IMIESA August 2018

www.infrastructurene.ws

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

infrastructure development • Maintenance • service delivery

INDUSTRY INSIGHT Werner Tessendorf

Business Development Manager, Tosas

Hannes Lambert Technical Manager, Tosas

Ralumac gains momentum on SA roads

AfriSam

Controlling quality is the key to success

Infrastructure Asset Management

Cement & Concrete

RCC pavement potential

Metering: A vital resource

Human Settlements Energy optimisation of IBT homes

IN THE HOT SEAT We continually upgrade and modernise our plants to meet future demand for larger quantities, more projects and increasingly sophisticated and diverse products.” Bennie Greyling Managing Director, Much Asphalt

ISSN 0257 1978

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IMESA

INSIDE

volume 43 no. 08 August 2018

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INDUSTRY INSIGHT Werner Tessendorf

Business Development Manager, Tosas

Hannes Lambert Technical Manager

Ralumac gains momentum on SA roads

AfriSam

Controlling quality is the key to success

Infrastructure Asset Management

Cement & Concrete

RCC pavement potential

Human Settlements

Metering: A vital resource

Energy optimisation of IBT homes

IN THE HOT SEAT

17

We continually upgrade and modernise our plants to meet future demand for larger quantities, more projects and increasingly sophisticated and diverse products.” Bennie Greyling Managing Director, Much Asphalt

ISSN 0257 1978

V o l u m e 4 3 N o . 8 • A u g u s t 2 0 1 8 • R 5 0 . 0 0 ( i n c l . VAT )

As a leading supplier of cement, aggregate and readymix concrete products, AfriSam’s focus is on quality control and the ongoing monitoring of its products’ performance, providing a foundation of trust for customers. P6

Editor’s comment

3

President’s comment

5

Africa round-up

8

Index to advertisers

60

Cover Story Controlling quality is the key to success

6

Hot Seat New horizons for Much Asphalt

10

Municipal Focus | Buffalo City A city hard at work

Bennie Greyling, managing director of Much Asphalt, speaks about current and future opportunities as the company repositions itself for local and international expansion, and potential product diversification. P10

27

CEMENT & CONCRETE Quality assured precast innovation

12

Industry Insight

Fulton Awards 2019 – Call for Nominations

29

CRB innovator gains ground

29

SUDS channels

30

Designing precast routes

32

South African roads

14

Roads & Bridges A brilliant interchange

17

Is the fuel levy the answer?

18

Cement & Concrete Cover Story Cementing opportunities in Africa

22

RCC roads revisited

24

Quality assured precast innovation

27

ENVIRONMENTAL ENGINEERING Gabion designs with hog clips

Energy optimisation of IBT homes

35

Geotechnical Engineering Stabilisation and drainage

37

Engineered from the ground up

38

Environmental Engineering Gabion designs with hog clips

40

Water & Wastewater WISA Conference | Building resilience 42 Landmark plant for Umgeni Water

45

Reuse with ultrafiltration

46

Ensuring safe water for all

49

Meters, Pumps & Valves

Ralumac gains momentum on

31

A brilliant interchange

Human Settlements

Regulars

IN THE HOT SEAT

ROADS & BRIDGES

3D advances in pump designs

51

Metering: a vital resource

52

Transport, Logistics, Vehicles & Equipment Commercial vehicle market shows resilience

55

Mini multi-taskers

57

Compact milling

58

Big on performance

60

INDUSTRY INSIGHT

14 Addressing maintenance backlogs is a pressing concern. IMIESA speaks to Tosas representatives Werner Tessendorf, business development manager, and Hannes Lambert, technical manager, about ways to add value.

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41

EDITOR’S COMMENT Publisher Elizabeth Shorten MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson JOURNALIST Liesl Frankson Head OF DESIGN Beren Bauermeister Chief SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter ContributorS Gavin Clunnie, Dominique Geszler, Mokate Ramafoko, Saied Solomons CLIENT SERVICES & PRODUCTION MANAGER Jayshree Maharaj Production COORDINATOR Jacqueline Modise financial Director Andrew Lobban 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 Email: jennymiller@lantic.net ___________________________________________________

150 Rivonia Road, Morningside, 2196 Publisher PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za Annual subscription: R600.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2018. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Fax: +27 (0)43 743 5266 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Fax: +27 (0)41 585 1066 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Fax:+27 (0)31 266 5094 Email: imesakzn@imesa.org.za NORTHERN PROVINCE Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Fax: +27 (0)86 628 0468 Email: imesafsnc@imesa.org.za All material herein IMIESA is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

Investment and municipal debt

T

he hosting of the 2018 BRICS Summit presents fresh opportunities for member countries to focus on beneficial trade exchanges that include joint initiatives in Africa, where China is especially prevalent.

This year marks the 20th anniversary of formal diplomatic relations between China and South Africa, and the ties continue to strengthen. China has so far invested or committed to spending more than US$25 billion in our economy across a diverse range of industries.

In a perfect world, South Africa would have a positive balance of payments. That’s definitely a longer-term goal, as provinces vie for local and international funding to develop manufacturing and Industry 4.0-related industries that will help drive this objective.

An overall goal is to progressively reduce GDP debt, which was recorded at around 53% in 2017. (As an aside: in 2017, Egypt’s stood at 103.26%.)

objectives, but the balance of the revenue streams needs to be derived from operations, like revenue from water and electricity tariffs, refuse collection and municipal rates.

At the moment, though, many of our municipalities are too heavily indebted, which impacts on their ability to deliver essential services. This has a well-publicised knock-on effect for Eskom and the country’s various water boards when it comes to non-payment, and they’re suing for performance.

Eskom also has internal challenges that need to be addressed, including substantial debt issues due to poor policy decisions and an oversized workforce that has to be rationalised. International investors regard Eskom as a major risk to South Africa’s medium- to longer-term growth prospects.

For many municipalities, the process of restoring profitability and governance will take a few years to fix, but the situation will be rectified thanks to stricter compliance measures implemented by national government. That will send the right message to the investor community.

During 2016/17, municipal debt was estimated at around R225.8 billion; of that amount, 43% was owed to creditors, which include Eskom. This is according to Statistics South Africa’s latest ‘Financial census of municipalities’ report. R142.2 billion of the R225.8 billion owed was incurred by four metros, namely Johannesburg (18%), Tshwane (11%), eThekwini (10%) and Cape Town (9%).

Over the same period, national government spent R1.33 trillion, of which financial grants made up the largest portion – at R764 billion. Approximately 65% of these grants were allocated to provincial government and some 14% was then subsequently transferred to municipalities.

So, the issues surrounding municipal performance have more to do with efficient expenditure rather than funding. Borrowing will always be a necessary factor, but it must simulate growth and have a quantifiable return on investment.

Infrastructure backbone None of these current or future investment plans will happen without a highly functional infrastructure network of roads, rail, airports and harbours.

Among those metros promising healthy infrastructure investment pipelines is the City of eThekwini. During a BRICS Business Council meeting in Durban, Sihle Zikalala, acting premier, KwaZulu-Natal, announced that the province plans to spend more than R200 billion on infrastructure projects over the next seven years.

Zikalala says that infrastructure roll-outs will serve as a catalyst for public and private sector developments.

These include initiatives linked to the Dube Trade Port and the Richards Bay Industrial Development Zone.

Along with a sustained infrastructure model, sound financial performance at local government level is equally important in providing a conducive business environment.

Municipal debt Before that can happen, South Africa’s metros and municipalities need to be going concerns, correctly sized and efficient. A certain level of debt is fine, as long as its supports macro- and microeconomic

Alastair Currie 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.

struc www.infra

turene.ws

City of Cape Inves ting in

@infrastructure4

magazine The official of the Institute l Engineer ing of Municipa Africa of Southern

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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 +27 (0)11 467 6223.

IMIESA August 2018

3

IMESA

President’s comment

Women in engineering August is Women’s Month in South Africa and recognises and celebrates the vital role that women play in our society. As an institute, we believe we should do more to support the growth of women engineers and ensure that they remain in the profession for the long term.

B

ack in April 2018, I had the opportunity to attend the International Federation of Municipal Engineering’s conference in Fiji, where the mix of speakers included a number of high-profile women.

These included Dr Marlene Kanga, current president of the World Federation of Engineering Organisations (WFEO). Among other roles, Kanga is a board member of Sydney Water Corporation, and was named the Federation of Engineering Institutions in Asia and the Pacific (FEIAP) Professional Engineer of the Year in 2014, among many achievements.

She heads an organisation that places a key emphasis on promoting global engineering workforce diversity. WFEO’s Women in Engineering standing committee is a prime example and is headed by Valerie Agberagba, a past president of the Association of Professional Women Engineers of Nigeria and a past vicepresident of the Nigerian Society of Engineers.

Institute representation Within IMESA, we currently have three women engineers on EXCO, and four on Council. Ideally, we’d like this to be a 50/50 split between men and women in the future, but that will also depend on the sustainability of medium- to longerterm infrastructure investments, and the funding frameworks and direction provided by government’s primary, secondar y and tertiary initiatives.

According to recent stats available from Consulting Engineers South Africa, approximately 9% of their

professional engineers and technologists are women.

The women on IMESA’S EXCO are Jeanine du Preez, Bhavna Soni and Emmarentia Stipp, all of whom are civil engineers. Du Preez presently holds the position of district manager within the City of Cape Town’s Transport and Urban Development Authority and has been involved with IMESA since 2003, where she served on the local Western Cape branch committee.

She’s been branch chair since 2010 and actively involved on the IMESA Council and EXCO, where she now serves for a consecutive term as vice-president: Operations.

Also working for the City of Cape Town, Stipp is a roads and stormwater engineer, who serves on EXCO as operations director: Membership and Branches.

Soni is currently deputy head: Engineering for the City of eThekwini’s Water and Sanitation unit. She is responsible for the planning and design of water and wastewater infrastructure, as well as providing strategic direction to reduce non-revenue water within the eThekwini region.

Soni serves on EXCO as operations director: Conferences. Another previous EXCO member now serving on Council is Lindsay Mooiman, a civil engineer from IMESA’s Southern Cape/ Karoo region.

As an institute, we actively promote transformation and diversity through our bursary programmes, as well as at our annual conferences, where key speakers have included Dr Allyson Lawless, an Honorary Fellow of IMESA and author of Numbers and Needs: Addressing imbalances in the civil engineering profession, among other renowned works.

Lawless is a highly respected innovator and thought leader, and an international role model for aspiring engineers in general, and women more specifically.

IMESA president Gavin Clunnie

We also acknowledge that engineering is not just for engineers. There are so many vital interacting disciplines, and in this respect, we’d like to acknowledge the contribution made by our IMESA head office manager and IMESA secretary, Ingrid Botton, a Microsoft Certified Professional.

In 2014, Botton was appointed as a system support technician with the core responsibility of assisting municipalities with the compilation of accurate infrastructure asset registers to meet the compliance requirements of GRAP 17 and to support the IMESA Infrastructure Management System (IIMS) developed specially for this purpose. She and other consultants were able to assist 12 municipalities, mostly in the Free State, and several were able to improve their GRAP 17 audit outcomes considerably as a result of standardising the data processing.

Every year, the role that women play in shaping our municipal engineering space keeps growing, opening the way for new industry leaders that will shape our collective future.

Cover story

Controlling quality is the key to success

As a leading supplier of cement, aggregate and readymix concrete products, AfriSam’s focus is on quality control and the ongoing monitoring of its products’ per formance, providing a foundation of trust for customers. This means ongoing process control testing of products produced by SA’s leading construction material supplier.

A

mit Dawneerangen, GM: Readymix at AfriSam, says test results are closely monitored for deviations beyond preset tolerances. “We analyse results to identify trends so that action can be taken timeously and products can be improved continuously,” he explains.

Among the quality control facilities are the plant laboratories based at AfriSam’s cement, aggregate and readymix operations around the country. At the cement laboratories, routine chemical and physical tests are carried out on raw meal, on in-process material and on the final product, allowing production staff to control cement quality during the entire process.

This complex chain extends from the selection of blast sites in the quarry to raw meal proportioning, adjustment of kiln temperatures and grinding parameters, blending proportions, and the final product. In the aggregate laboratories, samples are taken regularly and

6

IMIESA August 2018

AfriSam’s Centre of Product Excellence supports the company’s business units and customers with extensive quality assurance services

subjected to grading analysis and, in the case of stone, to flakiness index testing to ensure that no non-conforming aggregate leaves the quarry or crushing plant.

“This is vital to the customer, as grading and density results form the basis of concrete mix designs and their performance,” Dawneerangen says. To ensure trust in its laboratory testing, AfriSam’s Centre of Product Excellence (CPE) laboratory complies with ISO 17025, which governs requirements for the competence of testing and calibration laboratories.

At its readymix plants, AfriSam laboratories conduct slump tests on samples of concrete leaving the plant to check that the workability of the material is in line with customer requirements. Cubes are made up for testing compressive strength to ensure ongoing compliance with strength requirements. Any nonconforming results are reported immediately to management for in-depth investigation.

Active quality monitoring Underlying the organisation-wide commitment to quality are cutting-edge resources like AfriSam’s cement monitoring programme, where process control test results from all AfriSam plant laboratories are captured.

An electronic monitoring report correlates all results and gives managers immediate access to trend analysis reports. This allows empowered decisions concerning raw meal proportioning to ensure that the required performance criteria are always maintained.

Key to the focus on quality is AfriSam’s CPE, based in Roodepoort, Gauteng. The CPE supports the company’s business units and customers with extensive quality assurance services. With its chemical, physical and materials laboratories, it is well equipped to carry out a wide range of tests on cements and concrete, including mix optimisation and durability index testing. Developing and testing products to comply with specialised application

COVER STORY

requirements and project specifications, the CPE also conducts analyses and forensic investigations into situations where concrete does not achieve the performance characteristics for which it was designed.

To assist with the design of mixes, CPE has consultants available countrywide who can troubleshoot and conduct technical assessment of materials and processes at a customer’s site. Where necessary, these consultants arrange for trial mixes and other testing services to be carried out in controlled laboratory conditions at the Roodepoort facility.

Value-adding research By investing in the expertise and systems that sustain quality products, AfriSam is also well positioned to conduct and coordinate valuable research into the properties of cements, supplementary cementitious materials, aggregates and concrete. These research projects are initiated and rolled out in collaboration with customers, universities and other bodies.

Research projects that are currently under way include a long-term assessment of the effects of highly corrosive environments on concretes made with differing proportions and types of raw materials. Results from these tests feed into dedicated computer software that allows architects and contractors to specify the appropriate grade of concrete to suit their project’s environmental conditions.

Proactive monitoring, while part of its quality control function, also forms an important part of AfriSam’s product development cycle, giving it the scientific and experiential basis to constantly develop new innovations to add to its extensive range of offerings.

Cementing AfriSam’s lead An example has been AfriSam Rapid Hard Cement, which is ideal for a range of applications. For precast concrete, for example, it allows for faster demoulding times; while in a fast-track construction project, it can facilitate the early stripping of formwork, early bridge launching or higher sliding rates. It can also be used for post-tensioned and prestressed members.

AfriSam Rapid Hard Cement exhibits faster strength development due to the cement being manufactured to a carefully controlled fineness

AfriSam’s High Strength Cement is a specially developed composite cement for use in the manufacture of bricks and blocks, as well as for reservoirs, precast operations and structural concrete

4 million cubic metres

AfriSam can produce 4 million cubic metres of readymix concrete from its 40 readymix sites across South Africa

together with a per formance modifier to further enhance this feature.

It is ideal for cold-weather concreting where the high early liberation of heat due to hydration can offset the retardation effect of low temperatures. Where durability is important, AfriSam Rapid Hard Cement can be further blended on-site with ground granulated blast furnace slag, fly ash or condensed silica fume.

Other cement innovations include AfriSam High Strength Cement, a specially developed composite cement for use in the manufacture of bricks and blocks, as well as for reservoirs, precast operations, structural concrete, shotcrete and mining operations. The strength development of this cement is more than sufficient to allow for the normal progress of building operations and is ideal for use in specialised applications.

AfriSam Roadstab cement is another engineered composite cement used specifically in road stabilisation, ensuring uniform distribution of the stabilising agent throughout the stabilised layer and giving the bound material significant strength to improve the durability of road sub-bases. Effective across a broad range of road material types, AfriSam Roadstab reduces the plasticity of the soil and adds strength.

In line with Afrisam’s quality and safety commitments, all cement operations have ISO 14001 and OHSAS 18001 certification.

Rock solid performance One of the country’s largest suppliers of quality aggregate, AfriSam has the capacity to produce over 10 Mt of aggregate per annum from its quarries and crushing plants in Gauteng, Mpumalanga, KwaZulu-Natal and the Western Cape. All these operations – as well as their plant laboratories – have ISO 9001 certification, ensuring that all stone is fully compliant with the relevant specifications and customer requirements.

The product range covers every need in the aggregate field. Roadstone is supplied to the specific grading, shape and wearing proper ties required for asphalt and road surfacing applications, while concrete aggregates include a wide range of stone sizes within target gradings – as well as washed and unwashed crusher sands for use in all on-site and readymix concrete applications.

Material is supplied for road layer works, such as the base and sub-base materials that provide the interlocking support structure in road design, with different categories of graded material catering for varying load designs.

AfriSam also supplies speciality aggregate, including railway ballast, gabion and other larger-sized crushed stone for use in erosion protection, architecture and landscaping.

Ready to roll With more than 40 readymix plants in Gauteng, Mpumalanga, North West, KwaZulu-Natal and the Western Cape, AfriSam offers customers the competitive edge in construction. Here, the offering extends beyond the choice and proportioning of suitable and compliant raw materials to computerised weigh-batching, concrete pumping services, technical backup and quality assurance.

All the readymix plants have ISO 9001 certification and offer mixes for a wide range of applications, from foundations and pillars to suspended slabs and surface beds.

They also produce speciality mixes such as high-spec durability-grade concrete, selfcompacting concrete, flowcrete and fibrereinforced concrete.

www.afrisam.co.za

IMIESA August 2018

7

INFRASTRUCTURE NEWS

FROM AROUND THE CONTINENT

Algeria Stepping up desalination Algeria’s Department of Energy is preparing tenders for two 300 000 m3/day desalination plants.

The two plants, to be located in Zéralda and El Tarf in Algiers, will add to the 11 desalination plants that have been built in Algeria since 2003.

These plants form part of a programme, which proposed 13 facilities and a total capacity of 2.31 million m3/day.

The projects, which will be build, operate and transfer contracts managed by the Algerian Energy Company, will increase desalinated water as part of the national drinking water supply from 17% to 25%.

Tanzania must invest more in water and sanitation to achieve the SDGs

of over 1 000 km of fibre-optic cable to connect with Cameroon and Congo; the creation of a national data centre coupled with an electronic management platform; the operation of 20 digital community centres, and a digital training centre; and the creation of a business incubator at the University of Bangui.

In addition, the project will help improve the quality of services and reduce the costs of economic transactions with internet penetration of at least 20% by 2021.

Mozambique Central African Republic Boosting connectivity The African Development Bank has signed three grant agreements to the tune of $107 billion to finance the fibre-optic backbone project for Central Africa.

The Central African Republic’s 2016 National Recovery and Peace Building Plan recognises ICT as a principal source of growth and job creation. The project will see the installation

Rural roads to support agricultural productivity

Zambezia and Nampula provinces with high agricultural potential and a total population of around 2.2 million people, of which approximately 1.5 million live below the poverty line.

Another area of focus will be the rehabilitation of the primary road network, specifically the sections of N1 and N10 (Quelimane to Namacurra – 70 km), which have an average daily traffic flow ranging from 1 700 to 2 600 vehicles.

Nigeria IPPs to boost energy supply The Nigerian government has received a US$1.5 million (R20.2 million) grant to

implement Phase 1 of the Jigawa 1 GW Independent Power Producer (IPP) Solar Procurement Program.

At full 1 GW capacity, the programme will assist the government to achieve its national goals of reaching 75% electricity access by 2020 and electrifying under- and unserved areas, particularly in northern Nigeria where access rates are lowest, and increasing the share of renewable energy in the energy mix to 30% by 2030.

The grant will support the completion of outstanding technical and feasibility studies and the design of a master plan for the entire programme site.

Subject to the outcome of the technical and feasibility studies, the African Development Bank will provide additional support to the government in the form of funding of a transaction advisor to design and launch the competitive IPP procurement.

The government has committed to de-risking the programme through the provision of land and common facilities including transmission infrastructure.

Mozambique has received a $150 million grant in support of its Integrated Feeder Road Development Project.

The project will enhance road access in the provinces of Zambezia and Nampula, where most of the country’s rural poor live. About 6.5 million rural dwellers do not have access to a road in good or fair condition in Mozambique.

This project will specifically target 10 districts in the

Nigeria’s IPP programme will assist in reaching 75% electricity access by 2020

fast facts

25%

25% of Algeria’s drinking water will soon come from desalination

8

IMIESA August 2018

$150 million

Mozambique will spend US$150 million on enhancing agricultural roads

75%

Nigeria wants to achieve 75% electricity access by 2020

20%

The fibre-optic backbone project for Central Africa will help achieve 20% internet by 2021

BLUEPRINT 2267/E

THE MT EDGECOMBE INTERCHANGE CHANGES THE WAY WE SEE KWAZULU-NATAL The award-winning Mt Edgecombe Interchange is more than a masterpiece of architecture. It is a vital artery of the greater eThekwini metropolitan highway system for easing traffic, relieving congestion.

It is yet another construction achievement added to the list of iconic bridge structures undertaken in KwaZulu-Natal (KZN) by SANRAL. It relieves the congestion that had vehicles backing up on the M41 and onto the N2 in peak hours. The interchange upgrade has definitely changed the landscape forever and is sure to become a well-known landmark for years to come.

We are proud to have constructed one of the longest structures ever built in South Africa, without ever closing any of the roads permanently. We look forward to it delivering significant social and economic benefits to the KZN region.

SANRAL. Beyond roads.

www.sanral.co.za

www.facebook.com/sanralza/

Reg. No. 3790342109421. An agency of the Department of Transport.

@sanral_za

@sanral_za

Paving of NCRT warm-mix asphalt supplied by Much on Clarence Drive between Gordons Bay and Rooi-Els

IMIESA speaks to Bennie Greyling, managing director of Much Asphalt, about current and future oppor tunities as the company repositions itself for local and international expansion, and potential product diversification.

New horiz ons

Much As

What changes does Much Asphalt expect following your recent acquisition by AECI from Capitalworks for R1 988 million?

are, as will our commitment to providing customers with the best-quality products and services. Our values are very well aligned with AECI’s, so no step-change is necessary in that regard either.

The most noteworthy shift, and an exciting one for us, may be focused on markets outside South Africa’s borders. This is one area where we believe we can benefit from AECI’s extensive footprint and experience on the continent.

BG There will be no significant strategic or operational changes in the South African environment. Our brand and strategy will remain as they

AECI stated that the acquisition was based on Much Asphalt having a market-leading position

We have revamped our Benoni and Eerste River quality control laboratories this year and added new, state-of-the-art equipment.”

Bennie Greyling, managing director of Much Asphalt

for

phalt

with long-established customer relationships, a robust order book and project pipeline, and a highly experienced management team.

What benefits do you envisage?

Some synergies with companies in the AECI Group will be explored. This could provide Much Asphalt and our subsidiary, SprayPave, with opportunities to develop new chemical products to diversify our offering and expand our client base.

In addition, AECI has a strong balance sheet and thus the ability to support future potential value-adding projects that generate benefits for the business and its clients.

Can you comment on conditions in the road construction market?

Conditions are challenging, partly as a result of the hiatus in Sanral work pending clarity on funding policy. Other reasons

HOT SEAT

Technician Bonginkosi Xaba uses a dynamic shear rheometer in the Much Asphalt Benoni laboratory to test the rheology of bituminous binders over the in situ working temperature on the road

for delays in getting projects off the ground include community engagement issues in areas where work has been scheduled and contractual disputes initiated by unsuccessful bidders on certain projects.

How do you mitigate the impact of difficult conditions?

Much Asphalt’s single biggest differentiator is our nationwide geographic footprint.

This means that our revenue stream is generated across South Africa and is also less dependent on seasonal influences.

On the one hand, delays in the awarding of major Sanral projects are affecting the road building industry and hence the asphalt business in Gauteng – traditionally our strongest market. On the other hand, the Western and Eastern Cape are delivering better than usual opportunities.

How is the slowdown in Sanral business affecting the road building sector?

Sanral is a well-established, professional provider of road construction work that compares well with any of its first-world peers. Much Asphalt is proud to be involved in Sanral projects, which can represent anything from 15% to 40% of our order book.

The reduction in contracts awarded by Sanral in recent months is impacting the construction sector severely, which has a knock-on effect for us. Apart from what we have seen in the past six months in terms of the fortunes of the large construction companies, small- and medium-sized suppliers to the sector have also been impacted and many jobs have been lost.

However, I am confident that the issues are being addressed urgently and professionally and that an increased flow of work will follow.

What is Much doing to prepare for future demand and keep ahead of the curve?

We continually upgrade and modernise our plants to meet future demand for larger quantities, more projects and increasingly sophisticated and diverse

A view of Much Asphalt’s operations in Benoni, Gauteng

products, as well as adhering to stringent environmental requirements. A notable example is the current expansion of our Eerste River plant in the Western Cape in preparation for major projects in the pipeline.

Importantly, we have revamped our Benoni and Eerste River quality control laboratories this year and added new state-of-the-art equipment in line with international developments and trends.

Our laboratories need to be reassessed continually to ensure we are ready to provide optimal quality control for existing and new asphalt products required by our clients. Together with others in the industr y, we also play a significant role in developing and testing new products.

Last year, SprayPave commissioned a multistage bitumen converter. How has this unique technology impacted your business?

The technology has had a significant positive effect on our Western Cape operations, enabling us to convert locally available bitumen to asphalt-grade bitumen. This is more cost effective than transporting bitumen long distances and storing it, which we have had to do in the past in the absence of local supply of asphalt-grade bitumen products.

Bitumen produced using the converter in Cape Town is available to all asphalt manufacturers and plans are being evaluated to roll out this technology to other parts of South Africa.

Have there been any advances in the technology since you acquired it from Technix Industries in New Zealand?

Working with Technix, we have launched various R&D projects to produce multigrade bitumen, specific per formancegrade binders and even polymer-modified binders. While these projects are still at an early stage, indications are positive.

www.muchasphalt.com

IMIESA August 2018

11

Municipal Focus | Buffalo City

A city hard at work Cllr Xola Pakati, executive mayor, Buffalo City

The total budget for Buffalo City’s Medium-term Revenue and Expenditure Framework is consistently growing. Until 2021, more than R1.5 billion will be spent on infrastructure development each financial year.

T

he budget for the next financial year is R8.3 billion, prioritised in favour of water and sanitation, roads and stormwater, human settlements, transport infrastructure, economic development, refuse removal and disposal, electricity, and overall critical infrastructure maintenance, Cllr Xola Pakati, executive mayor, Buffalo City, told residents in his recent State of the Metro Address.

His vision is to build a productive and innovative city that achieves both higher levels of growth and revenue for the city, as well as higher levels of inclusivity to reduce inequality. To do this, the municipality is creating enabling conditions for new productive investments. This includes improving the quality of basic services, ensuring quality health and educational facilities, reducing the cost of logistics, and ensuring that the city is able to attract and retain skills.

“We need to build a strong identity as a place that is supportive of investment.

This means that we need to develop a track record of problem-solving to unlock business opportunities through, for instance, measures to reduce the cost of doing business and address infrastructure bottlenecks. We intend to work with private sector players to find ways of systematically addressing obstacles to productive investments across all sectors,” said Pakati.

In line with this, Buffalo City has formed a partnership with National Treasury and the World Bank to design and introduce interventions that will reduce the cost of doing business in the city. Pakati reports that this is paying off, with significant increases in private sector productive investment in the city.

An example of this is the award-winning East London Industrial Development Zone (ELIDZ), in which the city is a shareholder. Since its establishment, the ELIDZ has attracted R8 billion in investment from 42 investors across a number of strategic sectors.

Turning the city into a construction site “For our city to be productive, it needs to have the required infrastructure to carry a modernising industrial economy. We are a city hard at work in the provisioning of adequate infrastructure and, as such, we have turned the city into a construction site,” said the mayor.

12

IMIESA August 2018

Roads Buffalo City continues to construct, refurbish and rehabilitate road infrastructure.

In the current financial year, focus has been on several projects, including: • Beacon Bay Quenera Link Road Project Phase 2 • Mdantsane roads Phase 3, Cluster 1,2 and 3 upgrades • Fleet Street project.

“Over the past year, we have done our best to ensure that roads are maintained to a suitable standard through in-house construction teams in all the regions, and we will continue road rehabilitation and upgrade programmes in the next financial year. We will also be re-gravelling our rural roads through hiring plant and maintaining stormwater infrastructure,” said Pakati.

R286.9 million has been committed for the rehabilitation of bridges, roads and stormwater in the next financial year. In addition to this, Sanral will spend R186 million on the resurfacing of roads, and Prasa will spend R21.6 million on upgrading railway stations across the metro.

“We are working very hard to ensure that the hope[s] our people have [resting] on their current leadership and the faith that they have in the service delivery institution that we have made [of] their municipality [are] not in vain. We are moving properly in our work of building our city and we will work to ensure that the social compact that has been formed with business, labour, NGOs and other social partners in our city is maintained, and that we continue to work for the betterment of our metro and its people,” Pakati concluded.

Municipal Focus | Buffalo City

Electrification Buffalo City is continuing to reinvest 4% of generated revenue back into the electrical network to ensure that it remains reliable and meets safety standards. In FY 2017/18, R148 million was allocated for overall electricity expenditure, with the bulk of it going to capital works.

“We are proud to say that, due to our consistent investment of funds into the capital replacement programme, we have one of the best performing electrical networks in South Africa,” said Pakati.

In the current financial year, the city committed R40 million for the roll-out of electricity to thousands of formal households. A further R10 million was allocated to informal settlement electrification, seeing an additional 45 informal dwellings electrified in Mdantsane and Duncan Village.

Waste management Buffalo City recently held a two-day Waste Indaba, which acknowledged that landfilling is not a sustainable form of waste disposal. The city’s long-term waste management strategy will, therefore, prioritise waste reduction and minimisation, divert waste from landfill, and promote recycling and reuse.

The event was a cooperative effort between the city and the BorderKei Chamber of Business, with the aim to develop sustainable waste management through partnerships, exchange information on best practices, and empower the Buffalo City community with information about waste management.

“The need to transform the waste industry is critical in creating sustainable livelihoods for many of our people and it will assist in dealing with the challenge of unemployment and poverty. We can confirm that, in the current financial year, the municipality worked with the ELIDZ to identify waste economy opportunities,” said Pakati.

Water and sanitation Pakati reports that the number of households with access to a basic level of water is now 97%, with overall access to basic sanitation at 90%.

In the current financial year, the city has implemented four major water projects at the value of R146 million. These are ongoing infrastructure upgrades and maintenance that will continue into the next financial year: • augmentation of water treatment at Mzonyana Dam • construction of bulk water supply reservoirs and village reticulation • replacement of existing bulk water infrastructure prone to bursts and installation of water meters • continuing upgrade of the Amahleke Water Supply scheme.

R194.4 million is allocated to water projects in the next financial year.

Buffalo City also continues to upgrade and build new sanitation infrastructure. In the current financial year, several projects were implemented: • the third phase of the Reeston Bulk Services Sewer project • wastewater infrastructure capacity at the King William’s Town Regional Sewerage Scheme • R40 million for the provision of ventilated improved pit latrines to eliminate rural sanitation backlogs.

R287 million has been budgeted for sanitation and related infrastructure in FY 2018/19.

HOUSING According to the national government, Buffalo City has the second highest need for housing in the country, after Nelson Mandela Bay Metro. The municipality is currently implementing around 29 human settlements projects at a value of R259 million.

Over the next three years, the provincial government will give Buffalo City R241 million for the construction of housing units. A budget of R434 million will also be made available in the next three years, through the Urban Settlement Development Grant, for the installation of water and sanitation to each site and the construction of roads and stormwater for these settlements.

In 2018/19 alone, the municipality will provide 866 individual households with serviced sites and will build 583 top structures for the communities residing in informal settlements. In order to ease the implementation of these projects, the city is developing an Integrated Sustainable Human Settlements Plan to be finalised in the next financial year, for full implementation from 2019/20.

IMIESA August 2018

13

Industry Insight

Ralumac gains momentum on SA roads Addressing maintenance backlogs is a pressing concern. IMIESA speaks to Tosas representatives Werner Tessendorf, business development manager, and Hannes Lambert, technical manager, about adding value to the industry.

S

Werner Tessendorf, business development manager (left), and Hannes Lambert, technical manager

outh Africa’s roads infrastructure network is a vital socioeconomic conduit and, given budget constraints, innovative solutions are needed to extend their life.

One such innovation from Tosas is Ralumac® microsurfacing. The company has acquired the sole licence to produce this revolutionary cold asphalt formulation locally and is forging ahead on a series of roads contracts backed by a new slurry truck fleet.

In South Africa, Ralumac was first introduced during the early 1980s, but the brand subsequently exited the market in 2001. Tosas’ reintroduction of Ralumac now ensures positive traction for this costeffective product, well known worldwide as a

high-performance, versatile road maintenance solution when applied in microsurfacing, overlays and rut filling applications on deformed surfaces, highways and freeways.

Ralumac can be used with reinforced synthetic fibres that improve fatigue properties and surface texture. Pigmented binders can also be used for cycle lanes and pedestrian walkways.

“From a costing perspective, Ralumac’s life expectancy usually exceeds seven years and it’s an excellent option for maintenance interventions,” Lambert explains. “The product improves undulations, profile and skid resistance, and provides excellent cohesion.

Once applied, the bond is irreversible, and no tack coat is required.”

With fast-acting Ralumac, pedestrian walkways can be opened within 10 to 15 minutes and vehicular traffic can resume within 30 minutes within ambient temperatures of 25°C and rising. By comparison, conventional, slowsetting slurries can take up to four hours under the same climatic conditions.

Slurry trucks are equipped with special mixers and spreader boxes that allow for continuous agitation to prevent premature breaking. As the specialised machine moves forward, it spreads the microsurfacing material across the width of the traffic lane in a single pass. The specially engineered rut fill boxes are designed to place the largest aggregates in the deepest part of the rut to give strength and maximum stability in the deformed wheel path. The break rate can be controlled and slowed down by the use of chemical additives to assist with hand work or in very hot climates. Variable-width spreader boxes mounted on skids assist with road surface undulations and automatically compensate for width variations.

One of our strengths has been our ability to invest and adapt to costsensitive industry requirements.”

14

IMIESA August 2018

Industry Insight “Another advantage of Ralumac is that it promotes an element of labour-intensive construction, since a work crew of around 10 is normally required,” says Lambert.

Ralumac has been used successfully during night work due to its ability to meet a broad range of temperature and weather conditions.

The product can also be used on airfield landing strips due to the dense-graded mix and improved skid-resistant surface without the risk of loose aggregate that can damage small aircraft props.

Another advantage is that microsurfacing can restore the surface profile by eliminating areas where hydroplaning occurs. It will create a new, stable surface that is resistant to rutting or shoving in summer and to cracking during cold winter months.

core component of the final mix design and is being transported in specialised haulers to a Much Asphalt plant in Bloemfontein.

Here, the UTFC is blended and transported a further 340 km away to be paved on the N5 near Harrismith, made possible by the warm-mix capabilities of the NCRT. So far, more than 2 000 t of UTFC has been paved successfully on this contract.

Traditionally, a bitumen rubber plant would have to be established and installed with a header-tank system in order to get a consistent feed of binder to the asphalt plant. NCRT makes it possible to blend off-site with no specialised header systems.

Experiences in durability Tosas has an exceptional track record for product durability. A prime example is a bitumen rubber grid seal applied in Ruimsig, Roodespoort, as an alternative to regravelling in the late 1990s.

More than 25 years later, a recent site visit to this area has confirmed that this very thin layer has remained intact, without an interim treatment application and with limited damage.

“That was a very basic formulation, but it demonstrates our ability to think outside the box,” says Lambert. “A more recent example is an ultra-thin friction course (UTFC) paving contract on a section of the N5, which shows how we can find equally lasting solutions for more advanced applications.”

Blended at Tosas’ Wadeville facility, the company’s new AR2 (crumb rubber technology trademarked as NCRT™) asphalt forms a

QSE initiatives Alongside its product focus, Tosas is developing its qualifying small enterprise (QSE) programme to support the growth of new entrants in the paving industry. Recent developments include the signing of an agreement with Thandabantu Materials and Applications, which will become one of Tosas’ dedicated supply partners.

“As a leading industry player and Level 2 BBBEE company, Tosas is committed to driving transformation and we are excited about expanding our QSE pool,” Tessendorf explains.

A spokesperson for Thandabantu says that the agreement enables the company to help address the three main social challenges facing South Africa, namely alleviating poverty, inequality and high unemployment, through construction work that will flow from this agreement.

1 2 The Ralumac versatile road maintenance tool is well known worldwide for its cost-effectiveness and high performance

Industry overview

5

3

4

1. Aggregate bin

7 9

8

Alongside its mainstream Sanral projects, Tosas is

6

2. Mineral filler bin 3. Additive storage 4. Metered aggregate

targeting growth in the provincial market, where it believes Ralumac has a major role to play in “repairing more kilometres with less money”.

Currently, Tosas is working on key projects for TRAC and the Western Cape Provincial Government. Cross-border work is also ongoing in Botswana, Mozambique, Namibia and Zimbabwe.

“We have a good order book for the winter period; however, there’s a concern within the roadbuilding industry about delays in the awarding of Sanral projects for the upcoming summer period. There’s also very limited activity at provincial level, with the exception of the Western Cape,” Tessendorf continues. “This situation needs to be urgently addressed by National Treasury, the Department of Transport and Sanral to ensure the longer-term sustainability of the roads construction industry.”

Another concern is the rise in community protests and disruptions on roads projects, which has huge cost implications in terms of construction delays and the ensuing penalties for contractors. Together with the industry, Tosas is engaging with public sector stakeholders to find more equitable procurement solutions.

“One of our strengths has always been our ability to invest and adapt to cost-sensitive industry requirements, so we and the larger Raubex Group to which we belong are confident that we can win and deliver on new work over what is expected to be a very challenging twoto three-year period ahead. We will continue to do our part to drive industry transformation, while selecting technologies like Ralumac that are cost-competitive and promote job creation,” Tessendorf concludes.

5. M etered microsurfacing emulsion 6. M etered water and additive 7. Pugmill 8. Microsurfacing 9. Brown to black colour 10. Road water sprayer

www.tosas.co.za

IMIESA August 2018

15

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Roads & Bridges

A brilliant interchange The recent completion of the Mt Edgecombe Interchange upgrade has made a major difference for Durban commuters as well as those transiting to and from the N2 highway.

D

ue to the expansion of the uMhlanga and La Lucia Ridge areas, the existing interchange had been operating at capacity with vehicles backing up on the M41 and on to the N2 in peak hours. According to Sanral, an additional 40 000 vehicles enter or leave the N2 from the M41 daily, resulting in substantial queuing. This, together with expected future expansions and anticipated development of the Cornubia area, required the existing interchange to be substantially remodelled.

The new four-level interchange facility provides at least two lanes on each of the major movements. The upgrade includes the implementation of directional ramps, eliminating the need for controlled signalisation, thus ensuring free flow of traffic in all directions. As an indication of its complexity, at its peak, the project engaged around 80 designers.

Longest incremental launch Two incrementally launched bridges form part of the upgrade. The longer of the two measures 948 m in length and joins the Mt Edgecombe side of the M41 with the N2 South. The other bridge is 440 m long and

ABOVE LEFT The new four-level interchange facility provides at least two lanes on each of the major movements ABOVE RIGHT Anticipated development of the Cornubia area required the existing interchange to be substantially remodelled

joins the uMhlanga side of the M41 with the N2 North. The 948 m bridge, which is the longest incrementally launched structure built to date in South Africa, has 23 piers and two abutments and was built from two ends – one portion launched on a curve and the other on a straight.

To provide for the safety of pedestrians, a pedestrian bridge has been constructed over the N2 and will connect to new footways.

The project started in April 2013, with an envisaged construction timeframe of three years, and was jointly funded by Sanral and

1 200

The site office adjacent to the M41 has played host to over 1 200 visiting students, eager to align themselves with this worldclass project, which has drawn so much attention

PROJECT DETAILS Budget: R800 million, escalated to just under R900 million Project specifics: Upgrade from two-level to four-level interchange Impact on motorists: Travel time reduced from 25 minutes to an average of 1 minute

the KwaZulu-Natal Department of Transport, with the construction programme undertaken by main contractor CMC di Ravenna.

However, in the end, the project stretched into a fifth year due to several factors, including torrential rainfall, which led to long stoppages.

Another defining feature of this imposing interchange is the state-of-the-art and energy-efficient LED lighting set-up. The electrical reticulation for the interchange includes a distribution substation, as well as six mini substations and, in total, there are 400 light fittings and 20 000 m of cabling. Attention has also been paid to the positioning of the lights to protect motorists and pedestrians from glare.

IMIESA August 2018

17

Roads & Bridges

Road funding

Is the fuel levy the answer?

The funding of roads in South Africa continues to attract debate from all quar ters, par ticularly when the question of tolls arises. Most of these debates lack any factual foundation and are thus prone to emotional outburst, which polarises more than it clarifies.

By Saied Solomons*

M

any believe that the fuel levy should continue to be the answer to funding roads.

With the rapid urbanisation the world over, and South Africa being no exception, the provision of adequate capacity and management of trunk roads in urban areas face the biggest challenges.

If one considers the N1 between Pretoria and Johannesburg as an example, providing additional lanes will only assist to a certain extent.

Hence the answer lies not only in engineering solutions, but in managing the provided road capacity through other means, as has been done in certain parts of the world.

When the fuel levy was introduced in the early parts of the last century, the urbanisation

phenomenon was hardly on the horizon, and the issue then was connecting the various parts of South Africa. Here, the fuel levy played its role, but such a road pricing mechanism is woefully inadequate to deal with the issues of urbanisation, the imminent introduction of electric vehicles, air quality, safety, etc. To adequately deal with this new paradigm, a totally different approach will be required.

Here, we need a tariff-setting mechanism that influences behaviour; the fuel levy is not suitable

in this regard. The fuel levy raised as a means to finance roads is considered not ideal for the following reasons: • It is not fair (if considered a tax, it is a regressive tax): the poor pay the same as the rich; i.e. a person earning R5 000 a month pays the same rate of tax as one earning R50 000 a month or more.

• It is not equitable: the latest (more fuel-efficient) vehicles owned by those who can afford them use less fuel than more affordable, older models to travel the same distance.

• It is not transparent: while one can easily establish the rate per litre the fuel levy attracts, it is difficult to calculate trip costs.

• It cannot be utilised as a tool to manage congestion during peak periods, which is a dilemma all major cities face.

• It does not consider road damage caused by the mass of the vehicle. As a result of

Table 1 Vehicle fuel consumption and cost figures

ℓ/100 km R/100 km*

Old car 11 37.07

New car 6 20.22

Hybrid 2 6.74

Electric 0 0

*Fuel Levy at R3.37 per litre

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Roads & Bridges Road space

Weight

Light vehicle <3.5 tonnes

FIGURE 1 Factors to consider in calculating road-user charges

2-axle truck 6-9 tonnes 3-axle truck <18 tonnes

Road wear 3-axle prime mover with 3-axle semi trailer Common

4-axle truck with 4-axle trailer

GST/VAT

9-axle truck and trailer ‘50-Max’ combo

this, movement of freight by truck could possibly be subsidised by light motor vehicles and thus skew the comparison with the cost of freight on rail. Figure 1 – drawn from research conducted in New Zealand – which considers various components that could be considered in formulating a road user charge, explains the issue at hand.

• With electric vehicles on the horizon,

which attract no fuel levy for use of the road, the situations described above will be exacerbated.

The fuel levy is considered appropriate in two instances: • It is easy to collect.

• It is ideally suited to raising an emission charge, should this be considered.

In some form or another, road users pay to use a road. If it’s not in money, it might be

in time in the case of congestion or in vehicle operating costs where the road is not in ideal condition.

Many misconceptions can be dealt with if a new road-use charge system is cost-effective, efficient, sustainable, equitable, transparent and well administered. *Saied Solomons is the CEO of the Southern African Bitumen Association (Sabita).

IMIESA August 2018

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Cement & Concrete

READ INSIDE

Fulton Awards 2019

29

Cementing oppor tunities in Africa 22

CRB innovator gains ground

29

SUDS channels

30

Designing precast routes

32

RCC roads revisited

24

Quality-assured precast innovation 27

Cementing opportunities in Africa

Cement & Concrete | Cover Story

Cementing opportunities in Africa The construction industry is a key partner in the economic integration of the continent envisaged in the African Continental Free Trade Area agreement.

This is a broad region where PPC Cement plays an important role in supplying products and solutions that build critical infrastructure. By Mokate Ramafoko

T

We don’t see ourselves as just cement producers; we see ourselves as playing a bigger role in contributing to the growth and development of all our chosen markets.”

Mokate Ramafoko, managing director: International Operations, PPC

22

IMIESA August 2018

he world recently witnessed the signing of the biggest free trade area by heads of African governments in Kigali. Signed in March this year, the African Continental Free Trade Area (AfCFTA) is the largest such free trade zone when one considers the number of countries involved.

The African continent currently consists of 55 countries, with 55-odd currencies (some have chosen to adopt the US dollar), 55 regulatory frameworks and, in simple terms, 55 different sets of red tape. This scenario means doing business on the African continent can be challenging, for both foreign and domestic investors. There is thus a general consensus among economists and scholars alike that, when it comes into force, the AfCFTA will yield major economic benefits for the continent, its citizens and businesses alike.

But what does it mean for African businesses and international investors? What opportunities does it offer for our industry?

The AfCFTA gives the infrastructure-build programme an added impetus. Talkmore Chidede, a researcher at the Cape-based Trade Law Centre, contends that “the AfCFTA’s objective to boost intra-African trade cannot be achieved without adequate traderelated infrastructure”.

This is notable considering that the African continent has a serious infrastructure deficit.

A 2009 World Bank report, entitled ‘Africa’s Infrastructure: A time for Transformation’, estimated that US$93 billion (R1.24 trillion in current value) was needed annually for the continent to address this deficit. More recently, Kalilou Traoré, commissioner: Industry and Private Sector Promotion at the Economic Community of West African States, put this estimate at $100 billion (R1.33 trillion).

African governments, the private sector, the AU and its partners will have to embark on a serious and deliberate programme to build the necessary economic infrastructure to facilitate economic integration.

Need for megaprojects The construction industry should play a leading role in harnessing the development of this much-needed infrastructure. The rapid development of infrastructure, especially regional megaprojects, on the continent is urgent and critical. Infrastructure is a catalyst for economic growth, competitiveness and integration. An example is efficient port and transport infrastructure that facilitates and eases the movement of goods and people between different economies.

Modern and world-class infrastructure will expedite the economic integration as envisaged by the AfCFTA, ensuring that the barriers of trade are removed both on paper and physically.

With this understanding, the AU, in partnership with the UN Economic Commission for Africa, African Development Bank and the Nepad Planning and Coordinating Agency, among other significant role players, has developed a focused programme to attend to the infrastructure challenge – the Programme for Infrastructure Development in Africa (PIDA).

The programme is a continental initiative to help address the infrastructure deficit that severely hampers Africa’s competitiveness in the world market.

One of PIDA’s overall strategic objectives is to “enable Africa to finally build the common market”. It asserts that by improving access to integrated regional and continental infrastructure networks, countries will meet the forecasted demand for infrastructure

Cement & Concrete | Cover Story

services and boost competitiveness by increasing efficiencies, accelerating growth, facilitating integration into the world economy, improving living standards, and unleashing intraAfrican trade.

In my view, the construction and associated industries should continuously, and as a matter of urgency, engage the various governments and multilateral institutions that have the responsibility of providing the necessary infrastructure. This should be done with a view to understanding the priorities and development needs, especially the scale, impact and bankability. This will guide both our production capacity allocation and investment decisions.

Four priority areas In this context, PIDA identified four key infrastructure priority areas that require urgent attention, namely: the transport, energy, ICT, and transboundary water sectors. These sectors are the backbone of industrial development and offer significant potential for economic growth and development.

Three of the priorities offer abundant opportunities for industry players such as PPC. However, these will not materialise if the industry is not proactive and strategically geared to leverage off of these opportunities.

With the implementation of the various infrastructure projects, it is likely that demand for our products and services will increase.

The industry cannot afford to be found wanting when this happens. It is thus my contention

that, informed by solid and credible market intelligence, the industry should make the necessary investments before demand spikes. It is imperative that we start forming the necessary critical partnerships now to ensure that, when the time comes, we are well positioned to deliver world-class infrastructure.

PPC investments The investments such as those PPC has made in various African countries, specifically in South Africa, Rwanda, the DRC, Ethiopia, Zimbabwe and Botswana, will go a long way towards bolstering cement production – a critical product in any large infrastructure project. PPC’s choice of countries to invest in was deliberate. Not only do these countries have a high potential domestic demand for cement and related products, but they are strategically positioned to serve neighbouring countries in regions where they are situated.

Importantly, we don’t see ourselves as just cement producers; we see ourselves as playing a bigger role in contributing to the growth and development of all our chosen markets and the continent at large – igniting meaningful collaboration both within and outside our organisation. We call this ethos ‘Strength Beyond’, which is entrenched throughout our business.

Many of Africa’s 55 countries are small, with populations of fewer than 20 million and economies of less than $10 billion (R133 billion).

Their infrastructure systems, like their borders, are reflections of the continent’s colonial

past, with roads, ports, and railroads built for resource extraction and political control, rather than to bind territories together economically or socially. Most would struggle to build the critical infrastructure on their own and require partners that are driven by the same objectives.

A proactive approach involving deliveryfocused partnerships will be a game changer, as it will bring together small and big economies to deliver regional infrastructure megaprojects. The essential benefit of regional infrastructure is the formation of large, competitive markets instead of the current collection of small, isolated and inefficient ones. Undoubtedly, the industry will benefit during the construction phase, with large competitive markets forming as a result of integrated economic development.

Perhaps the most obvious example is logistics ports that will facilitate easy movement of goods across the continent, with a consequent reduction in logistics costs. Initiatives such as the North-South Corridor and the SADC Infrastructure Master Plan present massive opportunities for public-private partnerships (PPPs).

There is recognition that PPP arrangements assist governments to close material, financial, managerial and technical gaps, while supporting regional integration. For example, there is a $100 billion funding gap for the SADC Infrastructure Plan. The North-South Corridor project, conceived as the area between Durban and Dar es Salaam, is equally ambitious and costly. It comprises 157 projects, including 59 roads projects, 38 rail projects and six bridge projects.

The AfCFTA provides a single rule book for doing business and investing in Africa. It is precisely what the continent needs at this moment. Harmonisation of trade and investment rules, overcoming the constraints associated with small economies, achieving economies of scale, and integrating African economies are its ultimate objectives.

But this can and will only be realised if all critical sectors of the economy are mobilised, engaged and focused in a singleminded manner.

www.ppc.co.za

Cement & Concrete

RCC roads revisited There is renewed global interest in roller-compacted concrete (RCC) roads and industrial pavements, and the global concrete industry is now promoting this form of pavement construction.

B

ryan Perrie, managing director, The Concrete Institute, recently returned from the 13th International Symposium on Concrete Roads, held in Berlin, where he says RCC was a key discussion topic.

Perrie, an international authority on concrete pavements, has served on the International Technical Programme Committee for this symposium (held every four years) for the past 12 years.

He says RCC pavement was named after the construction method used to build it: the concrete is laid with conventional or high-density asphalt paving equipment before being compacted with rollers.

For more information, contact The Concrete Institute Information Centre on +27 (0)11 315 0300 or visit the RCC Pavement Council’s website at www.rccpavementcouncil.org.

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“The building material originated in Canada in the 1970s when the logging industry needed an environmentally clean, heavy-duty, allweather road network after switching to landbased log sorting. But RCC’s full potential as a robust urban roadbuilding material has never been realised and in South Africa, for example, there are but a handful of RCC roads, mainly in KZN to provide access to hilly areas,” Perrie explains.

RCC has the same basic ingredients as conventional concrete: cement, water and aggregates, but it is a much drier mix – stiff enough to be compacted by vibratory rollers.

Typically, RCC is constructed without forms or finishing, and does not contain dowels or steel reinforcing. These characteristics make RCC a simple, fast and economical form of concrete paving.

RCC can be used for any type of industrial or heavy-duty pavement because it combines the strength and performance of conventional concrete with economy and speed of construction. When RCC’s low initial cost, long service life and

RCC has the same basic ingredients as conventional concrete: cement, water and aggregates, but it is a much drier mix – stiff enough to be compacted by vibratory rollers

minimal maintenance are factored in, it is not surprising that it is emerging as a serious method of building roads and industrial pavements globally.

The high strength of RCC pavements eliminates common and costly problems traditionally associated with asphalt pavements, such as rutting and potholes. RCC pavements will also not deform under heavy loads, deteriorate from spills of abrasive fluids, nor soften under high temperatures.

“RCC is already widely used overseas when strength, durability and economy are primary needs for spaces such as parking and storage areas, streets, intersections, intermodal transport facilities and for some low-speed and low-volume roads,” he continues.

“But the concrete industry feels the message about RCC’s merits needs to be spread

Cement & Concrete

wider. In 2014, an industry trade association – the Roller Compacted Concrete Pavement Council – was formed in the USA to internationally promote RCC and support the research needed to establish the necessary high standards of concrete paving protocol.”

Perrie says RCC was a major talking point at the recent 13th International Symposium on Concrete Roads, with case studies from both the USA and Spain presented.

Street projects In the USA, RCC paving has a 30-year history, but only in the last decade has it been increasingly used for street applications.

For example, more than 70 lane miles of RCC residential streets were placed near Houston, Texas, over the past four years, with more planned for the future. Between 2011 and 2013, the percentage of RCC street applications increased to 16% of the total, with most of the RCC street projects performing satisfactorily. RCC is also becoming popular for residential driveways and housing estates in the USA. In another paper, the International Symposium on Concrete Roads was told that although RCC has not been widely used as a standard solution for pavements in Spain, there have now been several industrial applications in the last two or three years. RCC was, for example, used to build access roads for a new crushing facility in a cement plant in Alicante because of its long service life benefits.

The fact that high-density asphalt pavers used for RCC pavement

RCC pavements will not deform under heavy loads, deteriorate from spills of abrasive fluids, nor soften under high temperatures

construction are freely available in Spain is also likely to boost its future applications for streets and roads, the symposium heard.

Untapped potential Perrie says The Concrete Institute welcomes the international initiative to promote RCC for pavement construction: “RCC’s pavement potential has hardly been tapped locally. South Africa also has strong fleets of asphalt pavers that can be used to build low-volume RCC roads in rural areas and the Typically, RCC is constructed without forms or finishing, and does not contain dowels or steel reinforcing

townships where the local populations have been deprived of even basic streets for many years.”

The use of RCC for pavements at industrial facilities such as port and intermodal container terminals is particularly appropriate because of the ability to construct low-cost concrete pavements over large areas, allowing flexibility in terminal operations over time.

He says that although RCC is essentially Portland cement concrete, it must be engineered and constructed differently to conventional concrete and requires different placement and design considerations. “RCC pavements are unlike conventional concrete pavements in many ways, especially during production and placement, so it is important to bear this in mind when developing RCC specifications,” Perrie concludes.

IMIESA August 2018

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Cement & Concrete

Quality-assured precast innovation Whether for tilt-up construction, building cladding, paving, sustainable urban drainage or roofing, there’s a precast product to suit most applications, plus key advantages that include factory-controlled manufacturing and quality monitoring, which pass on time and cost savings. By Alastair Currie

W

hen it comes to precast, South Africa’s Concrete Manufacturers Association (CMA) continues to ensure the highest standards, which has major downstream benefits for the industry and end-users.

“The past few years have been challenging for South African construction, with everyone experiencing major cost pressures, coupled with lower margins,” explains Henry Cockcroft, marketing manager for the CMA. “This has placed an even greater emphasis on ensuring that standards are not compromised, despite the temptation to cut corners. CMA members have to meet strict requirements to join as producer members. Stipulations like adherence to

RIGHT ‘Alice Lane Phase 3’ in Sandton was the overall Aesthetics Excellence Winner (Paving – Category I) at the CMA Awards for Excellence 2018. The manufacturer was Bosun Midrand below ‘Coastal Protection Works, Strand’ was the overall Engineering Excellence Winner (Retaining Structures – Category 3) at the CMA Awards for Excellence 2018. The manufacturer was Concrete Units

Criteria for acceptance: Producer Member • Production must take place in a purpose-built manufacturing facility • A quality assurance system must be in place • Occupational health and safety procedures must be in place • Technical and engineering competence • Financial stability and environmental competence

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Cement & Concrete

Benefits of precast • Manufactured off-site with strict quality control • Rapid installation • A less cluttered site • Reduces project time and cost • Consistent uniformity

a quality management system means that buyers have a guarantee of quality.”

A few years ago, administrative backlogs at the South African Bureau of Standards (SABS) were impacting on first-time and renewal product certification applications.

SABS certification is valid for three years and then needs to be renewed. SABS is widely regarded as a hallmark of quality and compliance with national standards. For this reason, not being able to carry the SABS mark used to imply non-compliance.

In response, the CMA decided to launch CMA Certification Services (CS), which is

‘Amatole Municipality Sanitation Project, Butterworth’ was the overall Engineering Excellence Winner (Product Innovation 100+: Category 7) at the recent CMA Awards. The manufacturer was Rocla

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IMIESA August 2018

accredited by the South African National Accreditation System (Sanas) as a product certification body. In terms of standing, the CMA CS mark of approval is equal to and the equivalent of the SABS mark, with the added benefit that it is uniquely linked to the precast concrete industry.

“The uptake was slow initially, but is now gaining traction and becoming financially self-sustainable,” says Cockcroft. “We’ve also received excellent feedback from CMA members that have obtained CMA CS instead of SABS certification, particularly in terms of the fast turnaround times we’ve achieved: we can issue Sanas-approved product certification bearing the CMA CS mark of approval in four to six weeks.

“However, we still have a way to go in getting CMA CS widely recognised and accepted across the construction industry, so this remains an active part of our marketing drive.”

Compliance requirements To obtain the CMA CS mark of approval on a certain product, the applicant must comply with at least the following requirements: • For each product applied for, the applicant must prove compliance in terms of a specific SANS specification.

• The applicant must have an entrenched quality management system in place (ISO or similar), to be assessed and audited by CMA CS auditors.

• The applicant must conduct regular product in-house testing, as stipulated in the SANS specification, which will be witnessed by the CMA CS auditor during surveillance audits at the mark holder.

• If non-conformities are recorded during an audit, the applicant will first have to prove clearance of the non-conformities and demonstrate that corrective action was taken successfully before the CMA CS mark will be issued.

Adding new CMA members is a key focus area and includes SME producers. “The CMA is currently investigating the possibility of developing a more simplified quality management system for SMEs. The main reason for this is that implementing an ISO system, or similar, is costly and requires resources and dedicated personnel to introduce and maintain, something most start-ups would find prohibitively expensive,” Cockcroft explains.

There are 16 SANS specifications for precast concrete products (e.g. lintels,

We can issue Sanas-approved product certification bearing the CMA CS mark of approval in four to six weeks.” concrete block paving, concrete masonry units, pressurised and non-pressurised pipes, culverts and concrete roof tiles) and CMA CS focuses exclusively on these.

Cockcroft has now joined the SABS working group responsible for building, construction and concrete SANS specifications and codes.

Approval is currently pending on revisions to the design code for concrete block paving. The old code currently sets out three methods of performance measurement, namely abrasion, tensile splitting strength, and compressive strength. In terms of the proposed revision, compressive strength will be removed since this is not considered a relevant indication of product performance.

Technical experience One of the CMA’s core strengths is the pool of technical expertise shared by its members. Over the years, this has led to the compilation of a series of publications and technical manuals covering most precast disciplines. Recently, the CMA has updated its roof title manual and is busy with a concrete roof tile cost comparison brochure.

A new concrete block paving manual will also be released in the near future.

“We plan to start selling some of these manuals via retail outlets, making them accessible to a wide range of end users in the contracting market,” Cockcroft continues.

“The versatility and range of precast concrete products is endless, and the CMA’s role, along with its members’, is to gain greater acceptance and uptake from private and public sector stakeholders. As an example, in the municipal space, a number of towns and cities are leading the way with sustainable urban drainage systems in the form of permeable paving. Our hope is that precast products will be top of the list when it comes to public sector tenders, whether for roads or houses, retaining walls or pipelines.

That will pass on major skills transfer benefits for communities, bolster the growth of precast producers and contractors, and promote the spread of sustainable precast infrastructure,” Cockcroft concludes.

Cement & Concrete

Fulton Awards 2019 Call for Nominations

T

he Concrete Society of Southern Africa is calling for nominations for the 2019 Fulton Awards, which recognise and honour excellence and innovation in the design and use of concrete.

Nominations include any project/initiative completed in 2017, or substantially completed in 2018. Judging by a panel of seasoned industr y experts will take place on-site in early Februar y and March 2019.

For the 2019 competition, the adjudication panel comprises Prof. Mark Alexander, president of the Concrete Society; Stephen Humphries, director, Nyeleti Consulting; and Daniel van der Mer we, consultant architect, PPC. The focus of the awards and the adjudication will be on the material (concrete), and not on the project as a whole.

The categories for the 2019 Awards are: • Buildings up to three storeys: Residential, schools, commercial, warehouse, industrial, etc.

• Buildings more than three storeys: Hotels, office buildings, multi-family housing, etc.

• Infrastructure up to R100 million project value: Bridges, water resources, marine structures, power, transportation structures, etc.

• Infrastructure greater than R100 million project value: As above, but of greater size and value • Innovation in concrete on projects: Projects where totally new materials/ techniques/technologies/applications/ design and/or concepts, using concrete as the principal material, have been utilised

Sol Plaatje University Library C004 was the Fulton Awards 2017 winner in the ‘Buildings greater than three storeys’ category

• Innovation in concrete: Initiatives where totally new materials/techniques/ technologies/applications/design and/ or concepts have been developed • Architectural concrete: Use of concrete as the principal construction material, demonstrating a unique and exceptional structure, sur face finishes or particular detail, in an aesthetic manner The deadline for submitting nominations is 31 August 2018 and this can be done online through the society’s website at www.concretesociety.co.za.

CRB innovator gains ground

S

ince launching two concrete retaining block (CRB) types in 2017, the MVA-7 and the MVA-13, MVA Bricks has won at least half a dozen major CRB wall projects in Gauteng and Mpumalanga, alongside smaller-scale orders.

“Production began in June last year,” says Brennan Small, general manager, MVA. “Our first major order followed shortly thereafter, when we supplied the new Cummins Southern Africa Regional Distribution Centre and Filtration Plant Development in Waterfall Park, Midrand, with 26 000 MVA-7 blocks. These were used in the construction of a CRB fill-wall facing on a large building platform.”

The MVA-7 has a flat face and is designed for economical open-faced wall construction. As its name suggests, it is generally used on the basis of seven blocks per square metre, although this can be increased to a 10-block configuration when required.

“The MVA-13 is quite different; it has a rounded half-moon face and is designed for upmarket commercial walls in closed-faced designs,” Small explains. “As a heavier block, it has a much greater load-bearing capacity and can be deployed in walls with wall-face angles that vary between 60 and 90 degrees.”

The MVA-7 has a locking mechanism that restricts its usage to wall faces of between 60 and 75 degrees. However, it can be modified, as was the case for the Cummins project, where one section of the wall was built at an angle of 85 degrees. This was necessary due to space constraints and to accommodate an attenuation pond at the wall footing.

MVA Bricks continues its CRB product penetration following the launch of its new LokBlok in July 2018. These come with a tongue-and-groove configuration, which allows the blocks to interlock positively and means they are well suited for high walls of up to 90 degrees.

“LokBloks come into their own on walls in excess of 8 m – heights that require a very specific block because of high loadings and pressures,” adds Small.

IMIESA August 2018

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1

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SUDS channels A creative solution provides a durable and environmentally engineered inter vention for a new human settlements development.

O

ver 76 000 precast concrete Terracrete grass blocks, manufactured by Terraforce licensee and CMA member Klapmuts Concrete, have been used to line a 6.5 m wide section of a 1.8 km stormwater drainage channel next to what will become the Vlakkeland low-cost housing estate on the outskirts of Paarl, Western Cape.

The channel forms the major component of a sustainable urban drainage system (SUDS) designed to protect the new housing estate from water flows during heavy downpours. Specified by the Western Capeâ&#x20AC;&#x2122;s provincial government,

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Layer works The main channel is composed of four material layers: the subsoil, which was compacted with rollers to 93% MOD

IMIESA August 2018

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it was designed by consulting engineers Lyners and Associates based on input from Guillaume Nel Environmental Consultants and some initial stormwater sur veys undertaken by Graham McGill Consulting.

Several tributaries and stormwater pipes that previously flowed into several evaporation ponds, situated on the land earmarked for the new housing estate, now drain into the main channel (Channel 1) and two tributar y channels (2 and 3).

The unlined section of the main channel was designed to accommodate a 1:100 year flood (50.2 mÂł/s) whereas the lined section can accommodate a 1:5 year flood (18 mÂł/s).

The deployment of the Terracrete blocks and mini gabion dams, which were built into the downstream section of Channel 1, reduce flow rates and allow the SUDS system to better filtrate any run-off. The other major component of the system is a large attenuation pond excavated at the bottom end of Channel 1.

The pond further reduces the flow rate and prevents surges by releasing water gradually through a 450 mm outlet pipe at the far end of the pond. When the pond fills to capacity, the over flow pushes back into the main channel. Grass has been planted on the floors of both ponds to minimise dust during dr y periods and encourage water infiltration.

IMIESA August 2018

Cement & Concrete 1. The lined section of Channel 1 under construction 2. The partially completed Channel 1 in which the bio-charcoal fill material can be seen inside the Terracrete blocks 3. Newly laid, then filled, Terracrete grass blocks in Channel 1

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AASHTO; a layer of Grade A2 geofabric, which prevents the blocks from settling too much and allows filtration, while preventing the washout of locally sourced bedding

sand; and the Terracrete grass blocks.

The Terracrete blocks will be filled with a bio-charcoal material and mushroom spores, the former to absorb pollutants

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in the water and the latter to recharge the charcoal and keep it fit for purpose. The channel banks above the blocks will be planted with grass.

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Cement & Concrete

Designing precast routes Within the roads and stormwater segments, the range of applications for precast concrete provides designers with purpose-built solutions that lend themselves to fast-tracked projects that can include a labour-intensive component.

By Alastair Currie

O

utside conventional flexible pavement or concrete road construction techniques, there are a host of other options that can be considered by engineers, especially when the main brief is sustainability.

In this respect, precast concrete continues to push design boundaries in terms of time and cost savings, durability, aesthetics and environmental management. The latter includes sustainable urban drainage systems (SUDS) and permeable pavements. SUDS designs are intended to reduce run-off water discharge, enabling more controlled discharge to groundwater sources and rivers.

“In most cases, another key benefit of precast product innovations is that they promote labour-intensive construction, as well as create opportunities for skills training and SMME development,” explains Justin Kretzmar, technical sales engineer at Infrastructure Specialist Group (ISG), which

represents ISG’s Rocla and Technicrete precast brands and solutions.

Simplicity and minimalisation are key characteristics of precast applications for roads and stormwater, thanks to extensive research and development into replicated interventions, like concrete block paving (CBP) for sidewalks, internal and external roads. CBP is also an excellent choice for countering heavy truck turning movements at intersections in industrial areas. Here, asphalt surfaces have been shown to experience far more accelerated wear.

Adding to its product line, Rocla entered the wing wall market some years ago and is now a key supplier on major roads projects.

“Like all precast products, wing walls are precisely engineered under quality-controlled factory conditions to meet exacting industry requirements,” says Kretzmar. “Wing walls are a critical interface for culverts. Their key advantage is that they can be installed and

connected to pipe culverts within minutes, followed by routine grouting operations.”

Crash barriers When it comes to road barriers, ISG fields an innovative solution known as REBLOC®, a proprietary Austrian vehicle restraint system, now made locally under licence, that meets H4B containment requirements. REBLOC is a major advancement and improvement on the commonly known Jersey barrier, providing revolutionary safety features. Additionally, REBLOC consists of cast in situ and vandalproof steel couplings used to join adjacent barriers and form a tension bar along the barrier length.

On vehicle impact, the REBLOC barrier flexes in a controlled manner, making provision for the anticipated movement of the barrier into opposing traffic by staying within the set threshold of the breakdown lane. Especially important is that the system is designed to prevent the overturning of a vehicle after impact – essentially, it’s a deflective approach that aims to keep the car or truck travelling in a straight line, providing a chance for the driver (and passengers) to regain control and walk away from the accident unharmed.

Armorflex

Jeep tracks are commonly associated with remote access roads, frequently entailing in situ concrete ribbons that match the width of traversing vehicles. That definitely has its place, but another viable alternative is Technicrete’s Armorflex block An Armorflex road completed for an industrial complex. In this case, the client chose to grassseed the blocks to promote vegetation system, which greatly extends the design flexibility, for either single- or dual-lane traffic, and adds a further dimension in terms of the option to seed and green.

This enables landscape architects to naturally blend the road with the surrounding environment, which is a popular feature for both commercial and residential properties, for both roads and parking areas.

before

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Cement & Concrete

However, Armorflex is an all-terrain product, well suited for challenging access routes and steeper gradients that require extra grip.

In a recent case for a KwaZulu-Natal client, Armorflex proved to be an exceptionally effective choice, replacing a heavily deteriorated asphalt surface impacted by truck traffic and permanent inclement weather conditions.

“As an environmentally engineered solution, the primary purpose of Armorflex is to effectively cope with drainage and stormwater in a trapezoidal-type channel,” explains Kretzmar.

“Each Armorflex block is designed to interlock and be tied in and anchored to its neighbor, to form an interconnected system. Here, block density is important and Technicrete manufactures Armorflex units with specific weights to match design requirements. The higher the stormwater velocity, the heavier the block needs to be to resist potential upliftment.

In certain cases, an underlying geotextile layer needs to be specified to eliminate fines losses, but still promote water movement and vegetation growth.”

Armorflex construction is a precise process, but easily mastered with the right training and technical input. As a starting point, a focus on layer works preparation is essential.

The surface bed needs to be excavated and compacted such that the final riding surface of the blocks is level with the in situ ground surface. Attention to edge detailing is equally vital, as the final design must be able to counter lateral movement and erosion induced by passing traffic. As a rule of thumb, the concrete edge beam, usually cast in situ, should be placed at a depth at least twice as great as the specified Armorflex blocks installed, but this will vary depending on the severity of the ground conditions and terrain.

“Roads are seldom straight for long, so curves must be catered for,” he continues.

“However, Armorflex installations don’t follow curves and therefore need to be constructed in rectangular configurations that do, with the

An Armorflex installation for Umgeni Water. Extensive deterioration of the existing asphalt surface, as well as the steepness of the gradient, motivated a switch to Armorflex

before

help of interspersed concrete cross beams placed at varying angles to match the required curvature. Another advantage here is that if a section is extensively damaged or swept away by flooding, then the rest of the Armorflex road/channel remains intact.”

Permeable options and stormwater For public and private sector stakeholders, sustainability has become an overriding consideration, whether this is applied to buildings or civil infrastructure. In the stormwater context, there are precast systems that cater for reuse or attenuation (water capture for release). These are intended to counter the severity of stormwater run-off, particularly in urban areas. For drought-stricken areas, harvesting has added another necessary dimension.

ISG offers a number of permeable precast pavement solutions for infiltration or discharge applications, or a combination of the two.

Infiltration systems have an underlying bidim layer that promotes the controlled transfer of rainwater to groundwater sources. The alternative is to construct an underground

AFTER

tank or channel layer below the pavement, lined with HDPE. These tanks have outlet pipe connections purpose-built to steadily release stormwater flows into bulk lines at the permissible municipal rate.

“When it comes to precast and roads, there are endless possibilities. Just in terms of stormwater, our Beany Block system is a technology that has found traction locally, but we believe it deserves far greater attention, whether combined with a permeable solution or as standalone installations,” Kretzmar continues.

The Beany block performs like a standard curb; however, the key difference is that it’s interspersed with regular inlets that effectively feed rainwater into stormwater channels. So far, ISG has supplied the product for major developments that include BRT routes, as well as traffic circles. Fast inflows result in minimal standing water, greatly improving traffic safety.

“When it comes to roads, parking lots and urban landscapes in general, it’s clear that specifying precast is a cost-effective and highly sustainable solution,” he concludes.

An example of a pipe culvert wing wall, which can be installed within minutes. The one shown still needs to be backfilled and grouted

A permeable paving solution for a warehousing site: the paving’s wide coverage area eliminated the requirement for conventional stormwater run-off channels

The large flow capacity/unit ratio of the Beany Block makes it superior and more cost-effective than conventional kerbing and drainage systems

IMIESA August 2018

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Home-builder training and development The NHBRC provides training and skills development to builders to build skill capacity.

This entails developing and managing systems and processes for the delivery of training and developmental activities to emerging home builders, to assist home builders, through training and inspection, to achieve and maintain satisfactory technical standards of home building.

Customer Service Centres To increase its visibility and service excellence to customers, the NHBRC established Customer Service Centres in all nine provinces.

Activities range from registration of home builders, enrolment of new homes, inspection of homes and handling of complaints, to conciliation of unresolved complaints.

Service points in municipalities are also being set up to establish and improve the accessibility of the NHBRC. The National Home Builders Registration Council (NHBRC) is a statutory body with the main responsibility of providing protection in terms of the Housing Consumer Measures Act, 1998 (Act No 95 of 1998). Its mandate is to provide protection for housing consumers against defects and to regulate the homebuilding industry.

The mandate of the NHBRC Chapter 1 of the Housing Consumers Protection Measures Act, 1998 (No 95 of 1988) as amended, prescribes the mandate of the National Home Builders Registration Council. The Act states the objectives of the council as follows: • To establish and to promote ethical and technical standards in the homebuilding industry • To improve structural quality in the interest of housing consumers and the home building industry • To promote housing consumer rights and to provide housing consumer information • To communicate with and to assist homebuilders to register in terms of this Act • To assist home builders, though training and inspection, to achieve and to maintain satisfactory technical standards of home building • To achieve the stated objectives of this section in the subsidy housing sector • To regulate insurers contemplated in section 23(9)(a) NHBRC products and services In order to fulfil its mission the NHBRC is structured to provide a variety of valuable final products (VFPs) and services.

These are products (VFPs) and services.

These are: • Enrolment of new homes • Home-builder registration

• Home-building inspections • Home-builder training and development • Home-building dispute resolution • Litigation and legal advisory services • Geo-technical and materials engineering Enrolment of new homes New home builders need to be enrolled with the NHBRC before construction commences. With the enrolment of a home comes the necessary engineering input from competent persons that assist the home builder to take the necessary precautions in structural design, to ensure that the home is sound. An enrolment certificate is issued to all enrolled homes.

Subsidy housing At the onset, the mandate of the NHBRC did not cover the low-cost housing (subsidy) sector.

In February 2001, the Minister of Housing announced that the NHBRC Warranty Scheme will apply in the housing subsidy sector. In the subsidy sector, the NHBRC has initiated remedial works of housing-subsidy failures.

The organisation enrols new housing builds, conducts the geotechnical, civil and structural assessments required, inspects the builds and materials used and through its buildertraining programmes empowers builders in respect of product and technical knowledge.

When a house is enrolled, the NHBRC will conduct a minimum of four inspections on the home and deal with complaints and noncompliance during construction.

Alternative home building technologies The NHBRC has a vision to create a society living in secure, comfortable and decent homes.

The enrolled home will be covered for years by the NHBRC warranty scheme on major structural defects, from the day of occupation.

The NHBRC has been advocating the use of alternative technology in the home-building industry with the aim of providing quick to erect, quality and affordable products that would aid in eradicating the housing backlog in the country.

Home-builder registration Every home builder who is engaged in the process of building a home or selling a home should be registered with the NHBRC. Home builders undergo an assessment test to ensure that they meet the requirements.

They are also furnished with a registration certificate to show that they are included in the database of the NHBRC. Home-builder inspections Inspection services are provided to registered builders with enrolled projects/ homes to assist them in building homes with structural integrity, resulting in low levels of housing consumer complaints.

The Eric Molobi Housing Innovation Hub was launched in 2007, with the objective of identifying and supporting innovative housing systems developed nationally and internationally and which would provide a wider choice of quality and affordable homes to the housing consumer.

Contact details: Tel: +27 11 317 0000 Toll-free number: 0800 200 824 (SA only) Physical address 27 Leeuwkop Road, Sunninghill, Sandton, Johannesburg

www.nhbrc.org.za

Human Settlements

Energy optimisation of IBT homes The use of innovative building technologies (IBT) in low-income and affordable housing offers proven construction benefits, but it also presents opportunities to create thermally efficient structures – a view supported by a recent study comparing material systems on three homes at the Eric Molobi Housing Innovation Hub. By Dominique Geszler*

T

he South African government has encouraged the use of innovative building products to help solve the housing backlog.

However, more could still be achieved through sustainable design and resourceefficient interventions. Attaining sustainable homes with minimal or no upfront cost implications would have far-reaching benefits for the country and its people, even though these benefits are normally less tangible in the beginning.

Previous studies have failed to assess whether IBT homes that have the certification or rational design approvals actually show the relevant energy consumption reductions/ improvements. However, the recent study

undertaken by the National Home Builders Registration Council (NHBRC) at the Eric Molobi Housing Innovation Hub in Soshanguve has provided new empirical evidence.

The first objective of the study established how relevant ‘as-built’ IBT homes with Agrèment and rational design approvals per formed thermally in terms of energy savings. The second ascertained how these designs could be optimised in terms of energy efficiency and CO₂ emissions in relation to SANS 10400-XA requirements and what these benefits would actually mean.

Background context The South African government has provided more than 2.5 million low-cost houses and

another 1.2 million serviced sites. Over this period, the housing backlog has nevertheless increased from 1.5 million to 2.1 million units, while the number of informal settlements has gone up from 300 to 2 225 – an increase of 650%.

Environmental factors like minimising fossil fuel usage, energy pover ty, and climate change have become critical factors globally, but not yet intently addressed in South Africa’s subsidised housing sector. The main challenge in implementing energy efficiency in housing is that developers are reluctant to pay additional costs for a low-environmentalimpact house. However, there are norms and standards in place under the Department of Human Settlements, which took effect on

Table 1 IBT material specifications

Styrox

Eezybuilt

Shiebrook

Wall: 180 mm thick walls, consisting of 40 mm interlocking hollow expanded polystyrene building blocks – these blocks act as permanent insulation and shuttering, and are filled with 100 mm cementitious material Roof: 2 mm plastic roof tiles – no roof insulation and ceiling Floor: 100 mm concrete surface bed and ceramic floor tiles Windows: Single 6 mm floated glass in concrete frames Orientation: 345 degrees (DB angle) Area: 68.6 m²

Wall: 63 mm thick walls – the lightweight structurally insulated wall panel is used for the wall, floor and roof. The panel’s outer two sheets comprise 0.5 mm Chromadek steel cladding and a 62 mm polyurethane core Roof: The roof is comprised of the same panel as the wall Floor: Structural steel floor joists support the floor, which is the same panel as the walls Windows: Single 6 mm floated glass in standard steel window frames Orientation: 345 degrees (DB angle) Area: 62.7 m²

Wall: 150 mm thick walls – panels consisting of 3D welded wire mesh covering a 70 mm builtin expanded polystyrene insulation core. The panels are erected over steel reinforcing bars embedded in concrete foundations. Concrete is sprayed on to both sides of the panels to achieve the desired thickness (40 mm – 70 mm) Roof: The roof is comprised of the same panel as the wall Floor: The floor is comprised of the same panel as the wall Windows: Single 6 mm floated glass in standard steel window frames Orientation: 70 degrees (DB angle) Area: 54.9 m²

IMIESA August 2018

35

Human Settlements

Table 2 IBT thermal performance

IBT system

Actual CO₂ emissions (kg)

CO₂ emissions through optimisation (best results) (kg)

CO₂ emissions reduction potential (kg)

Styrox

1 363.88

1 281.97

695.57 (simulation)

Shiebrook

1 241.84

1 065.56

176.28 (optimisation)

Eezybuilt

1 094.86

615.36

479.50 (optimisation)

1 April 2014, to include energy-efficiency interventions.

There’s a strong argument for why South Africa should embrace energy efficiency in subsidised homes, especially since this country is one of the world’s largest emitters of greenhouse gases. South Africa’s dependence on coal has resulted in it having the highest levels of carbon dioxide emissions in Africa (accounting for 40% of total emissions) and being the 13th largest emitter globally.

Owing to environmental factors historically not being prioritised, people living in lowcost dwellings continue to spend significant por tions of their income on energy sources like fossil fuels, while suffering disproportionate health burdens.

Importance of IBTs IBTs demonstrate significant value-adding attributes, which could play a major role in the delivery of subsidised homes in South Africa.

CSIR investigations, for example, concluded that the national housing programme should prioritise the substitution of conventional material technologies with IBTs. Globally, IBTs form part of a larger initiative aimed at industrialising construction; i.e. the building process is more closely aligned with a manufacturing process: more of the components are manufactured and assembled on the factory floor and delivered to the construction site in modules of various sizes. This form of construction is known variously as off-site manufacturing, modular construction, modern methods of construction, and prefabrication.

IBT passes on key savings in terms of time (up to 35%) and cost (up to 41%) of construction, while improving the overall quality of construction. The need to create a stimulating and rewarding working environment is also a primar y driver, especially in attracting young people to the construction industry.

Thermal simulation For the NHBRC study, Design Builder simulation software was used to complete

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IMIESA August 2018

the ‘as-built’ IBT analysis in terms of energy efficiency. Design Builder is acknowledged as being one of the most comprehensive interfaces of the state-of-the-art Energy Plus building simulator, and is widely used by simulation experts and beginners alike.

Of importance is for the simulations to focus on the passive design parameters of the homes. The passive means of heating, cooling and lighting are closely related to building forms. The passive means are also the most important energy uses in a building, creating a strong influence on its form.

Method actually applied Three affordable IBT houses were selected to analyse energy consumption at Eric Molobi Housing Innovation Hub. These were show houses (without occupants). IBT systems were chosen to represent three different classifications: Classification A (lightweight), Classification D (hybrid), and Classification E (heavyweight).

The thermal per formance real-time results were unique for each system, so no direct comparisons could be made. The specifications for each system are indicated in Table 1.

For this paper, the homes were simulated to check how selected IBT systems performed in terms of energy consumption in kWh. Simulations were completed for the actual home, assuming there were occupants, SANS 10400-XA base-case, and improved specifications.

The optimisation was calculated within constraints (close to the actual) to determine improvements with minor or no cost implications.

Conclusion and recommendation It can be concluded that of the three IBT systems, the ranking of performance from worst to best in terms of total energy consumption was: Styrox at 2 262 kWh, with the highest usage; followed by Shiebrook, at 2 049 kWh; and then Eezybuilt, at 1 807 kWh. Although one cannot compare the three homes like-with-like, the results still indicated the design shortcomings of each house.

The heating and cooling loads using Design Builder indicated that Styrox required more heating than cooling (1 197.76 kWh heating and 394 kWh cooling) compared to the other two homes. In turn, Eezybuilt required more cooling than heating (245.82 kWh heating and 558.96 kWh cooling loads). Shiebrook also required more heating than cooling, but the loads were lower than Styrox (606.88 kWh for heating and 290.17 kWh for cooling).

When compared to the thermal performance results (undertaken in a previous study) using the ASHRAE 55 thermal comfort tool for summer, within acceptable 80% limits, similar trends were indicated, as shown in Table 2.

In the case of Styrox, the winter minimum temperatures did not comply with the thermal comfort limits; Eezybuilt did not comply with the maximum temperature thermal comfort limits in summer; and Shiebrook’s minimum temperatures in winter did not comply with the thermal comfort limits.

What this means is that the designs and specifications of the buildings at the time, as well as how the IBT system projects were approached/rolled out, were not optimised in terms of passive design elements. The improvements required from the variables chosen, such as the material thicknesses, window-to-wall percentage, cooling and heating set points, local shading and building orientation would have required minimal or no additional materials. On average, the three houses together could have reduced carbon emissions by 450.51 kg CO₂.

It is recommended that, when IBT projects are constructed, these variables are considered at the design stage to improve the performance and life-cycle costing of large-scale low-income housing projects.

Although the Agrèment certification provides some basic performance requirements, there is still potential to improve the passive design specifications of IBT homes to obtain better results.

Dominique Geszler* is an architect at the National Home Builders Registration Council.

The full version of this edited paper is available on request.

Geotechnical EngINEERING

Stabilisation and drainage

C

ompaction challenges caused by wet areas were effectively countered with a geotextile solution during the recent rehabilitation of a section of the R42, a provincial route in southern Gauteng.

The design included a pioneer layer of 500 mm dump rock wrapped completely (bottom, sides and top) with Kaytech’s RockGrid PC 50/50. An imported G1 blinding layer installed above provides protection for the geotextile.

RockGrid PC’s unique characteristics are derived from a nonwoven layer, offering

optimum drainage capacity and high installation survivability, in conjunction with high tenacity, bi-axially oriented multi-filament polyester yarns providing a high-tensile modulus.

To ensure adequate drainage, Kaytech’s FloDrain system was also specified. The in-plane drainage capacity of RockGrid PC will ensure the interception of migrating seepage, redirecting it to FloDrain collectors.

A premanufactured composite subsoil drainage system, FloDrain comprises a Flownet drainage core wrapped in a bidim filter jacket. The vertically installed FloDrain fin is connected to a Kaytech geopipe.

The latter’s 70% perforated surface area provides unsurpassed infiltration capacity.

In total, 6 500 m2 of RockGrid PC 50/50 was installed over the various wet areas, creating stable platforms on to which the normal road layer works could be placed, namely 500 mm dump rock, 150 mm lower sub-base C4, 150 mm upper sub-base C3, 150 mm base G1, and 50 mm asphalt.

The use of RockGrid PC and FloDrain provided the highest-quality basal reinforcement, separation and drainage, while significantly cutting down on the costs of the rehabilitation project.

11th ICARD | IMWA 2018 Conference International Conference on Acid Rock Drainage International Mine Water Association WISA Mine Water Division 10 – 14 September 2018 CSIR International Convention Centre Pretoria, South Africa

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A Green Conference www.ICARD2018.org www.IMWA2018.info

Geotechnical EngINEERING

A multifaceted approach ensures that all project phases are covered

by AECOM’s design team, starting with the right foundation.

R

ather than constituting a specialist service, geotechnical engineering is deployed in support of AECOM’s overall civil infrastructure capabilities, as the group explores growth opportunities in South Africa as well as further afield on the continent.

“Essentially, such an integrated solutions approach enables us to offer our clients a means of managing any attendant risk, due to the smooth interface between the different disciplines,” explains Dr Kim le Roux, lead: Environment and Ground Engineering for Africa. She has worked as a geotechnical professional for the past 20 years, most recently in Western Australia, with a particular focus on the mining industry.

Engineered from the ground up A major reclamation and ground improvement project

Given the cost associated with foundation work, a balance has to be struck between the expenses incurred versus the property value of the development site. “This is where ground engineering plays such a crucial role in terms of initial site ‘screening’,” Le Roux adds.

Current trends in ground engineering are refining the technology for non-intrusive investigation and improving the predictability of the results obtained. In collaboration with the larger Middle East and Africa region, AECOM has developed a high-end sensing capa-

bility that is ideal for larger sites. Innovation has also focused on foundation design itself, whereby technology applied successfully to the mining industry is redeployed in civil infrastructure and vice versa, in order to maximise any synergies.

Growth opportunities for geotechnical engineering are aligned with AECOM’s overall strategy for Africa, which focuses on largescale civil infrastructure requirements in Southern and East Africa, particularly in terms of road, rail and port developments connected to oil and gas expansion projects.

Geotechnical EngINEERING

Uganda The oil and gas sector in East Africa is on the verge of a major boom, with a number of greenfield projects in progress or at final design stages.

According to Bridget Ssamula, managing director, AECOM Uganda, the sector is embracing various procurement methodologies, from public-private partnerships through to design and build; engineering, procurement and construction; and engineering, procurement and construction management.

In addition, there is an increased focus on local content to ensure that the financial investment in the infrastructure sector trickles through to locally registered entities – a concept familiar to South Africa through the government’s supplier development programmes (SDPs).

“The experience AECOM has garnered through its own SDP has enabled us to propose and deliver local-content project offerings, based on the understanding that leaving a legacy of skills development, job creation and technology transfer is inherent in the way we deliver projects,” says Ssamula.

AECOM recently had to deal with a high-risk dolomitic site in Centurion

To date, AECOM has been involved in the environmental and social impact assessment for Total and Tullow for the Tilenga oil field development project in western Uganda. This project has posed a particular environmental challenge given its predominant location in the wildlife conservation areas of the Murchison

Falls and Queen Elizabeth National Parks.

AECOM Uganda was registered and incorporated in 2012; however, AECOM legacy companies have been in-country since the 1960s, with a project track record covering airports, roads, water, commercial buildings and hydropower.

IMIESA August 2018

39

Gabion designs with hog clips Elizabeth Park upgrade: river works and retaining walls Client: City of Cape Town Location: Belville, Cape Town Duration: Ongoing Engineers: AECOM Main contractor: Ditshimega Projects & Training Project value: R20 million

Alongside traditional installations like river embankment erosion protection and retaining walls, the use of gabions for architectural elements is another popular application.

New assembly techniques are further extending their versatility for engineering and building projects.

By Alastair Currie

A

growing trend is the use of gabions to build internal and external feature walls and terracing in place of conventional brick and mor tar or precast concrete for domestic, commercial and industrial developments, using in situ stone materials in some instances. A case in point is the greater Cape Town area, where river rock is commonly used as a gabion fill in place of shot rock imported from commercial quarries. â&#x20AC;&#x153;Eight to ten years ago, we were a mono-product supplier focused purely on civil engineering applications. However, the architectural side of our business has been gradually expanding, providing an excellent platform for diversification into the public

Environmental Engineering

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purpose. These can be specified in high-tensile galvanised steel, or stainless steel.

“We’ve been importing hog ring clips for the past five years or so, from either China or Italy, for the manufacturing and construction side of the business. Given the positive demand from our clients, plus escalating rand/dollar/euro costs, we took the plunge in 2018 and have now imported our own hog clip fabrication machine,” adds Cheyne.

The use of lacing is weaker and slower when it comes to on-site assembly. In contrast, hog clips are far faster to install and are extremely strong – virtually impossible to reopen. These C-shaped clips are closed using specialised tools. In the factor y, a pneumatic gun is employed; while for site work, there are various construction-grade, manually operated hand tools available.

One ring is required for ever y second mesh opening in terms of ASTM specifications.

However, when it comes to river projects, the recommended approach is to fit one ring per mesh opening to provide extra strength.

“Rather than carr ying bails of lacing wire to site, South African contractors now have the option of going the hog clip route and saving in terms of lower panel connection costs,” he continues.

“The process is still labour-intensive, so that’s a plus in terms of the Expanded Public Works Programme. Fast-tracked jobs also lower overall construction costs. From a health and safety perspective, hog clips also reduce the risk of installation injuries,” he concludes. In terms of current projects, Gabion Baskets assisted with the design

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External walls constructed with 50 mm x 100 mm square welded mesh

recommendations for a major remediation project in Alexandra entailing emergency repairs to eroded sections of the Jukskei River. Meanwhile, another river-worksrelated project where Gabion Baskets is providing materials is the ongoing Elizabeth Park upgrade in Bellville, Western Cape.

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Gabion Baskets’ local introduction of a new assembly technique aims to further simplify and speed up installations, while also adding a further aesthetic element. This follows the acquisition of a purpose-built machine to produce hog ring clips for the Southern African market.

In South Africa, the main assembly approach is to use Class A galvanised 2.2 mm mild tensile steel wire to weave and lace together the gabion basket panels.

However, Gabion Baskets is following the international shift towards the alternative use of specialised clips for this same

Contractor: Norland Construction

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New fabrication and assembly processes

New offices for Avbob Mthatha: architectural gabion elements and wall cladding

hog ring clips – bion a G

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and private building segments, including the affordable housing market,” explains Louis Cheyne, managing director, Gabion Baskets, which manufactures and provides design recommendations on gabion systems.

“A number of architects started out with standard hexagonal woven mesh, which is the norm for civil jobs. However, the demand for tighter tolerances subsequently led to the development of a variety of flat welded mesh configurations specifically made for architectural layouts,” he continues.

On a recent project in Mthatha, Eastern Cape, Gabion Baskets supplied 50 mm x 100 mm aperture square welded mesh for a new office development. Here, the architect used the gabions to form feature, boundar y and diversion walls to great effect.

An unusual element was the decision to frame the mesh walls on the edges using angled iron elements to make a distinctive statement. A vertical mesh design was also specifically fabricated for the gabion faces on this project. (The standard configuration is horizontal.)

“From time to time, we also receive enquiries on design recommendations for homes built from gabions,” says Cheyne. “The potential is definitely there for load-bearing and freestanding wall set-ups.”

IMIESA August 2018

41

Building resilience The 2018 instalment of the WISA Biennial Conference and Exhibition brought together almost 2 000 water professionals from around the globe at a time when Southern Africa faces increased uncertainty and vulnerability regarding water supply. By Danielle Petterson

F

itting for a conference held in Cape Town during the city’s worst drought in over a century, the focus of many of the speakers fell on resilience and the vital need to move toward more resilient water planning.

Cape Town is one of the cities in the 100 Resilient Cities network and is working on a major study of what resilience comprises.

Addressing the opening session, Western Cape Premier Hellen Zille highlighted what this means: being ready for all eventualities and being able to deal with them as they arise.

“The important thing is that resilience does not rely on old models of prediction because climate change is making those prediction models very unstable and very uncertain,” she said.

This has been made all the more apparent by the current drought in Cape Town, where

42

IMIESA August 2018

the models did not predict just how severe the drought would be. “Scenario planning is not what it used to be and for us on the cutting edge of having to make some key decisions, it is a major challenge.”

Another major challenge, said Zille, is who to listen to in a crisis. Amid a deluge of differing expert opinions, it is difficult to determine the best course of action.

This was particularly the case in Cape Town, where experts were pushing for large desalination plants – a course of action that proved to be ill-advised in Australia.

“How do you make those predictions and get those balances right, especially in a country like South Africa, when spending your budget is a zero-sum game, and when you have huge demands on a rapidly urbanising society?” questioned Zille. “On what basis do you start spending billions on

infrastructure that you may not need, but may be a question of life and death?”

Cape Town now seems out of the woods, with the municipality predicting that the city will not see Day Zero in 2018 or 2019, so long as restrictions are adhered to. Zille warned that people should not become complacent, but is optimistic that behaviour in the region and the national perception of water as a precious resource has changed permanently. “That change in perception is absolutely essential if we want to become a resilient country.”

However, there is a new challenge that this brings: as people move off of the water and electricity grids to become self-sufficient, funding service delivery becomes a major challenge. The costs remain the same while the market shrinks, and often that market is confined to the many people who can’t afford to buy private solutions. This creates

Water & Wastewater

Cementing international ties A new four-year MoU was signed by Minister of Water and Sanitation Gugile Nkwinti and the Netherlands’ Henk Ovink, special envoy for Water Affairs, at WISA 2018. Over the past four years, South Africa and the Netherlands’ cooperation commitment has generated almost €11 million (R175 million) for the water sector.

The Netherlands’ current total commitment to South African water projects stands at roughly €30 million (R478 million). In total, the projects generate about €90 million (R1.43 billion) in investments in South Africa’s water sector, excluding investments from the Dutch private sector. a huge problem of the poor having to rely on more and more expensive electricity and water.

“Wouldn’t it be ironic if the solution to the crisis actually exacerbated a deeper problem, which is inequality and differential access?” questioned Zille. “Our problems are not over; this has just been the hors d’oeuvre for what we require to become a resilient city.”

A call for better governance The challenge Cape Town faced in terms of governance and the drought was the role the Constitution assigns to various levels of government when it comes to water. These roles become critical in a crisis and every link in the chain needs to be working properly, explained Zille. She believes there is a long way to go to achieve this, but that a lot has been learnt through the water crisis.

Minister of Water and Sanitation Gugile Nkwinti agreed that there needs to be better cooperation and more openness. In line with this, his department has developed a five-pillar turnaround strategy, which includes: 1.

A national water resources and services authority to finance, develop, manage and operate national water resource infrastructure and sanitation.

2.

A national water resources and services regulator to independently regulate tariffs, standards and performance in the water services sector.

3. A water resources and services value chain that streamlines the current overly complex value chain comprised of a large number of institutions with divided functions.

4.

A water resources and services master plan that sets out prioritised actions and investments to be implemented between now and 2030.

5. Institutional rationalisation and organisational alignment to establish a business case for streamlined institutional rationalisation and organisational alignment in the water sector, in accordance with the outcomes of the Presidential Review Committee on Stateowned Enterprises.

“As a first step to give effect to these pillars, we have streamlined the organogram of the department in order to respond more efficiently and effectively to the challenges. As a second step, the National Water and Sanitation Master Plan will be shortly presented to Cabinet for approval. The five pillars are fully embedded into the master plan and the more detailed implementation plans will be finalised through an intensive round of stakeholder engagements, which will take place during the latter half of this year,” said the minister.

He believes WISA is well positioned to support the DWS and other government departments to address the many challenges South Africa faces.

“Through continued engagement on all water-related issues, strong partnerships, robust legislation and policies, and consistent implementation of our policies, we will be better placed to respond to the challenges of climate change, broadening access to water and BELOW LEFT Hellen Zille, premier, Western Cape BELOW RIGHT WISA board

sanitation services, ensuring acceptable drinking water quality and any other challenges that may confront us,” said Nkwinti.

A new vision Building on the minister’s speech, Dr Lester Goldman, CEO, WISA, spoke to the need for smarter water efficiency, infrastructure investment and collaboration. “If we are to meet South Africa’s future water challenges, smarter collaboration between us all is critical,” he said.

“The theme of this year’s event, ‘Breaking Boundaries, Connecting Ideas’, is the beginning of a new era in water,” he said. But to achieve this, the sector requires a few fundamental shifts: 1. Water resources are limited and we need to do more with less.

2.

Urbanisation is both an opportunity for economic growth and a threat to liveability.

3.

An uncertain future underpins the planning of our cities and the management of our ecosystems.

Water is essential for the well-being of citizens and the current thinking alone will not be sufficient to address the challenges of growing cities with growing demands, cautioned Goldman.

“Historical thinking will not be appropriate to plan future water systems. It can no longer be business as usual. As water professionals, we must inspire a new shared vision and, to achieve this, we will need to harness the power of collaboration, adapt our governance structures, engage smartly with all stakeholders and encourage active citizen involvement. It starts with us.”

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Water & Wastewater

Landmark plant for Umgeni Water

P

art of the Lower Thukela Bulk Water Supply Scheme (LTBWSS), the new bulk water treatment plant, constructed at a cost of R1.4 billion and funded by Umgeni Water and the Department of Water and Sanitation, will eventually supply approximately 340 000 people in the iLembe district with potable water, from inland of Mandini to Ballito in the south.

This will be the first time many of these people receive a reliable supply of safe drinking water.

In what is one of the largest municipal potable water treatment plants undertaken

by Veolia South Africa, Veolia was responsible for supplying the required mechanical and electrical components for the treatment plant

BELOW The plant is designed to supply roughly 340 000 people from inland of Mandini to Ballito BELOW RIGHT This R1.4 billion design and build project is one of the largest municipal potable water treatment plants undertaken by Veolia South Africa

A new 55 MLD potable water treatment plant will supply thousands of KwaZulu-Natal residents with clean drinking water.

as well as for the customised abstraction works that will pump water from the river.

“The remote location of the construction site required careful planning and logistical accuracy among each of the project stakeholders,” explains Pierre Michallet, senior project manager, Veolia Water Technologies South Africa. Veolia and its EPCM partners, as well as the primary stakeholders of the project, worked in close collaboration throughout the project to ensure successful execution and delivery.

The treatment process Raw water is abstracted from the uThukela River through a boulder and gravel traps system that prevents large matter from being deposited into the water treatment works. The stream is screened as it is split into four canals designed to allow finer sediments and sand particles to settle. The flow is further pumped from the low lift pump station up to the beginning of the water treatment – the hydrocyclone.

Additional filtering for sediment, grit, organic matter and heavy metals then takes place via gravity using clariflocculators, the Pulsator®

The 55 MLD treatment plant in iLembe has been handed over to Umgeni Water

pulsed sludge blanket clarifier and sand filtration. Underflow sludge accumulated across the treatment processes is dewatered through decanter centrifuges.

As part of the CPG proposal, Veolia was responsible for fostering and developing relevant professional and technical skills among the region’s communities that can be utilised in the operation and maintenance of the water plant. A coordinated recruitment plan was used to identify locally trained engineers, mechanical and electrical fitters, boilermakers, and other vocations that can be used in the plant’s operation. Veolia worked with Umgeni Water’s operations teams during the handover period in order to provide a seamless delivery of the plant at the end of July 2017.

Provision has been made to scale the plant’s potable water production capacity from 55 MLD up to 110 MLD, should it be required in the future.

IMIESA August 2018

45

Reuse with ultrafiltration The growing issues of freshwater scarcity in many parts of the world are encouraging more wastewater reuse ideas, which all depend on effective filtration.

T

Memcor CPII UF membranes are specially engineered to reduce design and installation requirements

he process of reusing water involves screening it to remove suspended solids, microbiological particles, inorganic salts and microorganics before disinfecting the by-product. Ultrafiltration (UF) has emerged as a more cost-effective water pretreatment solution to remove microbiological particles, as well as finer

Water & Wastewater

The factory-tested, pre-assembled skids take advantage of a ‘building block’ concept to achieve reduced valves, instrumentation and piping, simplifying design and operation

suspended solids prior to passing through reverse osmosis (RO) membranes, in the process preventing fouling. The UF process is also known for its ability to effectively remove viruses, bacteria and protozoa that could cause an immediate health risk.

For more than two decades, Cape Town-based company Quality Filtration Systems (QFS) has trusted Memcor CPII UF technologies for pretreatment in RO, recently installing three wastewater reuse plants in South Africa – two in the Western Cape and one in KwaZulu-Natal.

The Beaufort West facility in the Western Cape is a 2.3 MLD direct reclamation plant for drinking purposes. Memcor CPII UF membranes were installed to remove all total suspended solids (TSS) before feeding the treated water to a two-stage RO skid.

Permeate from the RO is further treated by ultraviolet (UV) light and hydrogen peroxide as an advanced oxidation step before being distributed. This plant has proved to be reliable and efficient, requiring minimal maintenance.

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Meeting potable and irrigation standards At Ballito, KwaZulu-Natal, the same pretreatment technologies are being used to remove TSS and microbiological particles greater than 0.04 micron before feeding the ensuing permeate to a two-stage RO skid. This municipal wastewater reuse plant treats 3 MLD of municipal sewer water to drinking standards.

Based on their reliability, the same technologies were used at the De Doorns plant back in the Cape. Here, 1.5 MLD of municipal wastewater is screened before being pretreated using Memcor CPII technologies. A combination of Memcor UF technologies, UV and granular activated carbon has been successful in treating the water to irrigation standards.

There are many factors that contribute to the outstanding per formance of Memcor CPII UF membranes, a key one being their robust hollow fibres. Their advanced PVDF formulation eliminates the risk of delamination, plus this fibre material is designed to be oxidant-free.

IMIESA August 2018

Memcor CPII UF skids are fully automated. The outsidein filtration set-up handles highly variable feedwaters and the proven air/water backwash efficiently removes solids.

Automated system drain-down further minimises the risk of contamination. Additionally, these units have direct integrity testing, ensuring that public health standards are met, plus their quick and easy installation ensures capacity needs are met on time and on budget.

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Water & Wastewater

Ensuring safe water for all Among the biggest challenges when it comes to water microbiology testing is achieving country-by-country approval. IDEXX Laboratories has overcome the related challenges, with approvals and acceptances in over 40 countries.

T

hrough its R&D and regulatory teams working with governments and supervisory bodies to adapt to local regulations and requirements, IDEXX has become one of the world’s leading water microbiology companies. Roughly 2.5 billion people drink water tested by IDEXX products every day, with over 22 million tests sold per year.

The company has a particularly strong footprint in sub-Saharan Africa, the company’s third biggest revenue region for the whole of Europe, the Middle East and Africa, says Andrew Headland, senior business manager: EMEA, IDEXX Laboratories.

IDEXX has invested significantly in its African business over the last two years and improved the way it manages its business in Southern Africa. “The region is now managed directly by IDEXX’s global Water Division instead of a local distributor, enabling us to be more focused. We now have two dedicated water salespeople, and a direct line to the UK office for technical and product support, enabling us to provide the best possible level of customer service to the water sector,” says Headland.

The company is also introducing modular, webbased training on basic microbiology and IDEXX products as part of the IDEXX Water Academy. “In Africa, we’re finding a huge desire for this type of training. We also bring people into our UK lab for training and send our analysts to specific labs for bespoke training where required,” he says.

Building on a strong product portfolio IDEXX recently launched a new product, Legiolert®, which specifically detects Legionella pneumophila – the primary cause of Legionnaires’ disease. This new test eliminates the subjective interpretation associated with the existing 20-year-old method,

which has been shown to indicate up to 40% false negatives.

“Previously, samples would have to be sent to a specialised lab for this kind of testing, but we’re opening up the market. We’ve had a lot of interest from local labs and municipalities, and the National Health Laboratory Service in Johannesburg is currently trialling Legiolert,” says Headland.

The test provides confirmed results within seven days and quality control can be performed in just 15 minutes.

This builds on the existing IDEXX portfolio of tests for detecting coliforms/Escherichia coli, enterococci, Cryptosporidium/Giardia, Pseudomonas aeruginosa, heterotrophic bacteria, and chlorine.

According to Brett Brewin, research scientist and technical manager: Water, IDEXX Laboratories, most labs worldwide test these parameters on a daily basis. “However, when you compare our tests to the traditional methods, we win on every account.

We can achieve high sensitivity and high specificity, with fewer false positives or false negatives, which can be very costly,” he says.

“But we don’t just sell a product; we sell a full solution. When you buy one of our tests, you also get a huge support network and training. Our lab in the UK provides full technical and product support for the whole of Europe, the Middle East and Africa.

We’ll investigate any issues our clients face, and conduct an analysis and investigation for them in our own lab if needed.”

Brewin believes that the IDEXX’s world-class expert team, focused purely on water microbiology, is what sets the company apart. “We have a small portfolio of products because we focus on the key things that work well, and couple them with training, backup and support, making IDEXX a world leader.”

IMIESA August 2018

49

82ND IMESA CONFERENCE

31st October to 2nd November 2018

2018

PORT ELIZABETH

Innovative infrastructure solutions CONFERENCE SOCIAL ACTIVITIES

GOLF DAY

S p o n s o r e d b y Te c r o v e e r Found in the coastal city of Port Elizabeth, Humewood golf course is a genuine seaside links, with wide and undulating fairways, fast greens and thick coastal bush. A round is a must for any golfer visiting the ‘Friendly City’ of Port Elizabeth.

CONFERENCE VENUE BOARDWALK HOTEL PORT ELIZABETH

Date: 30 October 2018 Venue: Humewood Golf Club Time: Registration from 9:30-10:30; shotgun start @11am Cost: R480pp (Fee covers Golf only) For players account: Hiring of Golf Carts and Caddies

COMPANION TOUR

Sponsored by AECOM Explore Route 67 filled with 67 Public Art Works celebrating our cities heritage and history. Be adventurous and climb the famous Campanile that contains the largest carillon of bells in the country. Tour the marine rehabilitation and education centre and experience nature through sight, sound and touch.

Dates: 31 October – 02 November 2018 Cost: R900pp (incl. entry to Opening & Thursday Social evening)

THURSDAY SOCIAL EVENING We having a BEACH Party! So come dressed for the occasion with your flip flops and something warm for the chills. Beer, wine and soft drinks will be freely available.

Conference endorsed by

Date: 01 November 2018 Venue: Happy Valley (under the bridge) Time: 18:30 for 19:00 Cost: Incl. in delegate full conference fee.

Exhibitors may purchase discounted event tickets.

Enquiries: conference@imesa.org.za

BOOK ONLINE NOW conference.imesa.org.za

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The Institute of Municipal Engineering of Southern Africa (IMESA)

IMESA

Meters, Pipes, Pumps & Valves

3D advances in pump designs

D

eveloping an electronic database of nearly half a million engineering design files doesn’t happen overnight. For APE Pumps, and sister company Mather+Platt, it has taken over 66 years of research and development, coupled with the ongoing design and fabrication of conventional and custom pump solutions.

“One of the strengths of APE Pumps and Mather+Platt is that we’ve never discontinued a range of pumps,” explains Richard Harper, project manager, APE Pumps. “This is definitely not the norm in our sector. Simply put, this means that we can refurbish or replace any of our units dating back to 1952. Plus, this pump will match the existing footprint, so there’s no need to change pipework.”

APE Pumps and Mather+Platt base their business success to date on ensuring that tried and tested technologies remain central to the business. “The classical training required for artisans and engineers hasn’t changed.

However, the tools available certainly have thanks to the advent of Industry 4.0 and the internet of things,” he continues.

A prime example of an ancient skill that hasn’t become redundant is wooden pattern making. At the company’s pattern making

shop, artisans can spend months crafting individual wooden pump models that will be used at the foundry to form the casting from the core box mould. Precise tolerances, to the exact micron, are essential for the final product.

“For our designers, the transition from formal drafting to CAD is greatly refining and accelerating the prototype development process thanks to the use of advanced simulation software, but the final casting models still need to be built by hand,” Harper points out.

Pushing the threshold Forming part of the multinational WPIL Group, APE Pumps, Mather+Platt and Italy-based sister entity Gruppo Aturia continue to play a key role

in South Africa and on the African continent in industry sectors that include mining, oil and gas, power, and municipal water supply. WPIL and APE Pumps are currently in the process of combining the group’s online pump selection programme into one format. This will make it easier for clients to make pump selections across a broad product range.

APE Pumps has also implemented a vault data management system that encrypts and protects the company’s information. This includes its engineering drawings, change orders and parts material lists. This database integrates seamlessly with existing design tools within the company and thus allows for flexible engineering options as per client requirements.

Using software simulation tools to refine a new prototype design

APE Pumps and Mather+Platt have access to nearly half a million unique design files produced over the past 66 years

IMIESA August 2018

51

Meters, Pipes, Pumps & Valves

Metering A vital resource Smart meters offer many benefits to municipalities, but the metering environment in many South African municipalities presents a minefield of challenges.

These must be overcome if municipalities are to reduce non-revenue water and increase revenue.

By Danielle Petterson

T

he installation of new water meters can reduce both unmetered and unauthorised consumption. In one municipality, it was found that about 40% of non-revenue water could be reduced by increasing customer metering. It is not just about repairing leaks or replacing pipes, says Dr Pieter Crous, senior engineer: Management Services, SMEC. Although savings can be made regardless of the meter type, smart meters offer several advantages.

Going ‘smart’ Smart meters can be categorised into two groups: prepaid meters and automatic meter reading (AMR) meters. AMRs typically consist of a conventional meter fitted with a communication device and user interface, while prepaid meters also include an automatic valve that is opened and closed based on the credit in the meter.

The biggest selling point of smart meters is that they are automated, explains Crous.

Smart meters aim to make the monitoring of meters simpler by gathering all the metering information into a centralised system, to see

52

IMIESA August 2018

to customers not paying their bills. Increased accuracy also leads to increased customer satisfaction.

The municipal experience whether customers are paying for services, to provide improved data on the billing system and, ultimately, to prompt the department to enhance billed consumption.

These meters enable municipalities to automatically see granular flow characteristics for a customer and automatically detect and flag customer leaks as they occur, as well as offer the ability to shut off water supply

Crous, together with SMEC, has worked throughout South Africa, and he presents experience from seven municipalities in the country. Some of these municipalities’ internal revenue was solely reliant on water services, making metering critical, while other municipalities had additional revenue streams.

Despite the critical nature of metering, there are many challenges municipalities face.

These include meters being buried or paved Automatic meter infrastructure

Meters, Pipes, Pumps & Valves

Smart meters

Prepaid meters

Token-based

STS-based

Postpaid meters

Automatic meter infrastructure

Driven by collection

information between departments. In one municipality, it took up to two years to update information on the billing system after the meter was installed.

These examples indicate that, despite the municipality choosing to install smart water meters, the smart meters were not a panacea for systemic challenges faced throughout the metering life cycle.

Conclusions

over, inaccessible meters, customers who won’t allow access to meter readers on their property, and information not uploaded to the billing system correctly.

In some cases, information from prepaid systems was added to the third-party systems but not to the municipal billing systems. The municipality could therefore not audit or validate the efficacy of these additional systems. In other instances, Crous found areas where meter readers were still physically reading AMR meters, even after they were automatically transmitting data.

In one municipality, there was no integration of tariffs and customers were charged through a prepaid system for their water consumption, as well as billed separately by the municipality for basic charges and

a connection fee, despite the fact that prepaid meters can accommodate both of these tariffs.

In another project, Crous found that about 2 000 customer meters weren’t being read where prepaid meters had been installed but the batteries ran flat. The municipality did not have a contract in place to ensure the meters were maintained, and these customers were not metered for years.

In many instances, meters are not on the billing system, or the customer data is incorrect, having a direct impact on revenue.

“Information on the billing system needs to be correct. If it’s not on the billing system, it doesn’t exist in municipal financial planning or the water balance,” he says. There are also often challenges in processing

“Metering is not a magical process,” cautions Crous. “Smart meters don’t install themselves. It is not about the smart meter technology only, but about getting back to the basics of how the metering processes work.

In order to reduce non-revenue water, municipalities will have to increase the customer metering component.”

He believes the barriers in metering are not a technology limitation. The main limitations are due to barriers within the management of staff and processes within the metering life cycle between the different stakeholders.

In principle, the installation of meters will increase billed consumption, whether smart or conventional meters. Prepaid meters, when working effectively, can be a means of reducing demand, but the systems need to be monitored and the processes followed and audited.

Crous cautions that although smart meters do make things ‘automatic’, they still require work. “You need people. As much effort as municipalities may be putting into specifying and selecting the appropriate meter technology, they need to spend time understanding their business and processes, from who is performing what, and what systems work, to proper management to enforce processes and monitor efficiency.”

Smart meters are also significantly more expensive and Crous recommends that municipalities first consider a feasibility study to determine the metering model that works for them. This will ensure that municipalities get value for money and a positive return on investment. Smart meters like AMRs should be prioritised for applications such as DMA meters, where the municipality can understand how its network operates, and how the AMR system works for it, before rolling it out to customers.

“Municipalities can improve billed consumption with or without the ‘smart’, but sustained metering requires a lot of interdepartmental collaboration, monitoring and processes,” concludes Crous.

IMIESA August 2018

53

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Transport, Logistics, Vehicles & Equipment

Commercial vehicle market shows resilience

A

ccording to the latest results, the commercial vehicle market ended the first half of 2018 with just a slight year-on-year decline of 1.3%. A total of 12 555 commercial vehicles have been sold this year. Meanwhile, statistics show that South Africa’s economy shrank from a quarter earlier, contracting 2.2% – the largest quarter-on-quarter decline since Q1 2009.

“Economic prospects look set to ride out the recent sluggishness of industrial output.

The South African commercial vehicle market has once again shown resilience amid challenging economic conditions.

Medium commercial vehicles

-7.1%

Heavy commercial vehicles

-6.3%

+5.0% Extra-heavy commercial vehicles

Buses

-1.3%

In addition, we believe that the stable current government will lead to more investment in infrastructure that, in turn, will increase commercial vehicle sales,” comments Gert Swanepoel, managing director, UD Trucks Southern Africa.

According to Swanepoel, the commercial vehicle market decline can mainly be attributed to the decrease in medium and heavy commercial vehicle sales, which haven’t picked up so far this year.

Sales in the medium segment are down 7.1% so far this year, to 3 644 units, while the heavy commercial vehicle segment saw a 6.3% decline, to 2 482 units, when compared to the same period in 2017. Bus sales are also down by a marginal 1.3%, to 462 units; however, the extra-heavy segment gained 5% during the first half of the year, to 5 967 units. “All things considered, we still believe that the market will end 2018 in the black, even if it is with a very slight margin, to reach around 25 400 units,” concludes Swanepoel.

IMIESA August 2018

55

82ND IMESA CONFERENCE

31st October to 2nd November 2018 B OA R D WA L K H OT E L

PORT ELIZABETH

2018

INNOVATIVE INFRASTRUCTURE SOLUTIONS

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Transport, Logistics, Vehicles & Equipment

hORIZONTAL dRILLS JT10 HHD

Mini multi-taskers

Trenchers, Horizontal Directional Drills and 2550GR

W

acker Neuson recently unveiled its two new mini excavator models in the 3.5 t class: the conventional ET35 and its zero tail counterpart, the EZ36, supplied with either rubber or steel tracks.

Designed for precise delivery thanks to their powerful hydraulics, the externally located guide rollers and optimised weight distribution on these machines ensure a high level of stability. Up to four additional control circuits are available to transform these units into versatile tool carriers, while an infinitely variable swivelling dozer blade with floating position can also be fitted.

A versatile option available on both models is a hydraulic clamp, or ‘thumb’, for the bucket. This feature makes gripping work easier – for example, when moving loose material such as branches, rocks or building rubble.

These excavators can also be equipped with Wacker Neuson’s Vertical Digging System (VDS). This tiltable, revolving superstructure provides additional flexibility and greater safety: inclines and declines of up to 27% can be compensated for at the push of a button. Through exact vertical digging, operators can save up to 25% in material and time when excavating and filling.

Based on the operating concept of the Wacker Neuson excavator models of the 6 t to 9 t class, the ET35 and EZ36 models optionally offer a 3.5 inch display in combination with a jog dial control element (rotary push knob). This is used for presetting and storing discharge volumes for hydraulic attachments, the engine speed control, as well as the monitoring of various functions.

The tie-down points have also been reworked on the new models: in total, eight large tie-down lugs on the vehicle chassis and on the dozer blade ensure quick and easy lashing, ensuring safe transportation.

IMIESA August 2018

57

Utility Guard Distribution and Product Support by:

www.elbequipment.co.za +27 (0)11 306 0700 elb@elbquip.co.za Branches and Dealers throughout South Africa and Southern Africa IMIESA August 2018

57

Transport, Logistics, Vehicles & Equipment

Compact milling The Wirtgen W 150 CF/W 150 CFi compact milling machine excels in surface course rehabilitation applications on medium to large job sites

T

he option of fitting a 1 800 mm milling drum assembly on Wir tgen’s W 150 CF/W 150 CFi unit increases the application range for this class-leading machine. Compact by design and powered by a 298 kW engine, the W

58

150 CF/W 150 CFi tackles a wide array of jobs. These include ever ything from small milling applications, such as partial road sur face repairs, to the removal of entire pavements.

With the Flexible Cutter System, users can switch between milling drums with

different working widths of 600 mm, 900 mm, 1 200 mm and 1 500 mm simply and ver y quickly. The new extension kit now enables users to extend the milling drum housing by 300 mm to 1 800 mm.

A larger cleat profile on the discharge conveyor of the W 150 CF/W 150 CFi guarantees optimum material transport, while high conveyor speeds ensure efficient loading. The extremely large conveyor slewing angle of 60 degrees to the left and the right enables milled material to be loaded under difficult site conditions, such as on traffic circles or crossings.

Since site-to-site mobility is a key requirement, Wir tgen has focused on optimising the machine transport weight despite the W 150 CF/W 150 CFi’s tremendous engine power to field the highest levels of productivity.

IMIESA August 2018

CLOSE TO OUR CUSTOMERS

For your success.

ROAD AND MINERAL TECHNOLOGIES. The WIRTGEN GROUP is a one-stop supplier of leading technologies encompassing the entire road construction cycle: From processing, mixing, paving and compaction back to rehabilitation. This is how close to our customers works, in the www.wirtgen-group.com/southafrica WIRTGEN GROUP. Find out more: www.wirtgen-group.com WIRTGEN SOUTH AFRICA (PTY) LTD. 52 Maple Street . Pomona . Kempton Park . 1619 . E-Mail: sales.southafrica@wirtgen-group.com

PROFESSIONAL AFFILIATES AECOM siphokuhle.dlamini@aecom.com Afri-Infra Group (Pty) Ltd banie@afri-infra.com AJ Broom Road Products ajbroom@icon.co.za ALULA (Pty) Ltd info@alulawater.co.za AQUADAM (Pty) Ltd sales@aquadam.co.za Arup SA candice.thorne@arup.com Aurecon Fani.Xaba@aurecongroup.com Aveng Manufacturing Infraset cgroenewald@infraset.com Averda claude.marais@averda.com Bigen Africa Group Holdings otto.scharfetter@bigenafrica.com BMK Group brian@bmkgroup.co.za Bosch Munitech info@boschmunitech.co.za Bosch Projects (Pty) Ltd mail@boschprojects.co.za BVI Consulting Engineers marketing@bviho.co.za Civilconsult Consulting Engineers mail@civilconsult.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za Development Bank of SA divb@dbsa.org.za DPI Plastics Farhana@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering Leonardus.Basson@honeywell.com ERWAT mail@erwat.co.za Fibertex South Africa (Pty) Ltd rcl@fibertex.com GIBB yvanrooyen@gibb.co.za GIGSA secretary@gigsa.org GLS Consulting nicky@gls.co.za Gudunkomo Investments & Consulting info@gudunkomo.co.za Hatch Africa (Pty) Ltd info@hatch.co.za Henwood & Nxumalo Consulting Engineers (Pty) Ltd pmboffice@hn.co.za Herrenknecht schiewe.helene@herrenknecht.de Huber Technology cs@hubersa.com Hydro-comp Enterprises dan@edams.co.za I@Consulting louis_icon@mics.co.za INGEROP mravjee@ingerop.co.za Integrity Environment info@integrityafrica.co.za IQHINA Consulting Engineers & Project Managers info@iqhina.co.za iX engineers (Pty) Ltd hans.k@ixengineers.co.za JBFE Consulting (Pty) Ltd issie@jbfe.co.za JG Afrika DennyC@jgafrika.com KABE Consulting Engineers info@kabe.co.za Kago Consulting Engineers kagocon@kago.co.za Kantey & Templer (K&T) Consulting Engineers info@kanteys.co.za Kitso Botlhale Consulting Engineers zimema.jere@gmail.com Knowledge Base info@knowbase.co.za Lektratek Water general@lwt.co.za Lithon Project Consultants (Pty) Ltd info@lithon.com Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Malani Padayachee & Associates (Pty) Ltd admin@mpa.co.za M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za

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

IMESA

Maragela Consulting Engineers admin@maragelaconsulting.co.za Marley Pipe Systems info@marleypipesystems.co.za Martin & East gbyron@martin-east.co.za Masithu Consulting & Project Management info@mcpm.co.za Mhiduve adminpotch@mhiduve.co.za Mogoba Maphuthi & Associates (Pty) Ltd admin@mmaholdings.co.za Moedi Wa Batho Consulting Engineers (Pty) Ltd info@wabatho.co.za Mott Macdonald Africa (Pty) Ltd johannesburg@mottmac.com Much Asphalt bennie.greyling@muchasphalt.com NAKO ILISO lyn.adams@nakogroup.com Nyeleti Consulting ppienaar@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za Pumptron info@pumptron.co.za Royal HaskoningDHV francisg@rhdv.com SABITA info@sabita.co.za SAFRIPOL mberry@safripol.com SALGA info@salga.org.za SAPPMA admin@sappma.co.za / willem@sappma.co.za SARF administrator@sarf.org.za.co.za SBS Water Systems mava@sbstanks.co.za Sembcorp Siza Water info-sizawater@sembcorp.com Sigodi Marah Martin Management Support lansanam@sigodimarah.co.za SiVEST SA garths@sivest.co.za Sizabantu Piping Systems (Pty) Ltd gregl@sizabantupipingsystems.com SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za SMEC capetown@smec.com SNA stolz.j@sna.co.za Sobek Engineering gen@sobek.co.za Southern African Society for Trenchless Technology director@sasst.org.za Southern Pipeline Contractors (Pty) Ltd spc@vinci-construction.com SRK Consulting jomar@srk.co.za Syntell julia@syntell.co.za TECROVEER (Pty) Ltd info@tecroveer.co.za TPA Consulting roger@tpa.co.za Ulozolo Engineers CC admin@ulozolo.co.za UWP Consulting nonkululekos@uwp.co.za V3 Consulting Engineers (Pty) Ltd info@v3consulting.co.za south-africa@vetasi.com Vetasi VIP Consulting Engineers esme@vipconsulting.co.za VUKA Africa Consulting Engineers info@vukaafrica.co.za Water Institute of Southern Africa wisa@wisa.org.za WAM TECHNOLOGY CC support@wamsys.co.za Water Solutions Southern Africa ecoetzer@wssa.co.za Wilo South Africa marketingsa@wilo.co.za WRP ronniem@wrp.co.za WRNA washy@wrnyabeze.com IMIESA August 2018 WSP Group Africa sam.herman@wspgroup.co.za

59

Transport, Logistics, Vehicles & Equipment

Big on performance

H

yundai’s latest-generation 25 t R260LC-9S hydraulic tracked excavator has entered the Southern African market, joining a comprehensive model line-up that extends from the 14 t R140LC-9S to the range-topping R1200-9, which weighs in at around 118 t.

“Notable features of the 9S series include advanced engine technology for high productivity, fuel efficiency and low emissions; computer-aided power for optimum control of the machine; and a high-strength operator cab, with exceptional visibility for greater safety on-site,” explains Alex Ackron, managing director of HPE Africa, the sole Southern African distributor for Hyundai earthmoving equipment.

“The redesigned hydraulic system ensures fast, smooth and precise control. Advanced hydraulic technologies offer improved pump flow, which minimises fuel consumption and the auto boom-swing priority function delivers maximum performance. Ground-line access to components enables easy maintenance, minimising downtime,” he continues.

Hyundai 9S series excavators are fitted with carefully selected components, designed for extended service life. Bushings have long-life lubrication intervals of 250 hours, hydraulic

filters offer a service life of at least 1 000 hours, and hydraulic oil offers 2 000 hours of service.

Efficient cooling systems and integrated preheated systems further extend service intervals and minimise operating costs.

For greater durability, the x-leg-type centre frame of the undercarriage is integrally welded, with reinforced box-section track frames.

Lubricated rollers, idlers, track adjusters with shock-absorbing springs and sprockets, and a track chain with double or triple grouser shoes form part of the robust undercarriage.

The R260LC-9S comes equipped with the new Hyundai Hi-Mate system, which enables users to remotely track and monitor machine performance. This advanced telematics system provides detailed reports of individual machines and a fleet’s working summary, supplying relevant information that is critical in preventative maintenance programmes.

Specifications: Hyundai R260LC-9S Operating weight (kg) 25 200 Max digging depth (mm) 6 450 Max dumping height (mm) 9 460 Bucket capacity (m³) 1.46 Net power (kW@rpm) 122 @ 2 000 Engine Tier II

The new Hyundai R260LC-9S: all buckets are welded with highstrength steel, and booms and arms are welded with a low-stress, full-box section design

index to advertisers 11th iCARD IMWA MWD

37

Dynapac SA

39

Sabita

19

Afrimat Shares Services

16

ELB Equipment

57

Sanral

9

Electra Mining Africa

31

Sizabantu Piping Systems

Afrisam

OFC,6-7

Alco-Safe

47

Ammann

OBC

BBF Safety Group

60

5

Grundfos IDEXX Laboratories IMESA

2

IBC

SMEC South Africa

38

IFC

Telematics

55

44,50,56,59

Terraforce

30

10

Bell Equipment

54

Much Asphalt

CAT Phones

20

NHBRC

34-36

Umgeni Water

48

Concrete Manufacturers Association

26

PPC

21-23

Wacker SA

18

Doosan International

17

Quality Filtration Systems

Wirtgen

58

IMIESA August 2018

46

Tosas

14-15