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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

SICELO XULU Leading City Power

PPC CEMENT Building a network of strength

Municipal Focus

Buffalo City – Bringing about balance

Smart Water Management Reducing municipal water loss

IN THE SPOTLIGHT The ability to eliminate human error in data transfer – to guarantee the integrity of the billing system – should influence your choice of service provider.” Christo Nicholls CEO: Smart Utility Solutions, Edison Power Group ISSN 0257 1978

V o l u m e 4 0 N o . 7 • J u l y 2 0 1 5 • R 5 0 . 0 0 ( i n c l . VAT )

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CONTENTS www.infrastruc

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VOLUME 40 NO. 7 JULY 2015

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

INFRASTRUCTURE

MAIN DEVELOPMENT •

TENANCE • SERVI

UTILITIES MANAGEMENT Creating tanks of the first water

CE DELIVERY

SICELO XULU r Leading City Powe

ENT PPC aCneEtwM ork Building of strength

Municipal Focus

Buffalo City ce – Bringing about balan

agement Smart Water Manwate r loss

MUNICIPAL FEATURE Buffalo City Municipality

Reducing municipal

IN THE SPOTLIGH

Regulars

ntee data transfer – to guara ate human error in of The ability to elimin d influence your choice billing system – shoul Edison Power Group the integrity of the Utility Solutions, Smart CEO: ) lls 5 0 . 0 0 ( i n c l . VAT Christo Nicho July 2015 • R service provider.” me 40 No.7 • 8 ISSN 0257 197

Vo l u

Pretoria Portland Cement is the corporate embodiment of its product. Through its extensive service offering, it ensures sustainability and skills transfer – literally, and figuratively, holding the built environment together. P6

3 5 8 76

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

Municipal Feature

Infrastructure Finance 10

Buffalo City Municipality

Government Voice 14

Sicelo Xulu leads City Power

Utilities Management

Creating tanks of the first water Power conference for African utilities Construction industry to solve infrastructure problems The quest for smart cities

20 22 23 24

Procurement compliance: Private and public sector projects

47 50

Cement & Concrete Sarma Conference 2015 Precast concrete is the answer Civilworks Time-saving concrete Mixing it up Providing concrete solutions Taking centre stage Smart turnkey solutions secure major projects

55 57 58 61 63 65 67 69

SHEQ

Fulton Awards 31 39

The 2015 Fulton Awards Sanral bags top awards

Building houses, mending fences

Rights and responsibilities of the Occupational Health and Safety Act 71

Construction Vehicles & Plant Equipment

Infrastructure Development Partnerships

THE 2015 FULTON AWARDS for excellence in concrete

42 45

Road Building & Maintenance

PPC: Building a network of strength 6

Edison Power Group: What’s so smart about smart meters?

Christo Nicholls, CEO: Smart Utility Solutions for Edison Power Group unpacks the methodology behind smart meter roll-out to unlock the technology’s true potential. P15

An age-old problem Reducing municipal water losses

Ammann SA makes the grade Wired for road safety

Cover Story

In the Spotlight

IN THE SPOTLIGHT

Water & Wastewater

Top 10 vehicles and equipment

WATER & WASTEWATER Reducing municipal water loss

IMIESA July 2015

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EDITOR’S COMMENT

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

Challenging the

future

E NEED HOPE; there is no doubt about it. South Africans from all walks of life have been so continuously subjected to news of problems, seemingly irreconcilable differences, and disruptive politics that it is easy to forget about the quite remarkable progress that is being achieved. In this edition, we look at projects that are making a real difference, and that relate to solutions to current challenges that don’t seem to make the headlines. From City Power rolling out a smart metering project that is already minimising loadshedding occurrences to its clients and removing demand from the grid in an intelligent way, to the innovative approaches from various public sector segments of the infrastructure sector that are making a real difference in the lives South Africans, from a deliver y and empowerment point of view. I had the privilege of spending time with the chairman of Inyatsi Construction recently. The company is based in Swaziland, and has a distinctly different take on how the public and private sector can work together. Frans Pienaar is engagingly optimistic and pragmatic, and one thing he said will always stay with me: “No one gets out of the bed in the morning planning to fail. Whether I am working with a private sector client facing funding challenges, or a public

ADVERTISING SALES Jenny Miller Tel: +27 (0)11 467 6223 ___________________________________________________

PUBLISHER: MEDIA No. 9, 3rd Avenue, Rivonia 2056 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: nicholas@3smedia.co.za www.3smedia.co.za ANNUAL SUBSCRIPTION: R550.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2015. All rights reserved. ___________________________________________________ IMESA CONTACTS IMESA Administration Officer: Narisha Sogan P O Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER BRANCH Secretary: Melanie Matroos Tel: +27 (0)43 705 2401 Fax: +27 (0)43 743 5266 E-mail: melaniem@buffalocity.gov.za EAST CAPE BRANCH Clarine Coltman Tel: +27 (0)41 505 8019 Fax: +27 (0)41 585 3437 E-mail: clarinec@africoast.com KWAZULU-NATAL BRANCH Secretary: Rita Matthews Tel: +27 (0)31 311 6382 Fax: +27 (0)31 701 2935 NORTHERN PROVINCE BRANCH Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 E-mail: imesanorth@vodamail.co.za SOUTHERN CAPE KAROO BRANCH Secretary: Henrietta Oliver Tel: +27 (0)79 390 7536 Fax: +27 (0)86 536 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: +27 (0)86 628 0468 E-mail: imesa.fsnc@gmail.com All material herein IMIESA is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

sector official struggling to specify a project, I always tr y to work towards to a positive end goal.” He explained that this does require a long-term approach, and it means ensuring that agreements are sustainable and fair for all parties involved; most importantly, however, it means taking the focus away from litigious outcomes and negative consequences. This approach has allowed the company to develop dramatically within a space in which challenges are often viewed as limitations. There will be more on this in later editions but, for now, it certainly led me to challenge my own view on how I deal with challenges, and how I could improve my own approach to sustainable outcomes. I invite you to enjoy the celebration of excellence to be found in our coverage of the Fulton Awards, and read about the projects making a difference in the concrete industr y. PPC is this year’s sponsor of the Sarma Conference, which takes place next month, and our cover stor y also notes how assisting an industr y is good for ever yone. We also look at how the mining industr y is contributing to public infrastructure, and how the utility sector in South Africa continues to grow. So, I invite you to let this edition of IMIESA cast a positive light on this world to which we all hope to contribute and sustain.

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

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INFRASTRUC

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

SICELO XULU Leading City Power

PPC CEMENT Building a network of strength

sport rated Public ofTran the integ The rise network transport

Municipal Focus

l Focus Municipa Local

Buffalo City – Bringing about balance

Overstrand Municipality than more – Much ing

Infrastructure News

IMESA

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

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

Smart Water Management Reducing municipal water loss

whale watch

s Smart Citie ng our future Safeguardi

IN THE SPOTLIGHT

r, we and morta er The ability to eliminate human error in data transfer – to guarantee T from brick be made Mi Panels are strong the integrity of the billing system – should influence your choice of of g that can a buildin properties ) MIBT Christo Nicholls CEO: Smart Utility Solutions, Edison Power Group service provider.” imagine ( i n c l VAT structural managing director, 50.00 If you can 5 • R physical ne 201 ISSN 0257 1978 V o l u m e 4 0 N o . 7 • J u l y 2 0 1 5 • R 5 0 . 0 0 ( i n c l . VAT ) an Chetty, too. The 6 • Ju 40 No. r.” Pragas can do it olume 78 V and morta 257 19 ISSN 0 than brick

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PRESIDENT’S COMMENT

IMESA

Engineering in the global village Duncan Daries, IMESA president

The first six months of my presidential term have flown by. One of my duties is representing IMESA on the board of the International Federation of Municipal Engineers (IFME), which meets biannually – every sixth meeting coincides with the annual congress of a member institute, resulting in the IFME World Congress.

HIS YEAR THE IFME honour is bestowed on the Institute of Public Works Engineering Australasia (IPWEA), whose conference was held in Rotorua, New Zealand, from 7 to 11 June 2015. This international federation has been in existence for a while and currently consists of 16 national members and two obser ver members. Based in the Netherlands, it has a strong base in English-speaking countries but also well-represented are the Scandinavian countries. The outgoing president of IFME is Ross Vincent, of New Zealand, who will be succeeded by Doug Drever, of Canada, as from the end of the current world congress. Doug's term of office is 2015 to 2018, after which he will be handing over to John Thomson, of Scotland. There is no longer a need to justify the benefits of belonging to an international body representing engineers active in the

municipal environment. Simply put, the world has changed within the consulting engineers’ community. I.e. The globalisation of major consulting companies such as Aurecon, Aecom, and SMEC, to name a few, is a reflection that IFME was ahead of its time. Engineering skills are in short supply globally and it is, therefore, important that we do not reinvent the wheel, but rather learn from each other. This relates not only to the smaller developing nations, but also the more established countries. Networking is an important aspect thereof, and innovation sometimes driven, from a resource constraint, happens all over. Engineering decisions are enhanced through experience. This experience is not only from oneself, but also from fellow colleagues. Therefore, conferences and seminars, where experiences are presented and shared, are a big part of

forming the necessar y engineering part of management skills required for day-to-day decision-making in municipal engineering environments. IFME has, therefore, re-examined the way it operates to ensure more value add to its membership. Board meetings, arranged in conjunction with either technical tours or conferences, have been a largely successful format for the participants. Meetings are, as a result, ver y well attended, with delegates remaining enthusiastic and eagerly awaiting the following event. It now needs to ensure that the best practices identified during these tours are properly documented and disseminated for the benefit of its wider membership. It is precisely these interactions, at international level, that have exposed the previous leadership of IMESA to the asset management best practices of the Australian and New Zealand models. From this

contact, IMESA, in conjunction with these international partners, developed the IIAMSA (International Infrastructure Asset Manual for South Africa). This has formed the basis to influence national government departments to buy into the concept of an asset management approach, to ensure appropriate budgeting for the prioritised infrastructure needs of municipalities. To this extent, MISA (Municipal Infrastructure Ser vices Agency) has contracted IMESA to roll out the asset management training courses on its behalf, countr y wide. One of the main takeaways from my interaction with IPWEA during the congress is its approach to engaging with its young engineering practitioners. It seems as if they have embraced the use of social media to keep this vital community engaged and, in so doing, have increased their membership levels significantly.

IMIESA July 2015

COVER STORY

Building a network of strength Pretoria Portland Cement is the corporate embodiment of its product. Through its extensive service offering, it ensures sustainability and skills transfer – literally, and figuratively, holding the built environment together.

EMENT AND CONCRETE are sustainable construction materials that support urbanisation. Both are versatile materials used in construction and contribute towards alleviating the numerous threats to sustainable development. The most pertinent of these threats include: • population growth • urbanisation • global warming • energy use • excessive waste generation • limited supply of natural resources • pollution of air, water, and soil. Concrete is the second most widely used material in the built environment, after water, and its use is expected to double in the next few years. It is an inherent component of our environment, used in the construction of schools, dams, bridges, airports, and commercial, industrial, and residential buildings.

Cementing its place Cement, constituting approximately 11% of concrete, is a vital construction material and strategic commodity. Cement is the key component in a concrete mix, and is responsible for strength development once activated by water during the hydration process. The manufacture of cement is identified as one of the major contributors to CO2 emissions and global

IMIESA July 2015

warming, primarily due to the volume of cement used globally. In response, the cement industry has taken conscientious steps to reduce this impact by manufacturing extended cement products and pursuing the active use of alternative energy sources. The built environment has a huge, but largely untapped, potential for emission reductions at the least cost. Concrete, for example, has excellent thermal mass. Concrete walls and floors slow the passage of heat moving through, reducing temperature swings. It reduces energy needs for heating or air conditioning, which is estimated at ~17%. Cement – when combined with other materials, such as cement kiln dust, lime, limestone, or lime kiln dust, and mixed with soil – can act as a binding agent that changes the chemical (stabilisation) and physical (solidification) properties of various contaminants. Cement-stabilised material is regularly used to reduce the plasticity index of soils, enhancing its structural properties for redevelopment. Sureroad has been specially developed by PPC for this application.

Building green PPC is a proud member of the Green Building Council of South Africa – the official certification body of green buildings. As a responsible, leading African cement producer, PPC

COVER STORY

understands that maintaining a sustainable business requires the balanced integration of performance, corporate governance and social, economic, and environmental factors into the strategy and operation of the business. Competent and experienced teams at PPC implement these strategies and make achievable the objectives outlined for sustainable development. “When it comes to designing green buildings, concrete is ideal, as it can be designed to incorporate supplementary cement materials (SCMs), such as fly ash or slag, resulting in a reduction of the carbon footprint. PPC is also incorporating these SCMs in the production of cement, making extended Portland cements with slag, fly ash, and/or limestone – such as Surebuild. Surebuild is a premium, generalpurpose cement, It is ideal for general building operations, structural concrete, and the manufacture of cement-based products. PPC also manufactures a Portland cement (which some may say adds to the carbon footprint); however, this CEM I 52,5N allows it to be blended with locally available SCMs or by-products that would otherwise end up in landfills. Concrete structures are durable – they do not rust, rot, or burn – and require minimal maintenance, if designed taking a holistic life-cycle approach at the onset. Concrete can be designed in conjunction with other materials like steel, timber, fibres, or glass. Concrete can be designed using a prescriptive or performance approach. Designing concrete according to performance criteria facilitates the incorporation of industrial by-products. The by-products have added benefits in that they improve durability, reduce the amount of cement required, improve fresh and hardened properties, and lower the heat of hydration. The beauty of concrete is that it can be manufactured in any shape or colour, and in a range of textures. Formwork can provide texture for readymix concrete and the production of concrete is resource-efficient. Most primary raw materials used in concrete are sourced and manufactured locally, which minimises transportation costs and supports regional economies.

Resource efficiency and sustainability PPC has responded to the threat of global climate change by reducing the effective footprint of cement manufacturing. Significant progress has been made through various initiatives. One of the main focal areas to improve the eco-impact of cement production is the

reduction of resource and energy requirements for the production of Portland cement. Energy accounts for a high proportion of production costs. To improve fuel and electrical energy efficiency, various process engineering solutions were implemented through technology upgrades and modifications. PPC has recently upgraded the kiln line at Dwaalboom (Limpopo) with an energy efficient cooler. Modifications to an existing line and installation of a new energy efficient line at Slurry Plant (North West), including key infrastructure upgrades, will commence shortly. To minimise emissions, various upgrade projects were undertaken – including the replacement of electrostatic precipitators with bag house filters at De Hoek (Western Cape) and Lime Acres (Northern Cape). There are various quality, process, and environmental benefits from co-processing secondary materials during the clinker manufacturing process. Environmental benefits include the reduction of landfill waste and the reduction of greenhouse gas emissions, mainly due to decreasing the use of coal. PPC has successfully implemented alternative fuels projects, like the use of waste tyres and carbonaceous spent pot liners in place of coal. Conserving water resources, by incorporating admixtures and/or using recycled water in concrete mixes, reduces the freshwater requirement. Certain admixtures reduce the amount of cement required, which, in turn, reduces the carbon footprint. The use of pervious concrete, which is a special type of structural concrete – consisting of a sponge-like network of voids – readily allows water to percolate into the ground. Used for parking lots, sidewalks, and other pavements, pervious concrete can help to retain stormwater run-off and replenish local water supplies. Concrete cisterns capture rainwater and store it for non-potable uses such as flushing and irrigation, or – after suitable treatment – bathing and drinking. Concrete is recyclable. It can be crushed and the aggregates reused in new concrete, in road bases, or as fill material, thus extending the life of the concrete and reducing the environmental impacts of extracting and processing aggregates from natural sources. Cements, with inclusions of up to 30% recycled coarse aggregate, having strengths of up to 30 MPa – without any modification to the mix design – have been reported. The use of manufactured sand is also an environmentally sustainable alternative to the use of river sand.

Sheena Murugan, technical analyst at PPC

A large portion of PPC’s sustainability lies in the technical support it offers customers. Sheena Murugan, technical specialist, says, “PPC’s contribution to sustainability – apart from using alternate fossil fuels, alternate raw materials, and modifications to and the installation of new plant – extends to skills transfer in the industry.” Skills transfer takes place through creating awareness and working with customers to implement sustainable solutions and produce sustainable products. PPC provides learning opportunities and assistance to students, contractors, customers, and SMEs. In doing this, the gap in skills shortages in the construction industry is narrowed, creating a more sustainable workforce. “For example, a civil engineering student who needs a greater understanding of cement and cement production is invited for a half-day seminar, which includes the technical theory behind cement production, followed by a tour of the cement manufacturing plant. The relationship created during the process of skills development and skills transfer is an ongoing, sustainable one, as the individuals become part of a network of professionals. These initiatives support PPC’s ‘Strength beyond the bag’ philosophy,” explains Murugan. “PPC’s mobile app and the Cement and Concrete Cube (C3), an online information portal, facilitate the skills transfer process through knowledge and information sharing. The provision of these services ensures that the development of the local industry keeps up with latest global trends and standards. Supporting and uplifting communities takes us a few steps closer to sustainability,” Murugan concludes.

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.

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IMIESA July 2015

AFRICA ROUND-UP

INFRASTRUCTURE NEWS FROM AROUND THE CONTINENT AFRICA World Bank and

KENYA Major grant signed for Mombasa port modernisation

Chinese firm partner to develop low-cost African houses The World Bank's private sector arm, the International Finance Corporation (IFC), recently inked a new partnership with a Chinese construction and engineering company to develop low-cost houses in three African countries. IFC and Citic Construction Co. will set up a joint venture and inject $300 million to develop 30 000 homes in Kenya, Rwanda, and Nigeria in the next five years. Construction chairperson Hong Bo says her company has a proven track record in the implementation of large-scale housing schemes in Africa. "Citic will take advantage of its engineering experience and delivery capability to develop more affordable houses for Africa through the platform with IFC," she explains, adding that new housing units will be built in accordance with IFC's green building standards.

ETHIOPIA ERA receives $370 million loan from World Bank The Ethiopian Roads Authority (ERA) received credit approval from the World Bank Group for $370 million, for the construction of a section of the ModjoHawassa expressway, in the next fiscal year. The highly concessional agreement, with a maturity date of 38 years and a grace period of six years, will finance the 57 km Batu Ziway-Arsi Negele section of the expressway. The Modjo-Hawassa expressway is 203 km long and is divided into four sections. The

IMIESA July 2015

The redevelopment of the Ghana Kumasi Central Market is ready for take-off

Mojo-Meki and Meki-Ziway sections are in the process of auction for construction. The 57 km Mojo-Meki section was financed by a loan from the African Development Bank, the 37 km Meki-Ziway section by Korea EXIM Bank, and the 52 km Arsi Negele-Hawassa section will be financed by China EXIM Bank. The upgrade to the road comes as a result of the increasing traffic flow on the route, which currently stands at 3 000 trucks a day, and is projected to reach 10 000 trucks, says Samson Wondemu, communication director at the ERA.

GHANA $298 million Kumasi Central Market, Kejetia Project ready for take-off All is set for the commencement of the $298 million redevelopment of the Central Market and Kejetia lorry terminal project in Kumasi, as plans to relocate transporters are finalised. The Brazilian construction firm Contracta Engenharia Limited, which is to execute the threephase project, recently handed

over 40 000 km2 of land to the Kumasi Metropolitan Assembly (KMA) for the relocation of all transport unions. The relocation of the transporters would enable the contractors to undertake a geographical mapping of the area, with the Ghana Water Company and Electricity Company of Ghana to prepare the place for construction works to begin. The first phase of the project comprises construction work at the Kejetia terminal, over a period of 24 months at the cost of $198 million, while the remaining $100 million will be expended on the second and third phases, which will focus on the redevelopment of the Central Market in Kumasi.

The United Kingdom’s Department for International Development (DFID) and TradeMark East Africa have signed a £23 million grant agreement towards the modernisation work at the Port of Mombasa. This includes infrastructure investments aimed at addressing energy efficiency, speeding up import and export trade handling, and minimising environmental impacts at the Port of Mombasa. Deputy head of DFID Tony Gardner says the modernisation work at the Port of Mombasa would take into account environmental and social aspects, and this will go a long way in complementing existing projects and in expanding the flow of benefits to stakeholders, including the population of Mombasa and East African Community residents.

NIGERIA $2 trillion infrastructure plan awaits Buhari As Nigeria transitions to a new government, a major concern for the country is the fate of the National Integrated Infrastructure Master Plan

Muhammadu Buhari, Nigerian president

AFRICA ROUND-UP

(NIIMP), a document that has projected $2 trillion for infrastructure development over 30 years. The National Planning Commission, in 2012, initiated the idea of drawing up a long-term infrastructure development plan for the nation's sustainable economic growth and development. The growth path had expected Nigeria to raise its investments in infrastructure to $51.1 billion, annually, as from 2014. The presidential launch, which is a cardinal requirement for the star t of the plan, initially slated for December last year and later postponed to Januar y this year, seems to have been abandoned for no disclosed reason. There are concerns that the NIIMP may go down the drain just like other previous national plans in Nigeria’s histor y. Over the years, since having gained independence, several Nigerian economic plans have been drafted by previous administrations to tackle the nation's infrastructure deficit.

TANZANIA Feasibility for Dar es Salaam flyovers underway The government has promised that Dar es Salaam will have flyovers and interchange roads to decongest the city from the daily traffic. The Minister of Works, Dr John Magufuli, stated that other flyovers would be constructed along the Dar es Salaam-Chalinze expressway, which is intended to have around five flyovers. The contract, wor th $7.72 billion, has already been signed for feasibility and detailed design. Magufuli adds that tendering for the construction of the Ubungo interchange is already in process, stressing that what he has said was not a

A cement factory in Dangote, Zambia

series of empty promises from the government, but would be a future reality for the countr y.

ZAMBIA Dangote roars to life The $400 million Dangote cement factor y in Masaiti has commenced operations, following the completion of construction early this year. Dangote Cement operations director Anand Kameshwar said, in a recent inter view, that work on the plant had been completed and it was already working ahead of commissioning, which will be done soon. The cement plant, which has an installed capacity to produce 1.5 million tonnes of cement per annum, has been equipped with a 30 MW power plant.

The power plant was put up at a cost of $50 million, to ensure uninterrupted supply and relieve pressure on Zesco. The opening of Dangote brings the total number of cement factories in the area to three, following the current operations of Zambezi Por tland and Lafarge Cement. Dangote, which is investing another $400 million in a similar plant in Lusaka, has operations in several countries in Southern Africa, including Tanzania and South Africa.

ZIMBABWE Green light for Mutirikwi mini-hydropower plant Work on a $13.5 million minihydropower plant on Lake Mutirikwi Dam is set to begin soon, now that the Masvingo

Rural District Council (RDC) has given the project the green light. Great Zimbabwe Hydro Power Company – a joint venture between Zimbabwean firm ZOL and New Planet of South Africa – recently got permission from the Masvingo RDC to go ahead with the project that will generate 5 MW of power upon completion. Masvingo RDC acting chief executive Mar tin Mubviro said, in late May, that the JV was jointly managing the power generation project with the Zimbabwe National Water Authority. Power produced at the plant will be fed into the national grid and is expected to ease electricity shor tages in Masvingo. The project will be broken down into several phases and will take up to two years to complete. This will be the second plant in Masvingo, with a similar project being planned at Tokwe-Mukosi Dam in Chivi south to generate about 15 MW.

Flyovers and interchange roads will become a future reality for Dar es Salaam in Tanzania

IMIESA July 2015

MUNICIPAL FEATURE

Located in the Eastern Cape, Buffalo City Metropolitan Municipality (BCMM) is a hub of developmental activity. In this municipal feature, BEATRIX KNOPJES looks at key projects that will balance the East London Industrial Development Zone with a rural population in need of infrastructure.

Buffalo City

Bringing about balance

UFFALO CITY HAS framed its development strategy to be in line with the Integrated Development Plan. According to Nceba Ncunyana, an engineer for BCMM, this “accommodates growth in particular areas, with a specific focus on roads and water, as these are at the core of the IDP.” Engineers face a number of challenges when working in the region. Says Ncunyana, “The terrain consists of undulating hills and valleys and, when building roads in these areas, you have to be specifically aware of the catchment areas of rivers for drainage and the high altitudes. “There are many dirt roads and a large part of the area is rural, which makes accessibility challenging. East London is a bustling industrial zone that is integral to the prosperity of the region. There is a great deal of infrastructure that supports this industrial zone and it is inherent in our provision of bulk infrastructure supply.”

Second Creek housing development Second Creek is a housing development built on a reclaimed dump, where residents scavenged out a living and lived in informal settlements, as a result of rapid urbanisation. Says Ncunyana, “The projects in BCMM

IMIESA July 2015

are committed to providing an integrated approach to designing human settlements that provide water, sanitation, and roads, as these are the keys to a successful project.” The waste disposal site was cleared in 2009, in preparation for construction, which began in 2013. The development consists of low-cost housing, as well all service infrastructure including roads, water and sanitation, and electricity. Over 260 homes have been built thus far, consisting of two commodious bedrooms, an open-plan kitchen and lounge, and a bathroom. Bigen Africa received a Govan Mbeki Award for its successful work on this project.

Queen’s Park Zoo Substation The need for a major tertiary injection substation has become necessary, due to the extensive electrification of housing developments in order to meet government’s call for universal access to electricity. In meeting the programme, the houses have been added to the existing network with no upgrade or enhancement taking place. The housing department has plans to build an additional 10 000 RDP houses, which will further add to the load. In addition, commercial and industrial consumers are being added to the system, making the Queens Park Zoo Substation an

important project for the sustainability of the electrical service in the East London area of BCMM. The BCMM requested funding for the project from the Department of Energy (DoE). The DoE approved funding in 2007, and have provided funding for the duration of the project. The Queen’s Park Zoo Substation has been designed as an 80 MVA firm capacity substation. That is to say, initially, three 40 MVA 132/11 kV power transformers have been installed. If required, the design allows for the substation to be upgraded in the future with an additional 40 MVA power transformer, together with the associated switchgear and ancillary equipment. The substation is equipped with the following: • t ubular low-profile busbar configuration mounted upon busbar and equipment supports • three 40 MVA 132/11 kV on load tap change (oltc) power transformers • space requirements for future 40 MVA 132/11 kV OLTC power transformers, but equipped with transformer plinths • three power transformer feeders, comprising 132 kV circuit breakers, voltage transformers, current transformers, surge arrestors, and isolators • space requirements for future power

MUNICIPAL FEATURE

DESCRIPTION INEP electrification programme

FUNDING SOURCE DoE

transformer feeders, comprising 132 kV circuit breakesr, voltage transformers, current transformers, surge arrestors and isolators, but equipped with essential supports and foundations for future equipment • double busbar arrangement with circuit breaker, isolator, and required interlocking mechanisms • lightning protection • substation earthing • brick-built substation switch/control room, housing the 11 kV switchboards for the power distribution cabling or overhead line feeders, outdoor switchgear control panels, oltc control panels, and quality of supply panel.

PROJECT NAME Queen’s Park Zoo Substation

CONTRACT PRICE R115 443 000.00

EXPENDITURE R106 523 057.00

Queen’s Park 132 kV overhead line

R10 704 692.00

R8 572 857.00

The substation will be supplied off a 3.6 km, 132 kV overhead line. This overhead line is a double circuit supported by eight towers/ structures. The structures are of a steel lattice configuration. Chickadee electrical conductors are utilised for the line, which is 1.8 km long for the single circuit and 3.6 km for the double circuit. Steel-wired armoured OPGW cable, commonly referred to as fibre-optic cable, also forms part of the aerial installation. The OPGW cable ser ves a data cable between protection relays installed in the Queen’s Park Zoo, Woodbrook, and West Bank substations. Local labour was employed during the early part of the construction process

but was not utilised during the latter part of the project, due to the high level of skills required. Excavations and the foundation preparations for the towers began in March 2014, and were completed in early May 2014. The towers were partially built off-site and transported to site for erection and installation, this portion of the work ran concurrently with the ground preparation stage of the project. The erecting of the towers began in May 2014, and was completed in June 2014. The stringing of conductors was done in stages, as towers became available to hold the conductors. The 11 kV circuit breakers, switches, and panels at Queen’s Park Zoo Substation are IMIESA July 2015

Specialist Waste Management Consultants

JPCE

Tel: +27 21 982 6570

www.jpce.co.za

Jan Palm Consulting Engineers

MUNICIPAL FEATURE

undergoing final testing. The total estimated cost to complete this project, which is near completion, R136 million, and it is within the budget.

Reeston Wastewater Treatment Works BCMM is currently undertaking the construction of diverting the current sewer flow to Reeston Wastewater Treatment Works (WWTW), whose capacity BCMM intends to increase from 2.5 Mℓ/day to 10.5 Mℓ/day. BCMM also intends to appoint an experienced mechanical and electrical contractor for the execution of the design, installation, commissioning, and performance testing of mechanical, electrical, and instrumentation equipment for the new 48 Mℓ/day inlet works and a new 10 Mℓ/day activated sludge reactor, complete with clarifiers and chlorination plant. The scope of works for both aspects comprises the following: • bulk excavation and earthworks to form terraces • modification and decommissioning of existing 2.5 Mℓ/d inlet works • new diversion box to the existing 15.5 m clarifier • connection of existing 350 mm fibre cement (2.5 Mℓ/d) reactor outlet • n ew inlet works •1 0 Mℓ/d extended aeration reactor • r eturn activated sludge pumps • two 26 m clarifiers and one 15.5 m clarifier on existing works • a new return activated sludge

pump station • sludge lagoon pumps • equipment of a new chlorine building • upgrading of the MV reticulation and extension to the substations • alterations to the MCC building • supply, installation, programming, and setting up a Scada system for the Reeston WWTW. The site’s official handing over and commencement date was 20 May 2013. Due to community disruptions, the completion date has been extended to February 2016. The contract value is placed at R101 249 087.10, and the costs expended to date since commencement are R51 158 448.18. The use of local labour has been prioritised in the project, there are currently 53 people employed from the Reeston community and one local SMME. The local SMME is being used for the trenching and laying of the 110 mm water supply line to the treatment works. The local labour that has been employed on the project has also received training on: • hand and tool safety • site awareness • plant awareness. The project steering committee members have also received accredited training and certificates.

Mdantsane roads upgrade This project is implemented by BCMM’s Roads Division staff and BCMM’s PIU Unit. It

Cluster Cluster 1 Cluster 2 Cluster 3

IMIESA July 2015

involves upgrading the Mdantsane gravel road to surfaced standard. The scope of works for Phase 3 is divided into three clusters, each of which entails the upgrading of 10 km of road network. The work to be carried out in this project includes the following: • earthworks for streets in residential areas, including selected rock fill layers, selected sub-base and base layers with a 30 mm asphalt surface • k erbs, channels, and edge beams • s tormwater catch pits and pipework • sidewalks • alterations to existing sewerage, water, and other services where needed • cable ducts, telephone, and electrical, where needed • f inishing of the road reserves. The works to be carried out per cluster, by each contractor, comprise mainly of the following: • construction of approximately 10 km of road network per cluster, which equates to 30 km for the combined three clusters and scope of made up of streets with a width of 5.5 m • construction of a stormwater drainage system consisting of approximately 8 000 m of concrete pipes up to 750 mm diameter • construction of appurtenant works such as service ducts and kerbing • location and protection of existing services, and relocation where necessary; correction of defects in the works in

Contractor Mamlambo Construction Down Touch Investments SC Contractors

Consultant Engineering Advice & Services GIBB MBSA

MUNICIPAL FEATURE

accordance with the requirements specified in the contract documents. This description of the works is not necessarily complete and shall not limit the work to be carried out by the contractor under this contract.

Cluster Contractor Consultant Ward/unit Cluster 1 Mamlambo Construction EAS Ward 14 Ward 17 Cluster 2 Down Touch Investments GIBB Ward 11, 20, 30, 48 & 50 Cluster 3 SC Contractors MBSA Ward 21 & 22; 13, 14 & 15

Length 7.3 km 2.7 km 12.4 km 9.87 km

Cluster 1 The project was awarded at a cost of R68 953 687.47, in December 2013, and will be completed in October 2015. To date, the project expenditure is at R30 182 851.03 and the progress on-site is 62%.

Cluster 2 The project was awarded at a cost of R53 472 541.32, in December 2013, and will be completed in August 2015. To date, the project expenditure is at R47 893 903.86 and the progress on-site is 88%.

Cluster 3 The project was awarded at a cost R67 022 176.85, in December 2013, and be completed in August 2015. To date, the ject expenditure is at R51 297 850.26 and progress on-site is 76%. All three clusters are under construction.

of will prothe still IMIESA July 2015

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