Issuu

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

2012

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

IMESA

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

in th he

IMESA Job creation: out-of-the-box solutions

Nelson Mandela Bay Building its future

Biogas to fuel National opportunity?

“Our commitment to quality research and development is facilitated by our state-ofthe-art laboratories.” Steven Single, managing director, SprayPave I S S N 0 2 5 7 1 9 7 8 V o l u m e 3 8 N o . 1 0 • O c t o b e r 2 0 1 3 • R 5 0 . 0 0 ( i n c l VAT )

MEDIA

CONTENTS

VOLUME 38 NO 10 OCTOBER 2013

134 Complex bridges

to 40 Biogas power

45 NMBM's economic growth

Engineering solutions

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

2012

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

Infrastructure

IMESA

eThekweni's engineering solutions

Water & wastewater

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

Driving down leakage Pump station security Biogas to power pilot project

25 33 40

in th he

IMESA Job creation: out-of-the-box solutions

Nelson Mandela Bay Building its future

Biogas to fuel National opportunity?

“Our commitment to quality research and development is facilitated by our state-ofthe-art laboratories.” Steven Single, managing director, SprayPave

IMESA news MEDIA

Northern Provinces AGM

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

Cover story National Asphalt reports that a high percentage of reclaimed asphalt and WMA technology was used on the road upgrade between Vaal River and the Kroonvaal Plaza

Regulars

Black gold Business in Africa Sabita members

3 5 64

Editor's comment President's comment Africa round-up

Projects between R50 million and R250 million: winner

112

Projects between R50 million and R250 million: commendation

113

Projects valued below R50 million: winner

114

Best international project: winner

115 117

Best international project: commendation

118

Business excellence: joint winners

Mentoring company of the year

119 122 124

Young engineer of the year: winner

125

Visionary client of the year

Sabita A global approach to bitumen excellence

111

Projects valued below R50 million: commendation

Municipal focus Nelson Mandela Bay: Building for business

Projects valued greater than R250 million: commendation

72 74 86 91

Young engineer of the year: commendation

126 127

Mentor of the year

Technical paper Artificial neural networks as a chemical dosing budgeting tool

Training 130

Investing in skills

Cover article 6

Ahead of the game

Events SARMA 2013: A tangible difference 9 SAPPMA conference report back CESA's upcoming conference and AGM

139

in th he

HO OT SE EAT

Power

Cape Town's rapid road transport system

107

Harnessing wind power

The complexities of a pedestrian bridge

134

Associations

132

145

CMA's footprint expands

144

Hot seat Growth through innovation

Roads & bridges

CESA Aon awards Sustainability is everyone's business Projects valued greater than R250 million: winner

108

Products & services Tooling up for tailored solutions

110

Cementing position

“Our commitment to quality research and development is facilitated by our state-of-the-art laboratories.” Steven Single, managing director of SprayPave

146 147

14 IMIESA October 2013

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EDITOR'S COMMENT

The more things change, the more they stay the same

PUBLISHER Elizabeth Shorten EDITOR Nicholas McDiarmid HEAD OF DESIGN Frédérick Danton SENIOR DESIGNER Hayley Mendelow DESIGNER Kirsty Galloway CHIEF SUB-EDITOR Claire Nozaïc SUB-EDITOR Patience Gumbo CONTRIBUTORS Candice Landie, Richard Jansen van Vuuren, Frank Stevens, Nicola Theunissen CLIENT SERVICES & PRODUCTION MANAGER Antois-Leigh Botma PRODUCTION COORDINATOR Jacqueline Modise FINANCIAL MANAGER Andrew Lobban MARKETING AND EVENTS COORDINATOR Neo Sithole ADMINISTRATION Tonya Hebenton DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS subs@3smedia.co.za PRINTERS United Litho Johannesburg +27 (0)11 402 0571 ___________________________________________________

It’s been 10 years since IMESA held its conference in Port Elizabeth, and coincidentally 10 years since I last attended it. IMIESA was the foundation of my career as an editor and I feel a sense of homecoming in taking up the word for members of the institute and civil engineering as whole.

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

HEN I first had the privilege of editing IMIESA it was always the people in this specialised sector who gave meaning to this work. In his letter from the president in this edition, Frank Stevens looks to the past as well, going back 50 years, rather than 10. Dipping into the papers presented at the IMESA Conference 1964, critical concerns included a skills shortage at senior level and the challenges of providing a city with a population of 700 000 with sufficient potable water. The reasons considered for these problems were vastly different from the ones we find now, but suspend your need for reason for a second and consider that as South Africans, we possibly have a psychological need to keep thinking that ‘we come short’. Short of skills, short of infrastructure, short of money. Now consider another possibility. While it is true that we need all these things, is there ever a moment when we have enough? Anyone involved in delivering public services and infrastructure will have learned to work in a framework of never quite getting ahead of the curve. This does not mean failure. It simply is. South Africa has serious challenges and we need to embrace them in order to evolve beyond them. The challenges faced today are actually the same as they ever were – regardless of their ‘reasons’. Knowing this provides us with an opportunity to respond

PUBLISHER: MEDIA No. 4, 5th Avenue, Rivonia 2056 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: nicholas@3smedia.co.za www.3smedia.co.za ANNUAL SUBSCRIPTION: R530.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2013. All rights reserved. ___________________________________________________ IMESA CONTACTS IMESA Administration Officer: Narisha Sogan P O Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Fax: +27 (0)31 266 5094 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER BRANCH Secretary: Melanie Matroos Tel: +27 (0)43 705 2401 Fax: +27 (0)43 743 5266 E-mail: melaniem@buffalocity.gov.za EAST CAPE BRANCH Clarine Coltman Tel: +27 (0)41 505 8019 Fax: +27 (0)41 585 3437 E-mail: clarinec@africoast.com KWAZULU-NATAL BRANCH Secretary: Rita Matthews Tel: +27(0)31 311 6382 Fax: +27 (0)31 701 2935 NORTHERN PROVINCE BRANCH Secretary: Rona Fourie Tel: +27 (0)82 742 6364 Fax: +27 (0)86 634 5644 E-mail: imesanorth@vodamail.co.za SOUTHERN CAPE KAROO BRANCH Secretary: Henrietta Oliver Tel: +27(0)79 390 7536 Fax: 086 536 3725 E-mail: imesa.southcape@gmail.com WESTERN CAPE BRANCH Secretary: Erica van Jaarsveld Tel: +27 (0)21 938 8455 Fax: +27 (0)21 938 8457 E-mail: erica.van_jaarsveld@capetown.gov.za FREE STATE AND NORTHERN CAPE BRANCH Secretary: Wilma Van Der Walt Tel: +27(0)83 457 4362 Fax: 086 628 0468 E-mail: imesa.fsnc@gmail.com

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

earr 2012 year he yea the th writer of xc encce al wri lle elle e ssional Exce n profession li hing Excellence blishing Non-profe ED Publishing DED WINNERCOMMEN OMMEND HIGHLY

Instit ute Africa ern zine of the al maga eerin g of South The offici cipal Engin of Muni

2012

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

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

RUC TUR

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• MAI NTE

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bilit Sustaina ned lear lessons

IMESA

@infrastructure4

Infrastructure

News

Cover opportunity

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

Nelson Mandela Bay

Biogas to fuel

Building National SHEQsolutions its future opportunity? pipess tic pipe Risk and ce asttic Plas Pla rk “Ourplian commitment to quality research and development is facilitated by our state-ofork ettwo Netw lly com the-art laboratories.” Steven Single, managing director, SprayPave cally critica ritty criti on-site grity teegr inte I S S N 0 2 5 7 1 9 7 8 V o l u m e 3 8 N o . 1 0 • O c t o b e r 2 0 1 3 • R 5 0 . 0 0 ( i n c l VAT ) tant porrtan mp impo blyy p err nd proba aand an Water NuW NuWat O off N CEO

row uee to grow nue nu s, s, inu ntinu mes, ont ccontin Ho Holm H lmes illll co hn Holme will wil JJohn John er w s..” Joh rs.” ars ears eea off yyears. uality water mbeerr o le high-qquite a numb R50.00 13 • for d for reliab ber 20 ip supply Septem “The deman No.9 • to outstr me 38 continue 8 Vo l u 57 197 2 ISSN 0

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

E RY ER I VER D LIIVER ICEE DEL VICE V RVIC R EER SERV SER • SSE

msIMESA th he perrfinfor Job creation: Ateggoo pe out-of-the-box Housing challengesy

Nicholas McDiarmid

SA SA ESA MES IIMESA IME IM

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

INFR AST

differently. Instead of catastrophising the state of our nation and distancing ourselves from the entities responsible for these failures, we can choose to strengthen our embrace of our nationhood, knowing that if we overcome this, South Africa will be stronger for it. This being the conference edition, we have chosen the Eastern Cape and Nelson Mandela Bay Municipality as our regional and municipal focus. You will find a host of projects including roads, water treatment, waste management and housing projects that indicate a vibrant and active region with strong industries. If there is something on your mind, or editorial you would like to see, I strongly encourage you to contact me at nicholas@3smedia.co.za, or on 27 (0)11 233 2600.

MEDIA

VA T ) ( i n c l VAT

IMIESA October 2013

2013

IMESA CONFERENCE

nelson mandela bay PORT ELIZABETH

23 - 25 OCTOBER 2013 Theme: Municipal Engineering – Meeting Peoples’ Needs EARN 2.5 CPD POINTS BY ATTENDING

N! E P O W O N S G N I K sa.org.za O O B E N e I ONL w w w. i m

The 2013 IMESA Conference will be hosted at the brand new Boardwalk Hotel & Conference Centre on the beautiful Port Elizabeth beach front. A variety of exciting technical tours are being arranged to SA Breweries, Koega Harbour, VW Factory and Van Staden’s Wind Farm.

Register & pay BEFORE 31 July 2013 - Early Bird for IMESA members @ R4500 - Early Bird for Non-IMESA members @ R4750 Register & pay BEFORE 30 AUGUST 2013 - Late Registration IMESA members @ R4750 - Late Registration Non-IMESA members @ R5000 Register & pay AFTER 30 AUGUST 2013 - Last Minute Reg IMESA Members @ R5000 - Last Minute Reg Non-IMESA Members @ R5500

For information: Tel: 031 2663263 Email: conference@imesa.org.za

PRESIDENT’S COMMENT

IMESA 1964 JOURNAL

Some reflections from 50 years ago Delegates who attended IMESA’s Golden Jubilee Conference, held in Gauteng in 2011, will recall the launch of Prof Johannes Haarhoff’s book, Reflections 2011 – An IMESA Journey Through Time, together with the emotive and inspirational function attended by some 14 past IMESA presidents as conference highlights.

HE SON OF late IMESA member AT Jobson of Pretoria has donated 16 mint copies of IMESA Journals (ranging from 1964 to 1994) to the Head Office Library and, after reading the 1964 journal, I decided that it would be worth sharing a summary of some of its contents. Before I do so, let me outline some of the international events of that year (which I’m sure will be appreciated by the older members such as myself, who was in standard 8 [now grade 10] at the time): • plans to build the New York Trade Centre were announced • the opening of the Rivonia Trial • the Federation of Rhodesia and Nyasaland were dissolved and Kenneth Kaunda became prime minister of Northern Rhodesia • the first Ford Mustang was produced • the Beatles second album, which included ‘I want to hold your hand’, was released and the Rolling Stones released their first album. Back to the contents of the 1964 Journal: • Page 1 reminds members that IMESA’s motto is Monumenta Circumspice – for their achievements look around you. • The Council consisted of 24 members, representing towns and cities such as Springs, Bloemfontein, Windhoek, Basutoland,

Frank Stevens, president of IMESA

Chinzola, Salisbury, Bulawayo, Germiston, Klerksdorp, Welkom, Roodepoort, etc. • IMESA’s membership was made up of 42 Associate Members, 106 Members and one Student Member (i.e. Keith Turner from Pietermaritzburg). All members had a BSc Engineering and held the position of either town or city engineer. Today, IMESA enjoys a membership of 1 086; we are expecting at least 800 delegates at this year’s Port Elizabeth Conference, and almost half of our membership consists of consultants, contractors and suppliers. The contents of the papers contained in the journal also make for good thought-provoking reading: • In his paper ‘Durban – the City in a Hurry', A Kinmont recorded that the city’s population had reached 700 000 (the eThekwini Metro’s population is approaching 5 million on

today) and warned that its “constant supply of high-quality water must always be the first care of the city engineer”. • F Anderson and T Harris released their findings on ‘Disposal of Wastes to Sea' (especially along the Natal South Coast) and concluded that “it should be possible to assess whether a marine disposal system is practically possible after extensive oceanographic survey has been carried out” (Durban installed its first 4 km sea outfall two years later). • The town engineer of Orkney, J van Zyl, pointed out the complexity of being a municipal engineer in 1964, which demanded that one also had to be a general manager, production manager, maintenance manager and an economic adviser to the council. He strongly proposed that city councils consider establishing an “engineering economist” post (with a sound working knowledge of engineering principles post) to assist the town/ city engineer with the running of his department.

In conclusion, I would like to include an extract from Van Zyl’s paper, which reads as follows: “We have many top-level men in the engineering profession who are spending their entire time on organisation, control and administration. The senior engineer in the organisation is not only burdened with the overflow, but has further to provide for technical control and economic reports. Is it therefore strange that in a dynamic, growing economic structure a shortage of engineers is experienced? And it is like a snowball – the higher geared development becomes, the more executive posts are created, resulting in drainage of our resources of senior men. Municipal government, which proportionately have more senior engineers' posts than industry, will therefore suffer more from a shortage in this particular category. Having the vacancies, however, which have to be filled, we can only fill them with men who are not as experienced as their predecessors. An ill state of affairs. Why? Because the top-level men, by taking more duties upon themselves than they should, are ar now forced to lower the required lo standard of experist ence of their immeen diate subordinates.” dia Sentiments that Se are still far too relevant evan today.

IMIESA October 2013

COVER STORY

NATIONAL ASPHALT

Ahead of the game The road upgrade between Vaal River and the Kroonvaal Plaza reports a high-percentage use of reclaimed asphalt and warm mix asphalt technology.

HE SOUTH AFRICAN National Roads Agency (Sanral) initiated this road upgrade as part of its routine maintenance programme. This particular section of road last received a light rehabilitation around the early 2000s, which comprised isolated base corrections and an ultra-thin friction course (UTFC). At the time, U-LM was applied for the first time in South Africa. V&V Consulting Engineers was appointed to design the rehabilitation of the section with the aim of extending the life cycle of the road by another 15 years. The structural capacity analysis of the pavement prior to the rehabilitation indicated that the remaining life of the pavement was inadequate to handle the required traffic load. Visual inspection of the northbound carriageway showed surfacing defects such as bleeding and deformation over the entire length and structural patches over the last 3 km. Surfacing defects on the southbound carriageway were mainly dryness and brittleness of the surface with aggregate loss and surface cracks. Some sections were badly cracked and pumping was visible in certain areas.

Crushing and screening operation on RA coming from the road

IMIESA October 2013

RA. The binder that was selected was an A first for South Africa A-P1, which was achieved by using EVA blendOne of the specifications and design paramed with 70/100 penetration grade bitumen eters Sanral insisted on was to reclaim and supplied by the SAPREF refinery. Not only is reuse the asphalt millings from the project. this the first project in South Africa where The new replacement asphalt mix therefore 40% RA was specified on a full-scale project, had to contain a minimum of 40% reclaimed but it was also the first where such a base asphalt (RA). The concept is based on the is overlaid with a UTFC. In this instance, the very successful warm mix asphalt trials, UTFC proposed by the contractor was the where 40% RA was used in a number of the National Asphalt licensed U-LM, which is also trial mixes. The main reason for using RA is certified by Agrément South Africa. to ensure the sustainability of our natural resources by saving on the use of aggregates. The fact that RA materials still contain Ahead of the game aggregates of a very good quality means that Due to National Asphalt’s extensive involvewith the correct handling and processing, it ment in the WMA and RA trials that have can confidently be reused. been ongoing since 2008, it was fortuitous The project duration is 10 months; site that they had placed an order at Comar handover took place at the end of last year Plant Design and Manufacturing to build a and the project was due for completion at mobile plant capable of handling at least the end of August. However, Project participation contractual changes have resulted in a completion date Client Sanral of end September. Project design & manager V & V Consulting Engineers To satisfy the design requirements while ensuring the extended life performance of the road, the old asphalt layers had to be milled to a depth of between 85 and 100 mm, and replaced with a new asphalt containing 40%

Main contractor

Road Mac Surfacing

Asphalt supplier

National Asphalt

Asphalt plant manufacturer

Comar Plant Design and Manufacturing

Base bitumen supplier

SAPREF – Shell

Rejuvenator supplier

Sasol Wax

COVER STORY

40% RA, well in advance of the project even being advertised. When contractors asked for asphalt for the project, it was much to the delight of National Asphalt that they had a home for the plant much sooner than they had anticipated. This allowed the company to give prices to the market with confidence. When the project was awarded to Roadmac Surfacing, and it became apparent that the plant would be positioned at Vanderbijlpark, certain adjustments had to be made to ensure that some of the infrastructure on the site could be incorporated with the new plant, including hot storage silos and cold feed bins.

were met, including the high RA content specified in both TRH 21 and SABITA manual 32 that optimise binder quantity. As mentioned earlier, the base binder selected is a 70/100, modified to conform to the TG1 A-P1 specifications. The high RA content not only required a base bitumen that was one grade softer to be used, but a rejuvenator was also required to achieve the correct binder properties after mixing. Sasol Wax’s SW 1665 rejuvenator was selected for this purpose. Modern rejuvenators not only rejuvenate the old binder in the recycled asphalt, but also have the additional benefit of transforming the asphalt into a WMA. Some of the advantages of WMA are: • longer haul distances can be achieved • it allows lower application temperatures, i.e. winter paving, night paving, etc. • lower mixing temperatures • fewer emissions, which improve worker comfort and safety • lower energy consumption, resulting in cost savings • various benefits to the environment. To date, the project has been a success for all the parties involved in this contract. The project commenced during the summer months and has maintained the same mixing and paving temperatures and rolling techniques well into the winter months to no ill effect. As to the time of writing, almost all of the total 43 000 t of base asphalt and 47% of the 13 000 t of UTFC had been placed.

The fact that the reclaimed asphalt materials still contain aggregates of a very good quality means that with the correct handling and processing, it can confidently be reused

ABOVE National Asphalt twin drum 40% RA asphalt plant BELOW 40% RA BTB being laid by means of MTV and a conventional paver BOTTOM Freshly laid 40% RA

The plant is a 100 tph twin drum with the drying drum incorporating a counter flow double barrel section for heating of the RA to a temperature of only 100°C, while virgin aggregates are still heated to normal requirements. The RA and virgin aggregate are then brought together at the end of the drum and transferred into the second “mixing” drum where the bitumen and fillers are added and thoroughly mixed. At the beginning of the project, there were challenges with handling materials into the existing hardware of the old plant. Ultimately, these were overcome and the plant is currently working very well and efficiently.

Finding the right mix The final asphalt mix design was done at National Asphalt’s Bon Accord facility under the guidance of Wynand Nortje. As technical manager at National Asphalt, he has had immense exposure and experience with RA and WMA mixes. All the design parameters specified

Project definition: NRA N001-1802011/1 National Route N1 Section 18 (kilometre 68.2 to 78.2)

t +27 (0)12 562 9500 • www.nationalasphalt.co.za IMIESA offers advertisers an ideal platform to ensure maximum exposure of their brand. Companies are afforded the opportunity of publishing a two-page cover story and a cover picture to promote their products to an appropriate audience. Please call Jenny Miller on +27 (0)11 467 6223 to secure your booking.

IMIESA October 2013

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

IMESA

AECOM siyanda.ngebulana@aecom.com AJ Broom Road Products ajbroom@icon.co.za Arup SA rob.lamb@arup.com Aurecon danie.wium@aurecongroup.com Aveng Manufacturing Infraset cgroenewald@infraset.com Bigen Africa Group Holdings otto.scharfetter@bigenafrica.com BMK Consulting brian@bmkconsulting.co.za Bosch Stemele bsdbn@boschstemele.co.za Bosch Munitech info@boschmunitech.co.za Brubin Pumps sales@brubin.co.za BVI Consulting Engineers marketing@bviho.co.za Civilconsult Consulting Engineers mail@civilconsult.co.za Concrete Manufacturers cma@mweb.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za CSIR Built Environment laustin@csir.co.za Development Bank of SA divb@dbsa.org.za DPI Plastics mgoodchild@dpiplastics.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering keith.bailey@za.elster.com Engcor Engineers masham@engcorengineers.co.za GIBB yvanrooyen@gibb.co.za GLS Consulting nicky@gls.co.za Hatch Goba leratom@goba.co.za Herrenknecht schiewe.helene@herrenknecht.de Huber Technology cs@hubersa.com Hydro-comp Enterprises dan@edams.co.za I@Consulting louis_icon@mics.co.za ILISO Consulting hans@iliso.com Integrity Environment info@integrityafrica.co.za Jeffares and Green dennyc@jgi.co.za Johannesburg Water rtaljaard@jwater.co.za Knowledge Base info@knowbase.co.za Lektratek Water general@lwt.co.za Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Maragela Consulting Engineers admin@maragelaconsulting.co.za

Mhiduve cgroenewald@infraset.com Mott Macdonald PDNA mahomed.soobader@mottmac.com Much Asphalt john.onraet@murrob.com Nyeleti Consulting ppienaar@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za Pumptron info@pumptron.co.za Pragma nicojobe.mabaso@pragmaworld.net Rocla karen.devos@murrob.co.za Royal HaskoningDHV francisg@rhdv.com SABITA info@sabita.co.za SARF administrator@sarf.org.za.co.za SBS Water Systems terri@sbstanks.co.za Sektor Consulting cradock@sektor.co.za Sight Lines sales@sightlines.co.za SiVEST SA garths@sivest.co.za Siza Water Company tionette.bates@sizawater.co.za SMEC capetown@smec.com SNA temple.d@sna.co.za Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Sulzer Pumps Wastewater sales.abs.za@sulzer.com Syntell julia@syntell.co.za Thm Engineers East London thmel@mweb.co.za TPA Consulting roger@tpa.co.za UWP Consulting craign@uwp.co.za Vetasi south-africa@vetasi.com VIP Consulting Engineers esme@vipconsulting.co.za VOMM commerciale@vomm.it Water Institute of Southern Africa wisa@wisa.org.za WorleyParsons chris.brandsen@WorleyParsons.com WRP ronniem@wrp.co.za WSP Group Africa dirk.hattingh@mbs-wsp.co.za Zebra Surfacing andrew@zebrasurfacing.co.za

EVENTS

SARMA 2013

A tangible difference

HE SOUTHERN African Readymix Association (SARMA) held its 2013 annual conference outside the city limits this year, in a rustic conference venue near the Hartbeespoort Dam. The conference opened with possibly the most energetic and compelling public speakers on the circuit these days, Vusi Thembekwayo. His ability to reach out and touch his audience was simply astounding, and set the stage for an engaging couple of days. SARMA’s general manager, Johan van Wyk, bravely took to the podium, following the storm of energy that preceded him, and successfully brought the audiences’ attention to the material issues facing the industry. No small feat. “A lot has happened in the past few years and our construction industry has gone from riches to rags and back too many times to remember. As a result, the rulebook has changed and so we need to look at the future role of readymix concrete from both an enduser perspective, as well as from producers and suppliers perspectives,” noted Van Wyk.

Training, safety and standards This was followed by a panel discussion, which focused on the many roles of SARMA and where it might have more to offer. On the training side of things, it was clear that there are many levels of education that need to be considered in the industry. This ranged from helping smaller member companies become more business savvy, the number of insurance and/or litigation claims occurring due to lack of knowledge, poor techniques and other simple errors that can lead to major problems down the line. Regarding the role of SARMA as the mouthpiece of the industry, it became clear that SARMA members and the organisation itself needed to learn to communicate better. Members acknowledged unanimously that their SARMA membership often assured clients and contributed to getting ongoing business. When it came to standards, audits and training, the association plays an intrinsic role at the centre of this trade. Working with the public sector An interesting comment was given by a member of the Cement Institute, and this was that a multi-representative body across the

construction industry to work with government in achieving the goals set in the National Development Plan could go a long way to developing a more integrated and efficient roll-out of infrastructure. There is also a need for trainers who are able to go out and give seminars in rural areas. The focus then moved back to marketing – this time directly to consumers and a clear strategy will be put in place on how to build readymix as a household name.

Safety on the roads SARMA confirmed that it does – and will continue to – perform spot checks on safety, quality and standards. Perhaps one of the most critical concerns mentioned at the conference was driver and traffic safety. The readymix industry depends on specialist trucks for transport of product, and the level of accidents on the South African roads demands a new level of safety awareness from business and the public alike. One interesting idea raised was to adopt the American practice of holding a national Drivers Safety Competition. With readymix trucks being among the most dangerous on the roads, this initiative would bring positive attention to the industry while giving its drivers a feeling of inclusion in the association and something to strive for. Ending with the future The closing speaker was none other than Clem Sunter, known for his ‘Mind of the fox’ theme, which he tailored with his usual cunning to the audience. The concept of probabilities and scenarios has gained worldwide attention, especially as it pre-empted some of the most significant occurrences of our age, including 9/11 and the collapse of the sub-prime market. Sunter amusingly explained why this concept would have originated in Africa instead of a developed nation: developed nations think they are in control, whereas Africans know they are not in control. The ability to adjust to ever-changing scenarios

is a hallmark of human survival, and so it is for business as well.

Keep evolving According to Sunter, most business games actually change every five to ten years. The more successful a company is in one game, the blinder it may be to the changes going on around them. He suggested South Africa needs another CODESA, but this time, one focused squarely on the economy. Major concerns include the violent nature of our strikes, the growing inequality between rich and poor, the country’s decline in competitiveness, the potential negative impact on the private health care sector that a poorly managed roll-out of the National Health System could bring, the secrecy bill, lack of support for entrepreneurs, the threat of land grabs and nationalisation of the mining sector, and ineffective leadership. The list is extensive, but far from conclusive. Each threat has several possible responses and the key to solving the country’s issues is participation. Leaders in both the public and the private sector need to become brutally honest about these threats and work out clearly what is driving them. Themes and resolutions As an organisation, SARMA itself has entered a phase of change and evolution. The appointment of Johan van Wyk represents a renewed commitment to its members and the industry, as well the industries it works alongside. “This year’s conference… ushered in a new era for SARMA, as we broaden our focus from mainly influencing standards and regulatory matters, to further focus on promoting the use of readymix and engaging all stakeholders,” Van Wyk says. The conference was extremely well thought out and attention was well focused in the relevant areas. SARMA’s message was on point in our changing society, and it has invested incredibly well in meaningful areas, including staff, media and tangible value for its members. Clem Sunter and Vusi Thembekwayo

IMIESA October 2013

PROFILE

HATCH GOBA WATER BUSINESS UNIT

Tending to the complete hydrological cycle Consulting engineering and project implementation firm Hatch Goba has successfully assisted municipalities across South Africa in streamlining their water management strategies by providing expertise and assistance through the company’s Water Business Unit, which boasts more than 100 water engineering staff nationwide.

ATCH GOBA’S Water Business Unit regional director, Andrew Officer, points out that the division specialises in the planning, designing, commissioning and operation of numerous types of water projects, including bulk water infrastructure; dams, tunnels and hydropower; mining and industrial water services; water and wastewater treatment; and trenchless technology. “We offer a full spectrum of services to municipal clients. This includes water demand and water loss management, in addition to bulk water supply and wet services infrastructure design. Our understanding of local water conditions, combined with project experience and technical knowledge enables us to develop strategic and integrated plans for short- and long-term water resource management,

while using practical approaches to minimise capital and operational costs,” he says. Among the most high-profile municipal projects currently being undertaken by the Hatch Goba Water Business Unit is the East London Sewer Diversion Tunnel. Officer reveals that the company was commissioned by Buffalo City Metropolitan Municipality to investigate the most effective method for diverting sewage to the new wastewater treatment works. “The client was looking at efficiently pumping a considerable amount of sewage from a large outfall sewer in East London to the wastewater works over a 30-year period. After a detailed analysis, the Hatch Goba team recommended a 3.5 km long, 3 m diameter tunnel gravity system instead,” he adds. Although this has a larger initial capital outlay, Officer claims that the total cost of ownership in the long term is greatly reduced due to the fact that a substantial amount of energy is saved. “This energy saving also makes the micro tunnel a more

environmentally friendly option. Following this successful recommendation, Hatch Goba was also appointed to oversee the design, tender documentation and construction management of this project.” Hatch Goba has also played an instrumental role in assisting KwaZulu-Natal water authority Umgeni Water in the Durban Heights booster pump station and water treatment works upgrade. The Durban Heights booster pump station is a 1.5 MW, 5 m3/s capacity potable water pump station fed from the Durban Heights Reservoir 3. Hatch Goba provided services for design and tender, detailed design and construction monitoring and commissioning for the project. Officer notes that Hatch Goba also provided Umgeni Water with project administration, documentation and construction monitoring of a valve replacement programme at the Durban Heights Water Treatment Works, which has a capacity of around 600 Mℓ/d. “Filter backwash valves and actuators are being replaced on all 66 filters. The existing Leros Sewer Line, Johannesburg

IMIESA October 2013

PROFILE

pneumatically operated actuators are being replaced by more advanced electric ones, which will be programmed to integrate with the existing supervisory control and data acquisition (SCADA) systems.â€? The eThekwini Water and Sanitation is another municipal authority that has commissioned Hatch Goba to undertake work on the Mahatma Gandhi Road Sewer Pump Station Relocation as well as the Durban Harbour Services Tunnel Replacement Project. â€œMicrotunnelling was identified as the most effective method for this project, due to the fact that the project had to be undertaken with minimal disruption to traffic, surrounding businesses, protected historical buildings and essential underground services that were in close proximity to the construction site,â€?. As part of the Durban Harbour Services Tunnel Replacement Project, the planned widening and deepening of the harbour entrance necessitated the replacement of the existing tunnel with a longer and deeper tunnel designed to carry various sewer, water, electrical and communication services across the

harbour entrance. Hatch Goba was responsible for the design and construction supervision of the 530 m long, 4.4 m diameter segmentally lined TBM driven tunnel. According to Officer, this was the first subaqueous soft ground tunnel in South Africa, designed with some of the steepest grades and tightest vertical curves due to space constraints. â€œDespite these unique challenges, the project was completed on time and within budget, with no major stoppages during the tunnel drive,â€? he states. Hatch Goba also boasts experience in stormwater projects, following its successful completion of the Majaneng stormwater management project for the City of Tshwane. The Kudube Extension 10 and Majaneng tribal area had been subjected to regular flooding during the rainy season due to a poorly defined watercourse. As a result, the company was appointed to determine options for the control and safe discharge of storm flows

through this area, including rehabilitation of the Majaneng dam spillway, as well as the design and construction of a separate retention dam and canal. Officer believes that water and wastewater treatment holds the potential for considerable growth within the Hatch Goba Water Business Unit. â€œA large number of treatment plants across South Africa are deteriorating and local authorities are seeking to upgrade them. Having established a proven track record in this area of expertise, I am confident that we will experience measurable long-term growth in this sector.â€?

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IMIESA October 2013

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PROFILE

SERVICE EXCELLENCE REWARDED

Corobrik’s East London team stands tall Corobrik’s East London sales centre has won the group’s coveted Centre of the Year Award for 2013, making it its fourth win in the past nine years.

TOTAL OF 28 Corobrik sales centres across the country compete annually for this sought-after award. Prizes were presented to the top performers for the previous financial year, which ran from 1 July 2012 to 30 June 2013. Two East London employees also scooped individual awards at the company’s annual conference in Pretoria in August. Steve Behrens was named Sales Manager of the Year and Vuzi Nhoyo walked away with the title of Sales Representative of the Year. A panel, comprised of senior company directors, evaluates all the centres against a number of criteria, including whether they have achieved their budgeted net trading profit and whether this has exceeded previous years. In addition, the company conducts a national customer service survey every quarter. Randomly selected

customers who have purchased Corobrik products in that respective quarter are asked about the customer service they received and this feedback is taken into account for the awards. Other factors influencing this decision are the standard of stock control and housekeeping, and internal auditing reports. “The East London centre attained the highest overall score and we congratulate Steve Behrens and his team on this achievement,” says Mike Ingram, Corobrik’s director of sales for KwaZulu-Natal and Border. “Since the centre opened in Bowles Road in 2002, it has delivered a consistently good performance because of the team’s dedication to customer satisfaction.” The centre covers the eastern part of the Eastern Cape from Port Alfred to Queenstown and east to Kokstad, Matatiele and Bizana. “This makes their achievement even more noteworthy as they cover an enormous territory and, in some areas, roads are

poor so delivery is a challenge,” Ingram continues. “Sales figures have been above average, although there have been no major projects in this area – purely ongoing work with sales stemming mainly from home consumers and small builders. Now in its 111th year of operation, the company is a leading provider of clay bricks, paving bricks and building materials in South Africa. Ingram and his team owe the success of the East London centre to the valued support received from the local building fraternity and from the company’s accredited distribution network. The team from the East London centre (from back left) Steve Behrens, Ntando Tsewu, Thandoxolo Futhuse, Hennie Pretorious and Zamuxolo Sokoni; (front) Vusumzi Nhoyo, Sibongiseni Situnda, Thabisa Nyangintaka, Mlulamisi Joyi and Eric Damesi

IMIESA October 2013

HOT SEAT

SPRAYPAVE

Growth through SprayPave has established itself as a dynamic presence in the South African road construction industry through constant innovation in both its operational structure and product range.

VER THE PAST 30 years, SprayPave has grown and matured from its humble beginnings as a family-run plant hire business to its current stature as industry “all-rounder”. Its footprint extends through South Africa as well as further north in Namibia, Mozambique, Zambia and Botswana. In addition to its two branches located in Johannesburg and Durban, the company is readying itself for the launch of its third South African branch. SprayPave’s new facility in the Western Cape is expected to be fully operational by January 2014. “The plant will feature a new bitumen reactor that will allow us to modify bitumen on a level not yet seen globally, let alone within the South African market,”

IMIESA October 2013

states the company’s managing director, Steven Single. He explains that the Western Cape facility will act as a template for the further development of existing plants in Johannesburg and Durban. “Our emphasis on quality and research and development, enabled through our state-of-the-art laboratories, coupled with our continuous product development and expansion stands us in good stead to remain a dominant force within the Southern African road construction industry,” he points out. The company’s growth has required an ever-expanding fleet of bitumen sprayers and haulers – the large majority of which are powered by Scania trucks. All sprayers are fitted with technically advanced Etnyre spray bar systems.

“Our newer haulers are powered by the latest R500 Scanias and coupled with ultramodern tankers,” explains Single. The company believes that keeping abreast of worldwide trends is a critical element to remaining a step ahead within the local road construction industry. SprayPave’s range of bituminous products currently includes: • CAT60, 65 and 70: cationic emulsions with 60, 65 and 70% binder content, as well as diluted variants • SS60: anionic emulsion with 60% binder content, as well as a diluted variant, SS30 • Opti-Prime: a popular and eco-friendly cold prime • SP1i: invert cold prime • Opti-Cote: an extremely effective pre-coating product

HOT SEAT

innovation • SE-1 and SE-2: effective and reliable polymer modified binders, which have become popular summer month binders for chip seals • SC-E1 and SC-E2: effective and reliable modified emulsions, which have become popular solutions for binders required in winter month seal designs • AE-1 and AE-2: effective polymer modified binders for asphalt surfacing • MC30, MC70 and MC300: cutback bitumen currently manufactured at SprayPave’s Durban facility (and, in due course, at the Cape Town branch). Over and above these specialised products, SprayPave also supplies all-penetration grade bitumen. All products are manufactured under strict guidelines in accordance with industry manufacturing and quality control standards. Each plant, including the company’s ompany’s fleet of mobile polymer and emulsion lsion plants, has fully equipped laboratories with with advanced testing apparatus used too monitor quality at production inter vals alss and also upon completion. SprayPave’s mobile plants ntts enable access to remote areas throughout rouughout the Southern Africa region. The company’s current growth is not limited to the launch of its Cape branch. Single reports that thee Durban facility has had its footprint increased and laboratory upgraded. The hee Alrode branch has been expandedd through through the acquisition of an adjacent add jacent

property where, among other things, a new workshop area is being established. In addition, the company has designed and built its highly energy efficient heat transfer system, which drastically reduces its reliance on power to constantly keep bitumen on-site heated to required levels. As with most success stories, SprayPave’s power lies within its people. The company’s dedicated team of experienced staff has ensured that along with the company’s physical growth its intellectual magnitude has been symbiotic. The bitumen market is one of constant flux and despite this, SprayPave has forged enviable, life-long bonds with industry experts and innovators – both locally and globally. “The recipe to any successful organisation is to have a team of like-minded individuals with a common goal and sound business ethics,” i ” concludes l d Single. Si l

t +27 (0)11 868 5451/2 www.spraypave.co.za

OPPOSITE SprayPave’s mobile AE plant being established onsite in Standerton ABOVE RIGHT SprayPave’s mobile emulsion plant on-site in Zambia RIGHT Steven Single joined SprayPave in 1997 as a civil engineering student (NDip Civil: Wits University). He was appointed as managing director in 2008

IMIESA October 2013

INFRASTRUCTURE

ETHEKWINI METRO

Out-of-the-box engineering solutions Job creation and sustainable enterprise development need to be the foundation of municipal engineering projects in South Africa. This requires municipal engineers and consultants to apply innovative, fresh engineering solutions.

OMMUNITY GARDENS, agricultural hubs, compost programmes, ablution block management, adventure tourism and various research and development projects – including projects such as vegetable soybean, biowaste, rainwater harvesting, dynamic aquaculture, waste recycling and invasive alien plant eradication. These are not the typical projects municipal engineers would keep themselves busy with. However, in light of expediting service delivery failures, inability to bring effective services to grassroots communities and a growing focus on sustainability, alternative approaches may be the future of municipal engineering in South Africa. “The implication for municipal engineers in South Africa is that we need to change

from being engineers with technical skills to becoming ‘engineers for change’. Many of these projects relate to work that engineers never thought they would get involved in – the typical ‘softer’ elements such as social sustainability and agriculture. However, I

Sustainable skills beat short-term labour

Many municipalities have star ted to embrace innovative, yet slightly less conventional ways to improve services such as water and sanitation provision, waste removal and infrastructure management. Pietersen, who also serves as deputy head of engineering at eThekwini Municipality, shares some of the out-of-the-box solutions eThekwini has adopted to improve access to basic services at reduced costs. “The imperative objective and foundation of all these projects, in line with national government’s priorities, is job creation and sustainable enterprise development. A great deal of technical proficiency prevails in the implementation of these projects, but they

Many municipalities have started to embrace innovative, yet slightly less conventional ways to improve services

IMIESA October 2013

think the engineering discipline is increasingly realising that it requires alternative design and implementation solutions to bring about impactful change at grassroots level,” says Jannie Pietersen, past president of IMESA.

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INFRASTRUCTURE

ABOVE Micro-economies are sustainable catalysts of job creation

require a paradigm shift. While traditional technical skills are vital for the municipal engineer, the key issue going forward is the development of non-technical and interpersonal skills. These abilities are measured by communities and are seen as an important indicator of an engineer’s worth. “We need to steer away from ‘hard’ engineering issues and instead use engineering to move towards the stimulation of microeconomies that will act as catalysts for the creation of jobs and local small businesses,” says Pietersen.

A focus on job creation – sustainable cornerstone Alternative engineering solutions are based on the premise of social, environmental and economic sustainability. In South Africa, the creation of job opportunities and small medium

IMIESA October 2013

enterprises (SMEs) remain the foundation for ensuring our country’s future economic growth. This imperative goes hand in hand with national government’s Extended Public Works Programme (EPWP). At eThekwini, EPWP falls under the municipality’s Infrastructure Management and SocioEconomic Development department, which coordinates all EPWP activities, as per council policy. During the second phase of the EPWP, government introduced an incentive grant to incentivise public bodies to create more work opportunities. To date, eThekwini Municipality has earned a total of R160 million incentive grants due to its performance and in 2012/13 created more than 20 000 work opportunities through projects. According to Pietersen, job creation is part and parcel of the municipality’s development approach and is closely interwoven with the projects it embarks on.

Skills to support job creation It is, however, futile to create jobs if the skills pool to support such opportunities does not exist. Training therefore forms an integral part of the job creation process. With this purpose in mind, the Infrastructure Management and Socio-Economic Development department (IMS), through its Training Academy, is running a Contractor Development Programme. It is currently in the process of establishing CETA accreditation.

The municipality also runs the Vuk’uphile Learnership Programme, an initiative between eThekwini, the Department of Public Works, the Construction Seta and Nedbank. The programme aims to develop emerging contractors and their supervisors into sustainable enterprises that are able to execute labourintensive projects. The three-year learnership takes learners through a series of classroom and on-site training, with the objective to develop their financial, administrative, technical, contractual, managerial and entrepreneurial skills. Selected candidates have to meet a set of predetermined criteria. The programme trains the contractor and supervisor in NQF level 4 and the company must achieve a minimum exit rating of CIDB 3. During the process, mentors provide expertise, minimise risk and assess learner progress for the duration of the learnership. The IMS department started this programme in 2005. The Vuk’uphile I learners have now successfully exited the programme and are working as contractors within the industry. The Vuk’uphile II learners (24 contractors and 24 supervisors) are currently completing their onsite training and returned to the classroom in August 2013 to continue with the theory training. IMS is now in the process of recruiting the third intake of Vuk’uphile II learners.

Agricultural hubs and community gardens The IMS department embarked on an Agricultural Zonal Budget Programme, aimed at assisting small farming cooperatives in 103 wards of eThekwini Municipality. The purpose is to provide small farming cooperatives with fencing, access roads, stormwater control, water, sanitation, micro-irrigation, tools, containers, sheds, compost and rural fish ponds, as well as training on garden maintenance. The initiative ties with the Contractor Development Programme as the emerging contractors, as part of their learnership programme, carry out the construction of these gardens. A total of R40 million has been allocated from the Zonal budget to develop the gardens, and the municipality established four agricultural hubs to provide agricultural guidance, technical support and training. The first phase of the garden’s infrastructure development has been completed by the emerging contractors and comprise of 27 gardens. The second phase comprises 40 gardens, while the municipality allocated the construction of 15 gardens for the third phase.

INFRASTRUCTURE

In some regions, partner farmer Agrihubs have been established to support small-scale growers and emerging farmers in a radius of 15 km. The Agrihubs provide free tuition and mentorship in organic- and intensive farming methods. It further supports the farmersâ€™ enterprises by coordinating discounted seedling supplies and purchasing fresh seasonal and niche vegetables from partner farmers. These are then delivered through a network of markets. The project runs in parallel with a compost programme and school garden projects, all executed within the boundaries of the agricultural hubs.

fed with crop residues from a fresh produce market. The skip contains a digester with blower, which decomposes crop residues into compost within a three-week period. An MSc chemical engineering student from the University of KwaZulu-Natal is developing an enzyme that can be used to fast-track the decomposition process. The skip can hold up to 15 mÂł of crop residues, which is mixed with wood shavings. Nutrient-rich compost, the end product, will be transported to the various garden projects. The process of decomposition occurs under aerobic conditions, therefore no methane gas or foul smell is emitted. The research project, under the supervision of Pietersen and John Parkin, deputy head, Plant & Engineering at eThekwini Municipality, forms part of larger research that aims to develop more environmentally appropriate and socio-economic sustainable biotechnological processes for converting biomass into biogas and

The IMS department is also testing biogas digester technology at rural farms within the municipality's borders

Biowaste projects Research and development is paramount to the successful implementation of more sustainable infrastructure development solutions. eThekwini has embarked on several R&D projects that will provide blueprints for full-scale implementation in the future.

The municipality has made specific inroads in terms of biowaste research. One such project forms part of the compost programme operated from the Northdene Research and Development Centre. It comprises a skip,

IMIESA October 2013

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INFRASTRUCTURE

organic-based fertiliser. Countries such as Denmark, Sweden, Turkey, Malaysia, Ghana, South Africa (eThekwini), Egypt, Italy and Morocco participate in the research. The IMS department is also testing biogas digester technology at rural farms within the municipality’s borders. One objective is to train a local contractor to competently build the 6 m³ biogas digesters with the longterm objective of creating jobs through a biogas roll-out. The department will test the two digesters at sites that adhere to the following selection criteria: ownership of livestock and enclosure for the livestock, a water source and active farmers. Ward 4, one of the most impoverished communities within the municipality, adheres to these criteria and has been selected as the test site. The biogas digesters were built according to design, using brick, mortar and a fibreglass dome. Following a one-month preparing period, the research team lit the methane gas, which can be used for cooking. The payback period in relation to the volume of the gas is dependent on the amount of manure inserted as well as the frequency of usage. At a rate of 30 kg of cow dung inserted per day, the payback period would be approximately 6.5 years.

sanitary sewers is impractical. Urine contains valuable nutrients for recycling to the soil. However, at certain concentrations, these same nutrients are pollutants, causing algal blooms and hypoxic conditions in rivers and waterways, therefore, exerting a burden on sanitation systems to remove them for safe release into the environment. Therefore, sanitation systems can recover valuable resources, and when properly treated and hygienised, these resources can be

phosphorus-rich solid fertiliser. Two options are available: a simple reactor for agricultural sites or an automated, computer-controlled reactor for more densely populated settings. The biological treatment unit works with evaporation and aims to recover the majority of nutrients by using bacteria to convert ammonia-nitrogen to nitrate-nitrogen. The nitrification/evaporation reactor yields a concentrated liquid fertiliser and water. Various agricultural trials are under way at the research site, which involves testing the DEWATS effluent, struvite fertiliser and LaDePa pellets (pasturised, dried pit latrine contents). The municipality is testing the reaction to a variety of food crops, as well as the nutrient availability in the soil and plant uptake. Although the research focus at the centre is holistic, it leaves certain questions around user satisfaction; operational costs for collection, delivery and maintenance; safety for occupational workers and use of end products. These research projects are under way with partners in South Africa and abroad.

The Agrihubs provide free tuition and mentorship in organic- and intensive farming methods

Innovative sanitation systems and resource recovery Adjacent to one of the Newlands hub, the IMS department selected a test site for integrated research on sanitation, decentralised wastewater treatment, nutrient recovery and recycling, and agriculture. Three main focus areas form part of the research at the site: various types of sanitation systems, technologies to recover valuable resources from sanitation systems, agricultural use recycling and recovery of resources to the soil. The two sanitation systems being evaluated at the Newlands Research Site include a decentralised wastewater treatment system (DEWATS) and on-site urine diversion dry sanitation toilet systems. DEWATS is designed to treat waterborne sanitation systems with no energy to low energy usage. It has the possibility of energy recovery from methane gas and water with dilute nutrients of nitrogen and phosphorus. Urine diversion dry sanitation toilet systems, on the other hand, are appropriate for areas outside the waterborne edge, where the installation of

IMIESA October 2013

reused and recycled into agricultural projects. It includes nutrients that are formed into fertilisers, purified water, soil amendments and energy. The main nutrients targeted are phosphorus and nitrogen. Phosphorus (P) supplies are finite, in decline and have no replacement. Phosphorus is essential for growing food and thus relates to concerns about food security. Nitrogen (N) fertilisers are produced by fixing nitrogen gas that is readily available in the atmosphere with electricity and thus require a certain expense for production. Diverted and collected urine from on-site urine diversion toilet systems contains high concentrations of phosphorus and nitrogen. The municipality constructed two reactors – a struvite reactor and biological treatment unit – to evaluate the recovery of these nutrients and incorporate it into usable fertilisers. The struvite reactor recovers most of phosphorus present in the urine by adding dissolved magnesium salts, yielding a BELOW Sustainable work flows equal community profit

Aquaculture In parallel with the roll-out of food gardens into rural eThekwini, the IMS department

INFRASTRUCTURE

Aquaculture in eThekweni

has commenced with the provision of Mozambique tilapia as an additional food source to substitute protein shortages in diets. As the project progresses, it will also become an economic empowerment initiative. Different aquaculture systems have been designed and tested at Northdene Research & Development Centre, namely a basic recirculating plastic-lined pond (also referred to as the rural pond), a six-tank system that can be used when minimal space is available (the urban system) and a concrete-based tank system for the grow out of fish (commercial system). “Our initial aim is to construct the basic recirculating rural ponds in selected gardens for food security. The community members at each site are to be trained in basic fish husbandry and pond maintenance. Each pond will be under an agri-tunnel for warmth, which is essential for good growth rates of the fish,” says Pietersen.

“When the male fingerling fish reach a size of approximately 400 g, they will be harvested, sold at market and the proceeds given to the community,” he continues. The aquaculture system, and all other projects described in this article, has carefully

considered the requirements of transferring skills, creating jobs and stimulating local economies through small enterprises. “At eThekwini Municipality, we view this as critical to the sustainability and economic growth of South Africa,” Pietersen concludes.

IMIESA October 2013

Sasol, Sasolburg, South Africa

They’re all around us, sometimes invisible, but always present… They’re an indispensable part of our daily lives, transporting clean drinking water; gas for heating our homes; drainage for the waste we produce and for surface water; and protection for our telecommunication systems… We’re talking PVC pipes, the hi-tech ‘lifelines’ of our complex, interconnected world... lifelines made possible by Sasol Polymers PVC. The power of high performance Super-smooth, efficient PVC pipes outperform pipes made from traditional metals. Here’s why: Exceptional smoothness: Unlike pipes made from traditional materials, the smooth walls of PVC pipes make it extremely difficult for sediment to accumulate. This is a major advantage for sewer pipe systems, which often need to transport waste water containing significant quantities of sediments. Outstanding cost effectiveness: Lower levels of friction mean more water can flow through at much higher speeds through a pipe of a traditional material of the same size. This in turn means that PVC pipes of smaller diameters can be used – requiring less space in buildings and under our streets and reducing overall cost.

The power of positive impact Cost effective products make a positive contribution to all areas of sustainable development because they: Save scarce money, thus promoting sustainable economic development. Are more affordable to socially disadvantaged people, both in industrialised and in developing countries; the money saved can be used to optimise sustainable social development. The money saved by low cost products can be used to optimise sustainable ecological development. In fact, the lower levels of friction inherent in PVC pipes means water flow requires much less help from pumps and hence less energy. This translates into lower cost and reduced greenhouse gas emissions.

This article was published by Sasol Polymers, a division of Sasol Chemical Industries Limited. Sasol Polymers is South Africa’s leading producer and marketer of monomers (ethylene and propylene), polymers (polyethylene, polypropylene and polyvinyl chloride), and chlor-alkali chemicals, including caustic soda, hydrochloric acid and mining reagents (sodium cyanide). For more information please contact Rishi Madho, PVC Product Manager 011 790 1325 or alternatively visit www.sasol.com.

A powerful case for

PVC pipes The power of longevity Smoothness and cost effectiveness are not the only advantages of PVC pipes. Longevity is another key attribute. As a thermoplastic, PVC can be as soft as rubber or as strong as aluminum, depending on how it’s made. Its combination of strength and adaptable flexibility gives it a distinct advantage over fully rigid materials. This is quickly apparent when you consider that any pipe buried in the ground must endure pressure from the weight of the soil above it, and must also resist stresses due to movements in the earth around it. PVC pipes excel at conforming to these dual demands by having the capability to support great loads as well as the capacity to bend and flex if required. Without this ability to adapt, pipes are more likely to be damaged, resulting in a shortened lifespan for the entire pipe system. In addition, pipe systems often experience localized concentrations of increased internal pressure. If the pipe is too rigid and inflexible, it can crack and leak. PVC pipes are able to flex and compensate for such pressure variations, thus reducing the risk of pipe ruptures and leaks. PVC piping is very resistant to a wide range of chemicals like detergents and other aggressive chemicals that are commonly carried by sewer pipes or which may be found in the groundwater through which the pipelines pass. Unlike metal pipes they do not corrode in service, so there is no weakening of the pipe over time through a loss of wall thickness. Once installed, PVC pipes enjoy a legendary reputation for low maintenance without the problems of rust, pitting or corrosion to which traditional metals are susceptible. In fact, studies have shown PVC pipes could last more than 100 years without any serious degradation in their performance.

The power of versatility PVC can be moulded, extruded and calendered into almost limitless numbers of shapes and forms. Because of this versatility, a huge range of PVC pipe fittings have been developed which can connect to pipelines made from other materials. Using special adaptors, it is possible to make connections to clay, concrete, ductile iron (and of course other plastic pipes), thus ensuring that a secure interface is maintained and system integrity is guaranteed.

The power of a built-in lightweight advantage Being light means that: Fewer vehicles are needed to deliver PVC pipes than is the case with conventional pipes. Fewer vehicles mean less fuel consumption and significantly less environmental impact in getting pipes to site. PVC pipes can be lifted into the trench without using heavy machinery. Once in the trench, PVC pipe systems are easily assembled by hand without the need for any other mechanical help. Making the joints, whether using push-fit or solvent cement, is a simple process which can be accomplished using basic hand tools and without the need for extensive training.

The power of recyclability For a more sustainable future, society needs to use less of our valuable, non-renewable resources. Recycling is one of the keys to achieving this. PVC pipes can be recycled over and over again without any degradation to their physical properties. In fact, it is quite common for commercial grades of PVC pipes to incorporate an internal structural layer made of recycled PVC with the exposed surfaces being covered by virgin material. ‘post use’ recycling is, however, limited as most PVC pipes have not yet reached the end of their service lives.

Powering up for growth The South African government’s Infrastructure Plan is intended, amongst other things, to transform the economic landscape of South Africa and strengthen the delivery of basic services to the people of South Africa. Low cost installation, outstanding durability, excellent hydraulic performance, low maintenance costs and recyclability, all add up to outstanding cost efficiency. PVC pipes offer significant advantages as South Africa powers up for growth to the benefit of all.

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WATER & WASTEWATER

WATERTIGHT

Driving down leakage With data access available online, remote logging is now the norm. By RS Mckenzie, managing director of WRP Engineers

EMOTE LOGGING, through GSM and GPRS devices in particular, is commonplace and easily accessible to all water suppliers in virtually every country. The costs associated with both the hardware and the software, as well as associated communication charges, have all decreased in recent years with the result that the financial viability of using such technology to assist with leakage reduction activities is now clearly evident. This article will provide a brief overview of the use of flow and pressure loggers in a water reticulation system to highlight the value of such information as part of any leakage reduction programme. The interpretation of minimum night flows (MNF) and various pressure checks will be discussed using a number of practical examples to demonstrate how such logging results can be analysed. It will also present details and interesting examples from a wide variety of case studies undertaken throughout Southern Africa using some of the latest internet-based data acquisition and display systems. Such technology is now widely available to virtually every water supplier in the world and the benefits of proper monitoring and rapid response to problems is without doubt one of the most effective measures in driving down leakage. The remainder of this article will explain some of

the key issues associated with both flow and pressure logging and provide some examples to highlight the value of such logging.

Importance of logging Managing a water reticulation system is a difficult and often confusing job in which problems continually occur due to either burst pipes or some operational problem usually associated with opening or closing of valves or equipment failure. Identifying the source of the problem is often a problem in itself and one of the most useful tools in addressing such problems is the analysis of logging data. Logging involves recording pressures and/or flows entering a zone and can be compared to a doctor recording the blood pressure and heart rate in order to determine the health of a patient. From a management viewpoint, the logging results often highlight problems within the water supply system, which can then be addressed. Without regular logging results and associated analyses, such problems can exist unnoticed for months if not years and result in higher leakage and/or poor service delivery. Logging of pressures and flows is one of the most important aspects of any water demand management (WDM) programme and one that is generally neglected if not ignored completely. In recent years, with the advent of GSM- and GPRSFIGURE 1 Flow entering a discrete zone over a three-day period based loggers, it is now possible to capture and transmit logging information with relative ease. Such information, if used properly, can help water managers to manage their water distribution systems effectively and efficiently and

they can often identify problems before they become major crises. There is no substitute for reliable “real-time” flow and pressure information and, where available, it will facilitate the analysis of MNF, which was the original foundation of any proper WDM programme. Over the years, more effort seems to have been placed on high-tech electronic solutions and software, which eliminates the need to visit the site or to get one’s hands dirty. Recording and analysing MNF has, in fact, become less common as the new technology and software models eliminate the need for any such analyses. In reality, many water reticulation managers have lost the ability to properly manage their systems in many parts of South Africa and there is a real need to move back to the basics and start using logging results to monitor the water reticulation systems and to find problems. Reliable logging information provides a manager with real-time data on what is really happening in the system as opposed to what the hydraulic models say should be happening. Having stressed the importance of undertaking regular flow and pressure loggings in a water supply system, it is equally important for the technician or manager receiving the information to understand what it represents. Analysing and interpreting logging results is often very confusing and difficult and can be compared to “detective work”. This article concludes with the interpretation and understanding of logging results and all graphs shown are from real examples collected by the author.

Understanding and interpreting logging results In order to identify problems within a reticulation system, it is useful to understand the flow and pressure logging results from the system in question. As mentioned previously, this can be compared to detective work in that the problems are not always obvious and sometimes the water supply manager

IMIESA October 2013

WATER & WASTEWATER

must give each set of logging resultss some serious consideration. Thiss skill can only be developed throughh practise and, for many people, loggging results are confusing and meanningless with little or no value. If thee results are explained, however, thee person examining a graph of flow w and/or pressure will quickly start too appreciate the value of the informaation. In time, the person examiningg the graphs will become skilled inn identifying problems, some of whichh can be very subtle and interesting. To demonstrate the value of thee logging results, a few real exampless are discussed.

FIGURE 2 Typical seven-day flow logging into a zone

FIGURE 3 Seven-day logging result for zone with serious leakage problem

Example 1 A typical flow logging result for a discrete zone over a three-day periodd is shown in Figure 1. This very simmple and clear-cut example indicatess a typical domestic demand patternn that is repeated each day and has a morning and evening peak demandd together with a minimum demandd sometime during the late evening orr normally around 02:00 in the morn- FIGURE 4 Typical flow logging for a zone with ing. As can be seen from the graph,, intermittent supply the MNF is around 80 m3/h with ann average daily flow demand of approxi-imately 150 m3/h. One of the mostt useful benefits of a flow logging is too help identify if the zone has a seriouss leakage problem. The MNF can bee analysed with relative ease using thee SANFLOW Model developed throughh the Water Research Commissionn (WRC, 1999). This model is freelyy available and is very easy to usee and will provide a realistic estimatee of what the MNF should be for a specific zone based on the key characteristics of the zone. The unexplained leakage is Example 2 basically the difference between the expected The second example as shown in Figure 2 MNF and the actual MNF. is a typical flow logging from a discrete zone If the water loss “detective” wishes to get a supplying a residential area. Once again, very rough and ready estimate of whether or the typical domestic demand pattern with not the zone has a leakage problem, they can a morning peak and evening peak can be simply calculate the ratio of the MNF to the seen. The MNF is approximately 17 m3/h average daily demand (ADD). If this ratio is while the ADD is estimated to be 64 m3/h. below 20% then there is generally no serious The ratio of the MNF to ADD is 27%, which leakage problem and if it is above 20% then suggests that there may be a small leakage there may well be a problem, which should problem; however, in most parts of South be investigated. In the case of Figure 1, the Africa this zone would not be considered a MNF/ADD is 53%, which clearly indicates that high-priority zone for leakage detection and there is a leakage problem. has no major problems.

IMIESA October 2013

Example 3 The third example again shows a seven-day logging result for a discrete zone supplying a residential area. In this case, it is clear that there is a very high MNF, which is indicative of high leakage. This is confirmed by the high MNF/ADD ratio of 83% and there is little doubt that this area has massive leakage. This type of graph is typical in many residential areas where payment for water is low and internal plumbing leakage is very high. The graph also shows the impact of a shutdown on the Saturday where the water supply was cut for several hours. Of interest is the sudden sharp increase in water demand immediately after opening the supply into the area. Such spikes in ‘demand’ are caused by the rapid filling of the pipes, which emptied when the water supply was cut. Great care must be taken when opening the water supply into an area after any shutdown, as such spikes can often damage the water meters in cases where a mechanical meter is used.

Example 4 The fourth example shows the logging result into an area of intermittent supply, which is fast becoming a common occurrence in some parts of South Africa and is the norm in most developing countries. Once again the spikes caused by the rapid refilling of the pipes (which can damage the meters) are clearly visible. The issue of air in the pipelines is also a serious problem since it can cause bursts if the air valves are not fully operational. Intermittent supply is a very serious issue and should be prevented if possible. If allowed to continue, the leakage rates in the reticulation system will increase to such an extent that the system will eventually break down completely. In this zone, it was not possible to evaluate the leakage levels due to the intermittent supply that prevented any indication of the MNF. To overcome this problem, the supply was opened for two days so that some estimate of the MNF could be established. As can be seen, the MNF/ADD ration was estimated to be 83%, which suggests extremely high leakage.

WATER & WASTEWATER

Example 5 The fifth example, shown in Figure 5, is a more complicated and interesting case in which both pressure and flow are presented for the zone inflow to an area controlled by a pressure-reducing calve (PRV) that was initially thought to be discrete. In this case, it can be seen that after a few days the MNF drops to zero and, at the same time, there is an increase in pressure at the downstream side of the PRV. It should always be remembered that there will always be some level of MNF in a zone and the MNF will never drop to zero, even after rigorous leak detection. If the flow into the zone drops to zero, then it suggests that the MNF is being supplied from another source, which immediately points to some breach in the zone. In this particular case, a boundary valve has been opened, which has little influence during the peak daily demands but during the off-peak demand periods when the inflow to the zone is low, the connection is capable of pushing up the overall zone pressure. When the zone pressure at the downstream side of the PRV increases above

the pressure set at the PRV, the valve closes and all flow through the valve stops â€“ hence the zero MNF.

FIGURE 5 Example of a zone with an open boundary valve

Example 6 The sixth example is by far the most complicated shown so far and demonstrates a number of interesting issues and clearly highlights the true benefit of monitoring the flows and pressures into an area. Figure 6 shows the flow into a discrete area that is controlled by a PRV. The downstream pressure at the PRV is shown in red. As can be seen, the pressure at the PRV is constant for a few days after which it increases at night much in the same manner as shown previously in Figure 5. In this case, however, the increase in night-time pressure is not due to the opening of some crossboundary connection, but rather the failure of

the PRV to maintain a constant downstream pressure. If the pressure increase was due to an open cross-boundary connection, the PRV would have closed with a subsequent drop in the MNF. In this case, it can be seen that the MNF increases, which is due to the increase in leakage caused by the higher pressure. Basically, this graph from a South African installation in Johannesburg depicts quite a complicated story and has been used in many textbooks around the world to demonstrate

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WATER & WASTEWATER

FIGURE 6 Example of logging result caused by leak and PRV failure

FIGURE 7 Flow logging into a large industrial area

the value of logging pressure and flow. The problem starts with a reasonably large mains burst in Day 2, which is evident from the spike in flow (as noted on the graph); this in turn creates a sudden increase in the MNF of about 20 m3/h. An average mains burst would be around 6 m3/h and so this burst is relatively large. The repair takes place on the following day and a spike in flow is evident, which is possibly due to some refilling of empty pipes after the water supply is restored to the area that had been isolated during the repair. It can be seen that the MNF drops back to near pre-burst levels on Day 3.

IMIESA October 2013

At this point, the PRV starts to fail for some reason and the failure gradually becomes worse over a period of a week after which it fails completely. The example shown in Figure 6 requires time to fully understand, but is one of the most interesting logging examples found to date. It not only provides a history of the failure of a PRV, but clearly highlights the pressure-leakage relationship of the area where the MNF gradually increases over the seven-day period in response to the gradually increasing night-time pressure.

Live logging Many logging results are derived from loggers located at or near valve chambers, which are left for a week or two and then downloaded manually by the technician. Such loggers are commonplace in most municipalities and provide much useful information. Unfortunately if a problem does occur, these loggers cannot respond immediately and the problem may only be identified several days later when the logger is downloaded. With the recent developments in logger technology, it is now possible to use real-time loggers that can transmit the data back to some central database on a daily or hourly basis. In addition, such loggers will

usually incorporate some form of alarm setting whereby any unusual flow or pressure reading can trigger an alarm that is sent immediately to a predefined location. Transmission of the data can be achieved in a number of ways, including radio-link or the cellphone networks using GSM or GPRS communications. A few more logging results from one such live system are provided to highlight the benefits that can be achieved from such information.

Example 7 The logging result shown in Figure 7 depicts the inflow to a large industrial area. It tells an interesting story and highlights some very serious issues. Firstly, if the first two days of logging are considered, it can be seen that the MNF is around 1 000 m3/h and the ADD is around 1 100 m3/h. While night-time use can be expected in an industrial area, it is highly unlikely for it to be in the order of 90% of the average daily demand. Typically, a value of 30 or 40% would be expected and, in this case, the high MNF is an indication of very serious leakage. Another interesting issue highlighted by the graph concerns the two large drops in flow on 8 and 10 June. The first drop occurred when the supply to a small factory was temporarily cut in order to install a new water meter to the factory. The project team undertaking the meter installation had closed a small section of pipe approximately 100 m in length in order to cut in the new meter and when they checked the flow logging results that evening on the internet, they picked up a drop of almost 350 m3/h going into the area. Initially they thought this must have been an error and they repeated the valve closures again two days later on 10 June and picked up the same result. What this result has identified is a leak of more than 300 m3/h from a very

WATER & WASTEWATER

short section of pipe at a cost FIGURE 8 Flow logging into an industrial consumer of over R13 million per annum to the municipality. While it seems implausible that such a large leak could remain undetected for any length of time, it is estimated that it has been running for years! The factory owners on each side of the nearby swamp area were told that the swampy marshland was due to groundwater and has been in existence for many years. This is a nice example highlighting the benefits of real-time flow monitoring and also touches on the concepts of â€œsteptestingâ€? in which small sections of a reticulaconsumers, particularly large industrial water tion system are isolated and the impact on users as can be seen from the graph shown the MNF is monitored. In this case, it was not in Figure 8. The graph shows the flows being necessary to look at the MNF as the impact used by a relatively large industry and it is was so significant that it was evident from the clear that some form of tank is being filled normal daily flow. every hour or two. This practice of intermittent filling causes serious pressure fluctuations in the water reticulation system in the vicinExample 8 ity of the industry and was creating probLive logging is not restricted to municipalilems for the municipality and other nearby ties and is also very useful to individual

industrial users. On presentation of the logging results to the industry in question, they were happy to modify their abstraction process to a more constant rate of abstraction that would not create large pressure fluctuations in the reticulation. Industries are often unaware of the demand pattern they impose on the municipal network and the live logging is of great use and interest to their water managers who generally wish to ensure that they are using water responsibly.

Example 9 Another interesting example is presented in Figure 9, which shows the flow entering a small complex containing around 50 townhouses. After receiving an unusually high water account for two consecutive months, which was approximately R50 000 higher than normal, the owners realised that it was not a mistake and that they had a leak. A GSM/GPRS logger was installed for a few days and immediately picked

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WATER & WASTEWATER

FIGURE 9 Flow logging result into small townhouse complex

up the fact that there was a leak of approximately 14 m3/h within the complex. The leak was repaired and the water use dropped back to normal in the following week. This example highlights the fact that such flow logging is not limited to large users, but can also be very useful to small townhouse developments. The typical cost of such a logger and the annual communication charges is generally between R10 000 and R20 000 per annum, which is often well below the cost of water lost through even a modest leak. Such logging is also very useful in identifying any small leak that is

IMIESA October 2013

gradually increasing with time as this can easily be picked up by the gradually increasing MNF.

Summary and conclusions Flow and pressure logging is already an essential element of any comprehensive water demand management strategy developed by a municipality. Such logging is now also being recognised as a cost-effective measure in managing leakage and water use in large industries as well as smaller consumers such as townhouse complexes and shopping centres. With the recent advances in cellular communication technology, the costs associated with real-time logging and the associated internet access have been greatly reduced to the extent that it is now within reach of many new potential users. When considering the use of real-time logging, a new user must carefully consider the available options and select a

system that best suits their needs and budget. Each data transmission system has its advantages and disadvantages. Some of the key considerations include: • cost of the logger • costs associated with the data transmission (SIM card costs, monthly rental, etc.) • reliability of the equipment • power source required for the equipment and battery life in case of battery powered units • software requirements for the equipment • ease of use and ease of programmability of the loggers • water resistance of the loggers (i.e. IP68 etc.) • easeful life of the loggers. Water is becoming a scarce resource throughout all of South Africa and the need to conserve water is being stressed on a daily basis by municipalities and government departments alike. Proper monitoring and control of leakage will become commonplace throughout the country as the technology becomes more cost effective and the price of water rises.

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PUMP STATION SECURITY

Pre-planning results in a complete solution After being seriously vandalised, the Boiketlo sewage pump station is now one of the most secure in the land.

FTER VANDALS stripped a pump station in a remote area on the outskirts of the West Rand of Johannesburg, resulting in undesirable spillages at a significant cost to the municipality, urgent interventions were required. This was not the first time that the Boiketlo sewage pump station had been broken into and its contents and equipment removed, including the pumps, pipes, control panel cables and even the fence. The municipality lost several hundred thousand rand in technology and equipment. In addition, the inconvenience and effects of having non-operating infrastructure meant that a viable solution was needed. The municipality chose Tecroveer to design and build a highly secure solution, which has resulted in one of the most secure structures in the country. The project was undertaken during 2012 and the construction of the new pump house was completed over a three-month period, as soon as the necessary approvals were received. Boiketlo is situated within the Mogale City Local Municipality. Known as the City of Human Origin, Mogale City is one of three local municipalities that form part of the supply area of the greater West Rand District Management area. Wimpie Olivier, project manager at Tecroveer, explains the client’s requirements at the outset: “It was necessary to move away from the traditional pump station approach, because of the remote location of the site, and the requirements were that the pump station had to be vandal/thief-proof to protect the assets of the local municipality.

It was important that the control panel for the equipment remained secure. In addition, as a result of us not wanting to make use of submersible pumps, the new pump station could not be kept below ground level, as was the former pump station.”

Design and building phases The client’s needs and requirements were well documented and incorporated into a simple design. This formed the basis of a preliminary design that was subsequently approved by Mogale City. Thereafter, the plans were drawn up by draughtsman and construction of the pump house commenced, including the mechanical design aspects. The project included the use of patented technology provided by Dams for Africa, which included a sliding concrete platform door, for complete access control. The sliding door, which is made from 60 MPa concrete, is supported by two wheels at either end that are guided on tracks partially embedded in the concrete. The concrete doors have a threedimensional aspect to their design, so that they are substantially stable against overturning, due to their significant weight. Concrete is immune to oxy-acetylene attack and is too thick for angle grinders to penetrate; since the door has 5% (vol/vol) steel reinforcing, it is impenetrable to chisel attack.

station be commissioned as a matter of urgency. Throughout the construction phase, security on-site was a crucial element. Olivier says that another challenging aspect was the ventilation, as this was a sewage pump station. This was overcome by one hundred 100-mm ventilation holes positioned on the top and bottom of the walls, as these allow for the cooler air to come in from the outside. The air rises as it heats and exits via the top holes.

Multidisciplinary team Gary Brown, marketing manager at the company, notes that the company has a multidisciplinary team that is well-coordinated. It provided a unique, yet simple concept and solution for this project, which overall represents a quantum leap in pump house design insofar as anti-theft measures are concerned. ABOVE Site of the newly constructed sewage pump station BELOW Tecroveer's complete solution

Challenges Initially, as a result of the vandalism, the pump station was not in service, and therefore Mogale City required that the new pump

IMIESA October 2013

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THE JOAT GROUP OF COMPANIES has moulded itself into an efficient and market-leading solutions-orientated team that primarily addresses the optimisation of water supply to consumers through the minimisation of water losses, application of appropriate technology, revenue improvement and energy efficiency. The groupâ€™s key focus areas of operation are consulting and operations engineering (essentially the reduction of nonrevenue water and stabilising of water supply), product sales and support, energy efficiency and mentorship. JOATâ€™s passion and vision is to ensure that municipalities become as efficient as possible in delivering water to consumers and has adapted its approach towards an outcomes-based partnership that has shared responsibility and accountability. The ultimate objective of any successful partnership with JOAT is to provide water service authorities with an efficient distribution system that they are fully equipped and trained to continue to operate.

In response to this approach, JOAT has invested in wide-ranging technology and partnerships that can be harnessed for the benefit of municipalities. Flow metering solutions (permanent or temporary, monitoring or revenue-generating), data management solutions (data loggers, GSM data loggers), control valve solutions (pressure-reducing valves, pressure controllers, surge control), leak detection solutions (leak detection equipment and service) and energy efficiency solutions (variable speed drives and system optimising) are all available to be presented into cost-effective, custom-made packages. JOAT has also expanded into the optimisation of energy consumption in the water cycle and has a number of in-house experts that can undertake energy audits and design energy efficiency solutions for pump stations and treatment works. This forms part of its overall approach to making the distribution of water as efficient as possible.

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UWP CONSULTING

Upgrade of Mthatha’s wastewater infrastructure Last year, President Jacob Zuma announced the rejuvenation of the City of Mthatha as a key Presidential Intervention.

HE CORNERSTONE of this intervention is the deliver y of 17 000 low-income houses in Mthatha by the King Sabata Dalindyebo Local Municipality, while informal settlement upgrades and various other public and private sector development initiatives are also on the drawing board for the town. A critical requirement to accommodate this planned growth is the refurbishment, upgrading and expansion of bulk water, sewerage and electricity ser vices. Building on many years of involvement in Mthatha’s development, UWP Consulting

was appointed in October 2012 by the OR Tambo District Municipality to undertake the planning, design and construction monitoring of the bulk sewerage projects needed

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UWP has been given the green light to implement a series of projects for the Presidential Inter vention. The projects are being planned and implemented under the direction of Amatola Water, the appointed programme implementing agent for all bulk water ser vices infrastructure for the Presidential Inter vention. Based on its in-depth needs analysis, UWP has been given the green light to implement a series of projects including: • the new 600 mm diameter, 8 km long Maydene Farm/Ncambedlana outfall sewer, including refurbishment of the existing Maydene Farm sewage pump station, as well as three new sewage LEFT Mondli Dlulane, director and Mthatha office manager, UWP Consulting

IMIESA October 2013

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pump stations var ying in size from 15 to 175 kW upgrades to the Kuyasa and Southridge Park outfall sewers entailing some 10 km of new sewer var ying in size from 160 to 900 mm diameter and four pipe jacked road crossings, as well as the high-pressure cleaning and refurbishment of some 4 km of existing sewer the new 12 Mℓ/d biofilter wastewater treatment works to be constructed at the site of the existing wastewater treatment works the refurbishment and recommissioning of five existing sewage pump stations var ying in size from 5 to 150 kW, including enhanced security and communication features and new standby power facilities at each station the upgrade of the Ngangelizwe outfall sewer and refurbishment of the Ngangelizwe Central and North collector sewers, entailing some 7 km of new sewer varying in size from 160 to 500 mm diameter, as well as the high-pressure cleaning and refurbishment of some 2 km of existing sewer.

WATER & WASTEWATER

A NEW PRECEDENT

Biogas to power pilot project The conversion of biogas to power is rapidly growing in stature across the globe. In some countries, biogas is used to power vehicles, but the most common application is of biogas to electricity.

HERE ARE numerous environmental benefits of this technology. Biogas is an effective, renewable, non-fossil fuel with a high methane content that does not compound the greenhouse effect. Furthermore, emissions of nitrogen oxides, carbon oxide, carbon monoxides and hydrocarbons are small in comparison to petrol and diesel. Biogas is an energy rich fuel and can be used to produce heat and power, and can also be used as vehicle fuel. Compared to the use of diesel for vehicles, biogas emits 80% less hydrocarbons and 60% less nitrogen oxides. The concentration of particles and dust is also negligible in when biogas is burned. Animal and food waste and sewage sludge undergo natural anaerobic digestion in an oxygen-free environment. This means that all animal and human waste can be broken down by a bacterial process. The remaining products of the anaerobic digestion are returned to nature, so biogas is included

in the category of renewable energy sources. In short, as long as humans and animals exist on the planet, biogas will continue being produced. The source of biogas can therefore be described as unlimited. As a source of power, it is classified as non-polluting. Wastewater professionals once accepted the high costs of operating wastewater treatment facilities as a consequence of meeting their discharge permit requirements. As the cost of energy rises and emphasis on renewable energy increases, local authorities and municipalities are seeing solutions that save money and meet renewable requirements. Waste treatment processes include energyintensive operations such as aeration and pumping. As a result, wastewater treatment works (WWTW) require significant energy consumption. As electrical prices increase, plant operators are facing higher energy costs in order to meet discharge permit requirements. The second leading expense to WWTW owners is the cost of energy, second only to personnel. For plants that employ anaerobic digestion for biosolids treatment, the process of combusting digester gas to produce electricity and heat through cogeneration/combined heat and LEFT A view of the biogas conditioning system BELOW The three generators currently operating at the WWTW

IMIESA October 2013

power (CHP) may provide a solution to rising operational costs. WEC Energy, a division of WEC Projects, is pleased to announce that its biogas CHP generation plant at a WWTW in Gauteng has been officially launched by Johannesburg Water while another nears completion. In 2009, a feasibility study was undertaken to find out more about biogas to electrical energy generation on WWTWs. The first part of the study was to try and find out the risks involved in the CHP operations on WWTWs. The second part of the study was to determine which of the contaminants would have to be removed from the biogas before it could be used effectively as a fuel in the CHP process. A number of processes that were available for use to scrub the biogas of the contaminants were investigated and the most efficient, cost-effective and sustainable method for the city was identified by Johannesburg Water. Thirdly, an investigation was carried out to find a suitable and cost-effective prime mover for the production of CHP. The last part of the investigation was to determine the volume and quality of biogas produced at the Northern WWTW, which is the largest wastewater treatment plant in Johannesburg. After all the findings from the investigations were finalised in 2010, a report was drawn up with all the findings and recommendations to which the board gave their approval and the project managers the green light. It was decided that the biogas project be implemented at the Northern WWTW first as a pilot before it is moved to other WWTWs. WEC Energy was commissioned by Johannesburg Water to design, build, operate and maintain the pilot biogas plant in September 2011. The biogas plant, which has been operational since October 2012,

WATER & WASTEWATER

uses biogas generated from four anaerobic digesters, which is normally used to fire a boiler, and the excess biogas is flared. The CHP gas engines generate both heat, which is fed back into the digesters, and electricity, which is supplied to the WWTW and runs in parallel with the incoming Eskom feed. “This is a particularly important aspect of the biogas plant as we can feed electricity into the WWTW’s existing electrical reticulation simultaneously, effectively lessening the WWTW reliance on grid power only,” explains Jason Gifford, head of Energy Projects at WEC Projects. For an energy-hungry facility such as a WWTW this equates to a massive saving on its power bill. Peter Louw, project engineer from Johannesburg Water, says this can be put into perspective by the fact that Johannesburg Water treats 1 billion litres of sewage a day at six of its WWTWs. He estimates that the cost of electricity to run these facilities will treble over the next 7 to 10 years from R95 million per year to more than R300 million. However, all six of these facilities have the potential to produce 8.5 MW of electrical energy. Louw states that the biogas plant built by WEC Energy can ultimately generate at least 55% of the WWTW’s required power through CHP biogas plant. Currently, biogas is sourced from four digesters (additional digesters are being refurbished to allow maximum capacity). The biogas is fed from the digesters onto a common gas ring from where the WEC Energy plant extracts the

Peter Louw, Johannesburg Water project engineer; Gauteng MMC for the Environment, Infrastructure and Services Department, Matshidiso Mfikoe; and Jason Gifford, head of Energy Projects at WEC Energy, at the official launch of the biogas-to-energy plant

biogas for use in the CHP plant. “The biogas sourced off this system is essentially a raw fuel that needs to be scrubbed to remove hydrogen sulphide, moisture, particulates, siloxanes and non-methyl volatile organic compounds (VOCs),” explains Gifford. This is achieved through using a bacterial process to remove hydrogen sulphide. From there it is taken through a coalescing filter, which removes any free moisture and particles; it is then sent through blowers to boost pressure and also heat the gas up by just over 80°C. The moisture in the biogas is greatly reduced through using a specially designed three pass heat exchanger. The final scrubbing stage, before the biogas is sent to the gas engines, is for the removal of siloxanes and non-methyl VOCs. The biogas is then fed to the

generators in a controlled manner to the engines. “The biogas is the fuel source for the generators and the recovered heat from the engines is used to heat the digesters, effectively making the on-site boilers a standby option only,” highlights Gifford. This is the stage of the process where the biogas, essentially a free by-product of a sewage plant, gets transformed into power and heat energy and the benefits of both are optimised. There are three generators in operation at the pilot project operated by WEC Energy. They have independent switchgear, which allows for synchronised feed-in alongside the grid supply. Additionally, should the grid supply fail, the biogas plant can supply power to certain sections of the WWTW. As more digester capacity comes online the CHP plant’s ability to supply a larger portion of the WWTW requirement is proportionally increased. WEC Energy is currently constructing a second CHP plant for Johannesburg Water, which will be operational by the middle of 2014. The scope for further plants to be built, not only at WWTWs, but any industrial, agricultural or commercial facility, is limited only to the availability of biogas sourced through anaerobic digestion. Johannesburg Water is aspiring to become as self-sufficient as possible for the electrical power demands of its wastewater treatment plants by 2016. Initially, CHP-generated power could possibly provide about 55% of the wastewater treatment electricity needs. IMIESA October 2013

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NELSON MANDELA BAY

Building for business The birthplace of South Africa’s greatest icon, Madiba, as well as the country’s hub for automotive, Nelson Mandela Bay Municipality is synonymous with pride, entrepreneurship and innovation. We take a closer look at some of the achievements emerging from the Eastern Cape.

ESCRIBED BY local authorities as “a land of opportunity, where a highly developed First-World economy meets the huge potential of an emerging economy”, the Eastern Cape, with its main metropolitan being Nelson Mandela Bay Municipality (NMBM), boasts a strategic location for trade with the rest of South Africa and neighbouring countries. Thanks to its vast rail, port and road networks, it is clear to see why this district is home to a host of manufacturing companies as well as two industrial development zones (IDZs), namely the Coega IDZ and the East London IDZ. IDZs are industrial estates that play an important role in the countr y’s macroeconomic strategy, providing transpor t,

logistics and business services tailor-made for export industries at highly competitive rates. Through these IDZs, the Department of Trade and Industry aims to generate sustainable local and international investment while stimulating the economy through the creation of much-needed jobs and skills transfer, as well as the development of SMMEs. Not only does this enhance South Africa’s growth, but investors also stand to benefit from direct cost savings such as VAT-free exports (on condition), while enjoying efficient operating standards.

In the zone The East London IDZ (ELIDZ) stands proud as South Africa’s first such operational

TABLE 1

About the Eastern Cape Languages (in order of dominance)

isiXhosa, Afrikaans, English

Major cities

East London, Port Elizabeth

Population

7 140 000

Area

169 580 km2

GDP contribution

Approximately 8.1% of South Africa's total

Major industries

Automotive, component manufacturing, agriculture, agro-processing, tourism

Source: Eastern Cape government

Nelson Mandela Bay Stadium, built for the 2010 FIFA World Cup

development, celebrating its 10th anniversary in December last year. As the first active IDZ, it set the platform from where government harnessed a policy for other zones. Boasting 11 investors and an area surface of 430 ha, the ELIDZ is also responsible for a large portion of the province’s income with its busiest period being felt during the 2006/7 financial year – equating to a R395 million investment. The current direct manufacturing job count for this IDZ stands at 1 118; however, this was not without challenges. In the earlier days of the ELIDZ, the biggest concern was diversification of the local economy, as this was dominated by the automotive sector. “Key to our [ELIDZ] mandate was the attraction of strategic investments that would not only leverage existing regional and industrial strengths, but would further upgrade the province’s industrial landscape,” said Simphiwe Kondlo, CEO of the ELIDZ, at the 10-year anniversary celebration. To date, 30 investors have been secured, R928 million in contracts have been awarded to BBBEE enterprises, and a further R281 million in contracts was awarded to SMMEs. In addition, due to its proximity to the equipment manufacturer DaimlerChrysler South Africa, the ELIDZ

IMIESA October 2013

MUNICIPAL FOCUS

commissioned and built an automotive supplier park, which later became home to many of its new investors. The latest production line to come out of this automotive park: the new C-Class Mercedes Benz model for export. Further across the province, with an impressive area space of 11 000 ha, the multibillion rand Coega IDZ is South Africa’s largest IDZ, and its location – adjacent to the Port of Ngqura – could not have been better planned. Ngqura is Transnet’s newest port, offering container, bulk and break-bulk terminals. Unlike its sister IDZ that has a keen interest in the automotive sector, the Coega IDZ is big on skills development in line with the Coega Development Corporation (CDC) vision. The main objective of the CDC is to boost socio-economic growth in South Africa – and it is doing just that, especially through its driver training programme. “Graduates from previously disadvantaged areas usually find it difficult to secure jobs without a valid driver’s licence,” explains Pepi Silinga, chief executive of the CDC. “We noted this gap and immediately moved to fill it – first on our home turf by offering free driving lessons to our 130 interns as part of the Coega graduate development programme.” Funding for this programme is absorbed by the Coega IDZ. According to figures published by the Eastern Cape provincial government, the IDZ is not just tackling unemployment in the province, The Mercedes-Benz automotive plant in the ELIDZ (Source: Eastern Cape Provincial Government)

IMIESA October 2013

TABLE 2

Eastern Cape IDZs Coega IDZ focuses on:

ELIDZ focuses on:

Metals/metallurgical: chrome, stainless steel, iron, etc.

Automotive and components: features a world-class motor vehicle terminal

Textiles: wool, mohair, etc.

Marine aquaculture: investors include the likes of Seatek (Abalone farm)

Automotive: components and original equipment manufacturers

Agro-processing: biofuels, food and timber

Services: business process outsourcing and call centres

Pharmaceuticals

Chemicals: both organic and inorganic

ICT and electronics

Energy: alternative energy sources

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Coega IDZ is South Africa’s largest IDZ, and its location – adjacent to the Port of Ngqura – could not have been better planned

Fast facts • R3.7 billion: the amount of investment the ELIDZ has attracted over the years • 200: the number of local companies the ELIDZ has transacted with • 30: the number of investors currently secured in the ELIDZ

but also set an unprecedented record by securing eight new investors to take up space in the zone during the 2011/12 financial year. These investments raked in more than R40 billion for the local economy, creating some 15 000 jobs in the process. Subsequent to this, a Development Framework Plan has been developed for Coega, which zooms in on building infrastructure for the IDZ’s core development area.

Square route Despite the success of its IDZs, the Eastern Cape continues to suffer from a major infrastructure backlog such as housing and lack of basic services. In a bid to foster change, especially in previously disadvantaged areas, the NMBM identified strategic developments that form part of its Vision 2020 Projects programme. The aim of Vision 2020 is to boost the local economy while stimulating job growth and maximising skills transfer opportunities. One of these projects is the Njoli Square Redevelopment Project, which comprises a civic centre, tourism facilities and a major intermodal transport interchange.

Located in the heart of the KwaZakhele Township, Njoli will breathe new life into this area, creating a diverse hub to attract tourism. Before work could begin, 76 privately owned properties will need to be acquired by local government in order to make way for the new design. In terms of finance, a R121 million grant was sourced from National Treasury through the Neighbourhood Development Partnership Grant; however, the initial total estimated project rings in at R177 million – not taking into account inflation and unforeseen construction costs. Despite the big investment cost, during this construction phase, it is predicted that Njoli Square will contribute R189 million toward the Eastern Cape’s GDP, not forgetting massive job creation in the region of 2 000. Following five years of talks and planning, local authorities were delighted when the Njoli Square Redevelopment Project kicked off.

Secure water supply In 2010, the Eastern Cape suffered a severe drought, which affected the important Algoa Water Supply System (Algoa WSS). Prompting a Strategy Steering Committee meeting of the Algoa WSS, the Department of Water Affairs decided to tighten excessive water usage in the province, with the NMBM by-laws being changed (in 2011) to promote the practice of rainwater harvesting tanks, thereby reducing strain on the municipal water supply. The Algoa WSS is also the primary water source for the Coega IDZ and this region relies

heavily on water for economic growth. The drought, coupled with the global recession that followed not too long thereafter, had a major impact on the IDZ and, in turn, the local economy. Apart from the Strategy Steering Committee, the NMBM’s Water Conservation and Water Demand Management (WC/WDM) Programme was launched with the objective of reducing water usage by a minimum of 25 Mℓ/d by simply repairing water leaks on municipal water mains and leaks on private properties. The achievements were so significant that the WC/WDM Programme was noted as “the most important intervention to be put in place to reduce water losses and thus water requirements”. Implementation of the WC/WDM was therefore afforded the highest priority during the Drought Emergency Interventions (Eastern Cape Government Report on Sustainable Water Supply for NMBM and Surrounding Areas, Nov 2011). Also on the cards to aid with drought relief was the proposed Nooitgedagt LowLevel Scheme, which would also relieve the necessity for an expensive desalination plant. Stemming from its 2012/13 financial budget, the Department of Water Affairs invested R450 million into the scheme, but an additional R351 million is still required. The department suggested outsourcing the development of the project to businesses within the municipality that purchase water. In another attempt, the municipality has approached National Treasury for funding but was declined. ▶

IMIESA October 2013

MUNICIPAL FOCUS

Due to the lack of funding, Nooitgedagt has been divided into phases, and contracts on the final four phases can only be awarded if the outstanding investment is obtained. In the interim, the municipality is using water from the Kouga system and has even gone beyond its limit. During the period July 2012 to March 2013, the municipality also used its full allocation from the Kromme Supply System, further stressing the importance for the Nooitgedagt Low Level Scheme. Once complete, this project will add an additional 90 Mℓ/d to the existing supply. Surplus potable water will also become available from Nooitgedagt. Despite the negativity surrounding water supply in NMBM, its Water Loss Programme has, to date, made significant progress owing to various initiatives. For the 2011/12 financial year, combined savings were in the region of just over R16 million and the plan is to forge ahead with more sustainable, targeted water reduction initiatives.

Urban renewal Back in 2001, then President Thabo Mbeki announced the Urban Renewal Programme (URP), which would be implemented in eight nodes across South Africa, directly affecting

IMIESA October 2013

2.5 million people. One of the URP recipients was Motherwell in NMBM, an underdeveloped urban settlement plagued by poverty and bad living conditions. The main aims of the project included poverty alleviation, enterprise development, crime prevention and human resource development, among other strategies. The 2005/6 financial year saw the successful completion of the following projects under the Motherwell URP banner: • 3 500 low-cost houses in Ikamvelihle at a cost of R80 million • tarring of roads in Ikamvelihle at a cost of R17.50 million • electrification of 1 100 erven in Ikamvelihle at a cost of 3.30 million • Hydroponics Project Phase II at a cost of R2.50 million • training for Ploughing Fields beneficiaries at a cost of R100 000 • Addo Road Fencing Phase I at a cost of R3 million • Small Business Incubator/Employment Centre at a cost of R2.40 million • Junior Traffic Training Facility at a cost of 240 000 • Motherwell Basline Study at a cost of R0.36 million.

A worker on-site at the FAW Plant in Zone 2 of the Coega IDZ (Source: Infrastructure ne.ws)

But Motherwell is not the only area receiving attention. On the outskirts of NMBM, another low-cost housing project had started, except this one had a R6 billion price tag. Dubbed “the city within a city” development, the project is meant to eradicate the housing backlog by an astonishing 40% while creating thousands of jobs in the process. The planning took six years and the final layout cleverly incorporates a holistic lifestyle development, including the construction of a 35 000 m² mall. Stemming mainly from the increased growth within the Coega IDZ and the arrival of new residents, this project will also include a space for schools, tertiary institutions, clinics, community shops and a hospital. The area is currently sitting with a housing backlog of 92 000, of which 39 000 are expected to be constructed over the next 15 years. And unlike Motherwell’s RDP housing units, this development will offer residents a variety of housing types, with upmarket properties priced from R1 million and the potential

MUNICIPAL FEATURE

for low-income earners to qualify for up to R83 000 on their new homes.

High flyers With tourism being an important revenue generator for the Eastern Cape, it became necessary to make it easier for visitors to enter the province. As a result, construction of the licensed commercial Somerset East Airport was commissioned, strategically positioned 60 km from the ever-popular Addo Elephant Park. Driven by the Blue Crane Development Agency (BCDA) and serving as an economic and social catalyst for the region, the airport will offer tourists easy access to the Somerset East region where they can experience a host of different attractions such as the Trout Fishing Festival, the Biltong Festival, the Bruitjieshoogte Marathon and the Mac Nab Competition.

When constructing an airport, especially a commercial one, it’s important to note that the opportunity it presents opens up a

were complete: electrified security fence, terminal buildings, two grass runways, two aircraft hangars, bulk services and approximately two-thirds of the main runway. However, funding has proven to be a challenge and the remaining components will take priority once the money is secured.

Serving as an economic and social catalyst for the region, the airport will offer tourists easy access to the Somerset East region particular province or area to private investments and, as a result, subsequent projects. Not only will the Somerset East Airport stimulate the region’s economy, but it will also assist with other aviation projects such as the relocation of Albasera Aircraft’s Light Sport Aircraft manufacturing from Johannesburg, and air safari operations to and from the area. At the end of 2007, the following elements

The green grass at home It’s not just infrastructure projects and new developments that are making headlines in the Eastern Cape, however. Entrepreneur and winner of the Transformation Africa Young Entrepreneurs Network Award, Manelisi Gibson, decided to use the province’s infrastructure backlog to his advantage – and made millions in the process. Established nine years ago, Zibele Construction is responsible for building schools and clinics in a place where these facilities ceased to exist. But Gibson led a IMIESA October 2013

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Did you know? The Algoa WSS comprises an infrastructure system of dams, pipelines and canals linking surface water resources from various rivers, to supply water to 1.1 million users in the NMBM and several surrounding towns.

Artist’s impression of the proposed integrated transport route for the Njoli Square Redevelopment (Eastern Cape Provincial Government)

tough life before his business took off. Today, however, he boasts a 58-employee company, which churns out millions, all thanks to a capital loan from the Eastern Cape Development Corporation (ECDC). This corporation assists with small to medium business funding, provided that the business is situated or headquartered in the Eastern Cape – so that the major developmental impact will be felt in the province. The ECDC helped Gibson realise his dream and maximise his full construction skills, having invested an additional R19 million into more than half of his company’s projects. Zibele Construction owns several trucks and transport load builders and employs a diverse workforce ranging from drivers, clerks and plumbers to electricians, painters and bricklayers. Major projects emerging from the company include: • R1.7 million school in Mthatha • two schools in Qumbu valued at R17 million each • construction of a mortuary in Mount Fletcher • R10 million construction of the King William’s Town Fire Station. The fire station is scheduled to be open in October this year and, through its construction, has created 200 jobs for local residents. There are many rural areas in the town and

fires are a serious cause for concern, particularly during the winter months, and due to the high number of bushfires. The new building will include an administration and office area, fire engine bays, a service area, and external and associated works for electrical and mechanical installations. But Gibson is just one of many SMMEs that the ECDC has invested in. Other interesting success stories include*: • Nelson Mandela Bay Technology Hub: technological innovation is an important precursor to sustainable development, especially in non-industrial sectors. With this in mind, the ECDC initiated, and continues to champion, the Nelson Mandela Bay Technology Hub. This is a division of the Eastern Cape IT Initiative (ECITI), a multifaceted

committee, which incorporates representatives from the Nelson Mandela Metropolitan University, Volkswagen SA, Small Enterprise Development Agency (Seda) and the National African Federated Chamber of Commerce and Industry (Nafcoc), will act as a de facto advisor overseeing the project. The hub has received funding from the Department of Trade and Industry (R9 million), with an additional R4.5 million being invested by the NMBM. • Tourism packages: the ECDC brokered a groundbreaking tourism agreement with TUI, a Germany-based tour company, to put together tour packages through the Eastern Cape. TUI is one of the world’s largest tourist conglomerates, with interests across Europe. It runs more than 3 500 travel agencies and 79 tour operators in 18 countries and owns 285 hotels in 31 countries, as well as numerous airlines, cruise ships and retail stores. This Eastern Cape agreement is extremely significant to tourism in the province as it offers, for the first time in the province’s history, major international tour packages that incorporate a road route link between Port Elizabeth and Durban. • Magwa Tea Estate: the 2 800 ha estate in the Pondoland area of the former Transkei produces 70% of South African tea and was reopened in 2004, following a lifeline from provincial government, which mandated the ECDC to support the estate with ongoing financial and technical assistance. In 2006/7, more than 3 million kilograms of tea – the best yield ever at the estate – was harvested. Government and the private sector (the European MAN Ferrostaal and the Indian JV Gokals) have together invested some R50 million in revitalising and reinventing the estate. This massive project has secured more than 2 800 permanent and seasonal jobs – and business continues to grow. During the same financial year, the estate doubled

The ECDC brokered a groundbreaking tourism agreement with TUI, a Germany-based tour company

IMIESA October 2013

programme focused on providing support to SMMEs in ICT and related industries. Support is through the identification of key competencies within the focus area being developed in the province where the hub is located, and is in accordance with local and provincial economic growth and development strategies. In 2006/7, the hub became an actualised entity with the appointment of a dedicated CEO, as well as a supporting steering committee. The

MUNICIPAL FOCUS

support. The ECDC is a crucial partner in • Assembly plant: the ECDC cultivated production from the previous year, despite this process through its involvement with the establishment of the province’s first harsh circumstances. The Outgrower’s the revitalisation of storage and milling scooter and motorcycle assembly plant Programme is encouraging some 1 000 capacity in the province. This initiative in the Markman Industrial Township in community residents to grow tea on their involved establishing several medium-sized Port Elizabeth. This followed a R20 milsmallholdings and sell to Magwa Estate. milling operations at specific locations, with lion investment by Italian company Ala • Particle board plant: this R1.3 billion plant a view to decreasing the province’s dependManufacturing. The ECDC facilitated relais an investment by Steinhoff/PG Bison, ency on imported milled maize products. tionships between institutional, accounting one of Europe’s top five furniture groups, • Biofuel industry: a major development for and financial partners, as well as local and is the anchor tenant of a timber cluster the Eastern Cape is the establishment of suppliers and government services. This being established in the north eastern a biofuel industry, and the ECDC has been investment is creating significant spin-offs part of the Eastern Cape. The largest of instrumental in facilitating and driving a and business opportunities in the region. its kind in Africa, the plant covers approxistrategic planning process that will culmiThe plant began production with a staff mately 36 ha of a 64-ha site. Government nate in an integrated, three-tiered biofuel complement of 20, and its establishment and its agencies have committed more project. This initiative is in line with than R56 million into critical infraan overall national strategy to create structure, such as power lines, TABLE 3 a South African biofuel industry in the and water and sanitation. Apart About Njoli Square province, with the potential to create from boosting the local economy, thousands of jobs and draw billions it is estimated the project will Njoli Square is situated in KwaZakhele, about 10 km north of Port Elizabeth of rand in investment into the local create around 3 000 direct jobs economy. The Eastern Cape governwith an initial annual salary bill of KwaZakhele has an estimated population of 250 000 ment has set aside R9.5 million for R88 million, as well as secondary and Njoli Square is the biggest public transport node in fencing land and planting canola, jobs in a severely underdeveloped this and surrounding areas while R8 million is being spent on part of the province. In 2006/7, Njoli Square links Motherwell in the north to the Port planting sugar beet in the Mbhasha the Steinhoff Group acquired 67% Elizabeth city centre in the south area. The biofuel project will create of North Eastern Cape Forests An estimated 10 000 people use public transport to or a huge new market for agricultural from Mondi. The ECDC has been from Njoli Square and this figure is set to increase to 30 products, including canola, soya involved in the planning and stra000 by 2020 beans and sunflower, and these tegic management of the project Through the redevelopment project, KwaZakhele crops would be used to feed a profrom inception, and continues to residents will have access to top municipal and posed 200 000 tpa biodiesel plant facilitate the implementation of medical facilities. in the ELIDZ, as well as other biofuel the infrastructure projects and to and agro-processing initiatives. act as the overarching implement• Project blueberry: this R45 million project will have a huge added-value impact on ing agent. in the Stutterheim area is expected to crecomponent suppliers in the region as Ala • SeaArk shrimp farming: the ECDC played ate more than 2 317 annualised jobs over Manufacturers has committed itself to a facilitation role in the SeaArk shrimp 10 years, in an area struggling with a 55% producing its range of 50 to 150 cm³ farming project at the Coega IDZ, which unemployment rate. The 410 ha greenautomatic-gearbox motorcycles entirely with has the potential for a massive commercial fields initiative, which includes a farm and local content within a year. While its target investment that could reach R3.5 billion packaging facility, is being funded by the market is largely domestic, the company over six years. The project is driven by Industrial Development Corporation based also aims to export to the SADC region SeaArk Africa, a 50% joint venture between on a business plan developed by the ECDC. and beyond. SeaArk Holdings, a US-based commercial Planting of the first 15 ha was complete in • Food security: agrarian transformation and aquaculture entity, and the Bosasa Group 2008 and the farm is expected to be fully food security are two of the biggest chalof Companies, a diversified BBBEE group, operational by 2015, reaching full maturity lenges and opportunities currently facing and involves a high-tech, indoor biosecure by 2020. It is envisaged that 80% of the the Eastern Cape. As a result, provincial prawn grow-out facility that uses state-offarm’s yield will be packaged fresh for the government launched the Massive Food the-art technology developed by leading export market while 20% will be processed Programme, aimed at encouraging confish-farming experts in the US. It will breed for local consumption. solidation of land for commercial producgiant shrimp primarily for the export market • LED Support Programme: the ECDC contintion purposes, particularly in the former and will include a processing, packing and ues to assist and support the Thina Sinako Transkei and Ciskei. The aim is not only to distribution function. The facility, which was Provincial LED Support Programme through increase the production of food crops, but fully operational in 2011, was constructed various partnerships and enterprises, as also to encourage access to new markets on 1 100 ha of land and will offer 62 000 well as in facilitating access to finance. ▶ through infrastructure, credit and training raceways as grow-out facilities.

IMIESA October 2013

MUNICIPAL FOCUS

This programme has trained more than 900 people in local economic development (LED) or project development. It has also trained 72 LED facilitators to assist people in the development of LED projects and grant fund applications. The ECDC focuses its involvement with this important initiative in support of a more integrated view of LED, which allows for system improvement and participation in innovation, as well as useful leveraging of economic development resources. A success around this programme has been the Makana Goat Project, which was awarded a R4 million grant from the European Union (EU). A flagship development initiative of the Makana Municipality, this project already creates direct employment for more than 100 people in a severely underdeveloped part of the province. The EU grant has

financed the training of 49 farmers, as well as provided for the building of sheds on 10 farms in the Makana area.

Looking ahead At the Eastern Cape’s 2013/14 budget speech earlier this year, Phumulo Masualle, MEC for Provincial Planning and Finance, highlighted the year that was and brought to light some of the stubborn challenges. Adding to the province’s infrastructure issues is natural disasters, with the 2008 and 2010 droughts, and then the flooding of 2012. Obviously, the impact of such disasters will require a higher budget to rectify the damages. The province’s 2012 focus included a substantial improvement on infrastructure spend, particularly in the education and health sectors. Also a plus for the Eastern Cape was the efficient roll-out of its school nutrition, scholar transpor t and learner

IMIESA October 2013

Degrémont, a subsidiary of SUEZ ENVIRONNEMENT, is the world specialist in the design and construction of water treatment plants and an important contributor towards sustainable development. Degrémont, a subsidiary of SUEZ ENVIRONNEMENT, is the world specialist in water treatment plants and as such makes an important contribution towards sustainable development.

COMMITTED TOGETHER TO WATER, A SOURCE OF LIFE

Degrémont’s subsidiary in South Africa previously trading as AQUAZUR, is committed to keep plants running smoothly. The objectives of Dégremont’s Spares Department are mainly to supply the needs of its clients with • The best and affordable quality spares, as per the original designs • Delivering the spares within the best speciﬁed delivery period

For PULSATOR Settling tank or similar • Bafﬂes • Lamellar blocks and plates • GRP pipes • Vacuum Fan For AQUAZUR V & T Filters or similar • Nozzles, Washers & Grommets • Partialisation Valves • Clack Valves • Silica Filter Media • Siphon • Slab mould Other Spare parts • Chemical dosing pump • Various pumps • Various valves • Pipes (GRP, Fibreglass, PVC, Steel) • Instrumentation • Air diffuser • Mixer • Membranes • Screening

DESIGN AND SUPPLY OF SPARE PARTS THE WATER TREATMENT SPECIALISTS For this and other Degrémont water treatment plant equipment, contact George van der Merwe, Technical mngr | george.van.der.merwe@degremont.co.za Mornay de Vos, Business Development Manager | mornay.de.vos@degremont.co.za

Tel: +27 (0) 11 807 1983

Fax: +27 (0)10 591 5095

www.degremont.co.za

MUNICIPAL FOCUS

teacher support materials programmes, collectively benefitting more than 1.754 million children. Another milestone that aided the province during its 2012/13 financial year was the establishment of the Centralised Project Management Unit (CPMU) – thereby fast-tracking infrastructure delivery. At the end of February 2013, the total provincial infrastructure spend for the 2012/13 year end was R5.4 billion – a huge 73.5% of the Eastern Cape’s budget. The massive infrastructure spend was based on intensifying basic ser vice deliver y while simultaneously pumping job creation. The 2013/14 budget also prioritises infrastructure, broken down as follows: • R715.1 million – Department of Spor ts, Recreation, Ar ts and Culture (R2.3 billion over the Medium-Term Expenditure Framework (MTEF)) • R69.9 million – Department of Safety and Liaison (R218.2 million over the MTEF) • R840.8 million – Department of Local Government and Traditional Affairs (R2.5 billion over the MTEF) • R16.5 billion – Department of Health (R51.8 billion over the MTEF) • R26.9 billion – Department of Education (R85.8 billion over the MTEF) • R2 billion – Depar tment of Social Development (R6.3 billion over the MTEF) • R3.6 billion – Department of Roads and Public Works (R11.3 billion over the MTEF) • R1.7 billion – Depar tment of Rural Development and Agrarian Reform (R5.3 billion over the MTEF) • R1 billion – Department of Economic Development, Environmental Affairs and Tourism (R3 billion over the MTEF)

• R1.5 billion – Department of Transport (R4.7 billion over the MTEF) • R2.8 billion – Depar tment of Human Settlements (R6.1 billion over the MTEF). National government adopted a National Infrastructure Plan last year, with the aim of transforming the country’s economy, creating new jobs and delivering on basic services such as housing, and water and sanitation. To see this plan come to fruition, government will, over the next three years, invest R827 billion into construction and renovating existing infrastructure throughout South

• SIP 8 (Green energy in support of the South African economy): sustainable green initiatives on a national scale and the support of biofuel production facilities • SIP 15 (Expanding access to communication technology): provision of broadband coverage to households by 2020, ICT infrastructure plan and school roll-out focus • SIP 18 (Water and sanitation infrastructure): 10-year plan to address the estimated backlog of water supply and basic sanitation, including the provision of new infrastructure, rehabilitation of existing infrastructure and the improvement of water management. With the fastest growing IDZs and the huge revenue being generated from the automotive and equipment component sector, the Eastern Cape is playing an even bigger role in the national economy than we give it credit for. Judging from the money being invested into the province and the progress that has been made to date, it’s clear that the province is fast becoming the business hub of choice!

The Eastern Cape is playing an even bigger role in the national economy than we give it credit for Africa. The objective is to improve access to health care, schools, water and sanitation, housing and electrification. Under the guidance of the Presidential Infrastructure Coordinating Committee, 18 strategic integrated projects (SIPs) were developed. The following are a few examples of projects that will directly benefit the Eastern Cape: • Phase I of the Nooitgedagt Water Scheme, which provides water from the Gariep Dam through the Orange-Fish-Sundays transfer scheme • SIP 3 (South-Eastern node and corridor development): N2 Wild Coast access into KwaZulu-Natal • manganese rail capacity from Port Elizabeth to the Northern Cape • manganese smelter • possible Mthombo refinery (Coega) • trans-shipment hub at the Port of Ngqura, and port and rail upgrades

Acknowledgement *Special thanks to the Eastern Cape Development Corporation for permission to use their success stories Sources: Contractors Director y, Nelson Mandela Bay Technology online, Media Club South Africa, SA Good News, Eastern Cape Business, Blue Crane Development Agency, Eastern Cape Development Corporation, East London IDZ online, Coega IDZ online, Nelson Mandela Bay online, Get News, Department of Water Affairs and Forestr y, National Government, South African Institute of Civil Engineering Contractors.

TABLE 4

Eastern Cape's ICT initiatives Fibre-to-the-premises

A type of network architecture where fibre-optic cable is run into a client’s premises, as opposed to the use of copper. Detailed strategy has been developed for the implementation of wireless and fibre-to-thepremises broadband.

e-Government Programme

Launched in 2008, the programme has raised the standards of services within municipalities through electronic efficiencies.

Computerised libraries

Full computerisation of six community libraries – equipped with office packages and public internet and e-mail facilities. Municipal departments are also connected with 100 MB wireless networks, which are more efficient and cost effective.

Traffic control system

New traffic signals and CCTV screens and cameras, which will form the core of the public transport system up to 2020.

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PROFILE

THE NELSON MANDELA BAY MUNICIPALITY

Sustainable water and sewage treatment The Nelson Mandela Bay Municipality (NMBM), South Africa’s sixth largest metro, is a vital economic hub and tourism destination for the Eastern Cape, therefore infrastructure construction and maintenance is critical. The municipality is currently engaged in an extensive refurbishment and upgrade programme of its water and wastewater treatment works.

HE ULTIMATE aim of this project is to provide sustainable highquality drinking water and maintain treated effluent discharge compliance, thereby upholding the health and safety of the citizens of the NMBM and their environment. The 2012 Blue and Green Drop reports were good indicators that the NMBM is achieving results in water delivery and sewerage service consistent with leading municipalities in the country. The development, maintenance and rehabilitation of water services infrastructure is extremely capital intensive. To optimise the performance of these assets, the NMBM requested that all appointed consultants prepare upgrade requirements suppor ted by detailed designs to achieve the required outcomes.

supply reser voirs from where it is then distributed to distribution reservoirs and consumers. This system provides water to the western areas of the metro. • Eastern System: The Eastern System receives water transferred from the Gariep Dam located on the Orange River via the Orange-Fish transfer system. The raw water is treated at Nooitgedagt WTW from where it is pumped to Grassridge Reservoir and then gravitates to a number of distribution reservoirs. • Secondary System: The Secondar y System consists of the older dams on the Sand, Bulk, Van Stadens and KwaZunga rivers and the Uitenhage groundwater aquifer, all of which are owned by the NMBM. The raw water is treated at Linton, Groendal and Springs WTWs.

Background to the water services The Algoa Water Supply System feeding the NMBM comprises of three components: • Western System: Churchill and Elandsjagt water treatment works (WTWs) are supplied water from the Kromme River (Churchill and Impofu Dams). The treated water is then conveyed via a series of pipelines and pump stations to a number of bulk

Background to the sewage services The NMBM maintains a sewerage network consisting of approximately 3 400 km reticulation and bulk sewers. The metro is divided into 13 drainage sub-catchments, which discharge to nine wastewater treatment works (WWTWs). The current cumulative flow to all the WWTWs is approximately 175 Mℓ/d. The consistent growth in the metro (2 to 3% per annum) necessitates continuous refurbishment and upgrading of all municipal WWTWs in order to treat raw sewage effectively and produce good quality final effluent that conforms to legal requirements and Department of Water Affairs (DWA) standards.

TOP Elandsjagt WTW, with the Impofu Dam in the background MIDDLE Churchill WTW filter gallery LEFT Automated lime feeders with saturation tanks at Loerie WTW

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PROFILE

ABOVE View from filter gallery towards newly roofed pulsator clarifiers (2009) at Nooitgedagt WTW ABOVE RIGHT Self-cleaning strainer to replace manually operated strainer (2013) at Nooitgedagt WTW

Planned improvements: Loerie WTW Loerie WTW was commissioned in 1968. The works has a design capacity of 100 Mℓ/d but operates with an average treated volume of 63 Mℓ/d, which is based on the NMBM water allocation from the Kouga Water Scheme. Refurbishment and upgrading of the Loerie WTW commenced in 2005 and the phases completed include replacement of outdated switchgear. A R6.5 million phase was completed in June 2007, which comprised replacement of variable speed drives, supply of new 6.6 kV switchgear including starters for the final water pumps, and new motor control centres and raw water pumps. The R4.6 million replacement of clarifier bridges and drives was completed in March 2007 and a R2.9 million phase was completed in June 2008. A R53 million contract for civil, mechanical and electrical upgrades of the entire chemical handling, storage, dosing and chemical feed system (lime, PAC, bentonite and chlorine) – inclusive of SCADA, filter backwash water and clarifier sludge effluent recovery systems, new backwash pumps and blowers, bulk chemical storage silos, modified water supplies, dosing points and new final water delivery manifold – commenced in 2008 with completion scheduled for the end of 2013. A further contract for the design, supply, delivery and installation of mechanical and electrical equipment for the rehabilitation of the 12 rapid gravity sand filters, worth R9.6 million, was completed in June 2008. An R11 million

contract for essential repairs and additions to civil, mechanical and electrical works is in construction phase and due for completion in 2014, with the last contract (R12 million) for the final architectural building upgrades and repairs on completion of all the previous works planned for 2014/15. This programme of upgrading works at the Loerie WTW resulted in a 45-year-old plant being improved to a state-of-the-art works supplying the metro of NMBM with quality water.

Churchill Water Treatment Works This 100 Mℓ/d WTW has been in service for over six decades and is currently experiencing several operational challenges and bottlenecks, mostly due to outdated operating methods and ageing equipment. Raw water is abstracted from a multiple arch dam and conveyed to the treatment works via a canal and pipeline. The main processes are chemical dosing, five clariflocculators and 15 candy tanks, 20 gravity sand filters, sludge thickening and disinfection. The upgrading of the Churchill WTW is, at present, being phased in with a number of contracts with Contract 1: Raw Water Pump station (R24.39 million) currently under construction with expected completion set for mid-2014. Other contracts are Contract 2: Chemical Dosing Facilities, Electrical Instrumentation and Control, and Raw Water Flow Control (R26.128 million), to be completed in 2015; Contract 3: Roads (R22.106 million) for 2016; Contract 4: Filtration (R38.595 million) for 2017; and Contract 5: Clariflocculators + Penstocks, Flocculation Blanket Clarifiers, Sludge Handling, Water Storage & Delivery Tunnel, Buildings (R27.765 million) for 2018. Except for Contract 1, the other contracts are in planning phase.

Elandsjagt Water Treatment Works The treatment works was designed to treat a flow of 105 Mℓ/d, and was commissioned in November 1984, together with the Impofu Dam. The main process units are the chemical dosing facilities, a bank of 16 flocculation blanket clarifiers (FBCs), 12 rapid gravity sand filters, and disinfection and stabilisation facilities. During 2010, a 35 Mℓ/d flocculation and sedimentation facility was completed, to operate in parallel with the FBCs. At the same time, a contract was completed for mechanical and electrical work, which included new chemical dosing systems throughout the plant including chlorine dosing facilities, general modernisation and automation of the entire treatment works, and provision of state-of-theart HMI and SCADA systems. Additional upgrading planned includes structural repairs to the existing rapid gravity sand filters, refurbishment of the filter valves and actuation systems, provision of instrumentation to monitor and control filtered water quality, and upgrading of the filter control system. It is anticipated that the contract will be awarded in October 2013 at a cost of approximately R30 million. The existing raw water pumps will be replaced and the pipework in the raw water pump station will be refurbished. The new pumps will be equipped with variable speed drives to allow the flow to be controlled to match the delivery requirements of the plant. It is anticipated that the contract will be awarded towards the end of 2013 at a cost of approximately R45 million, and with a construction period of approximately two years. ▶

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PROFILE

Nooitgedagt Water Treatment Works The first phase of 70 Mℓ/d was commissioned in 1992 at the end of a fouryear drought period. Treatment consists of chemical dosing (flocculants only) followed by flocculation, clarification (pulsators fitted with lamella plate settlers), rapid gravity sand filtration and disinfection (chlorine). Refurbishment and extensions to the WTW commenced in 2005 in a phased approach due to the limited funds available each year on the capital budget. A fourth final water pump unit (35 Mℓ/d x 1 000 kW motor) was added, an additional pulsator was built and equipped, and all pulsators were roofed to reduce algae development. A R450 million drought relief grant from National Treasury in 2010 enabled 40 km additional pipelines and a reservoir to be constructed as a “low level scheme” for additional capacity transfer to the metro. Additional sludge settling/drying facilities, an improved inlet control system and installation of a further 10 MVA 22/6.6kV transformer have been completed to date. Approximately R125 million has been invested in the works from 2005 up to present. The final R240 million of work will be done in the period 2014 to 2015 with the addition of six rapid gravity filters and a new low-level pump station (120 Mℓ/d) and from 2015 to 2016 with the addition of the third 70 Mℓ/d phase. Ultraviolet disinfection will be installed in combination with chlorination to improve the final water quality by reducing the chlorination by-products. The present design capacity of the works is 70 to 75 Mℓ/d and the average treated volume for 2012/13 is 72 Mℓ/d. The completed works will have a design capacity of 160 Mℓ/d, but could be operated under peak capacity of 210 Mℓ/d. The plant is key to the metro water supply and downtime must be minimised. Each phase will have cutting/breaking into previously constructed and operational filter and clarifier pipelines as well as delivery pipelines. This is a major operational and construction challenge as balancing storage capacity downstream is only 12 hours. The raw water quality is of such a nature that high disinfection chlorine demands are required, which developed some taste problems and the formation of chlorination byproducts. Included in the plant extensions are

IMIESA October 2013

2013. Feasibility, inception, design and construction of the refurbishment and upgrade of Linton WTW to accommodate future demand is expected to commence in 2014 at a cost of approximately R50 million.

ABOVE Water percolating at the eye at Springs WTW

treatment modifications such as UV treatment in combination with chlorination. Funding of the extended scheme has been a challenge as the increased treatment capacity was, in terms of the Water Master Plan, required by end 2013. This will now only materialise early in 2016 with increased risk onto depletion of balance of water resources.

Linton Water Treatment Works The Linton WTW is the oldest water treatment works in Port Elizabeth. It was constructed in 1934 and commissioned in 1936. It is supplied with water from the ‘older dams’, namely Sand River, Bulk River, Upper and Lower van Stadens. Several refurbishments have been implemented over the years. It receives raw water via a 450 mm diameter GRP through an in-line strainer and magnetic flowmeter before entering a flash mixer structure. From the flash mixer, the flow enters two horizontal flow sedimentation tanks with nine rows of four sectional hopper bottoms each, via an inlet structure that allows splitting of the flow to the two tanks. The water is then filtered in six rapid gravity sand filters and following chlorination, the treated water is stored in a 22.5 Mℓ service reservoir. The rest of the works comprises the filter house, chemical store, chlorine store and other ancillary facilities. The current design capacity is 20 Mℓ/d, but operates at an average capacity of 18 Mℓ d. Aged infrastructure and a change in the raw water quality led to a temporary decommissioning of the works. The current upgrade is to refurbish and modernise the existing infrastructure only. Linton has the lowest production costs of all Port Elizabeth’s water supply treatment works because there is minimal pumping involved both to and from the works. Remedial works and upgrades are in progress and are expected to be complete by end

Groendal Water Treatment Works The treatment process of the works consists of the raw water gravitating from the Groendal Dam to the raw water inlet channel where a booster pump station boosts the flow to 20 Mℓ/d. The process includes flashmixing where lime is added for pH correction and flocculation chemicals (PAC, Poly or Ferrifloc) added. The raw water then enters two horizontal flow sedimentation tanks where the floc is settled out and the clarified water then flows to the four rapid gravity sand filters. The final process is where the filtered water is disinfected by chlorination and final PH correction. The final water is gravitated to two reservoirs 4.5 and 13.5 Mℓ in capacity. The desludge water and filter backwash gravitates to a thickening basin and recycle water holding basin. The design capacity of the Groendal WTW is 20 Mℓ/d with the works operating at an average of between 10 and 12 Mℓ/d. During low dam levels, the raw water quality from the Groendal Dam deteriorates due to high levels of manganese. The use of Ferrifloc (ferric chloride) as the main flocculant under these conditions has proven to remove the manganese. Recently completed infrastructure upgrades include chemical dosing building, filters, chlorination room, blowers, desludging valves, flowmeter automation of the above works and provision of SCADA. The project cost amounted to R14 million. Planned infrastructure upgrades for 2014/15 and 2015/16 financial years include upgrade of the flocculation channels, sedimentation tanks, filter building extensions, sludge thickening tank, backwash tank, chlorination room, sludge ponds and access road. The cost to complete the above works is estimated at R16 million. Springs Water Treatment Works The Springs WTW, on the outskirts of Uitenhage, is the second smallest in the NMBM with a capacity of 6 Mℓ/d. This water source utilises naturally occurring spring water, which requires only pH stabilisation

PROFILE

and disinfection. The present configuration of the water treatment plant at Springs can be categorised into two components, namely the “eyes” of the spring and the water treatment plant. The eyes of the spring are situated approximately 450 m to the north of the water treatment plant. The plant itself consists of a lime dosing facility, a lime contact tank (not in use), a post-lime mixing tank, a chlorine dosing facility and a small office facility. On average, the plant treats 5.7 Mℓ/d. The current operational challenges at the plant are directly related to the antiquated equipment in use. Storage facilities for the lime stock are also limited and need improvement. The electricity supply to the plant is not always reliable and backup generators need to be installed. The access road is not properly maintained and access is made difficult due to overgrown vegetation and poor stormwater control. Remedial measures include construction of a post-lime settling basin, upgrading of the lime and chemical dosing equipment, rehabilitation and extension of the current chlorine dosing building, and construction of a by-pass pipe network with additional isolating valves along with modern pH, Mag Flow and residual chlorine meters. The access roads to the treatment works and to the “eyes” needs to be upgraded and the fencing around both these facilities replaced. To modernise the plant, a telemetry system is also proposed so that the plant’s performance can be monitored remotely. The estimated cost to complete the rehabilitation of this plant is in the region of R4.5 million.

Rocklands Treatment Works Rocklands is the smallest WTW with a capacity of 0.50 Mℓ/d. The works was commissioned in 2006 and no improvements are required. Sewage works upgrades: Fishwater Flats WWTW Fishwater Flats WWTW is a conventional activated sludge treatment works originally commissioned in 1976 to treat 80 Mℓ/d of domestic sewage and 32 Mℓ/d of industrial wastewater. In 1997, additional capacity of 20 Mℓ/d was added to increase the capacity of the industrial stream to 52 Mℓ/d. The current upgrade is to increase capacity from 132 to 155 Mℓ/d through the inclusion of membrane bioreactors, improving sludge handling facilities and the construction of energy recovery facilities. Due to changes in the quality and quantity of incoming flows, limited sludge treatment capacity, the overall age of the plant and the fact that the existing inlet works is reaching the end of its design life, it is currently a constant challenge to meet the licensed/ permitted final effluent quality compliance at Fishwater Flats WWTW. Improvements to the works have commenced and are expected to cost about R1.2 billion. The first phase commenced in March 2013 with the construction of a new inlet works (±R160 million). Currently, less than 1 Mℓ/d of treated effluent is commercially recycled. This is due to limited capacity and ageing infrastructure, which cannot meet the demand. It is expected that in future 30 to 60 Mℓ/d of reclaimed effluent will be supplied to the Coega Industrial

The NMBM maintains a sewerage network consisting of approximately 3 400 km reticulation and bulk sewers

Cape Recife WWTW

Development Zone and other industries. At the moment, sludge produced during treatment processes is thickened, stabilised and dewatered using heat treatment and centrifuges. The dried sludge is then used for brick making. The current heat treatment plant has reached the end of its design life and will be replaced by a new sludge treatment system. Once the sludge treatment system is upgraded, it is proposed that an energy recovery plant be built to generate electricity from newly constructed anaerobic sludge digesters. Additional uses of treated sludge will be informed by a plant-specific feasibility study.

Cape Recife WWTW The Cape Recife WWTW was commissioned in 1972. It receives sewage through the Lower Baakens Catchment with a drainage area of approximately 4 121 ha, including approximately 18 800 residential erven. The current works has a design capacity of 8.5 Mℓ/d. The plant obtained a Green Drop score of 82.6% in 2011, an improvement from the 71% awarded in 2009. While the WWTW is currently operating at its design capacity during dry weather conditions, the works lacks capacity to handle high wet weather peak flows. This results in a washout of bacteria and organisms. The capacity of the works will be increased to approximately 18 Mℓ/d during the planned medium-term interventions through the provision of larger clarifiers and aeration basins. The current extended aeration process will then be changed to a three-stage Phoredox process. Driftsands WWTW The Driftsands WWTW was commissioned in 1985. The existing works consists of the inlet works comprising mechanical screening and grit trap units, two oxidation ditch type extended aeration activated sludge units, sludge recycle and wasting pump stations, four circular clarifiers, a chlorine disinfection plant, two gravity thickeners and eight sludge drying beds. Mechanical dewatering and composting plants form part of the works, but is currently non-operational. The works capacity is in the process of being extended by adding the following treatment facilities: two new mechanical screens and a new grit trap unit at the inlet works, a nutrient removal activated sludge works equipped with surface aerators and recycling pump stations, two new clarifiers, extension of the chlorine facility and recommissioning of the dewatering facility. ▶

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PROFILE

ABOVE Aerial photograph of the Despatch WWTW

The historic design capacity of the oxidation ditches is 12 Mℓ/d. The extended section of the works, to be commissioned in October 2013, has a treatment capacity of 10 Mℓ/d and will increase total capacity to 22 Mℓ/d. Spatial development frameworks project that ultimately the works would have to be capable of accommodating an average dry weather flow (ADWF) of 42 Mℓ/d. The hydraulic load to the two future modules shall be fed by a separate future inlet works designed to handle a total ADWF of 20 Mℓ/d. Therefore, in addition to the existing works capacity, a phased extension of the works consisting of two modules of 10 Mℓ/d each will be required. It is projected that the second module should be commissioned by 2018, followed by the third module in 2022. Preliminary indicative cost estimates for these units are in the region of R110 million and R140 million respectively.

Rocklands WWTW The Rocklands WWTW, commissioned in 2006, is a small package plant designed to treat 200 kℓ/d. There are no plans to upgrade the works in the short to medium term. Kelvin Jones WWTW The Kelvin Jones WWTW, commissioned in 1930, is an activated sludge plant designed with full capabilities for biological, phosphate and nitrate removal. The works is divided into two sections with the treatment components situated on the Kelvin Jones site and the sludge handling component situated

at Koedoeskloof, approximately 5 km away. Some components of the works are old (30 years plus) and in dire need of replacement. Currently, the plant consists of two modules with design capacities of 14 Mℓ/d (Module 1) and 10 Mℓ/d (Module 2) respectively, with a combined capacity of 24 Mℓ/d. The current flow to the WWTW is approximately 21 Mℓ/d. The inlet works and sludge handling system dates from the 1980s and poses huge challenges to operating staff with frequent flooding and scum spillages. The improvements, planned to start shortly, include a new screw pump station, and mechanical sludge and scum dewatering. This, together with replacing the existing aerators with bigger units, will increase the capacity of the works to 31 Mℓ/d. The plant has an existing capacity to provide 1 000 kℓ/d of treated effluent available for industrial use. The process consists of a sand filter, storage dam and a pump station. The NMBM is currently busy with major upgrading of this facility to boost supply available for recycling to more than 2 000 kℓ/d.

Kwanobuhle WWTW The Kwanobuhle WWTW was commissioned in 1980. Limited refurbishment and upgrading of the Kwanobuhle WWTW will commence in the 2013/14 financial year. Current planning is for the works to be decommissioned in the medium term, with all flow diverted to the Kelvin Jones WWTW. Despatch WWTW The Despatch WWTW was commissioned in 1971 and comprises of three separate plants, each of different vintage. The inlet works at the head splits flow to each plant. Flow records indicate that the average flow received is 3.8 Mℓ/d, with a maximum average of 5.7 Mℓ/d. The works has a design capacity of 8.86 Mℓ/d. A number of backlog maintenance challenges have been identified and eradication thereof has commenced with the award of a contract for general improvements at the works, which is currently under way and will

be complete by the end of 2013. The contract entails civil, electrical, control, mechanical and building upgrades, in order to improve the general operation, safety and functionality of the works. Flow-proportional chlorine dosing is done on final effluent, which is then temporarily stored in a 5 000 m3 pond, after which approximately 45% is discharged to the Swartkops River in terms of the Water Use Licence. The balance is pumped to a storage reservoir and used for irrigation. Refurbishment and upgrading of the works commenced in 2003 and is currently 36% complete at a cost of approximately R35 million. A contract to the value of R6.99 million is currently under way at the Despatch WWTW. This contract will provide all the minor improvements to general operation, functionality and safety. Additional work to the value of R50 million will commence in the next few years to improve the overall performance of the plant.

Level of service provided to consumers One of the ways to measure the performance of the NMBM regarding water and wastewater treatment is the Blue and Green Drop evaluation and scores achieved during the last assessment, done during 2011. The NMBM achieved a Blue Drop score of 90.04%, which is the second highest in the Eastern Cape, with a provincial average of 82.1% and a Green Drop score of 80.8%, again the second highest in the Eastern Cape, with a provincial average of 67.2%. Conclusion Upgrading of both the water and wastewater treatment works are informed by the needs of the community (domestic, commercial and industry) as captured in the Integrated Development Plan and spelled out in the respective master plans. In approximately five years, all the refurbishment and upgrading work at all the treatment works will be completed. All the treatment works will then be highly automated and modernised. The operations of all the treatment works will be within the parameters prescribed by legislation and monitored through the Blue and Green Drop compliance criteria. Mr B Martin: bmartin@mandelametro.gov.za t +27 (0)41 506 5435 • www.nelsonmandela.gov.za

IMIESA October 2013

PROFILE

SEEING IS BELIEVING

pipe surveying technology

31 -in-

A specialist in pipe inspections and condition assessments Wasteman Sight Lines, a division of Wasteman Holdings (Pty) Ltd, is proud of its new system, which combines sonar, laser and HD CCTV technology.

HIS 3-IN-1 system utilises sonar technology to take measurements below water, while the laser technology is applied in above-water applications. The HD CCTV is used as a visual representation of what is happening inside the pipeline. Its cutting-edge technology, coupled with years of expertise, makes the company a key player in the pipe inspection and cleaning sector in South Africa and across the continent. Renowned for its largest fleet of CCTV inspection vehicles in South Africa and a wide range of non-man entry equipment, Sight Lines is committed to sustainable development techniques. By using both the company’s CCTV software – SightView – and its pipe management software – PicData2000 – clients can view pipe data graphically on ArcView GIS, allowing for better network analysis. PicData2000 produces a detailed report per pipe on its defects and grading, pipe profile and digital images linked to all severe and critical incidents. In addition, the software is able to produce scaled pipe profiles using inclinometer data gathered electronically from the company’s pipe survey CCTV equipment and SightView software. Using in-house developed software enables Sight Lines to customise reporting to client specifications. The company acquired the new technology earlier this year and is currently busy with an 80 000 m project

for the City of Tshwane – the first of its kind in South Africa for both size and technology. The HD Profiler unit contains a camera, laser profiler and sonar. It is pulled through the sewer at speeds of up to 15 m per minute and can survey a pipeline up to 3 000 m long from a single access point. The unit stores all information on-board. Upon retrieval, the data is downloaded for analysis and preparation of the reports. Sight Lines believes that the HD Profiler represents an advancement in pipeline inspection and assessment of large diameter sewers. Benefits in using the integrated sonar, laser and HD CCTV equipment include: • measure and accurately quantify debris volume between two nodes • measure corrosion to millimetre accuracy • measure pipe size • measure flow level • measure deformation and lateral protrusion and other structural abnormalities • lifespan prediction based on measured material loss • no plugging and overpumping required, inspection is done during normal flow conditions • can do up to 3 000 m in one deployment • cost effective. BELOW LEFT A scaled 3D pipe profile showing corrosion on the crown and debris on invert BELOW Sight Lines’ latest pipe inspection technology combines sonar, laser and HD CCTV

The equipment is able to assess the condition of water-filled pipes such as: • outfall and collector sewers from 450 up to 3 000 mm ID • siphon pipelines • boreholes • water-filled cavity profiling • open channel culverts profiling. The company’s service offerings include: • CCTV pipe inspection, condition assessment and structural grading of diameters 45 to 1 800 mm and larger • internal pipe diameter laser measurements • comprehensive condition assessment under high-flow conditions using sonar • integrated sonar, laser and HD CCTV for 360-degree electronic measurements of large diameter pipelines • combination vacuum and high pressure pipeline cleaning • high pressure jet cleaning • bucket dredging • non-man entry void and cavity inspections • well, shaft and borehole inspections • industrial pipeline inspections using EX CCTV equipment • asset and infrastructure management • GIS mapping and GIS correction of buried infrastructure • locating buried infrastructure utilising combination CCTV and radiosonde • data collection for hydraulic modelling • manhole condition assessment.

t +27 (0)86 117 4448 • www.wasteman.co.za Claude Marais: cmarais@wasteman.co.za

IMIESA October 2013

IMESA NEWS

Northern Provinces AGM The IMESA Northern Provinces branch met on 30 August 2013 at the Lux Mundi Community Church in Garsfontein, Pretoria.

HE NORTHERN Provinces’ AGM and branch seminar was well attended by 71 guests and has, once again, proven to be a highlight on IMESA members’ annual agenda,” said Werner Bruhns, engineering consultant at the City of Tshwane and current chairman of IMESA’s Northern Provinces branch. “On behalf of the branch, we would like to express our gratitude to our sponsor for the day: VOMM (manufacturer of sludge drying technology) and Techso Smart Solutions. We also like to thank all members who attended, especially our presenters who left the audience with interesting food for thought.” First on the agenda was Hilton Vorster, director of traffic engineering at the City of Tshwane’s Transport Department. Vorster provided worrying statistics about South African road safety and made a pledge to the audience to consider engineering interventions as one of the most critical elements of ensuring safer roads in the country. In his presentation ‘Designing for Safety – Important aspects to consider’, Vorster highlighted World Health Organisation (WHO) statistics, saying that although 88 countries have reduced their road traffic deaths, the global total of 1.24 million remains unacceptably high. More disconcerting is the fact that half of all recorded traffic deaths are pedestrians, cyclists and motorcyclists. “Progress has been made in high-income countries; however, the greatest need lies with low- and medium-income countries with small budgets and unacceptably high road death tolls remain,” explained Vorster.

IMIESA October 2013

According to the WHO Global Status Report on Road Safety 2013 quoted by Vorster, Africa has the highest road traffic death rate of all continents, mainly as a result of rapid motorisation. “If you look at road deaths in Africa, South Africa is not doing well; we are the second highest killer of people in Africa, with 33 fatalities per 100 000 – only slightly lower than Nigeria”. Vorster emphasised that traffic engineers should make allowances that help to compensate for human error. “Roads and roadsides must be built in such a way that their physical characteristics minimise potential harmful consequences to all,” was one of his central messages. The presentation that followed Vorster’s was given by Bavusile Ramekane from the same municipal department in the City of Tshwane. Ramekane is deputy director of traffic engineering and gave a historical perspective on the usage and uptake of non-motorised transport (NMT) in the city. Ramekane provided information about Tshwane’s Shova Kalula project, a partnership between the city, the national Department of Transport (DOT) and the Gauteng Department (front) Hilton Vorster, director traffic engineering at the City of Tshwane; Bavusile Ramekane, deputy director traffic engineering; Dikgole Seroka, managing director of Seroka Consulting Engineers; and Battista Errera, MD of VOMM SA (back) Werner Bruhns, current chairman of IMESA’s Northern Provinces branch, and Moses Maliba, former IMESA president

of Roads and Transport (GDRT). The programme comprises the provision of bicycles by the DOT and the GDRT, while the City of Tshwane provides infrastructure and training. The third presentation was delivered by former IMESA president Moses Maliba on the training of candidates for registration as professionals in municipal engineering. Maliba highlighted the several challenges associated with the registration of professional engineers and, from IMESA’s perspective, provided guidance on the professional registration process. Other interesting presentations included that of Louis Marais and Lizette Retief, consultants from Techso Smart Solutions, about a needs analysis of the Matroosberg and Garsfontein roads. The presentation highlighted how technological innovation could enhance traffic use modelling patterns. Dr Jeremy Gibberd, prominent environmental and green building researcher at the CSIR, presented a presentation on green building by-laws at the City of Tshwane. According to Gibberd, it is critical for city engineers to create cooler micro-climates through infrastructure by designing cooler cities, without using more energy. He shared some of the City of Tshwane’s green building by-laws, followed by examples of innovations that can used to achieve environmentally sound buildings, including water-neutral buildings. Other presentations included that of Dikgole Seroka, managing director of Seroka Consulting Engineers and Project Managers, about support to Rapid Response Units at water service authorities. Moses Maliba gave a second presentation on IMESA’s infrastructure management system (IIMS), which was followed by a presentation by VOMM South Africa’s managing director, Battista Errera, who focused on municipal sludge management and prevailing trends in the EU. In high spirits, the chairman closed off the presentations with a lucky draw, after which the IMESA AGM was held. “All presentations have been of outstanding quality, and we hope that branch members will take some of the concepts into their workplaces to continue striving for excellence in municipal engineering,” Bruhns concluded.

AFRICA ROUND-UP

INFRASTRUCTURE NEWS FROM AROUND THE CONTINENT ANGOLA THE DEPUTY governor for Social and Productive Affairs of Luanda province, Judith Pereira, has called for better coordination between districts, municipalities and technical departments following a site visit to infrastructure projects in Maianga, Rangel and Kilamba Kiaxi. Public works she visited included the construction and rehabilitation of schools, public administration buildings and road levelling projects. Lack of proper coordination between these bodies has led to an untenable situation in which a single contractor was awarded five projects simultaneously, leading to delays and a failure to meet deadlines. The minister emphasised the duty of municipalities to submit all projects to the provincial commission prior to making any awards. Pereira noted that a better distribution of awards, spread across several companies, was good indicator for fair and transparent tender processes.

MOZAMBIQUE THE COUNTRY’S Minister of Public Works, Cadmiel Muthemba, recently launched the construction of a factory that will produce asphalt in the city of Beira. The US$5 million (R50.3 million) factory will produce 300 t of asphalt a day, of which 30% will be for the export market. The plant will be run by local company Betumemulsao Mocambique, which has

IMIESA October 2013

scheduled 90 days for construction, with product on the market by January 2014. Located within the boundaries of Port Beira, raw materials will be transported along a short pipeline. The main application of the asphalt will be in the building of roads – a priority infrastructure for the country. The investors hope to build similar units in the other main ports, Maputo and Nacala.

NIGERIA THE NIGERIAN Institute of Building (NIOB) has reiterated its call for the establishment of a Building Industr y Development Board, which it obser ved is long overdue. The institute, in a communiqué at the end of its 43rd AGM and conference, held in Abuja, noted that an industry development board, when established, will coordinate and promote the development of industry standards, productivity measures and relationship between stakeholders in the industry, among others. In order to stem the tide of building collapse in the country, there was a need for all public and private sector clients to ensure that contractors handling building projects engage the services of registered builders to handle the management of sites as well as supervision of craftsman and artisans as stipulated in the National Building Code (2006). Emphasising the contribution made by the building industry to economic development, job creation and gross domestic

product, the NIOB called on both public and private sector clients to adequately fund housing projects to ensure this contribution was sustainable. The institute cited flaws in the public procurement system – and the abuse thereof – as a great threat to the industry and key reason for the rising costs of building projects. It therefore called on the federal government to review the system of registration of contractors to protect small- and medium-sized firms and promote national development.

TANZANIA TANZANIA RECENTLY held its 11th Annual Engineers’ Day, which was celebrated at a multi-sectoral exhibition in Dar es Salaam. A theme that emerged clearly during the course of the event was the impact of the harmful practice of putting cost above quality. Selecting materials and equipment based on the sole criteria of cost was putting the industr y in jeopardy, both in terms of safety, sustainability and reputation. A major concern has been the use of substandard wiring used in electrification and a cautionar y message predicting serious faults for the next years is concerning. Despite consumer pressure to choose cheaper options without consideration to quality and safety, it is up to engineers to maintain standards according to institutional frameworks. Tanzania has a number of bodies geared towards this aim, including the Association

of Consulting Engineers Tanzania and the Institution of Engineers Tanzania. The Engineers Registration Board chairman, Prof Ninatubu Lema, said that the board had powers to penalise engineers who failed to meet standards as well as overseeing matters related to competency in the industr y. “We have agreed that all registered engineers should take an oath committing them to abide with codes of conduct, but we should also go an extra mile in ensuring that we have a board in place that will oversee issues related to competence and also impose sanctions and punishments in case of misconduct.”

ZIMBABWE THE DIRECTOR of Harare Water, Engineer Christopher Zvobgo, has confirmed the completion of the refurbishment of the Morton Jaffray Water Treatment Plant’s pumps and valves, going a long way to solving the city’s water distribution problems. “We have finished the maintenance works on our pumps and valves that were leaking at the Morton Jaffray Water Treatment Plant.” Harare residents – mainly those in high-density suburbs – were experiencing perennial water shortages, which the council blamed on machine breakdowns, leaking pipes and the growing population. Occasional major pipe bursts saw residents fetching water from unprotected sources, which

AFRICA ROUND-UP

posed a serious health risk. The complete refurbishment of the Morton Jaffray Water Treatment Plant is expected to start next month and should mark the end of water problems facing Harare. The Harare City Council secured a US$144 million (R1.42 billion) loan from the Chinese Export-Import Bank to facilitate the project and has already acquired materials for the refurbishment of the 60-year-old plant that is delivering barely two thirds of its full capacity.

NIGERIA INDEPENDENT POWER firm Bresson A.S has revealed plans to invest an additional US$90 million (R889.22 million) for the construction of independent power plants in the countr y. It has already invested about US$10 million in the power sector. During a meeting in Abuja with the Minister of Power, Prof Chinedu Nebo, the chairman of Bresson AS Nigeria, Gbenga Toyosi Olawepo, said that government had made tremendous progress in the implementation of the Electricity Sector Reform programme with the successful privatisation of some distribution and generation companies. He noted that investment in that sector had become viable and the business environment had also been made friendly since the reforms began. According to Olawepo, if the current momentum was sustained, power outages could become a thing of the past in the countr y in the next five years. “The reform rests on two legs: privatisation of the operations

IMIESA October 2013

of existing companies and the promotion of independent power generation through greenfield independent power producers (IPPs). We need to see more support for the IPPs to come on stream. They are the ones that are bringing additional capacities,” he noted. Viable private sector investment in the electricity generation sector hinges on a conducive regulatory environment, including realistic tariff setting, credible off-takers and a reliable supply chain. Neither complete free market practice nor monopolisation are proving sustainable, and a strategic blend is difficult to achieve. Projects such as this one need to be tracked and assessed as examples to other countries in Africa struggling to create viable energy markets.

presidents for creating the window of opportunity for the business community to interact on ways to improve trade between the two countries. Dangote said that Kenya would assist Nigeria in boosting a sector where it has comparative advantages such as tourism and hospitality, horticulture, dair y, sugar and ICT. In reciprocation, Nigeria would assist Kenya in the oil and gas sector, movie and entertainment industr y, agriculture and banking sectors. Presidents Jonathan and Kenyatta assured the forum of the political will of their respective administration to support the initiative to a beneficial end.

LIBERIA KENYA THE DANGOTE Group is to invest US$400 million (R3.95 billion) in cement production in Kenya over the next two years. Group chairman Aliko Dangote announced this at the Nigeria-Kenya Business Forum held in Nairobi recently. The forum was jointly presided over by President Goodluck Jonathan and his Kenyan counterpart, President Uhuru Kenyatta. The business forum attracted more than 500 investors from Nigeria and Kenya. In his remarks, Dangote, who ser ved as the chairman of the dialogue group, said the forum underscored the need for Africans to look inward for partnership in trade and investments. He said the forum decried the situation where intra trade on the continent accounted for less than 12%. Dangote thanked both

THE GOVERNMENT of Liberia has signed a US$64 million (R636.29 million) loan with the African Development Bank (AfDB) for the commencement of the first phase of the pavement of the Fish Town to Harper highway. The first phase of the project will be the paving of about 50 km of the 125 km Fish Town-Harper road project. Finance minister Amara Konneh disclosed that the agreement will bring development to the historically marginalised south-eastern region, as well as facilitate commerce that will eventually boost national economy. The road project will also improve access to health centres and schools as well as create employment opportunities for close to five hundred Liberians and will help train Liberian engineers for the maintenance of roads around the countr y. The government is working with development

partners, including the AfDB, to mobilise resources to complete the entire stretch of road from Harper to Ganta. The project will also see the construction of a bridge eventually on the Cavalla River linking to San Pedro in Ivor y Coast. Funding is being raised through loans from the AfDB and the Nigeria Trust Fund, as well as Fragile States Grant, including the US$1 million contribution by the Liberian government, and will be implemented by the Ministr y of Public Works.

GAMBIA GUNJUR’S VILLAGE Development Committee (VDC) has embarked on a massive road rehabilitation exercise as part of an effort to ease traffic for pedestrians and vehicles. The managing director of the National Road Authority (NRA), Dodou Senghore, said the VDC initiated the project by detailing the scope and specification in a formal proposal. The NRA then provided technical assistance to the VDC and would continue to support it in further rehabilitation of its roads. The chairman of the VDC, Demba Jobe Touray, said it was ver y difficult for people and vehicles to pass through the village, which was why the VDC decided to use sandbags to rehabilitate the road temporarily. He further stated that they had also embarked on massive mangrove planting exercises at the Gunjur Bolong Fenyotoo in order to avoid sea erosion. He also revealed that they are planning to improve the facilities at the Gunjur Health Centre with more medicines and an ambulance.

KENZAM BITUMEN AND ASPHALT PRODUCTS Sourcing and supplying bituminous products in South Africa and beyond

KENZAM EQUIPMENT Supplying on-site storage and equipment for bituminous products

S A B I T A

SOUTH AFRICAN

BITUMEN BITU ASSOCIATION ASSO

LTS BULK Specialist list transporters of bitumen safely and cleanly anywhere in SADC

ADVERTORIAL

KENZAM BITUMEN AND ASPHALT PRODUCTS

Logistics and equipment to Africa Kenzam is a bitumen trading and logistical specialist supplying bituminous products to road contractors in South Africa, Mozambique, Malawi, Zimbabwe, Zambia, Botswana, the Democratic Republic of the Congo, Lesotho, Swaziland and Namibia.

ENZAM MEETS the challenges of obtaining, transporting and storing bituminous products to customers in the SADC region. The company provides bituminous product in the most costeffective mode to all parts of the SADC region, including areas that are challenging to get to. It also supplies drum decanters and heated static storage equipment on-site for its customers’ convenience.

Specifically, Kenzam supplies in all available modes, including Bulk Road Tanker, Drums by Road, Drums by Sea and Bitutainer. The company has a fleet of some 50 mobile and static storage tanks totalling approximately 2 500 t in capacity.

How Kenzam operates Bituminous products are black, sticky and easy to lose control over; these products are temperature sensitive and are notoriously difficult to handle Kenzam supplies the following products to and manage. Kenzam is able the road building industry to deliver hot bitumen to site All recognised penetration grade bitumen ready for use. Kenzam’s personnel have many years’ expeCut-back bitumen Polymer modified bitumen rience in all aspects of the asphalt, spray and chip, and Bitumen emulsions Aggregate prethe general surfacing industry coating products in South Africa. The company is Anti-stripping agents Burner fuels able to assist in troubleshooting on contacts where surfacing Kenzam sources and sells the following issues are causing problems for bitumen related equipment site management. Drum decanters Emulsion plants The company is able to source most equipment for the use in Bitumen pump units Mobile and static bitumen bitumen applications such as: storage tanks • asphalt plants Solid state diesel Bitumen hoses and most • pavers burners ancillary equipment • rollers • chip spreaders • bitumen distributors • hand sprayers.

t +27 (0)11 742 1073 • www.kenzam.co.za

IMIESA October 2013

ADVERTORIAL

LTS BULK

More than just transport LTS Bulk owns and operates a fleet of bitumen road rankers distributing bituminous products throughout Southern Africa, loading from refineries in Durban, Sasolburg and Cape Town.

TS BULK was established in 1987 and while keeping its focus on its core services, the complexity of bituminous products has dictated that the company has moved to extend its expertise to encompass a more complete service.

The LTS Bulk service LTS Bulk loads bitumen at all refineries as well as modifying and emulsifying plants in South Africa and delivers it safely to site within the SADC region ready to use. It supplies and delivers appropriate equipment and static storage units for use on-site. Handle with care A derivative of petroleum, bitumen is a viscous liquid or a solid, depending on its temperature, used mainly in the road surfacing industry and consists of hydrocarbons

and their derivatives. It softens gradually when heated, is black or brown in colour and possesses waterproofing and adhesive properties. Although bitumen has a low potential hazard when at ambient temperature, it can present some dangers when hot. Correct handling and transport of bituminous products therefore requires skills, knowledge and experience to achieve optimum safety standards and negate mistakes that can lead to environmental harm, not to mention the negative impact on people and budgets. LTS Bulk is a leader in the field of the transportation of bituminous products. Beyond being a transport company, the company is considered an expert in this field and offers a complete service that includes sourcing product, equipment and in-situ handling, storage and application.

LTS Bulk offers the following Products Mobile bitumen tanks

Static bitumen tanks

Solid state diesel burners

Bitumen hoses and most ancillary equipment

Additional services (by arrangement) Asphalt mixes

Seal designs

Set up of asphalt plants

Calibration of asphalt plants

Testing of emulsions

Testing of bitumen

Multiple options LTS Bulk can supply bitumen storage tanks on a rental basis and has a total of about 2 500 t of on-site storage in various different tank configurations, as well as bitumen pumps and ancillar y equipment. The company can also provide expertise and assistance in setting up and calibration of asphalt plants if

necessary, together with specialised testing of emulsions and bitumen.

Bitumen where you need it, when you need it and how you need it LTS Bulk distributes to sites both locally and across the border to Mozambique, Malawi, Zimbabwe, Zambia, Botswana, the Democratic Republic of the Congo, Lesotho, Swaziland and Namibia. Given the variation in geographic conditions, the company can arrange seal designs and asphalt mix designs by accredited laboratories in South Africa.

t +27 (0)11 742 1073 â€˘ www.ltsbulk.co.za

IMIESA October 2013

SABITA

A GLOBAL APPROACH TO EXCELLENCE

Foundations for social The global drive to develop and maintain a culture of sustainability in production processes has dictated a paradigm shift in emphasis and approach that has, in recent years, completely redefined the way in which global industry conducts business.

HIS IS ESPECIALLY true of bituminous products and road construction sectors, which bear the responsibility for creating an infrastructural matrix linking the services, communities and commerce on which the political, economic and social viability of a nation depends. An exponential increase in the volumes of heavy vehicles on South Africa’s roads, coinciding with demands for cost-effective road provision and the conservation of resources, has dictated the development and implementation of best practice technology, sustainable resource utilisation and global standards of occupational health, safety and environmental conservation. In pursuit of these objectives, the Southern African Bitumen Association (Sabita) has spearheaded the following notable developments:

Technology High modulus asphalt: A 2008 Sabita research programme to develop guidelines and

specifications for high modulus asphalt (HiMA) – a technology that combines superior deformation resistance with high structural stiffness and good fatigue performance – came of age in 2013. Repeated assessments of a HiMA trial section on the South Coast Road leading into Durban harbour, over a 20-month period, reported excellent performance and superior load-spreading characteristics. Sabita has now published a guideline that will enable the wider application of this technology on South Africa’s road network. “The results of this trial gives rise to optimism that HiMA presents a premium solution for road sections carrying concentrated, extremely heavy traffic in excess of 50 million ESALS [equivalent single axle load],” says Saied Solomons, Sabita’s CEO. Warm mix asphalt/recycled asphalt: After four years of trial, development and testing, warm mix asphalt (WMA) has been integrated into the arsenal of road construction technologies and in many cases has replaced hot

mix asphalt (HMA) as the preferred option. Manufactured and applied at temperatures 20 to 50°C below that of HMA, WMA is characterised by significant reductions in fuel consumption, greenhouse gas emissions and worker discomfort. WMA technology has also, with the addition of certain additives, made it possible to extend both the ‘compaction window’ (the period during which asphalt can be compacted to client specifications) and the viable transport times and distances between plant and paving. Incorporated into paving mixtures, recycled asphalt (RA) has been shown to have significant environmental, economic and performance benefits, and Sabita is currently driving initiatives aimed at increasing its use in South Africa to further enhance the sustainability of road sector projects. Further technology developments include: • A Sabita project to update the technology associated with the use of bitumen rubber was undertaken after a study tour by industry practitioners to the US in 2011. Recommendations for the alignment of South African practice will be incorporated in Sabita’s Manual 19: Guidelines for the design, manufacture and construction of bitumen rubber asphalt wearing courses. • The translation of South Africa’s industrial grading system for bitumen to the now internationally accepted performance grading system. This process was given significant impetus at a workshop held at the University of Stellenbosch in November 2012 and will facilitate and enhance quality assurance of bituminous binders for paving applications. • The Sabita-sponsored revision of South Africa’s national asphalt mix design method.

The even distribution from the spray bar is constantly monitored

IMIESA October 2013

SABITA

and economic growth Sustainable practices Greenroads: First mooted for application in South Africa at the Conference on Asphalt Pavements for Southern Africa in 2011 (CAPSA’11), the Greenroads concept makes it possible to quantify the sustainable attributes of a roadway project. The system provides a sustainability accounting tool, manages and improves roadway sustainability and stimulates the market for sustainable practices and products. A South African version of the American Greenroads Manual will soon be a reality following the establishment of a Greenroads South African Interim Board, which Sabita forms apart of and is tasked with overseeing the formation of the Greenroads Council of South Africa, mandated to protect South Africa’s natural environment and preserve natural resources where these are affected by roads projects. Health, safety and environmental conservation (HSE): In the past five years, Sabita launched a number of initiatives aimed at entrenching a culture of worker health and safety in the bituminous products industry. These include: • the publication of Sabita’s HSE Charter, which commits members to implementing best practice HSE techniques in their operations • a certification scheme (BitCert) that, after auditing and recorder compliance with the Charter, leads to HSE certification, with notable benefits for accredited companies • an incident reporting scheme (Bitinrep), designed to record and analyse hazard or safety incidents to facilitate avoidance of future incidents • a train-the-trainer safety course (BitSafe) designed to prepare selected representatives to initiate safety training in their own companies • the publication of HSE guidelines, DVDs and other material designed to benchmark best practice HSE performance in South Africa • the creation of an annual Sabita HSE award, presented to individuals who have made great strides in integrating sound HSE practices in the workplace.

“Ensuring a constant flow of knowledgeable, learned and highly trained individuals begins with Sabita’s support for the Go for Gold (G4G) initiative, a programme that has mentored selected students through matriculation in preparation for tertiary education and, later, a career in the construction industry.” Further initiatives aimed at ensuring an ‘informed’ industry include: • the development and presentation of a Materials Tester Course (MTC) as well as course-specific modules at NQF Levels 2 to 4 • tertiary-level courses devised and presented by the South African Road Federation (SARF) on behalf of the Asphalt Academy • the CAPSA conference, held every four years is acknowledged as a world-class forum for the presentation and evaluation of cutting-edge technology. “Sabita also interacts and invests on a continuous basis with organisations, associations and political groupings that have a stakeholding in promoting a functioning, world-class road network,” Solomons

continues. “It is internationally accepted that an investment of US$1 (R9.95) in road infrastructure generates a US$3 growth in GDP, but in countries like South Africa, where limited funding encounters strong competition from those requiring housing, sanitation, schooling and health facilities, road provision is at times relegated to the back burner. However, through focused interaction at all tiers of government, and initiatives such as Sabita’s SALGA (South African Local Government Association) workshops, Sabita has made significant progress in ensuring that road infrastructure provision is appropriately prioritised.

RIGHT Adhesion between the bitumen binder and the aggregate is critical BELOW Aggregate that is well coated with bitumen

IMIESA October 2013

SABITA

BOASTING BITUMEN

Black gold Bitumen, also known as asphalt, boasts durability, sealant and adhesive qualities unlike any other naturally occurring construction material. And with sustainable development moving up the ranks, IMIESA looks at why this highly viscous liquid is fast becoming the product of choice, particularly for use in local and cross-border road applications.

BOUT 89% of South Africa’s freight is transported by road. The total network includes both proclaimed and unproclaimed roads, with the latter accounting for an estimated 140 000 km of roads that serve mostly rural areas. The maintenance costs, as one can imagine, are enormous, effectively ‘forcing’

measurements such as the South African National Roads Agency’s (Sanral) e-tolling system in an attempt to recuperate muchneeded funds for road rehabilitation. South Africa’s economic activity depends on Sanral’s ability to develop and expand road networks. “Indeed we are excited about the pending increase in the size of Sanral’s

TABLE 1

Major road projects completed by Bigen Africa

Location

Details

Soweto

Upgrade of the entire road network in less than five years at a cost of R600 million. Client: Johannesburg Roads Agency

Mpumalanga

Rehabilitation of the N11 between Ermelo and Hendrina as part of the Mpumalanga Coal Haul Network upgrading. Distance covered: 53 km

North West

Rehabilitation of the N14 between Delareyville and Sannieshof. Distance covered: 39 km

Limpopo

Construction of the 11 km Maandags Hoek access road, as part of the mines Social Labour Plan. Client: Modikwa Mine and Roads Agency Limpopo

IMIESA October 2013

Installing Kaytech’s GlasGrid over the milled surface at Klipfontein

network to more than 18 000 km, with the process in place to incorporate some 2 000 km of Eastern Cape roads,” said Nazir Alli, CEO of Sanral, in the company’s 2012 Annual Report. He further stated that Sanral would continue to explore technological advances that improve the safety of the roads. “We aim to deliver better roads with intelligent features in the fastest, most affordable, safest and environmentally friendly way possible. Technology is therefore essential to improving value for money and overall transport pricing,” Alli explained. An example of this is Sanral’s freeway management system in the Western Cape, KwaZulu-Natal and Gauteng, which has grown since 2006. The company is also responsible for funding various research projects. The largest project – a five-year study on revising the

SABITA

TABLE 2

International versus local road infrastructure costs Cost factor

Australia

South Africa

Construction costs (R millions/lane km)

56.3

51.3

48.4

30.0

Maintenance costs (R millions/lane km)

2.5

2.4

0.5

0.3

Construction/maintenance costs

100

Source: asphaltNEWS (Volume 27, Issue 2)

South African pavement design method – was initiated in 2008 and involves 22 research teams. “The study’s end product will be pavement design software incorporating the latest models for the design of granular, stabilised (cement or bitumen), asphalt, concrete and block pavements,” he continued. “Two other research projects are expected to yield practical implementation plans for biodiversity management systems within Sanral.” On the other hand, state-owned company Transnet pledged R302 billion in 2012

toward its very ambitious seven-year Market Demand Strategy (MDS), which will see the company invest heavily in rail, port and pipeline infrastructure in a bid to shift freight transportation off the roads. While the MDS will see masses of money and new projects sweep across South Africa, Transnet’s freight rail division will receive the biggest budget – R205 billion – to shift transport from road to rail, lowering maintenance costs on the country’s road networks, thereby drastically reducing carbon emissions. However, the

MDS is still in implementation phase and it will take a few years before South Africa’s roads will reap the benefits. For now, road transportation continues to play a crucial role in the local economy and requires the necessary attention.

Cost factors In his 2012 State of the Nation Address, President Jacob Zuma called on the nation to join government in a massive infrastructure development drive. While the need for housing, education, health care and sanitation facilities is critical, we should not overlook the fact that roads are the arteries of South Africa – giving people access and connecting them to other vital networks. Toward the end of last year, the Department of Transport delivered a presentation to the National Tourism Portfolio Committee on the state of transport and road networks in South Africa. Results revealed that an astonishing 80% of the local road network is older than

IMIESA October 2013

SABITA

LEFT Klipfontein: Kaytech’s GlasGrid 8501 was laid in the bus lane and 8550 in the outer lanes

Logistics costs as a percentage of the transportable GDP was 44% in 2011 and 46% in 2012, and the upward trend of transport costs was identified as a major risk in previous surveys. Its contribution to overall logistics costs in 2012 is pinned at 61% – the highest it has been in the past nine years and far higher than the global average (9th State of Logistics Survey). Road-related factors contribute to 5 to 15% of fatal road accidents, of which 28% can be attributed to poor road surface conditions. The total cost of fatal accidents caused by poor road conditions in 2010/11 is estimated at between R207 million and R621 million. Hundreds of deaths could have been prevented if roads were kept in acceptable conditions (9th State of Logistics Survey).

Did you know? and Industrial Research (CSIR)* confirmed the following top three challenges facing the road transport industry: • poor road conditions • cost of fuel • lack of law enforcement and prevalent non-compliance (* Respondents were from both industr y and government.) The survey also notes that compared with Australian, UK and US costs at R30 million/ lane km (new) and R300 000/lane km (maintenance), South Africa is far cheaper. However, this is not reflected in the percentage of road transport costs to GDP (4.7%), where South Africa is the highest – “a clear indication of the cost impact of South Africa’s poor road conditions arising from the lack of maintenance investment,” Solomons continued. He says: “It is clear that significant value could be added to both South Africa’s global competitiveness and its economic growth potential if Sanral’s effectiveness was duplicated by other road agencies. The logistics survey further emphasises the strong need for private sector involvement – both from a funding and planning perspective – to ensure the success of transport infrastructure projects.

Plastics are nonbiodegradable and can last on the Earth for as long as 4 500 years.

the design life of 20 years. Conditions of the road network showed a gradual decrease of roads in good condition and a consequent increase in the length of network in poor to very good condition – leaving much to be desired. The main reasons for this rapid deterioration include a lack of investment and/or inadequate funding, with the current maintenance effort at funding levels that will not even begin to tackle the backlog. Add to this the lack of road condition data and maintenance of a Road Asset Management System, as well as the shortage of technical skills, and it becomes evident why government relies so heavily on the private sector. According to comments published in the August 2013 edition of asphaltNEWS by Saied Solomons, CEO of the Southern African Bitumen Association (Sabita), although South Africa is largely dependent on road transport, the cost factors associated with this sector have a strong influence on the end result. The 9th State of Logistics Survey prepared by the Council of Scientific

IMIESA October 2013

Recycling revolution While the studies conducted by the CSIR clarify the current situation and offer suggestions for future steps, companies must realise that sustainability initiatives can start immediately. A very good, and common, example is recycling. Companies such as Much Asphalt are not just focused on completing projects, they also have a keen interest in ensuring their carbon footprint is kept to a minimum. For example, the company’s Benoni plant produced a trial mix for use at OR Tambo International Airport that contained the highest known proportion of recycled material in a hot or warm mix asphalt product. The mix was successfully produced on 9 March 2013 and was used to pave the OR Tambo cargo area. The result: a subsequent order for an additional 2 000 t, setting a new record for recycled content. Manufactured using Much Asphalt Benoni’s state-of-the-art warm mix asphalt plant, the mix involved 500 t of bitumen treated base (BTB), containing 55% recycled asphalt (RA). Initially, an emulsion treated base was specified, but design constraints led the contractor, Power Construction, to approach Much Asphalt for an alternative solution. “We proposed the use of a high percentage recycled material mix,” explains Joanne Muller, Quality Assurance supervisor at the Benoni

SABITA

plant. “The mix chosen is based on the standard BTB gradation using warm mix foam technology. The decision to use 55% recycled material was made bearing both cost effectiveness and product performance in mind.” All specialised requirements were met, and test results and feedback from the external laboratory and paving teams showed that the 55% RA BTB exceeded expectations, producing a very consistent and stable mix. The workability of the mix has also been noted to be well on par with standard hot mix asphalt products at greatly reduced temperatures. Following the product’s success, Muller and her team strongly believe that RA mix has great potential to replace both standard BTB courses in addition to ETB courses in the South African road construction market.

FIGURE 1 Fuel's contribution to transport costs, more than double the second highest cost element (wages), is a serious concern

Resources in waste On the subject of sustainability, Ambika Behl, PK Jain and Girish Sharma of the CSIR-Central Road Research Institute in India conducted a study, in conjunction with IMIESA October 2013

TOGETHER WE CAN... That’s our ethos at Much Asphalt.

We are part of a team that delivers quality results – safely, sustainably and cost effectively.

T: +27 21 900 4400 F: +27 21 900 4468 E: info@muchasphalt.co.za www.muchasphalt.co.za

SABITA

TABLE 3

Properties

Percentage of PVC in bitumen 80/100 pen 3%

Penetration at 250C, 100 g, 5 seconds 1/10 mm

Softening point, 0C

Elastic recovery, %

Viscosity, 1500C, poise

4.30

5.0

Properties of 80/100 pen bitumen with different percentage of PVC content

the ARRB Group in Australia, titled ‘Waste Polyvinylchloride Modified Bitumen for Paving Applications’, in line with the current waste crisis being experienced worldwide. A big contributing factor to this problem is the excessive production of the plastic polyvinylchloride, commonly referred to as PVC. In this study, PVC pipe waste was used as a modifier up to a level of 3 and 5%, in making bituminous product for paving applications. Since PVC is not compatible with bitumen, making a homogeneous blend required initially treating the waste PVC with a chemical before being blended with bitumen. The visco-elastic proper ties of the bitumen-PVC blend, such as storage modulus, loss modulus and phase angle, were studied and compared with those of unmodified bitumen. Later, the performance characteristics of bituminous mix made up of these modified binders were also studied and compared with those of conventional bituminous mix. The results indicated that PVC pipe waste could successfully be used in road construction. Strength and stability of the mix increased after the incorporation of PVC pipe waste, and it was also observed that the addition of PVC pipe waste showed increased resistance to permanent deformation in terms of rutting.

Materials: Shredded PVC pipe waste (2 to 4 mm) materials were obtained from a local recycler. The mineral aggregate (coarse aggregate of 13.2 and 6 mm, fine aggregates [stone dust] and lime powder) was obtained from a local quarry. Preparation of blends: Mixing was performed in a laboratory using an arrangement of ovens, fitted with a stirrer and a speed regulating system. The frequency of the stirrer was 2 000 rpm for preparing the blends, with an allocated time of two to three hours. The waste PVC particles were thoroughly washed and dried at 60°C. After washing, the waste PVC was treated with a chemical for homogeneous dispersion into bitumen. Treated PVC waste material was then used to modify neat bitumen at two different percentages, 3 and 5%. The blends were prepared at a temperature of 180°C, and the resultant blend was stored at room temperature for further work. The physical properties of bitumen with different percentages of PVC are outlined in table 3. Marshall samples were made for each binder content at mixing and compaction temperature of 155 to 160°C, and tested for determining the optimum binder content of the mix. The optimum binder content was calculated to be 5.5%. The properties at

various percentages of binder content were recorded according to table 4. Rheology of modified bituminous binders: The viscoelastic response of the modified bituminous binders was evaluated using a Dynamic Shear Rheometer with parallel plate geometry, by measuring complex shear modulus and phase angle. Measurements were taken in the temperature range of 50 to 85°C. It is important to note that early in pavement life, rutting is the main concern, while later in pavement life fatigue cracking becomes the issue. While performing the test, the samples were denoted as: • Sample 1: pen 80/100 + 3% PVC • Sample 2: pen 80/100 • Sample 3: pen 80/100 + 5% PVC Retained stability test: Retained stability is the measure of moisture-induced striping in the mix and subsequent loss of stability due to weakened bond between aggregates and binder. The test was conducted on the Marshall machine with the normal Marshall samples. The stability was determined after placing the samples in a water bath at 60°C for half an hour and for 24 hours. Based on the results of the study, it was found that PVC waste could successfully be used in paving applications, the addition of PVC pipe waste to the bitumen enhances both the binder’s and the mix’s properties, and there was improved phase angle and complex modulus values after the addition of waste PVC to the binder.

Green manual With so many new developments, and technology and equipment constantly evolving in the construction sector, it’s easy to lose track of sound environmental practice. Fortunately, a local version of the American Greenroads Manual will soon be made available, thanks to the establishment of the

TABLE 4

Binder % by weight of mix

Bulk density, GB, gm/cc

Stability, kg

Flow (mm)

% Air voids Vv

VFB* (5)

VMA* (5)

4.76

2.34

1 225

3.3

5.74

66.01

16.87

5.21

2.35

1 357

3.5

4.65

72.42

16.87

5.66

2.36

1 019

3.8

3.66

78.33

16.87

6.1

2.35

910

4.1

3.06

88.39

17.4

Marshall Parameters at various binder percentages *VFB – voids filled with bitumen, VMA – voids in mineral aggreates

IMIESA October 2013

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SABITA

Greenroads South Africa Interim Board (GrSA IB), which was formed by stakeholders from the local roads industry. Almost three years ago, the Greenroads Foundation launched the Greenroads rating system in the US, with the aim of guiding best practice and independent third-party certification of road design and construction. Being innovative in road construction does not simply mean developing sophisticated technology or advanced materials – it also translates into building cities while at the same time protecting and preser ving natural environments and resources. Although this issue is significantly addressed in the existing Greenroads system, further investigation is required to ensure compliance and suitability within the context of South Africa’s road network. Locally, custodianship of the GrSA IB lies with the South African Road Federation (SARF) and is chaired by Benoit Verhaeghe of the CSIR, with Dr Rodney Milford of the Construction Industry Development Board (cidb) as the vice chairman. It will oversee the formation of the non-profit Greenroads Council of South Africa and will include committees for technical development, marketing and communication, and structure and finance. Thus far, volunteer representatives of the GrSA IB include: City of Cape Town, eThekweni Municipality, Sanral, CSIR, Consulting Engineers South Africa, cidb, National Depar tment of Transpor t, KwaZulu-Natal Depar tment of Transpor t, Sabita, the Development Bank of Southern Africa, Greenroads Foundation, South African Federation of Civil Engineering Contractors and SARF.

Being innovative in road construction does not simply mean developing sophisticated technology or advanced materials

Research results A few years ago, Kim Jenkins, chairman of Sanral, and Terence Milne co-authored a technical paper on road surfacing sealing per formance. The paper stated that pavement designers have a choice of two types of wearing course: either an asphalt wearing course or a surfacing seal. While asphalt surfacing design has received much attention, road seal design has remained dependent on empirical modelling and experience. From 1998 to 2002, a test regime using five different seal binders and three temperature regimes was implemented. A method of evaluating seal performance was developed to enable evaluation of the seals’ behaviour. Their paper presented a summary of the test results and provided an insight to the performance of the different seal binders under similar imposed loads and environment. Single seals with five binder types (with variation of the rubber bitumen manufacture process, making a series of six binders)

were tested. For comparison purposes, two different application rates were used, based on TRH3 (CSRA 1998) design parameters. Three prefabricated seal tiles of each were manufactured to enable averaging of performance under load and identification of dynamic effects where applicable. Traffic load of single wheels at 600 kPa and 2.1 kN per axle was applied, with 200 000 applications applied (with no ‘lateral wander’). This equated to an estimated equivalent five-year traffic load, using an equivalency factor of 40 ELVs (equivalent light vehicle) per E80 (80 kN axle load) and a conservative factor of three, increase owing to the effect of lateral wander in practice. Three temperature regimes were utilised as follows: • Ambient temperature: on average, the road temperature varied between 20 and 36°C throughout the days of testing, although it dropped to 16°C minimum during the winter months. Testing was done throughout the day and no undue

FIGURE 2 Determining the annual cost of fatal road accidents caused by poor road conditions

Average cost per fatal road accident

Percentage fatal road accidents caused by road factors

IMIESA October 2013

Number of fatal road accidents per year

Percentage road factor related fatal accidents caused by poor road conditions

Estimated annual cost of fatal road accidents

Y =

Percentage fatal road accidents caused by poor road conditions

Estimated annual cost of fatal roaad accidents caused by poor roads

SABITA

• provide insight into stress and strain development in the binder • explain various types of cohesive seal cracking • enable prediction of deformation in the binder and supporting base, resulting in stone rotation and punching. Recently though, Jenkins has been involved in researching a scientific model for the design of sprayed seals, aimed at the development of Finite Element Method (FEM) models for several widely used bituminous road seals. The broad research programme, motivated in part by long-held doubts about the contribution of seals to the structural performance of a pavement, will contribute to the revision of the South African Pavement Design Method (SAPDM), one component of which is the development of a scientific method for sprayed seal design. A team has been constituted to conduct the seal research as part of Sanral’s SAPDM project and it will cover empirical performance models based on field and laboratory analysis. A matrix of seal types, climatic regions, age and traffic considerations has been popPolymer modified ulated in the experimental design, with repbinders (PMBs) resentative seal specimens being retrieved and performance evaluations carried out at PMBs are generally considered to Stellenbosch University and selected laboraprovide prolonged life or enhanced pavement performance. tories. Seals have distinctive differences in In dense-graded asphalt applications, failure mechanisms in the short term and the PMBs are effective in reducing rutting long term, which is taken into account in the and improving fatigue crack resistance. research methodology. The higher shear resistance can have beneficial effects in roundabouts, tight In addition, the rheological response and corners and other high-stress areas. damage properties of a range of seal bindPolymers have also demonstrated the ers are being evaluated at the University of ability to prolong the life of open-graded Pretoria. Jenkins is working with US researchsurfaces by allowing thicker binder films, which are less prone to oxidation. er Johan Gerber on the research, whose work Different PMBs work in different ways on developing FEM models for several of the and it is therefore important to choose most widely used bituminous road seals to the correct binder for each application. It is equally important to design the mix investigate the expected life of a surface or seal correctly. seal is noteworthy. Elements of the project include the Sprayed Seal Design Model Bitumen is used as a binder comprising empirical in road construction and in protective coatings and per formance models adhesive for use in the developed by Gerrie construction industry. In the van Zyl, numerical most common processes, models of the pavebitumen is heated to extreme temperatures until ment system develfluid enough to mix with oped by Johan Gerber aggregate. The ‘hot mixed’ (both under the ausmaterials must be stored, pices of Stellenbosch transported and used hot to maintain workability. University, and mate(Image: AkzoNobel) rial (binder) models in

low temperatures were experienced on the test days. • Elevated temperature: blowers were used to elevate road surface temperature to 50°C for the full test duration. • Cold temperature: cold air was blown onto the seal surface to reduce the seal temperature to 10°C for the full test duration. Conclusions from the research suggested a need for the development of a mechanistic model for seal performance prediction to complement South African seal design codes and experience. The prototype model was a proposed micro-mechanical model for surfacing seal performance prediction. On the basis of the prototype’s per formance, as discussed in the paper, it was concluded that the model will prove to give insight into seal behaviour, and with further development should: • allow for distinction between physical/ chemical adhesion (interface behaviour) and mechanical adhesion (stone shape) • enable better understanding of loss of adhesion and thus loss of stone

the seal developed by Estimé Mukandila of University of Pretoria. It is well recognised that the primar y purpose of a seal is the protection of the base layer, preventing sur face moisture from penetrating into the pavement structure. Furthermore, it is required to provide adequate skid resistance to traffic in all weather conditions. If a seal does not achieve these functionalities, it is considered to have failed. The objective of the seal model research is to estimate, using numerical procedures, the life expectancy of a seal under vehicular traffic, for given failure mechanisms. In the FEM, seal failure is defined according to three mechanisms, namely loss of seal aggregate (adhesive failure), fatigue cracking (cohesive failure) and loss of surface texture due to aggregate embedment (punching). To evaluate the life expectancy of a seal, the binder component’s damage properties determined by the University of Pretoria needs to be related to the pavement response and accumulated damage under traffic loading. Undoubtedly, the development of a seal model will make a significant contribution to the advancement of a mechanistic seal design method – the results of which will lead to more realistic, structural analysis of pavements incorporating thin surfacings. Support for this project is being provided by both Sanral and Sabita.

Built strong Following on from the ageing infrastructure of 80% of South Africa’s roads (mentioned earlier), this tells us that, moving forward, increased emphasis must be placed on reinforced design and execution of road construction. In 2012, the City of Cape Town earmarked a section of Klipfontein Road in the suburb of Athlone as part of its annual road network rehabilitation programme. Supplier to the project is Kaytech, whose technical sales representative Norrin Stone recommended the company’s highperformance GlasGrid – a complete road reinforcement system – to the client as the product of choice. The road treatment option for Klipfontein Road was the Mill and Fill Programme, which extends the life of existing roads by up to 20 years and creates a smooth ride by eliminating the effects of ruts and asphalt movement that stems from years of wear and tear. Consultant engineers GIBB noticed cracks in the pavement layer of

IMIESA October 2013

SABITA

Chemical components of bitumen The substance is completely soluble in carbon disulphide and composed primarily of a mixture of highly condensed polycyclic aromatic hydrocarbons. Most natural bitumens contain sulphur and several heavy metals, such as nickel, vanadium, lead, chromium, mercury, arsenic, selenium and other toxic elements. Bitumen can provide good preservation of plants and animal fossils. Asphalt/bitumen can sometimes be confused with tar, which is a similar black, thermoplastic material produced by the destructive distillation of coal. Asphalt/bitumen can be separated from the other components in crude oil (such as naphtha, gasoline and diesel) by the process of fractional distillation, usually under vacuum conditions. Asphalt/bitumen is typically stored and transported at temperatures around 150°C. Sometimes diesel oil or kerosene is mixed in before shipping to retain liquidity; upon delivery, these lighter materials are separated out of the mixture. This mixture is often called bitumen feedstock (BFS). Diesel oil is no longer used as a release agent due to environmental concerns.

IMIESA October 2013

Production of the trial mix at Much Asphalt’s Benoni warm mix plant

Klipfontein Road, suggesting that reflective cracking could migrate through to the new asphaltic layer. This, in turn, would allow rain and moisture to penetrate the base and subgrade layers, leading ultimately to complete base failure. The company had no hesitation in using GlasGrid, which is a polymer-modified, bitumen-coated, woven fibreglass grid structure with a pressure-sensitive adhesive for asphalt reinforcement. The product is designed to redirect crack stresses horizontally and to dissipate traffic-induced stresses, thereby helping to retard cracks from reflecting through a new asphalt overlay to the surface. By sandwiching GlasGrid between the levelling and surface courses of asphalt, maximum reinforcement is achieved. Engineering in the configuration of fibreglass strands in GlasGrid provides a combination of high-tensile strength and high modulus of elasticity at low elongation. These properties make the product, pound for pound, stronger than steel. Its open aperture design promotes aggregate interlock

between paving courses, which significantly decreases shear potential – a factor commonly found with paving fabrics. By reducing both thermal and stressrelated reflective cracking, the product has been proven, in independent laborator y tests, to extend pavement life by approximately 84%. The surface course of asphalt may be placed immediately after installation of GlasGrid, resulting in no disruptions or delays to normal paving operations. The product is supplied in various sizes and tensile strengths and can also be custommade to meet unique specifications. The bus lane in Klipfontein Road was reinforced with GlasGrid 8501 (tensile strength: 100 kN/m x 100 kN/m) while the outside lanes were reinforced with custom-made GlasGrid 8550 (tensile strength: 50 kN/m x 50 kN/m). By the end of the project in early 2013, Kaytech had supplied 10 000 m2 of its highperformance product. Kaytech’s technology involves sandwiching GlasGrid between two layers of asphalt and is not the only research that is in support of this method. A technical study was conducted by experts Subrata Mondal, Animesh Das and Animangshu Ghatak of

bidim

SABITA

the Department of Civil Engineering at the Indian Institute of Technology, who looked at the effect of thickness of a sandwiched layer of bitumen between two aggregates on the overall bond strength. The study starts off by drawing attention to understanding the bond between bituminous binder and aggregate as an important consideration for bituminous mixes. It states that the cohesion within the binder and the adhesion between the binder and the aggregate interface affect the mix performance in terms of load transfer, propagation of crack and moisture sensitivity, among other factors. For the purpose of the study, bond strength between aggregate and bituminous binder – while varying bitumen film thickness – was researched and recorded. The test temperature and the displacement rate were kept fixed at 23±1°C and 1 mm per minute, respectively. The results proved to be in favour of increased bond strength when layering aggregates with bitumen. Also leading the way for its innovative use of sealants in road construction is GIBB. In a Paving at OR Tambo International Airport

IMIESA October 2013

joint venture with Development & Engineering Consultants, GIBB was appointed back in 2011 to manage the design and construction of the N1, Section 5, between Laingsburg and Dwyka. Situated along the N1 on the banks of the Buffels River in the Central Karoo, the Laingsburg Road connects citizens from Cape Town to Johannesburg (N1) and is responsible for generating a significant portion of the town’s income in conjunction with farming. The main focus of this project was the preservation of the existing road infrastructure that was largely achieved by the repairing and resealing of the road. Thanks to a new sealing process that will ensure longevity of this road network, the company has opened up a new innovative design to the local market. “The sealing process (surfacing) used in this project has not been widely used,” explains Alan Moffet, technical executive at GIBB. “However, as a result of its use in this project, it now opens up the possibility of more projects using this approach.” Completed in July 2013, the company’s role in this R142 million project included the construction of new climbing lanes, landscaping, repairs to

existing and damaged stormwater structures and bridges, the shaping of existing open drains and the patching, repairing and resurfacing of approximately 67 km of road.

Securing supply But according to Moffet, one of the major challenges facing the N1 Laingsburg project was the acute shortage of bitumen. Bitumen shortage is not uncommon in South Africa and is what fostered the relationship between Colas and FFS Refiners. As the largest supplier of industrial heating fuels in the country, FFS boasts an impressive client base of over 250 and a supply of more than 300 000 t of fuel oil per annum. Adding to this, the company is further expanding its bulk liquid storage facility at the Port of Cape Town, prompting the deal with Colas. The expansion sees the addition of thermal oil heating bitumen tanks and pipelines, and an obvious increase in turnover as well as improved productivity. Also new on the cards for Colas is the bitumen depot in Durban, opened earlier this year with a storage capacity of 5 000 t, further reinforcing the company’s commitment

SABITA

road, encouraging obser vations made during the inspection indicate that HiMA could successfully be designed, manufactured and paved in South Africa. As part of Sabita’s Technology Transfer project, the trial section was constructed to test resistance to rutting caused by heavy traffic loading on the South Coast Road leading in and out of Durban Harbour. As this was South Africa’s first use of HiMA in a real situation, a component of the trial was that the HiMA be monitored over a two-year period with regular long-term pavement per formance (LTPP) testing to evaluate its properties. The approximately 300 m long HiMA trial section was paved on the northbound carriageway, with its northern limit at the intersection of South Coast Road and Bayhead Road. The initial pavement surface was severely rutted under a continuous stream of heavy vehicles, many of them carrying containers and other goods in transit destined for export via the harbour. HiMA was selected since normal asphalt mixes cannot cope with this extreme loading, resulting in the type of deformation that was evidenced prior to rehabilitation, especially as the heavy vehicles slow down and queue at the intersection. The findings of the inspection are contained in the CSIR survey report Long-term Pavement Performance Monitoring of High Modulus Asphalt Trial Section on South Coast Road in eThekwini – April 2013, which was published as part of the Sabitasponsored LTPP monitoring of the trial section. This report contains a record of the visual and automated condition of the trial section, assessed at six-monthly intervals over a period of two years. The visual inspection was performed by the CSIR in accordance with the procedures stipulated in TMH 9: Pavement management systems: Standard visual assessment manual for flexible pavements (1992), carried out from the start of the trial section towards the intersection with Bayhead Road. After each inspection, analysis of the visual condition data was performed to track any distress development on the section. Overall, the

Bitumen emulsions provide an alternative approach in which the bitumen is liquefied by dispersing in water. Bitumen emulsion can be produced either in a batch or an in-line process plant. The batch process involves at least twoprocess steps: water phase (soap) preparation and the actual emulsion production. Emulsification involves the break-up of bitumen into droplets. (Image: AkzoNobel)

to ensuring continued supply of this product. Following the recent two-month shutdown of the SAPREF plant, the benefits of the additional Durban storage capacity were felt throughout the industry. And the company’s supply of bitumen is not just limited to South Africa. With only 14% of its road network at bitumen standard, Colas has stepped in to assist Kenya. Since an efficient road network is essential to building a country’s economic status, the Roads 2000 Plan was developed to improve the road network in Kenya with the government agenda of community participation and its subsequent support of labour-based initiatives. These initiatives must ensure that any road project is awarded in partnership with local stakeholders and procures majority of its requirements for labour, materials and contractors locally. As a result, Colas East Africa, in collaboration with various government and consultant agencies, developed K3-65 branded Colmix E to suit the specific needs in this sector. The main product advantage is that it is easy to apply through relatively ‘low tech’ means, and it has been formulated to specifically suit the aggregate found at these locations, with the company’s laboratory accessible for modifications should different conditions be encountered on-site. So far, 32 km of road have already been awarded to various contractors, with one contractor having commenced with construction.

Durability research Sabita recently published a study on the durability of bitumen. The case examined the high modulus asphalt (HiMA) trial section constructed by eThekwini Municipality in mid-2011, which is still proving to be highly successful after the third inspection conducted in April 2013. After 20 months under the heavy traffic loading experienced by this

survey aimed to monitor the performance of HiMA over time, and the findings can also be used for determining the maintenance needs for the section. The results of the study were as follows: although the HiMA section on the South Coast Road has, to date, only been carrying heavy traffic for 20 months, early results suggest that HiMA can withstand very high volumes of heavy traffic without displaying any visible or measurable form of structural distress. One of HiMA’s main attributes, apart from its better load spreading ability on account of its high stiffness, seems to be its ability to provide very good resistance to permanent deformation. More conventional treatments, such as those used in the past on South Coast Roads, would most likely have failed by now. Based on positive results obtained to date, the use of HiMA on other heavily trafficked roads, including BRT routes, should be encouraged. During May and June 2013, a significant number of instrumented experimental sections were built on Road R104 in Gauteng for Sanral, covering most types of pavements, namely rigid, semi-rigid and flexible. For these three pavements, the main purpose of the experiment is to better understand the effects of temperature, traffic speed and loading on the resilient response (stiffness) of the asphalt base courses, as well as the differences in the load spreading ability of those three layers. The sections are also ideally located to be subjected to accelerated pavement testing in future, depending on available budgets. In terms of the application of HiMA outside the realms of research and development, it is envisaged that HiMA will, in the very near future, be applied on the slow and middle lanes of the N3 between Durban and Pinetown. For numerous reasons, bitumen will continue to be a very popular choice of road construction material in South Africa and international countries. As it stands in the local construction industry, durability, versatility, sustainability and low maintenance are among the deciding factors for product choice – characteristics that bitumen is renowned for. Sources: asphaltNEWS, Sanral 2012 Annual Repor t, Depar tment of Transpor t, ARRB Group Australia, CSIR, Infrastructure ne.ws, Colas newsletter.

IMIESA October 2013

SABITA – AFRICA

BUSINESS IN AFRICA

Partnering for potential With Africa’s economic growth now exceeding Asia’s in actual and potential economic growth, an African strategy has helped one company in the construction and engineering sector secure a leading position among its competition.

USINESSES WITH established operations across Africa are on the rise and a recent industry breakfast hosted by Lafarge bore this out, attracting some 70 business leaders in the construction and engineering sector. The theme of this prestigious event was ‘Lafarge in Africa’ and some key elements to the company’s African operations were demonstrated. Lafarge South Africa is the local subsidiary of the international Lafarge Group and specialises in building materials. This forum gave a platform for speakers from large Lafarge businesses across Africa, who shared insights on their markets and business dealings on the continent. Africa has now surpassed Asia with a collective GDP of US$2 trillion (R20.03 trillion). This positive outlook has stimulated new interest in conducting business in Africa. It highlights opportunities for those looking to expand on the continent with the right skills and expertise and, importantly, with the right experienced partner. Lafarge South Africa’s Country CEO, Thierry Legrand, briefly outlined the group’s achievements, including its presence in Africa since

1985 and how that has grown to 13 African countries, resulting in Lafarge being the continent’s leading cement producer. “Although prospects for growth in the South African market in the foreseeable future are not as buoyant as we would like, there is huge opportunity in the African marketplace and Lafarge South Africa has capacity available and the resources to take advantage of it,” he says. “We believe in Africa, and with the company's established footprint on the continent, it is in a good position to partner and share skills with construction companies wishing to expand into Africa. The group demonstrated its belief in South Africa with its investment in 3.6 Mtpa of cement capacity, which is currently underutilised, resulting in us not utilising one of our kilns. As the demand escalates we will be revisiting this situation. It is our aim to build on our established reputation for providing the construction industry with innovative products, solutions and services at the right price, taking into account the escalating increases in fuel and electricity.” The country and construction industry will benefit greatly from the acceleration of the infrastructure programme. Government and private companies can facilitate this by working together, creating a great deal of much needed employment. The panel discussion was chaired by Lafarge vice president of sales & marketing for subSaharan Africa & Middle East, Ilsé Boshoff.

This positive outlook has stimulated new interest in conducting business in Africa

TOP The Lafarge panel (from left) Ilsé Boshoff, Joe Hudson, Thierry Legrand, Khaled Huraibat, Maria Sazeides and Kaziwe Kaulule LEFT CEO of Lafarge Nigeria, Joe Hudson, providing insight into the Nigerian market

IMIESA October 2013

She posed some interesting questions to the Lafarge speakers to mitigate the myths surrounding business in Africa. The CEO of Lafarge Kenya and Uganda, Hussein Mansi, spoke on the exciting prospects for his countries. A team of senior speakers from Algeria – one of Lafarge’s top performing countries – described how they achieved their exceptional growth. Particularly relevant for many of the guest executives was the chance to talk to the visiting CEO of Lafarge WAPCO Nigeria, Joe Hudson, who shared insights into the Nigerian market and dispelled a few of the myths around the difficulties of doing business in his country. An interesting perspective on operating in the Middle East was provided by Khaled Huraibat, Lafarge Jordan’s vice president of commercial marketing & sales. Kaziwe Kaulule, cluster marketing director for South East Africa (Zimbabwe, Zambia and Malawi), commented on his market and the implications of future prospects for this region. Legrand described the company’s recent brand repositioning, which addresses the huge global trend to urbanisation and the group’s signature theme of ‘Building better cities’. He said Lafarge South Africa was in a unique position to contribute to building better cities and infrastructure through having a strong presence in all its construction-related business lines: cement, aggregates, readymix and plasterboard. “We are committed to driving innovation and development on the African continent, in an ever-increasingly welcome competitive market. We are well positioned with our technical expertise and high safety standards to serve the markets with high-quality products and solutions.”

SABITA – PROFILE

THE AMMANN GROUP

Taking huge steps in the African market

The central slogan of the Ammann Group is ‘Productivity Partnership for a Lifetime’. It shows customers that they have a reliable and innovative partner in Ammann that thinks in the long term and provides them with products that offer the best possible customer benefit.

MMANN IS the manufacturer of asphalt plants that develop and produce all the system components, including controls, screens, dryers, burners, mixers and filters in-house on the basis of an integrated concept. This enables the company to offer its customers an optimised complete solution, with all elements of the plant ideally coordinated – from process analysis and design of the system components through to controls for all components of the plant.

Innovation through development Ammann is focused on driving further development of process engineering and process technology to meet the ever-growing demands from the markets in various regions with regards to the use of reclaimed asphalt, emission reductions and plant mobility. This has resulted in a completely new and innovative mixing plant concept such as Universal HRT (high recycling technology), a plant concept that consistently aligns the entire asphalt production process with the maximum possible use of reclaimed asphalt. Or the Unibatch range that combines high flexibility extendibility and large section of

IMIESA October 2013

variants with modularity, energy efficiency and reduced emission values. Ammann has over 400 asphalt mixing plants worldwide, 50 of which are in Africa, operating every day under tough conditions – this is a figure that speaks for itself. Two new mobile mixing plant types have been added to the Ammann range: • the Easy batch 140 range, for batch asphalt productions • the Prime 140, for continuous production process. Both stand for maximum compact mobility coupled with greatest possible output of 140 tph. At present, Ammann is commissioning a Prime 140 mobile asphalt plant in Zambia. Ammann is striving to be unrivalled, not only in its asphalt mixing plants and machines but also its emulsion, polymer modified bitumen plants, thermal oil heating and decanting units.

As1 process control and software ‘Designed to meet the needs of the building materials industry’ – this is the guiding principle behind the as1 software, a completely new development geared specifically towards the building materials industr y. Process

control systems, order management and fleet management systems as well as truck weighing systems for asphalt, concrete, gravel and dosing plants are also available based on the same as1 software platform. Ammann works with each customer to turn products into tailor-made solutions and implement them in an operative environment. The as1 process control system conversions for plants of any manufacturer have become an important mainstay. Ammann Service provides plant operators with expert support on-site or through remote maintenance. Customer service is a core expertise of sales activities at Ammann and the company considers employees with the best training possible to be an investment that guarantees effective technical support. Ammann’s experienced and practice-oriented support team offers first-class support 24 hours a day throughout the lifetime of your plant and machinery. There are over 60 000 spare and replacement parts in stock and a spare parts service around the clock guarantee a high degree of reliability and long-term conservation of value, as well as the highest possible availability of your plant and machinery.

SABITA – PROFILE

Ammann technology Engineers and process specialists at Ammann are working today on technologies and products for the building industry of tomorrow. New approaches are pursued and researched in collaboration with universities and colleges. This is where the foundations for innovative product platforms are laid. The company’s development departments turn the results gained from fundamental research into products with added value for the customer. A broad technological scope enables Amman to develop systems and machines for the building industry of tomorrow. Low-temperature asphalt Lowering the manufacturing temperature opens up new opportunities for asphalt as a construction material. Lower energy costs and fewer emissions are only part of the positive characteristics of low-temperature asphalt. Despite the growing number of varied solutions that have appeared on the market, Ammann believes that it is not enough to focus exclusively on a particular method of introducing additives or foam bitumen. The entire process chain is affected, starting with drying at a reduced temperature through to specific mixing sequences and on to the introduction of recycling. Ammann has focused its research and development on the complete manufacturing process for lowtemperature asphalt with an injection device being simply the beginning.

(Ammann Compaction Expert) measurement and control system to generate a reliable measurement value known as KB to indicate substrate consistency in MN/m and thus provide a comparable statement on the progress of work. The benefit to the user lies in an increase in flexibility and independence, which together result in greater productive output in modern road construction. The associated simplification of service and maintenance achieved through a standardised service tool offers significant benefits to dealers and customers alike. The new platform concept is also at the heart of significant progress in customer service and in the output achieved by customers. This development is an impressive and consistent confirmation of Ammann’s technological leadership and documents the company’s

innovative approach towards adapting quickly to changing customer requirements. Ammann recently launched the new AFT800 paver. The AFT800 is an extension of Ammann’s proven paver line into the Highway class. The tracked finisher is equipped with the Euro 3B engine and has a robust, highquality design. Ammann South Africa recently tested the AFW150G mini paver using hot mix asphalt, laying an industrial driveway successfully. It was also tested using a product called Repair Cold Asphalt to repair a badly worn road surface by laying a thin layer on top of the existing asphalt surface.

Ammann Construction Machinery South Africa t +27 (0)11 849 3939/3333 rocco.lehman@ammann-group.com

Ammann compaction Not every compaction application calls for a comprehensive measurement and control system on every machine. Thanks to an innovative extension to the measurement algorithm, it is now possible to intentionally forego certain process parameters. Virtually any compaction machine from the Ammann range (from lightweight vibratory plates to heavy rollers) with standard machine parameters can be equipped with a comparable measuring system as a result of standardised electronic components. The new standardised platform is available in various expansion stages; it uses the well-established ACE

OPPOSITE Prime 140 in Zambia TOP Testing of the AFW150G mini paver in close range INSET Testing of the AFW150G mini paver using cold mix asphalt RIGHT Drum Tek Series plant

IMIESA October 2013

SABITA

Sabita members Title

Initials

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Mr Mr Mr Mr Ms Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Ms Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Ms Mr Mr Mr Mr Mr Mr Mr Mr Dr Mr Mr Mr Mr Mr Mr Mr Mr Mr Mr Prof Mr Prof Prof Mr Mr Mr Mr Mr

J JJS R KP AJ H A R JPJ A P DA A F AL D DC P J J T B RC WAG R TW TD G AJ GM TF GJ AJ LC J R JK PA GR GM M MA W SRM W B JA S BC DS F M J N D N N L JR G T S M S KG C F PB JB BI D J SJ RL A T CH SO A MP P G RB GJ D WJVDM KJ C J G HC MD

Van der Walt Weidemann Bonser Thomas Broom Van Aswegen Pegge Lehman Webb Page-Wood Grindley Rose Ungerer Matahwa Botha Smith Collings Neal Phillips Botha Madelon Theron King Venter Ntombela McKune La Grange Brown Moffett Hattingh Moolman Loubser Laatz Raman Pietersen Makhomu Van Niekerk Olivier Tyndall James Fynn Van Reenen Tendaupenyu Adande Reusch Burger Kr端ger Dewnath Greyling Judd Samaai Manicum Strydom Nathoo Pagel Sobotker Govender Heathcote Uys Catin Freestone Vorster Kohlberg Rattray Rocher Ford Kemp Joubert Lansdell Jonsson Stuart Van Heerden Strydom Hornsey Taute Raseobi Loots Single Van Rooyen Prinsloo Hechter Diepraam Purchase Jordaan Bullock Steyn Jenkins Jacobs McLoughlin Verwey Thompson Winfield

ACTOPHAMBILI ROADS (PTY) LTD AECOM SA (PTY) LTD AFRISAM SA (PTY) LTD AG THOMAS (PTY) LTD AJ BROOM ROAD PRODUCTS CC AKASIA ROAD SURFACING (PTY) LTD AMANDLA GCF CONSTRUCTION CC AMMANN CONSTRUCTION MACHINERY SA AQUA TRANSPORT & PLANT HIRE (PTY) LTD ASPHALT SERVICES CC ASTEC ASPHALT TECHNOLOGY CC AURECON BIGEN AFRICA SERVICES (PTY) LTD BITUMEN CONSTRUCTION SERVICES (PVT) LTD BITUMEN SUPPLIES & SERVICES (PTY) LTD BITUMEN WORLD (PVT) LTD BSM LABORATORIES (PTY) LTD CAPE PENINSULA UNIVERSITY OF TECHNOLOGY CHEMIMPO SA (PTY) LTD CHEVRON SOUTH AFRICA (PTY) LTD COLAS SOUTH AFRICA (PTY) LTD CONCOR ROADS & EARTHWORKS DICK KING LAB SUPPLIES (PTY) LTD DMV HARRISMITH (PTY) LTD DUPONT DE NEMOURS INT SA DURBAN UNIVERSITY OF TECHNOLOGY EFG ENGINEERS (PTY) LTD GAVIN BROWN & ASSOCIATES GIBB (PTY) LTD GMH/CPP CONSULTING ENGINEERS (PTY) LTD GROUP 5 CIVIL ENGINEERING (PTY) LTD HATCH GOBA (PTY) LTD HHO AFRICA ILISO CONSULTING (PTY) LTD IMESA INSTANT ROAD REPAIRS ASPHALT (PTY) LTD JAVSEAL (PTY) LTD JEFFARES AND GREEN (PTY) LTD KANTEY AND TEMPLER (PTY) LTD KAYMAC (PTY) LTD T/A KAYTECH LAFARGE INDUSTRIES SA (PTY) LTD LETABA LAB (PTY) LTD LIDWALA CONSULTING ENGINEERS (PTY) LTD MDUBANE ENERGY SERVICES (PTY) LTD MILLING TECHNIKS (PTY) LTD MMILA CIVILS & TRAFFIC SERVICES (PTY) LTD MORE ASPHALT (PTY) LTD MTTC (PTY) LTD MUCH ASPHALT (PTY) LTD N3 TOLL CONCESSION (PTY) LTD NADESON CONSULTING SERVICES NAIDU CONSULTING (PTY) LTD NAMIBIA TECHNICAL SERVICES CC NATHOO MBENYANE ENGINEERS NATIONAL ASPHALT NEIL SOBOTKER AND ASSOCIATES NOLANS EARTHWORKS & PLANT CC OUTENIQUA LAB (PTY) LTD PD NAIDOO AND ASSOCIATES (PTY) LTD PHAMBILI ROAD SURFACING (PTY) LTD POLOKWANE SURFACING (PTY) LTD POWER CONSTRUCTION (PTY) LTD RAND ROADS (A DIVISION OF GRINAKER-LTA LTD) RANKIN ENGINEERING CONSULTANTS RAUBEX (PTY) LTD ROADSMART (PTY) LTD ROADSPAN ASPHALT PLANTS (PTY) LTD ROYAL HASKONINGDHV SALPHALT (PTY) LTD SARF SASOL OIL (PTY) LTD SASOL TECHNOLOGY FUELS RESEARCH SASOL WAX (A DIV OF SCI) SHELL SA MARKETING (PTY) LTD SMEC SOUTH AFRICA (PTY) LTD SOL PLAATJE MUNICIPALITY SPECIALISED ROAD TECHNOLOGIES (PTY) LTD SPRAYPAVE (PTY) LTD TAR SPRAY (PTY) LTD TAU PELE CONSTRUCTION (PTY) LTD TOSAS (PTY) LTD TOTAL SA (PTY) LTD TPA CONSULTING (PTY) LTD TSHEPEGA ENGINEERING (PTY) LTD UNITRANS SUPPLY CHAIN (PTY) LTD UNIVERSITY OF PRETORA, DEPT CIVIL ENG UNIVERSITY OF STELLENBOSCH VAN WYK TARMAC CC WORLDWIDE TANKS ON HIRE CC WORLEYPARSONS RSA (PTY) LTD WSP SA CIVIL & STRUCTURAL ENG (PTY) LTD ZEBRA SURFACING (PTY) LTD

011 894 1433 011 206 6980 011 670 5500 00268 518 4499 011 454 3102 012 562 9500 021 981 7070 011 849 3939 032 533 6883 043 745 2733 016 362 1310 021 526 9400 011 802 0560 00263 430 5506 011 8039338 00263 470 8358 031 764 6537 021 959 6664 011 293 2058 021 403 7287 021 531 6406 011 590 5843 011 499 9400 058 622 2676 011 218 8600 033 845 8916 021 975 3880 031 202 5703 021 469 9105 011 462 0601 011 409 6607 012 679 9300 021 425 2870 031 266 2600 031 266 3263 015 291 3225 031 902 5988 011 807 0660 021 405 9600 031 717 2303 011 657 1156 013 752 7663 0861 543 9252 031 304 2470 031 792 9580 012 993 3098 021 975 0784 012 800 3018 011 423 1004 011 454 3596 021 418 4988 031 265 6007 00264 6121 5324 031 312 2097 012 562 9533 021 863 2020 033 386 6455 044 874 3274 021 440 5091 033 346 1982 015 293 1221 021 907 1300 011 923 5310 00260 129 0085 031 700 6411 021 713 0129 011 321 8400 011 798 6051 011 823 2218 011 394 9025 011 323 2082 016 960 4068 016 960 2126 031 571 1000 012 481 3805 053 830 6300 031 700 4510 011 868 5451 012 669 0511 051 436 0103 011 323 2000 011 778 2241 031 765 1907 012 665 2722 021 521 6200 012 420 2171 021 808 4379 012 561 1871 031 362 0207 012 745 2000 011 450 2290 021 761 3474

johnamelia@mweb.co.za jurgens.weidemann@aecom.com ray.bonser@za.afrisam.com agthomas@realnet.co.sz angelabroombrp@gmail.com hardus@akasiaroads.co.za andrew@amandlaconstruction.co.za rocco.lehman@ammann-group.com peter.webb@aquatransport.co.za apage-wood@indepco.co.za pierre@zamail.co.za david.rose@aurecongroup.com Andre.ungerer@bigenafrica.com fmatahwa@bitcon.co.zw andre@bsspty.com duncan@bitumenworld.net davecol@iafrica.com nealp@cput.ac.za jenny.phillips@chemimpo.co.za jbotha@chevron.com thierry.madelon@colas-southafrica.com barryt@concor.co.za dickkinglabs@iafrica.com werner@dmvconsultants.co.za Richard.Ntombela@zaf.dupont.com tom@dut.ac.za theo@efgeng.co.za gavbrown@global.co.za amoffett@gibb.co.za georgeh@gmhcpp.com tfmoolman@groupfive.co.za gertl@goba.co.za andy@hho.co.za colinr@iliso.com imesa@webstorm.co.za rendani@irrasphalt.co.za nestus@iactive.co.za olivierp@jgi.co.za royt@ct.kanteys.co.za garth@kaytech.co.za marcel.fynn@lafarge.com mike@letabalab.co.za tadams@lidwala.com sadande@mdubane.co.za wolf@millingtechniks.co.za benburger@worldonline.co.za jkruger@moreash.co.za sunild@mttc.co.za bennie.greyling@murrob.com douglasj@n3tc.co.za fsamaai@nadeson.net mmanicum@naiduconsulting.com jss@ntscc.com nelnathoo@nme.co.za deon@nationalasphalt.co.za nsa@mweb.co.za nolans@nolansearthworks.co.za llewelyn@outeniqualab.co.za robbieu@pdna.co.za gary@phambilisurfacing.co.za trevorf@hillary.co.za svorster@powergrp.co.za mkohlberg@grinaker-lta.co.za srattray@rankinengineering.com kevan@rmsg.co.za chris@roadsmartsa.co.za Francois_Kemp@roadspan.co.za philip.joubert@rhdhv.com afribit@mweb.co.za operations@sarf.org.za donald.stuart@sasol.com jacques.vanheerden@sasol.com stefan.strydom1@sasol.com bob.hornsey@shell.com arthur.taute@smec.com traseobi@solplaatje.org.za hennie@srt.co.za ssingle@mweb.co.za anton@tarspray.co.za mprinsloo@tau-pele.co.za phillip.h@tosas.co.za gary.diepraam@total.co.za roger@tpa.co.za jordaangj@tshepega.co.za david.bullock@unitrans.co.za wynand.steyn@up.ac.za kjenkins@sun.ac.za carel@vanwyktarmac.co.za jerome@wtoh.co.za gerhard.verwey@worleyparsons.com hugh.thompson@wspgroup.co.za mdw@zebrasurfacing.co.za

IMIESA October 2013

TECHNICAL PAPER

RAND WATER CASE STUDY

Artificial neural networks as a chemical dosing budgeting tool The need for an empirical-based chemical dosing budgeting tool was identified by Rand Water in order to improve budgeting, reliability and accuracy. By P Naidoo, Rand Water; JJ van der Walt, Bigen Africa Services

ROM PAST experience, it is known that water treatment cost is affected by a number of aspects. The most common aspects that were considered during the development of the chemical dosing model included: • economic drivers such as the cost of the chemicals delivered to site • environmental aspects such as rainfall, temperature, time of the year, dam level, algal activity and colour • treatment chemicals used such as hydrated lime, carbon dioxide, activated silica, ferric chloride, organic coagulants (commonly referred to as polymers) and chlorine • raw water quality parameters • treatment rate. Rand Water treatment system can implement hydrated lime, activated silica and CO2 process (high lime process) or a polymer and low lime process. Compared to other water research fields, not much development was documented in the field of water treatment dosing models. Savic et al (1999) provides an excellent summar y of the data mining and knowledge discover y techniques that have been used in the water industr y. Predicting the required coagulant doses in response to water quality changes, a number of researchers have attempted to use the multi-variable regression (MVR) approach. However, the prediction capability of the MVR approach has not been satisfactor y. Artificial neural networks (ANN) were found to be superior in the estimation of non-linear relationship between dependant and independent variable. ANN-type models utilise an artificial intelligence to learn patterns and relationships contained in data sets. ANN predicts the output of a process given the values of process inputs and process control variables.

ANN is often used to model relationships (2000) provides a useful over view of how between large sets of variables. ANN can ANN has been applied in the water industr y, either feed the results to an operator the associated challenges and advantages. to make process control adjustments or Joo et al (2000) used the characteristics of implement appropriate control adjustments ANN to predict the optimal coagulant dosing automatically. Genetic algorithms are often rate accurately and quickly, and reported a employed to optimise the neural network, TABLE 1 Basic ANN parameters neurons and weights. A number of researchers have used this type of approach with Number of layers 3 great success and recommend using neural Number of 8 Input layer network models when relationships between neurons per layer inputs and outputs are not known and where 8 Hidden layer strong non-linear relationships exist. Baxter 3 Output layer et al (1999) described the development of a full-scale ANN model for the removal of Learning rate 1 natural organic matter by enhanced coaguMomentum 0.9 lation at the Rossdale Water Treatment Plant in Alber ta, Canada. Few attempts Transfer function Sigmoid have been made to develop a full-scale RMS error <5% model of the enhanced coagulation process due to extreme variability in the pro- FIGURE 1 Typical neural network architecture with input cess parameters and layer (red), hidden layer (blue) and output layer (green) the complex non-linear relationships between RAW WA TER QUAL ITY them. When applied to previously unseen data, the model predicted effluent colour with a high degree of accuracy. A recent study by Yu et al (2000) also compared the per formance of a regression analysis type model, a time series ARIMA (autoregressive integrated moving average) model and an ANN model. The neural network model outper formed the other CH EMICAL DOS ING models by a significant margin. Baxter et al

IMIESA October 2013

TECHNICAL PAPER

root mean square normalised error for the training data set and the raw data set of the ANN of 0.0058 and 0.0092, respectively. Bongards (2001) applied neural networks combined with fuzzy control to improve the efficiency of a wastewater treatment plant. Maier et al (2004) used ANN to predict optimum alum dosing and treated water parameters. Joo et al (2006) provides useful information on data preprocessing and verification of ANN applied to chemical dosing. Shariff et al (2007) demonstrated how advanced ANN model-based control systems can be used for drinking water treatment process control. Some researchers repor ted excellent results where neural network techniques were combined with fuzzy logic type techniques also referred to as neuro-adaptive fuzzy logic. Liu and Wu (1997) applied this technique in the control system of an activated sludge treatment plant. Scheffer (1999) developed a relational fuzzy logic model for the control of an activated sludge process and Van der Walt et al (2002) developed a fuzzy logic pump and reser voir level control system. Chen & Hou (2006) developed a chemical dosing control system

for a water treatment works. Wu & Lo (2008) combined neural network technology with fuzzy logic control methodology to predict real-time chemical dosing. The conclusion drawn from the literature study is that ANN offered the most promising potential for the Rand Water application. Data, for a period of five years (2005 to 2009), was used for the Zuikerbosch Water Treatment Works (WTW) operations. In order to have a better understanding of the variability and potential trends, the data was analysed using a number of different techniques.

Percentile distribution analysis It was evident from the daily operational data that there was a fair degree of variability as was expected from a sur face water treatment source. The level of variability is different for each parameter. If the Morrill Index (MI), calculated as the ratio of the 90th percentile/10th percentile is used as the degree of variability, the following MI values were determined as follows: • pH : MI 1.08 • alkalinity : MI = 1.3 • chlorine dosing : MI = 1.3

FIGURE 2 Comparison of actual versus predicted lime dosing rates

FIGURE 3 Comparison of actual versus predicted polymer dosing rates

IMIESA October 2013

• • • •

polymer dosing : MI = 4.1 raw water NTU : MI = 4.45 chlorophyll-a : MI = 14.5 faecal coliform : MI = 81

Time series analysis The percentile distributions provide good insight into the variability of data, but cannot be used to identify the cyclic nature of data. For this reason, time series analysis was also used. The time series analysis revealed a number of interesting aspects: • The chemical dosing strategy as well as the dosing rates varied significantly over time. • The raw water turbidity and alkalinity showed long-term non-cyclic behaviour. (It was expected to find that the turbidity follows a seasonal cyclical pattern, where high turbidity values are experienced annually during the rainy season. The data did not confirm this expectation.) • pH values showed a more frequent variation as compared to the other raw water parameters. • The faecal coliform counts showed a definitive annual cyclic behaviour. • Colour levels did not show a cyclical pattern. 

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TECHNICAL PAPER

The percentile distributions as well as the time series analysis provided insight into the variability and cyclic nature of the data, but the number of variables, amplitude and frequency of change makes it ver y difficult to develop a deterministic model. Based on the literature study it was decided to develop an ANN.

Development of the neural network predictive modelling tool Artificial neural networks An ANN is a large interconnected, parallel processing, dynamic system of interacting

processing elements that are similar to the human brain. The fundamental processing element is called the neuron, which is analogous to the neural cell in the human brain. The neurons are set in layers, and thus a network is formed as shown in Figure 1. Inputs representing the variables that affect the output of the network are feeding for ward to each of the neurons in the following layers with activation depending on their weighted sum of the inputs. The ability to learn is one of the characteristics of an ANN. The weights of the inputs are adjusted to produce a predicted output within specified

TABLE 2 Comparison of actual dosing, predicted dosing and dosing error over reporting period

Average (actual dosing)

Average (model prediction)

Absolute difference

Calcined Lime (purchased)

26.6

26.1

0.5

Polymeric Coagulants

7.1

7.2

0.1

Chlorine (primary)

2.6

FIGURE 4 Comparison of actual versus predicted lime dosing rates

FIGURE 5 Comparison of actual versus predicted polymer dosing rates

IMIESA October 2013

errors. ANNs have been increasingly used in recent years to predict or to improve non-linear system per formance in numerous industrial applications. An ANN system is characterised by its network topology, neuron activations transfer functions and learning method. For a more comprehensive discussion on the mechanism and application of ANN, the reader is referred to the vast quantum of literature available on the subject. A number of ANN software packages are available, most of which can be purchased in the form of an Excel add-in or macro. Neuralist (Palisade, 2012) was used in this case.

ANN preprocessing and parameters The entire data set was integrated and referred to as the base scenario data set. The data was checked for continuity, cleaned and divided into three sets. As a point of departure, the ANN model was set up using Neuralist with a three-layer ANN model with

TECHNICAL PAPER

eight neurons in the hidden layer and other model parameters as indicated in Table 1.

Results The modelling approach was to commence with the least amount of inputs and progressively add additional inputs until a desired level of modelling accuracy was obtained.

Base scenario The base scenario included the raw water turbidity, alkalinity, pH and production rate as well as the type of process that was employed, i.e. low lime or high lime processes. Lime dosing, polymer dosing and chlorine dosing were selected as outputs. The predicted and actual dosing rates are

compared in Figures 2 and 3. It is evident that the model underpredicted the chemical dosing required in the case of lime and polymer. One data set was used to train the ANN, a second set was used to test the training success and a third subset was used to validate the application range of the ANN. ď ľ

FIGURE 6 Comparison of actual versus predicted lime dosing rates

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TECHNICAL PAPER

The train and test sets were used during the data analysis stage to determine the success of an ANN approach. During the model development stage, the validation data set was used to validate the model developed.

The impact of polymer type and colour It was noted during the initial assessment of the data that the polymer dosing rates changed drastically during 2007. Rand Water indicated that the polymer that was used at Zuikerbosch No 4 system changed

twice during the study period. The first period was beginning of study period to Januar y 2006, the second was Februar y 2006 to October 2007 and the third was November 2007 to December 2009. An additional field was included in the input data to reflect three different polymers labelled polymer 1, 2 or 3. Colour was also added as an input. The predicted and actual values are compared in figures 4 and 5. It is evident that the model’s underprediction reduced significantly in the case of both the lime and the polymer dosing.

FIGURE 7 Comparison of actual versus predicted polymer dosing rates

FIGURE 8 Comparison of actual versus predicted lime dosing rates

FIGURE 9 Comparison of actual versus predicted polymer dosing rates

IMIESA October 2013

Split data set based on settled water turbidity less than 3 NTU The disadvantage of using all the settled water data to train the model is that ‘good’ operational data is mixed with ‘bad’ operational data, which could possibly force the network to learn ‘bad habits’. In order to assess the influence of this phenomenon, it was decided to train the model using a screened data set using data only where a settled water turbidity of less than 3 NTU was achieved. The results are indicated in figures 6 and 7.

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TECHNICAL PAPER

The inputs and outputs remained the same. The model was able to predict the dosing rate to a maximum error of 0.5 mg/ℓ.

Split data set based on polymer type In an attempt to establish if the prediction ability of the model can be improved, three separate models for the operational data during the three polymer dosing periods were developed. The periods for polymers 1, 2, and 3 were divided into the three periods: the first period was November 2005 to Januar y 2006, the second was Februar y 2006 to October 2007 and the third period was from November 2007 to December 2009. Each period was trained separately. It is evident from figures 8, 9 and 10 that minor model improvements can be made by subdividing the data set into the three polymer dosing periods. Graphically, the difference in the three separate models (green dots) and one model using three different types of polymers (brown dots) is hardly visible in terms of the lime dosing. A noticeable improvement can, however, be obser ved in the case of the polymer and chlorine dosing rates. High rainfall during end of 2009 As a result of the high rainfall and subsequent change in water quality, Rand Water requested that the model test be extended for this period as well. The model was trained only for the data where polymer type 3 was used from November 2007 to March 2010. The model was able to predict the dosing rates during the sudden change in raw water quality as shown in figures 11 and 12. ANN-based budgeting tool Once the ANN model has been calibrated with good operational data, it can be used to predict dosing rate given a set of input parameters. The input parameters would comprise data for each month of the year for: production rate, treatment process, polymer type and the key raw water quality parameters. The output will be predicted dosing rates for polymer, lime and chlorine. A table similar to the one shown in Table 3 will be used as input to the model and the ANN model output will then be used as input into the Rand Water budgeting spreadsheet. Conclusion Over many years, Rand Water collected valuable operational and water quality data with the intention to analyse the data and determine trends and optimise the chemical dosing and predict the treatment cost. A project was initiated where the data was ‘mined’ and an ANN model was developed to ‘learn’ from the data and make accurate chemical dosing predictions. A number of model refinements were considered in order to ascertain which input parameters influenced the model accuracy. The following general conclusions can be made: • The ANN model does require NTU, alkalinity, pH and colour inputs as a minimum. 

IMIESA October 2013

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TECHNICAL PAPER

• All input parameters should be sampled at the same frequency in order to improve ANN input data accuracy. • It is necessar y to indicate the treatment process type in order to bias the model for high lime or low lime treatment. The model is not able to predict the wide range of lime and polymer dosing rates if the treatment process type is not included as an input parameter. • It is necessar y to include the polymer type as the different types of polymers have different coagulation and flocculation properties. • It is necessar y to include the water treatment rate as settling efficiency is better at lower hydraulic loading rates and the reduced energy available for flocculation may impair flocculation at lower production rates. • It is necessar y to train the model with good operational data in order not to ‘teach’ the model bad habits.

• The model was able to correctly predict the dosing rates that were applied during a period where raw water quality spikes were experienced. • It was found that the model was more accurate for shorter modelling periods. • It was possible to reduce the prediction error to below 1% with sufficient model input as highlighted above.

References 1. Savic, DA Davidson, JW & Davis, RB (1999) Data mining and knowledge discovery for the water industry, Savic and Walters Ed 2. Rietveld, LC (2005) Improving operation of drinking water treatment through modelling, Technical University of Delft 3. Van Leeuwen, J et al (undated), modelling the application of inorganic coagulants and pH control agents for the removal of organic matter from drinking waters 4. Liu, JC & Wu, MD (1997) ‘Fuzzy control of coagulation reaction through streaming

FIGURE 10 Comparison of actual versus predicted chlorine dosing rates

FIGURE 11 Comparison of actual versus predicted lime dosing rates

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current monitoring’, Water Science and Technology (36) 2 5. Scheffer, E (1999) A predictive relational fuzzy logic model for activated sludge processes, Water industr y systems: modelling and optimization applications, Savic and Walters Ed, RSP Press 6. Van der Walt, JJ et al (2002) Fuzzy logic production control - The Vaalkop water treatment plant case study, WISA 2002 7. Chen, CL & Hou, PL (2006) ‘Fuzzy model identification and control system design for coagulation chemical dosing of potable water’, Water Science and Technology: Water supply (6) 3 8. Wu, GD & Lo, SL (2008) ‘Predicting real-time coagulant dosage in water treatment by ar tificial neural networks and adaptive network-based fuzzy inference system’, Engineering Applications of Artificial Intelligence 9. Baxter, CW Stanley S J & Zhang Q (1999) Development of a full-scale artificial neural

TECHNICAL PAPER

network model for the removal of natural organic matter by enhanced coagulation, Water SRT - Aqua 48 (1999) 129-136 10. Yu, RF et al (2000) ‘Application of artificial neural network to control the coagulation dosing in water treatment’, Water Science and Technology (42) 3 11. Baxter, et al (2000) Developing Artificial Neural Network Process Models: A Guide For

by fuzzy control and neural networks’. Water Science and Technology (43) 11 14. Shariff et al (2007) Real-time artificial intelligence control and optimization for a fullscale WTP, AWWA 15. Palisade (2012), www.palisade.com

Drinking Water Utilities, 6th Environmental Engineering Specialty Conference of the CSCE 12. Joo, D Choi, D & Park, H (2000) Determination of optimal coagulant dosing rate using an artificial neural network, J Water SRT - Aqua 49 (2000) 49-55 13. Bongards, M (2001), ‘Improving the efficiency of a waste water treatment plant

For information about this paper, please contact the editor at nicholas@3smedia.co.za

FIGURE 12 Comparison of actual versus predicted chlorine dosing rates

TABLE 3 Summary of model inputs and outputs

Year

2010

Month Jul

2011 Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Raw Water Quality Information

Unit

Input

NTU

47.00

57.00

62.40

77.00

64.10

58.00

58.95

41.10

34.00

41.95

46.00

ALK

mg/ℓ

74.00

81.05

70.00

71.00

70.00

70.60

67.00

70.00

79.00

73.00

79.00

COL

mg/ℓ

72.82

70.92

24.76

65.23

60.07

121.99 148.91 38.28

70.08

84.18

65.51

65.84

8.30

8.40

8.20

8.24

8.10

8.30

8.01

8.20

8.30

8.20

8.40

Process Information Unit

Input

Polymer type

1, 2, 3 3

% water treated with polymer

% water treated with lime

Treatment information

Unit

Input

Zuikerbosch #4 treatment rate

Mℓ/d

1426.5 1495.0 1563.1 1597.8 1544.2 1480.8 1467.7 1522.5 1495.8 1362.1 1400.2

Dosing Rate Information

Unit

Output

Lime

mg/ℓ

7.4

7.8

17.0

3.4

7.4

-6.6

14.6

7.7

6.5

3.6

5.0

6.0

Polymer

mg/ℓ

5.1

5.5

6.3

6.9

7.2

13.1

13.9

9.0

4.6

5.4

5.7

Chlorine

mg/ℓ

2.8

2.7

2.6

3.3

2.8

2.9

2.7

2.8

2.7

1352.5

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PROFILE

LEKWA CONSULTING ENGINEERS

Cooperation between public and private sectors Established in 2001, Lekwa Consulting Engineers is a small, fully representative Level 4 BBBEE civil engineering consultancy. Its dynamic approach is based on finding synergies with public and private sector stakeholders as well as its recipient communities.

S A MEDIUM-SCALE empowerment South African civil engineering consultancy, Lekwa is committed to world-class service delivery within the rich diversity of local South African context and is dedicated to promoting value-added services and technical skills development in the broader Southern Africa and African sphere of civil engineering discipline.

Mission Through its dedication, integrity, consistency and professionalism, the company offers: • quality value added • a high level of technical exper tise and professionalism • economically sound engineering and project management processes according to worldclass standards and specifications • a commitment to sustainable projects, taking into consideration socio-economic, community and environmental concerns • access to skills transfer and job creation initiatives within the local South African context. Improving service delivery Lekwa continuously strives to introduce creative solutions to support government initiatives to create jobs and improve service delivery. Its key specialist services include the design and implementation of municipal and other infrastructure projects. In addition, the company offers value-added project management according to internationally accepted standards. Achievement of project deliverables and excellence in service delivery invariably involves balancing the competing demands of

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scope, time, cost and quality within the context of the requirements of all project stakeholders. Its approach combines high-level technical expertise with integrated project management services to ensure excellence in terms of service delivery. Lekwa offers the value-added advantage of providing a more individualised service to its clients. For the convenience of clients, and to enhance service delivery outputs, the company has established office network covering Gauteng, KwaZulu-Natal, Mpumalanga and the Free State.

Ownership, management and staff The company places high premium on leadership and management skills, and regards the development of human resources as an investment. Lekwa is steered by two seasoned professional engineers: Kibiti M Ntshumaelo and Gert JN Smit. The company continually seeks to develop and nurture technical skills of our staff members and every effort is made to appoint suitably qualified professionals particularly from previously disadvantaged groups. The qualifications and experience of the company’s staff members cover the fields of civil, municipal and railway engineering, mining engineering, project management and administration. With a permanent staff complement of 20+, Lekwa’s services are available to both the public and the private sector clients. Infrastructure and equipment Lewka boasts a range of specialist computer hardware and software resources and specialist equipment such as surveying equipment, digital cameras and soil testing equipment.

Services Lekwa has thorough experience in the design and implementation of municipal, railway and mining infrastructure projects such as water and sewer infrastructure, roads and stormwater designs, housing, buildings and structures, permanent way structures, bulk earthworks, mine residue, dams and dirty water management. The company has intensified its efforts to ensure that projects are integrated and executed in terms of sound technical, economic and socio-economic, and environmental requirements. It continually strives to adapt to labour-intensive project alternatives and other job creation solutions through the implementation of the Expanded Public Works Programme. The company can execute projects in accordance with the Engineering Council of South Africa (ECSA) Guideline Scope of Services and Tariff Fees for registered professionals. Registration with professional bodies Lekwa Consulting Engineers is a member of CESA, and the South African Black Technical & Allied Careers Organisation. It employs professionals registered with ECSA and the South African Institution of Civil Engineering.

t +27 (0)11 868 2494 www.lekwaconsulting.co.za

Geospatial solutions for national development TGIS supports the NDP and the NGP in a year of change and development 2013 has become a watershed year for Total Geo-Spatial Information Solutions (PTY) Ltd. (TGIS). It is a year of change where after more than 14 years of laying solid foundations it has undertaken, amongst other initiatives, appointing a CEO and a formal marketing executive. Together with the redoubtable Lance Nel, visionary Johann Engelbrecht and innovative Ciska Engelbrecht, TGIS has undertaken a restructuring thrust to further empower and transform its operations and value to its client base. This has meant that TGIS wishes to translate its current technological innovations into durable solutions across Government as spatial intelligence and data integration are critical for SA's future, as both the NGP and the NDP affirm. After TGIS achieved ISO certification last year it has begun to look at how itâ€™s extends and deepens its offerings to the public sector. A key solution area in the last 5 years has been TGIS involvement in infrastructure asset registers and audits at municipal level to meet GRAP requirements. Through involvement in operation clean audit 2014 and utilizing its innovative data collection technologies (3D mobile mapping and Mobile GIS) TGIS has earned a reputation for effective municipal infrastructure asset register creation and audit assistance. A further advance has been the launch at the recent Geomatics conference on the 23/24 July 2013, of the integration of 4 technological spheres into a single data capture environment giving control of the creation and maintenance of massive and complex data sets such as information regarding, roads, sewer, water and electricity. The Integrated Municipal Information System (IMIS), furthermore continues to offer a range of mechanisms, which are deployed in stages (modules), to build towards an e-governance solution tailored to the African continent and our specific and unique circumstances. IMIS as a system that integrates documentation management on land data via a GIS, with business process functions such as HR and customer management, empower any municipality, government department, or entity to achieve their own development goals as well as producing a noticeable improvement in service delivery levels.

Enrico Fourie CEO enrico@tgis.co.za

switch 012013

Engineering Cape Town since 1950 As one of the oldest civil engineering contractors in South Africa, we have been partnering with the public and private sector to deliver innovative and effective solutions for more than 60 years.

www.martin-east.co.za

ROADS & BRIDGES

BETTER ROADS, BETTER LIVES

Cape Town’s rapid road transport system Martin and East is a civil engineering construction company that delivers high-quality construction management and civil engineering solutions for both private and public sectors.

VER THE past five years, Martin & East has had a significant stake in the roll-out of the City of Cape Town’s MyCiTi Integrated Rapid Transport (IRT) system. The group has been awarded a substantial portion of the trunk route contracts stretching from the CBD to Atlantis. Phase 1 has significant importance as it is considered by the City of Cape Town to be the pilot project that sets the tone for the roll-out of the remaining phases through critical areas such as the Cape Flats.

Setting the tone for city-wide impact In late 2008, Martin & East commenced construction of the Paarden Eiland bus lane, its first project under Phase 1 of the IRT roll-out. To date, the company has been awarded and successfully completed almost 60% of the trunk route tendered under Phase 1. In general, the primary works consist of the construction of red concrete bus lanes; various road widenings, realignments and reconstruction; bus station substructures and the upgrading of the existing street lighting scheme throughout the designated IRT route. The ancillary works comprise the installation of a surveillance network, upgrading the signalisation scheme and various landscaping and line marking works.

Translating values into delivery These projects required the management of the construction, environmental, health and safety, procurement and community aspects of the IRT construction. The company’s objective to invest in people, innovate, ensure integrity and honesty as well as high standards of safety and environmental awareness and creating partnerships have played a major role in the successful delivery of all IRT projects to date. The company’s involvement in the IRT project has allowed it to broaden its skill set and forge invaluable partnerships with specialist subcontractors within surveillance and signalisation fields and strengthen existing relationships with its suppliers. These relationships allowed Martin & East to provide the client with a high-quality product at the most competitive price possible.

associated with open trench excavation. Red ultra-thin friction course was developed on the CBD bus lanes by another subsidiary of the Martin & East group, Zebra Surfacing, which was also responsible for the asphalt paving on these projects.

Sustainable relationships and practices Environmentally friendly practices have been utilised extensively throughout the bus lanes completed thus far. The reuse of existing pavement materials through crushing and in-situ recycling methodologies have reduced both the burden on the province’s quarries and cost to the client. Martin & East is proud to have contributed to the upliftment of local communities through identifying and employing both local businesses and labour.

Innovations in trenchless technology Innovative drilling technology provided by Martin & East’s subsidiary, TT Innovations, has been used extensively throughout the IRT bus lanes. The trenchless installation of various services preserves the existing road surface, reduces installation time and eliminates the traffic congestion and safety risks

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C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3

Sustainability is everyone’s business The CESA Aon Engineering Excellence Awards were a celebration of innovation, quality, outstanding workmanship and professionalism in the industry.

HE EVENT SERVES as a platform to showcasee the important role that infrastructure plays in thee sustainable development of South Africa. Thee awards focus on consulting engineers and theirr clients who participate in or initiate projects that promote thee advancement of the nation and the people of the continent.. In South Africa, the need to collectively balance social, politi-cal and economic issues with a wide spectrum of complexx environmental issues is paramount. We need to create ann awareness of what the earth can provide and how carefullyy our natural resources can be used, especially those that aree not renewable. Leadership becomes all the more importantt and future leaders of developing countries need to be choosen on the basis of their ethical balance as well as their ‘sustainability savvy’! Risk advisors and insurance brokerage Aon has been the proud main sponsor of the event for a number of years now and it’s a relationship that Consulting Engineers South Africa (CESA) values highly. According to Aon: “CESA members have a pivotal role in South African society and in the greater South African economy. The progress of this country and its sustainability is touched on a daily basis by some facet of engineering, and without this science, the vast majority of development and upliftment we need would not happen – the role that engineers now play more than ever before in terms of the well-being of our citizens is immense.” Awards were handed out in the following categories: Engineering Excellence for projects with a value of less than R50 million, projects between R50 million and R250 million, and projects with a value of over R250 million. Other categories were Best International Project, Visionary Client of the Year, Mentor of the Year, Business Excellence, Mentoring Company of the Year, Young Engineer of the Year, Publisher of the Year, Job Shadow Initiative and Branch of the Year. The category of Engineering Excellence with a value greater than R250 million was won by ILISO Aurecon Joint Venture for the improvements to the Dr Chota Motala Road Interchange on the N3 National Road for the South African National Roads Agency (Sanral) and Msunduzi Municipality, with HHO Africa receiving a commendation for Atlantis Corridor ‘MyCITI’ System: Integrated Rapid Transit Infrastructure for City of Cape Town. The category of Engineering Excellence with a value between R50 million and R250 million was won by Aurecon for the Mayfair on the Lake office building for Growthpoint Properties. GIBB received a commendation for the rehabilitation of East London Airport Project for Airports Company South Africa.

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IMIESA October 2013

The category of Engineering Excellence with a value less than R50 million, was won by SMEC South Africa for the Tshelimnyama Pedestrian Bridge for South African National Roads Agency. ILISO Consulting received a commendation for the Top Gear Internal Race Track, Moses Mabhida Stadium, for eThekwini Municipality. In the category of Best International Project, sponsored by the Built Environment Professionals Export Council (BEPEC), Aurecon was announced the winner for the NBL Mbarara Greenfields Brewery for Nile Breweries, a subsidiary of SABMiller Group, and SMEC South Africa received a commendation for the widening and strengthening of the Okavango River Bridge for the Roads Authority of Namibia. Bigen Africa Services and Bosch Holdings were announced joint winners of the Business Excellence category. UWP Consulting won the Mentoring Company of the Year category, which was sponsored by Bosch Holdings. Kobus Viljoen from Bigen Africa won the category of Mentor of the Year. In recognition of the role that the media plays in the industry, Creamer Media received recognition for Publishing Excellence: Trade Media and Times Media received recognition for Publishing Excellence: Daily Newspapers. The Visionary Client of the Year Awards was bestowed on Transnet and its Transnet National Ports Authority division as well as to the Coega Development Corporation for the Coega IDZ and its dedicated deep water Port of Ngqura. The winner in the category of Young Engineer of the Year is Andreas Melusi Ndlovu from ILISO Consulting, with Jan Theron from Royal HaskoningDHV receiving a commendation. Hatch Goba was announced winner of the CESA Job Shadow Initiative, with ILISO Consulting as 1st runner-up and Royal HaskoningDHV and UWP Consulting joint 2nd runners-up. CESA’s Eastern Cape Port Elizabeth Branch was winner of the Branch of the Year Award.

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 WINNER: PROJECTS WITH A VALUE GREATER THAN R250 MILLION Improvements to the Dr Chota Motala Interchange

Major improvements to a major interchange The Dr Chota Motala Road Interchange is located at the intersection between the N3 and the provincial route R33, Dr Chota Motala Road.

HE NEED FOR a reworking stemmed from the diamond interchange and various intersections along the Dr Chota Motala Road operating at a low level of service. The section of the existing N3 freeway between the Dr Chota Motala Road and Sanctuary Road functioned as a commuter route in peak hour and the operations were affected by a high level of pedestrian activity through the interchange. The primary objectives of the improvements to the Dr Chota Motala Road Interchange on the N3 were to relieve current congestion on the N3 and the Dr Chota Motala Road, to eliminate problematic traffic movements and to provide additional capacity to year 2026. The client for this project was the South African National Roads Agency Limited (Sanral) together with the Msunduzi Municipality, where Sanral was the implementing agency. ILISO Consulting and Aurecon were appointed in joint venture as consulting engineers on the project. Aurecon was responsible for the major bridge works, and ILISO Consulting for the traffic planning and roadworks. The main contractor was Group Five Construction in joint venture with Phambili. Structural Systems was appointed as subcontractor for the bridge prestressing and jacking operations, and DNA Consulting Engineers was appointed for electrical and lighting works. The major structural work on this project comprised the demolition and reconstruction of two bridges, the construction of two new bridges and the widening of one bridge. A fundamental requirement â€“ and the major challenge â€“ was to maintain traffic flow through the interchange during

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IMIESA October 2013

construction. The most efficient and least disruptive measures for demolition or construction were adopted in each case. The 220 m long curved viaduct for Ramp E at the highest level was incrementally launched to avoid any impact on traffic or exposure to danger during construction. The Dr Chota Motala Road Bridge over the N3 was constructed in half widths, with the existing structure rapidly demolished with the N3 closed for 48 hours. The Dorpspruit River Bridge was widened and raised to eliminate future flooding potential. While the project included improvements to the N3, upgrading of the interchange and alterations or improvements to other structures, the directional ramp E is fundamental to the final scheme, and the incrementally launched viaduct demanded the most attention to detail and specification. The 220 m long deck consists of a single cell prestressed concrete box girder with a total of seven spans varying in length between 25.15 and 36.05 m, arranged symmetrically around the centre. The deck is supported on six piers, four of which are founded on piled foundations and two spread foundations. The piers, varying in height from 6.2 to 15.9 m, vary from 2 m diameter circular section at the base and flare out over the top 6 m to a 3.6 m diameter to yield a champagne flute shape for improved appearance. The existing N3 concrete pavement was in a poor condition and Sanral had a programme for rehabilitation and improvement, including widening to three lanes in each direction. On this project, an additional auxiliary lane was also required between the two interchanges to improve capacity and weaving movements. The design allowed for the widening to be accommodated in the median, with carriageways separated by concrete barriers. The design of the pavement included an asphalt interlayer over the existing concrete, both to improve the distortion in the surface levels and to separate the new continuously reinforced concrete pavement overlay.

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 COMMENDATION: PROJECT VALUED OVER R250 MILLION Atlantis Corridor ‘MyCiTi’ system integrated rapid transit infrastructure

Cape Town’s public transport pilot project

LTHOUGH BRT SYSTEMS have been developed all over the world, the MyCiTi System is the South African pilot design. For this reason, the consulting engineers were challenged to experience, evaluate and indigenise international design elements into local circumstances. Certain design elements of international best practice needed adaptations, thus encouraging inventive solutions, developments and applications by the team. These innovations were later embraced and even elaborated on by the client. The complexity and sophistication of this project lies in balancing the interactions and transportation needs of all road users safely, in what has historically been

a car dominated road network. The introduction of dedicated BRT infrastructure, the upgrading of pedestrian and cycling environments and the management of the complex interactions, prioritisation and safety measures implemented on the Atlantis IRT Corridor, have revolutionised the urban environment and public perception of an inclusive and sustainable roadway in South African cities.

IMIESA October 2013

Congratulations to Aurecon/Iliso JV on achieving this prestigious award. We are proud to be associated with SANRAL and Aurecon/Iliso JV as Electrical Engineers. Dr. Chota Motala Interchange stands as a milestone as the first national interchange in South Africa to be installed with LED Lighting Technology. The full design and site management of the electrical component was undertaken by DNA Consulting Engineers & Project Managers for South African National Roads Authority (SANRAL). DNA Consulting Engineers have extensive experience nationally and internationally in design, procurement and management of projects resulting in a satisfied clientele base and a mark of excellence with regard to project deliverables. Specializing in Low & Medium Voltage reticulation, street lighting and electrical and electronic building services. DNA Consulting Engineers are proudly South African waving a level 1 BͲBBEE flag and a multitude of certifications and affiliations that assure the private and governmental sectors of the unmatched service excellence that can be provided to them. Serious about excellence in design. DNA Consulting Electrical Engineers & Project Managers BͲBBEE Level 1

Email: info@dnaengineers.co.za Tel: (+27)31 208 2107/0652 Visit us at www.dnaengineers.co.za / www.dnaprojects.co.za

Scorecard Spend: 135% Value adding Supplier: +25 %

ENGINEERED TO DELIVER

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C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 WINNER: PROJECTS BETWEEN R50 MILLION AND R250 MILLION Mayfair on the Lake

Innovative engineering and design Growthpoint Properties commissioned the Mayfair on the Lake office building in the Umhlanga New Town Centre as the first untenanted Green Star rated building in KwaZulu-Natal.

HE ASSEMBLY OF an exceptional project team, which included Aurecon as Green Building consultants and HVAC engineer, in combination with a client committed to the execution of their vision produced a highly successful outcome. Mayfair on the

Lake is only the third building in South Africa to achieve both Office Design v1 and As Built v1 Green Star SA ratings. The development offers tenants cost-efficient and environmentally friendly office space. The adherence to sustainability and low energy consumption principles, while incurring an upfront ‘green’ premium, has created a sound, long-term investment. The building is an L-shaped, five-storey office building with a shared courtyard containing a ramp that provides access to two basement parking areas. A number of different design elements played a role in ensuring its sustainability. These include: • Maximising natural light in the building: The building was designed to maximise views to the scenic outdoors for building users, with all occupants being within 8 m of a clear window. • Proactively reducing the impact of pollutants: Outside air rates were boosted and surpass SANS 10400 Part O requirements for fresh air ventilation rates to counteract the build-up of indoor pollutants. • Low water consumption fittings: Water-efficient fittings such as dual flush toilets, waterless urinals, high-efficiency showers for cyclists and low-flow efficient taps have been used throughout the building to reduce the consumption of water. • Condensate harvesting reduces use of potable water: Condensate wastewater from the air-conditioning system, over and above rainwater harvesting, replaces the normal use of potable water for the building’s toilet flushing system. • Thorough insulation results in substantial energy savings: The energy modelling performed on the actual building showed an energy saving of 46% over the notional building designed by SANS 204 criteria. This was accomplished through the use of insulated walls and roof, double glazing on all windows, as well as clay bricks in the design of the building • Use of motion sensors to conserve energy in unoccupied areas: These automatically switch off lighting when areas are not in use and reduces the energy wasted by lighting unoccupied areas. • Tenant areas separated for flexible control: The mechanical system consists of air-cooled chillers, which supply chilled water to the separate air handling units located at each of the separate tenant areas. The design of each tenant system is such that unoccupied areas can be isolated to reduce the energy consumption of the main plan.

Aurecon provides engineering, management and specialist technical services for public and private sector clients globally. We work closely with municipalities to provide high quality, costeffective and sustainable services aimed at optimising economic growth and job creation, positioning assets to meet service delivery priorities and accommodating long term growth. We partner with governments to improve the quality of life of the communities in which we operate. Aurecon’s technical competencies span the entire infrastructure life cycle, including the planning and development of municipal infrastructure through to integrated and high-tech solutions for the provision of basic services. For more information contact Danie Wium Government Industry Leader T +27 12 427 2489 E danie.wium@aurecongroup.com

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IMIESA October 2013

COMMENDATION: PROJECTS BETWEEN R50 MILLION AND R250 MILLION

Steel Pipe for Water, Petrochemicals, Gas, Construction and Mining

Rehabilitation of East London Airport

Manufacturing Pipe Since 1924.

Unusual construction methods An extensive rehabilitation project, GIBB has won two awards for this project to date.

Hall Longmore ranks amongst the

leading

international

manufacturers of large diameter steel pipe for the transportation of water, gas and petrochemicals. The in-house application of high performance protective coatings and linings to steel pipe is an

HE MAIN FOCUS of the project was the structural rehabilitation of two runways and seven taxiways. Ancillar y items, such as associated subsur face drainage, electrical works and landscaping of surrounding areas also formed part of the contract. The project was initiated by Airports Company South Africa (ACSA) to optimise airport operations and passenger safety. Upgrading of the safety strips was then added to the initial runway and taxiway upgrades. The safety strips are a significant project in itself. GIBB first got involved at East London Airport three years ago with a drainage project. It then offered to monitor the condition of the runway and submitted a report, and this led to an initial mill and fill project before the current project was initiated.

IMIESA October 2013

113

essential ingredient when years of trouble-free pipeline service is a pre requisite. The Hall Longmore name is synonymous with quality and to this end holds the esteemed accreditation of the American Petroleum ISO

Institute

9001:2008,

18001:2007

and

BS ISO

(API, OHSAS 14001

JLY[PĂ„JH[PVU

Tel: Email: Web:

+27 11 874 7300 info@hall-longmore.co.za www.hall-longmore.co.za

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 WINNER: PROJECTS VALUED BELOW R50 MILLION Tshelimnyama Pedestrian Bridge

Socio-economic engineering Positioned on the N3, the two-span asymmetrical, cable-stayed Tshelimnyama Pedestrian Bridge is a new landmark for road users and pedestrians alike.

T WAS BUILT to create a key link in the larger pedestrian facilities upgrade project along the N3 between Westville and the Mariannhill Toll Plaza. With urban development taking place to the south of the N3, pedestrians began crossing the N3 at grade to access work opportunities in the Mahogany Ridge and Westmead industrial areas. With 800 pedestrians crossing the N3 at grade each day, the situation was unsafe and a grade separated solution was needed. The bridge is a two-span structure with a total length of 89.75 m, a main span length of 55.75 m and a back span length of 34.0 m. The 3.2 m wide deck is constructed from reinforced and prestressed concrete and is supported by 10 sets of stay cables. A 32 m long inclined, twin-legged structural steel tower supports the cables by means of spade and fork connections. Because the tower leans, the structural systems need lateral restraint. The end of the bridge deck is therefore integral to the southern abutment, which is anchored into the rock with 12 rock anchors. The first pair of cables on the bridge connects the tower to the rock anchored abutment. This connection to a rigid point provides much of the stiffness in the structural system and limits the deflection of the deck due to asymmetrical dead and live loads. The concept design of a cable-stayed bridge with a leaning structural steel tower was the winning entry in a design competition held by Sanral. The design team wanted to create something that had individual character but also responded to the context of the site and the client’s budget. As with any bridge structure, the design engineer had to use his ingenuity and technical experience in conceptualising the structural form. SMEC approaches design as a holistic process and in doing so actively engages with architects. This collaboration is well developed in the field of bridge engineering and the aim is never to subdivide the design responsibilities. SMEC has found the success factors in the

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integrated design team to be mutual respect and for the structural engineer never to shy away from taking on a leading role in the creative design process. In this instance, an arch, suspension or cable-supported structure was judged necessary to span the required 56 m over the N3. However, an anchored cable stayed bridge was proposed because: • it is a simple and elegant structure that sits comfortably in the site and it might be considered a positive landmark due to its dramatic form • it is a cost-effective solution that is appropriate for the purpose of conveying 800 pedestrians each day • it is very efficient materially and the use of a single steel tower and a reinforced concrete deck offers an economical and durable solution for the required span lengths • the technology required to build and maintain a cablestayed bridge of this form is tried and tested. A structural steel tower was chosen for the following reasons: • a cast in-situ concrete tower would have required complex staging that overhung the N3 • a precast concrete tower was considered too heavy to be practically handled and would have required significant temporary works to support it during the cable stressing operations • the reduction in weight offered by structural steel offered significant advantages when installing and temporarily supporting the tower • the use of structural steel offered an opportunity to sculpt the tower to a unique profile.

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 COMMENDATION: PROJECTS VALUED BELOW R50 MILLION Top Gear Internal Race Track at Moses Mabhida Stadium

A mainstream showcase for engineering The design and implementation of the Top Gear Track within the Moses Mabhida Stadium was completed on time and within budget.

HIS PROJECT facilitated one of South Africaâ€™s most successful Top Gear events and helped showcase Durban and South Africa as a world-class destination. Top Gear Festival has signed a contract to host within the stadium for a minimum of three years and is rolling out similar events around the world based on this South African model. The project included detailed design of the internal track alignment, pavement layer works and stormwater system. The track alignment needed to

accommodate the very high tolerances required for highspeed vehicles and ensure that there was no adverse effect to the pitch. This project was unique in its requirements and allowed the ILISO Consultingâ€™s professional team to use the experience gained on conventional civil engineering projects to produce a high-quality, fit-for-purpose race track within an operational stadium.

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A strong, multipurpose semi-rigid industrial surface founded on more than a 30 year track record, Salphalt combines the flexible characteristics of bitumen macadam with the abrasion and wear-resistant properties of concrete. With a thickness of between 30 and 60 m, Salphalt can be applied to any suitably prepared new or existing foundation.

SALPHALT INDUSTRIAL SURFACING SYSTEMS

Salphalt reaches its optimum strength in 28 days though pedestrians can use the surface within a few hours, light vehicles in two to three days, and heavy trucks often as soon as two weeks. Shorter periods are possible but should be judged on a project by project basis.

Salphalt Industrial Surfacing Systems primarily manufactures this internationally acclaimed product, as well consultations on the assessment of projects for the use of Salphalt and proper use.

PRODUCTS AND SERVICES

• Ideal for perpetual heavy vehicle wear • Chemical resistance • Extreme temperature tolerance • Jointless surface

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CESA AON ENGINEERING E X C E L L E N C E AWA R D S 2 0 1 3 WINNER: BEST INTERNATIONAL PROJECT

STRATEGIC PARTNERS

Nile Breweries' Mbarara Brewery

A complex construction solution Uganda’s largest brewer, Nile Breweries (NBL), is a subsidiary of the SABMiller group. NBL commissioned a project to build a greenfield brewery in Mbarara to double the company’s current capacity.

HE CHALLENGING site for the new brewery was on sloping, uneven ground alongside the Rwizi River. Through careful design and meticulous attention to detail, the project team achieved a highly efficient plant layout that makes provision of future expansion and meets the SABMiller global environmental standards. The project team was responsive to the surrounding community and the project has provided far-reaching commercial benefits for the local town population, as well as the country as a whole. The new NBL Brewery is one of the finest in East Africa and is a world-class example of project management and engineering excellence. In 2012, NBL embarked on the construction of a new greenfield brewery in Mbarara, south-western Uganda with the aim of doubling its annual capacity in the country to 3.6 million hectolitres. The company, which estimates that Uganda’s market for beer is growing at more than 28% a year, wanted to take advantage of the rapid growth. NBL sought full EPCM services for the massive US$80 million (R809.44 million) plant. To achieve these requirements, a project team was appointed, with Aurecon fulfilling the role of civil and structural consultant, working in close conjunction with process designer Krones AG. NBL’s project division, Capital Projects, set out to create what would be the most advanced brewery in the country. Some of the impressive characteristics of the brewery are: • construction meets international standards and world norms • efficient, cost-effective design • optimised ‘cost spent per hectolitre’ • reduced construction time due to implementing lessons learnt on previous NBL projects. Construction commenced shortly after the appointment of Aurecon as the civil and structural engineer, placing tremendous pressure on the design team to prioritise drawing deliverables based on the progress made on-site. The project team met frequently for design review meetings to track drawings and ensure the timeous delivery of information to the contractor. The short interval between design and construction called for high-quality, optimised design at all times, without any room for error. Tight project time frames were met through the sustained well-coordinated performance of the project team. The Mbarara plant is expected to produce 0.65 million hectolitres annually, with the capacity to increase output to 1.8 million hectolitres. All utility services, such as the water distribution, steam, power and compressed air systems, were fixed to a custom-built services spine located on the underside of the mezzanine floor. They are positioned above ground in this common area of the brewery to facilitate easy maintenance.

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Born and bred right here - Bell is Africa’s very own global equipment supplier. With Bell you get machines built tough for our harsh environment and support from Africa’s most comprehensive network of people dedicated to your success. Best of all, while you are creating infrastructure and jobs, so are we. Choose Bell as your equipment partner and enjoy the pride of knowing you’re not just boosting your business but helping make Africa a better place too. Tel: +27 (0) 11 928 9700 E-mail: sales@bell.co.za www.bellequipment.com

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 COMMENDATION: BEST INTERNATIONAL PROJECT Widening and strengthening of the Okavango River Bridge

An innovative deck overlay The Okavango River Bridge was constructed in the 1970s and was originally designed to carry a 60 t army tank on top of the 5.5 m wide deck and to allow army troops to walk through inside the deck.

S A RESULT of this design, all the structural elements are robust andd heavily reinforced. After the construction of the Zambezi River Bridge near Katimaa Mulilo, this road now became a major access for heavy and abnormall vehicles travelling from the harbour at Walvis Bay to Zambia and beyond, especial-ly the Zambian Copper Belt. The bridge has now become strategically important.. By utilising state-of-the-art engineering software and design practice, thee professional team hired to refurbish the bridge was able to design for complexx structural behaviour, leading to a durable yet cost-effective structure. The designn team was experienced at designing composite bridges, balanced-cantileverr bridges, cable-stayed bridge as well as other structural forms. This reduced thee risk associated with the innovative approach to widening and strengthening off the existing bridge.

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C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 JOINT WINNER: BUSINESS EXCELLENCE Bigen Africa

The S-Vision 2016 strategy In 2012, Bigen Africa formalised its path towards becoming a leading infrastructure development firm that provides the full spectrum of engineering, management consulting, project delivery services and project financing and advisory services in a five-year strategy that it called: S-Vision 2016.

LL ASPECTS of the strategy comply with the Third King Report on Corporate Governance, which Bigen Africa adheres to in all facets of its business. Its corporate governance framework is also underpinned by various management systems and charters that guide all facets of business. The ultimate goal of the strategy is to develop infrastructure sustainably and in such a way that its use promotes socially desirable developmental outcomes, including access to services, reduction of poverty, capacity building, empowerment and the creation of employment opportunities. This objective extends to delivering projects in such a way that they complement key public policy priorities in countries focused on developing and improving integrated human settlements, rural areas, renewable energy, road and rail freight transport, and the operation and maintenance of existing infrastructure. These services have been identified as priority areas for Bigen Africa’s participation and contribution. S-Vision 2016 includes expanding Bigen Africa’s contribution to asset management, roads and transport, mining and energy, while continuing to excel in water and sanitation, human settlement, structures and development financing services. The company has geared itself to expand its service delivery in South Africa and the African continent from its existing base of 14 offices across South Africa, Namibia, Botswana, Ghana and Zambia. Several senior management appointments were made in the past six months to add momentum to the company’s growth plans and its expansion into new areas of service delivery. The S-Vision 2016 plots the company’s expansion plans into Africa. The first objective is to expand its presence in SADC countries through the Pretoria head office and offices in Botswana, Namibia and Zambia. Bigen Africa’s reach into West Africa has been strengthened through a branch in Ghana and partnerships in Senegal and Mali. In this region, the roads and transport, industrial and mining, water and sanitation, and housing and commercial development sectors are focus areas. Bigen Africa also plans to expand into East Africa, through Kenya and North Africa. Bigen Africa’s business focus and value system combine to underscore the company’s conviction that infrastructure development is, first and foremost, about the sustainable

benefits stakeholders derive from its use. Bigen Africa has transformed into one of the country’s leading infrastructure development activists, committed to improving the quality of life of all people through appropriate, sustainable infrastructure development solutions. This is complemented by the company’s commitment to leadership development, sound financial practices, an ongoing focus on the triple bottom line and compliance with international best practices. Bigen Africa’s management and leadership focus aims to align the activities and objectives of all managers within the organisation. The management structure is flat in order to empower all tiers of management, ensure effective and direct lines of communication and keep red tape to the minimum. Management operates at three levels: the board, the executive committee and divisional management.

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C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 JOINT WINNER: BUSINESS EXCELLENCE Bosch

Massive growth in the past decade The Bosch group of companies was founded in 1961 and has grown to become one of Africa’s leading multidisciplinary engineering, projects and operations management groups.

HE GROUP HAS offices and business associations throughout South Africa, Africa and internationally. It has successfully completed projects in over 35 countries around the globe. Bosch has an exceptional leadership team with many years of experience, coupled with attributes such as integrity, excellence, delivery, innovation, commitment and teamwork. A combination of youth and experience provides a balance of wisdom, energy and passion. With these capabilities in its camp, the Bosch leadership team can respond quickly to opportunities and challenges. Under the leadership team, Bosch Holdings has grown from 163 to 450 staff over the past 10 years. The group’s turnover has increased from R41 million in 2002 to a budget of R451 million in 2013. The group has always been a leader in technology and innovation in the engineering sector. Some examples of technical excellence and innovation over the years include: • Durban sugar terminals: These have particular importance for Bosch Holdings. Their distinctive shape and design were noted in sugar industries around the world and won a prestigious award for outstanding engineering achievement in 1965 from the Institute of Civil Engineers. A subsequent contract to build a bagged sugar warehouse next to the terminals was awarded to Bosch Holdings. • Mhlabatshane Bulk Water Supply Scheme: The completed R200 million scheme will ultimately provide an assured potable water supply to over 100 000 people in the Umzumbe and Hibiscus Coast municipalities of the Ugu District Municipality. The project scope includes a composite earth embankment and central concrete labyrinth spillway dam, pump stations, rising mains, gravity mains, reservoirs and a new water treatment works. • Komati Sugar Factory: In 1992, Bosch Projects was appointed the managing and engineering contractor for

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TSB’s 225 tch (tonnes of cane per hour) greenfields Komati Sugar Mill. The mill was designed by Bosch Projects and constructed in 1994. • Mvoti River pipe bridge crossing: Bosch Stemele was appointed as the consulting engineers for the strategic North Coast Bulk Water Pipeline project between Ballito and KwaDukuza in KwaZulu-Natal, which incorporated the Mvoti River Pipe Bridge Crossing. The project provides an innovative design solution incorporating a 220 m long steel lattice bridge that will assist in increasing capacity and improving the security of water supply in the region. • City of Bulawayo Water and Wastewater Master Plan: Bosch Stemele’s proactive intervention and the resulting Water and Wastewater Master Plan for Zimbabwe’s City of Bulawayo are an excellent example of innovative engineering and institutional planning. The master plan will provide a sustainable economic, social and environmental solution for the delivery of water and wastewater services in the city. • National waste collection training programme: This groundbreaking initiative, spearheaded by Bosch Munitech, has assisted municipalities around South Africa to significantly increase their job creation capacity. The programme has reached some 7 500 workers from 28 municipalities in eight provinces and Bosch Munitech was awarded a subsequent contract to carry out Phase 2, which will extend to 30 additional municipalities. • eMalahleni Bulk Infrastructure Programme: Bosch Munitech, the eMalahleni Local Municipality and Rand Water Services acted quickly to rectify critical water shortages in Witbank. The R45 million emergency refurbishment project to upgrade the existing bulk water infrastructure back to design capacity was completed within three months. • Ubombo Cogeneration Project: Bosch Projects’ groundbreaking Ubombo Cogeneration Project, part of its flagship Ubombo Sugar 410 tch to 500 tch factory expansion, cogeneration and off-crop refining project in Swaziland, has enabled the Ubombo Sugar Mill to export surplus power into the national grid. Bosch Projects, Bosch Munitech and Bosch Stemele now operate from new offices in Peter Place Office Park in Bryanston. Bosch Holdings has also recently established a permanent base in East Africa.

16136 tenaka.co.za

BUILDING LEGACIES Basil Read is so much more than just a group that has become synonymous with excellence in the construction sectors of Southern Africa. Our reputation is built on quality, expertise and the most innovative solutions to complex and challenging projects. Our impressive and diverse portfolio includes our ďŹ‚agship airport project on the island of St. Helena, the rehabilitation of roads and the building of hospitals. The development of new housing structures and ďŹ nding sustainable energy resources contributes to a better future for all as Basil Read is involved in diverse communities across South Africa every day. Our legacy lives on in our people, our passion and our promise to make this country a better and more enriching place for all.

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

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 RECOGNITION: VISIONARY CLIENT OF THE YEAR Transnet, Transnet National Ports Authority and Coega Development Corporation

Socio-economic development drive In the category of Visionary Client of the Year, CESA acknowledged Transnet and its division Transnet National Ports Authority as well as the Coega Development Corporation for the Coega IDZ and its deep water Port of Ngqura.

HE COEGA INDUSTRIAL Development Zone, covering 110 kmÂ˛ of land, is situated within the Nelson Mandela Metropolitan Municipality near Port Elizabeth, in the Eastern Cape province of South Africa. The Coega Development Corporation is a state-owned entity formed in 1999, mandated to develop and operate ate the Coega Industrial Development Zone while offering ng global competitiveness through world-class infrastructure, re, tax incentives, rebates and a duty-free zone. It is purposesebuilt for manufacturing including beneficiation of expoort goods, investment and local socio-economic growth - skills lls development and job creation. Adjoining this, the largest IDZ in the Southern ern Hemisphere, is the Port of Ngqura â€“ a modern multiltiuser deep water harbour developed by the National Ports rts Authority of South Africa as a gateway to global markets. ts.

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In addition to this, Transnet is about to commence construction of a heavy haul iron ore line to ser ve the port. Since 1996, Coega has created jobs and opportunities to uplift the socio-economic status of local South Africans, and has created business investment opportunities to ensure that the investment potential is maximised. p

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 WINNER: MENTORING COMPANY OF THE YEAR

A blueprint for future technical professionals Initially, mentorship of engineering candidates took place very much on an ad hoc, as-andwhen-required basis. In 2003 UWP Consulting appointed a retired consulting engineer on a part-time basis as mentoring manager for the whole company.

HIS WAS A substantial move forward as it provided candidates with a passionate mentor who had the time to commit to the task. In 2008, with outside help, UWP developed and documented a system that has formed the basis of its present-day programme. The mentoring process was documented with the “invention” of a logbook system for engineer, technologist and technician candidates that covered all the disciplines and services offered by UWP. While this was a reasonably well-documented system, it was principally left to the candidate to take the initiative in engaging with the assigned mentors to walk the road to registration. By 2010 it was felt that mentoring in UWP was sub-optimal and a senior in-house engineer was assigned the position as mentoring manager. During 2011/12, a “gap analysis” was conducted from which a well-structured and managed programme emerged. The secret to the success is that the relatively simple processes are not only well documented, structured and communicated, but actively managed. The Blueprint Programme provides the blueprint for future technical professionals at UWP. In addition, UWP conducts a staff satisfaction survey annually where feedback is sought with respect to staff perceptions on a range of matters including training and staff growth and development. These outcomes are then evaluated and discussed by senior management and actions taken to address issues of concern. This is an integral part of UWP’s ISO 9001 accredited quality management system. UWP has, in the past year, increased the capacity of its Human Resource Department by creating a new posi-ition for a “manager human resources: staff welfare”” to actively manage the career development programmee for all UWP staff. This position reports directly to thee managing director. Given the importance of training andd development, Zulch Lotter, the previous managing direcctor of UWP Consulting, has been given the responsibilityy to actively manage its blueprint candidacy programme. e. UWP is putting its money where its mouth is by ensuringg that mentoring and staff development remains central too its strategic plan. UWP visits the major engineering facculties at tertiary institutions in South Africa annually too introduce the company and invites bursary applicationss and applications for permanent employment.

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By maintaining contact with the heads of faculties and by sponsoring annual awards for excellence in these faculties, UWP succeeds in attracting young graduates as part of its growth and succession strategy. The company sponsors awards at the Universities of KwaZulu-Natal, Johannesburg, Pretoria, Cape Town and Stellenbosch. UWP also offers bursaries to its own employees, particularly technicians who wish to qualify as technologists. The core focus of the UWP performance management system is to promote and ensure professional growth and development. As such, it encompasses and promotes continued professional development (CPD), which is an ECSA requirement for professional registration. In-house UWP experts present course/training lectures based on their own experience or provide feedback on information gained when attending seminar or external courses. These in-house lectures or courses cover technical and nontechnical topics. In terms of company policy, UWP pays the membership fee of staff members to join at least one learned institution as well as one statutory organisation such as ECSA. In addition, UWP actively encourages its staff to become involved in industry committees and activities such as the South African Road Federation, Consulting Engineers South Africa, South African Institution of Civil Engineering, Institute of Municipal Engineering Southern Africa, Water Institute of Southern Africa, Young Professionals Forum, etc. UWP has produced the presidents of the SARF and CESA as well as various branch chairmen and committee members of industry organisations.

Africa’s WINNER: YOUNG ENGINEER OF THE YEAR

Social upliftment campaigner Andreas Melusi Ndlovu completed his National Diploma in Civil Engineering in June 2002 at the Durban University of Technology (DUT) and then obtained his Bachelor’s Degree in Technology Engineering: Civil in December 2005.

IS TERTIARY EDUCATION at the DUT was funded by the National Student Financial Aid Scheme of South Africa (NFSAS), as his mother, a domestic worker with three children, was not able to financially support his career choice. In his final year, he was awarded a bursary by the KwaZulu-Natal branch of IMESA. Ndlovu currently chairs a programme that he initiated called the Nami Nawe Singakwenza (You and me, we can do it) – ISITOCKFELLA. This is a “savings” club with the purpose of helping communities to save money for their children’s school fees year-on-year. This programme has grown to a stage where the parents are encouraged and educated to open a savings account with their respective banks to continue this method of saving money for their children’s education. Over the past 12 years, Ndlovu has worked on a full spectrum of civil engineering projects, from entry level road maintenance contracts to multimillion rand freeway projects for public sector clients, including: • multiple contracts for basic engineering works along provincial roads using entry Level 1 emerging contractors, including specification, documentation, tenders and adjudication, contract administration • upgrading and rehabilitation of urban roads for the municipal roads authority, including technical design and documentation • geometric and related road design for major road projects (provincial roads in Eastern Cape, national freeway in KwaZulu-Natal) including detailed geometric design and modelling, contract specification and documentation • geometric and related road design for the Bus Rapid Transit (BRT) system for the Tshwane Municipality. Ndlovu has developed extensive knowledge on all aspects of road design, including tools and software, design standards, materials, contract documentation and administration. Within ILISO Consulting, as a technical director, Ndlovu has participated at a senior management level in planning, resourcing and running projects. He has managed all aspects of his projects, including planning, technical direction, and client liaison and fee negotiation. Within the company project management environment, he has spent considerable time on coaching less experienced technical staff, particularly on the more technical tools and aspects of road design. Overall, Ndlovu has developed extensive skills and expertise in the civil engineering consulting and construction industry to the benefit of the company and associated staff. In the management of the multiple contracts for the KwaZulu-Natal Department of Transport, Ndlovu has played a key role in the Vukuzakhe programme for emerging contractors and has spent considerable time and effort, inn the office and on-site, advising, direct-ting and mentoring the emerging con-tractors and site staff on technical andd administration requirements. Ndlovu has also been involved onn pavement engineering for reusing exist-ting resources in a sustainable way byy recycling the aged asphalt that is recovvered from their roads as part of theirr road rehabilitation strategy.

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leader in natural resource and development solutions

Tel: +27(0) 11 441 1111 www.srk.co.za

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 COMMENDATION: YOUNG ENGINEER OF THE YEAR

Water reuse specialist Jan Theron is a 34-year-old professional civil engineer with 13 years of experience in design, project and engineering management and site supervision in South Africa and the United Kingdom.

HERONâ€™S EXPERIENCE includes the design and construction of several water and wastewater treatment works (including desalination and water reuse facilities), bulk and internal township engineering services, and some dam safety and spillway design experience. On the majority of these projects, he has been involved in the full project cycle from conception stage to construction completion and operational and maintenance support as a project manager and civil project, resident and design engineer. These duties also included financial and contract administration. Theronâ€™s current responsibilities as Director Advisory Group: Water, Eastern Cape, include operational and financial management, business development, client liaison and marketing. He graduated with his BEng in Civil Engineering from the University of Stellenbosch in 2000 and

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has been working for Royal HaskoningDHV (RHDHV) since April 2004. During this time, he has worked for extended periods in the East London and the George offices of RHDHV and is currently based in Port Elizabeth.

C E S A A O N E N G I N E E R I N G E X C E L L E N C E AWA R D S 2 0 1 3 WINNER: MENTOR OF THE YEAR

Nurturing the future of engineering Kobus Viljoen is a principal in the land development division, responsible for township development and municipal infrastructure, at Bigen Africa Services.

ILJOEN IS responsible for skills transfer to all technical personnel as well as conceptualisation, support and reviewing of all projects in the land development division, technical software management and development, best practice development, and distribution and technical training. He plays a key role in Bigen Africa’s formal candidacy programme due to his technical experience, intimate knowledge of Bigen Africa’s culture, policies and procedure, and his passion for coaching and mentoring. During his employment at Bigen Africa, Viljoen was involved in the mentoring of 36 civil engineers, six civil engineering technologists and 18 civil engineering technicians. Thirty of the above persons are still employed by Bigen Africa. Nine of these employees reached the position of principal, of which five are also shareholders in the company. Four of the employees fill the position of associates. In order to develop the skills of all the employees and to enable them to grow and to work effectively, it is essential to provide them with the correct tools. Viljoen plays a key role in the company in this regard through his involvement in the following initiatives:

and still coordinates the process of best practice development and distribution to all personnel in the company. During the execution of his function to provide support, training and mentoring to all employees in the land development division, he collates all best practice and makes it available to everybody in the company through Bigen Africa’s system of standard drawings, standard documents, standard design aids, design manuals and standard measurement and estimation aids.

Technical training Viljoen implemented an in-house technical training programme in Bigen Africa in 2006, consisting of two-hour lectures presented by internal and external experts. The lectures are recorded on video and used for training in the branch offices that are unable to attend the lectures in the Pretoria office. They are also made available in the libraries of all Bigen Africa offices for individual use. Viljoen is a professional engineer who specialises in urban development and urban civil engineering services. He commenced his career in 1974 at the Department of Public Works. He established his own consulting engineering practice in 1979. He joined EVN Services, the predecessor of Bigen Africa Services, in 1995.

Software management and development Bigen Africa uses Autodesk and Technocad software for design and drawing production. The need was identified in 1997 for the customisation and optimisation of the software for use within Bigen Africa. An Autodesk programmer was appointed and is managed by Viljoen. Viljoen identifies the needs for development and customisation by interaction with the users during his project inputs and ongoing training and mentoring programme. He manages the implementing and training programme in the use of technical software and was intimately involved in the implementation and customisation of Autodesk’s Civil 3D software in Bigen Africa since the beta version of the programme was introduced in South Africa in 2007. Best practice development and distribution Bigen Africa commenced with an initiative to standardise and develop best practice in the company in 1998. This process culminated in Bigen Africa’s quality assurance system being certified under the International Standards ISO 9001: 2008. Viljoen was part of the process from the beginning

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ADVERTORIAL

CONCRETE SOLUTIONS

Engineering with “liquid stone” Architectural concrete is a special type of concrete that is subject to specific requirements regarding the quality and standard of its appearance to create a surface intended to remain on view after completion. IMIESA speaks to an industry expert to find out the finer points about the evolution of concrete.

IGH-QUALITY off-shutter architectural finishes require special attention. Client, architect, structural engineer, building contractor, formwork and concrete suppliers must all form part of a coordinated team so that what is created is also that which was planned beforehand. Decisions must be made throughout all the project stages, which will impact on the end product, and some important considerations are highlighted here. The importance of good communication between all parties involved in the building process cannot be emphasised enough and is the key to successful execution and achievement of a desired outcome. Designers must be aware of detailing issues that will impact on the placement and appearance of the concrete – items such as minimum

BELOW Precast concrete panels are a cost-effective, no maintenance and highquality finish cladding option BELOW RIGHT Formliners allow any texture or pattern to be reproduced in concrete

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wall thickness to avoid scoring the form surface during compaction, or the exposing of steel re-enforcement during post shutter tooling, and the spacing of reinforcing bars to facilitate concrete placement and to avoid unsightly honeycombing. When designing and specifying architectural concrete finishes, the architect or designer should consider several issues that will impact on the visual qualities. It is recommended that these different aspects be incorporated into the design specifications: • visual standard of the architectural concrete formwork and formwork panel system • surface texture • formation of joints between formwork elements • formwork ties and tie holes • subdivision of the surface • joints • detailing of corners and edges • colouring • sur face finish of areas not cast against formwork.

While the most appropriate approach will vary from project to project, precast concrete has some advantages over in-situ work in terms of the range and quality of off-shutter finishes that can be achieved. The main advantage of precast concrete is that elements are generally manufactured under factorycontrolled conditions. The finish and quality therefore are generally of a higher standard than concrete elements constructed on-site. The main disadvantages of precast concrete are limitations on the size of the elements that can be manufactured, transported to site and erected by crane, and the inevitability of joints between the panels or column/ beam junctions. Textured finishes are created by either attaching materials to the formwork such as form liners or other materials, or by using profiled form-face materials. Subsequent treatments such as tooling, bush hammering and abrasive blasting can also produce textured finishes. A new-generation concrete that is well worth considering is High Fluid Concrete, which

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The main advantage of precast concrete is that elements are generally manufactured under factory-controlled conditions

allows for superior finishes without the need for compaction and with reduced segregation. This type of concrete is achieved through the use of a super plasticiser – a chemical additive that increases the flowing quality of concrete without the additional use of water. This allows the concrete to increase its workability without sacrificing strength. Formliners are materials placed against the form face to provide a negative mould against which the concrete is cast. Almost any texture or pattern can be reproduced from rope and board-marked finishes to various stone/ rock patterns. The materials commonly used include styrene foam, rigid plastics and fibreglass, profiled steel sheet and elastomeric materials such as polyurethane and silicone rubbers. The use of formliners may be a more economical way to achieve a heavily textured finish over large areas, especially if a number of reuses are possible to offset the initial cost. Formliners can generally be reused many times, considerably reducing the cost per square metre. Some formliners can consist of different materials that become a permanent feature of the finish, such as various bricks and stone facings. Textured finishes can also be produced from moulds. Similar to formliners, moulds are mainly used in precast factories for the repeated provision of a pattern. If a pattern/texture is required on both faces, the top surface can be stamped. The pattern can also be designed to create a recurring, yet seemingly continuous pattern over a number of elements). Set retarders can also be used to provide texture and colour; they are applied to the form face to retard the set of the concrete surface. Once the formwork is stripped, the cement paste on the surface is removed to reveal the aggregates, changing the colour and the texture of the surface. Photo-engraved finishes are typical of this method where an image is revealed by altering the depth of

exposure of the coloured aggregate using varying amounts of set retarder. Water washing is used to expose the aggregates by removing the cement paste prior to the hardening of the concrete surface. While it is usually used for precast concrete elements, it may be used for in-situ work in conjunction with set retarders applied to the formwork surface prior to concrete placement. Tooled finishes involve mechanically tooling or hammering the off-shutter finish to produce a rough texture. Common methods include bush hammering, point tooling, abrasive blasting and hammered nib. Bush-hammered finishes range from removal of the surface cement paste to extensive removal of the matrix and possible fracturing of the stone. The depth of hammering must be specified (typically 1 to 8 mm) and the appearance verified by a test panel. Point tooling provides a very coarse texture about 15 mm in depth. The coarse texture is suitable for larger elements and

Daniel van der Merwe During his time at university, PPC’s architectural concrete specialist, Daniel van der Merwe, shared the common perception that concrete was ‘dull and boring’, being a mere construction material. This perception among architects and other decision-makers has since changed dramatically. Van der Merwe believes that the use of architectural concrete as a superior performing finish is fast evolving and it has become a preferred choice of material used. “Today, concrete as a high-end material has become synonymous with other more traditional luxury materials such as granite and marble,” he states. Van der Merwe studied landscape architecture at the University of Pretoria, and completed a degree in architecture at the University of the Witwatersrand in 1988. He gained extensive experience in the industry, convened the past two ArchitectureZA Biennale conferences, which PPC sponsors, and is currently the president of the Gauteng Institute for Architecture. He highlights that concrete is the most commonly used construction material that was initially limited in its use to only a structural material. “Today the possibilities are endless as one can mould, texture, colour, tool and stain concrete to create any desired architectural effect,” he adds.

will generally remove or conceal any surface imperfections. A large aggregate should be used. Abrasive blasting can also be used to remove the surface paste or matrix around the stone to expose the coarse aggregate. The depth of removal should be specified, but in no case should more than one third of the aggregate particle become exposed to ensure adequate bond into the concrete. Acid etching is an alternative method of exposing the aggregate. Its use is generally limited to precast elements. The coarse texture of tooled surfaces generally provides colour via the exposed coarse aggregate and a surface that is less likely to be affected by staining from atmospheric contamination and weathering. The location and method by which joints (expansion, control or construction) are incorporated into the concrete structure/element can have a significant influence on the final appearance. Off-shutter textured concrete finishes can be assessed objectively only if the project documentation makes it clear what is expected. This is usually achieved by nominating specific items directly and the general matters by reference to other documents. Once a mutual understanding of what is expected has been established, the assessment of what has been provided is relatively straightforward.

t +27 (0)11 386 9000 • www.ppc.co.za

BELOW Consider timber formwork to allow for a naturally textured surface aesthetic

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TRAINING

INVESTING IN SKILLS

Understanding quality We live in a world where we are constantly confronted by the headline, ‘Skills Shortage’. There always seem to be too many people wanting work, but they lack sufficient knowledge and capability to undertake the tasks required. This applies at all levels, from entry level to senior management. By Sue Rule and Ivor Evans of Binnington Copeland and Associates

S A RESULT, we are seeing huge investments being made in training to meet the huge demand. The number and variety of training practitioners, courses and programmes on offer seem to have grown exponentially. The cost of training is high and has become a significant segment of many companies’ budgets. In this article, a long hard look is taken at getting value for money when choosing training courses at the professional level, for people in senior and responsible positions, who need to be on top of their own game to fulfil their roles effectively.

Preparation and selection When embarking on an investment in training, an organisation should first determine its training needs. Where this involves subscribing to or attending training courses, a training provider must then be selected. The company must ensure that the product offered by the provider contains the key hallmarks of quality training. The procuring company must look to maximise its BB-EEE from the training offered. This is not to be confused with the wellknown acronym, BBBEE. Instead it stands for ‘Best Benefits from Expertise, Excellence, and Experience’. These are the attributes to be maximised. The points that follow are a framework for

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evaluating expertise, excellence and experience, to achieve ‘best benefits’.

Expertise Consider the following: • Does the trainer know their subject? • Has the trainer written the training manual or material? • Is the course material up to date? • Is the material constantly improved? • Are local, relevant case studies from real-life situations referred to? • Have they stated realistic outcomes that they intend should be achieved? • Will the training manual be a useful future personal work of reference? • Has the trainer a standing appointment, or are they appointed ad hoc? • Has the trainer access to readily available backup resources or facilities? Binnington Copeland and Associates (BCA), which is now part of the global Hill International Group, has operated for over 25 years as a specialist consultant in the legal field of the construction and engineering industries, and BCA Training has operated alongside the consultancy for more than 15 years. In pursuit of always offering quality, the company’s trainers have standing appointments to present topics that match their expertise. They write their own material and training manuals. Training manuals contain case studies to critically

evaluate real-life situations. Because material is regularly improved and the outcomes reviewed, fresh manuals are printed for each course. No stocks, which could become obsolete, are held. Backup, to support recommendations or clarify any aspects, is readily available from the specialist consultants at BCA. Access to the expertise of Hill International, a global leader in managing construction risk, is also possible.

Excellence Consider the following: • Are the courses offered relevant to the needs of industry today? • Is the material almost all generic or are specific problem areas addressed? • Is there evidence that high standards of presentation are being maintained? • Is feedback always sought from delegates for improvements or suggestions? • Is there a total review, at least annually, of performance and achievements? • Is the organisation well known, with a good reputation? • Does the organisation have a significant client base? BCA Training offer courses that, for example, include generic industry topics such as Contract Law, Contract Conditions, Professional Negligence, Construction Contracts Insurances & Liabilities, and

TRAINING

When embarking on an investment in training, an organisation should first determine its training needs Subcontracting. Other courses offered focus on frequently encountered problem areas, such as Delay, Disruption and Extension of Time; Principles of Contract Administration; Claims; Adjudication; and Project Planning, Scheduling & Control. All courses carry CPD points. Delegates complete feedback forms at every course. From an independent annual review at the end of 2012, some significant findings emerged: • 150 industry-related seminars were presented by 10 trainers at over 20 venues around South Africa • an overwhelming 98.5% of delegates confirmed their expectations had been met from attending a seminar. BCA Training enjoys the reputation of being frequently approached to provide in-house training courses to clients of BCA or under contracts awarded by large public organisations. In 2012, these included Eskom, Rand Water, Transnet and City of Cape Town.

Experience Consider the following: • Is the training organisation well established in its field? • Are the topics drawn from a wide spectrum of experience? • Do the trainers have ‘mud on their boots’ to demonstrate experience? • Do members of the training team collectively have extensive experience? • Is the experience of trainers supported by any experienced backup? • Does trainers’ experience go beyond the topics they train on? The combined experience of BCA and BCA training is unparalleled in South Africa and was a key factor in the decision by Hill International to acquire a major interest in the organisation. The ‘mud on their boots’ phrase, coined by founding partner Bill Copeland, reflects the policy of holding experienced staff in both the consulting and training divisions. Today, the trainers’ CVs speak for themselves, demonstrating the depths of their experience. The 2012 independent survey rated the average level of satisfaction with trainers’ knowledge at over 94%. FIDIC-accredited trainers in South Africa can be counted on one hand, and two of them are members of BCA. Many BCA consultants and trainers are involved in affairs beyond the contract and the job site, such as with Consulting Engineers South Africa, Engineering Council of South Africa, South African Federation of Civil Engineering Contractors and the Association of Arbitrators. Training procurers need to invest wisely to get best value for their training budget. They need to be able to and secure the ‘Best Benefits’ from the ‘Expertise, Excellence and Experience’ of the training provider. BCA Training can meet these ‘BB-EEE’ objectives.

Do you suffer from ... ... a lack of performance skills? In today’s highly competitive environment it’s becoming increasingly important to invest in selectively-tailored training courses and programmes, to improve skills and performance at all levels, from unskilled workers to established professionals. We, at Binnington Copeland & Associates, with over 25 years of specialist consulting experience in the legal fields of the construction and engineering industries, including our specialist Training Division’s experience of more than 15 years, pride ourselves in being able to provide hands-on, in-house, up-to-date, industryspeciﬁc training courses and programmes, taking care of all aspects in skills development and performance. Our unparalleled organisation’s combined experience in both consulting and training in South Africa was a key factor in the decision by the global leader in managing of construction risk, Hill International, in acquiring a major interest in our organisation. Additionally, International FIDIC-accredited trainers in South Africa can be counted on one hand, two of whom are permanent members of our team.

Inspiring the will and the passion to do better.

Binnington Copeland & Associates Tel: +27 (0)11 888 6141 Email: ivor@bca.co.za w w w. b c a .c o. z a

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POWER

HARNESSING WIND POWER

First wind turbine for PE MetroWind’s Van Stadens Wind Farm in Port Elizabeth boasts a series of firsts for both the country and the engineering and construction firms associated with the project. ABOVE The engineers on-site at MetroWind Van Stadens Wind Farm after the first of nine turbines goes up. (From left) Evan Jones of Basil Read Matomo, Elfias Masondo of Vanguard, Li Qingxian of Sinovel and Fanus Loots of Vangaurd

LEFT The preparation phases for the wind turbine assembly are engineering feats on display

Logistics S01, the Sinovel SL3000 3 MW turbine used in the project, was finally complete after two weeks of high-intensity assembly. Basil Read Matomo was the lead engineering, procurement and construction (EPC) contractor and according to Evan Jones, the company’s engineering manager for energy, there were many exciting first-ever experiences for the project team. “For us, the use of the largest crane ever used in South Africa has simply been incredible; we have never before seen a crane of this capacity,” he explained. “The Terex TC 2800 has a lifting capacity of 800 t and is the only crane able to simultaneously reach the height of the wind towers and carry the weight of the nacelles, hubs and blades.” The crane was imported from Poland earlier this year to facilitate the lifting of the 120 t nacelle. It took 56 trucks to transport the crane to site, where a normal 650 t crane

Pieces of the puzzle Jones said that while the assembly of the wind tower is not very complicated, the logistics, planning, engineering and timing required to put the giant puzzle pieces together was the challenge. “All tower lifts are a tandem lift and require two cranes. We use special grease, and health and safety standards are followed to the tee. Basically, we lower the one section on to the other and this process is followed by bolt torqueing, which is done with specialised calibrated equipment at high pressure.” Following the tower construction is the assembly of the more complicated nacelle and hub section. The hub and blades are collectively known as the rotor. “The planning and execution of the rotor lift has to be precise to ensure the 70 t rotor, which is also 113 m in diameter, is lifted properly. The higher you go, the windier it gets, so this is a critical exercise,” Jones continued. “The first nacelle lift had everyone on their toes.”

XCITEMENT WAS in the air at the wind farm in August when its first wind turbine went up. A further eight wind turbines – each one an engineering feat – are set to be assembled over the course of two months.

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requires only 20 trucks. “Moving it from one turbine site to another also takes days,” said Jones.

Industry insight According to Basil Read Matomo, South Africa is in a unique position to leapfrog technologically with the national wind farm projects and construct 3 MW wind turbines, rather than the older 1.5 MW turbines. “Not only are we able to use the most advanced wind turbine technology, but we are also engaging experts worldwide, with consultants from Spain, Italy and China working with us here at Van Stadens to ensure the installation is efficient and safe,” he said. Currently, seven of the nine turbines at MetroWind are 50% assembled with a further two set to start from the base up. “Everything has been going well. No expense has been spared. The core team visited a completed installation in Sweden and a wind farm under construction in Italy where identical turbines have been installed. This was very valuable for the whole team in preparation for the turbine transportation and assembly.” The MetroWind Van Stadens Wind Farm is one of eight wind energy independent power producers (IPPs) authorised in the first round of the Department of Energy’s Renewable Energy Independent Power Producers Procurement Programme in December 2011 and will be the first active to come online. The 27 MW wind farm will comprise of nine Sinovel SL3000 3 MW turbines and is expected to produce 80 000 MWh per year. The R475 million contract was commissioned late last year.

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PORT ELIZABETH

ROADS & BRIDGES

SMEC

The complexities of a pedestrian bridge A global engineering consultancy firm has been recognised at this year’s CESA Aon Engineering Excellence Awards as the overall winner of the ‘Projects with a value of less than R50 million’ for its design of the Tshelimnyama Pedestrian Bridge.

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ROADS & BRIDGES

HE STRUCTURE, which is located on the N3 between Westville and the Mariannhill Toll Plaza, was commissioned by Sanral and awarded to SMEC. Lead consultant on the project John Anderson says that the Tshelimnyama Pedestrian Bridge Project is a key link in the larger Sanral pedestrian facility upgrade project. BELOW SMEC has been recognised at this year's CESA Aon Engineering Excellence Awards for its design of the Tshelimnyama Pedestrian Bridge BELOW RIGHT The Tshelimnyama Pedestrian Bridge Project is a key link in the Sanral pedestrian facility upgrade project

The Tshelimnyama township, which is located on the south side of the N3, is home to many low-income families – a large portion of whom have found work in the nearby industrial areas of Mahogany Ridge and Westmead on the northern side of the N3. Due to a lack of shorter, more direct routes, many of the residents chose to cross the N3 freeway to access these work opportunities, risking their lives in the process. “This was extremely dangerous for those crossing the freeway; as well as for the motorists travelling on the freeway. In order to address this issue and to assist with determining a suitable solution, a pedestrian audit was conducted, which confirmed that a pedestrian bridge was required. To assist the residents while simultaneously allowing for future route upgrades, Sanral invited tenders for a bridge that could freely span the N3 without impacting current and future traffic requirements,” explains Anderson. Anderson points out that the challenge of the site was to attract pedestrians onto the bridge and to design a structure which integrated itself into the surrounding landscape. “SMEC was appointed as the consulting engineers for the project and produced a design that was functional as well as aesthetically pleasing. The slender deck floats over the N3, supported by the stay cables and anchored to the central tower and the rock cutting on the adjacent slopes. The bridge was constructed by JT Ross,” explains Anderson. There are many unique elements on this project, including the sculpted structural steel tower, which leans forward at an angle of

14 degrees with a continually varying cross section. The tower geometry is complex but aesthetically pleasing and testament to what is achieved with a strong collaboration between architect, engineer and employer, explains Anderson. The success of this highly complex design has allowed the people of the Tshelimnyama township to access their places of work in a well-lit, convenient and safe manner as evidenced by the high number of pedestrians who use the bridge on a daily basis. “This award winning project is testimony to the Sanral objectives of providing safe and efficient transport facilities to the motor-

The success of this highly complex design has allowed the people of the Tshelimnyama township to access their places of work ists and pedestrians using South Africa’s national roads,” states SMEC CEO, Dr Thomas Marshall. In addition to being awarded as the overall winner for the Tshelimnyama Bridge Project, SMEC also received a commendation for its work involving the widening and strengthening of the Okavango River Bridge, on behalf of the Roads Authority of Namibia. In addition to being recognised by CESA, SMEC has also recently been awarded the South African Institute of Civil Engineering (SAICE) Branch Awards Technical Excellence Award for its work on the Tshelimnyama Pedestrian Bridge Project.

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EDITORIAL

IMQS

Making cities work through IT By leveraging the latest browser, cloud and desktop technologies, as well as its own proprietary GIS software, international software company IMQS has created a modern, device-independent solution with a clean well-designed interface that is intuitive to use. This allows users to access information in real time, anywhere, in order to carry out their work.

HE SOUTH AFRICAN government recently adopted an infrastructure vision and plan that is intended to transform the economic landscape of the country, thereby creating a significant number of new jobs. This will strengthen the delivery of basic services to the people of South Africa and support the integration of African economies. Part of executing this strategy includes work by the Presidential Infrastructure Coordinating Commission (PICC) to assess the infrastructure gaps and identify areas of the country that are not serviced with water, electricity, roads, sanitation and communication. Based on this work, 17 Strategic Integrated Projects (SIPs) have been developed and approved to support economic development and address service delivery across the country. IMQS believes it is well placed to support government’s vision and plan, and its pedigree in the municipal infrastructure market means there are no asset classes, nor any scale thereof, that cannot be managed by the integrated, georeferenced IMQS infrastructure management system. The execution of these SIPs will require significant investment in capital works and supporting systems and processes over the next 15 years for it to be scalable and sustainable. Investment will be aimed at all infrastructure asset types including rail, water pipelines, roads,

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energy generation, transmission infrastructure and the like. The true value of each of these initiatives will not be realised on the day a road is completed or when a new school is built, but rather when the road remains in good condition even with increased traffic and age, or when a pupil graduates from the school. To achieve this, each of these assets needs to be treasured and carefully managed throughout its life. Key elements of Infrastructure Asset Management include: • understanding the impact of growth • managing risks associated with asset failures • continuous improvement in asset management practices • cost-effective management strategies for life cycle asset management • defined level of ser vice and monitoring performance • life cycle approach. In effect, government could spend an extraordinary amount of money investing in

infrastructure and, in doing so, transform the country’s economic landscape. To preserve this, however, the fundamental principles of asset management need to be applied rigorously and systematically. The IMQS infrastructure management system is designed to support the process of making a city work, ensuring sustainable infrastructure. Using an open-service-based architecture, the company seamlessly integrates with other mission-critical systems and is thereby able to extract information from underlying engineering, maintenance and ERP systems to intelligently inform – adding value to a client’s systems and infrastructure investment. The system also supports asset componentisation to the level where maintenance-significant items are easily identified, as well as providing a complete range of tools to manage key properties like life expectancy, impairment and value. The company supports all national and international standards such as GRAP* and PAS55**, making it the solution of choice for infrastructure asset managers. From this point, it is well positioned to support any asset management initiative, which will ultimately result in better infrastructure on which to build an economy and deliver service. *GRAP (generally recognised accounting practice) **PAS55 (the British Standards Institution’s specification for the optimised management of physical assets)

What makes a city work?

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SEWER

ROADS

STORM WATER

POWER

PROPERTY & BUILDINGS

IMQS HAS DESIGNED AND BUILT a fully integrated geo-referenced asset management solution that not only supports improved service delivery but also supports the asset management practice and reporting requirements of National Treasury allowing local authorities to configure and populate the system to be GRAP compliant. Our track record of 100% success on all our Infrastructure Asset Registers at over 30 Metropolitan and local municipalities proves that we have succeeded in bringing the technical and financial aspects of infrastructure asset management together in one integrated system.

Leaders in integrated infrastructure management and GRAP compliant asset registers.

WWW.IMQS.CO.ZA

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MEDIA

EVENTS

SAPPMA

Healthy indicators in growing sector An upbeat atmosphere prevailed at SAPPMA’s 7th Annual Conference, Pipes VII, held in Midrand this September.

AVING RECENTLY unveiled its new corporate identity and concluded its 9th AGM, the Southern African Plastic Pipe Manufacturers Association (SAPPMA) has been extremely active of late, and held its 7th Annual Conference in Midrand on 10 September 2013. While the conference took place over a single day, it more than delivered, with well-selected speakers and tailored topics, presenting a lively industry dealing with market challenges proactively and intelligently. In his introduction to the day’s proceedings, SAPPMA’s CEO, Jan Venter, emphasised the leading role of plastics in pipes today. Having shed its image of being the cheap alternative to metals, plastic pipes now account for an estimated 50% of installed pipelines globally. In South

Africa, that figure is higher, with 68% of the non-pressure pipe market and a startling 98% of the <500 mm non-pressure market going to plastic. With costs increasing on all sides, the industry appears determinedly competitive.

Classic keynote Dr Roelof Botha, well-known economist and seasoned speaker, delivered a classic keynote address. Invigoratingly opinionated and deeply logical, Botha pulled no punches when it came to South Africa’s economy and character, and was unapologetic in his stance on strikes. Obser ving that South Africa has possibly the most violent strikes in the world, he cited these as the greatest threat to our economy. Slating in his stance on the conduct of the country’s trade unions, he cautioned against allowing our economy to be

Plastic pipes now account for an estimated 50% of installed pipelines globally

hijacked. He was equally impassioned about the future – a keen futurist, he foresees the development of a universal digital currency, thought recognition technology and increasing equality between developed and emerging markets. Focusing on the future of South Africa, he pulled no punches, saying that to realise our incredible potential we have to get with the programme: fight corruption; increase privatisation; educate, educate, educate; and work towards socio-political security. He was also sure to point out the positive: we have built more RIGHT Jan Venter, CEO, SAPPMA

SAPPMA SAPPMA/IFPA members contribute more than 80% of the plastics pipe market, employ more than 6 000 people and have collective sales of more than R3 billion.

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EVENTS

than 3 million RDP houses, 1 000 new health clinics, new sanitation services for 7 million people, 4.5 million new electricity connection, to name but a few. So down to business…

history was about science and was truly fascinating. The impact of the material on the world is immense and this potential was recognised back in 1963 when Karl Ziegler received the Nobel Prize in Chemistry, together with Giulio Natta, The history, for their discoveries in the the testing, the field of the chemistry and knowledge, the results technology of high polyThe first session of the mers. As far back as 1955, morning was concluded by the first creep rupture tests Ulrich Schulte. His incred- Dr Roelof Botha, wellwere conducted on HDPE ibly interesting presentation known economist and pipes and in 2012, two pipe began at the beginning – the seasoned speaker specimens from those tests introduction of HDPE pipes were tested for the 56th consecutive year. more than 50 years ago. The real history of Understanding the causes and effects of the use of plastic in pipes lies in its testing. ageing on these pipes is extremely well One has to remember that it was not long ago understood now, with extremely long-term when plastic itself was an unknown entity, ‘tests-until-failure’ being a requisite in the both celebrated and feared, depending on evaluation of polyethylene raw materials used your point of view. Even to this day, there in pipes. These and other tests have resulted is caution around certain plastics, but this

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Tests have resulted in an extremely well understood material that exceeds a lifetime expectation of 100 years in an extremely well understood material that exceeds a lifetime expectation of 100 years. Moreover, this depth of understanding allows for design and installation techniques to accommodate varied environments, resulting in a remarkably stable infrastructure. This is just one instance of the strides made in plastics and the commitment of the industry to ensuring quality, safety and sustainability. It may not be a huge industry in terms of size, but it makes up for that in its ubiquity and passion. For more information on this year’s programme, speakers and presentation, visit the association’s website: www.sappma.co.za, and remember to look out for details of Pipes VIII in 2014.

IMIESA October 2013

Infrastructure Development Structural Engineering Electrical Engineering Mechanical Engineering Civil Engineering Project Management Town Planning HEAD OFFICE: BLOCK C - Menlyn Corporate Park C/O Garsfontein & Corobay Ave. MENLYN - PRETORIA Tel: +27 (0) 12 940 1111 FAX: +27 (0) 86 743 3100 E-

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MDP

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PROFILE

FIBERPIPE

Tailor-made pipe solutions A local manufacturer of pipe systems and accessories for water, sewage and industrial applications, Fiberpipe, is working towards becoming the leading manufacturer and supplier of GRP pipes and fittings to the civil engineering, mining, industrial and agricultural market segments in subSaharan Africa and the Indian Ocean Islands.

HE COMPANY is currently the only glass reinforced pipe (GRP) manufacturer in sub-Saharan Africa. Its products are manufactured in accordance with internationally accepted standards and meet the requirements of the ISO 9001:2008, and also adhere to all relevant SABS specifications. “Fiberpipe’s combination of manufacturing and sales engineering services enables us to deliver value-added services based on the requirements of its customers. Through partnerships, we find workable solutions aimed at achieving maximum utilisation of pipe systems where operational effectiveness is sought, while not compromising on quality,” says Hein Momberg, managing director of Fiberpipe. The company’s quality control department ensures that all products are produced in accordance with specified requirements and that continuous improvement of product quality and services is provided.

The extra mile “We also assist with advisor y ser vices for choice of material and calculation for projects. This is given in the form of on-site technical field support during installation to ensure that correct installation procedures are followed for optimal use of products.” In

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addition, installation training is provided and both services are free of charge to clients within South Africa. Fiberpipe also provides maintenance training, should it be required, to ensure that the full lifespan of the product is achieved.

protection line for cables. Standard and special fabricated fittings, such as bends, tees and reducers, form part of the range. The Vectus pipe system is manufactured from fibre reinforced polyester and vinylester. The production method is a discontinuous double helix reciprocal filament winding process that gives the pipes a balanced combination of axial and hoop mechanical properties. Vectus pipe systems are free of corrosion, lightweight and a well-documented product with good references worldwide. In addition to the civil and industrial markets, the pipe systems are also used in the oil and gas, shipbuilding and offshore industries. Within the industrial market, the pipe system is used widely as a cost-effective solution due to biaxial pipe systems with well-locked joint solutions for pipe and fittings. These locked joint systems are also successfully used in municipal water, cooling water and pressure sewerage systems in combination with Flowtite pipes to avoid thrust blocks. The Vectus pipe system also includes a complete range of standardised specialised fittings.

Through partnerships, we find workable solutions aimed at achieving maximum utilisation of pipe systems

Product range Flowtite is Fiberpipe’s leading product for water, sewage and industrial applications. GRP systems are a cost-effective piping solution as the pipes are corrosion free, have a proven resistance to acidic environment in water and sewage systems, and are lightweight and therefore easy to handle. Flowtite pipes and fittings are suited to applications such as: • potable water transfer • firefighting • sea and desalinatTechnical information ed water • power plants Flowtite Diameters*: DN 300 to 1 800 mm • chemical and Pressure classes: PN 1-6-10-16-25-32 industrial wastes Stiffness: SN 2 500, 5 000, 10 000 • sewer and Length: Standard length 12 m irrigation. Vectus The product can be Diameters*: DN 150 to 2 000 mm found in siphon lines Pressure classes: PN 4-6-10-16-25-32 or equally in seawaStiffness: SN 2 500, 5 000, 10 000 ter outfalls, bridge Length: Standard length 12 m dewatering, desalina*Large diameters available on request tion projects or as

t +27 (0)11 864 2040 • www.fiberpipe.co.za

EDITORIAL

New Capex from plastic manufacturer

966 part 2 9

A manufacturer of water reticulation, drainage and pipefitting systems is due to begin production of its new 630 mm bore PVC pipes in October 2013, following the final installation of its new KraussMaffei extrusion line in July 2013.

PI PLASTICS’ technical and product manager, Renier Snyman, explains that the company identified the need to increase the maximum bore of its PVC pipe range from 500 to 630 mm, following numerous queries from the local market. In the past, DPI Plastics’ only solution for large-scale projects was to lay two parallel 500 mm pipelines. Due to the fact that a 630 mm pipeline offers higher outputs, Snyman points out that only a single pipeline is now required. “This ensures substantial savings with regards to materials purchase and transportation costs, and also significantly reduces installation times and associated costs, as a direct result of less material being required,” he elaborates. The new extrusion line will also open up new avenues of growth for PVC as a competitor in the bulk water, stormwater and sewerage industries, which are currently dominated by materials such as steel and concrete.

PVC-M Pressure Pipe e SANS 966-2 –PVC-M (modified poly vinyl chloride) pressure pipe systems for potable water conveyance.

Ultraflo PVC-M pressure pipes are available in diameters of 50 to 630mm and pressure ratings of 6 to 25 Bar. Ultraflo is tough and reliable making it ideal for African conditions. Ultraflo is also energy efficient and has a low carbon footprint.

A PVC-M pressure pipe extrusion

For a complimentary copy of our latest Product and Technical CD, e-mail marketing@dpiplastics.co.za

Johannesburg : +27 11 345 5600 Cape Town : +27 21 957 5600

Southern African Vinyls Association

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info@dpiplastics.co.za www.dpiplastics.co.za

Member of the Dawn Group

EVENTS

CESA ANNUAL CONFERENCE AND AGM

Leadership is the key to sustainability The annual Consulting Engineers South Africa (CESA) Conference and Exhibition is a high-level event, providing consulting engineers and associated industries with a unique networking and learning experience.

HIS YEAR, the CESA Annual Conference and AGM will be held at the Westin Hotel, Cape Town, on 11 and 12 November.

Focus 2013 In his maiden speech as CEO of CESA, Lefadi Makibinyane pulled no punches on the issue of corruption; he likened it to a crime against humanity. “It is a crime against humanity and must be uprooted at all costs… The work of an engineer centres on harnessing the might of science for safe human use and benefit within the constraints of the natural environment.” This strong stance has informed much of the content for the conference. Other themes include sustainable engineering, working effectively with the public sector and the National Development Plan. BELOW Steering CESA to new heights: Naren Bhojaram, president of CESA; Lefadi Makibinyane, CEO; and Abe Thela, deputy president of CESA and the chair of the Staff and Finance Committee

Key speakers Speakers at the event include the newly appointed CEO of CESA, Lefadi Makibinyane; Naren Bhojaram, president of CESA; Abe Thela, deputy president of CESA and chair of the Staff and Finance Committee; and Frank Stevens, president of IMESA. Keynote Speakers Sought-after international speaker Jason Drew will get the ball rolling. Drew is a serial entrepreneur, passionate environmentalist and visionary who recognises that the sustainability revolution has begun. Alderman Ian Neilson, executive deputy mayor of the City of Cape Town, has consulted on many municipal projects in his capacity as civil engineer. Conference theme and programme The theme for the conference is “Leadership – Key to Sustainability”. One of the highlights of this year’s conference is a move away from the didactic approach of presentations towards the more interactive format of panel discussions. Covering environmental sustainability, enterprise sustainability, the

National Development Plan and green business, participants will engage in serious conversation and debate in front of an audience, leading to a blend of opinions and outcomes. Participants include Prof Piet Naude (Nelson Mandela Metropolitan Municipality (NMMU)), Arthur Taute (Chairman NMMU), Lullu Krugel (associate director, KPMG), Gregory Mofokeng (Black Business Council) and Jabu Mabuza (president, Business Unity South Africa), Frank Stephens (president of IMESA), Percy Sechemane (CEO, Rand Water), Peter Kleynhans (SAICE) and Max Clarke (Hatch Goba).

CESA Golf Day and Spouses Programme Keeping with tradition, CESA will be hosting a Golf Day at the magnificent Milnerton Golf Club. World-renowned, the course is known for its majestic views of Table Mountain and close proximity to the Atlantic Ocean. The abundance of foliage, trees and birds throughout the course makes the whole experience relaxing and gratifying. Enough to calm down even the most competitive of souls. The location for the Spouses Programme is the historic World Heritage Site, Kirstenbosch. The only botanical gardens in the world to hold this title, the gardens are home to many famous indigenous species. Three very good quality restaurants, each offering a distinctive menu, make the gardens an ideal venue for lunch. This excursion takes place on 10 November and the price includes all transport from the Westin Hotel, entrance into the gardens and lunch with limited drinks. For fur ther information, www.cesa.co.za t +27 (0)11 463 2022 E-mail: general@cesa.co.za

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please

visit

ASSOCIATIONS

CMA

Membership extends north of Limpopo The Concrete Manufacturers Association (CMA) has recently signed on 17 new members; due in large part to its broadened qualification criteria.

ALLY ARMSTRONG, executive director of the association, explains: “The association has been streamlined into two operating pillars: Precast Building and Precast Infrastructure. Unlike in the past when membership was dependent on fitting in with one of the former six product categories, it is now open to any precast manufacturer, provided certain quality-based criteria are met. And although our membership has always been open to companies north of Limpopo, we are now actively recruiting members from countries such as Botswana, Namibia, Zambia and Zimbabwe, and we even hosted a delegation from Kenya recently. “Five of our new members are based north of the border. The main reason why we are successfully recruiting new members from that quarter is that Southern Africa looks to South Africa and the CMA as world-class experts in precast concrete. And in recognition of our expanding African footprint, we have redesigned our branding to include the flags of all member countries. “We are the voice of the precast concrete industry in Southern Africa and the CMA logo is a widely respected brand and a recognised badge of quality. Many construction professionals in the private and government sectors insist on CMA members’ products and we engage with national and local government bodies and lobby for the greater use of precast

concrete. Some of our other current initiatives include training and the maintenance and setting of national standards through the SABS. We are also encouraging emerging manufacturers to join the association, as we believe existing members can assist them in becoming first-class precast concrete manufacturers,” says Armstrong. He says the CMA has done much to grow the precast concrete industry since its inception 41 years ago. “We know that the future opportunities for growth in Southern Africa are huge. We intend unlocking this potential over the coming years and believe that other manufacturers will join us in this process.” The 17 new members of the CMA are: • Afrisam • The Aggregate & Sand Producers Association of Southern Africa (ASPASA) • Bass Beams • British Precast (UK) • Colonial Stone • Delta Bloc • Dick King Labs • Fast Deck (Botswana) • Kavango Block Brick (Nambia) • Namib Roof Tile Company (Namibia) • PPC • Savanna Bricks & Paving • The Southern African Readymix Association (SARMA) • Style Décor

• Tjeka Training Matters • The Concrete Society of Southern Africa (CSSA) • Vaka Concrete (Zimbabwe). The CMA has cross membership with four of the new members: • ASPASA • British Precast • SARMA • CSSA. ABOVE Colonial Stone products, including Manor flagstone pavers around the pool, Fieldstone cladding on the back wall of the pavilion and Ledgestone cladding on the pillars, were used to great effect at this private residence BELOW A house built using Style Décor’s precast concrete water feature products and concrete columns

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PRODUCTS & SERVICES

DEMOS AND TRAINING

Tooling up for tailored solutions “Since its launch in November 2012, the Atlas Copco demo truck has been well received by industry,” reports Neville Stewart, Atlas Copco Construction Tools Division’s business line manager.

UR DEMO truck, a first of its kind on the African continent, is touring the country with great success, attracting many new and potential customers,” says Stewart, adding that distributors in particular have appreciated the value of the truck. He emphasizes that always using the right tool for every application is paramount for cost-effective, sustainable operation in order to remain competitive in the construction industry. “Our customers’ interests always take precedence, so it’s imperative that we continue to strengthen our focus on customers and products. The demo truck enables us to address both by showcasing our expansive range of construction equipment, introducing new technology and products, and providing hands-on product demonstrations.” “Taking our products, advice, training and service to the doorstep of our customers and distributors and demonstrating the productivity offered by our products on-site is one of the functions of the demo truck. We are able to move our products around the country with relevant ease, enabling us to heighten awareness of our product portfolio, giving us the scope to share options to do the job more efficiently and effectively than customers may have been

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unaware of. Several customers are showing interest in our broad solutions offering and are recognising the valuable contribution we can make to their businesses,” explains Stewart. “We aim to increase our presence in the small plant hire industry over the next few years and will concentrate our trips on this industry offering quality products that add value to the small hire company through excellent cost of ownership.” He also points out that the truck opens up cross-border markets. “We are planning a road trip to Botswana and Namibia in 2014 to address construction businesses in these regions.” Typical equipment on board includes concrete vibration and surfacing equipment, plate compactors, rammers and rollers, handheld hydraulic construction equipment, motor drill breakers and pneumatic demolition equipment, with new products being added. “Recent releases include ride-on trowel models, generator drive units for electric poker vibrators and a vibration reduced chipping hammer for handheld hydraulics.” But Stewart says that the company’s vast construction tool product range makes it impossible to showcase the entire range as there is limited space on the 3.5 t demo truck. “The challenge lies in choosing the right product arrangement for an event,

which can be difficult, especially if more than one show is visited over a short time.” The demo truck is creating career opportunities with theoretical and hands-on training given to employees. “This is part of our commitment to customers that they will receive sound advice and expert operator training from skilled personnel. We have a demonstration specialist in Aubrey Silidi, who has shown tremendous growth after attending three training sessions in Sweden,” says Stewart. “We have received positive comments on Silidi’s abilities. Following an open day during which we demonstrated our products, Richards Bay distributor AT-CO commented, ‘I felt it was well worth it. Aubrey’s knowledge was good on all the tools and he was very good with our customers’.” Demolition Technologies of Cape Town commented: “The presence of the very professional looking set-up as well as the well-trained staff added huge value to the success of our open days. With the range of equipment on show as well as being able to see products working has resulted in us being able to ‘close the deal’ on a number of potential orders.” Stewart says: “These accolades are most encouraging and we are looking forward to our next road trip to the Northern region in November. “The fact that we were once again included in the list of the world’s 100 most innovative companies by renowned business magazine Forbes, and acknowledged as one of the world’s most sustainable companies in the Global 100 list presented at the World Economic Forum earlier this year, bears testimony that we have the interest of our customers and the environment at heart. By continually improving our products, we offer our customers improved productivity and cost of ownership,” concludes Stewart.

PRODUCTS & SERVICES

Cementing position AfriSam recently upgraded its flagship product, All Purpose Cement, from the 32.5R to the 42.5N strength class

ELPING TO consolidating its position as a leading Southern African brand, the upgrade from the 32.5R to the 42.5N strength class further differentiates this all-round performance product from the low-end economy cements available on the local market. “Now in the ultra-high strength class and with 15% more concrete in every bag than the 32.5N class, All Purpose Cement delivers an early strength in excess of 15 MPa after only two days,” Mike McDonald, AfriSam product manager, says. “With the construction industry under constant pressure to fast-track projects, this early strength offers a major advantage.” Ideal for general use in concrete, mortar, plaster and screed applications, All Purpose Cement is a sophisticated composite containing milled clinker, advanced mineral components and additives, which improve the product’s workability and durability. This world-class product also reduces the risk of corrosion and is a more environmentally responsible choice, having the lowest carbon footprint in the 42.5N strength class.

Other product upgrades The company has also upgraded its High Strength Cement and now offers the highest possible strength class from each production plant. This product has been specially formulated and activated to allow for further extension with additional mineral components in the production of structural concrete. “In contracts where durability is specified, High Strength Cement has proven to easily meet the required levels of oxygen permeability, chloride conductivity and water sorptivity,” McDonald says. “And, despite its exceptional performance, High Strength Cement maintains a carbon footprint lower than pure cement.” All AfriSam bagged products carry the e-mark, reflecting compliance with SANS 1841 that guarantees accurate and consistent bag weights. AfriSam’s All Purpose Cement has been upgraded to a 42.5N strength class, providing customers with even more cement and all-round best performance for mortar, plaster and concrete applications

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If only I had used Genuine Cat parts! ®

Keep it Real, Keep it Cat

I thought I would save money by buying non-genuine Cat parts, in fact it cost me double in the long run, engine failure, twice, double the downtime, loss of productivity. In future I will keep it Real, Keep it Cat, It’s the inside that counts, Cat parts are made to match your Cat machine to perfection. For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

INDEX TO ADVERTISERS

INDEX TO ADVERTISERS Abeco Tanks 43 Aecom 65 Ammann Construction Machinery SA 88 & 89 Aquadam 27 Aurecon 112 Babcock 90 Barloworld Equipment 147 Basil Read 121 Binnington Copeland & Associates 131 Bell Equipment 117 Bigen Africa OBC BTW & Associates 30 BVI Consulting Engineers 140 Cascade 95 Corobrik 12 Degrémont 54 DNA Consulting Engineers & Project Managers 111 DPI Plastics 143 Dynamic Fluid Control 41 Elster Kent Metering 42 Esorfranki 67 Fibrepipe 142 Gast International 24 GIBB Engineering & Science 19

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Hall Longmore 113 Hatch Goba 21 IMQS 137 Incledon 141 Jan Palm Consulting Engineers 51 Jeffares & Green 79 JOAT 36 Kaytech 83 LTS Bulk & Kenzam Bitumen & Asphalt Products 69 - 71 Lafarge Industries 87 Lekwa Consulting Engineers and Project Managers 103 Martin & East 106 Mercedes-Benz SA 17 Model Maker Systems 47 Much Asphalt 77 National Cold Asphalt 92 National Asphalt OFC Nelson Mandela Bay Municipality 56 - 60 Robor 123 ROCLA 99 PPC 128 & 129 Precision Meters 44 SA Leak Detection 37 Sabita 75

Saint-Gobain Construction Products 133 SALPHALT Industrial Surfacing Systems 116 SASOL 22 & 23 SBS Water Systems 34 & 35 Sensus 29 SIKA 126 SMEC 115 Southern Mapping 63 SprayPave 14 & 15 SRK Consulting 125 TCTA 31 Technicrete 97 Tecroveer 32 TGIS 104 & 105 Tosas 109 Transtech Manufacturing 2 UWP Engineering 39 Verder Pumps 28 Videx Storage Tanks 46 Water & Sanitation Services South Africa IFC WRP Consulting Engineers IBC Zest WEG Group 48

IMIESA October 2013

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A Mi M Miy Miya iya G Gr rou oup C oup Company Co o Group

Water Demand Management and Water Resource Specialists Providing quality support to the South African water industry since 1997 • Pressure Management Specialists • WDM Training and Support • Data acquisition & Monitoring (GSM /GPRS) • Water Loss Reduction

WRP would like to thank all the attendees and speakers of the African Water Leakage Summit 2013 that took place in Midrand and Cape Town recently. Mr. Tim Waldron, the Chairman of the IWA Water Losses Specialist Group, commended the organisers and all the speakers on a very high quality event with excellent papers and presentations. He indicated that it is the best regional water loss conference he has attended and he will certainly give full IWA backing to future events in South Africa.

For further support contact Tel:+27(12) 346 3496, Fax: +27(12) 346 9956, Email: wrp@wrp.co.za • Internet: www.wrp.co.za

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Delivering sustainable infrastructure that improves our world. “DOING GOOD WHILE DOING BUSINESS”

Contact www.bigenafrica.com, or the office most convenient to you: Pretoria (012) 842 8700; Johannesburg (011) 802 0560; Bloemfontein (051) 430 1423; Cape Town (021) 919 6976; Durban (031) 717 2571; East London (043) 748 6230; Gabarone gaborone@bigenafrica.com; Kuruman (053) 712 2882; Mafikeng (018) 386 2111; Mthatha (047) 532 5234; Nelspruit (013) 755 1421; Polokwane (015) 297 4055; Richards Bay (035) 753 1235; Rustenburg (014) 597 3655; Umtata (047) 532 5216; Windhoek +26 461 237 346.