Imiesa July 2013 by 3S Media

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

2012

WINNER Non-professional ofessiona writer of the year HIGHLY COMMENDED Publishing Excellence

IMESA

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

EMS conversions in tth he

Water National Water Resource Strategy II

Infrastructure R1.2 billion for NMBM construction

Buffalo City Gonubie Road upgrade

“We pride ourselves on building services that enable people to better their lives.” Dempsey Naidoo, managing director of Mott MacDonald PDNA I S S N 0 2 5 7 1 9 7 8 V o l u m e 3 8 N o . 7 • J u l y 2 0 1 3 • R 5 0 . 0 0 ( i n c l VAT )

MEDIA

CONTENTS

VOLUME 38 NO 7 JULY 2013

53 CRCP solution

16 African review

37 Infrastructure construction

09 Resource strategy The official magazine of the Institute of Municipal Engineering of Southern Africa

2012

WINNER Non-professional ofessiona writer of the year HIGHLY COMMENDED Publishing Excellence

Insight

IMESA

Fiberpipe

Water resource strategy – Part 5 INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

Corestruc

Africa in review Project news from Africa Coastal protection works Entering new growth regions

Jan Kruger

16 18 22

Willie de Jager Structa Technology Rodney Cory

47 49 51

Water & wastewater Buffalo City

Air valves for pipeline project

24 27 30

Backing technology with experience

Pipes, pumps & valves

Asset acquisition secures investment

Leak detection installation

EMS conversions in tth he

Water National Water Resource Strategy II

Infrastructure R1.2 billion for NMBM construction

Improving living conditions

Buffalo City Gonubie Road upgrade

“We pride ourselves on building services that enable people to better their lives.” Dempsey Naidoo, managing director of Mott MacDonald PDNA

MEDIA

I S S N 0 2 5 7 1 9 7 8 V o l u m e 3 8 N o . 7 • J u l y 2 0 1 3 • R 5 0 . 0 0 ( i n c l VAT )

The benefits of a mid-size van-type ambulance include an ergonomically designed interior with a generously proportioned cockpit and comfortable seats, which offer a pleasant environment for the crew and patient comfort as well as sufficient storage and working space.

53 56

The real cost of metering

59 63 65 67 69

Water management essential for profits

Large diameter pipe installation Precision cuts with trencher Random quality tests

Industry news Addressing government’s infrastructure initiatives

WWTW nears completion

Project management muscle

Infrastructure construction Delivering employment and investment

CRCP solution for road upgrade

Products & services Concrete Institute services

Panel discussion Regulars 3 5

Editor’s comment President’s comment

Water reticulation and storage

Tenova Bateman Technologies

Merchen Naidoo

Cover article Vito: Ideal for EMS conversions

in th he

HO OT SE EAT

BVi Water Services Division

“We pride ourselves on building services that enable people to better their lives.” Dempsey Naidoo, managing director, Mott MacDonald PDNA

14 IMIESA July 2013

MORE CUBES FOR LESS WITH METSO AND CAT

速

Keep it Real. Keep it Cat

速

Metso Mobile has 3 new screening plants available ex stock at competitive 2012 pricing on orders taken in the next 60 days. Special crushing solution combinations of Cat 950H and Metso Equipment available at attractive promotional pricing. For more information contact your local Barloworld Equipment salesman or email: metsomobile@barloworld-equipment.com

EDITOR’S COMMENT

PUBLISHER Elizabeth Shorten EDITOR Richard Jansen van Vuuren HEAD OF DESIGN Frédérick Danton SENIOR DESIGNER Hayley Mendelow CHIEF SUB-EDITOR Claire Nozaïc SUB-EDITOR Patience Gumbo CONTRIBUTORS Candice Landie PRODUCTION MANAGER Antois-Leigh Botma PRODUCTION COORDINATOR Jacqueline Modise FINANCIAL MANAGER Andrew Lobban (ACIS, FCIBM) MARKETING AND ONLINE MANAGER Martin Hiller ADMINISTRATION Tonya Hebenton DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za PRINTERS United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________ ADVERTISING SALES Jenny Miller Tel: +27 (0)11 467 6223 ___________________________________________________

PUBLISHER: MEDIA No. 4, 5th Avenue, Rivonia 2056 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: richard@3smedia.co.za www.3smedia.co.za ANNUAL SUBSCRIPTION: R530.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2013. All rights reserved. ___________________________________________________ IMESA CONTACTS IMESA Administration Officer: Ingrid Botton P O Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: imesa@webstorm.co.za Website: www.imesa.org.za BORDER BRANCH Secretary: Melanie Matroos Tel: +27 (0)43 705 2401 Fax: +27 (0)43 743 5266 E-mail: melaniem@buffalocity.gov.za EAST CAPE BRANCH Elsabé Koen Tel: +27 (0)41 505 8005 Fax: +27 (0)41 581 2300 E-mail: elsabek@africoast.com KWAZULU-NATAL BRANCH Secretary: Rita Zaayman Tel: +27(0)31 311 6382 NORTHERN PROVINCE BRANCH Secretary: Cornel Taljaard Tel: +27 (0)82 899 8341 Fax: +27 (0)11 675 1324 E-mail: cornel@rchc.co.za SOUTHERN CAPE KAROO BRANCH Secretary: Henrietta Oliver Tel: +27(0)79 390 7536 Fax: 086 536 3725 E-mail: imesa.southcape@gmail.com WESTERN CAPE BRANCH Secretary: Erica van Jaarsveld Tel: +27 (0)21 938 8455 Fax: +27 (0)21 938 8457 E-mail: erica.van_jaarsveld@capetown.gov.za FREE STATE AND NORTHERN CAPE BRANCH Secretary: Wilma Van Der Walt Tel: +27(0)83 457 4362 Fax: 086 628 0468 E-mail: imesa.fsnc@gmail.com REST OF SOUTHERN AFRICA Representative: Andre Muller E-mail: imesa@webstorm.co.za

All material herein IMIESA is copyright protected and may ay not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

The cat is dead... long live the cat The Minister in the Presidency, Trevor Manuel, has been fending off recent criticism of the National Development Plan (NDP) saying it was never meant to be a “perfect” document.

ANUEL HAS pointed out that the country could not afford to wait for a perfect moment to implement the initiative – therefore it had to start as soon as possible regardless of circumstance. The NDP is still in early implementation and the potential it holds in the infrastructure construction sector involves creating five million new employment opportunities by 2020. The Presidential Infrastructure Coordinating Commission (PICC) hopes to realise the goals set out by the national government for the rolling out of infrastructure in the medium to long term – with a particular emphasis on the Strategic Integrated Projects (SIPs). The NDP is a long-term vision and it is still way too early to criticise its efficacy. It is the starting point of a journey that we are all going to be part of in the coming years. Personally, I am taking the precedent of the ‘Schrödinger’s cat’ theory to heart when it comes to evaluating the NDP. This results from my fondness for the documentary series Through the Wormhole, which leads me to believe I could understand the theories of quantum mechanics. This was an opportunistic outlook, considering years ago I read the first few pages of Stephen Hawking’s A Brief History of Time and realised I had no idea what the words on the page meant. Feeling confused and humbled, I was relieved to hear that a version of the book for the average person was available – A Briefer History of Time. The premise was very misleading and my knowledge of the history of time remains to this day remains… stunted. The official magazine of the Institute of Municipal Engineering of Southern Africa

2012

WINNER Non-professional ofessiona writer of the year HIGHLY COMMENDED Publishing Excellence

Then, one night, Morgan Freeman, the narrator of Through the Wormhole began speaking about Schrödinger’s cat. Bear with me. Schrödinger’s cat is a thought experiment that illustrates what Austrian physicist Erwin Schrödinger saw as the problem of the Copenhagen interpretation of quantum mechanics applied to everyday objects, resulting in a contradiction with common sense. The scenario presents a cat that may be both alive and dead, depending on an earlier random event. The Copenhagen interpretation is the most commonly held interpretation of quantum mechanics. In the Copenhagen interpretation, a system stops being a superposition of states and becomes either one or the other when an observation takes place. This experiment makes apparent the fact that the nature of measurement, or observation, is not well-defined in this interpretation. The experiment can be interpreted to mean that while the box is closed, the system simultaneously exists in a superposition of the states “decayed nucleus/dead cat” and “undecayed nucleus/living cat”, and that only when the box is opened and an observation performed does the wave function collapse into one of the two states. This is heavy stuff. My theory in a theory, one of which I am quite proud, proposes the premise that the NDP is the cat, project implementation is the box and only we can open the box represented by the policy and bureaucratic procedures when the box has been around for a while. We know the cat is in the box – simultaneously both alive and dead – and that sets a scenario for an interesting starting point!

IMESA

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 t cover story and maximum exposure. For more information on cover bookings contact Jenny Miller on tel: +27 (0)11 467 6223.

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

EMS conversions in tth he

Water National Water Resource Strategy II

Infrastructure R1.2 billion for NMBM construction

Buffalo City Gonubie Road upgrade

IMIESA July 2013 MEDIA

PRE- CONFERENCE WORKSHOP ON SALGA/WRC’s NATIONAL MUNICIPAL BENCHMARKING INITIATIVE FOR WATER SERVICES

How best can you improve your operational efficiencies? How can you adopt best practice efficiency innovations by your peers? Municipal Engineers, Municipal Officials, Municipal Councillors are encouraged to contribute to a dynamic and practical workshop focusing on key municipal benchmarking learning’s and progress: improving efficiency and effectiveness through performance benchmarking, peer-to-peer operational knowledge sharing, and benefiting from municipal peer group networks

SALGA/WRC Municipal Benchmarking Initiative: for municipalities, by municipalities, to the benefit of municipalities

21 and 22 October 2013 – 08.30 to 16.30, The Boardwalk Hotel & Conference Centre, Port Elizabeth Cost per delegate: R1, 800 (incl. VAT) (2 CPD points) Registration Form and Agenda Requests: training@imesa.org.za or click the IMESA Conference Logo Enquiries: IMESA PRE-CONFERENCE: Judy Stephens @ 031 2663263 Registration closes 4 October 2013 (limited to 100 delegates) CPD Validation No.

Provider

IMESA13-C09NAT

IMESA 031 266 3263

IMESA12-S14NAT

IMESA 031 266 3263

IMESA11/L01NAT

IMESA 031 266 3263

Description 2013 IMESA Pre Conference Municipal Benchmarking Workshop The SALGA IMESA MILE MBI Water Services Master Classes 2011 IMESA Pre Conference Municipal Benchmarking Workshop

Duration

CPD Points

2 days

1 day

CPD Validation no. for upcoming MBI workshop; 2012 Water Services Master Classes; 2011 MBI workshop

PRESIDENT’S COMMENT

SALGA’S MUNICIPAL CROSS CUTTING CHALLENGES

Funding bulk infrastructure and institutional arrangements In SALGA’s Voice of Local Government magazine (issue 7), Pascal Moloi, a commissioner in the National Planning Commission, states: “A conducive environment is essential to the attainment of the overarching goals of the National Development Plan,” adding that in order to deliver these, local government must provide the necessary amenities and services.

N THE SAME issue, Xolile George, the CEO of SALGA (South African Local Government Association), emphasises SALGA’s efforts to engage with municipalities on a continuous basis and to continue using platforms at its disposal to

interact on municipal finance and good governance in municipalities. It is in this light that SALGA BELOW The establishment of the envisaged bulk infrastructure fund must be accompanied by appropriate institutional arrangements

regularly refers to the valued partnership and cooperation that exist between itself and IMESA. Representing IMESA, I recently attended a one-day workshop held by SALGA, at Karridene on the KwaZulu-Natal South Coast, to discuss constraints such as the lack of funding for bulk infrastructure nationally. The need for a sustainable funding model was identified, and SALGA has commenced discussions with government regarding the introduction of a bulk infrastructure grant. Having started in KwaZuluNatal, this was the first of a number of workshops that will endeavour to seek meaningful input from local and district municipalities. The establishment of the envisaged bulk infrastructure fund must be accompanied by appropriate institutional arrangements for managing the ongoing operation and maintenance of these investments. There will be more urgency placed on the review of the local government fiscal framework and the implementation of rural rates and service charges is seen as vital. Emphasis will be placed on the following five

Frank Stevens, president of IMESA

infrastructure sectors: • electricity • roads • waste management • water supply • sanitation. Additional sectors such as public transport will also probably be included. IMESA has stated that the importance of regional and integrated planning is crucial and it has been pointed out by SALGA that the IMESA/SALGA and Water Research Commission benchmarking initiative, which is well under way, would be a vital tool throughout the project, and issues such as close alignment with municipal infrastructure grants will also need attention.

IMIESA July 2013

COVER STORY

MERCEDES-BENZ VITO

Ideal for EMS conversions The Mercedes-Benz Vito is an ideal base vehicle for conversion of ambulances for shor t- to mediumdistance transfers, mobile intensive care units and mobile clinics.

IMIESA July 2013

COVER STORY

HE BENEFITS OF a mid-size van-type ambulance include an ergonomically designed interior with a generously proportioned cockpit and comfortable seats, which offer a pleasant environment for the crew and patient comfort as well as sufficient storage and working space. Nicolette Lambrechts, brand manager for Mercedes-Benz Vans, says: “With its generous working area, high roof with rear wing doors and a low, ergonomic loading height for the stretcher, the Vito panel van offers unmatched versatility to the emergency services industry.” Lambrechts adds that Mercedes-Benz panel vans are versatile and can be converted into any emergency medical services (EMS) conversion requirement or solution. “We work with recommended bodybuilders that adhere to strict Mercedes-Benz bodybuilder directives. We also interface closely with the customer to

Mercedes-Benz Vito specs • 113 CDI (100 kW/310 Nm) or 116 CDI (120 kW/360 Nm) • two wide sliding doors (985 mm wide x 1 259 mm high) • through-loading width of 1 277 mm between the wheel arches • load compartment height 1.35 m, or 1.76 m in high-roof models • flat load compartment floor with loadsecuring rings • side-wall panelling in painted hardboard and continuous interior panelling up to roof height available as an option.

Mercedes-Benz panel vans are versatile and can be converted into any emergency medical services conversion requirement or solution

understand their application requirements,” Lambrechts continues. The prototype is then built and approved with the bodybuilder to ensure that it meets customer satisfaction and legal regulatory standards from National Regulator for Compulsory Standards.

Driver assistance The Vito’s intelligent driver assistance and safety systems are best in class and include Adaptive ESP, which maintains vehicle stability and superior handling in emergency situations. When it comes to interior design, the Vito is tough to beat. Its practical equipment and appointments, along with a wealth of intelligent system solutions, offer flexible usage options and allow a high degree of individualisation and specialisation for an emergency vehicle conversion. Safety a priority Mpumelelo Zulu, Mercedes-Benz Vans product manager, says: “Safety is essential for emergency services and it is one of the factors that have helped to make the Vito so popular. Our engineers have paid particularly close attention to the aspects of the vehicle that affect the customer’s bottom line: reliability, long-service life and engines that combine fuel economy with ample power reserves.”

Zulu elaborates that in the emergency services sector, quick response time, vehicle reliability and safety are of crucial importance. “Emergency ser vice personnel require a vehicle that is capable of responding to the demands and challenges they face when attending to cases. We firmly believe that the Mercedes-Benz Vito is up to the task. Additional benefits of using a Vito as EMS conversion are use of Code 8/B Licence for drivers, long service intervals of up to 30 000 km as well as an extensive MercedesBenz Dealer footprint nationwide. “We also offer driver training and CharterWay service and maintenance contracts in order for the customer to maximise the benefits that the Mercedes-Benz Vito offers. To ensure maximum uptime, we have a customer response centre and we are monitor all cases at head office level,” Lambrechts concludes.

t +27 (0)12 677 5936 • www.mercedes-benz.co.za

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

IMIESA July 2013

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

IMESA

Afri-Infra afri-infra@mweb.co.za AJ Broom Road Products ajbroom@icon.co.za Arup SA rob.lamb@arup.com Aurecon danie.wium@aurecongroup.com AECOM siyanda.ngebulana@aecom.com Bigen Africa Group Holdings otto.scharfetter@bigenafrica.com BMK Consulting brian@bmkconsulting.co.za Bosch Stemele bsdbn@boschstemele.co.za Bosch Munitech info@boschmunitech.co.za BVI Consulting Engineers marketing@bviho.co.za CBI Consulting Engineers durban@cbisa.co.za Civilconsult Consulting Engineers mail@civilconsult.co.za Civil & Blasting Solutions jane@drillingandblasting.co.za Concrete Manufacturers cma@mweb.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za CSIR Built Environment laustin@csir.co.za Davies Lynn & Partners dlpdbn@dlp.co.za Development Bank of SA divb@dbsa.org.za DPI Plastics mgoodchild@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering keith.bailey@za.elster.com EnviroServ Waste Management benoitl@millenniumwaste.co.za GIBB yvanrooyen@gibb.co.za GLS Consulting nicky@gls.co.za Hatch Africa leratom@goba.co.za Huber Technology fstammer@lantic.net Hydro-comp Enterprises dan@edams.co.za I@Consulting louis_icon@mics.co.za Iliso Consulting hans@iliso.com Infraset fmyburgh@infraset.com Jeffares and Green dennyc@jgi.co.za Johannesburg Water rtaljaard@jwater.co.za Kgatelopele Consulting kgatelopele@wol.co.za Knowledge Base info@knowbase.co.za Lektratek Water general@lwt.co.za

Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Maragela Consulting Engineers admin@maragelaconsulting.co.za Mhiduve deond@mhiduve.co.za Much Asphalt john.onraet@murrob.com Nyeleti Consulting ppienaar@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za PD Naidoo & Associates Consulting Engineers Johannesburg@pdna.co.za Pumptron info@pumptron.co.za Pragma Africa deang@pragma.co.za Rocla karen.devos@murrob.co.za Royal HaskoningDHV francisg@rhdv.com SBS Water Systems irene@sbsgroup.co.za Sektor Consulting cradock@sektor.co.za Sight Lines sales@sightlines.co.za SiVEST SA garths@sivest.co.za SNA Inc snapta@icon.co.za Siza Water Company tionette.bates@sizawater.co.za SMEC capetown@smec.com Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Sulzer Pumps Wastewater sales.abs.za@sulzer.com Syntell julia@syntell.co.za Thm Engineers East London thmel@mweb.co.za TPA Consulting roger@tpa.co.za UWP Consulting craign@uwp.co.za VIP Consulting Engineers esme@vipconsulting.co.za Water Institute of Southern Africa wisa@wisa.org.za WorleyParsons chris.brandsen@WorleyParsons.com WSP Group Africa dirk.hattingh@mbs-wsp.co.za WSSA nbinase@wssa.co.za WRP ronniem@wrp.co.za Zebra Surfacing andrew@zebrasurfacing.co.za

INSIGHT

WATER RESOURCE STRATEGY – PART 5

Addressing the challenges The vision underpinning the National Water Resource Strategy 2 (NWRS-2) is a democratic, people-centred nation with equitable social and economic development enabled through equitable, sustainable and effective water management. Compiled by Richard Jansen van Vuuren

LSO INCLUDED in the vision are these vital points: • water valued and recognised as a strategic national asset and fulfilling its central role in society and the economy • a prosperous society enjoying the benefits of clean water and hygienic sanitation services • a healthy, ecologically sustainable and protected water environment • a Department of Water Affairs and related water management institutions that serve the public effectively and loyally, meet their responsibilities with integrity, transparency, energy and compassion • a committed and dedicated water sector, actively cooperating and contributing towards sustainable water management and associated outcomes. This vision reflects and builds upon the principles of equity, efficiency and environmental sustainability that underpin the National Water

Policy and National Water Act. The policy and legislation are founded on the principles of integrated water resources management. However, it is necessary to reinterpret these principles within the context of a developmental state and recognise the linkages across the entire value chain from resource to tap and back to resource. This gives rise to the concept of developmental water management (DWM), which takes, as a central premise, the fact that water plays a critical role in equitable social and economic development and that the developmental state has a critical role in ensuring that this takes place. The core objective of this strategy is to introduce, facilitate and lead South Africa into a new era of smarter and DWM. The new approach builds on successes from the post-1994 period, BELOW Sustainability and equity are identified as central guiding principles in the protection, use, development, conservation, management and control of water resources

incorporates the lessons learned over this period (in South Africa and internationally) and draws on the development and equity imperatives of the government. It addresses both short-term challenges and longer-term sustainability and equity objectives. Key elements are: • A rigorous focus on implementation of policy and legislation, applying basic principles of good governance (“do the basic things right”). This includes good planning, effective organising, leadership, and control and programme management. • Extending water governance to include integrated planning, governance and sector partnerships, looking outside the water box to work with other critical sectors such as agriculture, mining, land reform, industrial development and environment. • Ensuring the involvement of stakeholders and sector partners in planning and management of water resources, including the marginalised and the poor. 

IMIESA July 2013

INSIGHT

ABOVE Work on the Gqobonco Nkondlo Bulk Water Supply Scheme LEFT It is essential that commitment to the new DWM approach is obtained from all stakeholders and that compliance to this approach is actively monitored and managed

• Continuing to extend the water management model to include options such as water use efficiency, local resource optimisation (groundwater), reuse, desalination, systems optimisation, improved regulation and control. • Taking a comprehensive view of water management across the entire value chain from resource to tap and back to resource. • Applying smart solutions by focusing on functionality, sustainability, technology, accountability, sector involvement and ownership, and harnessing the considerable research and development capability in South Africa behind this programme. • Mobilising the extensive capacity and knowledge in South Africa, including at the community level and in the NGO and private sectors, and drawing from a range of knowledge sources including indigenous knowledge systems. • Building a capacitated sector and workforce.

IMIESA July 2013

• Applying effective management principles such as life cycle management, sound asset and financial management, customer care and communication. • Ensuring the speedy establishment and transformation of the necessary water sector institutions to achieve implementation of the national water resource strategy and the aims and objectives of national water and development policy. • Measuring impact by a focus on the achievement of outcomes, not just outputs. It is essential that commitment to the new DWM approach is obtained from all stakeholders and that compliance to this approach is actively monitored and managed. It requires strong leadership to motivate and direct stakeholders along the transformation process and to manage their performance in a constructive cooperative and outcomes-based manner. It also requires diligent risk management to ensure that the transformation is effected in full compliance with legislation and consideration of environmental circumstances. The main challenge is to ensure that water managers across the board understand what is required and commit to implementation and ensuring achievement of goals. While there has to be realism in terms of ability and available resources of what can be achieved, the challenges demand brave and bold action and commitment to raise water management to a higher level. Water governance can be referred to as the

range of political, social, economic, organisational and administrative processes through which interests are articulated, input is absorbed, decisions are made and implemented, and decision-makers are held accountable in the development and management of water resources and delivery of water (and sanitation) services at different levels of society (modified from Nowlan and Bakker, 2007). According to United Nations Development Programme, water governance: • is about developing and managing water resources and delivery of services • includes a range of issues intimately linked to water – from health and food security to economic development, land use and the preservation of the natural world on which water resources depend • is concerned with drawing up and adopting the right laws, policies and institutions – also how these are established, enforced and implemented; governance in the water sector has political, administrative and economic dimensions and includes both the activities of government, as well as the interaction of civil society with these processes. Good water governance requires predictability, participation, transparency, equity, accountability, coherence, responsiveness, integrated and ethical decision making. This must be built around open policymaking, a professional bureaucracy and a strong engaged civil society. While the regulatory framework and institutional arrangements have changed since the advent of democracy, the water sector is still facing challenges. Such diagnosis raises our hope that the crisis can be averted by improving water use and management. But the task is extremely difficult, as it involves significant changes in the way water resources are developed, allocated and managed. At the heart of the NWRS-2 is how to design and sustain these changes on a durable basis within the economic, ecological and capacity constraints. Although much has been achieved since 1994, the performance of the sector has fallen short of expectations in three important respects. The outcomes of the sector relative to sector goals have been disappointing. Although substantial progress in increasing access to water and sanitation has been made, this progress has slowed in recent years and the number of people without adequate services is still too large, particularly among the poor. Second, progress in allocating water for productive purposes to promote transformation has been very slow and water use patterns are still highly skewed and unequal. Third, the

INSIGHT

stresses on water are increasing and water is not being managed in a sustainable manner. In other words, service delivery has fallen short of expectations.

Uncertainty and a lack of clarity lead to poor performance Proposed institutional reforms such as the creation of catchment management agencies and an entity to manage national water infrastructure have not taken place. In addressing this poor performance, it is necessary to address legal, institutional and implementation issues. The National Water Act and the Water Services Act are currently under review in order to address a number of challenges currently faced in the water sector. Promoting a deliberative and participatory agenda will also require adjustments in the structure and functions of water institutions. Issues related to expertise, accountability and democratic authority must be addressed in an integrated way at the highest level in the Department of Water Affairs. There is therefore the need to strengthen the capacity of the department at local, regional, and national levels to integrate the consolidation of democratic practices across the sector. But the intensity and scope of consolidation needed to advance democratic practices exceeds the mandate of any one department. All departments and non-governmental entities that have a direct relevance to water should be involved. Aligning all such departments and organisations to focus on water requires the use of political capital. The NWRS-2 addresses the proposed institutional arrangements to improve water resources BELOW Pipe jacking activities to accommodate a water pipeline running underneath a major highway BELOW RIGHT The installation of a large diameter water pipeline

management, within a governance framework that ensures that all water management institutions serve the national developmental agenda.

Core values Sustainability and equity are identified as central guiding principles in the protection, use, development, conservation, management and control of water resources. These guiding principles recognise the basic human needs of present and future generations, the need to protect water resources, the need to share some water resources with other countries, the need to promote social and economic development through the use of water and the need to establish suitable institutions in order to achieve the purpose of the Act (Summary of Chapter 1 of the National Water Act). Making it happen: The core water strategies The National Water Resources Strategy encompasses the following critical thrusts: • Building an efficient water administration by fostering innovation and knowledge management, investing in people’s capabilities, cultivating a more water educated and literate society, as well as increasing economic growth and social development. • Promoting an equitable water sector by eliminating unequal access to water and reducing imbalances within and among groups as well as regions, perpetuated largely by pervasive administrative inefficiencies. • Sustaining high water infrastructure investment and development by strengthening the sources of growth, the financial, corporate and water institutions as well as investing in pro-poor local level infrastructure. • Enhancing indigenous knowledge systems to meet the challenges of globalisation, focusing on the role of women and the youth.

The Water Research Commission should be required to conduct research on indigenous knowledge systems, focusing on the role of women and the youth. • Developing a knowledge-based water sector as a strategic move to raise the value added of all water initiatives and optimising the brain power of the nation. In this regard, also, the Water Research Commission has a special role to play. • Strengthening human resource development to produce an efficient, effective and knowledgeable workforce. • Pursuing water security and environmentally sustainable development to reinforce longterm growth. • Pursuing sound infrastructure management, and ensuring prudent investment policies as well as enhancing efforts to develop a knowledge-based water economy. • Strengthening and streamlining redress strategies and mechanisms to ensure balanced participation among and within cultural and income groups as well as enhancing performance of water institutions through improvement in user’s knowledge, skills and expertise as well as upgrading innovation, science and technology. • Increasing efficiency and economic growth through accelerating the shift of the workforce towards more efficient performance processes and high-value added activities. However, this should not be done at the expense of jobs and the growth must have job creation as its basis and rationale. • Expanding the usage of ICT across and within the water sector to accelerate the growth process. • Strengthening the human resource base to ensure the availability of person power with higher levels of knowledge, technical and analytical skills. • Adopting an integrated approach in addressing water quality and environmental issues to attain sustainable development. • Enhancing further the quality of life through improving accessibility to quality water as well as developing the aesthetic and spiritual dimensions of water.

IMIESA July 2013

SALGA / WRC National Municipal Benchmarking Initiative Workshop IMESA Conference 2013 st

21 and 22 October 2013 – The Boardwalk Hotel & Conference Centre, Port Elizabeth

Programme and Content DAY ONE: MONDAY, 21 OCTOBER 2013 08:30 – 09:00 Registration and Tea/Coffee 09:00 – 09:30 Opening Session: Welcome and Introduction 09:00 – 09:10 Welcome remarks by IMESA 09:10 – 09:20 Remarks by SALGA 09:20 – 09:30 Remarks by Benchmarking Ambassador 09:30 – 10:00 Overview of the National Municipal Benchmarking Initiative –update on key progress to-date 10:00 – 11:00 Session 1: Water Conservation and Demand Management 10:00 – 10:30 The two things you need to know to start constructing an IWA Water Balance 10:30– 11:00

Current status, key findings and emerging trends

11:00 – 11:15 Tea/Coffee Break 11:15 – 12:00 Session 1: Water Conservation and Demand Management (cont) 11:15 – 11:45Group facilitated discussion: Water Conservation & Demand Management What do I currently know? What do I need to know to move forward? How can my peer group help me? What PIs can I track? 11:45 – 12:00 Report back by groups 12:00 – 13:00 Session 2: Human Resources and Skills Development 12:00– 12:30

Which is my “real” organogram: the ideal, funded or filled organogram? Does my organogram meet my service delivery needs?

12:30 – 13:00 Current status, key findings and emerging trends 13:00 – 13:45 Lunch 13:45 – 14:30 Session 2: Human Resources and Skills Development (cont) 13:45 – 14:15Group facilitated discussion: Human Resources & Skills Development What do I currently know? What do I need to know to move forward? How can my peer group help me? What PIs can I track? 14:15 – 14:30 Report back by groups 14:30 – 15:30 Session 3: Service Delivery and Backlogs 14:30 – 15:00 How does scheme functionality impact your service delivery? 15:00 – 15:30 Current status, key findings and emerging trends 15:30 – 15:45 Tea/Coffee Break 15:45 – 16:30 Session 3: Service Delivery and Backlogs (Cont) 15:45 – 16:15Group facilitated discussion: Service Delivery & Backlogs What do I currently know? What do I need to know to move forward? How can my peer group help me? What PIs can I track? 16:15 – 16:30 Report back by groups 16:30

Closure: Day One

16:30 – 18:00 Sponsored Cocktail Networking Session Brought to you by SALGA/WRC’s Municipal Benchmarking Initiative: For Municipalities, By Municipalities, to the Benefit of Municipalities

HOT SEAT

COLLABORATIVE CONSTRUCTION

An open invitation... IIn April, PDNA was acquired by Mott MacDonald and has been trading as Mott MacDonald PDNA since 1 June. Richard Jansen van Vuuren speaks to Dempsey Naidoo, managing director of Mott MacDonald PDNA, about what this means for PDNA.

HE HISTORY OF PD Naidoo & Associates (PDNA) is an inspirational one. The company began in a small backroom in Lenasia on the back of a personal commitment made by the members of the firm – that they establish themselves as role models for the community. The company grew exponentially, with financial turnover figures growing organically 25% year-on-year, and, in turn, staff and resources increased as did the size of contracts undertaken by the company. “Today, having established ourselves as one of the country’s leading consulting firms over 27 years, it is satisfying to me that despite this we remain true to our origins,” states Naidoo. “The scale of our work has changed but its focus has not. We still pride ourselves in

“The values we began our journey with remain the core of who we are now and the work we do”

Ndwedwe street lighting

IMIESA July 2013

building services that enable people to better their lives and projects that contribute to the development of not only South Africa, but Africa as well. The values we began our journey with – integrity, humility and respect – remain the core of who we are now and the work we do,” he continues. In fact, it is these exact values that attracted Mott MacDonald, which had been looking for a local company to partner with, to PDNA. Mott MacDonald had been a significant role player on the African continent for many years with a modest local office in South Africa. Looking to bolster its South African presence with a local firm with specific requirements such as an existing African footprint, genuine BEE, succession planning and a strong ethos of business morals and ethics, it approached PDNA. “A decision was made by the board of PDNA to proceed with the negotiations based on the firm’s long-term strategy. We were looking at a scenario, three to five years from now, where the projects that will stem from the National

HOT SEAT

PDNA PROJECTS

ABOVE Expanded Public Works Programme

Development Plan and Strategic Integrated Projects will be either nearing completion or in full swing,” explains Naidoo. The management for Mott MacDonald PDNA will be South African stemming primarily from PDNA, repor ting to Mott MacDonald International. The deal is a major boost of foreign direct investment for South Africa. Mott MacDonald and PDNA were already working together on a range of significant projects, including the Eastern Cape Infrastructure Joint Venture, providing Transnet with engineering, procurement and construction management services, covering port infrastructure upgrade projects at Port Elizabeth, Port of Ngqura and East London. The new entity will operate from 15 centres in South Africa, Botswana and Mozambique, providing multidisciplinary design, implementation and management services across the proper ty, infrastructure, transpor t, water, industrial, mining, energy, communications as well as the health and education sectors. The South African consulting engineering sector has seen several larger firms partner with global entities to boost competiveness outside of the borders of South Africa – and in return, the international companies obtain the benefits of established local businesses. “We would like to secure larger projects going forward and be able to draw on a significantly larger pool of resources in order to do so,” outlines Naidoo.

“This will challenge not only our staff in terms of personal growth, but also the legacy we leave within the communities we work in. We are also open to discussions with local government entities to examine how we can train and empower them in disciplines such as institutional finance and operations. The firm is currently involved in the following local government projects and initiatives: • The Accelerated Schools Infrastructure Delivery Initiative in Gauteng valued at R8 billion. PDNA is leading the programme management of the school infrastructure roll-out programme. • The R2 billion upgrading of the Rooiwal Wastewater Treatment Works to address the sewerage capacity constraints within the Tshwane Metro area. • The Ndwedwe street light project in Stanger (KwaZulu-Natal) where the use of LED lighting technology should reduce long-term operational costs. This project aims to assist the communities in this area obtain energy efficient lighting as well as provide safety and security in the area. • The Department of Public Works took the decision to appoint PDNA as one of the leading consulting engineering firms to act as mentors for learner contractors within the Expanded Public Works Programme with their construction projects and aid them in business and financial management skills up to a point where the learner contractors can operate successfully on their own. • In the City of Cape Town, PDNA is a subconsultant to HHO Africa and is responsible for the electrical design of all aspects

R C

of the Atlantis Integrated Rapid Transport Infrastructure. The contract value is R113 million and the date of completion is scheduled for November 2013.

t +27 (0)11 566 8300 • www.pdna.co.za

IMIESA July 2013

PROJECTS IN AFRICA

AFRICA IN REVIEW ANGOLA

Impressive reconstruction FORMER NIGERIAN president Olusegun Obasanjo says he is impressed with Angola’s process of reconstruction and economic growth. Obasanjo mentioned the cranes and the construction of the buildings seen around as evidence of the country’s engagement in the reconstruction process. He said the people of Angola deserved to be congratulated as result of this. Speaking on the African Union, Obasanjo said the great difficulty of the organisation is related to the inadequate contribution by member states, mentioning that many have been in debt since 2000. Source: Angola Press

ETHIOPIA

Construction Management Institute PROJECT MANAGEMENT is being targeted as an imperative area of improvement, in order to strengthen the sector. Mekuria Haile, minister of Ministry of Urban Development and Construction (MOUDC), and Hailemeskel Tefera, state minister for MOUDC, stressed the need for establishing the Ethiopia Construction Project Management Institute to

IMIESA July 2013

alleviate the problem faced by the construction sector. In a bid to ensure the effective implementation of construction projects in the country, the MOUCD has prepared a regulation to establish the Ethiopian Construction Project Management Institute. The draft regulation is expected to be tabled to the Council of Ministers. “Because we need the institution urgently, we are expecting the regulation to be ratified soon,” says Hailemeskel Tefera, state minister for the MOUDC. The institute will be tasked with initiating policy and action plans in order to facilitate the building of competitive construction project management and identifying gaps within the current construction project management, according to the draft regulation. It will also have the responsibility of facilitating the certification of construction project management professionals to an international standard. Although there are close to 50 000 registered project management professionals in Ethiopia, the ministry was hardly able to find one certified professional in the country, while conducting a study to prepare the regulation, according to Hailemeskel. The idea of establishing the institute emerged in December 2010, along with plans to create the Construction Industry Council (CIC).

A draft proclamation, prepared by the MOUDC in order to establish the CIC, is currently in its final stage. The council’s first task will be to prepare a guideline, based on which every contractor and consultant will produce their code of conduct, in order to operate in the sector. The model for the institute was taken from India, South Africa, Nigeria and the US, according to Hailemeskel. The institute will give training in project management to professional trained as architects and engineers, as well as those who have graduated from technical vocational and educational teaching schools. To perform its duties, the institute is expected to generate income by providing consultancy services in the field of construction project management. Being accountable to the MOUDC, the institute, which will have an advisory council, will be led by a director general. The advisory council will advise the management of the institute by evaluating policies, plans and researches formulated by the institute, according to the regulation. Source: Addis Fortune (Addis Ababa)

US$1.26 billion (R12.58 billion), and funding will be coming from the African Development Bank (US$338 million), the World Bank (US$684 million), Kenya (US$88 million) and Ethiopia (US$32 million). The French Development Agency is also expected to provide US$118 million for the project. This Eastern Electricity Highway Project will provide cheaper power to Kenya from Ethiopia and, according to Kenya’s Association of Manufacturers, result in reduced production costs for companies and cost of living for workers as well as encourage investments in Kenya. The project is being implemented by Kenya Electricity Transmission Company and Ethiopian Electric Power, with Germany’s Lahmeyer International supervising. The project, expected to be completed in September 2018, involves construction of about 437 km of transmission lines in Ethiopia and another 631 km in Kenya as well as the building of associated AC/DC converter stations at Wolayta Sodo substation in Ethiopia and at Suswa substation in Kenya, with transfer capacity of up to 2 000 MW in either direction. Source: Government of Ethiopia (Addis Ababa)

KENYA

Power transmission line CONSTRUCTION WORK on the 1 068 km long Kenya-Ethiopia transmission line project will begin in September 2013, it has been announced. The cost of the project is estimated at

MALAWI

Government to complete abandoned schools THE MALAWIAN government says it is committed to completing over 300 unfinished school blocks that were abandoned by contractors throughout the country. Minister of Education Science and Culture Eunice Kazembe says government is aware of challenges that children are facing throughout the country due to the unfinished school blocks.

PROJECTS IN AFRICA

“We are aware of the issue and government has increased resource allocation for the construction of school blocks,” she says. “Right now government is focusing on the issue and is mobilising funds that will go towards finishing all uncompleted school blocks around the country, but meantime MPs who have the same problem in their constituencies can use the Local Development Fund so that our children should not continue suffering,” she explained. She stated that devaluation was among the reasons that made contractors abandon completion of building the schools as funds were provided for before devaluation therefore the money was not enough to purchase building materials. Government has allocated 2.5 billion Malawian kwacha (R75 million) to classroom blocks construction in the 2013/14 budget. Source: Malawi News Agency

NAMIBIA

N$120 million shopping centre construction A SHOPPING centre worth N$120 million (R119.99 million) is being planned for Okahandja, according to Namib Housing – the company that is developing the centre. Construction has already started on the centre, which is situated on the B1 road. Namib Housing said the two-phase development project will host popular South African retail outlets as well as local companies. “Moreover, the development will be an important enabler in contributing toward employment

creation in the town,” Namib Housing stated in a statement. With retail tenants such as Shoprite, Edgars Active, Legit, Jetmart, Pep, Dunns, Bears, Hungry Lion and Spur, the Okahandja Shopping Centre will be a welcome asset to the small town’s shopping landscape, the statement said. Financial institutions such as First National Bank (FNB) and Nedbank will also occupy space at the centre, it added. Phase one comprises approximately 9 600 m2 retail space and Phase 2 approximately 8 700 m2. “We can appreciate that approximately 300 jobs will be created indirectly as a result of this development and will create excellent economically viable opportunities for the town to grow and prosper further. We have secured a good tenant mix. This shopping centre will drastically alter the retail culture and lifestyle within the town,” said Garth Mouton, project manager for Namib Housing, adding that the investment will help boost the economy of the town. Source: Namibian

NIGERIA

Lagos replacing asphalt with paving stones CONSIDERING THE peculiar soil texture and the fact that Lagos State is prone to flooding, the state government has directed firms handling its road reconstruction jobs to adopt the use of paving stones instead of asphalt at troublesome spots. In fact, it has purchased paving stones production machines for

the Public Works Corporation of the Ministry of Works saddled with the responsibility of fixing street roads. Governor Babatunde Fashola commissioned the first ever paving stone production line of the Lagos State Public Works Corporation at Ojodu, saying government would continue to be creative and resourceful in its unceasing work to keep Lagos roads driveable. The newly commissioned production plant will produce paving stone making machines for interlocking blocks, which would be useful in many waterlogged areas of Lagos where asphalt and bitumen do not thrive. Commending the management of the corporation for being innovative and forward looking, the governor said: “So far, so good and the march continues. They have also built their moulds to start casting drains and are increasingly becoming a local arm for building our roads, so the capacity is increasing and I think the workers are happy.” The governor described the tonnage of cargo on Lagos roads as excruciating because “there is no other city that has and subjects its roads to the kind of tonnage that Lagos experiences without rail for evacuating goods from the port and still keeps traffic moving like this. I tell people that keeping Lagos traffic moving with the cargo that comes through our ports every day is perhaps the eighth miracle of the world. The Public Works Corporation is our parastatal for addressing the maintenance issue of our roads while the ministry uses contractors to build new roads.” With the launch, the agency is increasing its capacity as the

asphalt plant that was down before is now up and running while also selling asphalt to other government agencies within and outside the state. Fashola added that a lot was happening in terms of human capacity development, welfare of the workers, health and safety in the yard and environmental aesthetics, stressing that the journey continues. Source: Vanguard

TANZANIA

Road construction stalls ZANZIBAR NEEDS to settle outstanding payments it owes Mwananchi Engineering Contracting Company (MECCO) before it continues with the construction of roads on the island. “It is true that the government has not paid MECCO for work on Unguja Island. Therefore, due to insufficient funds, the company will not be able to continue with the project in Pemba,” said Rashid Seif Suleiman, minister for Infrastructure and Communication. “MECCO is a small company that depends highly on monies it receives; it is short of funds as government has not paid up. But we are working hard to have the debts settled so that the work can resume,” he continues. Suleiman also said that stalling is attributed to delays by government to compensate people who had their properties destroyed for the road expansion and construction. Source: Tanzania Daily News (Dar es Salaam)

IMIESA July 2013

AFRICA

MARINE EROSION

Coastal protection works Work is progressing well on the urgent Ada Coastal Protection Works project launched by Ghana’s Ministry for Works and Housing to reduce coastal erosion along the Ada Foah coastline.

HE PROJECT WILL protect local industries such as fishing and tourism, and prevent or retard the silting up of the river delta and is being undertaken by Frankipile Ghana, a division of Esorfranki Geotechnical. Ada Foah is some 100 km east of Accra near the Volta River estuary, which flows into the Atlantic Ocean. Conditions, constantly in flux and exacerbated by waves reaching heights of 20 m, were particularly challenging, with the ground profile below sea level

BELOW The completed rock groyne

IMIESA July 2013

consisting generally of sands interbedded with layers of silts and clays of varying proportions and consistency. Design and supervision of the project are being under taken by International Marine & Dredging Consultants, with Dredging International acting as the main contractor. Seven rock groynes varying in length from 100 to 200 m will be constructed perpendicular to the shoreline over a distance of approximately 4.7 km west from the Volta river mouth. Frankipile Ghana is responsible for the temporary works, including the main and support jetties and the cofferdams.

Garry Boyd, work director of Esor franki Geotechnical, says the company was able to draw on over 66 years of experience in geotechnical and marine work to design a customised and comprehensive geotechnical solution for this demanding and complex project. “Starting in June 2012, which was the season of the highest waves, we had a 12-month deadline to complete the project,” continues Boyd. “It represents the biggest we have undertaken in Ghana to date. We first designed and implemented the temporary works necessary to construct the offshore rock groynes,

AFRICA

ABOVE Removal of sheet piles from the support jetty

building one main jetty for the placement of the rock material, ranging in mass from 300 to 10 000 kg, for the full length of each groyne. These temporary works will total approximately 2.5 linear kilometres of jetties and 1.5 linear kilometres of sheet piles, with a total contract value of about €10 million (R134.01 million).

Design solutions “A sheet pile cofferdam was necessary to ensure that we could control the placement of material near and onshore, and we built this using two support jetties.” Dr Nicol Chang, senior design engineer in Esorfranki’s ISO 9001 accredited in-house design department, explains that these jetties were designed to cater for vertical and lateral forces from the 100 t CAT C385 excavator used by Dredging International to place armour rocks of up to 10 t, as well as for the dynamic forces from breaking waves. “We also used combined wave and excavator loading to establish safe operational conditions for the cranes and excavators on the jetties. The volatile seabed conditions required us to model standard solutions for the conditions that prevailed at the actual time of construction of the temporary works for each groyne.” The design also had to cater for scour around the sheet pile cofferdam and the tube piles, ensuring that scour conditions are monitored daily. “We had to take into account the corrosion of the

IMIESA July 2013

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AFRICA

ABOVE Aerial view of the temporary works RIGHT Removal of sheet piles from the support jetty

tube piles, which is critical to their bending resistance, so we also monitor corrosion rates after each use of the tube piles themselves,” Chang continues. The temporary structure as a whole was designed for annual wave conditions with sea levels shallower than 2.5 m for the cofferdams and support jetties and 5.5 m for the main jetties.

The works solutions Steel tube piles vibrated into the seabed with a hydraulic vibratory hammer hanging from NCK C75 or Liebherr H5845 cranes support the main and support jetties. A similar method was used to install sheet piles for the cofferdam, with the cranes operating off the two support jetties. Two purpose-made 40 t bogies supplied materials along the jetties. The difficulty of the work was intensified by the impact of the often 20 m high waves, which frequently damaged the wooden decks between the main beams of the jetties, causing delays during construction of jetties at the first groynes. “The sequence of work was revised to work on two groynes simultaneously, with the materials on the returning groyne used on

the advancing groyne,” Boyd points out “This significantly reduced standing time of the equipment while material placement was taking place on the returning groyne.” He adds that all the equipment necessary for the successful completion of the project is sourced from Esorfranki Geotechnical’s extensive in-house plant base. “This project

promotes Esor franki’s corporate strategic objective of expanding its footprint in Africa, exploring sustainable growth opportunities on the continent where our expertise can work to the benefit of projects that focus on mineral resources and marine infrastructure. It builds on the platform created by our first successful project in Ghana in 2011.”

IMIESA July 2013

AFRICA

AFRICAN FOOTPRINT

Entering new growth regions Having already established a strong foothold in Southern and East Africa, SMEC is looking to further expand its presence in West and North Africa.

ITH MAIN MARKETS indices in countries such as Nigeria and Kenya having risen by more than 50% in the past year and investor confidence in Africa rising at a rapid rate, SMEC South Africa CEO Dr Thomas Marshall explains that the company is targeting West and North Africa as potential growth areas. “Within West Africa where we are currently operating in a limited number of countries, we are focusing our expansion plans on mining-related and developmental infrastructure projects, while in North Africa we are targeting transport infrastructure, water and powerrelated projects. Countries such as Libya, Algeria and Morocco hold a vast amount of potential when it comes to structural development and reconstruction,” continues Marshall. He adds that since VelaVKE’s merger with the SMEC Group in

IMIESA July 2013

June 2012, SMEC South Africa has become involved in a number of projects across the traditional SMEC footprint, with both private and public sector clients. “Being part of the larger SMEC group has allowed us access to greater resources and a larger skills base for servicing African clients, but also enables us to service new

“In North Africa we are targeting transport infrastructure, water and powerrelated projects.” Dr Thomas Marshall, CEO of SMEC South Africa geographic market areas within other growth regions. An example would be our large bridge design capacity – we

ABOVE With the addition of GMC Global, SMEC’s mining consultancy and management capabilities will be substantially improved

have become one of South Africa’s biggest large bridge design companies, with engineers currently working on prestigious bridge-related projects in Asia, as well as on proposals for bridge-related projects in Australia,” explains Marshall. Meanwhile, the SMEC head of the Gauteng South office, David Gertzen, points out that the SMEC Group’s acquisition of GMC Global – an internationally recognised leader in the productivity improvements, cost control and infrastructure management services to the mining industry – will be a large focus for the company going forward. With the addition of GMC Global, SMEC’s mining consultancy and management capabilities will be substantially improved, says Ger tzen. Combining the exper tise and

AFRICA

SMEC is targeting West and North Africa as potential growth areas for the company

experience of both companies will prove to be highly beneficial to clients in Africa. “GMC, which improves productivity and cost control at mines, joined the SMEC Group in January last year. For the next two years, we plan to focus on rolling out GMC Global’s services and products in Africa, which are aimed at assisting clients in establishing and executing visions and strategies, as well as supporting leadership capabilities and enhancing technical skills through people, processes and skills,” explains Gertzen. He says GMC’s history of enterprise planning and development, paired with experienced consultants, has benefited the mining sector in over 115 productivity projects worldwide. GMC Global consultants have an in-depth understanding of a mine’s operations and have hands-on experience in operational productivity improvement.

IMIESA July 2013

WATER & WASTEWATER

DRAINAGE AND FILTRATION

Leak detection system A R50 million reservoir project has been approved by the City of Tshwane Metropolitan Municipality to meet the high demand for water in the region north of Pretoria, and Kaytech’s highly regarded drainage and filtration system was specified upfront.

S IS THE CASE in any new reservoir construction, the incorporation of a highly effective leak detection system is essential. With many years of experience, VIP Consulting Engineers was chosen to plan and design this system for the new Annlin Reser voir. In order to simplify the search for any future leaks, the system was compartmentalised into a grid system covering the floor area of the reservoir. Through different coloured pipes, each section of the grid would feed into a manhole constructed on the side of the reser voir. With each section of grid being represented by a particular colour, a leak would be easily and accurately detected. For their carefully planned leak detection system, consultants had no hesitation in specifying two of Kaytech’s well-recognised products, namely bidim and Flo-Pipe. KK BELOW The slotted pipe wrapped in bidim MIDDLE The protected pipe is covered by no fines concrete BELOW RIGHT The grid system for leak detection

IMIESA July 2013

Civils Construction was awarded the contract to install the system. Flo-Pipe (450 m), wrapped in bidim (1 060 m2), was placed into the trenches of the reser voir floor and covered with no-fines concrete. These trenches will then drain any leaked water into the adjacent manhole. Flo-Pipe is a high-strength, slotted drainage pipe consisting of a ribbed outer shell that can withstand massive confining pressure, and a smooth inner bore that ensures high flow velocity. It is this twin-walled, sandwich design that gives Flo-Pipe its strength and flexibility. Manufactured from the highest quality high-density polyethylene (HDPE) available, Flo-Pipe is optimally slotted for maximum infiltration with minimal blockage and is the ideal product for civil, mining, municipal and domestic use. The convenient length and lightweight construction of Flo-Pipe ensure easy transportation and handling, while installation is possible even with unskilled labour. Kaytech’s bidim, which was wrapped around the Flo-Pipe to ser ve a filtration function, is a non-woven, continuous filament,

needle-punched geotextile manufactured from 100% polyester. It has a high drainage capacity in both the transmissivity and permittivity planes. Bidim has the highest possible through-flow rate while providing excellent filtration characteristics. In sub-soil drainage, as required in this project, bidim per forms two functions: that of filtering and separating soils. The bidim A4 quantities used in this project equate to 4 122 recycled PET cold drink bottles. “Kaytech provides innovative, engineering solutions using recycled PET (rPET) in its products. By doing so, it supports the recycling sector by ensuring the collection and recycling of PET bottles and assuring an end-use market for rPET in South Africa,” says Cheri Scholtz, CEO of PETCO, the industr y body for recycling of PET plastic in South Africa. With its 20 Mℓ capacity, the new Annlin Reservoir will soon be providing precious liquid to the surrounding areas and, thanks to Kaytech’s unique products, this highly effective leak detection system will ensure that minimal water will be lost through leakages.

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WATER & WASTEWATER

COMMUNITY UPLIFTMENT

Shack-to-house conversion project DPI Plastics has played an important role in improving the living conditions of residents of informal settlements after donating PVC building pipes and fittings to the first-ever shack-to-house conversion project in Kayamandi, Western Cape.

HE TEST PHASE of the Kayamandi project, which was completed in March 2013, involved the conversion of a 23 m2 wooden shack into a solid 46 m2 double-storey home made entirely from ‘sand bag’ eco bricks built by 16 ‘off-the-street Kayamandi residents’ who were trained and supervised by an engineer from the Africa Responds Clearly Eco Homes team. The project’s test subject, Norie Lungisa, lived in the cramped and uncomfortable conditions of her shack with her two children for more than 10 years and is delighted with her new and improved eco brick home, which was officially handed over to her on 14 March 2013. Cape Town-based construction materials supplier Penny Pinchers approached 16 of its most trusted suppliers, including DPI Plastics, to assist the Kayamandi project with various donations. As a socially responsible corporate citizen, DPI Plastics places a strong emphasis on supporting community development projects, notes the company’s marketing manager, Martine Goodchild. She says: “DPI Plastics is committed to supporting projects that aim to uplift the living standards of fellow South Africans, especially with regards to adequate housing. The Kayamandi project supports DPI Plastics’ vision of building a better tomorrow, not only by providing residents with better housing facilities, but also by creating employment and skills development opportunities for locals. We also encourage the use of ‘green’ building materials that aim for energy efficiency within the home.”

ABOVE A view of the Kayamandi area RIGHT An interior view of a completely overhauled dwelling

Africa Responds Clearly Eco Homes spokesman Grahame Tomes highlights the fact that the new eco home is comprised of two upstairs bedrooms, in addition to an open plan lounge, dining and kitchen area and a bathroom. 

IMIESA July 2013

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“It is our plan to help the Lungisa family with the added benefit of receiving running water and a sewerage connection from the relevant authorities, once the authorities are able to generate enough budget to help the residents of Zone 14 in Kayamandi.” Tomes explains that the Kayamandi eco house is built utilising the National Home Builders Registration Council (NHBRC) certified eco brick/eco beam building system, which employs eco bricks and eco beams that are plastered and painted. “All eco brick houses are built with eco bricks that are 300 mm x 300 mm in size. The net result of such wide bricks is a home which is cool in summer and warm in winter,” he continues. According to Tomes, eco brick homes address a number of serious challenges that are currently facing the South African affordable housing industry. “The 300-mm thick walls provide a natural barrier to the harsh South African sun – even in temperatures exceeding 40 °C. The issues of rising damp, rain and even flooding are entirely eliminated with eco brick houses, as water cannot rise through sand. Instead, it is forced back downwards into the earth.” Tomes points out that the construction of eco brick homes also empowers communities.

“Residents are provided with employment and skills development, while playing an important role in developing their community. Under this scheme, we are able to employ approximately 1 000 people per community over a three-week period. During this time, we train them and equip them with the necessary skills to build around 120 high-quality eco brick/eco beam homes per month, in each respective community,” he adds. Another distinct advantage of eco brick houses is a reduction in overall costs, when compared to cement block houses. “The current government subsidy of R84 000 for first time home buyers is sufficient to build a 50 m2 eco brick or eco beam double-storey house. All the tests completed by the CSIR, the SABS and the NHBRC show that eco brick houses offer better performance specifications than those built with cement bricks and blocks or even steel structured houses.”

Despite their initial reservations, Tomes indicates that all 48 members of the Loyola Street Committee – where the transformed shack is located – are queuing up to have their shack homes replaced too. “The building of this first ever shack replacement double-storey home has been an overwhelming success, and would not have been possible without the support of all of our generous donors. We offer our sincere thanks to them all.”

RIGHT All eco brick houses are built with eco bricks that are 300 mm x 300 mm in size BELOW A view of one of the original shacks

IMIESA July 2013

WATER & WASTEWATER

WATER SUPPLY

Air valves for pipeline project In February this year, Incledon played a role in the development of rural water infrastructure by supplying R500 000 worth of ARI air-release valves to a large bulk pipeline project in Limpopo.

HE SEKURUWETO Fothane project is one of the highest value air-valve projects in Limpopoâ€™s history and involves the installation of a 15 km steel bulk pipeline by the appointed contractor L&R Civil, a company of the Raubex Group that specialises in bulk water, sewer and stormwater reticulation. L&R Civil predominantly tenders on government contracts and has an asset register of over R25 million, with annual turnover exceeding R120 million. The Johannesburg-based company commissioned Incledon to supply the ARI air valves in sizes ranging between 100 and 300 mm.

Israel-based ARI is an internationally recognised focused manufacturer and solutions provider for the protection of liquid transmission systems, including air valves, check valves, unmeasured flow reducers and software system analyses for surge and air valve sizing and placement. Incledonâ€™s civils representative, Alan Taylor, notes that all the ARI air-release valves supplied to the project are Pressure Nominal (PN) 16 and 25 pressure An ARI D-060 HFNS valve

IMIESA July 2013

WATER & WASTEWATER

operated, and are designed to discharge air from the pipe, in order to allow for the efficient filling of the pipeline. “The ARI air-release valves supplied to the project are designed to release accumulated air that comes out of solution within the pressurised pipeline. This air is in bubble formation and gathers at localised high points along the pipeline profile. The accumulation will occur when the bubble’s buoyancy is greater than the energy to convey the bubble with the liquid,” he explains. Taylor points out that by releasing the excessive air, the ARI airrelease valves contribute to the improvement of the efficiency of the water system, while contributing to the reduction of water losses and leakage. “The installation of ARI air-release valves also reduces the vulnerability and damage to pipelines, connections, accessories and pumps, thereby reducing maintenance costs.” According to Taylor, Incledon faced a number of logistical challenges during the delivery of the valves. “Due to the fact that the majority of the valves had to be imported, we faced a number of time constraints and the project could not afford any delays whatsoever.” He highlights the fact that, due to a strong working relationship and mutual understanding between the two companies, Incledon was able to ensure that all the ARI air-release valves were successfully delivered on-site at the agreed deadline and within budget. Looking at the South African valves market in general, Taylor indicates that there has recently been a measurable increase in demand for air valves among contractors and engineers. “The local industry is becoming increasingly aware of the fact that air valves are an integral part of a water transmission system, as they protect the pipeline from pressure transients and possible collapse.” Due to increased investment in infrastructural projects across South Africa, Taylor is optimistic of the future outlook. “The growing demand for valves is a direct result of government placing greater focus on developing improved water supply infrastructure. With this in mind, Incledon is regularly submitting tenders not only for the supply of valves, but pipes and fittings too,” he maintains. An ARI D-070 dynamic valve

IMIESA July 2013

WATER & WASTEWATER

TRANSFER PUMPS

Technology backed by experience Process plants are reliant on various technologies for successful production. Today’s reality is that these technologies are often forced to work under the harshest conditions. Related products must therefore be of uncompromising quality and backed by excellent service.

AST YEAR, Ecochem Pumps was appointed exclusive distributor of the Soméflu range of chemical transfer pumps throughout South Africa and neighbouring countries. In late April, Adrien Hourlier, Soméflu’s international sales manager, visited South Africa to provide support and further strengthen the relationship. Ecochem has supplied the market with Milton Roy’s range of chemical dosing pumps for many years. Although Milton Roy technology is not connected to the business of Soméflu, both companies are French. In addition, the Soméflu chemical transfer pump is complementary to the Milton Roy chemical dosing pump in process operations. These synergies are expected to help Soméflu with initial sales, and Ecochem Pumps made use of the installed Milton Roy product base during Hourlier’s visit to introduce him to existing customers, where he made presentations on the Soméflu product range.

Current trends During his visit, Hourlier and Ecochem Pumps general manager, Richard Rudling, issued a statement outlining current industry trends and Soméflu’s plans for the future. According to Hourlier, the market for chemical transfer pumps is generally shrinking in terms of small orders, but growing for larger orders. This is because of the trend towards the closure of smaller plants in many industries, and their replacement by larger plants with a greater throughput, which can then take advantage of economies of scale to deliver a lower cost of production per unit. Hourlier explained that almost any type of plant makes use of corrosive fluids of one type

or another, resulting in Soméflu pumps having almost universal application. He said that internationally the company’s main business is within chemical and fertiliser manufacture, petrochemicals and the mines. Soméflu technology is also applied to water treatment, which Hourlier sees as an important growth path for the company in Africa. Rudling added that Ecochem Pumps will also be looking at steel production for the Soméflu product, because of the company’s international experience in pickling applications and acid regeneration.

Plans for South Africa Ecochem Pumps recently received a significant order for Soméflu pumps from a leading platinum mine in North West province. These pumps, already supplied and installed, are expected to be commissioned soon. Besides mining, Rudling said that Ecochem would be making a particular effort to target new petrochemical and chemical manufacturing plants in South Africa and anticipates capturing a respectable share of the business emanating from locally designed and managed projects. However, he added that the challenge with new plants will be to gain entry to those that are funded from abroad. In such cases, he said that one could expect most of the products incorporated in the plant to be sourced from the country funding the project. “We will target replacement business in these overseas-funded projects,” said Rudling. “In some instances, the foreign products that will be used are not built to last and represent a comparatively high

lifetime cost of ownership. We will be ready to help when the plant operators discover this fact,” he continued. Soméflu recently received a very large order for a fertiliser super plant to be built in Morocco. This plant was funded by the US and designed in India. It required close cooperation by engineers from the three different countries. Hourlier said that such multinational projects would always present an opportunity for sales of the Soméflu product, provided the local supplier could provide on-site fault diagnosis. Soméflu’s international distribution manager, Adrien Hourlier, with Ecochem Pumps general manager, Richard Rudling

IMIESA July 2013

WATER & WASTEWATER

AFRICAN INVESTMENT

Marley Pipe Systems acquires assets In a bid to invest in the South African plastic pipe market, Marley Pipe Systems has successfully acquired the assets of Petzetakis Africa.

ARLEY’S JOURNEY has recently gained ground, literally, as it reaches one of its biggest milestones yet. In a public auction process conducted on 15 February 2013, Marley Pipe Systems was successful in acquiring the assets of the former Petzetakis Africa for an amount in excess of R100 million. The acquisition portrays a significant investment into Africa by the internationally

IMIESA July 2013

recognised Aliaxis Group, representing a confidence in Marley as a company to develop and grow the Aliaxis footprint in Southern Africa. Following Petzetakis’ somewhat controversial closing in 2010, this welcome development presented a positive public interest outcome, which is set to contribute not only to Marley as a brand, but also to the future of the South African economy. Included in the assets procured by Marley are the land and buildings of

the adjacent HDPE and hose sites at Rosslyn, and all productive equipment associated with these sites as well as all the movable assets of the PVC site. The purchase of the land and equipment will strengthen Marley’s position to better service the infrastructure and building markets by extending its product range and capacity. This includes additional solutions for large diameter stormwater and drainage pipe applications.

2013

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INFRASTRUCTURE CONSTRUCTION

ECONOMY

Delivering on jobs promise and investments Building projects in the Coega Industrial Development Zone (IDZ) have injected over R1.2 billion into the Nelson Mandela Bay construction industry over the past two quarters. COEGA in numbers Investors

Number

Comment

Operational

Coega Concrete Product, Dynamic Commodities (SA), UTI Couriers (SA), Cerebos (SA), MSC, PE Cold Storage (SA), Digistics (SA), Electrawinds, General Motors Parts and Accessories Distribution Centre, Cape Concentrate, Universal Wind, Coega Dairy, AP Moeller South Africa, Discovery Holdings NMBLP: First tier suppliers: Faurecia (French), Rehau (German), Grupo Antolin (Spain), Benteler (German) and Inergy (French) Logistics: Kuehne and Nagel (Germany), one importer (Hella, Germany) and four South African linked service providers to the automotive sector are also located in the central hub of the NMBLP, bringing the total tenants to 11 companies

Investors under construction

First Automobile Works (FAW) (China), Famous Brands (SA), Coega Chees (SA), Agni Steels (India), Rehau (Germany) Extension in NMBLP, DCD (SA)

Investors due to start construction [pending construction company appointments]

Air Products SA

Investors in process of completing an environmental impact assessment

AfriSam (SA), AMG (China), Casa Steel (SA)

Signed term sheets

TBA when lease agreements are signed

Pipeline information

Projects in negotiation stage are valued at R8.1 billion and those under feasiblity account for R116.3 billion

IX MAJOR construction projects are currently under way in the Coega IDZ including erection of: • DCD Group’s wind tower manufacturing plant • Chinese car and truck manufacturer First Automobile Works’ (FAW) plant • Famous Brands’ cold storage plant • the addition of Coega Cheese onto the Coega Dairy outfit • Agni Steels’ R400 million smelter facility • Rehau’s extension in the Nelson Mandela Bay Logistics Park (NMBLP). Industrial gas company Air Products South Africa is also about to begin construction of its R300 million state-of-the-art air separation unit in Zone 3 in July, bringing the total number of projects being built to seven. “The global economic climate is still not stable, yet investment continues to flow into the Coega IDZ and is literally taking root in the construction projects under way,” says Ayanda Vilakazi, Coega Development Corporation (CDC) head of marketing and communications. “We currently have 20 operational investors, and

Construction of the R1.2 billion infrastructure at Coega

IMIESA July 2013

INFRASTRUCTURE CONSTRUCTION

ABOVE A worker on-site at the FAW plant in Zone 2 of the Coega IDZ

once these seven construction projects are complete, we will be up to 27 operational investors by mid-2014.” Vilakazi said the activity meant major spinoffs not only for lead contractors, but also for subcontractors, suppliers and the whole built environment supply chain. “At a time when there is industry malaise at a national level, the

IMIESA July 2013

Coega IDZ is experiencing a construction boom to the value of R1.2 billion. “The unaudited results for the 2012/13 financial year also show that construction jobs in the Coega IDZ and the NMBLP for April 2012 to March 2013 amount to 1 722 and investor jobs created are at about 856 – meaning just over 2 500 jobs created directly through activity in the Coega IDZ,” says Vilakazi, adding that it was through these major investments that the CDC was delivering on its mandate to create jobs.

Famous Brands The Famous Brands project is near completion and the company was given access to the warehouse portion in the first week of May, allowing its service provider to start with racking on the warehouse floor. “Everything is on track, with time frames tight but on target to be met. The project is still well within original time, cost and quality parameters set, despite loss of a number of days due to inclement weather, mainly wind and rain,” explains Bruno Ponzi, CDC senior project manager for infrastructure development. Vilakazi states Famous Brands was a prime example of the short conversion times investors experience from the point of signing a lease with the CDC to full operation. “The turnaround times are much quicker now than they were a couple of years ago and we are able to construct buildings for investors relatively quickly, meaning that they move to operational phase within about a year of signing, depending on the size of the project,” explains Vilakazi. “This has implications for investors’ bottom dollar as they are able to start production relatively quickly.”

INFRASTRUCTURE CONSTRUCTION

A partnership between Famous Brands and Coega Dairy has also seen the dairy expanding its operations to supply cheese products to the group in a project dubbed â€˜Coega Cheeseâ€™, with a joint valued investment of R45 million pouring into the Coega IDZ as a result.

FAW In addition, says Vilakazi, the construction activity is creating needed jobs in the city, particularly on the FAW site, with the R200 million FAW construction project well under way. To date, about 304 construction jobs have been created on its site, a number that grows week to week. In total the construction phase will see about 2 000 jobs generated over the year-long duration. In the operation phase of the truck assembling plant, a further 280 jobs will also be created. According to Arnie van Jaarsveldt, WBHO Construction Eastern Cape managing director and lead contractor on the FAW project, the highlight of the construction will be its architectural finesse. Van Jaarsveldt highlights that Eastern Cape Architects Studio dâ€™Arc wanted to

make a statement with the Chinese automotive giantsâ€™ building in Zone 2 of the IDZ. â€œIts prime position on the N2 means it will get heightened attention. FAW management loved Studio dâ€™Arcâ€™s unique design on the office and reception area, particularly the exceptional use of concrete, so thatâ€™s set to be the highlight of the building,â€? explains Van Jaarsveldt. He says construction is on track for completion at the end of December 2013, adding that there is significant collaboration between the Chinese engineers and their South African counterparts â€“ a coup for skills development and mentorship.

use 10 000 t of scrap metal in Phase 1 and 20 000 Phase 2.

DCD Group DCD Group is also in the early phases of its R300 million wind tower manufacture factory, which, when completed, is expected to employ 168 workers, and produce between 110 and 120 wind towers annually. â€œCoega is boldly delivering on our jobs promise through the attraction of investments,â€? says Vilakazi.

Agni steels Agni Steels is also wrapping construction of its R400 million steel plant in Zone 6 of the 11 500 ha IDZ. Agni Steels will operate in a high-tech smelting facility to produce mild steel billets from scrap metal. The plant at Coega will RIGHT A snapshot of the inside of the Agni Steels plant in Zone 11 of the Coega IDZ

IMIESA July 2013

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INDUSTRY NEWS

PPIF 2013

Bullish about government’s infrastructure initiatives Bell Equipment feels it is important to answer the South African government’s call for strategic partnerships.

HIS WAS SAID by Gary Bell, CEO of Bell Equipment, while officially opening the recently held second PublicPrivate Infrastructure Forum. Bell Equipment was the main sponsor of the forum. “We would like to pay tribute to his Excellency the President of South Africa for driving the Presidential Infrastructure Coordinating Commission (PICC) with its 18 strategic integrated projects that will cost somewhere in the order of R4 trillion,” he said. “These are overarching projects that have up to 20-year project life cycles as opposed to the typical five-year projects designed to coincide with election cycles. “Colleagues, we know that infrastructure drives growth and development as it lays the foundation on which the industrial activities and economy of the nation takes place.” According to Bell, his company has closely followed the work of the PICC since its

establishment and is excited by the possibilities it represents. The further possibilities created by the work of the National Planning Commission coupled with the evolution of the National Development Plan and the Industrial Policy Action, could see South Africa becoming a global powerhouse. “The New Growth Path (NGP) is an ambitious plan designed to enhance growth, employment creation and equity, and we fully subscribe to its strategic objectives,” he added. “Bell Equipment has managed to grow its business from humble origins in Empangeni in 1954 and now supports and sustains more than 3 500 quality direct jobs worldwide and somewhere near 10 times that, through our multiplier effect. Support from government and its various programmes have assisted this growth. “We see the infrastructure programme as promoting broader industrialisation of the

economy through the use of locally manufactured components and supplies. In this context, infrastructure must also drive skills formation, particularly in critical areas such as engineers, artisans and technicians. As the only sizeable local manufacturer and distributor of mining, construction, agriculture and infrastructure equipment necessary for these projects, we reaffirm our pledge to support the various government programmes.” Bell emphasised that his company had invested heavily in the South African manufacturing sector and boasts an industry-leading 24 customer service centres with 30 more spread across the rest of the African continent. “The test of our effectiveness will be how well we can coordinate and integrate our work and the different elements of the Infrastructure Plan,” he said. “This means addressing capacity constraints in the state, promoting wider partnerships in the society and improving coordination. “Our government is helping to build infrastructure that will create opportunities for South African companies such as Bell Equipment to expand trade and investment across our borders. As an example, the Development Bank of Southern Africa and the Industrial Development Corporation are accelerating investment into the SADC region and are supporting infrastructure projects in numerous countries, particularly in the key areas of electricity generation and transmission, and in strengthening road links in the region.”

LEFT Bruce Ndlela (Bell Equipment director of business and public business sector), Leon Goosen (Bell Equipment: group commercial director), Philani Gumbi (Bell Equipment sales representative), Gary Bell (Bell Equipment CEO) and Thabo Semone (Bell Equipment sales representative)

IMIESA July 2013

PANEL DISCUSSION

Water reticulation and storage

ITH MANY RURAL and even urban areas feeling the strain of effective water supply and management, service delivery and sustainability in this regard should feature prominently on governmentâ€™s agenda. As such, there is a growing need for experts in the field of water reticulation and storage. The water reticulation sector includes the design, operation and maintenance of water distribution, stormwater and wastewater collection systems â€“ comprising municipal public pipe works, including pumping systems, access chambers and the construction and maintenance thereof. Water is not only vitally

important for the countryâ€™s ongoing economic success, for example in the agricultural sector, but is also crucial to the livelihoods of all people living in a developing country like South Africa. But what makes for an effective water reticulation system? What makes some water storage tanks more costeffective and reliable in comparison to other products on the market? This edition of IMIESA looks at water reticulation and storage solutions that are locally available, including some of the latest technologies and innovations on the market.

IMIESA July 2013

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Total Water and Effluent Treatment Solutions Unlock Potential, Create Value Innovative but proven solutions for domestic and industrial water and wastewater treatment, ranging from low-cost rural facilities to zero discharge and integrated industrial systems. With our expertise and technologies water is conserved, costs are reduced and investment returns are maximised. Conventional Water Treatment: ■ Potable water treatment ■ Sewage water treatment ■ Sludge dewatering Industrial Water Treatment: ■ Effluent treatment ■ Ion exchange ■ Membrane desalination ■ Process water treatment ■ Boiler feedwater preparation Tenova Bateman Technologies offers differentiated, project specific hydrometallurgical, mineral, water treatment and bio process technologies complimented by turnkey modular plant solutions.

58 Emerald Parkway Road, Greenstone Hill, Johannesburg, South Africa Phone +27 11 899 9111 Fax +27 11 899 3919 enquiries.TMM@za.tenovagroup.com www.tenovagroup.com TENOVA is a worldwide supplier of advanced technologies, products and engineering services for the iron & steel and mining industries

PANEL DISCUSSION

WA ATER RETIC CULATIO ON AND D STORA AGE Merchen Naidoo | Process Engineer | TENOVA BATEMAN TECHNOLOGIES With regard to potable water and sewage water treatment, what expertise does Tenova Bateman Technologies bring to this sector? MN Tenova Bateman Technologies, a division of Tenova Mining and Minerals, provides innovative, proven solutions for domestic and industrial water and wastewater treatment – ranging from low-cost rural facilities to zero discharge and integrated industrial systems. The technologies incorporated into our solutions include: aerobic digestion, high rate anaerobic digestion, biological nutrient removal, membrane bioreactor, clarification/thickening, dissolved air flotation, dewatering, filtration, ion exchange technologies, reverse osmosis/nanofiltration, evaporation/crystalisation and detoxification/neutralisation. We also offer a reference list in water and wastewater treatment business in Southern Africa dating back to 1941.

When it comes to stormwater and wastewater, just how important is an efficient water reticulation system? Sewage reticulation systems that are poorly designed, operated and maintained result in spillage into rivers, dams and oceans. The health risks associated with this include pathogenic microorganisms and chemical contaminants. The primary chemical contaminant is high nitrate levels, which are known to cause infantile cyanosis. Efficient stormwater reticulation systems are of extreme importance involving the management of urban catchments, flood control, ecological and social needs and as an important urban water resource. Without a doubt, stormwater and untreated wastewater need to remain segregated.

Do you offer a holistic approach to water reticulation, i.e. design, operation and maintenance? Tenova Bateman Technologies’ capabilities covering water and effluent treatment offer added value through in-depth understanding of technologies to the selection, design, supply and construction of the best process plant to suit the requirements. This ensures the most cost-effective solution to our clients’ needs.

In your opinion, what are the main challenges facing the local water and wastewater industries, particularly in rural areas? What are your recommendations? The challenge facing the South African government is the supply of potable water and sanitation to its people, with the majority of rural area residents lacking access to potable water and sanitation. As plants are nearing the end of their serviceable lifespans, the major bottlenecks to this are the elimination of service delivery backlogs as well as the threat of infrastructure maintenance shortfalls. Water quality continues to be a concern with acid mine drainage polluting catchment areas and waterways, particularly in rural areas. It is imperative that government reconsiders its funding scheme for these services to eradicate disproportional allocation to urban areas over rural. As such, plants will have to be designed using more efficient technologies, which, although attracting higher capital investment, will operate more efficiently, require less intensive maintenance and provide all South Africans with uninterrupted potable water and sanitation. In addition, operations

and maintenance must receive more funding to ensure the sustainability of existing plants, without forgetting the importance of knowledge sharing, mentorship and training at new and existing plants.

What top three water projects has your company been involved in? We have either commissioned in the last 18 months or are in the process of implementing the following projects: Meulwater: a potable water treatment plant for Drakenstein Municipality situated in the Paarl Mountain Nature Reserve was required to be environmentally friendly and aesthetically pleasing to ensure least disruption to the sensitive ecology of the area. Treatment capacity of the works is 8 Mℓ/d, upgradable to 15 Mℓ/d and the treatment process has been optimised to suit the relatively good raw quality of mountain water with provision A Tenova Bateman Technologies water treatment plant

for future water quality deterioration. We were the mechanical and electrical contractor for this project, category winner of the 2012 CESA Engineering Excellence awards. Riemvasmaak Water Treatment Plant: a fully automated potable water treatment was designed and built for the Siyanda District Municipality. The plant has a capacity of 30 m3/h and incorporates clarification, filtration and chemical dosing unit processes. Johannesburg Northern Waste Water Treatment Works: upgrade and refurbishment of Module 3 of Unit 2 at the plant, originally built by our company. This turnkey refurbishment project included supply, delivery, installation and commissioning of civil work, mechanical equipment electrical and instrumentation. The plant was completely refurbished with new mixing systems and aeration equipment, a new clarifier bridge, scum collection system and screw pumps.

Tenova Mining and Minerals is an integrated solutions provider to the global mining, bulk materials handling and minerals beneficiation and processing sectors, offering innovative technological solutions and full process and commodity knowledge across the mining industry value chain.

IMIESA July 2013

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PANEL DISCUSSION

WA ATER RETIC CULATIO ON AND D STORA AGE BVi Water Services Division | Engineers | BVI CONSULTING With regard to water reticulation and/or storage, what expertise does BVi Africa bring to this sector? BVi is involved with the complete life cycle of water reticulation and water storage projects. The company is involved from water pipe design through to the implementation phases, including construction supervision where required.

When it comes to stormwater and wastewater, just how important is an efficient water reticulation system? Efficient systems are of extreme importance throughout the grid. It is estimated that approximately 30% of all potable

water is lost through inadequate reticulation systems. In order to ensure stormwater and wastewater reticulation systems are compliant and efficient, it is important to supervise the implementation/installation of these. It has been found that incorrect installation contributes to the loss of water. Proper design and supervision when the water pipes are being installed will minimise the incorrect installation of these. Efficient storm management reduces flood risks. Efficient wastewater management reduces health and environmental risks.

Why are water storage tanks/devices becoming increasingly important for

rural areas? Rural areas are usually remote locations, which are distant from water networks and are frequently not even prioritised for such infrastructure in the medium term. Due to the remoteness as well as the geographical relief of some of the rural areas, these are, at times, not conducive to adequate water pressure. In these circumstances, water storage tanks are usually advisable, ensuring sufficient water pressure in order to deliver the resource to homes.

Do you offer a holistic approach to water reticulation, i.e. design, operation and maintenance? BVi takes a holistic approach to water reticulation in the following manner: throughout our design cycle, we take extreme caution in ensuring that the water systemâ€™s operation is optimal and requires minimal maintenance. Human resources in operating these systems are kept to a minimum as human error plays a big part in the failure of water reticulation systems. This is especially true in situations where smaller communities are dependent on pump systems, which are operated manually. In such instances, BVi would endeavour to include automation systems in the designs.

In your opinion, what are the main challenges facing the local water industry, and what are your recommendations? The main challenge faced is bureaucracy within departments, which makes expediting projects frustrating and lengthy. Certain TOP LEFT One of the water tanks installed in Kakamas LEFT Labour-intensive lining of the stormwater channel with energy dissipator

communities are in dire need of potable water. If the process is shortened to expedite projects of this sort, entire communities would benefit sooner.

What top three water projects has your company been involved in? BVi has been involved in large scale water projects over the past years. A large part of these projects were related to water pipelines in the Northern Cape, including the Kakamas Canal Project. This project entailed the design of the Neusberg Weir, canals, drains and other infrastructure. BVi was also responsible for construction management and supervision of the extension of the Soverby 216 ha Irrigation System linked to the project. As part of BViâ€™s CSR programme, the company recently made donations of water tanks to the community of Bloukamp (Kakamas). Along with the water tanks, BVi did the engineering and supervision of installation of these tanks. The tanks brought tremendous relief to the community, which, until then, had to extract water directly from the canal. In some instances, this proved to be quite hazardous to their health. The programme was supported by Department of Cooperative Governance, Human Settlement and Traditional Affairs (Department of Housing) and Kai !Garib Municipality. BVi was also involved in Marikana and Buffelspoort Village project.

BVi Consulting Engineers is a multidisciplinary firm, which offers professional services to the public and private sector. The company provides professional services in identifying and implementing engineering projects for medium to large clients globally.

IMIESA July 2013

PANEL DISCUSSION

WA ATER RETIC CULATIO ON AND D STORA AGE Jan Kruger | Technical Manager | FIBERPIPE With regard to water reticulation and/or storage, what expertise does Fiberpipe bring to this sector? JK Fiberpipe manufac-

In your opinion, what are the main challenges facing the local water industry, and what are your recommendations?

tures glass reinforced pipes (GRP) for use as bulk lines, either taking wastewater away or bringing water to networks. Flowtite is our leading product for water, sewage and industrial applications. The pipes are corrosion free and have a proven resistance to acidic environment in water and sewage systems, not forgetting lightweight and easy to handle. Our Vectus pipe systems are free of corrosion and lightweight, with good references across the globe. In addition to the civil and industrial markets, this pipe is also used in the oil and gas, shipbuilding and offshore industries.

In South Africa, the problem is that there is very little supervision on-site. This results in the incorrect handling and placement of pipes, hence our pipe system will not last its full 50-year lifespan. This is very serious, as we have to replace the pipelines before the 50-year lifespan is up, escalating installation costs. By ensuring that installations are done correctly the first time round, it will save the country millions at a later stage. The cost of the supervision is very small compared to that of an incorrect installation. Fiberpipe has realised this shortcoming and is now supplying field assistance to ensure installations are done correctly. Field assistance is for our cost.

When it comes to stormwater and wastewater, just how important is an efficient water reticulation system? It is very important that all pipelines are designed and installed correctly, and that the correct material for the specific project is used.

– a three-phase project, which diverted wastewater to a treatment plant instead of entering the dam, causing it to rise above the nearby railway line. Fiberpipe also recently completed an irrigation project in the Northern Cape for Berekisanang Farm. The company has completed various other projects, including Vredenburg Sewer Outfall, Wemmershoek WWTW, BELOW Haunching of pipes during installation BELOW RIGHT Nested pipes ready for export BOTTOM GRP Pipes are lightweight and easy to offload

Western Water Pipeline (Phase 2) and Sikondo BWS – all of which we are extremely proud of.

Fiberpipe is the sole manufacturer of Flowtite and Vectus glass fibre reinforced (GRP) pipes and fittings in sub-Saharan Africa. The company manufactures pipes and fittings locally for use in potable, raw, sea, industrial, waste, sewer and bulk water applications. Fiberpipe aims to be the preferred supplier of piping solutions in sub-Saharan Africa through its GRP product range.

What top three water projects has your company been involved in? We recently completed Kamfers Dam

Water technology is constantly evolving. What’s new/innovative on Fiberpipe’s radar? GRP is still a very new product to the local market even though it has been around for the past 60 years. The material, production and applications are still developing every day. GRP systems are cost effective, corrosion free, lightweight and last up to 50 years. They are also diverse and can be used in potable water transmission, firefighting, sea and desalinated water, power plants, chemical and industrial wastes, sewer applications and irrigation.

IMIESA July 2013

DESIGN AND CONSTRUCTION OF PRECAST CONCRETE ST T RUCTURES

CORESTRUC is the industry leader in South Africa at providing more cost-effective design and construction methods in shorter time schedules. Associated companies Coreslab precast concrete manufacturing and Corestruc steel construction allows the company the opportunity to provide clients with a total structural solution. The experienced, extremely innovative and competent design team combined with the precast concrete and structural steel factories enables Corestruc to construct the most economical structures for South African clients, thereby offering them an additional option to the conventional in-situ concrete method.

T 087 232 2462

F 087 232 2463

info@corestruc.co.za

www.corestruc.co.za

PANEL DISCUSSION

WA ATER RETIC CULATIO ON AND D STORA AGE Willie de Jager | Managing Member | CORESTRUC

reservoir at Perskebult: This project was commissioned by Polokwane Municipality. The baffle walls, columns, beams and suspended slabs were all done in precast. The centre hollow core slabs are 320 mm thick and span 16 m between the grid centres. Lebaka Sports Complex: The total concrete structure was pre-casted by Corestruc, including the columns, raker beams and seating benches. Giyani Civic Centre (currently under construction): This fourstorey office building is being constructed using precast, from the columns, beams, hollow core slabs, to the stairs and concrete walls.

When it comes to water services, what expertise does Corestruc offer the local sector? WDJ Corestruc currently specialises in

Corestruc specialises in roads (bridge beams and barriers), reservoirs, roof structures, water retaining walls, precast stadiums, precast concrete structures for

In South Africa, every drop of water is precious. The challenge facing the local water industry is ensuring safe and sustainable water supply to all communities precasting reservoir and water treatment works roof structures. We have done numerous reservoir roof structures, including the baffle walls in some projects. We will shortly supply water retaining precast concrete walls for reservoirs and tanks, especially in sewerage works.

With regard to supply, what areas of municipal infrastructure does the company specialise in?

office buildings, etc., and any structural precasts.

Explain the importance of secure reservoir structures While municipalities prefer low-maintenance structures, reservoir structures need to stand the test of time and must be durable. Precast offers clients a durable product able to withstand the harsh, corrosive environment. All our precast concrete elements are

rated Class 1, and usually above 50 MPa. But I think the main advantage is definitely the time saved on a project.

Technologies within the industry are constantly evolving. What technology does Corestruc make use of? State-ofthe-art European technology is employed in the manufacture of elements, which are used in our precast concrete structures. Our structural system offers distinct advantages in the construction of a wide variety of projects. These elements benefit from superior quality control achievable at a production plant where conditions can be properly controlled and managed.

Can you cite three of your most recent projects and the extent of Corestruc’s involvement thereof? 30 Mℓ square

In your opinion, what are the main challenges facing the local water industry, and what are your recommendations? In South Africa, every drop of water is precious. The challenge facing the local water industry is ensuring safe and sustainable water supply to all communities. In this regard, properly managed water treatment works and sufficient storage capacity is of the essence. Precast concrete solutions can help to deliver on most required infrastructure within in a short period of time, thereby alleviating the pressure on water authorities.

Corestruc’s main business is the design and construction of precast concrete structures in South Africa and neighbouring countries for reservoirs, office blocks, industrial warehouses, shopping malls, etc. The company prides itself on providing more cost effective design and construction methods in shorter time schedules.

IMIESA July 2013

Pressed Steel Sectional Water Tanks

sustainable and long term Water Storage Solutions Specialists in the manufacturing of domestic and industrial water storage Prestank tank capacities range from 1500 litres to 3,5 million litres designed to SANS 10329:2004 guidelines and SANS structural codes. Our Hot Dipped Galvanising units are easily transported and assembled on even the most remote sites.

Structa Technologyâ€™s Prestanks are hygienically safe, cost effective and a reliable way to store water for commercial sectors, private sectors and even for personalized storage. Choose from temporary or permanent erection at mines, powerstations, building sites, hospitals, water affairs,municipalities, rural communities and agriculture. There is a wealth of water storage applications, for which Prestanks are an answer.

STRUCTA TECHNOLOGY is part of the STRUCTA GROUP of Companies

Structa Technology (Pty)Ltd P.O Box 2538, Vereeniging, 1930 Tel: (016) 362 9100 e-mail: Sales and Marketing: tanks@structa.co.za Estimator: watertanks@structa.co.za Director: rodney@structa.co.za

www.structa.co.za

PANEL DISCUSSION

WA ATER RETIC CULATIO ON AND D STORA AGE Rodney Cory | Director | PRESTANK, STRUCTA TECHNOLOGY With regard to water storage, what expertise does Structa bring to this sector? RC Structa Technology, a member of the Structa Group of companies, is based in Meyerton, Gauteng, and manufactures pressed steel water storage tanks. According to Hercules Rossouw, MD of Structa Technology, the well-known pressed steel water tank’s track record speaks for itself. We are proud to note that we have successfully provided the Medupi Power Station with a 4.2 Mℓ Prestank (38.4 x 28.2 x 4.8 m), among various other notable projects. We also supply sectional steel water tanks to municipalities, rural communities, hospitals and schools, etc. Prestanks are hygienically safe, cost effective and a reliable way to store water for bulk supply. The Prestank may be used for various water storage applications, from temporary or permanent installations at mines, power stations, building sites, hospitals, water affairs, municipalities, rural communities and agriculture. Sectional steel water storage tanks are manufactured according to the client’s specifications. Structa

Technology’s pressed steel water storage tanks are manufactured according to SANS 10329:2004 specifications. Galvanising of tank plates and support steelwork is done according to SANS 121 SABS 1461 specifications.

ABOVE (Left to right) Rodney Cory, director of Structa Technology; Hercules Rossouw, MD of Structa Technology; and Bertus Booysen, production manager; in front of Structa’s 1 300 t Double Action Hydraulic Press Machine

Why are water storage tanks becoming increasingly important for rural areas? Government faces

detail on the challenges of water delivery, as our product simply acts as a water storage facility.

many challenges in water service delivery and infrastructure. We believe water storage tanks are well placed to assist government with this challenge, to provide water to the people where there is a lack of such infrastructure. Our primary function through our product, Prestank, is to provide a water storage solution. In rural areas, we install water storage tanks to house water for the immediate residential population. Water is supplied by the local council, Department of Water Affairs or, in some instances, via boreholes. In urban areas, our tanks are very often utilised in medical facilities, hospitality venues (hotels, etc.). If there is a council water network failure, the water stored in the tank can continue to service the establishment for a certain amount of time. We cannot comment in

Water technology is constantly evolving. What new technologies and/ or systems does your company offer and what are the benefits thereof? Our technology facilitates construction of an infinite range of sizes and configurations to meet the specifications and needs of the client. Handrails, walkways and lightning protection are just a few examples of the features available. The profile panel sections provide excellent rigidity and are structurally sound for storing water. Another major advantage of the sectional steel tank design is that it expedites easier handling and transportation over long distances and to remote areas, regardless of the final dimensions of the assembled unit. Assembly on-site is quickly

achieved without the need for sophisticated tooling methods. Minimum maintenance is required because the galvanised steel panels resist weathering from the elements, while maintaining the integrity of the water within from contamination of most forms. The purpose is to ensure extended maintenance-free life in situations where water with aggressively corrosive properties is required to be stored.

In your opinion, what are the main challenges facing the local water industry, and what are your recommendations? This would have to be infrastructure and services to rural communities (and in some cases, urban), water pollution/water purification, and wastewater management. Our recommendation is for local government to budget more spending on water utilities, services and infrastructure, including the implementation of sectional steel water tanks.

What top three water projects has your company been involved in? Eskom’s Medupi Power Station: 1 x water storage tank with a 4.2 Mℓ capacity; the provision of six water storage tanks to Amajuba District Municipality, with a capacity of 406 080 ℓ each; and the supply of two water storage tanks to Thembelihle Local Municipality, with a capacity of 3.2 Mℓ each.

The Structa Group of companies consist of nine subsidiaries active in the manufacturing and supply of structural steel products for water, infrastructure (electrification and telecommunications), mining, petrochemical and industrial sectors. For more information, visit www.structatech.co.za or www.structa.co.za.

LEFT The Prestank

IMIESA July 2013

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Applications of the Slipform Paver SP 500: t t

Slipforming of continually reinforced as well as conventional dowelled pavement. It is also capable of including offset additionals such as kerbs, drains and channelling as required.

Levelling features with the Slipform Paver SP 500 t

We have retroďŹ tted a Leica 3D system which facilitates stringless operation. The paver is guided in the X,Y and Z using pre-programmed modelling fed to it via prepositioned total stations. This gives unsurpassed accuracies that are unachievable through conventional wire and sensor type operations.

From the N12 Freeway in Johannesburg to the N6 and Gonubie Road in the Eastern Cape - and now the airport runway on the Island of St Helena, Basil Read Roadâ€™s concrete capabilities boast an enviable list of projects.

W: www.basilread.co.za E: communications@basilread.co.za T: +27 11 418 6300

ROADS

BUFFALO CITY

A FIRST FOR BCMM

CRCP solution for road upgrade The upgrading of the Gonubie Main Road (GMR) essentially began in 2005 with the appointment of a consultant and consultation with landowners flanking the road. Richard Jansen van Vuuren reports on the current status of the project.

HE BUFFALO CITY Metropolitan Municipality (BCMM) advised CBM Africa in August 2011 that funds had been secured through allocation from National Treasury for not only the preliminary design, but also construction over the next three financial years,” explains CBM Africa Consulting Engineers’ associate, Ian Swartz. “BCMM had already engaged iTEPA (local traffic engineer) to prepare a traffic model that would assist in predicting potential traffic volumes and movements along GMR. This information was needed to be able to design the junctions and intersections along the road; the design progressed and tender documentation was prepared,” he continues. Swartz outlines the scope of works as: • a 1 m hard shoulder on both sides of the road

• the widening of GMR from three lanes to four lanes (3.4 m) with a central median (2.61 m) that contains a precast concrete barrier • a 1.4 m verge between the carriageway and a 1.5 m wide footpath, on the south side • a 1.9 m concrete V-drain narrowing down to interface with the existing 3 m wide foot/ cycle path, on the north side • outside of the footpath, a 600 mm width to the shoulder break point to contain potential public lighting • incorporation of five junctions (four of which are to be 40 m diameter roundabouts and the fifth a T-junction with the existing Quenera Link Road • the surface is to be a continuously reinforced concrete pavement (CRCP). “We are only three months into the 18-month contract, and so far have widened 39% of the

Project participants Client Buffalo City Metropolitan Municipality Consulting engineers Chew Bowen and Marais Africa Contractor Basil Read

road, relocated services and installed Telkom ducts,” explains Basil Read project manager Barry Leech. “One of the significant challenges on the R150 million contract is to maintain twoway traffic at all times, as the road is extremely heavily trafficked at all times,” he continues.

The upgrading of the Gonubie Main Road includes the widening of the road from three lanes to four lanes

IMIESA July 2013

BUFFALO CITY

Swartz adds that issues with privately owned land adjoining the road alignment may hinder construction as â€œthe road can be contained between the existing fence lines; however, this would require the footpath and verge to be removed from the existing scope of the works.â€? In addition, junctions 4 and 5 may not be constructed at all as land has not been secured beyond the existing fence. â€œThis is not too critical as these junctions do not service any existing access points and are only required for future access when the proposed service lands come into existence,â€? points out Swartz. The BCMM has engaged with valuation processes and is hoping for a willing buyer/willing Following on from the selected layers, two 125 mm G6 stabilised sub-base layers to conform to C4 are to be constructed to bring the widening up to level with the existing surfacing on the existing road

seller before the scope of works The project in numbers can be reduced. â€œThe road bed preparation will Item Unit Quantity be compacted to 93% of Mod Removal of trees 370 AASHTO and layer works. The layer works comprise a lower 26 200 Cut and borrow to fill m3 150 mm selected subgrade layer 3 3 300 Cut to spoil m of G9 material compacted to 95% Mod AASHTO and 150 mm upper 10 500 Selected layers m3 selected layer of G7 material, also 3 12 000 Stabalised sub-base m compacted to 95% Mod AASHTO,â€? layers explains Leech. 1 600 G1 base course layers m3 â€œFollowing on from the selected 3 layers, two 125 mm G6 stabilised 3 340 Bitumen treated base m asphalt sub-base layers to conform to C4 are to be constructed to bring the 72 000 Continuously m2 widening up to level with the existreinforced concrete ing surfacing on the existing road. pavement Running concurrently with the earthHigh tensile steel tonne 970 works and layer works, a suite reinforcing of four Telkom ducts are being H1 containment m 3 504 installed alongside the four existing median barriers fibre optic cable ducts for the whole Service ducting m 1 750 length of the contract (3 800 m), along with associated manholes Concrete stormwater m 934 and junction boxes,â€? he continues. pipes â€œOn completion of the surfacing Kerb and channel m 2 400 work, a 180 mm layer of CRCP will be machine paved along and Telkom ducting m 16 000 across the entire road, including the widened sections.â€? â€œThe same Wirtgen SP 500 paver equipment Basil Read recently received two commendawill be used on the upgrading of GMR contions at this yearâ€™s Fulton Awards for the CRCP tract,â€? explains Basil Read contracts director on the N12 highway project in Johannesburg, Paul Walker. one in the Civil Engineering Structure â€œTo the professional teamsâ€™ knowledge, this category and the other in the Innovative is the first time this technology will be used Construction category. within the BCMM boundaries.â€?

IMIESA July 2013

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BUFFALO CITY

WASTEWATER

Expanded WWTW hits home stretch Residential development in the municipal area of Buffalo City will soon receive a shot in the arm, due to the increased capacity of the Quinera Wastewater Treatment Works (QWWTW) near Gonubie, East London.

HE FACILITY WAS nearing the limits of its installed capacity, and concerns about the possible overloading of the QWWTW resulted in Buffalo City Municipality (BCM) placing a moratorium on any new developments in the Quinera and Gonubie areas until its capacity could be upgraded.

Background BCM appointed SRK Consulting to investigate and estimate the future loading of the works; the findings of SRK’s report were published in September 2005, where it recommended that an upgrade was necessary – from the existing capacity of 6 Mℓ/d to 18 Mℓ/d – to accommodate future growth of the area. Phase 1 of the project was completed in September 2009 and focused on the civil and mechanical aspects of the expansion, including the construction of a new concrete inlet

IMIESA July 2013

works with rotating mechanical screens and vortex degritter, a new splitter box to distribute the screened sewage to two aerobic reactors, and a new waste-activated sludge dewatering system. As principal agent, SRK worked with principal contractor Erbacon Construction and mechanical subcontractors Huber Technology and Sulzer (previously ABS) on this part of the project.

Second phase In August 2012, the second and final phase of the project got under way, dealing with the electrical and electronic works, with a joint venture of Ursa Civils and Give Ziyawa as principal contractor. “In May 2013, we were about 50% through the construction of Phase 2, with commissioning scheduled to be completed by the end of November,” says Marinus Meiring, principal engineering technologist at SRK.

Clarifier under construction – Phase 1

The Phase 2 contract, worth about R45 million, comprises the supply, installation, and commissioning of: • medium voltage (11 kV) and low voltage (600/1 000 V) underground cables • indoor 11 kV and low voltage switchgear standby diesel alternator plant • motor control equipment • electronic programmable logic controllers (PLC) • flow measurement systems • supervisory control and data acquisition (SCADA) systems • ventilation and fire detection systems • associated electrical and electronic equipment. It also included the construction of a new substation building and alterations to the existing buildings.

BUFFALO CITY

The scope of works comprises the manufacture and installation of a five-unit 11 kV switch panel and two 1 250 kVA transformers in the new QWWTW substation building, and a 500 kVA miniature substation located in the vicinity of the QWWTW sludge dewatering building. “SRK has a full-time resident engineer on-site, overseeing quality aspects of the project, and we also oversee all financial aspects of procurement,” says Meiring. There was a small component of civil works under way, such as access roads and remaining water pipelines, but the main challenge in this phase was to divert the main effluent flow from the old works to the new works, he says. “It was quite a demanding task to integrate the new and old works, as this had to be done while the effluent was still flowing,” he highlights. “This required some fairly pressurised, through-the-night operations while the flow was low, pumping incoming effluent around the manholes where we were working and building diversions for the flow. We’d only have a four to five-hour window of opportunity before

Marinus Meiring is a principal engineering technologist in SRK Consulting’s Port Elizabeth office and has been involved in the field of civil engineering for the past 15 years. He holds a National Diploma in Civil Engineering (1998) and a Bachelor of Technology Civil Engineering: Water (2004) from Port Elizabeth Technikon, earning his registration as a professional engineering technologist (Pr Tech Eng) in 2008. His career has spanned a wide range of projects, including water and wastewater treatment, solid waste disposal, bulk water supply and municipal services. Through his experience in the sector since 1998, his expertise includes: • project management and contract administration • planning, design and detailing of general civil engineering infrastructure, water supply systems (also treatment works, bulk pipelines and reticulation) and wastewater disposal systems • preparation of tender and contract documentation. Meiring is a member of the South African Institute of Civil Engineering (SAICE), the Water Institute of Southern Africa (WISA) and the Institute of Municipal Engineering of Southern Africa (IMESA).

everyone started waking up and the flow would increase.”

Automated The new plant boasts a high level of automation, with the electronic engineering scope of work including access control systems and CCTV in addition to the SCADA installation, monitoring equipment (for flow, level and effluent quality) and the PLC controls for the plant and motor control systems. “The major benefit of these new automated systems is that the operator will be able to see, in real time, the key parameters of the plant’s operation,” points out Meiring. “This will allow him to make adjustments immediately on the basis of changed conditions, such as variations in the quality of incoming effluent. “The systems will also monitor the quality of the treated effluent being discharged and will make this information available in real time. The operator is then able to check that this quality is within compliance criteria and can take corrective steps if necessary.” Energy-efficient aeration A significant innovation in the new facility is the use of fine-bubble aeration instead of conventional surface aerators. While this is not a new technology in itself, it will be the first time it is being applied in Buffalo City. “This aeration method involves pumping air down a series of pipes to the bottom of the reactor tank so that bubbles rise through the Fine bubble action – diffusers installed in aeration basin

effluent,” says Meiring. “This is much more energy efficient in terms of kilowatt hours of electricity per milligram of oxygen supplied.” The aeration is vital to provide oxygen for bacteria in the reactor, to break down effluent and reduce odour. Apart from its normal automatic mode of operation, the integrated plant will also be able to run in an off-peak auto mode; this will allow reduced operation of the blowers during peak electricity tariff periods, if the flow load is light enough. The works will also be able to run on standby diesel alternator if the main electricity supply is interrupted. “Another improvement we will be making is to dewater sludge using mechanical filter presses instead of just evaporation,” he continues. “Previously the sludge was pumped to a lagoon where it would dry out.”

Training In terms of the contract, the contractor is responsible for training the BCM staff on the proper operation and maintenance of each element of the electrical and electronic plant; the training is required to be done over a twoweek period, during which time the staff will become familiar with all the necessary equipment manuals. The contractor will also maintain the installation for the first year of operation, involving BCM staff in all maintenance procedures to ensure skills transfer. Due to the high-tech nature of Phase 2, few people have been employed on-site this year, explains Meiring; the project is now employing about 30 locals and 15 specialists from elsewhere.

IMIESA July 2013

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PIPES, PUMPS & VALVES

SEDIBENG CASE STUDY

Large diameter installation A new Sedibeng Water Board pipeline installation is set to become the benchmark for rapid and robust piping installations for municipal water supplies and similar applications in South Africa.

FTER THE DISCOVERY of leakages in a major 500 mm diameter welded pipeline serving the Springbok area, the Sedibeng Water Board chose BVi Consulting Engineers to design the rehabilitation and replacement work on the existing main water supply pipeline. As a temporary replacement for part of the ageing but vital 54 km long pipeline, a 14 km bypass surface pipeline was designed for continuous water supply over difficult terrain. It involved 300 mm carbon steel medium pipe (300 NB) on concrete plinths. BVi, acting first as project manager and later as consultant, relied on Victaulic grooved mechanical pipe joining solutions to ensure continuous water supply to local areas. Employing Victaulic products allowed fast installation using local labour, and delivered considerable benefits over the flanged or welded alternative.

Alternative choice Traditionally, flanged or welded piping would be used on such a water distribution pipeline.

However, the decision to install a grooved mechanical piping system from Victaulic was based on the speed and ease of installation and the flame-free assembly this allowed, resulting in savings on total installed cost. Not only was the Victaulic system faster to install, but its ease of assembly allowed the use of a local workforce and created jobs in the area. Another key advantage that the mechanical pipe joining system offers is that it enables rapid assembly and disassembly, making tasks such as maintenance and system rerouting considerably more convenient. Some of the major advantages of installing Victaulic products are derived from their simplicity â€“ the design of a mechanical pipe joint is inherently easier to work with during installation than other more traditional joining methods. A mechanical joint, or coupling, is comprised of four basic but robust elements: the pipe groove, gasket, coupling housings, and nuts and bolts. A pipe groove is formed by cold forming or machining a groove into the end of a pipe

â€“ using an easy-to-use Victaulic grooving tool, it is possible to do this on-site, as at Sedibeng, or off-site in a workshop enabling prefabrication. The coupling gasket is pressure responsive and is encased by the coupling housing when it engages in the groove around the circumference of the pipe. The gasket then creates a seal unified joint that is enhanced when the system is pressurised. Grooved piping systems are dramatically faster and easier to assemble than their welded or flanged equivalents. Systems in which Victaulic products are installed are also considerably faster to disassemble than other pipe joining methods, with dramatic time and labour savings. At Sedibeng, this meant that while the process of replacing or rehabilitating the existing main line was in progress, the temporary bypass line could be assembled â€“ and in a fraction of the time of a welded or flanged LEFT The 14 km bypass surface pipeline involved 300 mm carbon steel medium pipe (300 NB) on concrete plinths BELOW Victaulic Style 77 flexible couplings feature a two-piece design that creates a flexible joint while reducing handling and enabling easier and quicker installation

IMIESA July 2013

PIPES, PUMPS & VALVES

system. In the future, once the original line is replaced and fully functional, the bypass may then be dismantled in a fraction of the time taken by a more traditional joining method. Parts can then be reused. BVi specified 300 mm Victaulic Style 77 flexible couplings on the project and 2 333 couplings were subsequently installed. Victaulic Style 77 flexible couplings feature a two-piece design that creates a flexible joint while also reducing handling and enabling easier and quicker installation. The couplings can withstand pressures of up to 800 psi/5500 kPa and are commonly used for a variety of industrial applications, including water and air applications. The main reason why BVi specified Style 77 flexible couplings is that, over time, terrain may be subject to displacement and ground movements, creating potential stress on pipework and even resulting in breakages. All these stresses are difficult for engineers to manage. Flexible couplings are especially designed to allow controlled linear and angular movement at each joint that can accommodate pipeline deflection. They offer security while also accommodating potential misalignments without the need to install the expensive and delicate specialised equipment, which is necessary with flanged or welded systems. “It did not take long to convince the Sedibeng Water Board, which soon realised the benefits of the Victaulic grooved system,” says BVi consulting engineer Winston Cloete. “The system clearly delivered significant advantages. We were all confident it was the right choice.” The ability to offer a totally secure leak-free joint, speedy installation and ease of maintenance secured the decision. “I would definitely use the Victaulic system again in a flash,” comments Cloete.

Contractor view Contractor NMC North was awarded the contract to install the pipework after a successful tender. The company had worked closely before with both the Sedibeng Water Board and BVi. “The biggest challenge from our perspective was the difficult terrain,” says Dallas van der Westhuyzen, contract manager with NMC North. “Once the installation started, we realised very quickly just how easy and fast the work could be completed with Victaulic couplings, despite the uneven ground.” For the local crew, learning to use the grooving tools and couplings was extremely easy. Training lasted under an hour and right from the start teams were taking only 10 minutes to complete a perfect joint. On average, the crews were completing 25 lengths of 6 m pipe per day, and by the end of the project they were reaching an astounding 37 pipe lengths per day. The entire initial 6.5 km pipe run was completed on time, although challenges occurred with the delivery of materials from other suppliers. In addition, the next phase of 7.5 km was completed four weeks earlier than the anticipated completion date. A flanged system would have required around 16 M30 bolts and nuts to be installed and tightened at each joint, and the handling of the pipe would have been more difficult due to the added weight. The Victaulic grooved system

ABOVE Difficult terrain presented some of the major project challenges, but Victaulic mechanical pipe joining solutions overcame them

offered the added advantage of reducing health and safety risks. As less time is spent on the joint, there is less exposure to worksite risks, reducing likelihood of injuries to fingers, compared with installing a flanged system. The crew also found it very easy to check if installation was correct and the joint was in place securely – simply by looking at the bolt pads and making sure they met each other without any gaps.

Conclusions In Sedibeng, installing a Victaulic grooved system made for easier maintenance, reduced material handling and risk of injury to workers on-site, as well as total installed cost. “The grooved system saved substantially on labour and I cannot imagine reaching the same productivity level with a flanged or welded system,” maintains Van der Westhuyzen. The Victaulic team also provided full support with on-site training, continued site visits and technical support. Cloete adds: “I am convinced that this is the fastest, easiest and trouble-free way to join pipes. “And I can see the considerable maintenance advantages this will offer the Sedibeng authority in the future.”

IMIESA July 2013

PIPES, PUMPS & VALVES

TRENCHING

Precision cuts with trencher For North West contractor Aquanic Environmental Services, the requirement for on-site mechanical versatility is mirrored in the diverse range of contracts that fall within the company’s project scope.

OUNDED IN 1990 as a landscaping and irrigation business, the company’s services have grown extensively to include an ‘A to Z’ solution for fluid management delivery. “We specialise in the design of water reticulation systems, including slurry, potable supply, wastewater and sewage, with implementation backed by our civil engineering capability for allied areas such as pump stations, stormwater pipelines and concrete run-off channels,” states Aquanic’s general manager, Nico Jacobs. Executing Aquanic’s various projects depends on the right equipment selection, the most recent being the acquisition of a Cat 226B skid steer loader together with a Cat T9B trencher work tool attachment to complete various underground service contracts. The Cat T9B forms part of a three-model trencher range within Caterpillar’s comprehensive work tool line-up, designed for fitment on Cat compact loaders and skid steers. The other Cat trencher units comprise the Cat T6B and the range-topping T15B. Standard boom lengths for the T6B, T9B and T15B are 914, 1 219 and 1 524 mm, respectively, with a unit weight, in turn, of 397, 551 and 601 kg. Optional cutting widths across the board are 152, 203, 254 and 305 mm. “These units are designed for cutting narrow straight trenches in the soil prior to laying electrical, telephone and cable lines, or water and gas pipes, making them ideal for tasks that include agricultural, construction and landscaping applications,” says

Barloworld Equipment Cat sales professional Bianca Herbst. For each tool interchange, Cat skid-steers are equipped with a manual quick coupler

BELOW Caterpillar fields three-trencher models in its work tool line-up; optional cutting widths for all three models are 152, 203, 254 and 305 mm to suit site specific applications BOTTOM Operating the trencher with the boom angled down between 45- and 65-degree angles from the horizontal position will ensure maximum performance

featuring a rugged, opposing edge design that holds the work tool securely in place. On the go, a distinctive feature on Cat trenchers is the auger flight system, which has been specially designed so that spoil piles are high and at a safe distance from the trench. This ensures a clean trench and easier backfilling. For Aquanic, the results speak for themselves. “The T9B, coupled with our Cat 226B, has cer tainly exceeded expectations, per forming well at daily work rates of between 200 and 300 m, depending on ground conditions and final cutting depth, accelerating the construction programme on a number of private and public sector projects completed going into 2013. These include various soccer fields, as well as services for mine housing,” adds Jacobs.

IMIESA July 2013

ASM LXH 15mm Brass

ASM LXHS 15mm Plastic

ASM LXH 20mm Brass

Meter in a Ground Box

The above meters are all NRCS TYPE APPROVED APPLICATION: Measures the volume of cold potable water passing through a pipeline. FEATURES: • Accurate registration across a wide ÀRZ range. • Mechanical drive for maximum reliability. • Corrosion resistant body. • Clear, easily read, liquid sealed 8 digit counter. • Registering begins at low ÀRZ rates. • Internal non return valve and strainer. • Each meter has a unique serial number. • Pulse prepared. • Inlet & Outlet threads compatible with I.S.O metric sizes. • Plastic Body Meters UV Stabilised. • Plastic Body exceeds 48bar.

MAXIMUM PERMISSIBLE ERRORS: • In the lower zone from (qmin) inclusive up to but excluding (qt) is ±5%. • In the upper zone from (qt) inclusive up to and including (qs) is ±2%. WORKING CONDITIONS: • Water temperature: 2°C ~ 40°C. • Water pressure: 03D EDU COMPLIANCE STANDARD: • Conforms to ,62 Class C Standard. • Conforms to SANS - INSTALLATION REQUIREMENTS: • May be installed on a horizontal or vertical pipeline (horizontal recommended). • Pipeline must be ÀXVKHG before installation. • Meter should be constantly full of water during operation.

We also have a range of BULK WATER METERS: LXLC 50A (mm) ~ 500A (mm) Cape Town: Tel: 021 510 4266 | 510 8408 Fax: 021 510 8759

Johannesburg: Tel: 011 609 6336 Fax: 011 6099 531 LEVEL 2

E: info@precisionmeters.co.za | W: www.precisionmeters.co.za

PIPES, PUMPS & VALVES

AFRICAN SUPPLY

Project management muscle A customer’s need for turnkey responsibility can be successfully turned to competitive advantage and then used as a lever to secure project work ahead of better known project houses unable to offer similar capability.

HIS IS THE opinion of Peter Robinson, managing director of APE Pumps, who says that his company’s ability to manage all aspects of design, manufacture, delivery and installation has been largely responsible for the its increasing project order book across Central and Southern Africa. Robinson claims an almost unlimited project capacity for present-day APE Pumps, even though the company has not until now been associated with project management work. “APE now has the expertise of what used to be PSV Services, reinforced by the funding of India-based parent WPIL,” he explains. “Together, these make for a potent force

in project management, and we are currently applying to the Construction Industry Development Board for a capacity rating, which we expect to be in the region of R100 million. “Actual capacity is far higher because of the financial muscle available to us.” Currently, APE Pumps is busy with Chileka, the Blantyre Water Board’s €8 million (R103.55 million) contract to upgrade the pump station supplying Blantyre from Walkers Ferry on the Shire River, in Malawi. Scope of work comprises the supply, installation and commissioning of eight multi-stage pumps together with electric motors, motor controls and associated valves, and civil works

Peter Robinson (behind pump) and Alan Sternsdorf, co-directors of APE Pumps

that include the demolishing and rebuilding all concrete plinths and bases in the pump house. All electrics, motor controls and HV switchgear for the project, including five 5 000 kVA transformers, will come from India. The pumps themselves will be Mather & Platt 750 m3/h multi-stage units manufactured by APE Pumps Wadeville. A secondary contract provides for inspection of the associated pipeline for leakage and examination of surge protection and sacrificial cathodic protection. IMIESA July 2013

uppe marketing A07782

INFR SET

BUILDING DURABLE INFRASTRUCTURE

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

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

PIPES • CULVERTS • MANHOLES:

RAILWAY SLEEPERS • POLES & MASTS

PAVING • RETAINING WALLS • ROOF TILES

Steeldale House

GAUTENG – TEL: +27 (0)11 876 5100

NATIONAL – TEL: +27 (0)11 813 2340

ROSSWAY (MIDRAND) – TEL: +27 (0)12 652 0000

TEL: +27 (0)11 876 5500

CAPE TOWN – TEL: +27 (0)21 908 1156

KWAZULU NATAL (EFFINGHAM) –

FAX: +27 (0)11 872 1713

KWAZULU NATAL (PIETERMARITZBURG) –

TEL: +27 (0)31 569 6900

EMAIL: infrasetinfo@infraset.com

TEL: +27 (0)33 387 2236

www.infraset.com INTERNATIONAL BRANCHES SWAZILAND – TEL: +2682 518 4236 | ZAMBIA – TEL: +260 21 131 1838

PIPES, PUMPS & VALVES

INDUSTRY STANDARDS

Random quality tests SAPPMA has just concluded the third round of random sampling of plastic pipes manufactured in South Africa in order to test for product quality and consistency.

UE TO THE fact that the plastics piping business is a strategic industry, hardware needs to be reliable for extended periods of time. Long-term product quality is fundamental and quality plastic pipe should be good for a minimum period of 50 years according to industry standards. To ensure industry compliance and high standards throughout, the Southern African Plastic Pipe Manufacturer’s Association (SAPPMA) launched the first in a series of random sampling exercises at the beginning of 2011, whereby a selection of pipes were randomly obtained from various stocking merchants.

How plastic pipes are tested A number of PVC and HDPE pipes, all bearing the SABS mark of quality, were randomly selected in the market and then tested at an independent certified laboratory, all according to the relevant SANS standards. Analysing the results According to Jan Venter, chairman of SAPPMA, the results of the tests showed that a considerable percentage of SABS mark-bearing pipes did

not entirely conform to the relevant standards. “The SABS mark is supposed to give consumers and end-users peace of mind that a product has passed performance and quality assurance tests stipulated in a standard or regulation, or that the product complies with a national and international standard or regulation governing quality and minimum performance requirements,” explains Venter. However, due to growing economic pressures, it is easy for a manufacturer to look for ways in which to cut costs, which often impacts negatively on product quality. “It is important to for SAPPMA to be seen as not working against the SABS, but as an association that is strongly supporting it as a custodian of the National Product Standards,” Venter says. “It is our vision to create absolute quality, trust and integrity throughout the value chain of the Southern African plastics pipe industry. To this end, SAPPMA continues to work very closely with the SABS in a joint effort to weed out inferior quality plastic piping systems.”

Raising the bar to become a member of SAPPMA Although the quality of pipes manufactured by

“The SABS mark is supposed to give consumers peace of mind that a product has passed performance and quality assurance tests.” Jan Venter, chairman of SAPPMA

SAPPMA members was generally superior to that of those manufactured by non-members, the association felt it necessary to develop a number of additional requirements that need to be met before pipe manufacturers would be allowed to obtain and use the SAPPMA mark of approval. These include: • the company’s products must be SABS approved and bear the SABS mark • the company must be listed under the ISO 9001 scheme, or working towards it (in the latter case, SAPPMA will conduct a full systems audit prior to accepting the member) • the company’s CEO must sign a Code of Conduct and Letter of Undertaking, outlining certain matters related to quality – this document must be refreshed annually before a Membership Certificate is issued. • regular, unannounced factory audits will be carried out, whereby pipe samples are to taken and tested at an independent laboratory • PVC pipe must be manufactured without lead or any other heavy metal stabilisers • additional internal standards are continuously developed and applied to further raise the product standard of member companies. The SAPPMA Board has decided to implement additional disciplinary steps against members whose products repeatedly do not conform to standards. The process for the fourth survey has already begun, and SAPPMA is expecting to release the results in the coming weeks.

IMIESA July 2013

The rugged range of Ditch Witch Horizontal Directional Drilling (HDD) equipment and Chain Trenchers gives you the punch you need to drill or dig through some of the toughest landscapes. And with a wide choice of attachments, Ditch Witch lets you triumph over those tough jobs – everytime! HammerHead® pneumatic piercing tools create a compact hole for almost any underground installation with minimal disruption to landscapes, buildings or normal traffic flow. The latest “must have” tool for municipalities, electrical, cable/ telecom, sewer, irrigation and plumbing contractors.

HammerHead® Tough and Trusted

For further information on hiring a Ditch Witch please contact ELB Equipment.

ELB EQUIPMENT LIMITED HEAD OFFICE: 14 AtlasOFFICE: Road Anderbolt Boksburg (011) 306-0700 • e-mail: Elb@elbquip.co.za • www.elbequipment.com HEAD 14 Atlas Road Anderbolt Boksburg (011) 306-0700 • e-mail: Elb@elbquip.co.za • www.elbequipment.com BLOEMFONTEIN: (051) 432-3594 • BRITS: (012) 250-1565 • CAPE TOWN: (021) 933-2383 • DURBAN: (031) 464-6522 EAST LONDON: (043) 748-1469 • GEORGE: (044) 878-0874 • KIMBERLEY: (053) 841-0040 BLOEMFONTEIN: (051) 432-3594 • BRITS: (012) 250-1565 • CAPE TOWN: (021) 933-2383 • DURBAN: (031) 464-6522 • EAST LONDON: (043) 748-1469 MIDDELBURG: (013) 246-2312 • NELSPRUIT: (013) 755-1003 • WOLMARANSSTAD: (018) 596-3032 GEORGE: (044) 878-0874 • KIMBERLEY: (053) 841-0040 • MIDDELBURG: (013) 246-2312 • NELSPRUIT: (013) 755-1003 • POLOKWANE (015) 293-1978 POLOKWANE: (015) 293-1978 • PORT ELIZABETH: (041) 451-0232 PORT ELIZABETH: (041) 451-0232 • WOLMARANSSTAD: (018) 596-3032 BOTSWANA: (00267) 240-4320 • NAMIBIA: (00264) 61-234-052 • SWAZILAND: (00268) 518-5348 • ZAMBIA: (00260) NAMIBIA: (00264) 61-234-052 • SWAZILAND: (00268) 518-5348 • ZAMBIA: (00260) 212-210-642 • ZIMBABWE: (00263) 4 485 771/2/3/4 212-210-642 • ZIMBABWE: (00263) 4 494-871 For further information on hiring a Ditch Witch please contact ELB Equipment.

PIPES, PUMPS & VALVES

WATER LOSS

The real cost of metering The decision to invest in good-quality water meters that are specifically designed and optimised for South African water conditions can significantly reduce non-revenue water and enhance and maximise an authority’s revenue.

CCORDING TO Mark Shamley, MD of Elster Kent Metering: “Water losses in the distribution system can be categorised into two types: the real losses from leakage or the apparent commercial losses that often result from inaccuracies in metering, meter reading errors or even billing errors. These losses can have a negative impact on the municipality’s revenue, despite these apparent water losses being easily reduced through choosing the best performing meter that is suited for the specific local water conditions.” Most domestic meters in South Africa are mechanical devices and performance degrades as a result of: • volume of water flowing through the meter • quality of water flowing through the meter – suspended solids (grit) in the water supply. Both factors cause the meter to under-read and hence the consumer pays a lower bill than the actual amount of water that has passed through the meter. Shamley says: “Some meters are designed for the harsh water conditions experienced in South Africa and throughout Africa and, hence, perform better by coping better with suspended solids under these local circumstances and thereby degrading at a slower pace than many of the imported meters.” It is not wise to buy the cheapest meters as this could end up costing a municipality more in revenue than was saved initially over the meter’s life cycle. “It’s not the cost of the meter, but the cost of metering that’s important, which ultimately takes into consideration the cost of lost revenue due to a meter under-reading,” continues Shamley. He states that when meters are tested, the tests are

Meters in South Africa are typically installed for periods of 20 to 30 years, but due to local water conditions, the optimal meter replacement period in South Africa is probably every 8 to 10 years

performed under ideal conditions with clean water. Elster Kent meters are designed and optimised to be utilised in South African and African water conditions, unlike many of the imported meters. Results of accuracy tests with grit in the water show a comparison between the performance of a good revenue 1.5 Qp Class C Elster Kent Meter against a cheaper model imported from the East. The test results show that the cheaper imported meter under-read by as much as 9.95% than a good locally produced Elster Kent meter. In this specific example, the under-reading of the cheaper import caused the authority to lose R45.83 per month per meter in lost revenue compared to the local meter (using Johannesburg tariffs for 2012/13), yielding a payback on the original cost difference of the meters of only 0.7 months. This would equate to R4.58 million lost revenue per month for the authority should it have 100 000 of the cheaper imported meters installed (or R55 million per annum – the equivalent of the total annual meter capex of an average-sized metro in South Africa).

Meters in South Africa are typically installed for periods of 20 to 30 years, but due to local water conditions, the optimal meter replacement period in South Africa is probably every 8 to 10 years, depending on the household’s water consumption, the quality of water going through it and the quality of the water meter. The Elster Kent KSM Volumetric meters are a fine example of a good revenue meter that caters for African water conditions. The unit provides optimum accuracy and performance at all times, even at the lowest flow rate. The meter can be installed in any position, i.e horizontally, vertically or inclined pipelines, maintaining optimum performance with no loss of accuracy. The Elster Kent low revving revolutionary grooved piston provides a long working life and ensures that meter stoppages are substantially reduced, durability enhanced and performance improved as a result of the uniquely designed grooved piston within the meter measuring chamber. The action of the grooved piston, with the stationary chamber wall, creates flow eddies that hold solids in suspension until flushed out, thus reducing meter stoppages. Another unique feature of the unit is the gear train that is mounted in a gearbox. This maintains optimum alignment of the gear and reduces friction. The compensating ramp is a unique way of allowing movement in the plastic body where there are pressure shocks. Other meters do not generally compensate for this movement leading to mal-alignment of the gear-train. “At the end of the day, the water meter is the cash till of the system. The cheapest meter is not necessarily the best revenue meter and in the long run, procuring a good quality, good revenue meter can pay back in less than a month. The actual cost of metering should take into consideration the average cost of the meter, plus the cost of water that the meter doesn’t measure,” maintains Shamley.

IMIESA July 2013

PIPES, PUMPS & VALVES

WATER MANAGEMENT

Water management for sustainable profits Over the years, ore concentrations have decreased considerably, with many companies having to mine and process more rock for every tonne of quality ore produced.

N A NUMBER OF cases, this has multiplied process water requirements to an extent that, on the back of stricter discharge legislation, low concentration mining may be losing some of its profitability, despite higher commodity prices. Chris Howell, the global market director for mining and primary metals at Veolia Water Solutions and Technologies, explains how better water management can help to maintain a mine’s feasibility: “Every mine would like to have a neutral water balance. In a positive water balance mine site, it may be a requirement to achieve a zero liquid discharge (ZLD), or zero liquid waste status,” he says. “For instance, process water can be treated and reused on-site, which reduces the environmental impact associated with fresh water intake. Some of the latest treatment technologies available to the market allow process water itself to be mined for valuable

by-products. This allows a mine that’s primarily focused on supplying a particular mineral to expand its mineral offering and grow additional revenue streams,” says Howell. This ‘solution mining’ can produce valuable yields of salt, ammonium sulphates, hydrogen chloride, sulphuric acid, among various other by-products. As a total water and wastewater solutions company, Veolia has experienced rapid growth in the mining market. The largest industrial project in Veolia’s 155-year history involved solution mining is a potash plant in Saskatchewan, Canada, which extracts water soluble minerals through crystallisation, resulting in a solid product that is easy to handle and sell to fertiliser manufacturers. Closer to home, Veolia Water Solutions and Technologies South Africa recently completed a large evaporation plant in Ambatovy, Madagascar, which produces ammonium sulphate left behind by the primary nickel and

ABOVE Chris Howell, Veolia Water Solutions and Technologies’ global market director for mining and primary metals was recently in South Africa to participate in Veolia Water Solutions and Technologies South Africa’s technical seminar in Johannesburg BELOW Veolia Water Solutions & Technologies is building a 1.7 Mℓ/d seawater desalination plant in Lamberts Bay, which will alleviate growing pressures on the region’s water system

cobalt extraction processes, while achieving a ZLD status. Ambatovy is positioned to become the world’s biggest lateritic nickel mine by 2013/14. “We’ve seen globally that a lot of existing mining facilities have had to upgrade or make changes to their water treatment processes to comply with stricter discharge requirements. This is the right time to investigate whether advanced water treatment solutions and product recovery is indeed feasible for that particular mine,” says Howell. Greenfield projects currently have the opportunity to benefit from ZLD technology from the beginning of their life cycles. This better optimises mine profitability, as well as better prepares a mine for eventual closure – whether 20 or 50 years from now – which can be very expensive if refinement processes leave behind a legacy of toxic tailings ponds. “Helping mines become more profitable and more environmentally sustainable falls within Veolia’s global service, value and responsibility model. As a large multinational, we will continue to develop technologies that enable further advantages, including energy savings, while reducing the risk of wasting valuable resources. Water is too valuable to only be used once,” maintains Howell.

IMIESA July 2013

PRODUCTS & SERVICES

INDUSTRY SERVICES

C&CI services preserved by new Concrete Institute Three of South Africa’s leading cement producers have stepped in to fund the establishment of a new company to preserve the vital education, and consulting services previously provided by the Cement & Concrete Institute (C&CI).

FRISAM, LAFARGE and Sephaku are now financing the operations of The Concrete Institute, which, from 2 May this year, started providing most of the major services previously provided by the C&CI. The C&CI closed down at the end of April following the withdrawal of funding. Bryan Perrie, the former MD of the C&CI, is in charge of The Concrete Institute, a non-profit company, with a number of key members of the C&CI staff retained. The Concrete Institute will offer vital concrete technology services to the construction industry, including: • education and training • an information centre • consulting • publications. With regard to education and training, Perrie says all the courses listed in the C&CI’s School of Concrete Technology 2013 training programme are still being offered.

“We are, in fact, hoping to expand the curriculum by including even more courses. The Concrete Institute has also taken over the responsibility of running the comprehensive and highly respected Advanced Concrete Technology course that was under way when the C&CI closed,” states Perrie. The Concrete Institute is currently also offering a free advisory service as well as chargeable consulting services, including on-site visits by technical staff. The institute will continue to offer a comprehensive information centre. The centre, equipped with top specialists and

state-of-the-art computerised systems, is one of the largest and most respected sources of information on concrete on the southern hemisphere. The institute will also distribute the wide range of C&CI publications. “There was widespread dismay within the building and construction industries when the C&CI was forced to close doors. With the new support of new cement producer, Sephaku, as well as AfriSam and Lafarge’s continuing support, we are now confident that the Concrete Institute will continue to provide the services that made the C&CI an industry icon over the past 75 years.”

“The Concrete Institute has also taken over the responsibility of running the comprehensive and highly respected Advanced Concrete Technology course.” Bryan Perrie, managing director of the Concrete Institute

INDEX TO ADVERTISERS APE Pumps Aquadam

Aveng Manufacturing Infraset

Babcock

Barloworld Equipment

Barloworld Equipment Metso

Basil Read

Bosun

BVi Consulting

CBM Africa Consulting Engineers

Corestruc

Ecochem Pumps

IMIESA July 2013

ELB Equipment ERWAT Fiberpipe Gast International Group Five Pipes Incledon Khrone SA Mercedes Benz SA National Asphalt PDNA PPC Cement Precision Meters Quality Filtration Systems

68 26 46 28 60 62 31 OFC 38 14-15 20 64 32

Rainbow Reservoirs

SBS Water Systems

IFC

Structa Technology

Sulzer Pumps Wastewater

Tenova Bateman Technologies

UWP Engineering

Veolia Water Solutions & Technologies South Africa

Victaulic

Water and Sanitation Services South Africa WRP Consulting Engineers

OBC IBC

Supported by the International Water Association

Main supporting organisation Midrand event:

20 & 21 August 2013 DBSA Vulindlela Auditorium, Midrand, South Africa

Main supporting organisation Cape Town event:

MARK YOUR CALENDAR

22 & 23 August 2013 Rotunda Hall, Bay Hotel, Camps Bay, Cape Town, South Africa

WRP Consulting Engineers is pleased to announce the dates for the 2013 annual Water Leakage Summit which will be held this year at the DBSA Vulindlela Auditorium in Midrand on 20 and 21 August 2013 and at the The Bay Hotel in Camps Bay on 22 and 23 August 2013. Places for the Summit will be limited to 150 at each venue and will be allocated on a first come first serve basis. Please diarise the dates and ensure that you book your place at this year's event early to avoid disappointment. Closing date for registration is 26 July 2013. Tim Waldron from Australia, who is the chairperson of the International Water Associationâ€™s Water Losses Specialist Group will present a key-note paper at the event on behalf of the IWA on the latest international Trends on Water Loss Reduction. Dr Guenter Hauber Davidson from Australia - a specialist on Industrial Water Auditing and Water Demand Management in the Industrial Sector will also present at the summit. Feedback from the 2012 Summit was extremely positive thanks to the tremendous support from DWA, WRC, DBSA, SASOL and the City of Tshwane and the numerous specialists who kindly presented at the events. Based on the feedback we have received we therefore plan to tailor the content of all future Water Loss Summits to reflect the latest developments in Water Loss Control as well as the specific needs as suggested by the delegates. Each annual event will therefore provide new and useful information that will assist all Municipal Water Loss personnel to reduce their losses. The events are aimed at Municipal personnel and those in government organisations who have an interest in understanding water loss management. The summit will carry 2 CPD points. The cost of this year's event will again be held at the 2010 rates namely R3420 (including VAT) per person for the 2-day event. All WISA and International Water Association members attending the summit, will receive a discount on the summit.(Discounted rates for IWA/WISA members: Summit - R2736 (including VAT)). Please note that special room rates (B&B) have been negotiated with the Bay Hotel for the duration of the Cape Town event and have also been extended to the following week for those wishing to stay on in Cape Town. The Bay Hotel can be contacted directly for any bookings. For further information and to register your interest in attending this event as a delegate, sponsor or exhibitor, please email: constancem@wrp.co.za or call + 27 (12)346 3496 (Constance Makola or Zama Siqalaba). We look forward to seeing you at the African Water Leakage Summit again this year! Ronnie McKenzie & Willem Wegelin Conference Directors, 3rd REGIONAL IWA AFRICAN WATER LEAKAGE SUMMIT 2013 CPD Accredited (2 points) SAICEwat13/01351/13

Participating organisations :

A Miya Group Company

-GPV /GVGTKPI 2V[ .VF

4Water Supplies (Pty) Ltd