other spiral-wound pipe methods – SPR, SPR EX and SPR RO – differ in particular according to two important features: on the one hand with regard to the static stability, and on the other hand, the positioning of the winding machine in the winding process.” The company also offers a SPR ST steel-reinforced flexible PVC liner for applications where greater stiffness is needed.

Hungarian case study Consistent application of spiral-wound technology along many kilometres of pipe for several years has made Budapest into a model city for extensive spiral-wound pipe rehabilitation. Since 2010, almost 19 000 m lengths of round, as well as custom shaped pipes, have been rehabilitated in Hungary, with almost 6 000 m of those being located beneath the Budapest city centre. The latest large-profile rehabilitation project in the north-east of Budapest was commissioned in the third quarter of last year. Contractor Agriapipe rehabilitated 565 m of badly corroded cement pipe with dimensions of 1 400 mm x 2 100 mm underneath the Pozsonyi Street – a busy main road. From the end of June to the beginning of October, the pipe rehabilitation team repaired the egg-shaped sewer while maintaining a controlled live flow using the SPR spiral-wound pipe method. “Since the sewer network of Budapest features various diameters and shapes, the spiral-wound technology, with its different method versions, is the ideal solution for the operators. This provides a rehabilitation process for all standard diameters in circular form, as well as for the most diverse custom shapes, such as box- or mouth-shaped, or even egg-shaped profiles, up to 5 500 mm,” commented Zoltán Varga, the MD of Agriapipe.

Host pipe condition Budapest Sewage Works operates the complete 5 400 km long sewer system of the metropolis. Beneath the sewer line, there is also a 730 m long cement pipe with a diameter of 1 400 mm x 2 100 mm that acts as a combined wastewater and stormwater pipe – a system that is widely used in Europe. The combined wastewater sewer, which has been in operation since 1907, had begun to show signs of deterioration, including cracks and damage due to corrosion, after being in continuous operation for more than 100 years. Bacteria and caustic sulphuric acid inside the pipes had taken a toll over many years, despite low concentrations, causing enough damage that the structural stability of the concrete sewer was threatened.

Controlled live flow The ailing sewer section was rehabilitated with the spiral-wound method by winding a steel-reinforced profile strip of PVC-U into a new, highly resistant plastic inner layer directly within the host pipe. For that, the guide frame of the spiral-wound machine was lowered through a standard manhole into the rehabilitation section, installed into the host pipe directly and adjusted to the eggshaped profile of the sewer. The 52 spiral-wound pipe spools stationed one after another above ground continuously supplied the winding machine with profile strips via the standard manhole. The winding machine moved forward with every rotation by one profile width and locked the profile with a tongue-and-groove mechanism to create a watertight liner. Once one of the 52 spiral-wound pipe

IMIESA April 2015

TRENCHLESS TECHNOLOGIES

spools was used up, the new profile strip was joined in a portable, butt welding unit. The whole process was carried out during controlled live flow in the old sewer. This could be achieved due to a masonry wall being built at the upstream point so that the pump could transfer the combined wastewater into the sewer section. After about 250 m of rehabilitated sewer section had been completed, the stone wall was moved from the upstream point into the middle of the rehabilitation section to control the live flow for the remaining length requiring rehabilitation. Heavy rainfall posed a challenge occasionally, as the water level rose to 1 m and the winding process had to be interrupted briefly. Since the winding machine always remained stationed in the old sewer, winding could resume promptly after the water level had dropped and the pipe was cleaned.

Corrosion protection In the long term, the new rehabilitated pipe will offer an important operational advantage, in that it will permanently protect the

host pipe and the filled-in annular space grout against mechanical abrasion and corrosion from the combined wastewater.

Port Elizabeth case study The Budapest case study demonstrates how adaptable the technology turns out to be. However, South African sewerage design is quite different to that used in Europe. It’s fair to ask how spiral-wound technology stands up to local conditions. The answer is that it has been applied with just as much success in South Africa, in the Eastern Cape. The Nelson Mandela Bay Development Agency needed to rehabilitate two parallel sewers beneath the busy Govan Mbeki Ave in Port Elizabeth (PE) seven years ago. The spiral-wound method was used seven years ago on the first phase of the project, and again three years ago on the second phase. Trenchless Technology was the contractor on the second phase. The company’s MD, Marco Camarda, explains why spiral-wound technology was selected as the best option: “The 525 DN sewer is located under a heavily

trafficked roadway, while the (parallel) 1 050 DN sewer is under the newly built Bus Rapid Transport Lane. Consequently, only trenchless, non-disruptive techniques could be used for the rehabilitation as both road and bus lanes are used on a daily basis.” Despite severe corrosion on both sewer pipelines, the PE project was a success, requiring no excavation whatsoever, and it did not disrupt traffic at any point. It was also the first time SPR RO was used in Africa.

Conclusion Spiral-wound technology offers a fast, costeffective solution which is as applicable in South Africa as it is in Europe, or anywhere else in the world. It fulfils a dire need in countries with long-established markets like the United States, where large networks of old infrastructure are common, and looks to grow in popularity in South Africa, at a time when several pipelines are reaching the end of their useful life and are in urgent need of repair. IMIESA April 2015

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PANEL INTRO | TRENCHLESS TECHNOLOGIES

Digging deeper, better, smarter

HE BENEFITS OF trenchless technologies must be considered ver y broadly in order to understand how to assess the value of using the technologies as it relates to cost. Digging up a road using hammers and drills has cost implications far beyond the equipment used and the manhours spent. As Craig Burnie, managing director of Vermeer Equipment Suppliers South Africa, points out in this Panel Discussion: “When ever ything is properly understood and considered, what seems initially like a more expensive option (trenchless) is actually extremely costeffective. It shouldn’t even be compared to open trenching from a price perspective.” From health and safety impacts, future road repair and maintenance, and

traffic disruptions – which affect cost in terms of congestion and loss of business – to the environmental impacts, the sum of trenchless technologies’ benefits far outweighs its par ts. More specific technical advantages are fur ther explored in this Panel Discussion, with Phillip Mc Callum examining the intricacies and benefits of pipe bursting (such as eliminating 85% of the excavation required in traditional methods), and Herrenknecht elaborates on its range of tunnelling machines available for utility tunnelling. IMIESA is a proud suppor ter of the trenchless technology community in Southern Africa, and wishes to congratulate Vermeer Equipment Suppliers on its 10th anniversar y.

IMIESA magazine dedicates this passage to the late Joop van Wamelan, past president and honorary director of the Southern African Society for Trenchless Technology (SASTT), who passed away on 13 February 2015. Van Wamelan’s contribution to South Africa, as a civil engineer, was felt in many areas, including the municipal, nuclear and construction materials sectors, and in technical innovations. Van Wamelan, who was instrumental in founding SASTT, is survived by his wife Diana, and his three sons, Paul, Arend, and Riaan.

IMIESA April 2015

CRISIS:

Deteriorating Infrastructure

SOLUTION: Pipe Bursting A proven method of replacement

Traditional open cut methods have inherent social, economic and political costs and disrupt traffic patterns. Pipe Bursting can reduce excavation on most projects up to 85%, decreasing costs associated with site restoration. Pipe Bursting is the only rehabilitation method that installs new pipe of the same or larger diameter in the same path. ELB Equipment services its client base through a network of branches and well-established dealers throughout South Africa, Southern Africa and East Africa.

Head Office: TeL: +27 11 306-0700 Website: www.elbequipment.com

PANEL DISCUSSION

PIPE BURSTING TECHNOLOGY Phillip Mc Callum | Sales Manager | ELB Equipment

LB EQUIPMENT is the sole supplier of HammerHead trenchless machinery in South Africa. Internationally, as well as in South Africa, water, sewer, gas and other utility pipelines are in regular need of replacement. Most of these are located in congested urban areas. Pipe bursting offers a convenient and cost-effective method of replacing pipelines.

Briefly explain what pipe bursting is. PM Pipe bursting involves the breaking of an existing pipe and expanding the broken pipe shards into the surrounding soil. Before this can be done, the existing pipeline must be thoroughly investigated with a camera to determine if there are any internal obstacles that would hinder the process. Soil conditions also need to be carefully evaluated as these impact the rate at which pipe bursting can take place and the type of equipment needed. The new carrier line, usually high-density polyethylene (HDPE), is simultaneously pulled through. This is done with either a pneumatic or static system, using an entry and exit pit. With pneumatic bursting, an existing manhole is often used as an exit pit, eliminating the necessity of digging a new pit.

What are the advantages of using pipe bursting over other methods of pipe replacement? The biggest advantage of pipe bursting is the ability to install a new pipeline to replace ageing infrastructure and eliminate 85% of the excavation necessary for traditional methods. Construction times can be reduced by up to 50%. There are also fewer disturbances to traffic patterns,

and it reduces the annoyance of noise and dust pollution for the general public. Pipe bursting allows the pipe to be upsized and thus allows for pipes to be upgraded. The pipeline follows the path of the existing utility and can be applied for any kind of pipe damage, as long as bursting rods can be pushed in (static bursting) or the winch rope can be pulled in (pneumatic bursting). It reduces emissions and adheres to high quality and safety standards. It is more cost-effective than open trench replacement as it has a high daily output of up to 150 m.

Trenchless technology has been around since 1980. Is this technology widely used? Trenchless technology is widely used in the UK and US. More than 70 000 km of pipelines have been installed worldwide. It is controlled by international standards, norms and regulations set out by the International Society for Trenchless Technology.

For which pipelines does this technology work best? Pipe bursting works best on sewer, water and gas lines. Pneumatic systems are best applied on sewer and water lines, while static systems are best for non-fracturable pipes such as ductile iron, steel and galvanised with specialised tooling.

FLOW COMPARISON CHART AC pipe DIPS HDPE SDR17 pipe 4″ ID = 109 gpm 4″ = 132 gpm; 6″ = 299 gpm 6″ ID = 217 gpm 6″ ID = 247 gpm 6″ = 300 gpm; 8″ = 469 gpm 8″ ID = 340 gpm 8″ ID = 388 gpm 8″ = 469 gpm; 10″ = 706 gpm 10″ ID = 511 gpm 10″ ID = 583 gmp 10″ = 706 gpm; 12″ = 997 gpm 12″ ID = 723 gpm 12″ ID = 824 gpm 12″ = 997 gpm

Cast iron pipe 4″ ID = 96 gpm

however, is a great construction option that has become very competitive cost-wise in high-traffic areas where there is limited access. This is ideal for the boring and laying of new pipe lines.

Can you give an example of a project in which you were involved where pipe bursting was used effectively? We supplied equipment to Grocor Construction to increase a 150 mm sewer line to 200 mm in Tembisa, for the Ekurhuleni Metropolitan Municipality. There were favourable soil conditions, allowing us to lay a phenomenal 70 m of HDPE pipe in 38 minutes. The advantage here was that we were able to lay the pipeline in a traffic-dense area with minimal disruptions. The project presented significant cost savings for the client. In using

Hammerhead catamount piercing tool with ¼ reverse

trenchless technology, cost savings could come from not needing to replace asphalt. The entry pit would be limited to the size of the pipe, allowing 20% additional play to allow for the free movement of the pipe.

How, do you think, can pipe bursting gain more acceptance in the South African market? Dated pipes need to be replaced. South Africa is falling behind on this and the state of our infrastructure needs to be addressed. Pipe bursting offers municipalities a cost- and time-saving way to achieve this while, at the same time, creating employment opportunities. In the US alone, $1 trillion will be spent over the next 20 years upgrading the underground utilities.

What are its limitations? Pipe bursting is effective for replacing existing pipelines, especially old, dated pipelines in dire need of replacement. Horizontal directional drilling, RIGHT Pneumatic pipe bursting illustration

IMIESA April 2015

PANEL DISCUSSION

TRENCHLESS TECHNOLOGY Frank Stevens | Representative | Herrenknecht South Africa By adopting the correct tunnelling equipment one can avoid deep and costly open trench excavations, minimise traffic disruptions, and ensure safer working conditions

technical alternatives along with their benefits and limits, which lays the foundation for a successful project.

Where is tunnelling needed and best used in the area of utility service delivery? FS Utility tunnelling involves tunnels for service delivery projects such as water and sewage pipelines, stormwater pipes, sea outfalls, and river or wetland crossings. It can also involve oil and gas pipelines.

Generally speaking, what are the advantages of tunnelling in utility environments? Often utility tunnelling is carried out in urban areas, within cities and where natural barriers have to be overcome with minimal disruption. By adopting the correct tunnelling equipment, one can avoid deep and costly open trench excavations, minimise traffic disruptions, ensure safer working conditions (compared to deeply shored trenches), and reduce construction noise and dust, along with causing the least damage to existing services within the vicinity of the project.

What types of geological conditions can a tunnel boring machine handle? Generally speaking, there are technical solutions for all geologies. To choose a suitable tunnel boring machine, however, good knowledge about the subsoil characteristics is crucial. Therefore, in the planning

stage, geotechnical information needs to be collected, such as grain size distribution, cohesion, stiffness modulus, permeability, Atterberg limits, rock compressive/tensile strengths and abrasiveness. This information determines the machine used. Soils can be roughly classified as: • Soft ground: Cohesive soils such as clay, silt or loam with low water permeability. • Heterogeneous ground: Noncohesive soils such as sand, gravel or stones with high water permeability or mixed geological conditions. • Rock: Rock such as sandstone, limestone, basalt or granite, partly with high compressive strengths.

Please give a brief description of tunnelling machines available. Some of the core machines types offered by Herrenknecht are: •A VN Machine (slurry machine) designed for soft or heterogeneous ground as well as rock (diameters from 0.4 m and 4.2 m). •E PB (earth pressure balance) shield for soft ground (diameters from 1.7 m to 19 m) • s ingle/double shield TBM (tunnel boring machine) designed for soft rock (diameters from 1.5 m to 14 m)

• gripper TBM designed for hard, stable rock (diameter from 2 m to 12.5 m) • auger boring machine designed for displaceable soils (diameters from 0.1 m to 1.4 m) • HDD (horizontal directional drilling) rig designed for soft ground or rock (diameters from 0.2 m to 2 m). For detailed information and animations of the products, please visit herrenknecht.com.

What assistance and advice could Herrenknecht offer consultants, contractors and clients in the early stages of a potential tunnelling project? The successful execution of a tunnelling project depends, to a high degree, on reasonable planning, design and pre-investigation. During the last 30 years, Herrenknecht has proven, in thousands of projects, what is possible with trenchless technology. By drawing from its vast bank of experience and tapping into its pool of engineering expertise, Herrenknecht assists and gives advice on the viability of a tunnel, the most suitable machine type, and other relevant information required in the early stages of a project. By engaging with Herrenknecht, clients and consultants can get a better understanding of the

Please give examples of projects where utility tunnelling has been used successfully in South Africa. In South Africa, Herrenknecht machines have been used in three projects: • Durban Sub-Aqueous tunnel under the harbour mouth (diameter 5 150 mm, length 492 m) • Mahatma Gandhi (Point Road) micro tunnel (diameter 1 200 mm, length 230 m) • Gautrain tunnel (diameter 6 680 mm, length 2884 m). Currently, more than 850 Herrenknecht utility tunnelling machines are in operation around the world.

In the South African context: How else can municipalities benefit from utility tunnelling? Reduced pumping costs! Any large city has several hundred large water and wastewater pumps within its system that were designed and installed at a time when the cost of electricity was low. Thus it made sense to simply follow the topography for trunk main laying. Today, large water authorities are faced with monthly electricity bills of more than R8 million for pumping water to reservoirs and treatment plants. Installing deep sewers drastically reduces pumping stations and the time and money spent on maintenance and electricity.

IMIESA April 2015

VERMEER HELPS MEET

YOUR TOUGHEST UNDERGROUND CHALLENGES.

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tight, congested urban setting or a remote river crossing, Vermeer and ourglobal dealer network will be right beside you. We know the conditions you work in are demanding — it’s why we make equipment that’s up to the task. We offer the industry’s most complete lineup of horizontal directional drills, tooling, and accessories designed to take on your installation challenges. So when it’s tough going out there — look to Vermeer —

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Vermeer, the Vermeer logo and Equipped to Do More. are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries. © 2014 Vermeer Corporation and Equipment Suppliers (Pty) Ltd. Southern Africa. All Rights Reserved.

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NEW, PURPOSE-BUILT PREMISES EARLY 2015!

PANEL DISCUSSION

TRENCHLESS TECHNOLOGY Craig Burnie | Managing Director | Vermeer

S SOUTH AFRICA’S Vermeer Equipment Suppliers turns 10 years old, Craig Burnie, managing director, weighs in on the pressing need for a better and more complete understanding of the fundamentals of trenchless technology, in order to unlock the enormous value it could add to the South African infrastructure sector.

What is the biggest challenge facing the development of trenchless technologies in South Africa? CB Well, it’s a complex set of issues that are, essentially, not properly or thoroughly understood. Possibly, the key problem driving these issues comes down to cost evaluation. The full cost of ripping up pavements is simply not fully understood, and neither are the impacts on health and safety, nor future maintenance repair costs. This results in a zero-sum comparison with the cost of digging, which is just not a realistic comparison. Because of this, there is a tendency for smaller contractors offering trenchless solutions to really undercut each other in the market, and to cut corners in their projects. This does nothing for the reputation of trenchless technologies.

What should be factored in when evaluating the full value of using trenchless technologies? When you dig up a road, instead of tunnel beneath it, you cannot reinstate that patch of road 100 per cent, not to mention that the quality of those reinstatements varies considerably. So beyond the cost of reinstatement itself, the resulting cracks,

potholes and erosion of the road surface are such that the ongoing repair and maintenance costs are major. This is without factoring in the civil claims that originate from damage caused by potholes. Then there is the impact on the public: from a convenience point of view; a health and safety point of view; and the severe traffic disruption that can be caused. Whole city blocks can become inaccessible for significant periods at a cost to business and commuters that should be factored in. Certainly, as far as the public and business is concerned, the value of using trenchless technologies is extremely high and this, in turn, definitely adds value for the agency doing the work. And then there is the impact on the natural environment; it is always best practice to leave the surface environment intact, and to minimise the impact on the flora and fauna. So in terms of the environmental impact of large tunnelling jobs over long distances, the value of trenchless technologies is significant. When everything is properly understood and considered,

what seems initially like a more expensive option (trenchless) is actually extremely costeffective. It shouldn’t even be compared to open trenching from a price perspective.

You touched on the reputation of trenching technologies; what do you see as the biggest challenges in this regard? Again, it comes down to understanding. While using trenchless technologies is not rocket science, there are very specific fundamentals that must be observed to deliver optimal results. We see a lot of poor practice in the use of trenchless technologies, with the result being that, when problems do occur, assumptions are made about the technology. However, the problem often lies in the practice. The use of fluids is a good example: fluids play a major role in successful tunnelling, and technically-sound fluid practice needs to be deployed, making use of correct bentonite-based fluids that are adequately formulated for the environment in question. We

Getting it right – unlocking the full value of trenchless technologies

see cases where water is used, and the resulting collapse of the tunnel leads people to the conclusion that the technology is at fault. In fact, we have found a trend in municipalities not trusting the use of moles for smaller applications, so instead you find full drill rigs being used when a mole would be ideal. Moles do work, but they need to be utilised properly for the environment they are used in. Again, some negative assumptions have been made, based on insufficient research and understanding of the problems encountered. The correct application and use of trenchless technologies is as varied as the environments they are used in.

How does Vermeer counter poor practice and support the need for properly trained technical teams? We are not engineers; we are suppliers. But a good supplier should always be available to advise. The most important message we can give to the industry is to insist on the right conditions to get the maximum benefit from trenchless technologies. The benefits are incredible, and it is a waste of good technology not to use it properly. Vermeer offers training courses, which includes handson workshops and can provide a rock-solid understanding of the fundamentals of successful trenchless tunnelling. We offer a drilling course for municipal engineers, and we provide all this as a service to the industry. Trenchless technology is not complicated; it just needs to be done right. Do it right, and you will reap massive rewards.

IMIESA April 2015

SALD

SA Leak Detection Distributors

South African team uses Sewerin equipment to trace leaks in Saudi Arabia Location: Saudi Arabia Lionel Christie traced a leak in a 300 meter Glass Fibre pipe line. The pipe lay beneath concrete that in some places was as thick as 400mm and the line up to 3.5 meters below ground. Lionel Christie was able to detect a very small leak in the pipe line using a Sewerin Aquatest T10.

How it works When pressured pipelines leak, water gushes out of the crack into the ground. The pipe material vibrates at the leakage point. These vibrations are transmitted by the pipe and can even be noticed at distant contact points, e.g. Fittings. This is known as structure-borne sound and is made audible by the Aquatest T10. The Aquatest T10 displays an accurate visual comparison of the noise intensities. The visual display is particularly helpful for novices or those Need Leak Detection Equipment? who do not use the system often. Contact us: Pipe Inspection Cameras

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WATER & WASTEWATER

PART 2 OF 2

Water conservation and

water demand management In this second and final part, the authors take an in-depth look at the model performance-based WCWDM contract and implementation and funding methods. The first half of this article appeared in the March 2015 issue of IMIESA.

By Stewart Gibson, Dr Nicole Kranz & Nick Tandi

The model performancebasedÂ contract Flowing out of the testing and experience from the Emfuleni project, the SWPN (of which Sasol is a partner) requested GIZ to assist in developing a model performance-based contract, which could be used by municipalities to establish appropriate WCWDM contracts that would build on the success of the work at Emfuleni. The key concept of a performance-based contract is the use of performance-based incentives to provide the specialist WCWDM contractor with a financial bonus linked to the value of the water that is saved through the WCWDM measures employed. Appropriately used, such incentives can ensure the most cost-effective outcome. This is because the contractor is not just performing a service but is invested in the outcome of that service and will, therefore, be that much more creative, innovative and proactive to ensure that the best possible outcome is achieved. The model contract contains options for the use of performance-based incentives and provides a contractual basis on how this can be tendered and applied. As the drafting and administration of WCWDM contracts is more specialised than the drafting of conventional water supply construction contracts, this model contract sets out an appropriate process and documentation for both the tender and the final contract. It is, however, important that the person responsible for compiling the final

IMIESA April 2015

WATER & WASTEWATER

Ref.

Item

Unit

Amount

A Total f rom BoQ

5 000 000

B Baseline Volume projection: month 7 to end

63 165 870

C Expected Eﬃciency Gain

10%

D Expected saving in water

6 316 587

E Performance Bonus Rate

R/kl

0.75

F Expected Performance Bonus

4 737 440

G Total Tender Price

9 737 440

H VAT

1 363 242

11 100 682

Total Tender Price incl VAT

Set by Municipality

tender and contract documents is someone with a good background and knowledge on such work, and its application within the water environment. The model performance-based contract document pack is available free of charge in electronic format and contains the following documents:

Model tender and contract document This is issued in Word format so that each user can add specific contract data and adjust the documentation (if necessary) to suit both the requirements of the contract and any specific requirements of the issuing authority. The basis of the pricing of the tender provides a schedule that allows each submitted tender price to be compared on an equal basis. It also allows for a mix of both reimbursable items as well as a performance-based fee. The contract uses the General Conditions of Contract for Construction Work (GCC), Second Edition, published by the South African Institution of Civil Engineering, as the basis for the contractual arrangements and the tender uses the Standard Conditions of Tender as issued by the Construction Industry Development Board (cidb). The format of the model tender and contract is as follows:

IMIESA April 2015

Total of Reimbursable Items Predicted water use without WCDM contract Assumed saving % for tender purposes Assumed saving in water using the % in row C (B x C) Rate tendered for Performance Bonus Based on assumed saving and tendered rate (D x E) Performance bonus plus Reimbursable items (A + F)

Total Tender

Tendered Rate or Amount

• Part T1: Tendering procedure • Part T2: Returnable documents • Part C1: Agreements and contract data • Part C2: Pricing data • Part C3: Site information • Part C4: Scope of works • Part C5: Generally applicable specifications • Part C6: Particular project specifications. In addition to the above, the following additional documents are also included: • Standard Conditions of Tender (cidb): These are the standard conditions of tender as applied in South Africa. These standard conditions can be amended through the insertion of special clauses in Part T1 of the model tender and contract document. • Standard set of returnable schedules required in the municipal sector in South Africa: The South African municipal sector is required to conform to a rigorous process as part of its supply chain management regulations. This process is designed to protect municipalities from corruption, promote the use of BBBEE companies, and ensure that a fair and balanced process is used in assessing and awarding tenders. The normal returnable documents that are used are included in this section for use where necessary in tenders. In many cases, municipalities will have their own formats for such schedules and, where appropriate,

FIGURE 3 Example of calculation of tender amount

these should be used rather than the standard forms included here.

Model bill of quantities

A formatted model bill of quantities is provided as an Excel spreadsheet. This contains typical sections and items that would be applicable to a range of WCWDM interventions. The user is required to select those that are applicable and it may also be necessary to include additional items. The bill of quantities deals with work that will be paid for on a reimbursable or measurement basis. It is the skill of the user that decides what work will be covered on this basis and what work (if any) will be included in the performancebased portion of the contract.

Guideline for the use of the model performance-based tender and contract The guideline document provides information for the user of the model tender and contract on when the performance-based contract is important, and how it should be structured. Also included are worked examples of the determination of the tender price to include the method of measuring the financial effect of the performance bonus, as well as how to determine performancebased payments during the contract.

Guideline for monitoring and evaluation A further guideline is provided as to how the performance-based contract should be monitored and evaluated, both during the contract and on completion.

Selected lessons from international experience A number of interesting examples from other countries are presented in this section. These case studies can inform current thinking, although recognition has to be given to the varying conditions in the different countries.

WATER & WASTEWATER

Public-private partnerships – practice note There are very strict rules in South Africa about municipalities entering into contracts that are too long in duration or that attempt to transfer high levels of risk to the private sector. This practice note discusses the factors that would turn a performancebased contract into a public-private partnership, and defines the implications for such an occurrence.

Implementation Figure 4 gives an indication of the actions that would typically be required for a municipality to implement a WCWDM contract. This process should be followed irrespective of whether a performance-based contract is being used or not.

Funding models The involvement of the private sector in the implementation of a per formance-based contract is not a pre-requisite. It would be perfectly reasonable for a municipality to undertake such work using its own funds to kick-start the project, most of which could be expected to give positive returns within a three-year cycle. It is, however, important to remember that nearly every business sector is waterdependant, in some way or another. Water stewardship within a company goes beyond being an efficient commercial water user, it means that companies should be contributing to the responsible, sustainable management of freshwater resources. Water stewardship helps governments, companies, investors and others to understand their water footprints and become better water stewards. Beyond water footprints and reducing the impact of individual water users, companies are being urged to look outside their own operations and become involved in advocating, supporting and promoting better water resource governance and utilisation – for the benefit of all people and the environment. On this basis, there is an opportunity for cash-strapped municipalities to seek help from local companies and to offer them the opportunity to assist in supporting the local community in terms of water security for all. With a relatively small contribution, these companies can help fund the

Municipalities now have a tool that will help them to be able to prepare an appropriate tender and contract to employ a specialist service provider star t-up costs of a per formance-based WCWDM contract.

self-sustaining operation for the municipality to continually reduce its water wastage or over-use.

Conclusion In the model performance-based contract, municipalities now have a tool that will help them to be able to prepare an appropriate tender and contract to employ a specialist service provider to assist them in reducing the wasteful component of their water use. The results of such contracts will add to their efforts to comply with the latest No Drop requirements, and contribute to a reduction in their water consumption. The option also exists to obtain assistance from a private company, committed to water stewardship, to help fund the initial work of the programme with a view of creating a

Acknowledgements: The documentation for the model performance-based contract was prepared by the team of David Still, Peter Ramsden, David Schaub-Jones and Alex Nash from Partners in Development. GIZ financed and project-managed the work on behalf of the SWPN. For a full list of references, please contact the editor at nicholas@3smedia.co.za.

Stewart Gibson, advisor: Development Partnership Projects, GIZ South Africa 2 Dr Nicole Kranz, advisor: Water Stewardship, GIZ 3 Nick Tandi, programme manager, South African Strategic Water Partners Network 1

FIGURE 4 Implementation process for a performance-based contract

IMIESA April 2015

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WATER & WASTEWATER

Clean

bubbles Fine bubble diffused aeration is arguably the most energy-efficient and environmentally sustainable wastewater treatment system. By Beatrix Knopjes

INE BUBBLE DIFFUSED aeration (FBDA) mimics the natural, rolling actions of rivers and streams. This fast-moving flow of water provides the circulation and oxygenation to naturally treat waste as it moves downstream. Elevated levels of dissolved oxygen allow for microbes to convert waste into minerals and gases. Oxygen is essential in promoting respiration for microorganisms in wastewater treatment. The oxygen, combined with the sewage food source, allows the bacteria to produce enzymes that help break down the waste so that it can settle in the secondary clarifiers or be filtered by membranes. Eftec has been developing FBDA systems since 1999. Managing director Hennie Basson says that municipal and water authorities continue to move from surface aeration to FBDA, which achieves higher oxygen transfer and consumes less energy. “Surface aerator turbines operate on the same concept as a mixer: water is extracted into the air, and a splashing motion creates oxygen transfer into the water. Surface aerators are limited because they need larger tanks with depth limitations and numerous support structures,” he says. Large mechanical and electrical installations, in terms of cabling and motor control centres, add to costs. “What’s more, the splashing motion releases sewage aerosols into the air, which is a major health and safety hazard,” states Basson. FBDA diffusers – commonly manufactured in tube, disc, plate and dome forms – are evenly spread out in a grid formation on the bottom of the tank floor, thereby ensuring that it is not depth and size restricted. Basson points out that this provides the plant with improved operational flexibility.

ABOVE Fine bubble aeration system now operational in the bioreactor

“This allows for a more precise tracking and supply of oxygen to satisfy the oxygen demand of the biological process,” he explains. Depending on the individual variables at each water treatment plant, Basson states that FBDA technology can result in energy savings of between 40% and 70%, compared to surface aerator turbines, which achieve on average 1.8 kg of oxygen per kWh of absorbed power. With continued constraints being placed on the national power grid, industries are being encouraged to adopt more environmentally friendly operational practices, in order to keep its FBDA systems as energy efficient as possible. Despite the numerous advantages of FBDA, Basson admits that it is still in its infancy in South Africa. “A major challenge in promoting FBDA locally is to change the industry mindset. As a water-stressed country, it is important that we conserve this precious resource by adopting newer and more sustainable technologies. FBDA is essential not only in conserving water, but in lowering electricity consumption too. This is particularly advantageous as power prices continue to soar. “There are approximately 20 fully operational FBDA plants in South Africa at present; there are more than 1 000 wastewater treatment plants countrywide, and the potential for growth is overwhelmingly positive, provided that the advantages of FBDA are communicated effectively to the industry,” he concludes.

IMIESA April 2015

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ROADS & BRIDGES

New overpass bridge

over N1 in Midrand

HE BRIDGE WILL provide an additional access route to the Waterfall area from Tembisa, Kempton Park and the Buccleuch area. It is meant to alleviate traffic flow on the over-burdened Allandale Road by providing an alternative link to avoid the congested interchanges with the K101 and the N1. The significant features of the Bridal Veil Road Overpass Bridge include four lanes of traffic, a pedestrian walkway and a cycle track. Pautz says: “The bridge has been designed in accordance with the Sanral Code of Procedure for the Planning and Design of Highway and Road Structures in South Africa, February 2002. Traffic loading is in accordance with TMH 7, parts 1 and 2, and the design has allowed for normal traffic loading (NA), abnormal loading (NB36), and super loading (NC). The conceptual

BELOW An artist’s impression of the completed bridge

IMIESA April 2015

Derrick Pautz, development manager at Atterbury Property Group, talks to IMIESA about the new Bridal Veil Overpass Bridge being built over the N1 freeway in Midrand. By Beatrix Knopjes design of the bridge was dictated by the possible positions where piers could be constructed between the northbound and southbound carriageways of the N1 freeway, as well as the on- and off-ramps of the Allandale interchange where the bridge crosses.” The durable concrete design, and suitable concrete cover reinforcement, were specified to ensure a 100-year design life for the structure. According to Pautz, the main structural elements of the bridge deck are pre-cast, pre-stressed concrete M-beams. These beams are manufactured off-site and are

transported to site when the substructure has been completed. The beams are erected over weekends, with special measures in place for the accommodation of traffic. Precast reinforced concrete facade panels are erected on the elevations of the deck and cast in with the bottominfill concrete between the beams. The top deck consists of reinforced concrete cast in situ on permanent formwork spanning between the beams. The five-span deck is made fully continuous for live loads, necessitating expansion joints only at the two abutments. The substructure comprises reinforced concrete piers on

ROADS & BRIDGES

The N1 freeway through Midrand is the busiest road in South Africa and, therefore, it is of utmost importance to minimise the effects of construction of an overpass bridge on the traffic flow spread footings and perched abutments on piles through reinforced earth embankments. On Bridal Veil Road, over the bridge, reinforced concrete F-type pedestrian safety barriers of 800 mm high are provided between the traffic lanes and pedestrian walkway and cycle track. These barriers are designed to prevent errant vehicles on the bridge from driving into the walkway and cycle track spaces. The barriers are designed to redirect vehicles to the traffic lanes in the event of a collision, with minimum damage to the vehicle and maximum safety of the occupants. On the N1, below, the bridge piers are protected by similar F-shape barriers, or New Jersey barriers, for the median pier to suit the existing N1 median barrier. The pier between the southbound carriageway and the Allandale off-ramp is further protected by an impact attenuator for the safety

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IMIESA April 2015

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ROADS & BRIDGES

SUSTAINABLE STREETLIGHTS

250 W HPS (high-pressure sodium lamps – a standard for street lighting) lamps are being used. These fittings are of similar efficiency to LED (efficiency values: HPS – 120 lumen/W and LED – 100 lumen/W). The design is focused on using the lowest number of fittings possible while still maintaining uniform and acceptable light levels. The fittings are angled to ensure the light is under the bridge and focused on the road – to reduce any spillage lighting that may contribute to light pollution. of any errant vehicle during a collision with the pier protection barrier. The construction of the new Bridal Avenue road, which the new bridge is part of, required that a full environmental impact assessment to obtain the relevant approvals from the Gauteng Department of Agriculture and Rural Development. To obtain the relevant approval, environmental specialist studies were done to determine the level of impact the new road and bridge on the surrounding area. The

project is being undertaken in an environmentally sustainable way. The N1 freeway through Midrand is the busiest road in South Africa and, therefore, it is

with traffic shoulders on each side. Through the Allandale interchange, both carriageways are restricted by traffic barriers on both sides due to the limited space that was available

“The durable concrete design and suitable concrete cover reinforcement were specified to ensure a 100year design life for the structure.” – Derrick Pautz, development manager at Atterbury Property Group

of utmost importance to minimise the effects of construction of an overpass bridge on the traffic flow. With five traffic lanes, on both the southbound and northbound carriageways, carrying high volumes of peak-hour traffic, Sanral insisted that no lanes could be closed for long periods during construction of the bridge. This would prevent back-up of traffic on the N1 in both directions and improve the safety of road users. It would, however, dictate the way in which the piers could be constructed. The 10-lane N1 freeway does not have a wide median in which a bridge pier can be constructed. It only has a median barrier

to fit in 10 traffic lanes in a built-up urban environment. For these reasons all five traffic lanes are moved away from the median pier position by narrowing the lanes and repainting the lane markings in the vicinity of the construction area. Although speed restrictions are in place, the benefit of not closing any lanes is that traffic flows very well through the construction area. With traffic diverted away from the median, the foundation excavation and construction of the median pier can take place in a predetermined minimum period during this first phase. As soon as the median pier and associated permanent

IMIESA April 2015

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ROADS & BRIDGES

LEFT Construction of the bridge over the busy N1 in Midrand is on track

protection barriers have been completed, traffic lanes on both carriageways are moved as close as possible to the median to create space for construction of the two piers on the outside. When these piers are completed, the lane markings can be repainted in their original positions. Short-term lane closures are used when the precast beams are placed, but these are limited to weekends with prior press releases to inform road users. As soon as the beams have been placed, construction can proceed over traffic, with proper protection for falling objects. The construction programme of 16 months is quite tight for a bridge of this size. The contract, therefore, has interim milestone dates to track progress and assist the contractor in achieving the project deadlines. Progress on-site is good. The excavation for the median pier has been completed and construction of the pier is in process. IMIESA April 2015

ROADS & BRIDGES

One death is one too many Top priority for the South African Road Federation (SARF) is road safety. Innocent Jumo, president of SARF, and Basil Jonsson, operations director, explain how engineers and maintenance teams can contribute to making our roads safer. By Beatrix Knopjes

HE LATEST ROAD safety reports show the staggering number of accidents on South African roads, and emphasise the importance of awareness, particularly among pedestrians. Pedestrians account for 40% of the deaths on South African roads. To minimise the risk of accidents, there are a number of factors that engineers can take into consideration when designing roads. Jumo explains, “First and foremost, the design aspects of all roads have to meet national road safety standards. Many accidents happen on road construction sites where there is not sufficient warning for people using the road or protection for those working on it. There may also be a lack of adequate signage warning motorists to decrease their speed before they encounter the work zone hazard. Motorists may also be impatient and fail to observe the reduced speed limit in the work zone. This is where enforcement becomes very important and traffic officials need to be more visible. “Engineering refers to the actual design of the road, based on years of empirical studies, where engineers need to make sure that the geometrics of the road are correct; e.g. if a curve needs to be placed in the road, it has to be of a certain radius for a specific required design speed.”

The sight distance of a road is also important. This refers to the distance of road a driver is able to see ahead, and affects the time the driver has to react to a hazard that may be on the road. The environment the road is in will play a fundamental role in determining its layout, as well as the accompanying ‘road furniture’ such as road signs, road markings and vehicle restraint systems (i.e. steel and concrete barriers as well as guard rails). Key peripheral infrastructure elements on a road, such as placing high-visibility signs in areas where inclement weather is commonplace, contribute to road safety. These elements are included on an individual basis according to the need of the particular stretch of road in question. These needs are determined by careful road investigation and by speaking to local inhabitants in the area to determine what trends need to be taken into consideration to make the road as safe as possible from an engineering point of view. Says Jumo, “Sometimes we speak to the local inhabitants to determine if the area is prone to fog, mist or animals crossing at specific places, as these are aspects that must be taken into consideration when determining what safety measures need to be implemented on any given stretch of road.” There is no single system that can be applied to all roads. Each road has to be

"Engineering refers to the actual design of the road, based on years of empirical studies, where engineers need to make sure that the geometrics of the road are correct." Innocent Jumo, SARF president 64

IMIESA April 2015

designed on its own merits, to determine, for example, what barriers need to be constructed next to the road. Jumo says, “There are vehicle restraint systems that become a hazard themselves if they are inappropriately used.” When a road has been designed and built, it needs to be subjected to a road safety audit to ensure that all safety elements have been included in the design process. Basil Jonsson, SARF operations director, explains, “What Sanral has implemented on all their road contracts is the appointing of an independent road safety auditor. This independent auditor – who must be a registered, professional geometric design engineer and/ or traffic and transportation engineer – must have successfully completed an accredited road safety audit course, as well as been involved in a number of road safety audits within a period of two years. This auditor will serve as the team leader of the road safety audit team. As the South African Road Federation, we run a Sanral-approved road safety audit course, but we will not perform the audits ourselves as these must be done by an unbiased and independent external road safety audit team.” Jumo states that road safety audits minimise the risk and severity of road crashes that may be affected by the road project at the construction site or on adjacent roads. They minimise the need for remedial works after construction, reduce the whole life-cycle costs of the project and improve the awareness of safe design practices by everyone involved in the planning, design, construction and maintenance of roads. Road maintenance should also take the safety of the road users and construction workers into consideration, as many accidents happen near construction sites.

ROADS & BRIDGES

Legislation dictates where warning signs and delineators need to be placed in order to safely navigate road users around the hazard, and construction workers need to be vigilant of their safety and the safety of motorists at all times. While engineers designing roads can – and should – take considerable measures to minimise risks on the road, these are rendered insignificant by driver negligence and recklessness. Jumo and Jonsson stress the importance of education (in the form of road safety awareness campaigns and road safety included in school curriculums) and enforcement of the traffic rules of the road by traffic officials.

ROAD DEATH STATISTICS FOR DECEMBER 2014 FESTIVE SEASON

Of the festive season fatalities and incidents, 39% were passengers, 36% pedestrians, 24% drivers and 1% cyclists. As for gender, males contributed 75% to the road fatalities and crashes, while 22% were female. Based on the driver age group, those between the ages of 30 to 34 contributed 13% to the total fatalities. Those between 25 and 29 years old made up 12% of all fatalities, while 9% were between the ages of 35 and 39. Below is a summary of other road deaths categories: Passenger age group • 20 to 24 (6%) • 25 to 29 (8%) • 30 to 34 (7%) Total 21%

www.sarf.co.za

Pedestrian age group • 20 to 24 (6%) • 25 to 29 (8%) • 30 to 34 (7%) Total 21% Source: SAnews.gov.za

ABOUT SARF SARF is an organisation dedicated to the promotion of the road industry in South Africa through the dissemination of information, the promotion of sound policies and by education and training. IMIESA April 2015

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ROADS & BRIDGES

Partnering for

growth On 20 February, Swiss equipment and asphalt mixing plant manufacturer Ammann held an open day for its partners to showcase the company’s mini paver and other machinery. IMIESA brings you the highlights.

MMANN BUILDS ITS business on a strong ethos of partnership for growth. The open day was intended to showcase the mini paver, though other equipment, including Ammann’s asphalt mixing plant, was also on display. The mixing plant was sold almost immediately. Speaking at the event, Rocco Lehman, managing director of Ammann South Africa, said: “We decided to have this day with Kenzam, our manufacturer, to bring our customers out of their offices and into our environment.”

Partnering for finance Members of Uhuru were in attendance at the open day. Uhuru is a consortium of African banks, which has established a civil aspect to its business, set on entering the African market by providing financial banking. This is important for companies like Amman as Uhuru is able to secure financing for projects that would otherwise not get off the ground. John Hart, a founding member of Uhuru, explained: “Uhuru Capital South Africa was formed by a group of businessmen that got together to finance projects. It was just a matter of starting the first project. We are well connected in Africa through business, and we started financing Globitech, which is a mobile telephone system. In the process we were able to connect with African countries and establish an extensive network.”

ABOVE A practical paving demonstration with the mini paver

overwhelming corporate social investment component into the venture,” says Hart. According to Hart, some projects never get off the ground because they fail to get funding. Uhuru got together and raised an amount of money, and that was enough to fund a greenfield project, which was then able to get a return. Thus they only needed the first project to be successful in order to

“Partnership works by letting people do business. Ammann is very good at that; it brings in Swiss business, but maintains local culture.” Rocco Lehman, MD, Ammann South Africa

Partnering with ELB Equipment Lehman elaborates on Ammann’s decisions regarding choosing partners by saying that “the partnership choice was a long road for us. The Ammann Group is a very family-oriented business. CEO Hans-Christian Schneider is the sixth-generation son running the business, and he has been CEO since 2013. “Sometimes when you meet with people, you can tell immediately if they are your kind of people or not. When we first met with ELB Equipment, we knew almost straight away that we wanted to partner with them. Part of the reason is that ELB is also a family business. The cultures are

BELOW A selection of Ammann’s road building equipment on display at the event

keep investing in further projects. “We see fantastic potential in Africa for growth and this is one way in which we are able to promote that. All of the members on our board have a heart for people, so any excess money – after dividends have been paid out – will go into a social project such as building a school or supplying medical equipment for a hospital, thus incorporating an

IMIESA April 2015

ROADS & BRIDGES

very similar. We signed the partnership agreement last year January, in the past year the machine business has grown into something nobody could have anticipated!” says Lehman. “Partnership works by letting people do business. Ammann is very good at that; it brings in Swiss business, but maintains local culture. The company supports and fosters local business through these partnerships,” adds Lehman.

Asphalt mixing plant & mini paver Ammann’s asphalt mixing plant is able to use both warm and high temperatures for asphalt mixing. This is done with a foam generator to foam the bitumen, which makes it possible to cover the aggregate in a lower temperature range. You will save 30% on CO2 emissions, and 15% to 20% on fuel. Fuel and bitumen make up the largest operational costs. The plant is also able to reuse asphalt, by milling it out from the road and adding it in different percentages to the mix. It is able to handle 40% reclaimed asphalt in

IMIESA April 2015

Günter Tesch of Ammann Group showing off the asphalt mixing plant

new mixes, both hot and warm. Speaking about warm mix asphalt, Günter Tesch of Ammann Group says: “Warm mix asphalt is still a niche market in South Africa. It is only just now starting to gain traction. In Europe, it is understood that the specifications are the same as those for hot mix asphalt, so it is just a case of introducing it and gaining permission from the authorities to use it. It is becoming a more accepted technology in South Africa.” Ammann’s mini paver was put through its paces in a short presentation to show the attendees how effective the machine is. In no time at all, a neat, level layer of paving stretched across the yard. Says Lehman:

“We want to get the mini paver into the municipalities, as it is an ideal machine for road maintenance.”

Environmental considerations The Ammann open day was concluded with a presentation by Etienne Hinrichsen from Aqua Eco about the legal implications of environmental assessments in road building. He emphasised the importance of getting environmental authorisation beforehand and not attempting to do this retroactively, as it complicates the process. He also stressed that mobile and permanent plants require different authorisations, which need to be taken into consideration.

ROADS & BRIDGES

Asphalt plants

The global awareness of environmental issues has resulted in environmental management becoming a core component of almost allÂ industries.

THE ENVIRONMENT

By Etienne Hinrichsen, AquaEco

ANY ENVIRONMENTAL MANAGEMENT practices have become obligatory through law and a suite of environmental legislation has developed rapidly over the past two decades in South Africa. These laws also apply to the construction of roads and the operation of asphalt plants. Moreover, a range of environmental authorisations is required before roads can be built or asphalt plants established. Because an asphalt plant causes emissions, an atmospheric emissions licence (AEL) is required in terms of the National Environmental Management: Air Quality Act, No. 39 of 2004, and related regulations. This requirement for an AEL in turn triggers the need for an environmental authorisation in terms of the National Environmental Management Act, No. 107 of 1998, and the related environmental impact assessment (EIA) regulations. The assessment and application processes for these authorisations are procedurally demanding and they are best dealt with by an environmental practitioner who understands the specific sector. A dispensation has been granted, as of March 2014, for the establishment and operation of temporary asphalt plants; so as to eliminate lengthy assessment and authorisation processes in situations where contractors need to establish an asphalt plant to serve a particular road building contract. In order for this dispensation to apply, a contractor may operate an asphalt plant for a period of two years on a specific contract without an emissions licence, but with due cognisance that emissions standards will still apply. This concurrently eliminates the need for the associated environmental authorisation. In terms of the December 2014 EIA regulations, the building of a road outside an urban area, which is wider than 8 metres or has a reserve wider than 13.5 metres, triggers the need for an environmental authorisation. In environmentally sensitive areas, these parameters are more stringent. Care must also be taken of the authorisation needs of secondary activities such as the storage and handling of fuels and bitumen, the clearing of vegetation, dust generation, waste handling, and water use. The fact that so many environmental aspects require investigation, authorisation and continued management, makes it essential to involve an experienced environmental practitioner from the planning (or tender) phase of a road or asphalt project. Such a practitioner will be able to provide advice on the best options from an environmental perspective, direct the authorisation processes, and establish the required environmental management systems.

IMIESA April 2015

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SKILLS & TRAINING

ENGINEERING COUNCIL OF SOUTH AFRICA

Transforming the

engineering profession

Sipho Madonsela was appointed CEO of the Engineering Council of South Africa in October 2014 and is a man eminently suited to the job. Madonsela has been a registered professional with the council since 1996 and speaks to Nicholas McDiarmid about the dynamics and structure of the profession, and his vision for its role in transformation in South Africa.

Starting at the beginning, what is the role and structure of ECSA? SM ECSA’s core mandate starts with setting the policies, standards and qualifications for the engineering profession. ECSA is a statutory body established in terms of the Engineering Profession Act (EPA), 46 of 2000. ECSA's primary 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. ECSA plays a core role in the development of engineering skills and regulating the performance of the discipline in an ethical and competent manner, while maintaining proficiencies through continued professional development.

What does ECSA regard as its developmental role in supporting young engineers in the market place?

Our ‘value chain’, so to speak, starts with establishing and developing policy, as drawn from the Act, and the setting of academic standards for the profession, as they relate to qualifications. We consult and offer guidance, as experts in the field, to the South African Qualification Authority. We develop these standards from the full curricula for universities towards qualifications that are relevant and can lead to professional registration. We have decided to make a further contribution through our Sakhimfundo Trust. This

is modelled on what the accounting profession has done through the South African Institute of Chartered Accountants (Saica). It is carefully configured to ensure that ECSA does not find itself as both referee and player. It is an independent educational trust that will be run by a board of trustees independent of ECSA. ECSA’s role in the trust is essentially that of a catalyst to establish the trust and influence other stakeholders in the engineering profession to contribute

IMIESA April 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

SKILLS & TRAINING

and participate. In partnership with universities and the Guateng Department of Infrastructure Development, we are offering financial support to promising and deserving students. The trust was launched on 6 October 2014. When it was launched in Johannesburg last year, we had 17 students benefiting from the trust.

How are you addressing the need for young engineers to gain practical experience? Young graduates face a conundrum in the market place. Without experience, they cannot be professionally registered, and will struggle to get work in both the public and private sectors. This is why I am working with the SETAs to play more of a facilitation role in linking qualified graduates – without the necessary skills and experience for registration – with potential employers and training entities. However, the links they make must be with institutions that meet the appropriate standards and formal experience they require. This is to ensure that the provided training serves a defined purpose, be it road building, dam building or any other civil engineering discipline. We are assisting the SETAs in setting the selection criteria of training organisations to close the gap.

Can ECSA play a role in the development of opportunities for employment in South Africa? There is a disjuncture in South Africa when it comes to this and I think it is an issue that contributes to our unemployment problems. If you consider that WITS was established, when mining was still a nascent industry, as a school of mining, what is happening to cater to today’s new industries? Telecommunications is massive and the service providers themselves are large institutions that employ a lot of technical staff who must be qualified. Try and find a university with a curriculum that speaks to this industry… it doesn’t exist. In the US, fracking has taken America from a net importer of hydrocarbon energy to a net exporter. In Europe, renewable energy is big business and the EU has had a regulatory body for this new sector for many years already. Where are we in SA?

It sounds like there is a need for some innovation within ECSA... We must innovate. It is important to me that

ECSA adopts a more aggressive approach to pioneering in the space of education and qualifications. Some parastatals, like the DBSA, are establishing their own ‘academies’. Sanral has established one in the Eastern Cape where graduates are groomed to acquire professional registration with us. Rand Water is following suit, with more to come. It is a very direct and active way that the public sector is addressing the challenge, and we will assist. The education system, however, is actually struggling to keep pace with economic advancement. ECSA’s role is to develop the standards for education and qualifications, and to work with the SETAs in providing the right kind of training, and producing candidates ready to operate on a practical level in the market. This is our developmental contribution and, given the massive unemployment levels in South Africa – especially unemployment of graduates – we need to act urgently. It is about matching opportunities with the country’s current socio-economic challenges. We have to partner with relevant stakeholders and deliver on our mandate of ensuring a register and pool of qualified engineers in these new areas of economic activity.

in the infrastructure development space in government departments and state-owned enterprises. While not all of them need this detailed design expertise, they need to be at a high level of planning and coordination.

So this will encompass some disciplines that fall outside engineering? At ECSA, we have been developing standards that are, by and large, confined to people dealing with engineering design and not those at the level of procurement and plan-

“Government is more in need of engineers who have this level of oversight than those involved in design of infrastructure itself… [it] is in need of people with the skills to procure, consult with communities, and implement proper planning and so on.”

Local and national government are in serious need of infrastructure planning and implementation skills; what is ECSA’s role in supporting this skill set? The standards we have developed for competency have, by and large, spoken to consulting engineers in the private sector. As respondents to tenders, they are required to have ECSA registration and, simply put, this has driven much of our activities. But – and this is the paradox – the people issuing the tenders from the public sector itself don’t have a unique set of standards for the highlevel management of such engineering activities. The view we are presenting to council is to extend what is provided for in the Act, with specified categories of registration. We will speak to those in municipalities and

ning, who exercise engineering supervision and oversight. Government is more in need of engineers who have this level of oversight than those involved in design of infrastructure itself. It is not their core business actually; it is the realm of the consulting engineer. The public sector is in need of people with the skills to procure, consult with communities, and implement proper planning and so on. This function comprises quite a broad skill set, which does require definition that ECSA must assist with. Some of the standards do go beyond the engineering sphere, such as procurement and project/social planning. We can act as a referee between other bodies to achieve this, and thus create something that speaks to directly to this critical need. All of the standards, however, must be encapsulated under the Engineers’ Code of Conduct. This is the code that guides all legislated activities, including procurement, public participation and, of course, engineering itself. This is a critical way in which ECSA contributes to national development.

So what is the road forward for ECSA, particularly in the short term? When one reads Section 18 of the Engineering Professions Act, it becomes clear that it was

IMIESA April 2015

SKILLS & TRAINING

“We must innovate. It is important to me that ECSA adopts a more aggressive approach to pioneering in the space of education and qualifications.” defined largely with consulting engineers in mind. The reasons for this are primarily to do with our country’s history, and we have to transform this. ECSA can no longer function as a gate-keeper; it needs to be progressive and play its role in ensuring the right skills are quantified, regulated and registered to benefit all engineering professionals and the country’s economy as a whole. We have to set standards that are relevant to the evolution of industries. And we have to address ECSA’s professional categories to become inclusive, in support of transformation and job creation.

What is stopping ECSA and the Energy and Water Services SETA from going to America or China

IMIESA April 2015

to understand the standards they have developed for fracking?

South Africa has significant pockets of shale gas and, make no mistake, these will be exploited to assist us in becoming energy-independent. We need to learn about the standards now to ensure employment in the sector happens locally and that the competencies are understood and regulated. This will ensure that, by the time government calls for professionals to work in this field, only those who completed the required curriculum and have the appropriate registration will be considered. That is our role. If we don’t do this now, government will still make the call and, in the absence of the appropriate skills, South Africa will have to turn to foreign enterprises, and the local benefits will be lost. The only way to eradicate poverty and unemployment is to coordinate growth sectors to the benefit of all South Africans. ECSA has a clear and important role in facilitating this.

ABOVE Sipho Madonsela, CEO of ECSA and chairman of Emzansi Engineers

ABOUT SIPHO MADONSELA

Sipho Madonsela, CEO of ECSA, is also chairman of Emzansi Engineers and, over and above his work as a mechanical engineer, Madonsela’s commitment to the profession and its role in South African society is reflected in his five-year presidency of the National Society of Black Engineers (NSBE), his four-year tenure as chairman of the Council for the Built Environment, and his ongoing service as a board member of Sanral.

CEMENT & CONCRETE

CONCRETE TRAINING:

Don’t be fooled

Supposed top-flight, high-priced concrete training workshops that are being actively marketed to the concrete industry are often not worth the time or paper they are written on.

LEFT Johan van Wyk of Sarma advises companies to first investigate the credentials of providers before sending staff on any of the concrete technology workshops currently being offered by a host of ‘new’ providers

GROWING NUMBER OF these workshops are being offered within the industry but contain information that is irrelevant to the local market and not recognised by any of the local industry’s representative bodies. Although not illegal, the type of information being presented may be counterproductive or even harmful to the industry, and can have a negative effect on the quality of concrete produced in future. A personalised email invitation recently piqued the curiosity of Johan van Wyk, general manager of the Southern Africa Readymix Association (Sarma), who found several inaccuracies in the marketing material he had been sent and, as a result, decided to investigate further.

while other information was clearly designed for cold climates that are completely unlike any conditions we have in Southern Africa. Yet, even after confronting them with this information, they still continue to market this workshop. “We suggest that instead of spending money on seemingly impressive, well-marketed courses, you should first check with the industry body that represents the sector to find out if the concrete courses on offer will be of any value. The cost of a phone call may well save thousands of rands in useless training,” says Van Wyk.

False claims Upon closer investigation, the workshop offered by a foreign media house operating from Randburg was found to be using the names of at least two well-known professionals who had not even heard of the workshop until then. In addition, the course claimed to offer continuing professional development (CPD) points through a professional institution, which, when approached by Van Wyk, knew nothing of the workshop. “I became suspicious when I saw the terminology used. Some of the sample material they sent was completely incorrect

Upskilling the industry In addition, professional bodies such as Sarma provide industry-specific workshops on a wide range of topics annually. Requests can also be made (where relevant) for workshops to be organised and may be hosted by either the association, or by an accredited training provider. The workshops are affordable as they are not driven by profit and attendance. In most cases, it is advisable to seek technical training from local suppliers. Apart from the vastly differing building techniques

employed in South Africa, compared to places such as the USA or Europe, geological and climatic conditions are also vastly different. What works overseas may not work here and may not even be legal. South Africa has some of the world’s most accomplished concrete professionals and local industry bodies, and training authorities have a wealth of expertise (and experience) to call upon when compiling local training programmes and schedules. They also understand local conditions, by-laws, standards and best practices better than anyone else.

Making sure “Sarma is 100% behind bringing new technologies and expertise from abroad to South Africa. At the same time, we would also like to caution the industry against forking out money to just anybody who happens to offer a workshop.

“The cost of a phone call may well save thousands of rands in useless training.” Johan van Wyk, general manager, Sarma

“Before doing so, we would strongly suggest that anyone interested in attending a course first do some research to find out if it is legitimate. Just like you will investigate any new supplier, we suggest companies also investigate workshop and training providers,” concludes Van Wyk.

IMIESA April 2015

CEMENT & CONCRETE

Leave it to LAFARGE

AFARGE SOUTH AFRICA is in a unique position to provide the construction industr y with building materials and solutions through having a strong presence in all of its construction-related business lines – cement, aggregates, readymix concrete, fly ash and gypsum plasterboard. The company focuses strongly on the needs of its customers and their projects to develop innovative, holistic product supply solutions. The approach is 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 towards urbanisation and reflects Lafarge’s commitment to help create cities that are desirable and sustainable environments for all people. This means contributing to better solutions that meet the needs of communities for decent housing, hospitals, schools and offices, and the associated infrastructure – such as roads, airports, water and power utilities.

All-round support at Eteza Lafarge South Africa’s efficient, integrated service was highlighted on the Sanral contract to construct an overload control facility and full diamond interchange at Eteza on the N2 in KwaZulu-Natal. The main contractor was concerned about two concrete issues. The driver of the project was the contractor’s ability to place the continuously reinforced concrete pavement (CRCP) on time and within specification, with the closest commercial readymix

IMIESA April 2015

commercial readymix concrete plant and concrete plant 45 km from the project site. this represented a potentially significant The second concern was ameliorating the risk in terms of compliance with the tight heat of hydration (HOH) in the extremely durability specification. hot, humid conditions. The solution from Lafarge South Africa Lafarge’s successful offer to supply all was to position a mobile concrete batching main building materials – concrete, cement, plant optimally on-site in order to service fly ash, and 165 000 t of road aggregates, the major concrete pours and take on the as well as 4 500 t of the company’s specialdurability risk. This was conditional on ised cementitious road binder, RoadCem being awarded the full supply package of 32,5N – made it viable to provide a Lafarge building materials. mobile concrete batching plant on-site. The successful outcome was the supply of This enabled the required combined total of 13 000 m³ of CRCP mix and other con- 10 000 m³ CVC concrete, on specification and on time. This involved the supply 3 500 ventionally vibrated concrete (CVC) to be t of Lafarge Powercrete Plus 42,5R cement, supplied without compromising the quality 7 000 t of aggregates, 1 000 t of fly ash, or integrity of the concrete. as well as 8 000 t of cementitious road The solution to assisting the contractor to binder RoadCem. 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 Mike Fisher, development (compared with the EN 197-1 criterion of manager: Infrastructure Road & Rail, Lafarge South Africa <270 J/g at 41 h), but it can also be “Our construction contractor customers extended further on-site with fly ash to meet appreciate the benefits of having their buildthe various mix requirements. ing materials supplied and managed from Meeting a tight durability a single reliable source,” comments Mike specification Fisher, development manager: Infrastructure Similar suppor t was provided to the Road & Rail, Lafarge SA. “By matching our main contractor on the Sanral contract extensive capabilities with the needs of to upgrade Section 14 of the N1 freethe specific construction project, and the way between Trompsburg Interchange and individual construction company, we achieve Fonteintjie – a distance of 20.8 km. The consistent quality and better value all round site is some 120 km from the nearest fixed for the stakeholders.”

“Our construction contractor customers appreciate the benefits of having their building materials supplied and managed from a single reliable source.”

CEMENT & CONCRETE

Quarries need a

champion in government

WIDENING CHASM SEEMS to be developing between quarries that produce materials and government departments that legislate the industry, but are not directly involved with construction or the supply of construction materials. This is giving rise to a situation that is making it extremely difficult for legitimate quarries to survive in an overregulated but price-sensitive market. According to Nico Pienaar, director of the Aggregate and Sand Producers Association of Southern Africa (Aspasa) there is no government department that is directly responsible for overseeing the sand and stone quarrying industry, and ensuring that it remains viable and sustainable into the future. On the other hand there are various government departments nationally, regionally and within local government that are regulating the industry and introducing increasingly onerous legislation, and bylaws, which need to be complied with.

No easy money “The end result is that quarrying for building materials – sand and stone – is becoming increasingly specialised and, as a result, it is becoming more and more expensive to produce a tonne of sand or stone. Simultaneously, however, temporary landuse permits are being widely issued to construction companies, municipalities and even some ‘fly-by-night’ producers to excavate sand and stone on a temporary basis without the need to comply with most of the onerous requirements that hamstring the organised quarry industry. “Furthermore, illegal pits and quarries are an ongoing problem and those in the enforcement and legislative departments within government are either not committed or too apathetic to raise a hand and really stamp these kinds of practices out,” says Pienaar. He continued that the industry has challenges to sustain itself in the medium to

long term and that the entire building and construction industry may, in years to come, have more challenges if government does not respond to calls from the industry to have a dedicated government department take responsibility for the supply of building materials to the construction industry. Aspasa represents the basic material for infrastructure development. In some countries this industry is known as the “construction materials” industry or the “extractive industry”, which has different rules for different parts of the mining industry. In South Africa, however, the industry is regulated by the Department of Mineral Resources and, as such, is subjected to the same legislation that applies to, for example, the underground mining of platinum and gold.

Building blocks of society “By comparison, sand and stone are different types of minerals. They are essential

PLAYING BY THE RULES

These are some of the many compliance issues that are adhered to by the formal sand and aggregate quarrying sector but that are ignored by temporary permit holders and illegal operators: • Paying taxes • Paying royalties • Upholding ethics • Ensuring environmental sustainability • Upholding employee relations • Maintaining health and safety • Creating equal opportunities • Building good community relations • Engaging in stakeholder engagement • Applying BEE • Preventing and treating HIV/Aids

IMIESA April 2015

CEMENT & CONCRETE

"Building materials producers need a champion within the South African government in order to ensure the continued supply of adequate and suitable materials for both the civil construction and building industries.”

ingredients to our construction industry and without them the construction industry cannot exist. Allowing the formal quarrying industry to suffer would be tantamount to committing environmental and social suicide though. Borrow pits and ground scrapings would scar most of the open spaces near developments, and the damage to waterways and the destruction of arable land would be catastrophic to the community. “The long-term effect would be that the land usage of these areas would be forever changed and that communities would have to live with the consequences for generations to come. We have always said that we welcome legislation that protects the environment and looks after the rights of employees and surrounding communities. However, we are appealing to all levels of government to level the playing field and make the same rules that apply to quarries also apply to temporary land users and, at the same time, it must be enforced to stop illegal operators anywhere in South Africa.” Tightening requirements have given rise to the need for more skilled quarry staff who understand the job of running a modern-day quarry. This is another area that needs to be championed by the appropriate government department so that we can ensure the quarry industry remains properly skilled and able to supply the needs of the construction industry now and into the future. At present, there are no training institutions with courses specifically tailored for quarrying. As a result, graduates with formal mining qualifications know little (if anything) about the challenges of running a quarry.

Rising prices shrinking margins Operating a quarry in South Africa is an onerous task and requires well-trained people, who are able to properly manage a quarry, to extract a profit. However, the Department of Mineral Resources continues to push for increased regulation of the industry while offering little if any protection from part-time land users and illegal operators. The South African Revenue Service has simultaneously taxed the industry to the point where finding a profit is difficult and where it is almost impossible to employ new staff or create jobs. “While the industry is governed by the same rules as mines, our tax benefits are not as favourable while our profits are usually smaller. Many of our ministers’ portfolios cross the sector, but no singular ministry focuses on the sustainability of this key sector. That needs to change! We need a government department that will become the champion of the quarrying industry,” concludes Pienaar.

IMIESA April 2015

CONSTRUCTION VEHICLES, EQUIPMENT & LOGISTICS

Deterring a

dusty disaster

HE SOCCER CITY Precinct, a highpopulation-density area, needs to have its surrounding tailings dams managed on a consistent basis. Communities in the vicinity of tailings dams surrounding the FNB Stadium were fortunate enough to have the impact of dust minimised with the help of the TDS 2005 tailings dam seal solution. The solution was implemented by environmental solutions company I-CAT Environmental Solutions – in partnership with gold producer and world-leading surface gold tailings retreatment expert DRD Gold. I-CAT non-executive director Professor Jan du Plessis explains that the challenge is to prevent wind from eroding the ultrafine dust under 0.1 micron off the tailings dams and open-soil areas. “The wind

causes a dust cloud to be swept into the atmosphere, which settles on populated and agricultural areas. The nature and size of the dust is undesirable and creates an environmental hazard.” TDS 2005 is a matrix blend of a patented anionic surfactant and other environmentally friendly binding products. The unique properties of this liquid gel allow it to penetrate the surface of the dump and open-soil areas, creating a durable bond that binds loose aggregate by forming a crust. According to Du Plessis, this crust allows water to penetrate the surface, without running the risk of being washed away under heavy precipitation. “The crust remains porous, allowing rainwater to penetrate, without being washed away,” he continues. TDS 2005 is designed to last six months to

The dry climate in Johannesburg makes dust suppression a more challenging task in densely populated areas of the city. a year, depending on weather conditions. In this particular area, the TDS 2005 seal was applied more than a year ago, and is still offering 95% coverage of the area. Another major benefit of TDS 2005 is that only 10% to 20% of the original product is required to maintain standard coverage during reapplication, thereby resulting in cost savings. Being an environmentally friendly product, Du Plessis reveals that TDS 2005 is not applied to the detriment of the growth of vegetation as a more permanent rehabilitation solution. “If used in conjunction with strategically placed I-CAT wind-brake netting, which allows for vegetation growth, the lifespan and effectiveness of the TDS 2005 seal can be significantly extended,” he concludes. IMIESA April 2015

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

IMIESA

is an award-winning maga zine that promotes ser vice deliver y and the knowledge and practice of infrastructure development in Africa by reaching consul ting engineers, municipal engineers and managers through i ts coverage of the following topics

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Municipal Infrastructure Summit 2015 25-26 May 2015 | Durban ICC Advancing Local Economies Through Infrastructure Development The Local Government Business Network, supported by various government departments and the private sector will be hosting municipalities, government departments and state owned enterprises in an intense two-day Summit to review, consult and address current issues facing government in further investments on Infrastructure development, the application of labour intensive technologies, methods and programmes, the second phase of the expanded public works programme, public private partnerships as well as partnerships with other government agencies to create jobs and accelerate service delivery. This summit will take place on the 25-26 May 2015, Durban ICC – City of eThekwini – Kwazulu Natal, where senior government and municipal officials, business and civil society will network, engage and share ideas on the way forward. The Summit will take stock on the progress of the R3.2 Million spend on Infrastructure Development, as well as progress made by the various structures that have been set to advance the plan. While a big chunk of the money is expected to come from the National Fiscus, especially for public service facilities, there is a call for State Owned Enterprises and private sector to partner and ensure that various forms of financing were explored to fund the build process. Through this Municipal Infrastructure Summit 2015, the Local Government Business Network will create an open opportunity for government and municipalities to meet a wide range of stakeholders including the private sector, SOE's and social partners to explore various innovations and solutions to accelerate infrastructure development and map out alternative funding models

Major Drivers and Insights for this year's summit will include: Ÿ Stirring developmental duties to the right path to structure and manage infrastructure development in the local governments Ÿ Addressing municipal funding model and how it affects the national economic picture Ÿ Develop a capacity building process to sustain economic growth for available infrastructure Ÿ Evaluating situational analysis to determine level of development and priorities Ÿ Foreseeing social and economic issues before hand to prevent public unrest and interruption to infrastructure programmes

More than 500 delegates are expected to attend the summit in an environment that actively encourages and facilitates the cross-fertilisation of ideas and experiences. The Summit format will be heavily based on case studies to enable participants to immediately use that information within their own organisations. The roles and priorities of infrastructure development practitioners will be examined in detail during the following Breakaway Commissions (Sessions). Ÿ Ÿ Ÿ Ÿ Ÿ

Municipal Infrastructure Financing and Investment Rail, Roads and Public Transportation Housing, Water and Sanitation Municipal Energy, Environment and Green Solutions Municipal Technology Solutions and Service Delivery Innovations

For further information or partnership opportunities on the Summit or to book a package, kindly contact Baatseba on 011 807 5359 or 011 039 2211 or Bainang directly on 082 474 3748 or email bainang@lgbn.co.za or visit our website at www.lgbn.co.za. BROUGHT TO YOU BY:

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TECHNOLOGY & INNOVATIONS

Advanced

reality modelling

ENTLEY SYSTEMS announced the acquisition, saying the move was to align design modelling and construction modelling with existing conditions’ context – for every infrastructure project and asset.

Reality modelling Through reality modelling, observations of existing conditions are processed into representations for contextual alignment within design modelling and construction modelling environments. Rapid technology advancements in scanning and photography – and especially the burgeoning application of unmanned aerial vehicles (UAVs) for these purposes – are making the capture of such observations broadly and continuously affordable in sustaining infrastructure. Acute3D’s software automates the generation of high-resolution, fully 3D representations from digital photographs taken with any camera, whether highly specialised or embedded in a smartphone. Scalable from site to city, and with precision limited only by the quantity and quality of photography, Acute3D’s technology can assure that existing conditions are contemporaneously considered throughout the architecture, engineering, construction, and operations of any infrastructure asset. Now that photo sequences from UAVs are likely to become the most feasible source for surveying, construction monitoring, and inspection workflows, Acute3D’s industrial-level accuracy and unlimited scalability are making it a preferred technology for UAV manufacturers and professionals around the world. Bentley Systems founder and CTO Keith Bentley said, “The worldclass Acute3D developers have already achieved two breakthroughs that remove the barriers to the adoption of reality modelling. “First, Acute3D has made it possible for anyone to sufficiently capture existing conditions with just a camera. Of equal importance is the value of the result. Rather than a voluminous cloud of discrete points, the software produces a 3D ‘reality mesh’ – intrinsically in the same geometric idiom as engineering models, readily aligning the real-world context. “Just as Acute3D’s innovations have now brought reality modelling within reach of every infrastructure professional, we and our new colleagues are excited to be working together to incorporate Acute3D functionality throughout our platform and application portfolio, enhancing information mobility throughout infrastructure asset life cycles.”

The reality modelling market is set for major advancement as a leading company acquired France-based Acute3D, provider of Smart3DCapture software for reality modelling. ABOVE Smart3DCapture of a gas facility

3D city modelling for several megacities, from both aerial and streetview photography. Other applications of the software have included existing conditions capture for construction sites, manufacturing facilities, mining operations, pipelines, and oil and gas exploration.

Acute3D Acute3D was founded in 2011 by Dr Jean-Philippe Pons and Dr Renaud Keriven, who have attracted and led an accomplished team of researchers and developers, headquartered in Sophia Antipolis. Since its founding, the software has attracted a rapidly expanding user base that includes Nokia, Pasco and Saint-Gobain, and OEM licensees that include Airbus Group and Autodesk. In China, Internet giant Tencent is working with the software to do large-scale

IMIESA April 2015

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

IMESA

PROFESSIONAL AFFILIATES AECOM vanessa.partington@aecom.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 Hatch Goba info@hatch.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 john.onraet@murrob.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 Royal HaskoningDHV francisg@rhdv.com 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

TECHNOLOGY & INNOVATIONS

Preventing

soil erosion

S THE LARGEST pipeline project ever commissioned by eThekwini Metropolitan Municipality’s Water and Sanitation Unit, the Western Aqueduct has been designed to significantly increase the capacity of bulk water flowing from the KwaZuluNatal Midlands to the greater Durban area. During the design of the Western Aqueduct, Naidu Consulting approached Kaytech regarding soil erosion protection for the many steep gradients and delicate grasslands through which Phase Two of the pipeline would traverse. Once complete, this hilly 7 km section will run from Alverstone Nek reservoir to Ashley Road in Hillcrest.

only effectively combats soil erosion by trapping surface soil particles, but also conserves moisture and helps prevent wind erosion. The open structure provides space for plant propagation and growth. According to strict environmental legislation, areas vulnerable to soil erosion must be rehabilitated to their former states once construction had taken place. Having extensive experience with the installation of SoilSaver, Rietvlei Landscape was awarded the contract and, the company has installed 38 000 m2 of SoilSaver. Without the protection of SoilSaver on these steep gradients, the increase in overall kinetic energy of the surface water run-off would quickly lead to severe erosion.

Environmentally friendly Environmentally friendly SoilSaver was indisputably specified as the ideal solution to this challenging project. Manufactured by Kaytech, from a biodegradable 100% jute yarn woven to form a 65% open-mesh structure, SoilSaver not

Economical, versatile and simple Simple to install, SoilSaver is pegged down in close contact with topsoil, thereby creating a more tortuous path for surface water run-off. Within approximately two years, during

SoilSaver secured in place with wooden pegs on the Western Aqueduct

which time vegetation would be re-established, SoilSaver will undergo biodegradation and breakdown. Unlike many other natural materials, the fibrous residue from SoilSaver actually adds nutrients to the topsoil. SoilSaver is an economical, highly versatile product that is suitable for use in numerous applications in any climatic conditions. It is supplied in highly compressed bales comprising about twelve 84 m2 laps each of which can easily be carried up a slope by one person. Once completed, this massive water pipeline is expected to ultimately supply eThekwini with up to 400 Mℓ per day, which should meet the region’s needs for the next 30 years. A highly successful project to date, the installation of SoilSaver has been problem-free and grass is already flourishing in some of the rehabilitated areas. IMIESA April 2015

INDEX TO ADVERTISERS

INDEX TO ADVERTISERS Affiliates Page AECOM SA African Utility Week

82 14 & 15 35

Pumptron 24

Incledon 42

Quality Filtration Systems

IMESA Social events

SABITA 68

Afrimat 61

IMESA Registration

SA Leak Detection

Ammann Construction

Jan Palm Consulting Engineers

SA Industry & Technology

Machinery South Africa

Kaytech 70

Fair (INDUTEC)

Aquadam 58

Lafarge Industries

SA Road Federation

Aqua Eco

Lektratek Water Technology

SEW Eurodrive

IFC

A-OSH Expo

Maccaferri Southern Africa

Sizabantu Piping Systems

Aveng Manufacturing Infraset Barloworld Equipment Bell Equipment

Herrenknecht South Africa

2 OFC 12

39 & LI

Mercedes-Benz 30

SMEC 63

Model Maker Systems

Stalcor 34

Much Asphalt

Structa Group

Builders 32

Municipal Infrastructure

CAPSA 84

Summit 2015

Trenchless Technologies

Coatings for Africa

National Cold Asphalt

TT Innovations

Corobrik 4

PH Bagale Consulting

ELB Equipment

Civil Engineering

Water & Sanitation

Gibb 25

Precision Meters

WRP Consulting Engineers

Tosas 65

Vermeer Equipment Supplier

52 OBC IBC

IMIESA April 2015

Innovation for Quality and Value Registration Deadline Dates

CAPSA '15 Focus Areas 1. Optimising structural design in new construction and rehabilitation 2. Up-to-date procurement practice for products and services to promote efficient, sustainable and innovative delivery 3. The design of asphalt layers and spray seals to ensure efficient application and adequate performance 4. Construction, practice and materials assessment for a high level of efficiency 5. Low volume surfaced roads to promote access and mobility in southern Africa

Early Bird: Closed Ÿ Regular: Tue 3 Feb – Mon 1 June ‘15 Ÿ Late: Tue 2 June – Fri 7 Aug ‘15 Ÿ Late Reg / Penalty: From 8 Aug ‘15 Ÿ

Satellite Events @ CAPSA2015 SANRAL SARDM Workshop: Thursday 20 August 2015 3rd ISAP APE Symposium: Sunday 16 August 2015 Please visit the website for more information.

High Municipal Water Account? Zednet provides a complete GPRS/SMS based data acquisition, control, monitoring and reporting system for: • • • • • • • •

Auto Reporting

Flow and pressure logging Water level monitoring Pump status (on/off) monitoring Rainfall monitoring Identification of leakage through Minimum Night Flow analysis Real time data monitoring Identification of pressure problems Ideally suited for industrial or large consumers

Leak Identification If the leak had run undetected for 2 months: Volume of water loss = ± 2 000m³ Cost of water loss = ± R78 000

Leak occurs Leak Repaired

Leak @1,4 m /h

Additional features: • • • • • •

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Developed and supported by:

A Miya Group Company

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