IMIESA November/December 2018

www.infrastructurene.ws

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

infrastructure development • Maintenance • service delivery

INDUSTRY INSIGHT Partnering with communities Lucky Kgatle

Senior Vice President, Sasol Mining

Ammann Quality guaranteed across the value chain

No-Dig 2018

Trenchless technology builds capacity

Municipal Focus: Tshwane Out with the old

ISSN 0257 1978

IMESA Awards

The best in municipal engineering

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SANRAL. Beyond roads.

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volume 43 no. 11 November/december 2018

www.infrastructurene.ws

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INDUSTRY INSIGHT

INSIDE

Partnering with communities Lucky Kgatle

Senior Vice President, Sasol Mining

Ammann Quality guaranteed across the value chain

No-Dig 2018

Trenchless technology builds capacity

Municipal Focus: Tshwane Out with the old

ISSN 0257 1978

14

IMESA Awards

The best in municipal engineering

SASTT TRENCHLESS NEWS

Trenchless technology builds capacity

Water Treatment

V o l u m e 4 3 N o . 1 1 • N o v e m b e r / D e c e m b e r 2 0 1 8 • R 5 0 . 0 0 ( i n c l . VAT )

Embracing UF technology

Engineering projects are dependent on exact results, both at the design stage and at project implementation.

When it comes to the mechanisation component, whether for asphalt, concrete or road compaction and finishing, Ammann has a nocompromise, quality solution that caters for both SME and top-tier contractors. P6

Roads & Bridges

Municipal Focus | Tshwane

Out with the old

11

INDUSTRY INSIGHT

22

ROADS & BRIDGES Expanded Cape route

22

High production and mobility

23

Geomatics Surveying pitfalls in the municipal environment

26

IMESA Awards

Editor’s comment

3

President’s comment

5 52

The best in municipal engineering

28

Steel reticulation design excels

35

SAFCEC Conference Stimulating a struggling sector

36

Project Management

Cover Story

Infrastructure roll-outs must be integrated

38

Quality guaranteed across the value chain

The importance of project management in Industry 4.0

41

6

Industry Insight

Making a lasting difference, Sasol Mining is passing on sustainable benefits that are shaping and adding value, says Lucky Kgatle, senior vice president, Sasol Mining. P8

Expanded Cape route

Roads to social and economic growth 25

Regulars

Index to advertisers

20

Partnering with communities

Environmental Engineering 8

Municipal Focus | Tshwane Out with the old

Designing with stones

44

Cement & Concrete 11

Stabilising a dangerous slope

47

Why pavements crack

49

SASTT Trenchless News Trenchless technology builds capacity

14

Transport, Logistics, Vehicles & Equipment

The future of utility locating

17

Designed to perform

50

Advancing trenchless infrastructure

18

Founded on equipment durability

52

28

IMESA AWARDS The best in municipal engineering

47

Cement & Concrete Stabilising a dangerous slope

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EDITOR’S COMMENT

Efficiency gains will define 2019

Publisher Elizabeth Shorten MANAGING EDITOR Alastair Currie SENIOR JOURNALIST Danielle Petterson JOURNALIST Liesl Frankson Head OF DESIGN Beren Bauermeister Chief SUB-EDITOR Tristan Snijders SUB-EDITOR Morgan Carter ContributorS Gavin Clunnie, Bryan Perrie, Herman Smit, Pieter Steyn, Altus Strydom CLIENT SERVICES & PRODUCTION MANAGER Jayshree Maharaj Production COORDINATOR Jacqueline Modise financial Director Andrew Lobban DISTRIBUTION MANAGER Nomsa Masina Distribution coordinator Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za Printers United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________

A

Advertising Sales Jenny Miller Tel: +27 (0)11 467 6223 Email: jennymiller@lantic.net ___________________________________________________

150 Rivonia Road, Morningside, 2196 Publisher PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za Annual subscription: R600.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2018. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Fax: +27 (0)43 743 5266 Email: celestev@buffalocity.gov.za

If it’s not measured, it’s not managed: a worn cliché, like most, but it still holds true. So, why am I saying this? It’s because every successful endeavour in life begins and ends with project and programme management, which has to take into account the implications of Industry 4.0.

In this issue, we have an excellent article from Professor Piet Steyn, a registered engineer and principal of Cranefield College, a locally based education leader, which is a must read for every decision-maker.

In our modern-day real-time environment, I believe these skills are mandatory for infrastructure leaders – especially since the timelines for implementation are becoming so urgent.

KWAZULU-NATAL Secretary: Ingrid Botton Tel: +27 (0)31 266 3263 Fax:+27 (0)31 266 5094 Email: imesakzn@imesa.org.za NORTHERN PROVINCES Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Fax: +27 (0)86 629 7490 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7114 Email: imesawc@imesa.org.za

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

Coupled with project and programme management is technological innovation and excellence as a means of addressing critical infrastructure backlogs like water and sanitation. For a burgeoning number of urban shack dwellers, that’s an absolute priority that must be remedied in the short term. This is on top of the medium- to longer-term need to constantly maintain and eventually replace South Africa’s approximately 197 000 km sewer and water network, as it presently stands.

I recently had the opportunity to attend the International No-Dig South Africa 2018 conference in Cape Town, where tackling this requirement was top of the agenda. Neil van Rooyen, a Southern African Society for Trenchless Technology board member, presented the opening paper – a summary of which is published in this issue. It’s an important presentation because it demonstrates, based on case studies and research, how trenchless technologies can accelerate pipeline construction, create new jobs and foster SME contractor development while coexisting with opencut methodologies.

Going forward, three interlinked priorities were mentioned in the 2018 MTBPS, namely the government’s proposed economic stimulus and recovery plan, improved governance and financial management, and the reforming of SOEs. It’s a lot to tackle all at once, but hopefully there will be more priority funding for infrastructure in 2019. In the meantime, I’d like to wish all our readers a great festive season and a happy new year.

Project management is the key

EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Fax: +27 (0)41 585 1066 Email: imesaec@imesa.org.za

FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Fax: +27 (0)86 628 0468 Email: imesafsnc@imesa.org.za

A trenchless response

s we close the year, every public and private sector stakeholder in the infrastructure segment is wondering what 2019 will reveal, since no one wants a repeat of 2018. That will chiefly depend on the right policy decisions and how the local and international investment community interprets and accepts them. Then there’s the matter of adhering to plans laid out in the recent Medium Term Budget Policy Statement (MTBPS), as well as allied strategy documents.

There’s a surfeit of economic data and statistical information that confirm past trading conditions and forecast future trends. That’s always valuable when it comes to planning and execution. It also provides an accurate historical record of what really happened, as opposed to what was promised.

Either way, there are always opportunities for business growth. Although it will now rest increasingly with the private sector to back any government stimulus package. In return, there’s an obvious requirement for security guarantees.

Finding the middle ground here will definitely yield the best results, which will be measured by stock market sentiment.

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

struc www.infra

IMESA

turene.ws

@infrastructure4

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

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Cover opportunity

with Partner ing Lucky Kgatle t, Sasol Mining vice presiden senior

n Amman Qua lity

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

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Part ners in Infra struc ture explored

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IMIESA November/December 2018

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President’s comment

IMESA

A holiday message I am writing this comment as IMESA’s immediate past president, having served two years in office as the leading representative of a voluntary association dedicated to municipal engineering. Those two years are a proud period in my career as a civil engineer.

M

y focus as an engineer has been on road and allied stormwater infrastructure.

These are key conduits needed to facilitated smooth traffic flows. That’s vital because every vehicle, whether private or commercial, is indirectly and directly linked to sustaining our economy.

Plus, stormwater designs in the present and future will need to evolve beyond conventional run-off and channelling, primarily to maximise road safety, to establish more innovative practices that promote urban sustainable drainage systems. At IMESA, one of our major mandates is sustainability, so reusing water from road systems is part of that vision.

More importantly, though, is IMESA’s mandate to assist local government with the roll-out of a

full suite of services for affected communities.

Let’s continue to find the best solutions in 2019, promoting service delivery and much-needed jobs, particularly among the youth. IMESA is well placed to assist in building employment capacity and transitioning job seekers into artisans, technicians and engineers.

State of construction Reflecting on the state of construction, it’s true to say that times have been tough. Construction is a cyclical market; however, the demand for infrastructure, anywhere in the world, remains constant.

That’s my December holiday wish for everyone working in construction or aspiring to join this great industry, particularly in the infrastructure space, which is the engine of the economy. The

IMESA 2017/18 president Gavin Clunnie

private and public sectors’ willingness to engage is at the highest levels since 1994. We need to regroup and move forward to reach South Africa’s National Development Plan targets. Implementing the R400+ billion South African Infrastructure Fund in 2019 will be a major boost.

In the January 2019 issue of IMIESA, we will be introducing our new IMESA president – a registered professional with many years of experience in municipal engineering. As immediate past president, I will be there, along with the 2019/20 executive committee, to provide my full support.

Enjoy the December break and get ready for 2019 – it’s a pivotal year for South and Southern Africa’s future growth.

IMIESA November/December 2018

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Cover story

The 11 tonne ARS122 BS III singledrum roller is a recent addition to the Ammann line-up for the African market

Quality guaranteed across the value chain Engineering projects are dependent on exact results, both at the design stage and at project implementation. When it comes to the mechanisation component, whether for asphalt, concrete or road compaction and finishing, Ammann has a no-compromise, quality solution that caters for both SME and top-tier contractors.

I

n 2019, Ammann will celebrate its 150th anniversary, a significant milestone that demonstrates the Swiss-based OEM’s ability to evolve and respond to the changing needs of the construction market.

This commitment to sustained research and development (R&D) means that there’s a product solution at every stage of technological maturity in the construction sector.

“That’s an important statement to note because Ammann’s intensive approach to R&D means that every product class leads in terms of innovation, either as a high-tech solution or a slightly lower-tech and value-added option for less sophisticated and emerging sectors, so that customers have access to cutting-edge technology at the right entry point for their current and future operations,” explains Rocco Lehman, managing director of Ammann South Africa. “As businesses mature, they inevitably scale-up to the more premium range. Either way, every Ammann product is manufactured to exacting quality.”

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IMIESA November/December November 2018 2018

The Ammann value-added range is particularly well-suited to African conditions in terms of high durability and efficiency, combined with competitive pricing. “South Africa and Africa definitely need a value-for-money product in these challenging economic times,” Lehman asserts.

India factory visit During the first quarter of 2018, Ammann South Africa led a group of local customers on a tour of the Ammann Group’s new factory in Ahmedabad, India. Lehman says the impression gained was very positive. Built at a cost of €85 million, the construction of this state-of-the-art facility follows an initial joint venture and the subsequent acquisition of leading Indian asphalt plant and road construction OEM Apollo in 2013. This was a strategic move that enabled Ammann to enter the paving segment and grow its market share from a zero base to a leadership position by 2018, currently selling between 500 and

600 Ammann pavers annually. Apollo asphalt pavers continue to dominate in India.

African market A targeted range of Ammann machines is supplied locally, based on current market demand. However, the full product line is available ex-factory from any of Ammann’s worldwide factories, which includes manufacturing centres in Europe, South America, India and China.

In South Africa and a growing number of African countries, the direct customer interface is via Ammann-appointed dealer ELB Equipment, which is well represented in the SADC region, as well as further afield.

Major prospects in East Africa recently led to the establishment of an ELB branch in Kenya, which opens up exciting new opportunities for Ammann.

“Ammann Goup recognises ELB as a worldclass dealer and a critical and highly effective link in the value chain,” Lehman continues.

COVER STORY “For this reason, Ammann invests extensively in dealer training and development. In October this year, for example, we conducted detailed training with some 53 ELB sales and aftersales personnel. This follows a similar workshop in Q4 2017. Technical excellence requires technical competency.”

Asphalt plant gains For the concrete and asphalt plant range, Ammann deals directly with the South African and African markets. Take-up in the asphalt segment has been very positive, while the rollout of the concrete offering is still in the early stages locally.

“In South Africa, the construction sector has traditionally used dry mix concrete plants, but Ammann is focused on changing that viewpoint with the progressive introduction of its proprietary wet mix plants,” Lehman explains.

Ammann’s concrete plants are a common sight on construction projects in Europe, South America and Asia. In parts of Africa where contractors do following trends adopted in Europe and China, Ammann believes that the demand for the concrete range will grow significantly, based on proven efficiencies.

Recent asphalt plant sales in Africa include the delivery of a ValueTec 140 (140 tonne capacity) to a contractor in Ghana.

Another recent cross-border sale entailed the deliver y

of an Ammann 90 drum mix plant (90 tonne capacity) as well as two Ammann ARS122 BS III single-drum roller machines for a company in Zimbabwe.

“To support our Africa drive, we have recruited new sales, product and after-sales specialists, based in Johannesburg and travelling regionally.

Strategic sales, parts and product support for Africa and the Middle East region is provided by Ammann Group’s regional hub in Dubai. In South Africa, we have a multimillion rand parts inventory on hand for all immediate requirements,” says Lehman Locally, asphalt plant sales include the supply of an Ammann ValueTec 140 to Polokwane-based company MM Surfacing, which also acquired two Ammann paving trains.

These comprise two AFW350 pavers, two AP240 pneumatic tyred rollers, and two AV70 tandem rollers.

Benoni-based company Instant Tar also recently acquired a new Counterflow 120 plant, which expands its fleet to two, following the acquisition of a Counterflow 90 unit towards the end of 2017.

New machine launches New machine products entering the South African and broader African market include the Ammann 11 tonne ARS122 BS III single-drum roller, and the Ammann ARX91 double-drum roller, with confirmed sales already reported by ELB. Both units are manufactured at Ammann’s Ahmedabad facility. To meet immediate demand, Ammann also keeps asphalt plants in

Ammann’s AFW400 paver has an operating weight of 10 500 kg. The minimum and maximum paving widths are 0.7m and 4.7m respectively

stock to minimise factory shipment delays. A Counterflow 120 unit is currently available.

“When we entered South Africa in 2013, we aimed for a 20% market share of the machine segment. We have to date achieved a satisfactory percentage on specific products, as recorded by CONMESA statistics. That’s a great result given the tough conditions in the local building and civils segments.

“Ammann Group remains committed to Africa and continental growth, and the future, although challenging in economic terms, is certain to rebound with promising socio-economic benefits. Providing the best value position for construction equipment owners will definitely be part of the medium- to longer-term solution.

It starts and ends with quality engineering,” Lehman concludes.

www.ammann-group.com

Expanding its African penetration, Ammann recently sold a ValueTec 140 asphalt plant to a contractor in Ghana

The Ammann ARX91 tandem roller has a drum width of 1 680 mm and an operating weight of 9 470 kg

INDUSTRY INSIGHT

Making a lasting difference, Sasol Mining is passing on sustainable benefits that are shaping and adding value, says Lucky Kgatle, senior vice president, Sasol Mining.

S

Partnering with communities

asol has been part of the South African landscape since the 1950s and is one of the country’s largest industrial conglomerates, as well as a pioneer and global leader in the conversion of coal into a multitude of products ranging from fuels and oils to chemical derivatives and fertilisers.

In South Africa, it all starts with Sasol Mining, which operates six mines that, together, represent one of the world’s largest underground coal complexes.

They supply feedstock for the Secunda Synfuels Operations and Sasolburg Operations refineries.

Sustainability to at least 2050 - As Sasol Mining has been mining coal at the Secunda complex for around 40 years, large areas have been mined out. Therefore, Sasol Mining must acquire additional coal resources to replace the areas where coal has been depleted to meet the requirements of Secunda Synfuels Operations.

- Sasol Mining’s annual supply mandate is approximately 41 Mt. - Sasol Mining will invest in the communities where it operates to until at least 2050.

An example of a Sasol Mining housing project

8

IMIESA November/December 2018

While the coal that Sasol Mining supplies to Secunda Synfuels Operations is mainly used as gasification feedstock, some is used to generate electricity. The coal that Sasol Mining supplies to the Sasolburg Operations is used to generate electricity and steam.

Sasol Mining also exports coal from the Twistdraai Export Plant to Europe and Asia.

Communities surround and interconnect with all of these operations, either directly as employees or indirectly in terms of Sasol Mining’s social labour plans (SLPs) and local economic development projects (LEDs), which are making a major difference for municipal residents.

“Our host communities in four municipalities in Mpumalanga and two in the Free State have benefited in many ways from a variety of projects, such as clinics, a fire station, roads and bridges, sewer lines, and electricity network upgrades,” explains Kgatle.

“Sasol Mining has regular engagements with the leadership structures in all municipalities.

These engagements serve as a tool to identify the most important community needs in terms of infrastructure. The identified projects are then signed off by both parties and submitted as part of the SLP.”

experience the joy of becoming a first-time homeowner. Sasol Mining says this also helps to instill a sense of togetherness and family culture among employees.

“As a company, Sasol Mining recognises the importance of decent housing for our employees and community members,” says Kgatle. “We have built and handed over 101 houses in eMbalenhle as part of our SLP. We have also handed over 59 houses to our employees in Secunda and 57 in Sasolburg this year, with more planned.

“The promotion of home ownership forms part of Sasol Mining’s broader transformation goals to ensure that the areas in which we operate benefit from our presence and that we leave a positive legacy by fostering longterm, sustainable development.”

Education, training outreach and procurement The SLP also makes provision for the training of community members in adult education

Importance of home ownership In support of the SLP, comprehensive strategy to ownership and provides qualifying employees so

Sasol has a promote home assistance to that they can

Lucky Kgatle, senior vice president, Sasol Mining

Mine and shaft replacements: key facts Minister of Mineral Resources Gwede Mantashe officially opening the Shondoni colliery

and training, bursaries, and por table skills. These programmes provide opportunities for the development of local residents.

To support these initiatives, Sasol Mining has established relationships with accredited training institutions such as the Gert Sibande and Flavius Mareka Technical Vocational Education and Training colleges. On average, support is provided to 128 people per year.

Education forms the foundation of effective transformation, skills upliftment, employment and SMME development.

In the SLP, the commitment to promote local empowerment is very important for compliance in terms of the Mining Charter.

At Sasol Mining, the decision was taken to implement a comprehensive preferential procurement strategy.

“To this end, one of the elements contained herein provides the opportunity to set aside all our local economic development and housing projects to be implemented by locally based BBBEE-compliant companies,”

explains Kgatle. “This, in turn, leads to stimulating the local economy, job creation and skills transfer.”

Sasol Mining follows the Sasol Group’s procurement policies and promotes the use and development of locally based suppliers through the central enterprise and supplier development team within Sasol. Prospective suppliers can consult the website at www. sasol.com for guidance on how to register.

“We have taken a keen interest in ensuring that we affect our fence-line communities in a positive and sustainable manner. We have invested in the local development of our infrastructure, and will continue to do so, enabling us to leave a lasting legacy as a proudly South African company,” adds Kgatle.

“Our employees must be proud and be able to point out the positive impact that we are making in the communities where we conduct our business,” Kgatle concludes.

www.sasol.co.za An early childhood development project funded by Sasol Mining

• Sasol Mining is in the process of completing a R15 billion mine replacement programme to ensure uninterrupted coal supply to its Secunda Synfuels Operations.

• Mine replacement projects support Sasol’s strategy to operate its Southern African facilities until 2050. This ongoing project is being undertaken to replace 60% of Sasol Mining’s operations in Secunda by 2020.

• Projects are expected to be completed below budget and within schedule.

• The first of these new replacement mines is the Thubelisha shaft, which was inaugurated in May 2012 at Twistdraai Colliery.

This shaft supplies coal to both Secunda Synfuels Operations and export customers.

• The Impumelelo mine will replace the Brandspruit operation. This coal will be used exclusively by Secunda Synfuels Operations.

• Shondoni Colliery, a brownfield extension, is in operation and will eventually replace Middelbult Colliery. Impumelelo, when in full production, will replace Brandspruit Colliery.

• The Syferfontein Tweedraai project was completed in 2015 ahead of schedule and within budget.

Municipal Focus | Tshwane

Out with the old The City of Tshwane recently completed a 2 058 m water pipeline replacement project as part of its broader pipeline replacement strategy, in an effort to meet water demands over the next decade.

By Danielle Petterson

T

he R13 million pipeline replacement project in Moreleta Park has brought an end to frequent water outages as a result of bursts on the pipeline. The existing 400 mm pipe could not withstand the pressures and was replaced with a new 450 mm Class 16 oPVC pipe in line with the required standard.

This is one of a number of pipeline replacement projects in the city. According to Darryl Moss, MMC: Utility Services, City of Tshwane, pipes have also been replaced in Garsfontein, Eersterust, Clubview, Babelegi and Alphen Park, among others.

These form part of a large-scale pipeline replacement strategy that began in earnest last year.

The city-wide programme is expected to continue over a number of years, focusing on replacing pipes, which experience significant leaks and bursts. Old asbestos cement pipes are a high priority, as they were installed 30 to 40 years ago and are past their design life, explains Moss.

Replacements are being prioritised in accordance with Tshwane’s computerised water asset management system, to which all of the city’s reservoirs, pump stations, hydrants and other major infrastructure are connected. The system monitors that vast majority of the city’s water infrastructure in real time and provides very good information on a number of aspects, including the state of various pipelines. By monitoring flow and pressure, the city is able to detect

and address leaks and bursts timeously, explains Moss.

Moss has worked to secure significant budget allocation for pipe replacements. A total of R2 billion is expected to be spent on the entire initiative, with R79 million allocated this year and R105 million and R85 million allocated for the following two years, respectively.

The municipality has also begun to prioritise sewer pipe replacements, particularly in the northern areas of the city where many sewers are far beyond their design life. A replacement programme began last year and trenchless methods are being utilised in many cases. According to Moss, trenchless technology will also be applied in the replacement of water pipes, many of which are located in the busy, older, urban areas of city.

Making every drop count Tshwane’s percentage of non-revenue water (NRW) sits at around 28% of its bulk water input of 880 Mℓ per day. Of this, real losses account for 22%, with 6% accounted for but unbilled.

Although Tshwane’s NRW management is the second best in the country behind Cape Town, Moss believes it needs even better management. He would like to see NRW reduced to 20% over the next five years, depending on the availability of the appropriate resources.

The drive is especially important, as Rand Water has reached its licence cap in

IMIESA November/December 2018

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JHB 63491/OJ

Sustaining communities.

An attractive characteristic of PE100 piping systems is the creation of leak-free joints through heat fusion, which creates a joint that is as strong as the rest of the pipe. Ensuring on fulfilling the needs of the local potable water pipe market, for generations to come.

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Municipal Focus | Tshwane

terms of the volume of water it can extract from the Integrated Vaal River System. As a result, its water supply to the city is capped at an average annual monthly demand of 22 000 000 kℓ/month, until Phase II of the Lesotho Highlands Water Project comes online, which is expected in 2026, but could be as late as 2030.

“This means our water is fixed for roughly the next 10 years. We have a growing city and people wanting more water, which puts us in a difficult situation,” says Moss. He believes this is the most critical long-term sustainability issue that Tshwane and other Gauteng municipalities have to deal with.

Water-saving measures Aside from replacing pipes to reduce losses, Tshwane has a number of initiatives in place to address the water supply situation.

These include water conservation and water demand management programmes, efforts to improve management efficiency, and encouraging lower consumption by residents and industries. Although water restrictions were lifted several months ago, Moss says

the municipality is considering re-imposing them. Water usage has increased as a result of the warmer weather and Rand Water has restricted certain reservoirs, mainly around Centurion, which has led to shortages.

There are currently two large water conservation projects under way to detect and repair leaks, particularly underground leaks, which often go unnoticed. The first, in the far east of Pretoria near Cullinan, is being funded by the Development Bank of Southern Africa, while the second project – in

the Ga-Rankuwa and Soshanguve areas – is being funded by South African Breweries.

In addition, Tshwane will be significantly increasing its purification capacity over the next five to six years. This will allow the municipality to boost its water supply with resources from the Rietvlei and Roodeplaat dams.

“We have lots of plans and we know what needs to be done, but it is all a case of resource allocation and making a strong case for provision in the budget,” says Moss.

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IMIESA November/December 2018

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SAST T Trenchless News

Trenchless technology builds capacity

S

peaking at the opening of No-Dig 2018, Deputy Mayor of Cape Town Ian Neilson said that, as a former consulting engineer specialising in water engineering, he has always taken a keen interest in the latest technologies and ser vices for the construction and maintenance of infrastructure.

“I am encouraged by the possibility of applying some of the technologies presented at this conference in addressing key challenges we face as a rapidly expanding city,” he said. “As the urbanisation trend grows, it is critical that we provide sustainable services.”

The city adopted the use of trenchless technology as early as the mid-1990s for the upgrading of its sewer and water networks. During that initial period, the technology available was mostly based on slip-lining of existing sewers with smallerdiameter HDPE pipes, and pipe cracking of water mains with HDPE sections of the

Installation of liner in Black Mac Sewer

In October, subject experts from around the world came together in Cape Town for International No-Dig South Africa.

Hosted by the Southern African Society for Trenchless Technology (SASTT), No-Dig 2018 saw the conference’s African debut. The opening paper expanded on the integral role that trenchless techniques play in socioeconomic development. By Alastair Currie same or slightly larger diameter. Since then, Neilson said that the technology has increased substantially and the city is now making use of techniques like horizontal directional drilling, cured-inplace pipe lining, and piperamming used in combination with pipe cracking.

A pipeline project completed by the city using microtunnelling technology was the longest installation of its kind in Africa south of the Sahara. This entailed the installation of a 1.2 km long, 1 000 mm diameter pressure pipe, and underscores Cape Town’s innovative approach to trenchless technology, winning SASTT’s

Joop van Wamelen Award of Excellence in 2017.

“Trenchless techniques ensure minimal disruption to suppor ting communities and have proven to be a cost-effective alternative to conventional construction for large-scale project roll-outs in congested urban areas,” said Neilson. The city is planning to replace around 50 km of sewer and water networks in the current financial year. In the longer-term, the city ultimately plans to replace the entire sewer and water network, which comprises a total asset length of 20 000 km, using trenchless technology.

Trenchless technology as an economic catalyst Sam

Efrat, president, SASTT, introduced keynote speaker Neil van Rooyen, a SASTT board member and director at Chrysalis Projects, based in Cape Town, who delivered a paper entitled ‘Unlocking economic growth in South Africa through the use of trenchless technology’. A key theme was the need to create new SME contractors, as well as immediate direct employment opportunities, while at the same time passing on multimillion-rand savings on infrastructure investments.

“Innovation has always been regarded as the forerunner to

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IMIESA November/December 2018

SAST T Trenchless News

economic growth so it’s no coincidence that of the top ten trenchless societies worldwide, seven belong to countries with the highest ranked GDP outputs. These comprise Canada, China, France, Italy, Japan, the UK and the USA,” said Van Rooyen.

“These economies are able to grow because of their investment in infrastructure.

They are also among the oldest, which means that they have the greatest need for pipe replacement.”

Within the South African context, a sharp contraction in GDP and a drop in business confidence levels have impacted on domestic and foreign investment inflows, increased unemployment levels to around 27%, and caused a backlog in infrastructure delivery, which poses a major risk to macroeconomic growth. This places an even greater emphasis on the need to develop creative solutions that drive down costs and accelerate construction projects.

South Africa’s current network comprises around 197 000 km of reticulation pipeline

Keynote speaker Neil van Rooyen

for water and sewer combined. “Many of our pipelines have already exceeded their lifespan, resulting in failures and an ensuing impact on health and well-being.

The problem is being compounded by the inflow of rural job seekers to urban centres.

That places further pressure on the existing infrastructure, which is struggling to keep pace with current demand. So are we hanging on a ledge, or can we change the way we tackle the problem?” Van Rooyen continued. “As SASTT, we believe trenchless technology is a major part of the solution.”

Van Rooyen said an important starting point was to dispel misconceptions about trenchless technology as a potential competitor to open-cut techniques, which some regard as being more conducive to labour-intensive techniques, and thus job creation. “However, as with the case for trenchless applications, mechanical excavation techniques perform the bulk of the work on open-trench projects.

Plus open-cut trenches must comply with strict health and safety regulations to protect

The jacking frame within the jacking shaft

them from collapse, for example by installing shoring. The latter approach can be timeconsuming and inefficient.

“Using the open-cut method, studies have shown that a typical pipe section of 100 m takes around seven days to complete, in the process creating employment for some 28 unskilled and nine skilled workers,” said Van Rooyen.“For the same project, the timeframe would be similar for a trenchless application and require the same number of personnel.

The key difference is that the number of skilled workers is much higher. Creating jobs for skilled workers translates into higher wages, and other career opportunities in the construction sector.”

Case studies On a recent project in Gauteng, a comparative and parallel study was undertaken to evaluate the economic advantages of trenchless technology versus open-cut. The project value was approximately R1 million in each case and entailed the installation of a 160 mm diameter HDPE sewer pipeline.

Around 1 000 m of pipeline was laid using open-trench methods, compared to some 1 300 m using trenchless techniques.

In another project example, a comparison was made between open-cut with and

Installation of vortex drop structure 800 mm diameter PVC shaft

Photos by Terry February

Deputy Mayor of Cape Town Ian Neilson

IMIESA November/December 2018

15

SAST T Trenchless News

Pulling product pipe into position with DD10

an important point to note because it means that any solutions we bring to the table must be efficient and cost-effective.

“For municipal water infrastructure, R27.8 billion was assigned and R19.5 billion for sanitation, for all aspects and not just pipeline reticulation, which accounts for at least 12% of the budget. The money earmarked for pipelines is, therefore, about R3.34 billion and R2.34 billion for water and sewer lines, respectively. The actual amount for 2017 is R2.05 billion and R1.58 billion.”

Doing more with less and creating employment without shoring during the installation of a 110 mm diameter HDPE pipeline. The study showed that open-cut with shoring was almost 2.7 times more expensive.

“Currently, national infrastructure funding has proposed that a budget of R89.9 billion be made available annually for the next 10 years to address South Africa’s water and sanitation infrastructure needs,” Van Rooyen continued.

“However, the money made available for all water and sanitation infrastructure in 2017 was less than that, at around R56.6 billion. This is

Taking the best-case budget of R2.34 billion for sanitation lines, Van Rooyen presented a scenario that allocates about 10% of the work for trenchless applications, in this instance using pipe-bursting techniques.

“Calculations based on extensive research indicate that 3 839 km of pipeline could be installed in combination with open-cut excavation. However, if 50% of the money available is allocated to trenchless applications and the balance to open-cut excavation, the numbers increase significantly. Some

4 682 km of pipe could now be installed, in the process generating at least 100 000 new employment opportunities. The market value of the trenchless sector would then be over R1 billion,” he pointed out.

By increasing the trenchless component to 60%, 4 892 km could be installed for the same budget allocation. Job opportunities then rise to over 105 000 and the market size increases to some R1.4 billion. This would also enable the accommodation of more than 70 new emerging contractors, each being able to generate a minimum annual turnover of R20 million.

The same exercise was carried out for the water sector (with the employment of pipe bursting), with corresponding results, again presenting a conclusive argument for trenchless techniques.

With a 50/50 approach close to 5 000 km of pipe could be installed annually and at least 53 000 new jobs created. Increasing the trenchless component to 60% creates more than 100 SME contractor opportunities.

“Open-trench excavation remains a viable application, especially in rural and less congested areas, but increasing the trenchless component just makes economic sense,” concluded Van Rooyen.

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SAST T Trenchless News

The future of utility locating Utility locators, construction professionals and land surveyors all need a reliable, non-destructive method to locate subsurface targets prior to digging, trenching, conducting site assessments and mapping.

U

tilityScan by GSSI provides infrastructure professionals with a compact groundpenetrating radar system for utility locating. Supplied locally by Red Dog Scientific Services, UtilityScan’s rich set of features redefines the level of performance available in a low-cost utility locating system.

Field-proven performance UtilityScan is based on GSSI’s patented HyperStacking technology, which provides excellent near-sur face resolution and increased depth penetration in all soil types.

This patented real-time sampling technique improves performance while maintaining measurement speed and minimising radiated emissions. The technique uses multiple stacking (averaging) during data acquisition in order to reduce noise and improve data quality.

The lightweight system is incredibly compact and collapsible, and a new wireless antenna eliminates the need for cabling, resulting in a system that can withstand challenging field conditions. Furthermore, the simplified app-based, touchscreen user interface ensures that UtilityScan is easy to use and quick to deploy.

Advanced capabilities The most impor tant requirements for utility locators are ease-of-use, accuracy and reliability. To address these needs, UtilityScan can be provided with the new LineTrac power detection module, designed to identify and trace the precise location of underground and RF-induced utilities. UtilityScan also uses enhanced software features for gain control, target detection and horizontal banding reduction.

An integrated GPS is included with the system and a built-in pole mount is available for mounting GPS systems on survey poles where high-resolution positioning is needed. A Bluetooth interface is provided to facilitate communications with userprovided GPS systems.

Additionally, the system deploys dynamic gain control, which monitors the system gain on the fly during data collection.

This enhances ease of use by eliminating the need to repeatedly change gain settings when scanning areas with varying soil conditions.

UtilityScan’s simple operation is ideally suited to meet the needs of ser vice

providers, engineering contractors, and state and local municipalities. Best of all, the breakthrough technology designed into UtilityScan results in high-quality data sets that are second to none.

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IMIESA November/December 2018

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17

SAST T Trenchless News

High-pressure HDPE-lined steel spools or pipe sections manufactured and supplied by Aegion SA

Advancing trenchless infrastructure

No-Dig 2018 provided the perfect opportunity to showcase and reinforce Aegion South Africa’s pipeline rehabilitation technology leadership and cradle-to-grave value proposition to leading experts and decision-makers.

T

he international No-Dig South Africa 2018 conference and exhibition held in Cape Town was a momentous occasion for leading local pipeline rehabilitation technology provider Aegion SA, which was established to address the deteriorating state of much of Southern Africa’s pipeline infrastructure.

Conventional methods of repair involve digging up old pipelines and replacing them.

However, in highly dense industrial, urban and peri-urban areas, this is often an almost impossible task, as it involves major and costly disruption to other infrastructure along the route of the pipeline.

“As Aegion SA, we circumvent this problem through the application of our tried and tested, proprietary international trenchless technology. Combining excellent local experience and expertise with this technology achieves permanent, stronger and safer solutions for the rehabilitation of pipeline infrastructure,” says Johann Scholtz, general manager, Aegion South Africa.

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IMIESA November/December 2018

Cradle-to-grave value proposition “The No-Dig event really lived up to our expectations of a premier trenchless technology showcase – with the added benefit of a local and pan-African audience. We were also really pleased with the opportunity to increase the target market awareness of our brand, technology and cradle-to-grave project approach, which our presence at No-Dig provided,” says Scholtz. He adds that he was impressed by the high levels of interest shown in Aegion SA. He comments that Aegion SA was also particularly pleased to be exhibiting in Cape Town, as the company has recently opened a new facility and branch office in the Mother City.

“Regarding pipeline rehabilitation, the Western Cape has been the site of much of our previous CIPP (cured-in-place pipe) project work and is, as such, also a key target area for us to showcase the effectiveness of our CIPP technology and its associated brands.”

Aegion SA has, for example, carried out a number of environmental pipeline

rehabilitation projects in the Western Cape agricultural sector. In the context of the recent water shortages in the Cape, these pipeline rehabilitation projects not only restored water reticulation quickly and effectively, but also saved many kilolitres of much-needed water.

Added benefits with Aegion’s iPlus glass-fibre reinforced liner Regarding the Insituform I-Glass UV liner, speaking at the No-Dig conference, Craig Bennett, manager: CIPP, Aegion South Africa, presented a paper on the benefits of this innovative brand and solution, and its practical applications compared to the traditional ambient and thermal curable solutions.

Aegion SA employs iPlus® Glass, a glassfibre reinforced liner that rehabilitates damaged infrastructure. When compared to standard CIPP, iPlus Glass requires less resin, provides higher mechanical properties and forms a thinner tube, increasing flow capacity. iPlus Glass is a more environmentally friendly rehabilitation option and, as it is a pull-in process, the result is that there is less material waste and the job-site footprint is typically smaller than a traditional CIPP installation. iPlus Glass is cured by using UV light, which reduces energy and is ideal for areas where water is in short supply. In addition, when using the UV cured process, the iPlus Glass installation is typically quieter, faster, less disruptive, and requires less equipment than a traditional CIPP installation.

SAST T Trenchless News Aegion SA’s presence at No-Dig 2018 showcased and reinforced the company’s pipeline rehabilitation technology leadership and cradle-to-grave value proposition

Aegion SA’s exhibition stand at No-Dig 2018 showcased trenchless pipeline solutions

No more ‘digging around’ for data The No-Dig event also afforded Aegion SA the opportunity to showcase its latest CIPP service vehicle. This new vehicle has been fully equipped with cameras for pipeline inspection and a range of technologies that allows the company to quickly and accurately execute, monitor and manage the cradle-to-grave process.

Quality control has now been taken to the next level with a full visual report for clients on-site. This versatile new vehicle is currently deployed at Aegion SA projects across the country. The No-Dig event attracted engineers and No more ‘digging’ for data! Aegion SA’s full-service vehicle was showcased at No-Dig 2018

other representatives from municipalities and companies in sectors such as water management, waste management, mining and agriculture from all over South Africa, and even some from the rest of Africa. The key interest areas were pipeline rehabilitation in sewer and water reticulation systems.

“We were also able to further strengthen the overall market awareness of the Aegion SA brand when meeting with representatives of most of the major municipalities in South Africa, including those from the Western Cape,” Scholtz remarks.

In addition, Scholtz and his team met representatives of both the petrochemical and mining industries at the event.

Many of the visitors to the Aegion South Africa stand were there to gain a deeper understanding of the technologies utilised in this relatively new sector of the industry and were able to leave with the valuable information they needed.

Aegion SA was also ver y excited, through No-Dig, to be able to assist young engineers in particular to become more conversant with the trenchless technologies that will

assist in dealing with the pressing pipeline infrastructure rehabilitation backlog so prevalent in South Africa today.

Technology key to better infrastructure rehabilitation “We have always been early adopters of new technology. Today, we are ensuring our company’s future growth through focused investments in advanced technology, which ensures that our clients will get the benefit of the world’s latest solutions in the fields of pipeline rehabilitation and hydrotransportation,” Scholtz continues.

In terms of these technologies, in the near future, Aegion SA will be bringing all of these to bear in a major new pipeline rehabilitation project to be undertaken in the North West province. “While we have access to the world’s best technology through our USAbased principal, Aegion, our experience in providing solutions to suit local conditions has had extensive benefits for our South African and pan-African clients,” Scholtz adds.

Best in the business Apart from its premier technology, Aegion SA has been selectively recruiting individuals known for their outstanding industry experience and expertise. “The business has been transformed over the last year.

Increased resources, capacity and the best people in the business have seen a 38% increase in sales,” Scholtz asserts.

“Given the increased target market awareness of our brand, technology and cradleto-grave project approach, we are now better positioned than ever to service our customer base and provide solutions that are even safer and stronger than before,” he concludes.

IMIESA November/December 2018

19

Embracing UF technology Ultrafiltration membrane systems provide the ability to treat poor-quality feedwaters and produce excellent final water quality. By Herman Smit*

U

ltrafiltration (UF) systems are ideal for new installations or upgrades to existing filter systems or clarifiers, cutting operating costs and decreasing the plant footprint while delivering exceptional value over the entire system life cycle. The main benefit of UF is a fully automated process that reduces

operator involvement. This eliminates the need for constant monitoring and decision-making, addressing South Africa’s skills shortage while providing the opportunity to upskill operators, as well as ensuring quality water output. Each module comprises thousands of membrane fibres with microscopic pores on the membrane surface, which reject particles

greater than 0.04 Âľm. The experience of Quality Filtration Systems (QFS) in the implementation of membrane technologies in South Africa not only provides exceptional final water quality but an improved operational experience. However, it is important for clients to understand the UF membrane system to effectively and confidently implement the technology.

Filtrate system Raw water must be screened to remove large solids before it enters the UF membranes.

Some systems include other raw water pre treatment, such as coagulant dosing or pH

Water & Wastewater

Retained solids from feed

Electron micrographs of typical MemcorÂŽ hollow-fibre membranes: (a) sectional view enlarged about 200 times, (b) close up of membrane cross section with outer fouling layer visible, (c) enlargement of interface between fouling layer and membrane

Feed

Fibre Wall A sectional view through a typical hollow fibre membrane during filtration

correction. UF systems reduce chemical consumption, as no coagulants are required to form a bigger floc for filtration.

Filtrate flow rate is typically controlled by a variable-speed drive on the feed pump. Filtrate typically flows to a local filtered water tank where a level switch or transmitter is used to monitor the maximum level and place the membranes into standby while the tank is full.

Backwash The backwash process is key to efficient operation. As feed passes through the membrane barrier, a filter cake builds up on the membrane surface, increasing the resistance to flow. Short reverse flow of filtrate removes the retained solids from the membrane fibre surfaces.

The control system typically initiates an automatic backwash every 20 to 60 minutes of filtration, depending on feed quality. This allows waste solids to be completely drained from the membrane surface, eliminating solids accumulation and biological fouling.

Clean-in-place (CIP) cleaning cycle When the build-up of foulants on the membrane modules increases the trans membrane pressure or reduces flow rate, a CIP cleaning cycle is usually required. Cleaning may also be initiated simply on an elapsedtime basis, a particularly useful strategy to maintain cleanliness in potable water systems.

Automation Standard UF systems are supplied with a feed and filtrate pressure transmitter and may have additional local instruments such as flow, temperature and pH sensors, to monitor the operation of the system. A programmable logic controller controls all operational functions while a human interface module allows the operator to make limited adjustments.

If the UF operates outside normal limits, a warning is typically generated, while operation outside wider limits can generate a shutdown alarm, reducing the risk of damage to system components.

Conclusion The assurance of excellent final water quality with less operator

IMIESA November/December 2018

21

involvement is a big advantage in the simplification of plant operation.

The configuration of UF membrane systems offers the ability to treat poor-quality feedwaters with excellent output results, in line with government’s drive to increase the production of potable water.

QFS has in-house mechanical and electrical engineering capabilities to support the design of these systems and provide local components and engineering practices, ensuring competitive costs and adherence to local requirements. The company provides a complete installation and commissioning service, as well as operations and maintenance services, to assist operators with training. *Herman Smit is the managing director of Quality Filtration Systems.

QFS would like to acknowledge the assistance of Evoqua Water Technologies in compiling this article.

Roads & Bridges

Expanded Cape route

J

G Afrika is overseeing the upgrade of a 48 km section of the N2 highway between Caledon and Riviersonderend in the Western Cape, with the works being carried out by main contractor Group Five. The main scope entails the widening of the road, which was originally built between 1978 and 1983, as well as upgrading its intersections to accommodate increased traffic volumes.

“The road mainly comprised a single carriageway with surfaced lanes and shoulders,” explains Duncan Murphy, technical director, JG Afrika. “Its surface width varied between 11.5 m and 17.5 m – except for the first 1.12 km, which consisted of four lanes with a raised median island in areas.”

Once completed, the route will have a minimum surface width of 13.4 m, including two 3.7 m wide lanes and 3 m wide shoulders, in areas. Where there are existing climbing lanes, the road is being widened to allow for 3.7 m wide passing and 3.7 m wide climbing lanes, as well as a 1.5 m wide surfaced shoulder.

River bridges The work scope also includes the widening of the Droogas River and Maandagsout River bridges, as well as the lengthening of 14 major culverts along the route. Droogas River Bridge Construction of new surfaced intersection with Divisional Road 1303

Widening of the existing N2 to accommodate a new climbing lane

comprises two spans of simply supported reinforced concrete deck, supported by a walltype pier and closed-face abutments. It is being widened by two simply supported spans with about a 3.5 m clearance above the access road and 4.5 m above the riverbed, to create a 1.95 m solid reinforced concrete deck.

The existing barriers will be replaced with cast in situ F-shape barriers, while the foundations for the abutments, wing-wall extensions and central pier comprise pad footings on the hard shale, and are identical to the structure’s existing foundations.

Maandagsout River Bridge comprises three spans of simply supported 610 mm thick reinforced concrete deck with wall-type piers and closed-face abutments. The new deck, which has a minimum depth of 550 mm, is being constructed with concrete and is similar in appearance to the existing structure. Its existing piers and abutment walls are supported by caissons. Due to the close proximity of the works to the existing structure, pilings support the widened section’s piers and abutments, which have also been founded on hard shale.

A total of 94 of the 117 minor culverts along this section of the N2 are being lengthened, while new concrete-lined drains, down chutes, catch pits, cut-off drains, toe drains and erosion protection are being constructed along the widened sections.

Widening of the existing N2

Roads & Bridges | Asphalt Technology

Transportation costs of the Ciber Inova 2000 are about 60% below the average of other asphalt plants of its class size

High production and mobility Manufactured by Brazil-based OEM Ciber, which forms part of the Wirtgen Group, the new Inova 2000 continuous mobile asphalt plant is the first in the range to arrive in South Africa. It was acquired by Actop Asphalt for a major road upgrade in Mpumalanga.

A

ctop Asphalt’s acquisition of the Ciber Inova 2000 sets a new production benchmark for the company and now increases its total asphalt plant fleet to four units. Setting new standards with its range of innovative technologies and, more importantly, its ‘super mobility’, the Inova 2000 can produce up to 200 tph (tonnes per hour).

The plant is a contract-specific investment to ser vice the Bambi-Lydenburg road rehabilitation project over an 18-month period, entailing the supply of 38 000 tonnes of hot mix asphalt. This will be supplied to Actop Asphalt sister company Actophambili Roads, a specialist road surfacing contractor, which has been subcontracted by main contractor Klus Civils.

Growing capacity From inception, three years ago, Actop Asphalt’s sturdy growth to date has hinged on its relentless focus on quality

asphalt production, says Francois Kemp, managing director.

“Our early success has, to a large extent, hinged on our affiliation to the larger Actophambili Group, a key player in the roads construction sector in South Africa,” says Kemp. He adds that while almost 90% of Actop Asphalt’s work stream has come from Actophambili Roads in the past three years, the pattern has started to change in recent months – with a steady flow of external contracts.

Key drivers A key driving factor in acquiring the Inova 2000 was the plant’s rapid deployment capability.

“We were looking for an asphalt plant that we could install in a very short space of time,” says Kemp.

The Ciber Inova 2000 fit the bill due to its high production capacity and compact build: it comes in just two units. This is in stark contrast to some of the existing plants in the stable, which come in six units, but only produce

120 tph. “The compact nature of the plant translates into lower transportation costs when moving from one site to the other, as well as a smaller footprint and lower cost of installation,” says Kemp.

According to Waylon Kukard, sales manager, Wirtgen Group South Africa, transporting the Ciber 2000 costs about 60% less than most other asphalt plants of its class size. “The plant’s mobility is its key strength. It can simply be hauled to site on two trailers, get plugged in, start production, and be easily decommissioned and commissioned again at the next site,” he explains.

Rudi du Toit, operations manager, Actop Asphalt, has already experienced the benefits.

“With some of the competitor plants, you are looking at up to a month to put it up. The Innova 2000 takes only seven days to mobilise and commission, which translates into three weeks of extra production when compared to other plants,” he says.

Du Toit, who was recently part of a South African contingent that made the trip to Brazil to witness Ciber’s innovations first-hand, also makes special mention of the EasyControl system – intuitive software that affords total control of all the production processes. “It allows for automated control – without operator interference – of the burner flame and other components,” Du Toit concludes.

IMIESA November/December 2018

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Roads & Bridges

Roads to social and economic growth Africa poses unique challenges for the provision and preservation of roads and road transport. In an effort to address these challenges, the South African Road Federation (SARF) recently hosted its Regional Conference for Africa. By Liesl Frankson

U

nder the theme ‘Roads to Social and Economic Growth’, SARF – together with the International Road Federation (IRF) and the PIARC (World Roads Association) – gathered 73 high-level speakers and hundreds of delegates at the Durban International Convention Centre.

The first day of the conference saw a wide variety of presentations from industry stakeholders, with a strong focus on finance, the preservation of the continent’s road assets, and training and education in the roads sector.

The conference also featured a Young Professionals session, which was very well supported by the conference delegates.

Safety and training The presentations from the plenary session set the tone for the conference, with Michael Dreznes, executive vice president, IRF, discussing a variety of pertinent safety issues.

Dreznes urged delegates to be proactive rather than reactive with regard to safety in the design of roads. “Safe systems infrastructure needs to be a central part of road design from the beginning. Africa needs to start designing five-star roads and this is where design engineers have a key role to play.”

Dreznes also conducted a workshop on the third day of the event where he shared his many years of experience under the theme: Work Zones Can and Must be safer in South Africa.

Dr Allyson Lawless, author of Needs and Numbers, discussed engineering needs in the SADC region and noted that the number, limited resource and poor quality of graduates have become major problems for the engineering sector.

“The complexity and recognition of qualifications as well as the conditions for registration, across the region, are inconsistent, so this is something we need to work on. We are also faced with the challenge of too few experienced engineers left to develop graduates.”

Lawless also called on engineers in government to be the critical thinkers the country needs. “We need our engineering professionals to step up and play a more substantial role in national leadership structures. Formal graduate support is urgently needed and ongoing training is something that must be institutionalised,” she said.

Access to finance Turning to roads finance, Skhumbuzo Macozoma, CEO, Sanral, noted that money itself is not a problem but rather the access to funds that is the real challenge. “This is not about funds; money is everywhere but the question is how we access it. This is also not about finding funding models and options – all of these things already exist. The real issue is that people need to make a decision on which way to go,” he explained. Macozoma noted that it was absolutely essential for

authorities to determine their needs before they could look at funding. He also asked the critical question: how much does engineering inform roads needs and priorities in a political landscape dealing with a tight budget and a scarcity of skills?

“One of our greatest challenges is that we are choosing to fix our roads when they are at their most expensive – when the damage has been done and we are desperate. We are focusing on preventative maintenance at the end of our design and operation processes, which is not financially smart.”

Sustainability of road design Sustainability took centre stage on the second day of the conference, with Manfred Uken from Royal HaskoningDHV unpacking the Sustainable Roads Forum’s Rating Tool. The tool is a rating system for roads projects that promotes the use of sustainable best practices in the planning, design and construction of roads.

“One of the reasons for this tool is to help government meet its commitments for the Paris Agreement. This tool was developed by stakeholders within the roads industry and allows roads authorities to set sustainability intervention targets for their projects and to start measuring and reporting them in a clear, transparent and aligned manner.

“We are saying to the roads industry: get involved with these matters or someone else is going to tell you how to do it,” Uken noted.

IMIESA November/December 2018

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Geomatics

Surveying pitfalls in the municipal environment SAGI is taking a multi-pronged approach as it drives home key issues that need addressing in the municipal environment when it comes to understanding the role and duties of cadastral and engineering surveyors.

Ignoring the risk factors has major implications for current and future infrastructure delivery. By Altus Strydom*

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t’s common knowledge that most municipalities are in dire need of service upgrades: published reports confirm that the South African government is budgeting substantial funds to effect this as it strives to meet National Development Plan goals aimed at fostering macroeconomic development.

However, before anyone can do any development, planning, design or construction work, they need up-to-date maps and data. That job rests with the surveyor, who has an intricate task to perform. By definition, the term surveying encompasses all activities that measure, model and record information about the physical world and the environment.

The term is often used interchangeably with geomatics, both of which are the science of determining the position of points on, above or below the surface of the earth. The technique is ancient and highly effective: think of the maps of the world drawn up by cadastral surveyors thousands of years ago.

SAGC-registered sur veyors conduct topographical and detailed surveys of construction projects. They provide construction verification of as-built plans, the underground detection of services and the mapping thereof, as well as forensic investigations, control and monitoring surveys, and 3D scanning, among other key tasks.

The engineering survey discipline does not include cadastral work, which must be done in association with a professional land surveyor.

Cadastral surveys relate to property ownership

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IMIESA November/December 2018

and rights and restrictions in registered property.

Inclusive to cadastral surveying is the demarcation confirmation of new townships, subdivisions, servitudes, sectional titles and mining rights.

By supplying highly accurate and current spatial data, the geomatics profession distinguishes itself as the only profession that specialises in positioning, land information and mapping.

New technologies may make it easy for a nonsurveyor to try their hand, but the results will be a disaster. For example, not all drone operators and aerial survey companies employ or use SAGC-registered surveyors to sign off their plans.

Quality control by means of ground control points and ground survey checks of survey data is an essential part of an aerial survey.

The check-list Let’s expand on the vital role that surveyors play by reading off the following check-list. Answering ‘yes’ to any of the following indicates an urgent need to refresh spatial information, survey and mapping policies: - The current spatial/geographical data is inaccurate.

- The municipality or department doesn’t have standard survey and mapping specifications.

- There’s no mapping deliverables policy in place.

- The location of services cannot be confirmed - Spatial/GIS data is not current.

- Data is not accurate enough for design purposes.

- There are different data sets with conflicting data.

- There’s a clear understanding that the

A SAGC-registered surveyor carrying out a survey

organisation will function better with accurate data.

Spatial requirements encompass data that includes cadastral and boundary information, plus layout plans of sewerage, water, and electricity.

This information is essential for design and construction, but equally so for effective tariff revenue collection.

Professionals that need this data cover the full built environment spectrum, from developers to architects, town planners, civil engineers and utility service providers.

Legislation There are more than 30 Acts where the use of the survey profession is required or where the profession delivers a service. These include the Geomatics Professions Act (No. 19 of 2013), the Sectional Titles Act (No. 95 of 1986), the National Building Regulations Act (No. 103 of 1977), and the Spatial Planning and Land Use Management Act (No. 16 of 2003).

The Geomatics Profession Act is particularly significant. This makes provision for the registration of persons in the geomatics industry.

In turn, the South African Geomatics Council (SAGC) is the body that safeguards the public and controls the registration of survey and geographic information science (GISc) professionals.

It is illegal for a non-registered person to execute survey work. By law, surveyors must be registered with SAGC to perform cadastral or engineering surveys. So be careful not to place your project at risk by inadvertently committing an offence and jeopardising both your development work and professional indemnity.

In general, the cost of survey versus the cost of the infrastructure installed is negligible

Geomatics

and estimated at approximately 0.1% of the overall construction budget. However, where poor and non-registered surveyor work occurs, this frequently means that services are incorrectly designed and installed. That often translates into millions in wasted expenditure to rectify mistakes.

Minimum requirements for tenders and appointments The following should be part of a submission if there is a survey requirement in any tender for development and construction: - detailed response to the brief, stating price, deliverables and timeframe - proof of registration with SAGC and eligibility to contract in the form of a letter of good standing; alternatively, ask SAGI to investigate and confirm - proof of current professional indemnity cover - a proper survey specification, which details confirmation of cadastral and engineering quantities, accuracies and deliverables - proof of quality control.

Examples of what can go wrong Houses and small construction projects are all too

often built over building lines, municipal servitudes and boundaries. The cause: municipalities do not apply the building regulations that clearly stipulate that the boundaries need to be replaced by a professional land surveyor.

The following case study examples further illustrate what can go seriously wrong when a qualified surveyor is not employed with some common pitfalls. In some cases, working with incomplete data was a contributing factor, as illustrated in the first point below.

- Municipal pipelines were damaged and several suburbs were without water. The cause: an engineering surveyor conducted the setting out of a construction site with incorrect co-ordinates. Construction then started over a municipal pipeline that was clearly demarcated by a municipal servitude. No one checked the cadastral (surveyor general) data, which only a land surveyor can do. Plus no one checked that setting out was done from established benchmarks.

- A municipality accepted as-built plans that were not certified by a SAGC registered surveyor.

The result was that its GIS data was incorrect and damage occurred when other construction projects started. There were several court

actions against fibre optic firms that damaged municipal services: the municipality could not claim because their supplied data was not up to date or correct. So what went wrong? In this instance, the municipality did not have an as-built plan policy, which would have clearly stipulated that data must be signed off by a SAGC registered surveyor.

- Piling for a multi-storey building was incorrectly set out by an unqualified surveyor and the pillars were built in the incorrect position. The problem in this case was an error on the architects’ and engineers’ plans. A qualified surveyor was not present to compare the setting out data with the existing plan.

- A railway line, built without calculation of transition curves, had to be re-built. On this project, neither the engineer nor the unqualified surveyor realised that they needed to do this.

Obviously, a very costly mistake.

From these discussions, it’s clear that there are too many examples out there of shortfalls in survey compliance. In addition, it’s alarming to note that most of the currently available municipal survey data is outdated. This presents a major obstacle to infrastructure delivery.

In the interests of South Africa and the survey profession, SAGI is offering to assist municipalities in updating and drawing up new survey specifications and data management policies. It’s vital for all stakeholders to understand that without this, no legally compliant development can take place. *Altus Strydom is chairman of the Northern Provinces branch of the South African Geomatics Institute (SAGI).

Farm beacon erected in 1896

Drone landing on ground control point

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IMIESA November/December 2018

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IMESA Awards

The best in municipal engineering The 2018 IMESA/CESA Excellence Awards recognised municipal infrastructure projects that demonstrated significant achievement through innovation, design or construction.

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resented at the 82nd IMESA Conference, the 2018 awards recognised outstanding achievements in municipal infrastructure, demonstrating the best of civil engineering as a science and how engineering enhances the lives of local communities.

Awards were presented across three categories: 1.

Engineering Excellence in Structures & Civils 2. Community Upliftment & Job Creation 3. Environment & Climate Change.

A total of 20 projects were entered this year.

The following were recognised as the best in municipal infrastructure.

Category 1: Engineering Excellence in Structures & Civils WINNER: Western Aqueduct Phase 2 – Inchanga to Hillcrest Comprising Contracts WS6190 and WS6191 Client: eThekwini Municipality Consulting engineers: Western Aqueduct JV – Knight Piésold Consulting, Royal HaskoningDHV and Naidu Consulting

WINNER

Western Aqueduct Phase 2 – Inchanga to Hillcrest Comprising Contracts WS6190 and WS6191

Conceived in the mid-1990s to address water shortages in the northern and western parts of Durban, the Western Aqueduct Bulk Water Conveyance Project eclipses all other water distribution systems within eThekwini Municipality, being the area’s single biggest project in terms of size, complexity and cost.

Phase 2 of the project consists of 56 km of steel pipeline ranging between DN 1 600 and DN 500. This phase runs from Inchanga to Ntuzuma and has been constructed under six different contracts. For the WS6190 and WS6191 contracts, advance work was required in road reserves and private properties to prepare the required working corridor.

Road rehabilitation and reinstatement was also undertaken.

Innovation was required from both the consultants and contractors for this complex project. This included modified scour chambers that significantly reduced the drowning risk to maintenance workers while speeding up pipeline repairs, as well as the use of the historical Durban-to-Johannesburg railway line and the ‘Inchanga Choo Choo’ to move a large proportion of the pipes during construction, saving both time and costs, protecting the environment, creating employment, and

upholding the heritage of the area. One of the immediate benefits of this pipeline was that its higher residual pressure is presently being used to supply water under gravity to Botha’s Hill Reservoir, effectively replacing a pumped supply that was originally commissioned in the 1970s.

2ND PLACE: M25-C9 Underpass Interchange Client: eThekwini Transport Authority Design engineer: eThekwini Municipality Roads Provision Department Contractor: Inanda JV (Main contractor WBHO, with Qanza Construction, Lakeshore Trading, Ethos Transport, Phakama Construction and Thekwane Logistics) The M25-C9 Underpass connects to Bridge City, a mixed-use private-public ‘town centre’ development in the north of Durban. The link, for vehicles and pedestrians, plays an important role in integrating Bridge City developments into the surrounding area.

Space for the new interchange was severely limited by neighbouring properties, as well as the C3 route, which travels alongside the M25 highway. The interchange needed to include two bus corridor ramps that would allow

IMESA Awards

2ND PLACE

M25-C9 Underpass Interchange

take account of delays in receiving approvals from Prasa, as well as the inclusion of additional works such as the upgrading of the Point parking area at Kalk Bay and the demolition of the old Clovelly Station railway platform.

OTHER ENTRIES: • Installation of Municipal Engineering Services (Bulk and Internal) for the Watervalspruit Mega Housing Development: Phases 1 & 2 Client: City of Ekurhuleni Consulting engineer: Infraconsult Engineering Contractor: Sikhumba Construction

the C9 route to split away smoothly from the C3 route and loop back on itself, a viaduct for the continuing C3 route, realignment of an existing highway off-ramp and creation of a matching on-ramp, and, of course, the underpass itself, which connected the two highway ramps in a halfdiamond configuration. eThekwini’s M25-C9 Underpass uses integral piers and abutments to test the limits of reinforced concrete bridge deck skewness and slenderness, a necessity for the ultra-compact multimodal transport interchange designed around it. The deck is not pre-stressed and its shallow depth is maintained across the span, creating an aesthetically refreshing, lowmaintenance structure that is also materially efficient and rapidly constructed.

By carefully negotiating space and level constraints, the interchange provides an essential connection between a cluster of new Bridge City developments and a neighbouring industrial area, while threading an entirely new transport system through the city’s existing infrastructure.

3RD PLACE: Rehabilitation of Main Road between Atlantic Road, Muizenberg, and Clovelly Road, Clovelly – Phase 3 Client: City of Cape Town Consulting engineer: Knight Piésold Consulting Contractor: Martin & East The scenic 4.5 km stretch of coastal road between Muizenberg and Clovelly, one of only three routes linking the Cape Town metropolitan area with the far south, had last been resurfaced in 1994 and was designed to last approximately 10 years.

In 2006, Knight Piésold was appointed by the City of Cape Town to rehabilitate Main Road from Muizenberg to Clovelly, as well as repair or replace the municipal services including, inter

alia, water, sewerage and stormwater. Due to the complexity of the route, the project was undertaken in three phases, of which the Atlantic Road to Casa Labia and Kalk Bay Harbour to Clovelly Road is Phase 3. A key factor in the design of this project was that all services had to remain fully functional and that Main Road had to be able to accommodate traffic at all times during construction. This required the utilisation of very innovative techniques, as all components had to be constructed in an extremely confined space.

A critical aspect for the City of Cape Town was that the end product be aesthetically pleasing due to the scenic nature of the area. The road itself is part of a historical route that passes through a number of historical villages that attract tourists from across the world.

Phase 3 commenced in February 2014 and was completed in January 2018, in accordance with the contract programme. This was revised to

3RD PLACE

Rehabilitation of Main Road between Atlantic Road, Muizenberg, and Clovelly Road, Clovelly – Phase 3

• BRT Cable-stayed Bridge Client: City of Johannesburg Consulting engineer: Hatch Contractor: WBHO Subcontractor: Form-Scaff • Lower Thukela Bulk Water Supply Scheme Client: Umgeni Water Main consultant: Aurecon Consultants: Bigen Africa & Madan Singh Contractors: Group Five Coastal, Stefanutti Stocks & Esorfranki Subcontractors: Veolia Water Solutions, Consolidated Power Projects and Strategic Environmental Focus • Cape Flats 3 Bulk Sewer – Phase 2 Client: City of Cape Town Consulting engineer: AECOM Contractor: CSV Construction • Special Maintenance of N2 Section 11 between Bramlin and Soutwerke Client: Sanral Consulting engineer: Bosch Projects Contractor: Roadmac Surfacing Cape

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IMESA Awards

WINNER ePhatheni Water Supply Scheme

Category 2: Community Upliftment & Job Creation WINNER: ePhatheni Water Supply Scheme Client: uMgungundlovu District Municipality

Consulting engineer: Royal HaskoningDHV Contractors: Hidrotech Infra (Phases 1 & 2) and Egxeni Engineering (Phase 3) ePhatheni is located south of Richmond in the rolling hills of Kwazulu-Natal. The local community was in need of a safe and reliable source of potable water.

The community was reliant on water from two springs fed through a water reticulation

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system comprising reservoirs, pipelines and standpipes. However, the system was frequently not operational and the supply was inadequate.

The need for safe and reliable potable water led the municipality to implement a new reticulation system, supplied with water from Umgeni Water’s Midmar Water Treatment Works through a series of bulk gravity pipelines, rising mains and reservoirs.

The community currently consists of 737 households with an estimated population of 4 700; however, the new water scheme will have the capacity to serve in excess of 7 000 people once fully developed.

The new water supply scheme was implemented in a phased approach. Phase 1 saw the construction of an 11 km bulk gravity main from Ndaleni Reservoir to ePhatheni Reservoir.

During Phase 2, 31.9 km of bulk and reticulation pipelines and associated appurtenances was installed. The design incorporated water conservation/water demand management concepts. This hilly supply area was modelled to establish pressure and metering zones to reduce non-revenue water by active management of the water reticulation network.

IMESA Awards

The final phase involved the construction of a 1.5 Mℓ reinforced concrete circular reservoir.

The project ensures the provision of a reliable and sufficient potable water supply to the ePhatheni community. This has improved the quality of life for the community, facilitating increased economic growth opportunities.

2ND PLACE: Tugela River Pedestrian Bridge Client: Maphumulo Local Municipality/ iLembe District Municipality Consulting engineer: Hatch Africa Contractor: Ingonyama Nicon The new Tugela River Pedestrian Bridge is a landmark structure that forms part of the Pedestrian Bridge Programme initiated by the KwaZulu-Natal Department of Transport. The programme seeks to redress past imbalances to historically impoverished communities by implementing infrastructure that will improve their quality of life.

The new bridge, with an overall length of 180 m and towers that are nearly 27 m high, was opened to the public in June 2017 as the first steel pedestrian suspension bridge in Mvumase, Maphumulo District, northern KwaZulu-Natal.

Prior to the construction of the bridge, community members crossed the 150 m wide Tugela River by removing all clothing and wading across the river with their valuables held over their heads in a bucket. Local community members suffered loss of life and attacks by wildlife while trying to cross the river to access jobs, schools and essential amenities.

3RD PLACE

ePhatheni Water Supply Scheme

Local residents now have dignified and safe access to essential amenities and work opportunities. The bridge also provides learners with a tangible reason to aspire to careers in science and mathematics.

3RD PLACE: Provision of Water and Sanitation to Informal Settlements Client: eThekwini Municipality Water and Sanitation Consulting engineers: Bosch Projects, MMK Consulting Engineers, Impande Consulting Engineers and TLS Consulting Engineers Project manager: SMEC The Provision of Water and Sanitation to Informal Settlements Project involves the delivery of communal ablution facilities to informal settlements across eThekwini Municipality.

The project seeks not only to provide a secure supply of potable water and basic sanitation services, but to restore dignity and improve the quality of life of some of the poorest communities in KwaZulu-Natal.

The three-year project commenced in September 2015 and involved installing both containerised and modular ablution blocks and refurbishing existing ablution blocks.

Large bulk sewer and water pipeline infrastructure was put in place and tied in

2ND PLACE

Tugela River Pedestrian Bridge

to eThekwini’s existing network.

Existing bulk sewerage pump stations were refurbished and a 45 m³/day package sewage treatment plant was installed to serve communities without immediate and adjacent access to existing sewerage infrastructure.

The estimated final contract value is in the order of R1 billion, with approximately R2 million for wages. The project has provided both direct and indirect benefits to the surrounding community by creating employment and training opportunities.

Ultimately, the project illustrates the success that can be achieved in service delivery to informal settlements via partnerships between national government, the local community and private sector professional service providers.

OTHER ENTRIES: • Resurfacing, Repair and Upgrading of Dal Josaphat Athletics Track Client: Drakenstein Municipality Consulting engineer: SMEC Contractor: Amandla Construction Subcontractor: CK Industries • Hilton Water Reticulation Replacement Client: uMgungundlovu District Municipality Consulting engineer: Naidu Consulting Contractor: WK Construction • Habu Community-based Water Supply Scheme Client: Botswana Government, sub-district of Habu Main consultant: JG Afrika Consultant: Initiatives

IMIESA November/December 2018

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A strong foundation for infrastructure success

WINNER New City of Johannesburg Council Chamber

Category 3: Environment & Climate Change WINNER: New City of Johannesburg Council Chamber Client: City of Johannesburg Consulting engineers: WSP/Studios Mass Contractor: Enza Construction The Council Chamber is the first phase of the City of Johannesburg’s Space Optimisation Programme, which seeks to optimise space, and improve efficiencies and service delivery. The development of the new Council Chamber by Joburg Property Company embodies the city’s commitment to transparent governance as well as environmental sustainability.

The building has achieved a five-star Green Star rating, representing a holistic approach to sustainability. While energy and water efficiency are important elements of sustainable construction, the quality of the indoor environment, resource-efficient material selection and quality processes are also taken into account.

The final design represents an environmentally friendly building that supports the health and well-being of its occupants. The chamber is designed as a transparent drum that enables an unimpeded visual link between indoor and outdoor, representing the city’s commitment to transparency and accountability.

2ND PLACE:

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Diversion of Solid Waste from Landfills in Six Municipalities in South Africa Client: Department of Environmental Affairs Consulting engineers: JG Afrika and RWA (UK) The Diversion of Municipal Solid Waste initiative was a flagship project between the South African National Department of Environmental Affairs and the Deutsche Gesellschaft für Internationale Zusammenarbeit.

JG Afrika, together with UK-based firm Resources and Waste Advisory Group (RWA), was appointed to project manage the coordination of a multidisciplinary team of five local subconsultants and one international partner.

In just 12 months, the team had to prepare six locally appropriate feasibility studies, business and implementation plans that would allow the municipalities to divert waste from their landfill sites to achieve major reductions in greenhouse gas emissions.

The selected local municipalities were: Rustenburg (North West), City of Mbombela (Mpumalanga), Emfuleni (Gauteng), Mangaung Metro (Free State), Msunduzi and uMhlathuze (KwaZulu-Natal).

The project offered an opportunity to make a step change in the development of integrated solid waste management practices in the partner municipalities and aimed to achieve effective waste management, proper climate change response and the development of a green economy. More than 40 alternative interventions were identified and each municipality selected projects tailored for

IMESA Awards

Diversion of Solid Waste from Landfills in Six Municipalities in South Africa

2ND PLACE

the surrounding environment and community.

Mangaung Metropolitan Municipality, for example, aims to divert 27 000 t of green garden waste a year by establishing centralised chipping facilities at its Northern and Southern landfills, and supporting 5 000 home composting operations.

This flagship waste project highlights collaboration between multidisciplinary experts, engineers, government and international partners, to ensure a positive outcome to difficult challenges.

3RD PLACE: Organica Water Resource Reclamation Demonstration Plant Client: eThekwini Municipality Water and Sanitation Consulting engineer: Murray & Roberts Water Subcontractors: Fountain Civil Engineering and Duys Engineering Group Murray & Roberts Water (MRW) currently holds the exclusive licence to Organica Water FCR technology in South Africa. Although predominantly used in larger municipal plants from 4 MLD to 100 MLD, Organica Water also supplies small containerised, or Bluehouse, solutions.

MRW has deployed one of the Bluehouse plants at eThekwini Water and Sanitation’s Verulam Wastewater Treatment Works as a demonstration facility. The Organica Bluehouse is a pre-engineered and prefabricated facility that captures all the benefits of Organica wastewater treatment.

The package plant is compact, odourless and energy-efficient, all while providing a unique, botanical garden-like look, maximising flexibility in planning and placement while minimising the negative impact on the surrounding land.

The conventional activated sludge process of treating domestic wastewater has been in use for more than 100 years. The Organica FCR technology offers various innovations and improvements. It is an integrated fixed-film sludge system offering substantial economic benefits versus alternative solutions.

FCR drastically improves the CAS process by leveraging fixed-bed biofilms that grow on both natural (plant-based) and engineered (patented biofilm media) root structures in a cascading reactor design, allowing for a much greater quantity and diversity of organisms to thrive in the same physical space.

The technology also addresses the psychological impact of wastewater treatment plants, by being housed in an aesthetically pleasing, odourless, greenhouse structure, making it acceptable to live and work near a wastewater plant.

OTHER ENTRIES: • Nanofiltration Membrane Water Purification Treatment Plant for Various Boreholes in eThekwini Municipality Client: eThekwini Municipality Water and Sanitation

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Organica Water Resource Reclamation Demonstration Plant

3RD PLACE

Consulting engineer: eThekwini Municipality Water and Sanitation Contractor: Veolia Water Solutions • Thermophilic Digestion at Northern WWTW Client: eThekwini Municipality Water and Sanitation Consulting engineer: eThekwini Municipality Water and Sanitation Contractor: Aquest • Pilot Ultraviolet Disinfection at Amanzimtoti WWTW Client: eThekwini Municipality Water and Sanitation Main consultant: eThekwini Municipality Water and Sanitation Consultant: GIBB/Aquest JV

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IMESA Awards 2018 | Steel Pipelines

Steel reticulation design excels Showcasing excellence in steel pipeline construction, the Western Aqueduct Phase 2 (Inchanga to Hillcrest) project won first place in Category 1: Engineering Excellence in Structures & Civils at the IMESA/CESA Excellence Awards 2018.

S

erving the growing needs of the City of eThekwini’s industrial and residential sectors is an expanding network of steel pipelines that traverse the hilly terrain common in this region. The challenging topography calls for innovative design and construction methodologies, which had a direct bearing on the pipeline reticulation system adopted.

For the Western Aqueduct Phase 2 component from Inchanga to Hillcrest, the steel pipes selected were manufactured and supplied by Hall Longmore, a market leader in South Africa and internationally since 1924.

Both contracts for Phase 2 were completed in 2015.

ABOVE LEFT The historical Durban to Johannesburg railway line and the ‘Inchanga Choo Choo’ were used to move a large portion of the pipes during construction, saving both time and costs ABOVE RIGHT The pipeline’s external coatings and internal linings were selected to achieve the maximum possible design life from the pipeline asset

Contract WS6190 comprised some 7 km of DN 1 600 steel pipe from Inchanga Station to Alverstone Nek Reservoir, with a short section of DN 1 400 steel pipe at Alverstone Nek Reservoir. The maximum static pressure in this stage is 29 bar, requiring 13.5 mm thick X65-grade steel pipe.

The final section (Contract WS6191) Pipe laying in progress comprised approximately 7.5 km of DN 1 400 steel pipe from Alverstone Nek Reservoir to the Ashley Drive Break Pressure Tank (BPT). The maximum static pressure in this case is 25 bar, requiring 12 mm thick X65-grade steel pipe at high-pressure sections. The Ashley Drive BPT was designed for a through-flow capacity of 400 Mℓ/day.

The Western Aqueduct was conceived as a large-diameter, thinwalled, continuously welded steel pipe. The steel pipe was selected to be both economical and functional. In

Client: eThekwini Municipality Consulting engineers: Western Aqueduct Joint Venture – Knight Piésold Consulting, Royal HaskoningDHV and Naidu Consulting Steel pipe manufacturer: Hall Longmore

low-pressure areas, this typically meant using the thinnest available X42-grade steel pipe, subject to typical slenderness limits not being exceeded. The thinnest wall was 10 mm on the DN 1 400 pipeline and 12 mm on the DN 1 600 pipeline, giving respective slenderness ratios of 140 and 133.

When pressure increases necessitated higher-strength pipe, the grade of steel pipe was changed in the first instance before increasing the wall thickness, as this was found to be a more economical solution – e.g.

10 mm wall thickness X42-grade pipe was upgraded to 10 mm thick X52-grade pipe, rather than, say, 12 mm thick X42-grade pipe.

The highest grade of pipe specified was a 13.5 mm thick X65-grade steel pipe with a minimum yield strength of 448 MPa. The pipeline was designed to be continuously welded, which resulted in the pipe wall stresses having to be calculated at every point of intersection. Because concrete thrust blocks were not a practical means of restraining longitudinal forces in such a large-diameter pressurised pipeline, these forces were taken up in the pipe itself.

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SAFCEC Conference

Stimulating a struggling sector The South African construction and civils sectors have taken a major beating over the past few years. Although confidence levels are at an alltime low, there may be hope moving forward.

By Danielle Petterson

T

he South African construction industry, and particularly the civils industry, is in dire straits, with contractors of all sizes going into business rescue or liquidation. While the construction sector did grow by 2.3% in Q2, this is coming off a low base following several quarters of negative growth.

This is largely tied to poor economic performance.

Speaking at the recent SAFCEC Conference, David Metelerkamp, senior economist, Industry Insight, stated that – based on income per capita – South Africa has essentially been in a recession since 2014. And although the country has been growing at 1% to 2% since the financial crisis, this hasn’t benefited the majority of South Africans. In fact, the average South African has been getting poorer every year for the past five years.

“There has been an absolute lack of investment in the South African economy over the last four to five years,” says Metelerkamp. Added to this, the uncertainty of land expropriation, coupled with the fall-out of state capture, which has recently led to yet another Minister of Finance resigning, is scaring off investors.

However, Metelerkamp believes the country’s new leadership under President Cyril Ramaphosa is a step in the right direction for the local economy. The new administration has brought with it a better degree of policy certainty, with better dialogue taking place between government and the various sectors of the economy. He also has confidence in Minister of Public Enterprises Pravin Gordhan to turn around state-owned enterprises (SOEs), whose budgets could be key to boosting the construction sector.

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IMIESA November/December 2018

“SOE reform is absolutely crucial to unlocking growth in the construction industry in South Africa. State capture runs so deep in some of the SOEs that it’s absolutely systemic. It is going to take a concerted effort by government to reverse some of those effects, and it’s not going to be a short-term fix, unfortunately,” said Metelerkamp.

A declining civils sector Construction sector confidence levels are at almost rock bottom. Almost 97% of respondents in the latest SAFCEC State of the Industry Survey were highly dissatisfied with conditions in the sector. Metelerkamp believes this is the lowest confidence has been in the civil industry in democratic South Africa.

The main contributing factor to the recent downturn of the civils sector was an infrastructure spend cut of more than R1 billion from the budget in March. Although this was expected to have an impact, it was not expected to have such a major impact in such a short space of time. And while a reduction in government spend was necessary, Metelerkamp believes it would have been more prudent to cut other parts of the budget, as there is significant evidence that spending on infrastructure is crucial to facilitating economic growth.

There hasn’t been any major growth in the construction industry since about 2011, and the current levels are in recessionary territory, explained Metelerkamp. There has been a changing dynamic over the past few years, with transformation, a push for SMMEs and the division of projects into smaller pieces all having

Key stats from the SAFCEC State of the Industry Survey • Since 2014, there has been a significant decline in employment - This equates to 30% of employees lost since Q2 2014 • There has been no real growth in order books • Late payments account for ±10% of respondents’ turnover • There is much fiercer competition for tenders - 90% of respondents reported that there had been more than 11 bids per contract • The nett satisfaction rate with the number of projects coming out to tender is -93% in Q3 • Profitability has been declining on a quarterly basis • The capacity of contractors is declining • Confidence levels are at -96.2 in Q3 • Slowdown in infrastructure spending, skills shortages and late payments were the most prominently mentioned issues

SAFCEC Conference

SOE reform is absolutely crucial to unlocking growth in the construction industry in South Africa.”

David Metelerkamp, senior economist, Industry Insight

an effect. According to StatsSA’s figures, the large contractors have lost about a 20% share of the overall pie in the construction industry over the last few years. The small and medium-size players filled the gap, but are now also beginning to feel the impact of a declining sector.

Skhumbuzo Macozoma, CEO, Sanral, noted, “The market capitalisation of the listed construction companies has shrunk to alarming levels.” However, the market share of smaller contractors has grown from 17% to 40%. “Of course, this is natural. If you are pushing for inclusivity, the market share has to shift. But of course it would not be such a problematic issue if the economy were growing,” he said.

Over the past year, the number of tenders awarded has also decreased, and there has been a 26.2% decline in the value of nominal tenders awarded. While tender activity has begun to increase, they are largely for smaller projects. “There has been a big lack in those CIDB Grade 8 and Grade 9 contracts,” said Metelerkamp. There has also been a significant increase in cancelled and postponed tenders since the beginning of 2017.

Macozoma, however, argued that with the continued roll-out of private infrastructure, such as the special economic zones and private residential developments, the South African construction industry should not be struggling for work.

The market capitalisation of the listed construction companies has shrunk to alarming levels.”

We hope that the infrastructure rollout will not come too late, at a time when many of our companies would have lost even more critical capacity.”

Skhumbuzo Macozoma, CEO, Sanral

Isabella Makuta, president, SAFCEC

“It is my contention that improved alignment of investment plans between government and the private sector – including joint planning, joint project prioritisation, joint funding and spatial alignment of projects – will lead to a better bang for the buck, with better returns and impact,” he said.

“For us to have a thriving construction industry with a healthy balance of public and private sector investment, we need to work better as a team in South Africa. The private sector must align itself more with government and planning, particularly at a local level.”

That said, deficiencies at provincial and municipal levels must also be addressed, and it is important to find a model that works to capacitate struggling government departments and municipalities, Macozoma added.

The R400 billion infrastructure fund announced as part of the stimulus package is expected by many to ignite industry activity.

According to Macozoma, this R400 billion is expected to translate into a whopping R1 trillion investment in infrastructure, with private sector input hoped to be almost double that of government’s. This should create a substantial and sustainable infrastructure fund to boost the economy.

Despite this, Metelerkamp cautioned against too much excitement and optimism, as no details have been provided and the money will likely be drawn from existing funds, which means it won’t stimulate the industry to a large degree in the short run.

“There are some well-thought-out policies, but the magnitude thereof is just not big enough in my opinion,” Metelerkamp commented. “While it could be something very positive going forward, this would likely only be over the longer term.”

Makuta also emphasised that the likely delay in the implementation of the infrastructure programme could spell the demise of many of the industry’s key players – something that can and must be avoided at all costs.

She concluded: “We hope that the infrastructure roll-out will not come too late, at a time when many of our companies would have lost even more critical capacity required to build such a huge infrastructure programme.”

Government’s stimulus plan Addressing delegates, Isabella Makuta, president, SAFCEC, noted: “For the industry to be revitalised requires large construction projects to come on to the market and increased expenditure in the infrastructure sector, both from government/SOEs, as well as large corporates.

“We are, therefore, encouraged by the recently announced stimulus and recovery package, which, according to President Cyril Ramaphosa, prioritises infrastructure spending as a key driver for economic activity.”

IMIESA November/December 2018

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Project Management

Monré Meyer, delivery excellence lead: Africa, AECOM

Infrastructure roll-outs must be integrated Project and programme management are essential tools that need to be applied by all public and private sector stakeholders to keep developments on track and within budget.

Plus, life-cycle costing is an equally impor tant consideration when it comes to implementing the recently announced South Africa Infrastructure Fund (SAIF).

T

o achieve the best return on investment, the R400+ billion SAIF announced by Cabinet in September 2018 should avoid adopting a shor t-term, ‘quick-fix’ approach. Rather than focusing on standalone projects, it should follow a long-term, integrated and sustainable programme that takes both maintenance and social development into account.

This is the view of Monré Meyer, deliver y excellence lead: Africa, AECOM. Registered with the Project Management Institute (PMI), Meyer is in charge of project management training and certification at

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IMIESA November/December 2018

AECOM, as well as all internal processes and procedures for Africa.

Commenting on the SAIF’s role as an economic stimulus measure, Meyer believes it’s highly unlikely that it will be spent in a single tranche. Realistically, it takes 12 to 24 months for a single infrastructure project to just get up and running, irrespective of size or complexity.

“We need a set programme to deal with our infrastructure deficit. We can no longer rely on the old ‘hammers-andspanners’ approach. We need to drill down from establishing the initial need and requirement, all the way through

to implementing that asset, and then maintaining it as well,” says Meyer. “If the money required for long-term maintenance is not allocated up front, a much higher cost will be incurred in future in order to fix it.”

This is the situation that South Africa currently finds itself in. However, advances in technologies like geographic information systems (GIS) can give local municipalities an accurate over view of both their existing infrastructure and capacity constraints.

“We now have the capability to map an entire metropolitan area in terms of all ratepayers, their ser vices and usage, and be able to tie this back into the design of the asset itself. However, most of our metropolitan councils, let alone the smaller municipalities, lack this capability,” Meyer highlights.

Technological edge This is where a ser vice provider like AECOM can play a critical role, as it is the world’s biggest licensed user of major software such as Bentley and Autodesk. It is also one of the first consultancies globally to deploy the BIM 360 construction management platform from Autodesk, which allows a client to review project designs over a hyperlink.

Technology like BIM speeds up the design process – and once construction kicks off, all the issues have already been ironed out. “You can walk through the virtual design and see it in operation.

Project Management

It also involves the client from the get-go, and allows for maintenance and operations schedules to be put in place timeously,” says Meyer.

Going hand-in-hand with costing, constructability and maintenance are the dual issues of environmental awareness and community responsibility. “The time is gone where you are only required to deliver a hard capital project. We see that increasingly with government projects, where there is a certain level of local content and supplier development that must be incorporated.”

However, this raises the issue of the viability of companies nurtured by means of enterprise supplier development. “There is no point in spending all of this money on a local supplier only to have no follow-through once that project has been completed. There is a misconception that ‘sustainability’ pertains only to the environment; it also has socio-economic implications.”

Now that the infrastructure fund has been announced, a key question being raised

is how it will affect the local consulting engineering industry. Meyer argues that greater collaboration is called for in order to ensure that the fund is successful.

“It is a proven fact: in order to boost the economy, governments need to invest in both basic and enabling infrastructure.

Hence, it makes eminent sense to spread the load among all of the consultancies, and develop what we have,” Meyer reflects.

This also applies to expansion into Africa, where AECOM is currently active in Botswana, Ghana, Kenya, Mozambique and Namibia, where it is developing bulk electricity supply networks and working on other infrastructure projects.

“We are also leveraging off funding from the United States Federal Government, where AECOM is one of its largest service providers. We are hoping to tender successfully for the upgrade of various infrastructure projects in Mozambique in conjunction with our Canadian office. There are big projects in Africa at the moment,” Meyer concludes.

The next logical step in project management is for national and local government to embrace the advantages offered by technology. However, municipalities and other public sector bodies need to upskill themselves first, so that they are able to engage proactively at this level.

IMIESA November/December 2018

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Project Management

In the Industry 4.0 economy, an effective and efficient design capability has emerged as an important competitive key success factor, due to the advent of modern process technologies and crossfunctional virtual partner networks. Within this context, embracing project management is a critical success factor.

By Professor Pieter Steyn*

T

he Fourth Industrial Revolution (Industr y 4.0) business ecosystem has brought with it profound changes and does not depend only on optimisation, automation, innovation, and competitiveness of resources, but also on inter-organisational value chain innovativeness, complementary partner technologies, innovative products, digitisation and supporting services systems.

As a result, project management principles and techniques are assuming a much more important, holistic role and influence in the

The importance of project management in Industry 4.0 governance of organisational value chains than ever before.

The World Economic Forum states that Industry 4.0 affects four main organisational elements, i.e. customer expectations, product enhancement, collaborative innovation and organisational forms. All these elements are dependent on sound project management.

Customers are increasingly at the epicentre of the economy. Leaders and managers have a duty to ensure that design for customer needs delivers a competitive advantage.

Innovative inter-organisational value and supply chains are created in collaboration with partners, and these resultantly operate in local, regional and global collaborative organisational ecosystems. Primary drivers and causes of the necessary changes lie in the rapid development, availability and affordability of modern key enabling technologies that are knowledge-intensive and associated with high research and development intensity, rapid innovation cycles, high capital expenditure, and betterskilled employees. The aim of key enabling

technologies is overall digitalisation with the internet of things (IoT) and services.

The dynamic complexity of modern technologies – robotics, artificial intelligence, mass data, IoT, and the integration of information technology and operations technology, to name but a few aspects – calls for specialisation and sustainable collaboration among partner organisations, and also demands exceptional project management talent.

Consequently, organisational design, development and governance have entered a challenging new phase, with project management principles and techniques as the foundation.

Competitive factors Product, service, and process design and development have become complex project management challenges and highly important, project-driven competitive factors. When the creation of the product or service has been completed and a commercialisation strategy for its production and marketing has been established, attention is turned to designing

IMIESA November/December 2018

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Project Management

Table 1 Primary challenges and critical success factors of Project Management 4.0

Primary challenges

Critical success factors

Business complexity Technology complexity Business and technology literacy Organisational complexity Behavioural complexity Environmental complexity Legal complexity Risk complexity

Sound attitude and transformational leadership of multi-organisational and multidisciplinary project teams Sound technology literacy of project stakeholders Project-based organisations as an open, high-performing innovation ecosystem Continuous change and improvement capabilities Support for the effective and efficient transfer of knowledge and experience Generating value for all project stakeholders

and developing the operational process for order fulfilment. Product, service, and process design and development are best achieved by utilising a supply-chain-based, cross-functional project and programme management approach.

The emergence of new business models means that organisational culture, organisational forms and the harnessing of human talent need a rethink. The shift from the simple digitalisation of Industry 3.0 to innovation based on combinations of Industry 4.0 technologies is forcing organisations to re-examine the manner in which they operate and do business. However, the bottom line remains that leaders, particularly senior executives, must understand their changing environment, challenge the assumptions of their operating teams, and relentlessly and continuously innovate.

In addition to new technologies, business models and systems, the Industry 4.0 economy demands new relationships, enhanced personal competencies, and a sound corporate culture. The critical integrators of new value chains and business

processes are research, innovation and development (RID) collaborative projects and programmes that act as organisational vehicles and enablers of novelties, transformation and change, technologies, and systems. In addition to project management processes, the characteristics of most organisational business processes – e.g. the supply chain and manufacturing processes – are moving towards approaches based on project management principles and techniques.

Project Management 4.0 Hence, it is clear that project management is a core element of the Industry 4.0 economy, popularly referred to as Project Management 4.0, due to its profound contextual influence.

Table 1 depicts the primary challenges and critical success factors of Project Management 4.0.

Project and programme management play a central role in the successful operational and strategic governance of Industry 4.0 organisations, and are the proverbial ‘blood vessels’ of Industry 4.0 organisational and inter-organisational value and supply chain systems. Unfortunately, people often experience difficulty in utilising project and programme management

techniques, and in integrating them into a workable, value-driven organisational system.

Modern technology-driven organisations require a high level of technology literacy, skills in techno-entrepreneurship, and innovation. Importantly, they need to be exceptionally well versed in project management to be successful.

It is essential that the modern workforce be educated and skilled to cope with the Industry 4.0 dispensation. When human resources are elevated to higher levels of education, the benefits are exponential.

Project and supply chain processes must be cross-functionally structured and must be programme-managed. Industr y 4.0 cross-functional processes of necessity incorporate collaborative virtual networks of partners that improve organisational effectiveness and efficiency, leading to much higher levels of competitiveness.

Partnering also boosts small and mediumsized enterprise creation and associated job creation.

Effecting the above transformation and change holds profound benefits for all stakeholders. Importantly, none of this can be achieved if all staff members – from the executive to the operational levels of the organisation – do not appropriately apply project management techniques.

As organisations implement advanced integrated and coordinated collaborative systems in an environment of ever-increasing complexity and change, it is absolutely vital not to neglect the foundational principles and techniques of project management. *Professor Pieter Steyn is the principal of Cranefield College.

IMIESA November/December 2018

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An unconventional example showing how gabions can be used creatively, in this case to form fence posts

A gabion bench donated and installed by Gabion Baskets at a nursery school and after-care centre. If built with the right materials and a professional installation team, these structures are safe and sturdy, in addition to providing aesthetic appeal

Designing with stones

At first glance, building gabion structures seems like something anyone can try their hand at, but that’s only true if installers and designers have the necessary training and experience. By Alastair Currie In Limpopo, the local agent for Gabion Baskets supplied, trained and assisted in the construction of a 7 m high and approximately 200 m long retaining wall using galvanised woven mesh. This 500 mm stepped-backed wall provides highly effective embankment protection. Local rock was supplied from the area

L

eft in the wrong hands, and when incorrect materials are used, gabion structures soon lose their integrity, creating a potentially unsafe situation. This is especially the case for retaining walls.

“Gabions, in their various forms, are environmentally engineered structures, which require expert design and qualified construction supervision,” explains Louis Cheyne, managing director of Gabion Baskets. “Under these controlled conditions, their assembly and installation is relatively straightforward, making them ideal for labour-intensive construction projects, and their durability means they can last for many decades.”

Gabion Baskets specialises in the manufacture and supply of gabions systems,

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IMIESA November/December 2018

together with design advice, training and installation assistance.

Gabion retaining walls can be built to impressive heights well in excess of 20 m, using the classic stepped-back formation to shape stand-alone mass gravity structures.

The alternative is a reinforced soil approach that combines compacted fill layers with specialised systems, a prime example being gab-tail gabions.

The gab-tail comprises a front-facing gabion unit interconnected at its base to an extended hexagonal woven mesh tail, which extends into the soil, normally to a width of around 80% of the height of the wall. For example, if the structure is 10 m high, the reinforced block would be 8 m wide.

The founding depth is always 10% of the height, irrespective of whether it’s a mass

gravity wall (constructed entirely of gabions) or one that incorporates a reinforced soil design.

The key difference is that a reinforced soil wall requires a much larger footprint, and therefore more gabion fill material. In mass gravity walls, the base width will be approximately 55% of the height, depending on soil parameters. So if the height is 4 m, the founding depth is around 400 mm. This ensures the passive resistance at the wall toe needed to prevent the wall from sliding.

“Generally, when your gabion structure is higher than 4 m, and built in a fill situation, the reinforced gabion soil system becomes more economical and faster to install,” Cheyne explains.

With gab-tails, the front-facing baskets provide internal stability, while the mesh tails improve the lateral shear resistance,

Environmental Engineering

A low-level bridge crossing constructed in rural KwaZulu-Natal: these structures are built using a combination of gabions and reno mattresses

providing improved overall stability. “The selected backfill material needs to be at least a G6 or G7 specification. Normally, this material is compacted in layers of not more than 150 mm, normally to 95% Mod Aashto,” he expands.

Three modes of failure When installation procedures go wrong, there are generally three modes of failure that occur for all gabion retaining wall structures: overturning, sliding forward and overall slip stability.

A case in point is a project for a mining operation in the DRC where an approximately 8 m high mass gravity tip wall was constructed to form a truck tipping platform for the primary crusher. In this instance, the incorrect use of a large vibratory roller on the successive layer

works led to an excessive load on the gabion wall’s front face. The end result was that the gabion wall tilted forward and came into contact with the crusher.

“The gabion wall could not be pulled back and the entire system had to be dismantled and rebuilt from scratch,” explains Cheyne.

“The lesson learnt here is that, at lower levels, it’s permissible to use a vibratory roller, but not closer than 2 m from the back of the wall.

Once the height increases, only light compaction is required.”

Low-level bridge crossings Alongside retaining walls, river erosion and allied works are a very common application.

For example, gabions and their reno mattress derivatives are a perfect choice for low-level

bridge crossings. This is a more economical alternative to a purely concrete structure.

The roadway is protected on either side by gabion wing walls, with reno mattresses on the upstream and downstream ends to provide effective erosion control.

Designers have the option of selecting a gravel, asphalt or concrete surface for the roadway; however, on shorter crossings, the mattress can form the surface of the roadway, covered by a gravel layer to protect the mesh from vehicle tyre damage.

“Once a purely civils application, we are seeing an increasing cross-over into the architectural and building markets for design elements that include facades, walling elements, stairways and public seating. The key advantage of gabions is their endless flexibility,” Cheyne concludes.

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Environmental Engineering

Stabilising a dangerous slope An environmentally engineered solution provides an aesthetically pleasing result on a complex soil stabilisation project.

I

nitiated by the Department of Public Works, the construction of a large-scale Terraforce concrete block retaining wall system within Saldanha’s Pepper Bay harbour area proved highly effective in stabilising a series of eroded embankments that posed a risk to public safety.

The embankments consist of multiple layers of sedimentation up to 21 m in height and 2.5 km in length: the softer material had eroded, leaving harder layers of overhanging and unstable rock. The Terraforce system was specified by Ulwazi Consulting Engineers as offering practical, stable and weather-resistant surface protection. Before block installation could begin, all vegetation and loose material

had to be removed to expose the underlying rock face of the embankments.

“These were swept clean and benched for slip prevention, so the extent of stabilising could then be determined and the angle (generally between 60 and 70 degrees to the horizontal) of the final face slope set out,” explains Adriano Guerrini of Guerrini Marine Construction.

Using soil-crete (a sand cement mix), the rock face was covered by backfilling

An estimated 180 000 blocks were supplied by Van Dyk Stene, a Terraforcelicensed manufacturer on the West Coast

in well-compacted layers. The depth of the backfilling was monitored and minimised to follow the natural contours of the exposed face. At the same time, the block facings were built up and the blocks filled with soil-crete and stepped back towards the rock face where appropriate. This helped to minimise the depth

The tops of the step-backs and the finished level were capped with a concrete slab

IMIESA November/December 2018

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Environmental Engineering of backfill and reduce the visual impact of a sheer wall. Finally, the tops of the step-backs and the finished level were capped with a concrete slab.

During the course of the project, some 80 workers, 90% of whom were local untrained labour, underwent on-site training under the auspices of the Expanded Public Works Programme. A further 25 official learners were also given basic construction skills training over a period of approximately three months.

On completion in March 2018, indigenous plants were planted by a company specialising in West Coast vegetation to provide a natural and sustainable look.

For each 1 200-block section, around 100 m² of backfill sand was required

Quality standards Terraforce is a member of South Africa’s Concrete Manufacturers Association. The company also adheres to the Canadian and US international Standard Specification for Loadbearing Concrete Masonry Units, following a successful ICBO evaluation in 2002. Prior to this, the system was also extensively tested in South Africa by Hawkins, Hawkins & Osborne Consulting Engineers in 1992, which resulted in the drawing up of a comprehensive design and specification manual

and user guide. Composite retaining wall design and construction procedures incorporating Terraforce blocks have been subjected to rigorous laboratory tests. These include an evaluation of the mechanical performance of the connection between blocks and grids. In all of these tests, the primary mode of failure was the rupture of the geogrid outside the blocks.

Overall, the performance of these blocks was

found be above average, based on comparable product data and systems information gathered over many years.

Terraforce products also undergo regular MPA testing, locally and overseas. Currently, the blocks are undergoing further shear tests at Curtin University in Perth, Western Australia.

The results will be made available once tests have been completed.

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Cement & Concrete

Why pavements crack When constructing concrete pavements – whether for roads, commercial hardstanding areas, or domestic driveways – it’s essential to protect the concrete against environmental factors that could result in damage or cracking, writes managing director of The Concrete Institute Bryan Perrie.

T

he Concrete Institute (TCI) provides guidance and advice on the best methods to avoid such mishaps. Where they occur, they can lead to substantial disputes for paving contractors and distress to property owners and roads authorities.

Plastic shrinkage cracking is one of the key culprits. It occurs on the surface of fresh concrete shortly after placing and while the concrete is still in a plastic state – i.e. when it is still soft and workable.

The principal cause of plastic shrinkage or cracking is rapid drying of the concrete at the surface and this is influenced by the relative humidity, concrete and air temperatures, as well as wind velocity. Even relatively small changes in atmospheric conditions may have a pronounced effect on the rate of evaporation and hardening, especially if these changes occur simultaneously.

The rate of evaporation is highest when the relative humidity is low, when concrete and air temperatures are high, when the concrete temperature is higher than the air temperature, and when wind is blowing over

the concrete surface. The combination of hot and dry weather, coupled with strong winds, results in the removal of moisture at a faster rate than it can be replenished by bleeding (the process where free water in the mix is pushed upwards to the surface because of the settlement of heavier solid particles of

cement below). This almost inevitably leads to cracking.

If the rate of water evaporation exceeds one kilogramme per square metre per hour, precautions must be taken to prevent plastic shrinkage cracking.

Countermeasures Procedures for minimising the causes of this form of cracking are: • dampening subgrade/sub-base and formworks • dampening the aggregates if they are dry and absorptive • erecting windbreaks to reduce wind velocity over the concrete surface • providing sun shades to control surface temperature of the concrete • avoiding excessive temperature differences between concrete and the air • lowering of concrete temperatures in hot weather • avoiding overheating of the concrete in cold weather

IMIESA November/December 2018

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Cement & Concrete • protecting the concrete with temporary coverings during any appreciable delay between placing and finishing • reducing the time between placing and the start of curing by improved construction procedures • protecting the concrete during the first few hours of placing and finishing to minimise evaporation – the application of moisture with a fog spray nozzle will help prevent evaporation of the concrete until effective curing procedures can be applied to the surface • using monomolecular films to reduce evaporation between placing and finishing operations. This is particularly applicable to concrete road construction. The films protect fresh concrete from the effects of excessive moisture loss in rapid drying conditions, without increasing the bleed. The product is sprayed over fresh concrete surfaces to form a continuous barrier film over the entire surface.

Damage To prevent damage to the concrete surface in rainy and hail conditions, frame-mounted waterproof plastic sheeting covers or other

D

oosan’s DX220LCA-2 excavator builds on the class-leading per formance of the previous-generation model, with a key focus on further refining

suitable materials should be used to protect unhardened concrete surfaces. In fact, when rain appears imminent, all concrete paving operations should stop and the emphasis should then shift to means of protecting the concrete.

Restrained drying shrinkage The correct way to prevent restrained drying shrinkage cracking and ensure a hard-wearing concrete surface is the effective and timely application of the curing process.

Curing ensures that the concrete remains moist enough for cementing reactions to take place. This is best achieved by using a suitable atomising spray to apply an approved whitepigmented, resin-based, membrane-forming compound. To ensure uniform consistence and dispersion of the pigments in the curing materials, it should be agitated in the supply container immediately before transfer to the distributor and kept agitated during distribution.

The vertical sides of the pavement should be coated within an hour after the removal of the

Designed to perform hydraulic efficiencies that increase outputs at lower fuel burn rates.

With an operating weight of around 22 t, and powered by Doosan’s 109 kW (net) DB58TIS power plant, this utility machine

Outstanding features of the Doosan DX220LCA-2 excavator include an up to 12% improvement in fuel efficiency without compromising work intensity and productivity

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IMIESA November/December 2018

side formwork. Any areas of the coating that show signs of damage within a week should immediately be repaired.

Other curing methods, such as placing white or light-coloured plastic sheeting over the concrete, may be considered where membrane curing is not possible; however, such coverings may mark the surface.

The plastic sheeting should be placed while the surface is still moist. If the surface looks too dry, it should be wetted with a fine spray before the sheeting is placed. Adjacent sheets should be lapped at 500 mm and weighted so that they remain in contact with the concrete surface. The sheeting should extend beyond the pavement edges to completely cover the sides of the slab after the sideforms have been removed. The sheeting should remain in place throughout the curing period.

Damp hessian covering or damp sand as a means of curing are not recommended. All methods of curing should be in place for at least seven days.

meets a wide range of applications within the construction segment. Every aspect of the design is geared towards low total cost of ownership and high availability.

A rotor-type of pre-cleaner, for example, filters out particles larger than 20 microns, with over 99% accuracy. Doosan has also designed a high-capacity water separator to further improve engine durability, while a larger cooling module ensures extended service life.

On the go, a new vertical fuel level sensor provides highly accurate readings irrespective of the working angle of the machine.

The newly designed frames, undercarriage, swing bearing, sprocket roller and reinforced heavy-duty boom and arm offer greater durability.

To protect the base of the arm, reinforced bars have been added and the arm centre and endboss have also been strengthened.

A new general-purpose bucket is installed as a base spec, either with a 0.92 m3 or 1.05 m3 capacity, and equipped with open-type side cutters for improved loading operations. The H-class bucket has a maximum capacity of 1.4 m³.

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

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

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Founded on equipment durability

O

ne of the Western Cape’s fastest growing civil contractors, JVZ Construction, attributes a large portion of its success to the procurement of reliable and durable equipment, which has enabled it to complete projects effectively and timeously.

As a result of its on-time performance and high standard of work, the company has enjoyed unprecedented growth, from a oneman show in 2006 to a large-scale contractor with a workforce of approximately 150 and a capability to undertake R200 million projects.

During this time, the company has focused mainly on bulk water and sewerage contracts, including well-known flagship projects like the Paarl Bulk Sewer, the 11 Mℓ Newton Reservoir in Wellington, the 35 Mℓ Spes Bona Reservoir in Durbanville, and the Kleinberg Dam Scheme.

Johan van Zyl, founder and director, JVZ Construction, says hard work and partnerships with the right suppliers placed the company on a growth path from inception, the selection of earthmoving machines being a prime example.

“ELB Equipment has been a major influence in my business from the beginning when I purchased my first Terex 860 backhoe

52

IMIESA November/December 2018

loader,” says Van Zyl. “Due to the service we received and the per formance and versatility of the Terex TLB 860, I decided to standardise on ELB Equipment wherever possible, the acquisition of our first Sumitomo excavator being a case in point. Sumitomo has proved to be among the best excavators I have ever worked on, with superb economy and durability.”

Subsequent JVZ Construction fleet acquisitions include a further six Sumitomo excavators, as well as 10 backhoe loaders.

Johan van Zyl of JVZ Construction with one of his Sumitomo excavators

With over 12 500 hours logged, the company’s original Sumitomo SH200 LC continues to operate with excellent availability.

JVZ’s growth has also given rise to the establishment of two new companies, Vakala Construction and JVZ Plant, operating in separate but complementary sectors, and spurred future plans to establish demolition and recycling businesses to ensure the future sustainability of the group, as well as the conservation of the Western Cape’s environment.

BLUEPRINT 2514/E

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Distribution and Product Support elb@elbquip.co.za

Branches and Dealers throughout Southern Africa

+27 (0)11 306 0700

www.elbequipment.co.za