Imiesa September 2014

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

IIMESA

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

MARLEY PIPE Partnering for quality SYSTEMS without compromise

SAPPMA Pipes VIII The A to Z on plastic pipes MEDIA

In the Spotlight Minister of Water and Sanitation, Nomvula Mokonyane

Trenchless Technology Pipe ramming in South Africa

in the

HOT SEAT

“We see an opportunity in the future management, operation and maintenance tenancce of municipal infrastructure in cooperation with municipalities.” alities..”

JJ Grobler, CEO, BVi Consulting Engineer EEngineers i rs

I S S N 0 2 5 7 1 9 7 8 V o l u m e 3 9 N o . 9 • S e p t e m b e r 2 0 1 4 • R 5 0 . 0 0 ( i n c l VAT )

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 group’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. JOAT’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.

HEAD OFFICE Unit 19 Alexander Park, 24 Alexander Road, Westmead, Pinetown, KZN, SA 3610 • Postnet Suite 23, Private Bag X4, Kloof 3640 t +27 (0)31 700 1177 • f +27 (0)31 700 9853 • Contact Daryl Spencer daryl.spencer@joat.co.za c 083 555 9996 NATIONAL OFFICES • Pietermaritzburg • Port Elizabeth • Johannesburg • Cape Town • Shelly Beach

CONTENTS

VOLUME 39 NO 9 SEPTEMBER 2014

Regulars Editor’s comment President’s comment Africa Round-up Index to advertisers

3 4 8 80

Cover story A passion for pipes

6

Municipal feature N8 corridor: linking urban centres Established in 1963, Marley Pipe Systems is recognised globally as the leading name in plastic pipe conveyance and reticulation systems. Driven by a passion for the industry, the company’s all-encompassing approach is demonstrably structured to deliver on its promise: quality without compromise. P6

in the SPOTLIGHT Interview with newly appointed Minister of Water and Sanitation Nomvula Mokonyane. P14

in n the e

HOTT SEA AT With a positive outlook on the local and national government infrastructure market, BVi Consulting Engineers’s CEO, JJ Grobler, explains how the company is excellently positioned to help the public sector meet its ambitious infrastructure targets. P12

16

Hot seat The BVi Group: big enough to matter, small enough to care

12

Minister Nomvula Mokonyane has a plan

60

Suspended paving: It’s in the bag

62

16

The benefits of composite technology

64

Social housing Elevating social housing in eThekwini

20

69

New simple method for cutting marble blocks

69

39

Backhoe loader: productivity, versatility, efficiency

71

40

New products expand dealer network

72

The importance of coolant in vehicle maintenance

74

28

Trenchless technology Tunnel boring technology delivers for Qatar Pipe ramming in the South African context

Pipes Macsteel tube and pipe 50 Further contracts in the pipeline for the Western Aqueduct 51 HDPE solution for R4.3 m 54 pipeline project

Pipe ramming in the South African context

Infrastructure, construction equipment and vehicles New hydraulic drill aimed at large depths

SAPPMA – Pipes VIII Pipes and the industry: a year in review

Cement and concrete

14

Human settlements Stepping out of the margins

Stepping out of the margins

Aiding the enhancement of cementitious materials: Part 2

In the spotlight

40

28

10

Pipes and pipelines SAICE-Rand Water Schools Water 78 Competition 2014

64

The benefits of composite technology

SAPPMA – Pipes VII

IMIESA September 2014

1

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EDITOR’S COMMENT

PUBLISHER Elizabeth Shorten EDITOR Nicholas McDiarmid EDITORIAL ASSISTANT Danielle Petterson HEAD OF DESIGN Frédérick Danton SENIOR DESIGNER Hayley Mendelow DESIGNER Kirsty Galloway CHIEF SUB-EDITOR Tristan Snijders SUB-EDITOR Beatrix Knopjes CONTRIBUTORS Ruby Estela Cardona, Carolina Giraldo, Juan Guillermo Morales, Claudia Rodriguez and Neil van Rooyen CLIENT SERVICES & PRODUCTION MANAGER Antois-Leigh Botma PRODUCTION COORDINATOR Jacqueline Modise FINANCIAL MANAGER Andrew Lobban MARKETING MANAGER Hestelle Robinson 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 ___________________________________________________

Balancing acts

T

HE YEAR is rushing by and already it is nearly time for the annual IMESA conference – one the largest conferences and exhibitions of its kind in Southern Africa. This is the 78th IMESA conference and will be held at the Durban International Convention Centre, and is co-hosted by the City of eThekwini.

The conference theme chosen by the institute is ‘Balancing Service Delivery’, which acknowledges the new infrastructure development legislation that is putting pressure on all stakeholders in the built environment to achieve Government’s service delivery objectives. The balancing act refers to requirements involved, from first planning to commissioning within extremely tight deadlines, in delivering quality infrastructure. This year’s sub-themes include: • Political and Legislative Perspectives • Ecological and Environmental Impacts • Financial Considerations • Transport and Traffic • Water and Sanitation • Roads and Stormwater.

This year, IMESA will also present its biannual Excellence Awards and I am reliably informed that this year has seen the most entries ever, with some categories reaching as many as 13 entries. We recently attended the CESA Aon Excellence Awards and, again, the number and quality of entries and winners was impressive. While acknowledging the challenges faced by our industry, I think it is important to realise that there are indeed positive stories to tell. We need more projects and we need them fast, but work has far from dried up and there appears to be some real movement from National Government to truly engage with the private sector, and coordinate with local government, to speed things up and enforce accountability.

In this edition, we speak to Minister Nomvula Mokonyane about the Department of Water and Sanitation’s short- and medium-term strategies and it is heartening to see that, already, she has made great strides in bringing stakeholders together from all tiers of government and the private sector at the recent Water Summit held by the department. Concrete steps have flowed from there, and we will soon see legislation that ring-fences municipal budgets for the maintenance and refurbishment of water and wastewater infrastructure, and the department’s bulk water infrastructure works are without doubt moving in the right direction. Minister of Human Settlements Lindiwe Sisulu has also recently announced a number of very direct initiatives, including the 100-day programme, which outlines steps to deliver 1.5 million houses over the next five years. With strategic meetings planned with the Chamber of Mines, SALGA, the Banking Association and South African Women in Construction, the department will host the National Human Settlements indaba in late September to hammer out solutions to meeting the target.

IMESA and its stakeholders are intrinsic to Government’s objectives and this year’s conference will speak to this. There is something special about IMESA conferences – the sense of togetherness and progress, regardless of challenges faced, is always inspiring and crucial to building the foundation for the coming year.

I look forward to seeing you there, catching up and getting down to business.

See you in Durban.

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

PUBLISHER: MEDIA No. 4, 5th Avenue, Rivonia 2056 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: nicholas@3smedia.co.za www.3smedia.co.za ANNUAL SUBSCRIPTION: R550.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2014. 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

Nicholas McDiarmid

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

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Infrastructure News

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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.

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

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IMIESA September 2014

3

Frank Stevens, president of IMESA

Look how far

Historically, the IMESA head office activities were run by long-servicing members and volunteers but, as time went on, these members retired while activities at the head office increased. The need became apparent for IMESA to lease office space and revamp its operations.

NOW

THEN

O

VER THE PAST two years I have often made mention of the constant growth and importance of IMESA’s engine room – ‘IMESA House’ our head office based in Westville.

Yet another significant milestone was reached at the beginning of August 2014 with the appointment of Pradeep (‘King’) Singh as our office manager and I am sure that he already feels at home and is enjoying being part of such a vibrant team.

King comes to us with a wealth of managerial and

technical experience. He is a member of the Institute of Municipal Finance Officers and holds an IMESA certificate in Asset Management. King is well versed in how best to work with engineers, consultants, project managers and technical staff in order to ensure optimal service delivery.

King’s impressive track record in local government spans 24 years and he was in charge of the Capital Expenditure Programme of the eThekwini Municipality for over a decade.

King is a very keen sportsman with several notable achievements to his name, including being captain of the South African volleyball team and completing two Comrades Marathons. He plays soccer and golf (handicap 10).

LEFT Pradeep Singh, IMESA head office manager RIGHT Ingrid Botton, IMESA administration officer FAR RIGHT Judy Stephens, IMESA training coordinator

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IMIESA September 2014

Looking back The arrival of our newest staff member is the latest milestone in a journey that began in October 2008, when IMESA leased a small suite of offices in Westville. From a staff complement of two, we now have six. Look how far we’ve come!

While King may be the head office ‘newbie’, Ingrid Botton, our longest-serving member of staff, is now a part of the furniture.

Ingrid Botton was appointed as the administration officer for IMESA in August 2009.

ABOVE LEFT (THEN) Maryvale Road, Westville ABOVE RIGHT (NOW) Head Office, Derby Downs, Westville

Since then, her duties have grown and developed. She has been involved with the IMESA Infrastructure Management System (IIMS) from its inception and was formally appointed to IMESA (Pty) Ltd from 1 March 2014. Her current duties centre on training and assisting local municipalities with the collection and upload of fixed asset data to the IIMS programme

we’ve come for extracting and reconciling GRAP17 compliant fixed asset registers for municipal audits.

Ingrid is passionate about game conservation and lists Hluhluwe and St Lucia as her favourite destinations. During downtime, she enjoys handcrafts, particularly the making of unusual and arty Christmas trees.

By April 2010, IMESA training had proved so successful that a part-time training coordinator was needed – and so Judy Stephens joined the team. She oversees all of IMESA’s training activities – for example the popular course in infrastructure asset management, which is offered nationally. IMESA has also been successful in tendering and being awarded a big contract with MISA (Municipal Infrastructure Support Agent).

This will definitely keep Judy busy for the foreseeable future.To relax, Judy enjoys watching movies.

Debbie Anderson joined IMESA in June 2011, just in time for IMESA’s Jubilee Conference.

She describes her job as “Exciting, with never a dull moment.” Every year, she works closely with the local organising committee of the

city where the annual IMESA conference is held and is involved in every aspect of conference coordination, a challenge she relishes.

Debbie’s interests include photography, camping, visiting game parks, hiking and travel.

She has climbed Kilimanjaro and to Base Camp Everest.

Anurah Sathnarain joined IMESA in July 2011, when it became clear that additional administrative support was required to deal with the growth of the organisation.

She handles the switchboard, general office and membership administration, maintains the membership database and liaises with IMESA clients on a regular basis, including email correspondence with debtors, creditors, ECSA and 3S Media.

Anurah is currently studying for a bachelor’s degree in education through UNISA. In 2005, she worked as a camp counsellor at one of America’s top 10 camps in Texas and took the opportunity to travel around the US – a year she describes as one of the most exciting in her life.

Zanele Dlamini is the office assistant. She ensures our offices are always neat and tidy,

she makes a mean cup of tea and coffee and, in the afternoon, she does all the filing, Zanele joined the team in 2011.

In her spare time, Zanele is an avid reader.

Last but certainly not least, Narisha Sogan has been with IMESA since March 2013. Her job is critical for IMESA’s smooth functioning, as it involves maintaining all accounting systems and processes, including SARS VAT, PAYE and reconciliations and generating the financials (Pastel/year-end audits and reconciliations). Narisha also handles administrative and personnel services for IMESA, such as staff salaries.

In her free time, Narisha enjoys reading, shopping, and spending time with her family.

I hope you have enjoyed meeting our dynamic team at IMESA head office. On behalf of IMESA, I’d like to extend a warm welcome to King. We are confident that his extensive knowledge of local government, leadership qualities, team spirit and determined and ‘can do’ attitude will ensure that IMESA continues to grow from strength to strength in the years to come.

BELOW FROM LEFT Debbie Anderson, IMESA conference coordinator Anurah Sathnarain, IMESA receptionist and administration assistant Zanele Dlamini, office assistant Narisha Sogan, IMESA financial officer

IMIESA September 2014

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COVER STORY

A passion for pipes Established in 1963, Marley Pipe Systems is recognised globally as the leading name in plastic pipe conveyance and reticulation systems. Driven by a passion for the industr y, the company’s allencompassing approach is demonstrably structured to deliver on its promise: quality without compromise.

M

ARLEY PROVIDES plastic pipe infrastructure into several sectors such as mining, industrial and infrastructure, including municipal infrastructure. “We offer an alternative to the conventional systems,” explains Pranesh Maniraj, head of sales and marketing, PE Solutions. “We look to provide these solutions not simply from a product perspective but also from quality, technical support services, capacity and range points of view.”

While many companies like to consider themselves market leaders, Marley sees itself as a steward of the plastic pipe industry in general, and is active across a number of initiatives that raise the bar for quality, standards, testing and market education.

Partnering for quality product Marley’s approach to all the markets it serves is one of partnership. The company

can produce up to 1 000 mm in diameter in solid-wall pipes and up to 1 800 mm in diameter in structured wall pipes, with the technological potential to manufacture up to 3 500 mm. State-of-the-art fabrication underpins the company’s philosophy: ‘If you can draw it, we can make it.’

The company does more than sell pipes and fittings: it involves itself from the point of specification all the way through to commissioning. Quality is viewed holistically and the company has invested in ensuring that its production processes follow its SANS ISO 9001 quality management system.

“We have the equipment, the facilities and the trained personnel to ensure that our products and systems are manufactured to and carry the SABS mark of trusted quality as for the various permit requirements,” explains Ian Venter, product specialist, Petroplas and Weholite. This includes the resources to conduct destructive and nondestructive testing, carry out X-rays on

products and ensure that all permit conditions are met.

Marley is also creating standards for the South African market, and works closely with several bodies to ensure this happens.

“Our work sees us introducing a plastic alternative to a traditional product (typically cement or steel or GRP), developing a standard for it and working with the SABS to have it translated into a National Standard.

An example of this is a project we are working on with the City Of Tshwane, in which we have developed plastic manholes suitable for the dolomitic nature of the area. Made from Weholite and solid-wall HDPE, the plastic manhole is gaining traction in the market due its versatility, quality, water and chemical resistance and ease of installation. The city was not familiar with its properties so we have developed the standards in conjunction with Department of Public Works, which will now become the SABS standard,” explains Venter.

Partnering for quality and price Marley’s aim is to improve efficiencies, solve industry challenges and ensure safe and sustainable operations in a broad spectrum of pipeline applications. Substandard raw materials account for 85% of PE pipe system failures, due to the use of non-conforming recycled raw material in production.

Marley Pipe Systems is dedicated to ensuring that plastic pipe systems deliver on their promise. “Plastic is entering a more mature phase in the market and is recognised now not only as a valid and recognised substitute, but as a first-line Marley Pipe's African mining footprint

6

IMIESA September 2014

Pranesh Maniraj (2nd from left), Faize Gafoor (4th from left) and, to his right, Ian Venter with members of the Marley team

product that can deliver a 100-year lifespan. Cheaper products, which by nature are of a lesser standard, are not going to deliver that. The common message out in the industry is that plastic will outperform traditional materials in specific applications,” says Venter.

The bottom line when it comes to price is that the only way a manufacturer can drive its price down is by compromising on raw material.

Partnering for support Marley’s technical expertise is second to none and is founded on its strong support structure of mechanical engineers and polymer technologists. From the specification of a project to development and commissioning, Marley sees each installation as a new opportunity to reinforce and improve both the reputation of plastic pipe systems and market knowledge and expertise. Transferring knowledge and skills to its client-partners is fundamental to each project.

This applies as much for contractors as it does customers. Faize Gafoor, sales executive: projects, explains, “We want to empower contractors and are driving this in partnership with Plastics SA by setting the standards and certifying welders in line with SANS/national specifications. Butt-welding and electro-fusion-welding processes are the critical elements of an enduring pipe system. We align ourselves with butt-welding equipment companies and also produce electro-fusion fittings up to 1 200 mm.”

Partner networks of innovation and capacity With some of the largest, state-of-theart manufacturing facilities in Nigel and Rosslyn in Gauteng and multiple branches and depots throughout the country, Marley

“Plastic is entering a more mature phase in the market and is recognised now not only as a valid and recognised substitute, but as a first-line product.”

Ian Venter, product specialist

constantly adding new products to its stable and further increasing its abilities to provide complete solutions. This capacity, coupled with its expertise and a long heritage in the plastic pipes market, allows Marley Pipe Systems to continuously innovate new products, techniques and equipment.

“We have been active in developing new products and methods, including a technology to manufacture fire-retardant pipe. Our acquired Weholite technology from Finland and our innovative seals from Europe have created a thorough joining system perfect for both stormwater and sewer systems. We have also developed void-free stubs which significantly increase the integrity of piping systems.” says Venter.

Marley is also the only manufacturer that can offer fluorinated pipe for use with petro-chemicals. Fluorination essentially combats permeation by turning the inner and outer layers into a Teflon-like material, preventing permeation.

Partnering for the long term Pipe Systems’ manufacturing capacity is extensive, catering not only to the local market but also export markets in Europe, Australia, and across Africa. Further supporting the company’s capacity is its position as an Aliaxis company. Marley is continuously bringing new innovations from around the globe to the local market, by

IS THIS THE FUTURE? TTHE POLYOLEFIN MANUAL AND CATALOGUE Marley ha has compiled and published The Polyolefin Manual and Catalogue Catalogue. This publication is dedicated to information on PE 100 polyethyl polyethylene and polypropylene polymers as manufactured or supplied by Marley Pipe Systems. Based on more than 50 years’ experienc with PE and PP pipe systems, the manual is intended experience to provide appropriate information for the complete supply chain in the the thermoplastic pipe system industry, including sales, purchasing, cconsulting, engineering, and construction and draughting personne It is also aimed at project owners and clients. personnel.

For elect electronic copies visit: www.marleypipesystems.co.za/images/pdfdownloads/productbrochures/marley-pe-technical-manual-secured.pdf d ownloads

Engaging with its customers, taking a longterm perspective and ensuring an uncompromising approach to quality from cradle to grave is what differentiates Marley in an increasingly competitive market. These principles have attracted large, high-profile clients over the years, such as Transnet and Sasol.

When working with clients of this nature, Marley’s approach of shared responsibility in risk completes the package. “We work as a unit with our clients and contractors and are as sensitive to their needs as they are,” notes Gafoor.

t 0861 MARLEY (627 539) www.marleypipesystems.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 September 2014

7

AFRICA ROUND-UP

INFRASTRUCTURE NEWS FROM AROUND THE CONTINENT SUB-SAHARA Infrastructure spend to reach $180 billion Infrastructure spending in subSaharan Africa is projected to grow by 10% a year over the next decade, exceeding $180 billion by 2025 while maintaining its 2% share of the global infrastructure market.

Nigeria and South Africa currently dominate the infrastructure market, but other countries such as Ethiopia, Ghana, Kenya, Mozambique, and Tanzania are also poised for growth, according to a new report by PwC. In South Africa, infrastructure spending overall is forecasted to reach around $60 billion by Four SADC countries have launched the Limpopo Watercourse Commission

2025, having grown by 10% on average a year. However, South Africa is likely to lose share of regional spending relative to Nigeria. Nigeria’s better fiscal position and oil revenues will likely enable it to outperform South Africa over the coming decade, says the report.

Overall infrastructure spending in Nigeria is expected to grow from $23 billion in 2013 to $77 billion in 2025. A more investor-friendly environment towards oil investment is also likely to boost this projection.

The report also shows that spending on utility infrastructure is expected to be significantly stronger in countries that need to upgrade deficient energy, water and sanitation services and in economies that are rapidly urbanising, such as

Ghana and Nigeria. The greatest growth of spending for utilities is expected in sub-Saharan Africa where an annual rate of 10.4% between now and 2025 is forecasted.

SADC

Improved water management

Four Southern African Development Community (SADC) countries will now be able to collectively manage their water resources more efficiently with the launch of the Limpopo Watercourse Commission.

Launched in Maputo, the Limpopo Watercourse Commission (LIMCOM) will help South Africa, Botswana, Zimbabwe and Mozambique – which all share the Limpopo River Basin – better organise their water management resources.

The basin has a total catchment area of approximately 408 000 km² and very diverse characteristics, covering different climatic and topographic zones as well as land-use types, including protected areas.

In 1986, the four states made a commitment to manage their water resources together with the establishment of the Limpopo Basin Permanent Technical Committee. In 2003, this cooperation was fostered through the multilateral agreement to establish LIMCOM.

AFRICA Significant investment in Power Africa Two out of three sub-Saharan Africans (600 million people) lack access to electricity. In June 2013, US president Barack Obama announced the launch of Power Africa – an initiative to double the number of

8

IMIESA September 2014

people with access to power in sub-Saharan Africa.

Speaking at the ‘Powering Africa: Leading Developments in Infrastructure’ session during the US-Africa Business Forum, World Bank Group president Jim Yong Kim said, “We think that the US Power Africa initiative will play an extremely important role in achieving the goal of providing electricity for Africa.

The World Bank Group, following President Obama’s lead, will support Power Africa by committing $5 billion in direct financing, investment guarantees and advisory services for project preparation in Power Africa’s six initial partner countries.”

The $5 billion will go towards technical and financial support for energy projects in six African countries, namely Ethiopia, Ghana, Kenya, Liberia, Nigeria, and Tanzania, which have partnered with Obama’s Power Africa initiative.

The African Development Bank (AfDB) president, Donald Kaberuka, has reaffirmed AfDB’s support to advance the Power Africa initiative with a commitment of $3 billion over a five-year period.

Under the enhanced partnership announced at the US-African Leaders Summit, the US and the AfDB will collaborate on scaling up the use of off-grid and mini-grid technologies, supporting geothermal power development and strengthening regional power trading between African countries among others.

The government of Sweden announced a commitment to catalyse investments of $1 billion to the Power Africa initiative. The Millennium Challenge Corporation (MCC) signed a $498.2 million compact with

AFRICA ROUND-UP

the government of Ghana to transform the country’s power sector by investing in projects focused on distribution, energy efficiency and renewable energy.

According to MCC CEO Dana Hyde, the compact represents the largest US government transaction to date under the Power Africa initiative.

“The compact we sign today takes a system-wide approach to transforming Ghana’s power sector,” said Hyde. It invests in projects focused on distribution to make Ghana’s energy sector financially viable and capable of attracting private investment, as well as funds initiatives supporting greater energy efficiency and cleaner renewable energy.

$2 billion by 2018 Africa will see an investment of $2 billion in facility development, skills training, and sustainability initiatives by 2018.

Africa has emerged as the most promising growth region for General Electric (GE), with total revenues in Africa in 2013 sitting at $5.2 billion and more than $8.3 billion in orders across Africa.

The company will focus its $2 billion investment in Africa in three strategic areas: building infrastructure, delivering localised solutions to customers, and capacity building. It will achieve this by providing skills training and growing supply chain development in local communities.

Core infrastructure needs in Africa represent a $90 billion opportunity. GE’s technologies generate 25% of Africa’s gas power and nearly 70% of the electricity distributed across Algeria.

GE is working with partners in Africa to drive sustainable development and solve local challenges by investing in technology, building capital markets and developing technical skills

within communities.

The company empowers the communities in which it operates by providing skills training and developing leaders through partnerships with local governments, schools and hospitals.

UGANDA Lamu Port project Ugandan president Yoweri Museveni, Prime Minister Hailemariam Desalgen of Ethiopia, South Sudan president Salva Kiir Mayardit and President Uhuru Kenyatta of Kenya have resolved to fast-track the implementation of the Lamu Port project.

The Lamu Port, South Sudan and Ethiopia transport corridor project is an infrastructural venture that aims to facilitate trade, and promote regional economic integration, as well as connectivity between African countries. The aim is to boost trade and investment in the region.

The Lamu project’s seven components require funds amounting to $24.5 billion,

of which Lamu Port alone will need $32 million for its construction. Kenyatta believes the project will need a joint innovative approach for its quick implementation.

The Kenyan president has signed a $480 million agreement with a Chinese firm for the construction of the first three berths of Lamu Port.

He said his government has already set aside for $50 million to immediately commence the construction works.

NIGERIA National Water Resources Bill The Minister of Water Resource, Sarah Reng Ochekpe, has said that the National Water Resources Bill – which is in the pipeline – will ensure equitable, efficient and sustainable use and management of water resources in Nigeria.

A workshop was recently held to obtain comments, observations, suggestions and all necessary inputs into the Water Resources Bill. “This is a major step towards finalisation of the water bill which would

subsequently be forwarded to the Federal Executive Council for approval and thereafter the National Assembly for passage into law,” Ochekpe said.

The Bill will take into account the meeting of the basic human needs of present and future generations, promoting equitable and affordable access to water; encouraging collaboration between federal and state governments in the provision of water services; facilitating social and developmental programmes on poverty reduction; improving public health and economic development; as well as reducing and preventing pollution and degradation of water resources.

European Union ambassador Michel Arrion, represented by programme manager of water specialists Martin Mbonu, said that the EU would support the Nigerian government to ensure that the Bill is finalised and forwarded to the National Assembly for approval.

Africa will see an investment of $2 billion in energy by 2018

IMIESA September 2014

9

MUNICIPAL FEATURE

N8 CORRIDOR

Linking urban centres

In its aim to make Mangaung a city where people can live, work and invest, the Mangaung Metropolitan Municipality has developed an extensive Spatial Development Framework. Danielle Petterson looks at one of the projects earmarked under the framework of the N8 corridor development.

T

HE N8 CORRIDOR development is situated along the N8 route, one of the major roads stretching from the east of the Free State, through a number of towns, to the west through Petrusberg, all the way to Kimberley in the Northern Cape.

This major project focuses on the development of the N8 as a development spine linking the three urban centres of the Mangaung Metropolitan Municipality. It also serves as an important link to the neighbouring Mantsopa Local Municipality and Maseru in neighbouring Lesotho.

The primary aim of the Mangaung N8 development is to stimulate economic activity in existing nodes and spark the development of new economic nodes along the length of the corridor. The project comprises the development of, among others, an international

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IMIESA September 2014

convention centre, a government complex, a regional shopping mall and an array of sustainable housing typologies. New industrial development and human settlements will predominantly take place towards the east of Bloemfontein, especially in the vicinity of the N8 development zone.

The N8 corridor development also incorporates the airport, the possibility of a dry port, revitalisation of rail transportation between Mangaung and Ladybrand and road infrastructure; establishing increased economic linkages with the main economic hubs in the north and south as well as across the constituting authorities of the city region.

“The N8 corridor development project promises to be a significant investment opportunity, creating jobs for many residents and contributing towards building a better life for all. The envisaged

development at Naval Hill will undoubtedly be one of the municipality’s world-class recreational facilities and tourism destinations that will give the local economy a great boost,” says Thabo Manyoni, executive mayor of Mangaung.

“Similarly, through the ongoing development of the Bloemfontein Airport, Mangaung is positioning itself as one of the emerging ‘aerocities’ in the country. The proposed Bloemfontein Airport precinct, to the south of the airport entrance, is a multibillion-rand infrastructure and property development project that has kicked off implementation of the first phase.”

Airport development node Bloemfontein International Airport is one of the most important activity nodes identified within the N8 corridor development.

MUNICIPAL FEATURE

The Mangaung Metropolitan Municipality announced, in its medium-term revenue and expenditure framework for 2013/14 to 2015/16, that the city will continue making a significant investment of R85.6 million over the next two years to install reticulation services such as water and sanitation to support the development at the airport development node.

Located along the N8 road towards the Mangaung towns of Botshabelo and Thaba Nchu, the aerocity will boast services ranging from a shopping mall, educational and civic sites and an urban square to an international conference centre, hotels and housing.

Kaba Kabagambe, head of department for planning at Mangaung Metropolitan Municipality, believes that the airport node will anchor the province’s strategy to develop eastwards from Bloemfontein and westwards from the settlements for a development corridor to be created.

According to Kabagambe, the airport node is the largest municipal-owned and -driven airport city project within the Southern African Development Community region.

Revenue generated from the project to be used for cross-subsidisation of critical projects in Botshabelo and Thaba Nchu, making the project significant in the overall development of the two areas.

Developing an aerocity The node will be developed on 2 000 ha of strategically located land, of which the first phase is 700 ha. The site-servicing phase of the project, which is currently underway, is expected to create 11 000 jobs.

This phase will include a number of major developments, such as a 50 ha urban square, an international conference centre and related amenities such as hotels, business centres and niche shopping facilities.

Once fully developed, this phase will have an investment value of approximately R100 billion.

The second phase of the project will see the node evolving into a dry port that will be a central area where all the modes of transport converge for the development of the area.

Providing water services The municipality is making steady progress in relation to the provision of water services to households in the municipality. To ensure that there is continued provision of water and sanitation services, the municipality has

begun to implement a number of bulk water and sanitation projects in the city.

These projects will strategically position the city to ignite the N8 corridor development and lay a solid foundation for broadening the revenue base of the municipality and dealing with the distorted, inherited spatial form of the city.

Naval Hill reservoir The north-eastern development area has the largest need for additional storage capacity due to continuous development. To remedy this, one of the bulk water projects under the N8 project was the construction of a 35 Mℓ reservoir on Naval Hill. Construction of the reservoir began in May 2013 and was completed in October 2013.

This is the first phase of a planned 70 Mℓ additional reservoir capacity for Bloemfontein to provide emergency storage capacity for the eastern developments and a sufficient static head in order to supply the proposed secondary storage reservoirs. The reservoir will be the main supply reservoir to the N8 corridor development.

The reservoir will enable the extension of water delivery to some disadvantaged communities and will serve as buffer capacity for peak water demand periods. Naval Hill is the highest point in the area with extremely steep slopes. By the positioning of the reservoir on the highest point in the area, there is sufficient pressure to provide up to 24 hours of emergency supply in the event of electrical or mechanical interruptions.

The location of the reservoir presented challenges to its construction. Getting the concrete to the site was particularly difficult because it was restricted to 4 m2 truck loads at a time. Lafarge – which supplied 700 m³ of standard 25 MPa concrete for the foundations, with 30 MPa and 35 MPa high-strength grades for the walls – worked closely with the main contractor to overcome the challenges of the difficult location.

North Eastern WWTW The existing Bloemspruit Wastewater Treatment Works (WWTW) is currently hydraulically overloaded and a new North Eastern WWTW is being constructed to relieve the load on the existing facility.

Diversion of the wastewater flow from the existing Bloemspruit WWTW to the new North Eastern WWTW will also allow the municipality to undertake necessary maintenance work on the existing Bloemspruit works.

TOP Mangaung intermodal transport ABOVE Averting a greater water crisis OPPOSITE The proposed Mangaung aerocity

The project includes: • the construction of new inlet works including screw pump lifting station, mechanical screening, grit removal structures and a chlorination tank • a buffer pond • an emergency overflow pond downstream of the inlet works • two 35 m diameter secondary settling tanks and three concrete-lined sludge lagoons.

The WWTW will also house a biological reactor comprising anoxic and aerobic zones as well as internal recycling streams. A pump station will pump raw activated sludge to the biological reactor and waste activated sludge to the sludge lagoons.

The project’s scope also includes the construction of various small concrete structures including flow diversion and collection chambers, boundary fencing, main access and internal roads, general landscaping and the construction of earth retaining walls.

Construction on this bulk sanitation project commenced in February 2013 and once complete, the North Eastern WWTW is expected to benefit approximately 45 000 people in the long term.

IMIESA September 2014

11

HOT SEAT

THE BVI GROUP

Big enough to matter, small enough to care With a positive outlook on the local and national government infrastructure market, BVi Consulting Engineers is excellently positioned to help the public sector meet its ambitious infrastructure targets.

A

S EVIDENCED by the recent pronouncements from Pravin Gordhan, Nomvula Mokonyane and Lindiwe Sisulu, the South African government understands the crucial role the private sector must play in getting the country on track, and BVi Consulting Engineers is ready and able apply its skills and services to the management, operation and maintenance of municipal infrastructure. JJ Grobler, CEO of the BVi Group, talks to IMIESA

about the company’s innovative approach to infrastructure delivery, with its focus on community inclusion and upliftment.

IM What makes BVi unique in the African market? JJG We firmly believe that what sets us apart from our competitors is the fact that the BVi Group is big enough to make a difference and small eenough to care.

Bvi Group’s growth since its in inception in 1967 has been a re remarkable one. Bvi was establilished as a multidisciplinary cconsulting engineering firm

offering ‘traditional’ consulting services in the fields of civil, structural, electrical and mechanical engineering. Today, the Level 2 BEE company has a 47% black ownership status and counts on its 300+ strong team of professionals to deliver engineering excellence to private and public sector clients.

The journey from 1967 to present has taken BVi from a small two-office start-up business to a nationwide organisation with fifteen local and four international offices. In 2008, the group added to its portfolio by providing EPCM services to

its clients and thereby adding the mining industry to its client base. Expansion across South African borders into the SADC region became a strategic focus in 2009 and, since then, BVi has successfully completed numerous projects on neighbouring African soil. BVi Group has offices in Angola, the DRC, Mozambique and Namibia.

What does BVi prioritise when working on local government projects?

Working on a multidisciplinary engineering projects base, BVi has focused on the basic need

“BVi embraces innovative thinking, taking a labour-intensive approach on many of its projects. This approach does not only create employment, but also involves the community from inception right through to the final handover of the project.” JJ Grobler, CEO, BVi Group 12

IMIESA September 2014

THREE PHASES OF THE PROJECT The project is now in its second of three phases, which is focusing on the replacement of the gravity main pipeline from the Eenriet reservoir at Steinkopf to the Vaalhoek reservoir in Springbok.

PHASE 1: June 2010 – March 2013 • Emergency repair work at pump stations and purification plant to ensure supply of water • Feasibility study to determine the design capacity for the next 30 years • Upgrade personnel housing • Building a 13 km bypass pipleline from Vrieskloof to Kliphoogte PHASE 2: April 2013 – March 2016 • Replace the gravity main pipeline (55 km in length) from the Eenriet reservoir at Steinkopf to the Vaalhoek reservoir at Springbok.

Various fronts of replacement of the gravity main pipeline from the Eenriet reservoir at Steinkopf to the Vaalhoek reservoir in Springbok.

for infrastructure development such as housing, water, sanitation and electricity to local communities. BVi embraces innovative thinking, taking a labour-intensive approach on many of its projects. This approach not only creates employment, but also involves the community from inception right through to the final handover of the project.

Innovative thinking has lead BVi to facilitate smarter processes, management and programmes together with its clients.

What water projects has BVi been involved in over the past years?

BVi has been involved in a few large-scale water projects over the past years. One of these projects is the Namakwa Regional Water Supply Scheme: In January 2010, the then Minister of Water and Environmental Affairs requested Sedibeng Water to conduct an assessment of the Namakwa Regional Water Supply

Scheme’s infrastructure. Since 2009, interruptions of the water supply to the Springbok area have been rife, with continuous pipe failures, leading to towns being without water for periods of up to four days. BVi was appointed by Sedibeng Water and the Department of Water and Environmental Affairs in October 2010 to conduct a study to provide a single technical solution for solving the infrastructure problem, as well as increasing and sustaining the water supply of the Namakwa Scheme.

As implementing agent, Sedibeng Water tasked BVi with the following: • determining the current and future water demand for all towns and villages in the region • liaising with all stakeholders in the region to determine and analyse future developments and associated water demands • conducting an assessment of the current

PHASE 3: Envisaged commencement: April 2016 – March 2019

• Upgrade the rising main pipeline (50 km in length) from the Orange River to the Eenriet reservoir • Refurbishment of pump stations and the purification plant • Local distribution pipelines to Okiep, Nababeep, Concordia, Carolusberg and Springbok • Community involvement The entire workforce of 138 people, both skilled and nonskilled, consists of members of the local community. The next phase of construction will open the opportunity of even more local employment. The towns of Steinkopf, Concordia, Okiep, Carolusberg, Nababeep, Springbok and Kleinzee will benefit from the refurbished water scheme. infrastructure condition • conducting a GAP analysis to determine current and future needs • investigating and evaluating all water supply options • selecting a single, technically feasible solution and developing a project scope for construction • calculating estimated capital requirements, as well as the operating and maintenance costs • compiling a Water Master Plan for the Namakwaland region.

What is BVi’s outlook for the coming years? With the ever-changing environment

we operate in and taking into consideration the latest trends in the industry, we as BVi have made some significant changes to our operational and management model. I strongly believe that this will now put us in an even better position to procure work and execute our projects to an even higher standard, thus securing our future growth targets. We’ve set us some very exciting short- to medium-term goals, which will be renewed and updated frequently.

t +27 (0)12 940 1111 •www.bvigroup.co.za

IMIESA September 2014

13

IN THE SPOTLIGHT

Water is life, MINISTER NOMVULA MOKONYANE’S VISION The repositioning of the Depar tment of Water and Sanitation has come at a crucial time in South Africa’s infrastructure journey through its new democracy.

H

AVING MADE MAJOR inroads in the delivery of water and sanitation services to all South Africans, Government is now accelerating its role out of water and sanitation infrastructure in seeking to fulfil its promise of ‘Water is life; sanitation is dignity.’

In this exclusive interview, newly appointed Minister of Water and Sanitation Nomvula Mokonyane speaks to IMIESA about how the government’s integrated approach is set to deliver.

IM The establishment of the Department to Water and Sanitation suggests a new emphasis on the latter. What is behind this? Min. NM Years ago, Nelson Mandela was quoted in a document titled ‘Why advocate for water, sanitation and hygiene?’ as saying, “Sanitation is more important than independence.”

Imagine that!

The transformation and deracialisation of South Africa should be fast-tracked through the provision of water and sanitation. We have to do things differently if we are to realise the objectives of the National Development Plan (NDP) and our electoral mandate.

Most of all, we need to change the lives of women in our communities – especially those in rural areas. No woman should have to share

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IMIESA September 2014

her water with animals; the image of the barefoot, pregnant woman fetching water has to be wiped out once and for all. Particularly when she’s living right next to a dam!

Opening the sector to the disenfranchised through skills development and economic empowerment is one way of increasing access to water and sanitation.

You have mentioned ‘game changers’ and that what follows is no longer business as usual. What are priorities at this stage?

At the Department of Water and Sanitation, we have identified six priorities that will require game changers. These are: • meeting the service delivery challenges • water and sanitation challenges, water research,

technology and innovation • understanding the state of water as a national resource • the role of the private sector • community participation.

This requires us, both as a department and as individuals, to embrace some key principles, including effectiveness, efficiency, accountability, accessibility and the ability and willingness to cooperate.

I commit to South Africans to provide decisive leadership with the ability to assert authority in the right places to makes these happen.

You have previously mentioned a reduction in outsourcing; what is your vision for public sector skills? The water sector, when it comes to public services, has become too dependent on outsourcing generally. We are going

to engage in a changemanagement process to ensure that we have the skills required to perform optimally. This may require the sourcing of skills in cooperation with the Department of Public Service and Administration, but the issue extends further than that.

We need to be innovative as well and there is no doubt that, in partnership with our own Water Research Commission, science and technology could facilitate opportunities for employment in local communities. Inclusive growth in our sector has to include local communities. We will also work with other relevant departments to ensure that we create job opportunities by including them in the allocation of contracts.

We can only achieve our objectives if we put our communities first.

IN THE SPOTLIGHT

sanitation is dignity Protecting existing infrastructure is also high on your agenda; what are the current challenges and what structures are needed to achieve this? We have agreed with the minister of COGTA that all water ser vices authorities (WSAs) ring-fence a minimum of seven per cent of their total budgets towards the maintenance and management of existing infrastructure.

We have to ensure that each municipality has the capacity and capability to carr y out this task efficiently and effectively.

Please note that this includes sanitation infrastructure.

Both water treatment and waste treatment must be prioritised. As government, we will no longer tolerate excuses about ageing or nonfunctioning water infrastructure and we are introducing legislation to effect this.

this financial year, open up this protected space so as to ensure that water as a natural resource is available and shared by all. This includes those who live in villages, townships and beneficiaries of land reform nearer to the mines and new industries will benefit.

The participation of our people in the water sector is key.

We will extend our stakeholder relations by ensuring that water and sanitation forums are established in: every

correctly for maintenance of infrastructure. While this applies to all municipalities, we are moving away from a one-size-fits-all approach.

The notion of ever y district or local municipality having the powers and functions of a WSA, yet viability and capacity is questionable, is an obvious problem. Already, a number of support inter ventions in specific targeted municipalities have been identified and will be implemented as a matter of

R670 billion. This is across the whole value chain and cannot be done in isolation. The NDP contains strategic integrated projects (SIPS) and SIP 18 requires the development of a comprehensive and integrated investment framework for water and sanitation that we are now working on. This framework will inform budgeting and integrated planning based on a life-cycle approach, which includes planning and construction costs, operation and maintenance, financing costs and the costs of sustainable water management.

“This framework will inform budgeting and integrated planning based on a life-cycle approach, which includes planning and construction costs, operation and maintenance, financing costs and the costs of sustainable water management.�

Access to water is a fundamental to wellbeing and development; how will you tackle this crucial area? As part of the drive towards radical socio-economic transformation, we need to ensure that solutions to water and sanitation challenges must include opening the sector to those that have been disenfranchised.

Ownership of access to water continues to perpetuate inequality in our country.

Working together with all South Africans, we will, in

metro and district representing communities, business and academia, as well as among women, youth and people with disabilities.

Educating and creating awareness in these communities about conser vation, preser vation and security of water is also crucial.

There is concern about capacity in certain municipalities, especially around water infrastructure and operational issues, like metering and billing. What role will the department play in the current structures?

This area is going to change significantly. I mentioned earlier that we are taking a no-nonsense approach with all municipalities with regards to budgeting

extreme urgency. We are also developing specific provincial action plans, alongside the premiers, to deal with challenges that could be classified as cross-cutting.

Ageing infrastructure and maintenance and the lack of technical capacity are two such examples.

We will also be working with the South African Local Government Association on matters related to water tariffs, water losses and preser vation.

Going back to the theme of integration, what action is being taken to improve planning across water and sanitation?

We have estimated that the investment required in new water and sanitation infrastructure over the next decade will be in the region of

You have mentioned the harmonisation of roles and respon-sibilities of institutions and spheres within Government.

What can the private sector do to add their support? We call

on consulting engineers especially to partner with us on the basis of providing a better life for all. Consulting engineers are capable of delivering innovative solutions within the context of life-cycle design and planning of the needed infrastructure. It is not business as usual; the deliver y we are determined to achieve will be done so in partnership with the private sector.

Structures like the Presidential Infrastructure Coordinating Committee and Operation Phakisa are there for us to engage and develop an optimal environment for delivery and the private sector is very much a part of these.

IMIESA September 2014

15

HUMAN SETTLEMENTS

Coordination of Diepsloot's infrastructure

in Diepsloot is coordinated. In particular, the JDA will participate in the Diepsloot Coordinating Forum meetings.

Property development facilitation work in the marginalised areas includes developing a small-scale retail programme that brings together a retail development partner, a funding partner and the city to develop small, mixed-use properties along activity streets in Diepsloot and other priority areas.

Kliptown development The history of development proposals for Kliptown extends as far back as the early 1990s with emergency services provided to the area. In 2001, a new development project was drawn up and partially implemented over the following five years.

The Greater Kliptown Development Framework of 1996 made proposals for boosting Freedom Square as a historical tourism site, with a museum, public spaces, a park and a mix of shops and informal trading.

The Greater Kliptown Development Project, also referred to as the Greater Kliptown Regeneration Development, was established in November 2001 under the auspices of Blue IQ. The JDA was appointed as the implementing agent.

The initial impetus for the Kliptown project was to commemorate the 50th anniversary of the adoption of the Freedom Charter in Kliptown. This commemoration would centre on architecturally upgrading Freedom Square.

The Greater Kliptown Development Project was initiated with the launch of an architectural competition to design Freedom Square in April 2002. The square was renamed the Walter Sisulu Square of Dedication (WSSD).

In addition to the WSSD, the JDA built a new taxi facility, improved access roads, rehabilitated the wetlands and constructed community facilities, including a museum.

Stepping out of the margins The development of human settlements, be it new settlements or upgrading existing ones, has an impact on society far beyond the intended recipients. With stability and permanence come exponential business opportunities that impact the surrounding communities.

T

HE JOHANNESBURG Development Agency (JDA) has prioritised three strategic nodes for upgrading human settlements: Sol Plaatjie, Kliptown and Diepsloot in Gauteng.

These selected areas focus on neighbourhoods with large, residential, low-income populations. The intention is to develop sustainable economic hubs to shift jobs and economic opportunities closer to where these lower-income people live and develop public amenities and easy access to affordable public transport facilities.

The medium-term implementation time frame, which concludes in 2016, is

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IMIESA September 2014

guided by the City of Johannesburg’s Growth Management Strategy and the Gauteng 2055 discussion document.

Full municipal services In addition to these precinct developments, the JDA is providing technical assistance to the city’s Directorate of Health to build and refurbish a number of clinics across the city. The JDA is also assisting to build roads and upgrade services in Sol Plaatjie to support the development of new housing. The JDA will play a supporting role for the Department of Development Planning to ensure that infrastructure investment

Public environmental improvements In 2010, the JDA began a new four-year project to extend the public environment improvements to the residential and business areas around the WSSD. The work that has been completed so far includes:

Partnering our skills with the public sector to manage, support and maintain the projects that move our country forward.

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• upgrading the Union Pedestrian Bridge and installing new ramps and building pedestrian areas across the railway line • installing 600 m of paving and lighting to create a safe pedestrian walkway along the railway’s western side • a public environment upgrade of Union, Beacon, Future and Main roads, and 1st, 2nd, 3rd, and 4th avenues; Daffodil Street, Klipspruit Valley Road and the Northern Precinct (the street and pavement upgrades were intended to create an improved environment for economic activity in the neighbourhood around the WSSD and create safe public environments for pedestrians walking to public transit services; and improve or rehabilitate basic municipal services such as stormwater drainage and street lighting) • installing CCTV around the square • repairing tower mast lights and installing new cables at the visitor centre and street lighting behind the WSSD • refurbishing the study centre, crèche and community hall • refurbishing the youth centre • building sports facilities (basketball and netball courts) • upgrading the public park • upgrading the soccer facility and landscaping at the visitor centre • installing artwork commemorating the area’s history This phase of development is scheduled for completion by the end of 2014. The focus will be on upgrading the 5th Avenue and Union Road soccer facility and constructing a small park opposite the Soweto Hotel.

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Diepsloot development

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The Diepsloot township was established in 1994 to relocate informally settled households from Zevenfontein. It subsequently accommodated informal settlers relocated from the Alexandra Far East Bank in 1995.

Diepsloot covers approximately 5.18 km². It is located on the northern edge of the metropolitan council area, some 40 km from the Johannesburg inner city and 20 km north of Sandton.

It is in close proximity to the Fourways regional node and the Midrand corridor. Diepsloot is bordered by the N14 highway to the north and William Nicol to the east. The Diepsloot area falls under Region A in the City of Johannesburg’s administration, comprising Ward 95 and 96.

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IMIESA September 2014

ABOVE The new Diepsloot taxi rank OPPOSITE Walter Sisulu Square in Kliptown

The City of Johannesburg’s Development Programme for Diepsloot intends to establish the area as a socially, economically and environmentally sustainable human settlement that is spatially integrated into the City of Johannesburg, with access to basic services and opportunities for social mobility and economic development.

The City of Johannesburg has implemented the following initiatives: • a public environment upgrade of Ingonyama Road in 2009/10 • constructing two pedestrian bridges, upgrading the taxi rank and constructing

second year, one clinic was refurbished and three new clinics were completed. The clinics are Petervale Clinic in Bryanston, Davidsonville in Roodepoort and Freedom Park near Eldorado Park.

In 2013/14, the City of Johannesburg aims to construct clinics in Mountainview, Mpumelelo and Slovoville. The clinics will offer improved healthcare and access to healthcare facilities for the communities in these areas.

Sol Plaatjie The Gauteng Department of Housing conceived the Sol Plaatjie Housing Development in the early 2000s. After initiating the project, it was ceded to the Johannesburg Social Housing Company via the City of

“The JDA will play a supporting role for the Department of Development Planning to ensure that infrastructure investment in Diepsloot is coordinated” commuter links between the bridges and Ingonyama Road from the Expanded Public Works Programme fund • completing the public environment upgrade along Ingonyama Road in 2011/12 • planning and design work for the Ingonyama link road extension in 2012/13 • the 2013/14 scope of works will entail the first phase implementation of Ingonyama link road extension, including paving sidewalks, upgrading stormwater drains and kerbing, road surfacing for 1.3 km, planting at least 200 new street trees and installing 80 street lights and associated electrical reticulation infrastructure.

City of Johannesburg clinics programme The City of Johannesburg’s Directorate of Health appointed the JDA to manage its capital works programme in 2011/12, 2012/13 and 2013/14.

In the first year, the JDA appointed a professional team to design a model clinic that could be adapted for any site. Some work was done to prepare two clinic sites for construction, and costing was done for the budget request for future work. In the

Johannesburg Housing Department in the beginning of 2006.

In 2012/13, it was requested that the JDA take on the role of implementing agent to build road infrastructure on behalf of the city’s Department of Housing and the Johannesburg Social Housing Company. This is regarded as a technical assistance project in the JDA portfolio. The JDA completed the first phase of the roads and stormwater construction projects in Sol Plaatjie Area 1 and Area 2.

The JDA has now been appointed to help implement internal roads construction, and construction on associated stormwater and attenuation ponds for Sol Plaatjie in 2013/14, 2014/15 and 2015/16.

In addition, the JDA has requested permission to appoint an urban designer to develop an urban design framework for Sol Plaatjie.

The area is identified as a priority for highdensity, affordable residential accommodation. The vision is for a transformed area, with vacant and underutilised land developed for higher-density housing and supporting social facilities. This will lead to development opportunities that will attract private sector investment, including business development.

IMIESA September 2014

19

SOCIAL HOUSING

Elevating social housing Prudent sourcing and selection of building materials, fittings and fixtures has delivered Lakehaven Phase II – a groundbreaking social housing project that will definitely raise the bar in the housing arena.

Nicholas McDiarmid talks to Dirk Meyer, managing director of Corobrik, about this greenfield project.

M

EYER SAYS that Corobrik is proud to have been associated with what is Durban’s third greenfield project.

Lakehaven Phase II has a proud lineage.

Its predecessor, Phase I, received the coveted Social Housing Project of the Year 2011 award from the Southern African Housing Foundation.

“Lakehaven Phase II takes this a step further. Through the far-sighted substitution of cheaper building materials with higher-quality building materials, First Metro Housing and

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IMIESA September 2014

construction, cost and project managers HDH have redefined social housing and made it aspirational,” he says.

Social housing is a government-subsidised rental or cooperative housing option for people with monthly household incomes of between R1 500 and R7 500. Lakehaven Phase I comprises 312 units. The second phase provides a further 280 units in 34 double-storey blocks of flats. Construction began in early 2013 and it is on track for completion by mid-year. The first 88 units are already occupied. Selection of tenants

for the remaining units will begin during the second half of the year.

A full house Each unit has two bedrooms, a bathroom, an open-plan kitchen and fully tiled living area with a DSTV point. A granite kitchen counter top, taps and aluminium windows are quality features.

A gated, security-controlled entrance and individual parking bays provide a step up for social housing. There are also plans to create a park, sports field and community hall.

SOCIAL HOUSING

in eThekwini All upgrades were facilitated well within strict budgetary constraints and to meet strict objectives outlined by government.

Mehmood Hoosen, HDH’s principal agent, points out that, while costs were kept low, the end product was of a high standard to the point where Lakehaven Phase II had definitely added value to the area.

Making the best choices He says his company worked within strict parameters but had enjoyed a great deal of flexibility when it came to overall design and choice of materials. “We may have started with a blank page but it was not straightforward. We put a project team together and then workshopped (the project) in terms of finishes. It was about finding the best products for the development.

It came down to speaking to people like Corobrik to make the best choices.”

Hoosen says that the objective was to deliver a quality project through an

improved choice of materials and top-notch workmanship. “When you look at housing delivery, you realise that these units are made available to tenants from low-income

in 2002 by the Institute for Housing in recognition for its pioneering efforts to provide sustainable accommodation for the lower- to middle-income rental market.

“We are able to provide a home that is much more than a rental unit while allowing them to have greater disposable income for a better lifestyle and to fund important aspects such as education for their children.” Mehmood Hoosen, principal agent, HDH households who are paying minimal rent. For them, living in something similar elsewhere would be unaffordable. We are able to provide a home that is much more than a rental unit while allowing them to have greater disposable income for a better lifestyle and to fund important aspects such as education for their children.”

Building a community In line with capital subsidies provided through the Institutional Subsidy and the Capital Restructuring Grant, social housing developments must adhere to strict principles that extend beyond construction.

Government policy calls for the integrated provision of services, which involves the inclusion of social facilities in a location that is close to both cultural amenities and work opportunities. This approach also provides for better spatial planning and greening of the environment.

First Metro Housing, Lakehaven’s developer, was established in December 1998 and is Durban’s foremost social housing company. As an independent Section 21 Company, it is responsible for the development and management of social housing in the eThekwini region. Its primary purpose is the development of quality and affordable residential rental accommodation for low- to medium-income households.

The company was awarded the KwaZuluNatal Housing Developer of the Year award

Newly completed homes built at Lakehaven Phase II at Newlands East in KwaZulu-Natal

Environment and aesthetics In addition to aesthetic considerations, Hoosen pointed out that environmental concerns are top of the First Metro Housing agenda. In line with these, greening of the environment and the planting of trees as well as the selection of building materials with low carbon footprints was important. Corobrik products were well suited to the Lakehaven project and included their Country Cottage face bricks, clay Ironstone pavers and Geolok 400 retaining blocks.

Face brick was used instead of stainless steel for balustrades. Aprons around the buildings were redesigned so that the vibrant colours of the Ironstone pavers could be introduced in place of concrete, while Corobrik Geolock retaining blocks provided for a practical and attractive landscaping throughout the complex.

Maintenance and sustainability Hoosen points out that his client, First Metro Housing, was responsible for maintenance for the next 20 years. Corobrik products allow for near-zero maintenance. For example, the face brick inserts will require no maintenance whereas stainless steel balustrades need to be cleaned every six months to remove a patina that tends to develop on the surface, especially in the warm, coastal climate.

In addition, he says, the choice of Corobrik products enhances the sustainability of the housing project. “These products will last longer and are more sustainable. When we build, we need to look at the aesthetics as

IMIESA September 2014

21

SOCIAL HOUSING

Abdool Mahomed of Corobrik and Mehmood Hoosen, HDH’s principal agent, outside one of the blocks of flats built at Lakehaven

A vision for the future

well as how we will impact on the environment. This is the first time we have gone this route and our client is happy with the outcome.�

On the aesthetic side, Hoosen notes that Country Cottage face bricks blend well with the environment and provide a designenhancing contrast to plastered walls. Face

22

IMIESA September 2014

brick was also used to build communal facilities such as refuse storage areas. He says that the tone and texture blend very well with the environment while meeting engineering requirements.

He adds that the Geolock retainers are a pleasant pink colour, which also blends well with the environment.

Hoosen says that, going for ward, HDH would take a similar approach when selecting materials for future social housing projects as well as with the construction process itself.

He says that during the building of Lakehaven Phase II, they had prioritised the empowerment of women and youth both from within the immediate community and the broader eThekwini region.

Meyer says that this was a per fect fit with the vision of Corobrik, which endorsed both environmental and community upliftment via its own corporate social investment initiatives.

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COMPANY PROFILE

ERWAT

Into action

The recent restructuring of the Department of Water and Sanitation has put sanitation on the map.

ERWAT (East Rand Water Care Company), is a leader in providing wastewater services and poised to get behind the new department’s core vision: ‘Water is life, sanitation is dignity.’

I

T GOES BEYOND that though: “Ever yone is sitting downstream from wastewater treatment and the discharged contaminants. Treating wastewater properly is a major contribution to the availability of potable water, which is a scarce resource in South Africa. By treating wastewater properly, prior to discharge into the natural resource, you ensure that the infrastructure used for treating potable water is protected and relevant for its intended use.

For example, you cannot use the conventional water treatment technology to treat some of the pollutants that the plant was not designed for, like acid mine drainage. If it makes its way into the potable water system, it will have a massive impact and capital investment in new and appropriate technology will be required to remedy the situation. This will ultimately increase the price of potable water,” states Mikgane Tsotetsi, executive manager: commercial business.

A complex business Wastewater treatment is a complex enterprise, being far more than simply setting up and commissioning a treatment plant.

It entails the ability to understand the context in which the plant will operate, the future of its environment, monitoring and maintenance, the enforcement of bylaws, asset management, plant upgrades and refurbishment and highly trained personnel. ERWAT leads the way in all these elements.

ERWAT already holds a significant position in the South African water industr y, providing wastewater ser vices to approximately 2 000 industries and more than 3.5 million people.

Commercial business division As custodian of 19 wastewater treatment works and treating some 696 megalitres of water per day, this innovative company is set to make a crucial contribution to solving South Africa’s water challenges, notably through its commercial business

24

IMIESA September 2014

division. Providing sur veys, studies and technical ser vices to clients in the public and private sectors, this division offers a complete wastewater solution within the broader context of the South African water sector.

“As far as implementation of rolling out our services to municipalities is concerned, we are now way beyond the feasibility stage,” states Tsotetsi. “Around South Africa, you find similar problems in municipalities when it comes to wastewater treatment and management, and we are familiar with these challenges from our previous feasibility studies that were conducted in various provinces and have the solutions to them.”

The municipal challenge There is a dire need for these services, as Tsotetsi explains: “We have found during our technical site assessments, research and reporting, that many municipalities’ wastewater treatment systems are in a dire state. When the function of implementing and maintaining these plants fell to them, they fell short. Preventative maintenance is almost non-existent and they really struggle to retain skilled personnel.” These issues lead to plant and equipment failures which not only require replacement at great expense, but put communities at risk.

Water and Sanitation Minister Nomvulo Mokonyane recently hosted a Water Summit, in which wastewater got a lot of attention. Tsotetsi attended the summit and emphasises that ERWAT is ready to play its role. “The time for action is now,” he says. “We were invited to the summit and, in general, are ver y pleased at the emphasis now being placed on sanitation within the water cycle. We hear that the department is taking sanitation ver y seriously and this was evidenced by the department’s determination that at least 7% of their total budgets should be committed towards maintenance and management of wastewater treatment infrastructure.” This, believes Tsotetsi, will go a long way towards securing the sustainability of this infrastructure throughout all the local

COMPANY PROFILE

authorities. It will ensure infrastructure is maintained and that skills are attracted and retained outside metropolitan areas.

for example, appointed by the Bela-Bela Municipality and is also working closely with Sekhukhune District Municipality to implement the findings of the report.

A deeper understanding “When we visit a municipality and start our technical and process audit, research and reporting, we try to get alongside them.

It is very important that people in charge do not feel fearful of poor results. If they do, they are unlikely to be transparent about the report, which means progress cannot be made,” explains Tsotetsi. “We take the Green Drop reports and look at all the criteria and see how they have been assessed in their report. We do not address compliance in isolation. Each element influences the whole, and where sometimes a municipal manager or technician looks at their report and simply wants to fix the lower-scoring elements, we have to show them that the systems and procedures are far more integrated than that. It requires a comprehensive set of procedures and operating standards to achieve compliance, not simply fixing a small problem.”

Tsotetsi places great emphasis on viewing systems as a whole: “We cannot implement inter ventions in isolation. Taking the Blue and Green Drop reports as a yardstick, we will measure process control, maintenance and management skills, by-law enforcement measures, treatment capacity of the works and asset management, for example. All the criteria should be addressed to ensure correct discharge and water quality standards. If all the municipality does is compliance testing and ignores the other criteria required for the Green or Blue Drop audits, they are going to miss opportunities to optimise their plants and operations.”

ERWAT recently completed a full operational and technical sur vey of all of Limpopo’s municipalities and visited about 73 wastewater plants. “We looked at ever y wastewater treatment plant from an operational and technical perspective and we found that the current status of this infrastructure and the technology including process control, maintenance and management skills as well as asset management need urgent attention.” After completing the report, ERWAT has been engaged by some of the municipalities to address these challenges. ERWAT was,

Grey water for all ERWAT was recently contracted by one of the biggest parastatals to address their discharge issues at all their operations around the countr y in an effort to check their compliance to their permits and ensure the protection of the countr y’s national resources.

“Our team of experts, ranging from project managers to technicians, went out on-site and conducted studies of pollution point of source within the company origin and then offered technological solutions to address the pollutants. We are also helping the same parastatal to recycle their water so that they can rely on their own grey water

“Operational and maintenance budgets must now be ring-fenced, with an allocated budget strictly committed for refurbishments and maintenance of infrastructure in order to prolong its useful lifespan.”

Mikgane Tsotetsi, executive manager, commercial business

without paying for (and removing from the system) potable water,” Tsotetsi explains.

ERWAT is also supplying their own treated grey water to industries in the Ekurhuleni area, for both industrial application and irrigation. “We are also working with companies that have been tasked with getting rid of some of the mine dumps. They will now be using grey water to process slurr y, which is going to save them an awful lot financially, while protecting the environment at the same time. Golf courses – which are ver y heavy consumers of water – are also buying into using grey water for irrigation.” Other industries that could benefit from using grey water include pulp and paper manufacturers and power stations.

ERWAT also offers complete technical assessments for the needs of communities in the long term: “It is essential that you factor in population growth and industrial growth in areas to ensure that capacity is sufficient for at least the next decade. We have seen situations where this hasn’t happened and plants have been working beyond their capacity from the day of commissioning. Using integrated development plans is essential in managing this kind of situation.”

Sustainable support ERWAT has a role to play in South Africa’s water sector: beyond its work with industr y and parastatals, its ability and capacity to support municipalities should be a game changer. With laborator y facilities, technical expertise, operational know-how and research capacity, it is per fectly structured to come alongside ailing municipalities, put their houses in order and assist them in keeping it that way.

ERWAT’s ser vices are geared to get municipalities to the point of compliance that is now demanded of them, thanks to the newly established Department of Water and Sanitation together with to COGTA’s mandate under Pravin Gordhan. It is time to stop the waste.

t +27 (0)11 929 7000 • www.erwat.co.za

IMIESA September 2014

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SAPPMA PIPES VIII

SAPPMA | PIPES VIII

PLASTIC PIPES IN REVIEW

A new wave Plastic pipe manufacturers and suppliers are increasingly focused on quality, innovation, standards and testing as HDPE and PVC pipes continue to prove their value in the market place.

An integral part of this progress is ensuring that end users understand the products’ properties and get the best performance possible.

Nicholas McDiarmid presents a summary of what was presented at the South Africa Plastic Pipes Manufacturing Association (SAPPMA) annual conference, Pipes VIII.

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IMIESA September 2014

A word from SAPPMA

J

AN VENTER, chairman of SAPPMA, noted that: “This is still the only event of its kind, providing specialised technical information to people who design, specify, manufacture or buy plastic piping systems.” Reflecting on the state of the industry, concerns that are becoming increasingly apparent nationwide have also had a deep impact on the plastic pipes industry.

“The plastic pipe industry again finds itself in a situation of low demand, together with the accompanying negative consequences,” noted Venter. “This is unfortunate, because it is arguably one of the most important industries in the country. It is critically important, in fact, as it provides the means of supplying clean water and the disposal of effluent.”

There are not too many other industries that operate under these conditions, “providing a community service by manufacturing products that need to last for 100

years, while gross margins are being suppressed to unacceptably low levels, due to poor demand,” opined Venter.

SAPPMA’s message to government was clear: the time for delivering on its promises is long overdue, and if an effective rollout of infrastructure projects is not soon realised, the impact on this industry will be profound. “The Department of Water Affairs and Sanitation tabled a budget of R7.8 billion for the current financial year, of which a large portion will hopefully be spent on pipelines. We trust this will indeed happen,” said Venter.

SAPPMA’s message to the industry was somewhat more upbeat: “The mediumto long-term outlook for piping systems is good and, before long, we may again find ourselves in a position of strain on installed capacity.

“Let us therefore make sure that we do not compromise on standards while the going is tough, but rather be tough ourselves and ensure we do not lose our

“The plastic pipe industry again finds itself in a situation of low demand, together with the accompanying negative consequences.”

Jan Venter, chairman, SAPPMA

SAPPMA | PIPES VIII

long-term view and affinity for this industry,” concluded Venter.

The behaviour of leaks in plastic pipes South Africa has a profound level of unaccounted-for water loss. Recent research suggests this to be as high as 37%. The University of Cape Town has been conducting research into the behaviour of leaks in distribution systems, with particular focus on uPVC and HDPE pipes. The findings of this research were presented by Kobus van Zyl of the University of Cape Town “Plastic is the most commonly used pipe material for new water distribution system developments worldwide. Like all other materials, plastic pipes develop leaks through various mechanisms such as excessive system pressures, external loads, construction damage and manufacturing defects,” reported Van Zyl. “Leaks in pipes are not static, but change due to variations in system pressure, visco-elastic creep, plastic deformation and erosion due to soil-leak interaction.

Understanding the behaviour of leaks in pipes may be useful for water loss and pressure management, leak detection, construction practices and the manufacturing of pipes.”

Thermoplastic pipe standards Mike Smart of Genesis Consulting, in an overview of the role thermoplastic piping systems play in our lives, emphasised the significance of thermoplastic piping systems to the quality of our lives through water supply, sewage disposal and maintenance of the environment.

The availability of cheap local and imported products that do not conform to relevant standards are a particular hazard to the industry, placing its reputation at risk and leading to weak and/or failing systems.

Smart provided insight into the applicable standards, the rigorous quality control of locally produced products, particularly by SAPPMA members, as well as the worldclass technology of the products.

He concluded with a cautionary note to insist on SABS Mark products and SAPPMAmarked products and not be seduced into purchasing cheap, nonconforming local or imported counterfeit products.

A dangerous compromise: quality versus cost Ian Venter of Marley Pipe Systems voiced a major concern affecting the industry: “In an economic society where most commodities are designed to sell, not to last, the reality is that, in order to provide the

“Understanding the behaviour of leaks in pipes may be useful for water loss and pressure management, leak detection, construction practices and the manufacturing of pipes.” Kobus van Zyl, University of Cape Town

Mike Smart, Genesis Consulting

lowest price and remain competitive, quality standards are often compromised. To achieve lower costs, plastic pipe producers make trade-offs in: • the quality of raw materials • the quality of PE pipe fittings • quality specifications • quality management processes • social and environmental responsibility.”

Venter noted that purchasing decisions are too often made on the basis of cost alone without understanding the hidden costs and risks of substandard pipe systems. “Part of the problem is that there is little awareness of the industry standards and specifications such as those prescribed by the SABS and ISO, and the consequences of nonconformity to these standards in relation to the overall life cycle of pipe systems.”

Marley Pipes Systems employs watertight systems, state-of-the-art testing equipment and manufacturing standards that are transparent and compliant. The company has worked with the SABS and SAPPMA towards the development in standards and

IMIESA September 2014

29

SAPPMA | PIPES VIII

method of, performing the field pressure test on plastic pressure pipelines. He also outlines the equipment needed to properly perform a pressure test and the topic of equipment condition and calibration is discussed.

Quality assurance in PE piping systems: elimination of failures when connecting pipes

“I find that the purpose of field pressure testing is often misunderstood and that details like test pressure and test duration are often misinterpreted.”

Renier Snyman, technical and product manager at DPI Plastics industry norms, contributing to the development of the industry’s reputation.

Field pressure testing 101 Renier Snyman, technical and product manager at DPI Plastics, also began his presentation with a concern: “As a technical person in the plastic pipe industry, I regularly come across engineers, installers and contractors that do not properly understand the procedure for field pressure testing, as specified in SANS 2001-DP2. I find that the purpose of field pressure testing is often misunderstood and that details like test pressure and test duration are often misinterpreted.”

Snyman’s presentation provided guidance in terms of the reason for, and correct

With a history of almost 80 years, polyethylene in its current form has been around almost 20 years. Colm Lyons, regional sales manager for GF Piping Systems, explored why failures on PE pipes still occur and what methods are available to eliminate potential failures. On behalf of GF Piping, he presented the next innovative steps the company is taking to make its Utility Piping Systems safer in the very near future.

Observing that it should be possible to eliminate all failures when installing PE pressure pipes, Lyons gave an overview of GF Piping’s automated manufacturing process for PE fittings and the methods of controlling these fittings after production using, for example, X-ray technology and noted that on the manufacturing side, everything is done to reach outstanding quality. “It is of course of utmost importance, as the same fittings are used when installing gas pipes up to 10 bar pressure,” he said.

Broadly speaking, GF Piping Systems develops, produces and markets a comprehensive range of piping systems and components in a variety of materials used worldwide to transport water, gases and aggressive media.

Quality fittings: your link to a reliable system Jacques van Eck, sales manager at Klamflex Pipe Couplings as well as product manager: PVC and imported fittings at Petzetakis Africa, is passionate about quality and actively involved in various technical committees and forums to ensure that quality standards regarding products and installation methods are adhered to.

Colm Lyons, regional sales manager for GF Piping Systems

“Joints have always been the weakest link in a piping system but, with price being the deciding factor in purchasing, poor-quality fittings are often being installed in applications where they are bound to fail.” Jacques van Eck, sales manager, Klamflex Pipe Couplings; product manager: PVC and Imported Fittings, Petzetakis Africa “Joints have always been the weakest link in a piping system but, with price being the deciding factor in purchasing, poorquality fittings are often being installed in applications where they are bound to fail,”

“Part of the problem is that there is little awareness of the industry standards and specifications... and the consequences of nonconformity to these standards in relation to the overall life cycle of pipe systems.” Ian Venter, Marley Pipe Systems IMIESA September 2014

31

SAPPMA | PIPES VIII

said Van Eck, whose concern echoes that of several other speakers.

“Quality, ease of installation, longevity and ease/cost of maintenance are generally overlooked and real cost saving comes from the designing of the system and not purchasing of the components.”

With the myriad pipe joining options out there, Van Eck’s presentation aimed to provide decision-makers with the tools and the knowledge to make informed decisions that will go a long way to ensure the sustainability of the piping systems.

While quality and standards were very much the watchwords of this conference, other focuses included training, trenchless

“Learning can happen everywhere, even in your workplace and while working.” Kirtida Bhana, training executive of Plastics SA

32

methods and the use of HDPE for potable water reticulation.

From training provider to performance consultant Quoting Blade Nzimande when she said, “Ever y workplace is a training place,” Kirtida Bhana, training executive of Plastics SA, is passionate about finding nontraditional yet practical ways of making every plastics manufacturing workplace a learning space.

Bhana highlighted concerns, challenges and solutions to the complex issue of skills development in South Africa, while acknowledging that every effort made in the workplace to address the skills gaps should be made in favour of empowerment, skills development, efficiency and competitiveness.

“Do you need fancy training rooms and fancy equipment to do this? No, no and no again,” she emphasised. “Learning can

IMIESA September 2014

• Manufacturers of HDPE Reducers • Butt welding stub-ends and Electrofusion welding stub-ends to SABS ISO 4427 speci¿cations • Moulded bend and tee ¿ttings • Recycling & Pelletizing of HDPE pipes

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SAPPMA | PIPES VIII

happen everywhere, even in your workplace and while working. “Learning is the ability to acquire new ideas from experience and retain them as memories,� Bhana quoted Eric Kandel of Columbia University (Nobel Laureate for work on learning and memory).

According to Bhana, the existing plastic manufacturing qualifications have only been in effect since 2010. “As a result, the qualifications and training undergone by many employees who were trained and qualified before this time are not being recognised. Plastics SA has developed a series of steps to prepare candidates for an integrated summative assessment. The process starts with learners assessing

themselves against the specific outcomes of the level of qualification they wish to be assessed against, in order to gauge their readiness. “We facilitate the entire process, while the learners gather relevant evidence of their competencies,� she explained.

Thermally Fused PVC Pipe Helps Accelerate Adoption of Trenchless Pipe Installation Techniques In North America, trenchless pipe installation methods continue to see rapid adoption growth in municipal markets, with 71% of utilities having used trenchless methods in the past 12 months. This

adoption rate is a function of improving equipment, installation experience and improved materials.

Andrew Seidel, CEO of Underground Solutions, discussed the fused PVC pipe technology that is enabling trenchless growth and highlighted two case studies where fused PVC was utilised: a 1 158 m HDD bore with 600 mm and 150 mm pipe pulled in simultaneously under a live airport runway in Portland, Oregon, and a

“The three most recognised trenchless installation methods for pressure pipes – horizontal directional drilling, slip lining and pipe bursting – are seeing rapid growth in application.� Andrew Seidel, CEO, Underground Solutions IMIESA September 2014

33

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SAPPMA | PIPES VIII

water utility in Colorado that installed over 45 000 m of fused PVC via pipe bursting. “The three most recognised trenchless installation methods for pressure

pipes – horizontal directional drilling, slip lining and pipe bursting – are seeing rapid growth in application,� explained Seidel. “Improved methods and materials have stretched the limits of these technologies, allowing longer, larger pipes and increased project constraints to be managed.�

New pipe joining methodologies for thermoplastic pipe materials, and the advent of thermally fused PVC pipe, have had the largest impacts on the growth of these installation modes in North American water and wastewater infrastructure.

Rehabilitating pipelines using polyethylene pipes and liners Farraj Tashman and Andrew Wedgner of Borouge, a leading raw materials partner

“One of the very first applications for pressure pipes made from HDPE was drinking water pipes.� Ulrich Schulte 34

for the pipe industry in the Middle East and Asia, and based in the UAE, presented a paper. The paper continued the theme of innovations in trenchless technologies.

During the lifetime of a pipeline, a point is reached where the cost of water loss, leakage management, maintenance and repair works, together with the poor service to the customer, justifies its replacement or rehabilitation. Trenchless rehabilitation techniques can have a lower cost and cause substantially less disruption to existing assets and the general population than conventional open-cut techniques.

As trenchless technology has developed and increased in use, so has the use of PE pipes in applications such as slip lining, close-fit lining and pipe bursting. The majority of pipeline renovation and replacement techniques now use polyethylene as their principal pipe material and the techniques have been developed to the point where they have been used to rehabilitate pipelines of up to 1 400 mm internal diameter.

Their presentation provided an introduction to the different methods by which

IMIESA September 2014

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SAPPMA | PIPES VIII

SAPPMA’s message to government: the time for delivering on promises is long overdue water pipelines can be rehabilitated using polyethylene pipes and liners through the use of a variety of trenchless technology techniques. It also explained how engineers and other technical staff working for water utilities can use the standard ISO 11295 to help identify and specify the most appropriate technique for their particular situation.

The original polyethylene pipe materials were not intended for such applications and so the greater use of polyethylene in trenchless technology has been a key driver in the development of tougher materials. One development has been PE100 materials that have a high resistance to slow crack growth through the wall of the pipes. Such materials are referred to as HSCR PE100 and PE100-RC. Tashman also explained how slow crack growth can be initiated by the use of trenchless technology applications and how the new generation of PE100 materials resist the growth of cracks through the pipe wall.

HDPE for drinking water pipes: the European experience Ulrich Schulte of Germany provided what turned out to be a truly fascinating history of the implementation of HDPE pipes in Europe for the purposes of distributing potable water.

“One of the very first applications for pressure pipes made from HDPE was drinking water pipes. A survey of the German DVGW dated back to 1961 identified already 449 km of water service pipes made from HDPE. A study on the residual lifetime of these first generation pipes, again by DVGW, resulted in a real lifetime of more than the expected 50 years,” notes Schulte.

Schulte’s presentation covered the regulatory approach, the requirements and the approval process followed by European water utilities. Compulsory training of welders forms an important part of the scheme.

It also included case studies from utilities in the German Ruhr area, and Scottish Water confirms the positive experience with HDPE pipes.

An example of the fascinating information Schulte presented is from a survey carried

out in 1961 by the German DVGW, covering the period from 1957 to 1960. Some of the results include: • there were 1085 water supply companies covered by the survey; of those, 599 replied • these replies represented 43.7% of the total German water supply industry • 522 companies stated that they used plastic pipes • 123 companies used metal connectors when laying HDPE pipes • one company was already using buttfusion technology.

Schulte importantly observed that the composition of the water grids in a number of selected European countries shows there is a clear trend towards the growth of this segment.

Professor Fanie van Vuuren of the University of Pretoria presented on a conceptual model for dealing with microbial growth phenomena in pipelines and their impact on hydraulics.

Amit Raga of the SABS presented on conformity assessment and Alaster Goynes spoke on the modelling of operating conditions for gravity and low pressure pipelines with factory tests.

Conclusions There can be no doubt that plastic pipes can no longer be seen simply as an alternative to cement and steel pipes. Although not appropriate for every application, innovations and technologies are seeing the applications for plastic pipes expand and, with the right raw materials, exacting manufacturing and testing processes – quality control, training and standards – the material has come into its own.

Pipes VIII delivered on its promise and once again presents a comprehensive overview of the latest information and opinions on the industry.

Amit Raga of the SABS

IMIESA September 2014

35

Bm l all around us, sometimes invisible, but always present… ,W V 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 LZlhe <a^fb\Zel 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 lh keducing overall cost.

The power of positive impact Cost effective products make a positive contribution to all areas of sustainable development because LW: Savel scarce money, thus promoting sustainable ^\onomic development. ,V 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 ;Zl^ <a^fb\Zel, a division of Sasol Chemical Industries Limited.

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 localiled 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 bm doHV 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 pithout 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 SouthFSO Africa powers up for growth to the benefit of all.

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Sustainable In the Ruhr area River Emscher ecological restoration project, for 20 years construction companies have relied on Herrenknecht tunnelling technology.

Tailor-made In the main project, the Emscher Sewage Tunnel, Herrenknecht customers are installing a total of 42 km of new pipelines. The 4 EPB Shields and 5 AVN Machines (Ø 2,065–3,625 mm) are fast, precise and safe.

As new Top service: we professionally refurbished our customers’ machines, ready for re-use.

Pioneering Underground Technologies www.herrenknecht.com

TRENCHLESS TECHNOLOGIES

QATAR

Tunnel boring delivers Despite being one of the most arid landscapes on ear th, Qatar experiences extensive flash flooding in the densely populated capital of Doha.

A

COMPREHENSIVE drainage system covering an area of 170 km² aims to ensure improvement in the southern section of the city populated by half a million people.

Two Herrenknecht tunnel boring machines are being deployed for the construction of the almost 10 km tunnel, which is one of several major infrastructure projects for which the city has ordered more than 20 Herrenknecht machines.

Abu Hamour Southern Outfall Project Two Herrenknecht tunnel boring machines (TBM) are driving a tunnel 20 to 30 m underground for the so-called Abu Hamour Southern Outfall Project. The earth pressure balance shields (EPBs), with a diameter of 4 470 mm, are designed for Doha’s soft limestone soil. Muck comprising excavated material serves as the support medium for the EPB, providing the requisite pressure balance at the tunnel face. Protected by the shield skin, the tunnel is excavated using ring-shaped reinforced concrete segments. These are transported through the tunnel as it is completed and connected to

Location Application Tunnel length Geology Client

form closed rings (segmental lining process) directly behind the TBM with an erector.

Up to 16.5 m3 of water per second will later be conveyed over 9.5 km to a central pump station near the New Doha International Airport via the main tunnel.

Large-diameter pipe jacking Herrenknecht tunnelling technology was also used in designing some of the inlets during an initial construction phase. A total of 4 km of tunnel, with an outer diameter of 3.60 m, was excavated in 2008 using the pipe jacking method. This is a remarkably large diameter for pipe jacking and was achieved using Herrenknecht’s slurry AVN machine.

Tunnelling the Doha Metro With its ‘Vision 2030’, Qatar aims to offer its citizens the highest possible standard of living. Some projects are already being implemented and range from surface water discharge to traffic infrastructure. Herrenknecht is also involved in the new Doha Metro system, which will require a total of 21 EPB shields, many of which have already been delivered.

TOP The Al Thummama and Al Rawada machines, prior to delivery from the Herrenknecht plant. In Qatar, a 9.7 km tunnel is being driven under one of the main streets in the centre of Doha’s lively south-western section while traffic continues to flow smoothly on the streets above ABOVE Site assembly of the Herrenknecht tunnel boring machine, which is the first TBM to drive a tunnel in a segmental lining process in Qatar. Apart from the two Ab Hamour machines, the Emirate will also be deploying another 21 Herrenknecht EPB shields during construction of the Doha Metro BELOW Early June saw Sheikh Abdul Rahman bin Khalifa Al Thani, Minister of Municipality and Urban Planning, visit the project undertaken by Qatar’s public works authority Ashghal. He visited the second Herrenknecht machine before it disappeared underground in July

Project data Doha, Qatar Surface and groundwater drainage 4 500 m and 5 000 m Limestone

Machine data M-1795M and M-1796M Machine type 2 x EPB 3700 Shield diameter 4 470 mm Cutting-wheel 660 kW power Qatar’s public works authority Ashghal Contractor Impregilo

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Pipe ramming in the South African context As trenchless installation methods gain momentum, it becomes imperative to showcase and share project experiences in order to provide confidence to market stakeholders. By Neil van Rooyen, director, TT Innovations (member SASTT)

T

HIS ALSO underscores the notion that local trenchless contractors are capable and have the necessary skills and expertise to deliver complex and challenging projects. One such trenchless method is pipe ramming.

Pipe ramming in the South African context The trenchless industry in South Africa is relatively young. Project engineers and clients are often loath to use new technologies due to a lack of information, such as, local case studies, technical specifications and product know-how. This coupled with the inherent resistance to change, is the context in which various trenchless methods are deployed, often in instances when no other feasible construction alternative exists.

Pipe ramming is one such trenchless method that has struggled to gain momentum in

the local market. It is frequently confused with pipe jacking, a better-known and -established trenchless method. However, recent activity in the construction industry has enabled various contractors to use pipe ramming as a means to install large-diameter steel conduits.

How it works: pipe ramming methodology Pipe ramming is a ‘no-dig’ method used for the installation of medium- to large-diameter steel pipes and casings under roadways, railways and other obstructions. An openended steel sleeve is driven into the soil using percussive force until the entire pipeline is installed. The process allows for a wide variety of pipe sizes to be used, ranging from non-man-entry-sized steel pipes (300 mm in diameter) to large-bore pipes up to 2 000 mm in diameter.

FIGURE 1 (Below) Pipe ramming is an excellent, cost-efficient method for placing steel casing under roads, railroads, finished landscapes and structures. The casing is installed open-ended and cleaned out after installation is complete

The size of the installed steel sleeve is directly proportionate to the size and capability of the rammer being used. Pipe ramming is especially useful for shallow installations where other trenchless methods could cause surface deflection. The majority of installations are horizontal, although the method can be used for vertical installations as well (e.g. installation of piles). The horizontal method is traditionally used to install casings for utilities and to replace damaged culverts under roads and railway tracks.

Unlike other trenchless methods which use innovative and complex systems, pipe ramming relies on brute force.

The pipe ramming process consists of four primary steps: • procurement of materials • site preparation • installation of the steel sleeve • installation of the product pipe.

Materials For large-diameter installations, pipes are manufactured from steel at least 16 mm thick. This is necessary to withstand the impact force generated by the pneumatic rammer as it pushes against the pipe. Individually rolled steel sections, or cans, are welded together to form complete lengths of pipe.

These pipe lengths are limited to 12 m, to enable transport via road freight (see Figure 3). As a final step of the manufacturing process, the pipe material is coated to protect it against corrosion in accordance to the client’s specifications. This leaves the pipe with smooth exterior and interior surface.

FIGURE 2 (Far left) Steel sheets rolled into cans FIGURE 3 Du Noon Pipe Ramming site – Completed 12 m pipe lengths being off-loaded on site

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TRENCHLESS TECHNOLOGIES

Site preparation A pit is excavated (to the required size and depth) on one side of the roadway or obstruction to be crossed. This excavation, which serves as the launch pit, measures approximately 18 m in length and houses the 12 m length of pipe as well as the pneumatic rammer (attached to the rear of the pipe). To support the pipeline and rammer assembly, a concrete slab, which spans the length of the pipeline, is cast on the pit floor. After the concrete slab has set, a metal I-beam, turned on its side, is affixed to the slab (see Figure 4). Both the concrete slab and I-beam are constructed to the required alignment and grade. The I-beam forms a ‘cradle’ which supports the steel pipe and serves as a rail on which the pipe moves, preventing it from deviating from the set alignment.

Installation of the steel sleeve Once the steel sleeve is lowered into position and set on the rail, the pneumatic rammer is attached to the rear of the pipe by means of interlocking metal discs known as collets.

Two air compressors, capable of producing a combined airflow of 1 750 cfm, are used to power the rammer. The percussive hammer action inside of the rammer assembly provides the kinetic energy that drives the open-ended steel pipe into the soil. The hammer action occurs at an impressive rate of approximately 177 blows per minute when set at maximum, delivering 1 010 t of force per blow. This process continues until the required length of pipe eventually enters the soil. The next 12 m length of pipe is then lowered into place and welded to the installed pipe.

The rammer is then reattached to the rear of the newly welded pipe and the ramming process resumes.

The cycle of ramming and welding consistently repeats itself until all the pipe lengths are installed and the crossing is complete. Once the steel pipe reaches the target end, the spoil material is removed from the inside of the pipe. The removal of spoil, however, is often undertaken periodically during the installation process as a means to reduce weight, thereby, assisting the installation.

Installation of the product pipe Upon the removal of the spoil, the steel sleeve is ready for use. In many cases, the product pipe is assembled on the outside and pulled or pushed into the steel conduit (Figure 5 below). The annulus between the steel sleeve and the product pipe is grouted in place according to the consulting engineer’s specifications.

Advantages of the pipe ramming method A benefit of the pipe ramming method is that the risk of surface subsidence is eliminated due to the spoil only being removed once the steel casing is installed, making it ideal for shallow installations (Figure 6 and 7).

Another advantage of this method is that the kinetic energy required to drive the pipe is generated within the rammer assembly, FIGURE 4 (Below) View of the I-beam ‘cradles’ placed on top of the concrete slabs FIGURE 5 (Bottom) Left picture shows rammer attached to the steel pipe being installed. Right picture shows ductile iron pipe (product) installed inside the steel conduits

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TRENCHLESS TECHNOLOGIES

FIGURE 6 (Above) View of a largediameter pipe being installed under an active railway line FIGURE 7 A large-diameter pipe being installe, with its steel sleeve in place

thus no external thrust wall or support is required. This self-contained rammer also makes it fairly portable and allows for multiple installations where the rammer is simply detached and moved to the next location.

The ramming process uses an open-ended steel pipe, challenging soil formations such as boulder material. For other trenchless applications, it would prove difficult and almost impossible to navigate through, but it is achievable with pipe ramming. The

prerequisite being that the largest boulder should be smaller than the pipe opening in order to enable the boulder(s) to be ‘swallowed up’ during installation. The flexibility in pipe size also gives it an added advantage as it is suitable for use with nonman-entry-sized pipes (smaller than 900 mm in diameter).

The ramming process relies on percussive force and is therefore unsuitable for use in solid rock formations. Another drawback of this percussive mechanism is that it does not enable steering, but instead relies exclusively on the correct alignment and gradient being set prior to the pipe entering the soil. Once the leading edge enters the

soil, the pipeline generally tends to stay on the set alignment, but is susceptible to deviation caused by hard and soft material layers with the pipe following the path of least resistance.

Disadvantages Long bores exceeding 70 m are not recommended for use, as the frictional resistance increases as the length increases, counteracting the maximum available percussive force generated by the rammer. Due to these forces exerted on the pipeline during installation, steel is the only suitable material for use. This makes the process costly, influencing economic feasibility.

PROJECT CASE STUDY 1 DU NOON PIPE RAMMING Project background The City of Cape Town approved the construction of a pump station facility as an FIGURE 8 Aerial view of the site where the large-diameter pipes crossed Blaauwberg Road

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Trenchless Technology Specialist

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upgrade to the existing sewer works located in Du Noon. Part of the project scope for this R23 million project included the construction of a new pipeline network – among these, the installation of two parallel 600 mm diameter cast iron rising mains.

The alignment of these rising mains traversed one of the busiest roads in the area, Blaauwberg Road. This dual-carriage roadway is heavily trafficked and serves as one of the main access routes into the Tableview area.

Blaauwberg Road was being upgraded and was still under construction to accommodate

the Integrated Rapid Transport system’s new bus lanes. The only feasible option for this road crossing would be to use trenchless construction methods.

FIGURE 9 (Above left) Du Noon pipe ramming site – view of two parallel pipe installations

Why pipe ramming?

TABLE 1 (Below) Trenchless method selection criteria

The selected trenchless method needed to satisfy the inherent project constraints, such as a zero tolerance for surface deflection (in particular, any subsidence of the roadway due to voids being created during the installation process). The roadway servitude housed a Chevron pipeline which imposed

FIGURE 10 (Above) Du Noon pipe ramming site – view of excavation pit showing the different soil layers

certain construction restrictions and negated the use of mechanical plant near this pipeline. The use of ductile iron pipe for the sewer rising main throughout (including the section to be installed by trenchless means)

1) Zero tolerance for any surface deflection, in particular that no voids are created Method

Factors considered when evaluating the various trenchless options

Selection

The pipe jacking method inherently requires a cavity to be created in order for the concrete pipe to be ‘jacked’ into this void. This increases the potential for voids to form, which eventually leads to surface deflection.

No

Horizontal directional drilling uses drilling mud to stabilise the bored tunnel. For larger-diameter bores, the volume, fluid design and fluid pressure required to stabilise the tunnel significantly increase. This increases the HDD (horizontal risk for either a frac-out from occurring, which results in drilling fluid finding its way to the surface through a directional drilling) soil fissure, or alternatively the incorrect functioning of the drilling fluid, which causes an unstable tunnel that is prone to collapse.

No

The pipe ramming process does not create any voids – as the open-ended steel sleeve is forced into the ground.

Even when the spoil is removed during the installation process, a 1 m soil plug is left in place and prevents any cavities from forming at the leading edge of the pipe.

Yes

Pipe jacking

Ramming

2) Two parallel large-diameter conduits required Pipe jacking

The pipe jacking method is ideally suited for large-diameter pipeline installations. As the excavation at the tunnel face is done with manual labour, this limits the rate of progress of a pipe jacking installation. The combined installed length measured 112 m, which would require a lengthy jacking process.

No

HDD

The HDD methodology requires the bored tunnel to be at least 30% larger than the project pipe. This would require a tunnel diameter of at least 1 000 mm. As the project required two parallel installations, this significantly increased the risk and complexity of the operation.

No

Ramming

Due to the stable nature of the ramming operation, it was possible to align both conduits in close proximity, as required by the project specifications. The size of the available ramming equipment also allowed for the large diameter pipe installation. Another advantage of the ramming process was that the rammer could easily be moved from one pipe to the other – and allowed for both pipes to be simultaneously installed by alternating between ramming the one pipe while welding the other, and vice versa.

Yes

3) Limited geotechnical information available, in situ material presumed to be sandy with a high water table

Pipe jacking

No Any jacking operation where a high water table is present increases the complexity of the project as the water (based on ingress tends to erode the soil at the tunnel face. The constant movement of soil has the tendency to create the assumed voids around the leading edge of the jacked pipe. Although it is common practice to fill the voids around the sandy soil and high pipe by grouting, the potential still exists for these voids to cause surface deflection. water table)

HDD

Providing the drilling fluid mixture is designed in accordance to the in situ soil conditions and sandy material – even a high water table is not problematic for this process.

Yes

Ramming

Sandy material, along with a high water table is ideal for this method of installation. The force generated by the rammer, coupled to the bevelled leading edge of the pipe, is capable of installing this sized pipe over the 56 m distance.

Yes

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TRENCHLESS TECHNOLOGIES

FIGURE 11 View of installed pipelines at exit pit

necessitated the use of a conduit that would be large enough to accommodate the 600 mm diameter ductile iron pipe and a 75 mm flange at the joints (effectively increasing the profile of the ductile iron pipe to 750 mm in diameter).

Pipe ramming was selected as the preferred trenchless method as it satisfied all the project requirements. The selection criteria for the appropriate trenchless method are shown in Table 1.

How the pipe ramming installation fared and the challenges encountered during installation The first hurdle was encountered as the launch pit was being excavated. As the 1 m thick layer of sandy material was removed, it exposed an underlying clay/shale formation, which extended all the way to the invert of the pit. Although not an insurmountable hurdle, this clay layer was harder than the anticipated sandy material and resulted in a slower rate of progress.

Upon installation of the first two lengths of pipe, the East and West

pipeline, measurements were taken of both pipelines to assess their trajectory and alignment. Although not visible to the naked eye, it was discovered that the East pipe seemed to be on an upward trajectory – this despite both pipelines being set to the same gradient and being 1 m apart (wall to wall). The reason for this upward trajectory could not be empirically determined, but the trenchless contractor theorised that this was due to the clay formation becoming progressively harder at the invert of the excavation, which meant that the invert of the pipe’s leading edge encountered harder material than at the crown, which was 1 m apart in elevation (due to the 1 064 mm diameter pipe). The pipe then followed the path of least resistance: upwards towards the softer clay formation, thereby causing the upward deviation.

To correct this trajectory, both pipelines were lifted by means of hydraulic jacks and set to a new trajectory (the West pipe was elevated by approximately 50 mm and the East pipe by 90 mm). The installation of the East and West pipeline continued until completion.

When the pipelines reached their target end, the West pipe was higher than the intended invert level by 20 mm. The East pipe was higher by 320 mm.

It appears as if the hard underlying shale material counteracted the initial downward trajectories and caused both pipelines to deviate upwards – although this was more pronounced in the East pipe.

Critical success factors Despite the difference in design invert levels, the project outcome was still successful as both pipeline conduits could still be utilised for the intended purpose, i.e. to house the 600 mm diameter ductile iron rising main. The 1 064 mm steel pipeline allowed for minor corrections to be made when installing the smaller ductile iron pipeline. The pipe ramming process proved successful despite the challenging in situ soil conditions. It was further notable that both 1 m diameter pipelines were installed over a total distance of 112 m to a reasonable accuracy. No surface deflection was caused at any point of the installation or as a latent defect after completion.

PROJECT TECHNICAL DETAILS • Individual crossing length: 56 m • Total pipe installed: 112 m • Pipe diameter: 1 064 mm (outside) • Pipe material: 16 mm thick steel • Corrosion protection: Internal and external coating; external coating applied to 1 200 microns thick • Pipeline depth: 4 m below road level • Product pipe: 600 mm diameter ductile iron pipe (inserted into the steel sleeve by the main contractor) • Equipment used: 24-inch pneumatic rammer capable of delivering 1 010 t of impact force per blow • Project start date: March 2013 (time of award – which enabled the ordering of the pipe material) • Project completion date: November 2013 • Client: City of Cape Town • Consultant engineer: ICE Group • Main contractor: Vula Indlela • Trenchless contractor: TT Innovations

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IMIESA September 2014

PROJECT CASE STUDY 2 MOSSEL BAY PIPE RAMMING Project background As part of the water augmentation initiatives, the local authority in the Southern Cape commenced the construction of a desalination plant in the Mossel Bay area. To amplify the need for such measures, in 2010, Mossel Bay and the surrounding towns had water-use restrictions imposed on all residents. As part of the network upgrade, new pipelines were installed and connected to the existing reservoir structures. To expedite construction and reduce the project risk, the engineering team elected to use trenchless technology for the pipeline road crossings and the connection points into the reservoir structures.

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Why Pipe Ramming?

The new larger-diameter feeder pipeline needed to be connected to both reservoirs. This posed a unique challenge as these reservoirs were still operational, which only allowed for a limited window period for construction to take place.

Instead of breaking through the side wall of the circular structure, the consulting engineers decided to use pipe ramming and install a steel conduit underneath the reservoir itself (Figure 12). This would then allow access from inside the reservoir as a means to connect the feeder pipe. This innovative solution had numerous advantages, the most important being that the external concrete structure could remain intact.

A vital component of this was that no voids or cavities were created during the installation. Therefore, the structural integrity of the reservoir was never at risk.

The advantages of using pipe ramming versus conventional construction are indicated in Table 2.

These factors were critical to the success of this project as it allowed the client to deliver critical milestones ahead of schedule when compared to conventional construction methods. ď ľ FIGURE 12 Left picture: pipe in position to be installed below the reservoir.

Right picture: pipe successfully installed

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Conventional construction

Pipe Ramming

Speed of construction (affects the length of time the structure would be out of service) Work could take place on both reservoirs simultaneously, without As connection points were required for two separate reservoirs, any affecting the usability of either asset. This dramatically reduced the alterations would require work on two fronts. project duration.

Structural integrity of the reservoir, during and post construction Any alteration to the reservoir wall would increase the project risk As the pipe ramming operation did not create any voids or cavias this would affect the structural integrity and possibly lead to futies, the structural integrity of the reservoir wall was never at risk. ture latent defects. Recasting and curing of the concrete works for The steel conduit was installed below the base of the structure the reservoir wall would also require careful design and monitorand the crown of the pipe was approximately 500 mm below this ing (and possibly the employment of a specialist engineer for this foundation level. aspect of the project).

Design Any alternative connection design would require alterations to the reservoir wall or the roof structure. This would also have neces- The fact that the new pipeline could be connected at the invert of the sitated additional bends and restraints and would not have been reservoir enabled a simpler and more efficient design. hydraulically efficient.

PROJECT TECHNICAL DETAILS • Installation lengths: 3 m and 6 m • Pipe diameter: 1 064 mm (outside) • Pipe material: 16 mm thick steel • Corrosion protection: Internal and external coating; external coating applied to 1 200 microns thick • Pipeline depth: approximately 500 mm below the reservoir base (when measured to the crown of the pipe) • Product pipe: 630mm diameter HDPE pipe (inserted into the steel sleeve by

PROJECT CASE STUDY 3 MFULENI PIPE RAMMING Project background The construction of a housing development in an unpopulated area required the installation of water and sewer services. One of the sewer pipelines traversed an existing municipal servitude which housed an active 1 500 mm diameter bulk water main. The sewer design level constraints meant that

TABLE 2 Selection consideration for using pipe ramming

the main contractor) • Equipment used: 24-inch pneumatic rammer capable of delivering 1 010 t of impact force per blow • Project start date: 10 November 2010 • Project completed: 3 December 2010 • Main contractor: Entsha Henra • Consultant: MVD Consulting Engineers (Mossel Bay) • Trenchless contractor: TT Innovations

How the pipe ramming installation fared and challenges encountered during installation

the sewer pipeline needed to be installed under the bulk water main. With the prevailing in situ soil being of a sandy nature, in conjunction with a high water table, the project engineers decided to use pipe ramming as a means to install a steel conduit below this bulk water main.

water main. Any movement of the joints or damage to this pressurised pipeline during excavation would cause catastrophic damage to the surrounding area, especially given the unstable, sandy nature of the soil. The initial depth of the existing water main, and the fact that the new sewer pipeline needed to be installed below this pipeline, increased

The pipe ramming operation proceeded as planned with the bulk of the project duration required for the preparation works (excavation and casting of the ramming support base). The actual ramming installation required only two days for both pipelines to be installed.

Why pipe ramming?

The reason for this trenchless application was to prevent any excavation near the bulk

Shored trench excavation

TABLE 3 Open trench versus pipe ramming

Pipe ramming

Speed of construction The bulk water main was approximately 6 m below the natural The pipe ramming launch pit would be situated within the existing ground level. With the new sewer pipeline designed to cross under sewer pipeline trench (which was excavated using battered slopes). this pipeline, an excavation and shoring system would be time-con- The immediate soil around the water main would be left intact formsuming – in particular since the sewer line crossed the bulk water ing an 18 m wide in situ support for this pipe. Both 18 m pipe crossmain at two places. ings were installed within a total of four days.

Risk to the existing water main Even if shoring is used, the surrounding soil could still become un- As the 18 m wide section of soil surrounding the pipe would remain instable due to groundwater seepage, which ‘erodes’ the soil parti- tact and undisturbed during the installation, the risk of settlement was cles, leaving voids behind. Once settlement occurs below the pipe- avoided. Furthermore, the ramming process does not cause any cavities, line, it is very difficult to reinstate and support the pipeline. thus eliminating all potential settlement risk elements.

Convenience Construction of the project was already being delayed due to external facThe sewer pipeline crossings were identified as potential risk items tors beyond the main contractor’s control. The project team needed a swift by the main contractor. Instead of dedicating additional resources solution that enabled the project to get back on programme. Any solution to attempt a successful installation, the entire item was outsourced other than trenchless would be too risky and time-consuming. The emand a trenchless alternative used. This mitigated the risk and was ployment of a specialist trenchless contractor also freed up valuable reconsidered an easier alternative. sources, which the main contractor could deploy to other areas of the site.

IMIESA September 2014

47

TRENCHLESS TECHNOLOGIES

FIGURE 13 View of the Mfuleni site layout. The sandbag wall at the foot of the slope as well as the dewatering system (blue pipeline) are visible

How the pipe ramming installation fared and challenges encountered during installation

the project risk significantly. Furthermore, this pipeline served as one of the main potable water supplies to the surrounding area. Any disruption to this service was to be avoided at all costs. The use of a trenchless solution was therefore justifiable considering the risk.

The only other feasible alternative to pipe ramming was to trench under the water main and to use timber shoring to stabilise the excavation, preventing it from collapsing.

However, due to the soil pressure at that depth, and the high groundwater level, the potential risk outweighed the reward.

PROJECT TECHNICAL DETAILS • Installation lengths: 18 m and 18 m • Pipe diameter: 600 mm (outside) • Pipe material: 16 mm thick steel • Corrosion protection: No. The pipe was grouted in place after installation • Pipeline depth: Approximately 6 m below natural ground level • Product pipe: 350 mm diameter UPVC pipe • Equipment used: 24-inch pneumatic

Pipe ramming applications The versatility of the ramming process enables client and engineers to apply this technology in numerous ways. However, the method is ideally suited for the following project constraints: TABLE 4 Pipe ramming selection template

Project parameters

rammer capable of delivering 1 010 t of impact force per blow • Project start date: September 2008 (award date) • Project completion date: April 2009 • Main contractor: Burger and Wallace • Consultant: KV3 Consulting Engineers • Trenchless contractor: TT Innovations

Medium- to large-diameter pipe installations installed over short distances Dependant on the ramming tool used, the diameter of the installed pipe could vary significantly and be as small as 300 mm.

However, smaller-sized pipes can also be economically installed using other trenchless methods and, therefore, the feasibility range

Project constraints

The main focus of this project was to stabilize the 6 m deep launch pit. In order to achieve this, the excavation slopes were battered to a 45 degree angle (approximate) and a wall of sandbags packed at the base of the slope for further stability, see Figure 13. The groundwater table needed to be reduced and a temporary dewatering system was installed in order to achieve this. The actual installation was swift and the first pipeline was installed within ten minutes. The second length of pipe was put in place and prepared for installation the following day.

One of the unforeseen outcomes of the high water table was the pipe settlement that occurred during installation. As the excavated pit was the only section being dewatered, the rest of the soil, including the portion below the water main, still remained saturated.

During installation, the rammer’s dynamic energy transferred through the steel pipe and caused the soil directly below the pipe to liquefy (similar to a poker vibrator when it agitates concrete). This caused the pipe to settle due to its own weight. The change in level, however, did not alter the project success as the 600 mm diameter steel pipe was still able to accommodate the 350 mm diameter sewer pipeline, which could be adjusted within the steel pipe to suit the required gradient.

of pipe ramming installations is typically from 600 mm in diameter up to 1 400 mm in diameter.

The installation length is limited by the size of the pipe and the in situ soil medium it travels through. Accordingly, the resistance generated by the leading edge of the pipe as it ‘cuts’ through the soil counteracts the applied ramming force. Further frictional resistance

Pipe ramming variables

Large-diameter Shallow installation depths Ideal for 600 mm to 1 400 mm pipe diameters trenchless pipe Zero tolerance for surface deflection or Crossing lengths between 50 to 70m heaving Straight drives only installation High water table In situ soil Pipe diameter must be larger than boulder size (must be able ‘swallow’ boulders) Boulder material or loose rock No thrust wall required Installation under steep embankment Site conditions Rammer can be easily moved from one set-up to the next Multiple installations – time constraints (for multiple installations)

48

IMIESA September 2014

TRENCHLESS TECHNOLOGIES

also occurs between the in situ soil and the pipesâ&#x20AC;&#x2122; skin surface area (both the outer and inner surface area). Consequently, the larger pipe sizes, having a larger cutting profile and surface area, are subject to more frictional resistance, leading to shorter installation lengths. Typical crossing lengths range from 70 m long for smaller pipe diameters (600 mm) and reduce to about 50 m as the pipe size approaches 1 400 mm in diameter.

Pipe installations exceeding 1 400 mm in diameter have successfully been installed, but are the exception due to their limited application window (ideal in situ soil conditions required, short installation length, economically feasible for the project).

(man-entry-sized pipes only), a soil plug is left in place at the front section of the pipe to prevent the uncontrolled movement of soil into the pipe, possibly creating a cavity. This makes the ramming process ideal for railway or airfield runway crossings.

Pipe ramming project selection template

Pipe installation under embankments

Conclusion

Where trenchless pipe installations are required under raised platforms, such as embankments, the pipe ramming process is ideal as it does not require any thrust walls to achieve installation. This reduces the construction and site mobilisation requirements and increases the process versatility.

Table 4 provides a list (not exhaustive) of the various project parameters and constraints which are ideally suited for the pipe ramming method.

Zero surface settlement or heaving

Unstable and challenging soil formations

Pipe ramming, like many other trenchless applications, is ideally suited to the project parameters for which it is designed. With sufficient knowledge, contractor experience and expertise, the local market would be better positioned to uncover the various opportunities where this technology can be deployed and transform challenging project constraints into practical solutions.

Why dig when you can go trenchless?

Due to an open-ended steel pipeline being driven into the soil, the surrounding soil is supported by the steel conduit. No excavation is required at the leading edge of the pipe, which prevents any voids or cavities from forming. Even when the spoil is manually removed midway through the installation

The pipe ramming method is often used in soil formations where other trenchless methods would fail. The process can accommodate soil formations containing loose rock or boulders, even with a high water table. The only restriction here is the size of the boulders â&#x20AC;&#x201C; which must be smaller than the pipe diameter.

Sources: Figure 1: http://www.groundforce.uk.com/ Trenchless+Technology/products/ramming Figure: 6 http://www.infrastructures.com/0310/ ramming.htm Figure 7: mhttp://www.nodig-bau.de/Nachrichten/ Tunnel-unter-Bahngleis-mit-GRUNDORAM-203.html Figure 8: extracted from Google Maps

IMIESA September 2014

49

ADVERTORIAL

Macsteel Tube & Pipe has a long histor y of excellence and commitment in the manufacture of welded steel pipes to SABS/SANS standards, as well as to equivalent international specifications.

M

ACSTEEL’S RETICULATION division has positioned the company as a leading manufacturer and supplier of valueadded steel pipe systems to the mining, engineering, agriculture and potable water industries. The company has sought to meet and exceed the expectations of customers across these industries through continuous improvements and innovations. Macsteel Tube & Pipe is accredited and conforms to ISO 9001:2008 Quality Management Systems.

High-quality product innovations Among Macsteel’s latest high-quality product innovations are the Cable-Lock pipe system and the Lula pipe system. These products do not require any couplings, flanges or bolts and nuts to join them. Also, neither system needs any specialised tooling or expertise to install and local labour can be trained to do the installation, thereby creating muchneeded employment.

Cable-Lock uses the same tried and tested socket system with additional restraining flex cable locking the pipes together, making it suitable for both buried and overland applications. The system operates at a maximum

Pride and performance working pressure of 25 bar with a safety factor of three. The system also comes with a full range of fabricated fittings.

Lula pipe is a steel pipe made to PVC sizes, making it completely interchangeable with PVC products. Also operates at a maximum working pressure of 25 bar and comes with a full range of fabricated fittings.

Macsteel is a sole distributor of high-quality Shurjoint Piping Products. Shurjoint is owned

by Tyco International and has a worldwide footprint. These products allow Macsteel to offer complete alternative solutions to the water industry. The company’s unique RingJoint system makes it easier and economic to install large-bore pipes as compared to the conventional welding methods.

Water reticulation The Shurjoint products have been used in the South African water reticulation market for over ten years. They have been successfully installed on water reticulation lines ranging from 50 NB up to 300 NB. The concept is simple: a grooved pipe is joined by a coupling, which is suitable for working pressures of up to 69 bar. The coupling will also allow for angular deflection between the pipes, which is useful when the pipe is installed in trenches or on plinths. This feature will help the alignment of the pipes on uneven surfaces.

Macsteel offers a complete system of pipes, couplings, fittings and valves, which ensures that all the required products work perfectly together. This system can save up

to 60% on the installation time and will allow involvement of the local communities in the installation process, unlike welding where skilled labourers are required. Prior to the installation, Macsteel will train and certify the workers on the installation of the couplings.

Water distribution Up to now, the water distribution pipes are commonly butt welded on-site. Welding onsite is influenced by many factors such as rain, humidity, dust and access to the job site, which cannot always be controlled. It is normally required to X-ray the joints and prepare the surface for the internal and external lining.

By moving the welding, lining and coating issues from site to a controlled workshop environment, it will increase productivity onsite and the quality of the connection. The Ring-Joint system will allow the pipe to be pre-fabricated in a workshop. A round ring is welded on the pipe end and subsequently the pipe is cement-mortar-lined and -coated on the exterior. The lining is done completely up to the pipe end, which means that the pipe is ready for installation and no welding, X-ray, coating or lining is required on-site.

On-site, the pipe-ends are connected with the Ring-Joint coupling where only a spanner is required. The C-shaped gasket is positioned between the pipe ends and the centre leg protects the lining from damage.

The coupling housing grips over the ring and provides a fully restrained joint capable of pressures up to 40 bar. This system can be used on any pipe-wall thickness as it derives its strength from the ring, which acts as a shoulder, unlike with a grooved connection where the working pressure largely depends on the pipe-wall thickness.

Macsteel Tube & Pipe continues striving for excellence through partnerships and ongoing research and development.

FAR LEFT R88 Ring-Joint coupling TOP LEFT Cable-Lock pipe system LEFT Lula pipe

50

IMIESA September 2014

PIPES

Further contracts in the pipeline Construction work on Durban’s Western Aqueduct bulk water pipeline wor th more than R700 million will be in progress by 2015.

T

O DATE, 7.5 km of the 55 km second phase has been completed and the project is well on track for its expected completion in 2017.

“Four contracts, along the full length of the pipeline, have been awarded and work on each is well under way,” says Neil Macleod, head of eThekwini Water and Sanitation. Two additional contracts – one for the Wyebank reservoir and the other for a spur pipeline going from the main pipeline to Mount Moriah and Tshelimnyama – are expected to be awarded by year end.

The Western Aqueduct (WA) is Durban’s largest ever bulk water pipeline project and is intended to both replace and augment existing infrastructure bringing water from

various dams surrounding Durban into the growing city.

“The WA is intended to provide an additional injection of much-needed water to the eThekwini Municipal Area and provide for the bulk water distribution needs of the

and ending at Inchanga. This was completed at the end of 2010. However, the full effect of this first phase will only be felt once the second phase has been commissioned. This stretches between Inchanga Station and Ntuzuma with spur pipelines going to Mount Moriah and Tshelimnyama.

The estimated overall cost for the Western Aqueduct Phase 2 and associated branch pipelines is R1.8 billion.

Macleod stresses that construction of the Western Aqueduct Phase 2 is logistically complex in that the large-diameter pipeline is constructed through extremely hilly terrain and along suburban roads. “Competent contractors have been appointed to execute the work and this is augmented by a large consulting engineering team that has extensive experience in this type of work.”

The Western Aqueduct is Durban’s largest ever bulk water pipeline area for the next 30 years. The completed WA is expected to significantly strengthen the capacity of bulk water supply to the western regions of eThekwini, initially injecting up to 80 Mℓ/d into the system, with the ultimate capacity exceeding 400 Mℓ/d,” says Macleod.

Phase 1 and 2 Work on the 20 Ml break pressure tank at Ashley Drive is progressing well

The first phase of the WA measures 20 km, beginning at the Umlaas Road reservoir

IMIESA September 2014

51

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

Manufacturing Pipe Since 1924.

The WA project has been designed and is being monitored by the Knight Piésold/Naidu Consulting/Royal HaskoningDHV Joint Venture.

According to project manager Martin Bright, work on the first contract, which covers the 7 km stretch between Inchanga Station and Alverstone Nek awarded to Cycad Pipelines, is progressing

“The completed WA is expected to significantly strengthen the capacity of bulk water supply to the western regions of eThekwini” well with 2.5 km of pipe already in the ground. He says there has been minimal disruption of traffic flow and the contract was well on track for completion in April 2015.

The second contract, which begins at Alverstone Nek and continues to Ashley Drive in Hillcrest, was awarded to WK SA Construction in August last year. Work is proceeding well with 2.5 km of pipeline in the ground and the completion date of April 2015 well within reach, he says.

The contract for the third and largest segment of the pipeline reaching from Ashley Drive to the NR5 reservoir at Ntuzuma was awarded to Esor Construction earlier this year.

As this is a 25 km stretch of the pipeline, work has commenced at three fronts in Kloof, KwaDukuza and Ntuzuma. So far, 0.5 km of pipeline has been laid.

Bright confirmes that work on the 20 Mℓ break pressure tank at Ashley Drive was awarded to Icon Construction. The duration of the contract is one year with completion scheduled for the first quarter of 2015. At this point, earthworks are complete and the commencement of concrete works is imminent.

Hall Longmore ranks amongst the

leading

A pipe jack along Old Main Road will see the Western Aqueduct pipeline cross underneath this busy thoroughfare en route to the Ashley Drive break pressure tank

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 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[PÄ JH[PVU

Contact Details Tel: Email: Web:

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

52

IMIESA September 2014

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PIPES

HDPE solution for R4.3 m pipeline project džȕ ĵÝǻɳ

ŷŗ ǻÝōr

Ýŗ ǻÝōr

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ǻsĶ ʹ˟ˢˠʺ ˦˧ˡ ˢ˦˧ˠ | ® ɮ ʹ˟ˢˠʺ ˦˧ˡ ˢ˦˧ˡ | rŎ ÞĶʲ ÞŘ¯Ÿ˔ǣ Ř¶ÞŸƼÞƼsʳOŸʳʊ

Municipalities across South Africa continue to invest more capital into pipeline upgrades.

One such project is a potable water upgrade project in Vosloorus, on the East Rand of Gauteng.

A

S PART OF A municipal upgrade project to replace an existing asbestos cement (AC) pipeline that was installed in the 1980s, Incledon was contacted in mid-2012 to supply more than 1.4 km of 560 mm diameter locally manufactured high-density polyethylene (HDPE) pipe.

Incledon sales representative for civils Robinson Patji highlights the fact that HDPE was selected as the material of choice to replace the existing AC pipeline, due to its high impact strength, low friction properties and environmentally friendly characteristics.

“AC pipelines pose some potential health concerns for both workers and end users. These pipes are also ver y brittle and tend to crack under stress from trench loads. The brittleness also makes this type of pipe difficult to cut and splice to undertake repair work,” he explains.

54

IMIESA September 2014

PIPES

OPPOSITE Incledon was contacted in mid-2012 to supply more than 1.4 km of 560 mm diameter locally manufactured HDPE pipe RIGHT TOP HDPE is non-toxic and entirely safe for supplying drinking water, while the lightness of the material makes it an easier and quicker type of pipeline to install RIGHT BOTTOM HDPE was selected as the material of choice to replace the existing AC pipeline

Why HDPE? Patji reveals that HDPE is non-toxic and entirely safe for supplying drinking water, while the lightness of the material makes it an easier and quicker type of pipeline to install. “The lightweight properties of HDPE make it easier for workers to carr y and lay. More pipes can be loaded onto a truck, thereby reducing carbon emissions too. HDPE pipes also boast more impact strength than AC pipes, which substantially reduces the risk of cracking and subsequent leaks.”

According to Patji, the SANS 4427 approved pipes, which have a pressure rating of 12 bar, were delivered to the project in 12 m lengths. As part of its comprehensive ser vice offering, Incledon also sourced a professional welding contractor on behalf of the municipality, in addition to supplying the project with a range of AVK valves in sizes including 200 mm, 300 mm and 500 mm.

IMIESA September 2014

NOW AVAILABLE up to 630mm SANS 791 PVC-U (unplasticized polyvinyl chloride) solid wall sewer and drain pipe systems • • • • • •

Resistance to abrasion and scouring Resistance to attack from acid or alkaline soils Impervious to chemicals found in all sewage Good flow characteristics Not damaged by modern cleaning methods Good impact properties, an important factor in installation, transportation and use

DETAILED PIPELINE DESIGN TECHNICAL INFO CONTAINED IN CD OR PDF FORMAT IS AVAILABLE ON REQUEST FROM DPI PLASTICS AND CONTAINING, INTER ALIA: • Trenching, bedding & backfilling • Repairs • Testing • Handling & storage • Soil / pipe Interaction • Deflection, live loads & wall stress • Velocity & flow chartss

• www.dpiplastics.co.za •Tel: +27 21 957 5600 • info@dpiplastics.co.za •Tel: +27 11 345 5600

Member of the Dawn Group

Southern African Vinyls Association

55

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WATER & WASTEWATER

Swayimane Water Supply Scheme upgrade The Swayimane Water Supply Scheme was completed in March 1998. Sixteen years later, it is ser vicing a much larger population than its original design can cope with and is now in need of an urgent upgrade.

T

HE INITIAL SCHEME was designed for a basic level of service, at the outset of the then new Government’s Reconstruction and Development Programme. This service comprised an allowance of 200 litres of water per person per day available at communal stand taps within an average of 200 m walking distance from homes. However, the norm within the Swayimane community has been the use of individual yard connections, which people have applied for and the Umgungundlovu District Municipality has installed.

Higher level of service This ‘higher’ level of ser vice has increased the demand for water, which has long outgrown what the existing Swayimane scheme can supply. There is therefore an urgent need for the upgrade and extension of the Swayimane Water Supply Scheme.

The uMgungundlovu District Municipality appointed multidisciplinary consulting engineers and project managers Bosch Stemele to investigate and report on the feasibility of providing an assured, potable and reticulated water supply to

the communities of Ekupholeni, Emabheleni, Odameni, Vumuthando, Cupulakha, Mbhava and Mpethu, all of which form a part of Swayimane.

Feasibility and design The feasibility study took the form of a project business plan that was submitted to, and approved by, the uMgungundlovu District Municipality and the Department of Water Affairs. The project is currently in the preliminary design stage and will progress to the detailed design stage in order to agree on an implementation plan, based on construction cost estimates, availability of grant funding, cash flows and phasing of the project.

The main aim of this project is to supply a rural population of approximately 57 200 people with a higher level of assured reticulated water supply. Bulk water will be

Swayimane is part of the uMgungundlovu Districty Municipality

sourced from Umgeni Water’s Bruyns Hill reservoir. Where possible, existing infrastructure will be incorporated into the proposed upgrade. This will include existing reservoirs, pump stations and pipelines. Two days’ (6 Mℓ) storage is planned downstream of the Bruyns Hill reservoir, together with approximately 354 000 m of new pipelines.

It is also worth noting that the Bruyns Hill reservoir and Swayimane bulk supply pipeline will provide bulk water to a community within the bordering Ilembe District Municipality. This has been agreed between Umgeni Water, uMgungundlovu District Municipality and Ilembe District Municipality, thus ensuring service delivery to all South African communities, irrespective of borders.

IMIESA September 2014

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WHY BUILD THE SAME

WHEN YOU CAN BUILD BETTER?

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CEMENT AND

CONCRETE Data shows a significant steady growth in cement consumption, indicating a continuous increase in the use of concrete in general construction and infrastructure. As cement and concrete markets become increasingly dynamic, the need for innovation is important, while precast cement has seen some important developments.

CEMENT AND CONCRETE

XRD AND XRF

Aiding the enhancement of cementitious materials PART 2

Within the cement industr y, chemical and mineralogical control is one of the principal means of guaranteeing the quality of the final product and its optimum per formance in the final application. Par t one of this ar ticle was published in the August edition of IMIESA. By Juan Guillermo Morales, Claudia Rodriguez, Carolina Giraldo and Ruby Estela Cardona, Research and Development Department, Cementos Argos S.A.

Cement pathologies

T

HE BEHAVIOUR OF cement in different environments can also be measured by using XRD and XRF. It is possible to recognise the hydrated phase’s degradation through the use of acid solutions, or the formation of new phases in different atmospheres or solutions. In a CO2 atmosphere, for example, it is possible to find CaCO3 in an aragonite and/or calcite form, which is produced as a result of the reaction between the free

calcium hydroxide and the CO2 gas. Also, in sulfate solutions, it is possible to follow ettringite increases and thaumasite formation, which are phases that are produced as a result of more complex reactions between hydrated calcium aluminates and hydrated calcium silicate and alkaline sulfates (such as Na2SO4 and K2SO4) that come from the sulfate solution.

The effects of other compounds Other materials and phases that are very

common and known in cement analysis are calcium sulfate (gypsum) and C4AF (tetracalcium alumino ferrite). Nevertheless, research has focused more on other phases of clinker, such as C3S, C3A and C2S, and other materials, such as SCMs, limestone, chemical additives, etc. There has not been much research about the two formerly mentioned and important compounds, which will always be present in cement and which, in some ways, affect the main reaction in the hydration process of Portland cement.

In the case of gypsum (CaSO4•2H2O), it is clear that its role is to control the setting time of cement when it reacts with C3A, delaying the hydration and giving end users time to handle and pour the product. This is a very useful characteristic as accelerating or delaying the setting time is a common request in the industry. On the other hand, the amount of gypsum has to be optimal in the formulation of cement because an excessive or low dosage will have an effect on the setting time and it will also affect Cross section of a composite MgO•CaSiO3 (matrix) reinforced with glass fibre (rounded shape sections sticking out located on the left lower part), in which CaSiO3 with elongated grains (cluster located on the centre of the image) act as a reinforcement as well stopping possible cracks

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the durability. Furthermore, gypsum is an expensive material. All of these aspects can be controlled through the correct identification of the main phases of calcium sulfate, dihydrate or gypsum, hemihydrate or bassanite and anhydrite, because the behaviour of the mineral is not only affected by its purity – usually measured as the amount of SO3 – but also by the relative presence of these phases, due to their different capabilities in controlling the hydration of the cement.

In the case of C4AF, in the formation of clinker it acts as a fluxing agent and allows the formation of the main phases through the ion interchange between the chemical species. However, what are the effects of increasing the amount of iron in the raw materials? The first result is that higher amounts of C4AF will be detected in the clinker. So, a new question arises: what happens during the cement hydration process and to the final performance of cement when there are high amounts of C4AF? The answer is that C4AF stimulates the formation of a layer that delays the setting time and the normal development of strength, not only as a consequence of less C3S formation, but also because this phase has its own pattern and is needed during hydration.

Again, a question arises: How can this particular situation be identified? This can be achieved via a complete analysis of the hydration of pure clinker phases using XRF and XRD tools.

New functionalities With the increasing need for new houses, buildings and roads, new materials and more specific applications and functionalities are demanded of construction materials. More environmentally friendly and intelligent materials have to be developed for the future. An environmentally friendly material can mean, for example, a material that allows us to reduce energy consumption in houses and buildings. This is a challenge for materials science because scientists need to think about materials that keep their temperature in indoor spaces. Perhaps they need to devise materials that allow light to pass through (translucent or transparent materials), or maybe they need to think of cement materials that can conduct electricity. Other opportunities could be found in the area of cleaner materials, such as photocatalytic types of cement that absorb NOx and SOx, and that could allow us to develop a material

that absorbs other contaminants from the air, water or soil. Finally, there are also the so-called intelligent materials, which can provide useful information about the state of the structure after many years of use or, for example, after an earthquake or similar situation. No doubt the development of these materials will need the help of advances in technical analysis and tools such as XRF and XRD.

Conclusion Technical analysis tools such as XRD and XRF represent a significant help to R&D teams in the cement industry when it comes to understanding and developing new products. The complete chemical and mineral characterisation of the materials used in cement production and the products generated after the hydration process play an important role in the process of obtaining more detailed and accurate knowledge of all the mechanisms and phenomena that govern the reactions and functionalities involved in its production and performance.

More refined technical analysis tools have to be developed in order to be able to gain a deeper insight into the structures and to identify all the aspects of the relationship between molecules and atoms and, in some way, manipulate them in order to produce the materials that we need to transform our environment whilst remaining in harmony with nature.

Bibliography: TAYLOR, H.F.W, Chemistr y of Cement, 2nd Edition (1997).

KOMNITSAS, K., and ZAHARAKI, D., ‘Geopolymerisation: A review and prospects for the minerals industr y’, Minerals Engineering20 (2007) pp. 1261 – 1277.

THOMAS, M.D.A, and HOOTON, R.D., ‘The Durability of Concrete Produced with Portland-Limestone Cement: Canadian Studies’, Portland Cement Association (2010).

BENTZ, D.P., et al., ‘Fine limestone additions to regulate setting in high volume flyash mixtures’, Cement & Concrete Composites 34 (2012), pp.

11 – 17.

LOTHENBACH, B., et al., ‘Influence of limestone on the hydration of Portland cements’, Cement and Concrete Research 38 (2008), pp. 848 – 860.

SCRIVENER, K.L., and KIRKPATRICK, R.J., ‘Innovation in use and research on cementitious material’, Cement and Concrete Research 38 (2008), pp. 128 – 136.

World Cement, ‘XFR and XRD based solutions’, Februar y 2004.

WESSELSKY, A., and JENSEN, O.M., Synthesis of pure Portland cement phases’, Cement and Concrete Research 39 (2009), pp. 973 – 980.

IMIESA September 2014

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A strong foundation for infrastructure success

CEMENT AND CONCRETE

SUSPENDED PAVING

Itâ&#x20AC;&#x2122;s in the bag Conver ting a dull bitumencoated flat roof or terrace into an attractive paved sur face without the use of grout or any other form of binding agent is challenging, unless you use suspended paving.

Concrete Culverts

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Where time-critical installations of culvert crossings are required, then the ROCLA Precast Culvert Base Slab is an ideal solution. It is designed and manufactured to suit the ROCLA Precast Concrete Portal culverts and LV SURĂ&#x20AC; OHG WR VXLW WKHVH VSHFLĂ&#x20AC; F W\SHV RI FXOYHUW ZKLFK complete most projects.

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USPENDED PAVING is a process that uses concrete flagstone pavers without the use of any binding agent. Unlike conventional paving or tiling on a concrete surface, in which the pavers or tiles are attached directly onto a concrete base layer, the pavers are mounted on small polythene sandbags without the use of any adhesive or binding agent. All that is needed to keep the pavers firmly in place is their weight. They are laid 10 mm to 12 mm apart, which creates a water-permeable surface.

These and other advantages are why suspended paving is finding increased favour among some of the countryâ&#x20AC;&#x2122;s leading architectural practices. The process has already been used on some major construction projects using pavers supplied by Capeâ&#x20AC;&#x201C;based Concrete Manufacturers Association NPC member Revelstone. Recent high-profile projects include: â&#x20AC;˘ Liberty Lifeâ&#x20AC;&#x2122;s headquarter premises in Century City â&#x20AC;˘ Bloemhof in Tyger Valley â&#x20AC;˘ Wembley Square in Gardens â&#x20AC;˘ student residences in Stellenbosch â&#x20AC;˘ Dainfern Square in Johannesburg â&#x20AC;˘ Liberty Lifeâ&#x20AC;&#x2122;s Umhlanga offices.

According to Johnny Schwartz, a partner of Louis Karol Architects, who are suspended-paving pioneers, the process offers some distinct advantages over conventional roof-top or terrace paving.

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“First, it allows for the creation of a level paved surface on a base that is sloped for drainage purposes. Flat surfaces are achieved by altering the thickness of the supporting sandbags to compensate for the slope. Second, because the paved surface is permeable, there is no water pooling even during the heaviest of storms.

This means that as soon as the rain has abated, the surface can be walked on without any concerns for wet feet.

“Another major advantage is the fact that the paved surface creates a protective layer that shields the waterproofing on the base layer from the sun’s UV rays and from other forms of possible damage. However, in the event that the base layer does require some routine or other maintenance work, it is easily effected by simply lifting the pavers and then reinserting them once the job is completed.

“Contrast this with the expense and inconvenience of lifting and replacing pavers that have been grouted to the base layer. No expansion joints are needed with suspended

RIGHT TOP Wembley Square, Cape Town, where a suspended-paving installation is taking place RIGHT BOTTOM The completed suspended-paving surface at Wembley Square

paving and there is no possibility that the pavers will crack or lift due to wind or earthinduced movement,” says Schwartz.

Revelstone director Alex Cyprianos says that suspended paving is generally used in low-traffic areas such as concrete roofs, balconies and terraces.

“The pavers tend to be large, averaging 600 mm² and 55 mm thick. We produce a wet-cast flagstone paver, which is also steel reinforced for extra strength, and we can make up special shapes to accommodate curved borders.”

The sandbags used in suspended paving are filled with a mixture of sand and cement that hardens once the laying process has been completed. Over time the polythene outer casing will deteriorate, leaving a hard and durable concrete core.

IMIESA September 2014

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CEMENT AND CONCRETE

The benefits of composite technology 64

Composite technology reduces the carbonintensive Por tland clinker content of cement ensuring that cements tread more lightly on the environment. Their mineral components carr y significantly less embodied carbon than clinker, effectively reducing the carbon footprint associated with cement production.

IMIESA September 2014

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CEMENT AND CONCRETE

T

HROUGH THIS process, cement maker AfriSam is able to conser ve natural resources such as limestone. The use of composite technology (C-tech) minerals in the manufacturing of composite cements makes constructive use of by-products from other industries, reducing the need to landfill these materials.

Introducing engineered mineral components in increased proportions to cement clinker presents AfriSam customers with enhanced functional performance qualities. The less water required to reach the desired consistency and workability, the better. This is because less water promotes higher concrete strength levels. The lower water demand of C-tech cements is a result of the additional mineral components employed and the use of carefully selected chemical admixtures.

Another superior attribute of these cements is their reduced heat of hydration. C-tech cements typically generate heat over a longer period of time, substantially lowering thermal gradients and reducing the likelihood of cracking.

The use of fly ash results in a dense concrete matrix that prevents deleterious materials such as aggressive chemicals and sulfate-containing liquids from entering the concrete. This resistance to ingress of deleterious elements gives the composite cements their corrosion-resistance properties.

While any steel reinforcement exposed to chloride ions in solution is prone to corrosion, GGBFS is known to capture the chloride ions that cause corrosion in steel reinforcement, thereby enhancing the corrosion-resistance properties of composite cements.

The finer particles in GGBFS, fly ash and limestone afford composite cements reduced permeability properties. This resistance to water and sulfate penetration from the refined pore structure helps protect the concrete from attack, preventing deterioration.

AfriSam C-tech cements also contain mineral components that produce superior long-term strengths compared to pure cements, where strength-gain typically flattens out from 28 days onward.

“Our C-tech products are the result of an ongoing development process that began in 2000 and is still moving for ward, beyond conventional boundaries,” explains Mike McDonald, manager of AfriSam’s Centre of Product Excellence. “The mineral components in these cements have been engineered to make the resultant composite cement superior to pure cement. These products offer a spectrum of functional attributes that provide our customers with guaranteed quality per formance.”

OPPOSITE TOP C-tech cements offer a spectrum of functional attributes that provide customers guaranteed quality performance LEFT C-tech personifies AfriSam’s ethos of innovation, aimed at ensuring that its customers enjoy the benefits of highperforming products

IMIESA September 2014

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IMIESA September 2014

CONSTRUCTION

VEHICLES

EQUIPMENT

CONSTRUCTION EQUIPMENT | VEHICLES

New hydraulic drill aimed at great depths New simple method for cutting marble blocks

A A

NEW HYDRAULIC, underground, handheld rock drill system is one of the most powerful underground handheld rock drills on the market.

The Atlas Copco HRD100 boasts an outstanding drill rate and considerable energy efficiency compared to conventional pneumatic or electrical rock drills.

THE HRD system consists of the rock drill (RD100), the power pack (PP100) and a selection of water-pusher legs.

The smart power pack monitors all vital functions and can compensate for pressure changes automatically. The system also monitors oil volume and compensates for pressure differences.

That allows you to work with the PP100 at a 45 degree angle, without power loss. Simple tools make it easy to top up hydraulic oil in the mine. The five-step water adjustment helps the operator use the right amount of water for each step. When drilling stops, the flow stops automatically. Measured noise is approximately 50% lower than that of a pneumatic drill. The polyurethane cover shields noise and makes the unit shockproof.

Safety first â&#x20AC;&#x153;We really made an effort to provide high drill rates at low operational cost. But it is equally important to create a system that save the operators energy by being light and reliable,â&#x20AC;? says Oleg Korobotchkine, product line manager.

Working underground is difficult, but thanks to one-handed operation and carrying handles, the HRD system makes it easier.

The stackable PP100 power pack basically manages itself.

Smart functions monitor oil flow and oil temperature. Watercooling and automatic overheat protection means safety and reliability are at its core.

NEW STAR is making its debut in the marble quarry sector: a B100C backhoe loader that has been equipped with a support arm and chain cutter, mounted in place of the traditional backhoe. This offers an ingenious and simple method for cutting blocks of marble, which is both fast and efficient.

The B100C was fitted with a chain cutter (CST 965) developed

by Benetti Macchine, who specialises in supplying marble-cutting machines. Benetti worked in close collaboration with the New Holland Construction Engineering division in Lecce. The prototype underwent several months of vigorous testing in the Carrara marble quarries, in which the most expert operators in marble extraction made the machine work at full speed for long periods. The result was that the New Holland B100C backhoe loader passed with flying colours, and made its official debut at the Marmomacc Trade Fair in 2013.

Chain-cutter alternative Fitting a backhoe loader with a chain cutter is an alternative to the diamond-wire cutting machines normally used to cut large blocks of marble. The New Holland solution offers greater safety and a considerable reduction in working time. The backhoe loader, however, is able to move up to the marble blocks autonomously and square them up, allowing them to then be transported by truck to the facilities dedicated to transforming them into slabs.

B100C features The B100C is equipped with an engine that meets with the strict Tier IV Interim (EU Stage IIIB) emission standards. The 3.4 litre engine produces 97 HP. Developed by FPT Industrial and produced in the Turin plant, this engine is particularly responsive and frugal. C Series backhoe loaders are equipped with the LDS loadsensing system, with a load sensor and a variable displacement pump. Together, this system reduces consumption considerably.

The B100C backhoe loader also has a new base configuration which includes Powershuttle transmission and mechanical controls, gear-type pumps, two front and rear lights and a ROPSFOPS cab. The forward-tilting engine hood is easy to open and provides excellent ground-level access to the points that require routine maintenance.

IMIESA September 2014

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CONSTRUCTION EQUIPMENT | VEHICLES

BACKHOE LOADER

Productivity, versatility, efficiency FEATURES • Fuel efficient • Heavy-duty design • Maximised up-time • Best operator environment

SPECIFICATIONS

C

ASE CONSTRUCTION Equipment fur ther expands its industr yleading backhoe loader range in Africa and the Middle East with the new Case 570T, designed for productivity, versatility and fast return on investment.

The Case 570T model represents the continuity of the Case DNA. This entry-level backhoe boasts several high-productivity features. These include its fuel-efficient FPT Industrial S8000 engine, the S-styled boom, heavy-duty front axle (also available in 4WD) and the largest cab in the segment.

• Engine gross power: 86 HP • Travel speeds: 4+4 • Max ground-level reach: 5 583 mm (Extendhoe version) • Dipper digging force: 4 300 kgf • Bucket breakout force: 5 630 kgf • Loader max lifting capacity: 3 700 kg IMIESA September 2014

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5th Annual

OMEN IN ENGINEERING CONVENTION DATES: 26, 27, 28 November 2014

VENUE: Gallagher Estate, Midrand

OPENING ADDRESS

INTERNATIONAL PERSPECTIVE

Hon. Zanele Magwaza-Msibi Deputy Minister DEPARTMENT OF SCIENCE AND TECHNOLOGY

PRIORITISING YOUR WORK SCHEDULE TO IMPROVE YOUR WORK-LIFE-BALANCE LIVE VIDEO LINK Panel Lead by: Bonita Seaton Deputy Ground Segment & Operations Manager NASA GODDARD SPACE FLIGHT CENTER (USA)

CONFIRMED SPEAKERS INCLUDE:

SIEMENS IRONVELD (PTY) LTD ESKOM GROUP TECHNOLOGY INTENS ENGINEERING SOLUTIONS TRANSNET ENGINEERING SKA SA EKURHULENI METROPOLITAN MUNICIPALITY CILLUTIONS SASOL SYNFUELS WORKPRO SOUTH AFRICAN SPACE AGENCY AURECON WSP

DESHUN DEYSEL & ASSOCIATES

SOME OF THE KEY STRATEGIES TO BE DISCUSSED INCLUDE:

Playing a pivotal role as a woman engineer in South Africa’s infrastructure boom How to successfully manage Mega Projects Maximising your project objectives through due diligence and contract management skills Mapping the characteristics of a true leader that sets you apart from the pack : By Remedying your personal skills gap through ed lop e strategising your career development v De & ... and more ed

Quote WIE-IM to receive a 10% discount. For more information contact Amrita on +27 (0) 11 326 2501 or email bookings@intelligencetransferc.co.za

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CONSTRUCTION EQUIPMENT | VEHICLES

New products expand dealer network

A

RANGE OF light, medium and heavy rig-mounted hydraulic breakers for construction and demolition, as well as two improved CPLT light tower models for portable autonomous site lighting, are now available.

In South and Southern Africa, the Chicago Pneumatic range of construction and mining equipment is only available RX range of medium rig mounted hydraulic breakers from Chicago Pneumatic

72

through dealers. Jacques van der Westhuizen, business development manager for Chicago Pneumatic in South Africa, explains: “With the recent launch of our new hydraulic breakers and light towers and with more new products in the launch pipeline, it is our objective to bring the complete Chicago Pneumatic product range and support services to our customers. We are establishing a solid countrywide dealer network, selecting only discerning dealers.”

Rig-mounted hydraulic breakers The new RX line of rig-mounted light, medium and heavy hydraulic breakers fit any breaking application, from day-to-day construction with the lighter models to tougher quarrying

applications with the larger breakers. The light and medium rig-mounted breaker range comprises nine models designed to match various applications in general construction, light to medium demolition, renovation and trenching.

Max performance, min. costs “RX hydraulic breakers have been designed to keep performance to a maximum, and operational costs to a minimum,” says Van der Westhuizen.

All features built into the RX breakers focus on reliability, easy maintenance and efficient performance. The units are engineered with fewer components and working parts, which reduces maintenance. The state-of-the-art mono block’s, two-in-one design with a combined cylinder and tool holder, eliminates the need for side bolts.

Design features The Power Boost is designed to achieve greater breaking performance in tough applications

IMIESA September 2014

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Green Terramesh® Retaining wall Lamontville Housing Project: Barcelona We now have 8 SAICE Accredited Complimentary CPD Lectures available. Visit www.maccaferri.co.za for information on lectures in your area.

National Tel: +27 87 742 2710 International: Tel: +27 31 705 0500 Branches: Durban (HO), Johannesburg, Cape Town, East London, Tongaat (Factory) www.maccaferri.co.za

CONSTRUCTION EQUIPMENT | VEHICLES

Chicago Pneumatic CPLT M12 manual light tower

without requiring additional hydraulic input.

The enhanced percussive per for mance is achieved by reusing the recoil energy.

The RX line also features advanced noise and vibration damping technology; with the RX recoilabsorbing system and insulated breaker boxes, the RX series is one of the quietest breakers on the market. The PowerControl Plus valve enables the operator to adjust the operation mode of the breaker to the application in the field without opening the hydraulic circuit. Additional design features

and improvements include an established hybrid gas/oil technology, a field-replaceable cylinder sleeve for decreased service times, elimination of a high-pressure accumulator to increase reliability, an internal control valve for increased efficiency and a reinforced breaker box design with rock claws.

situations. Both light towers have been carefully designed to be extremely easy to position in any desired location to obtain optimal work-area lighting while the metal halide lamp technology delivers long periods of autonomous operation. The four energyefficient, long-lasting 1 000 W metal halide lamps are capable of generating 440 000 lumens of lighting power.

Portable lighting Chicago Pneumatic’s two new arrivals in the portable lighting industry, the CPLT M12 and CPLT H5 light towers with manual and hydraulic masts respectively, build on the success of the existing CPLT M10 light tower renowned for delivering highly reliable, easy-to-use and manoeuvrable autonomous, portable site-lighting solutions.

The new CPLT range, driven by the powerful Kubota engine, suits a variety of applications in construction, mining and oil and gas industries, as well as public sectors, sporting events, entertainment and emergency

THE RANGE RX 2 • Service weight: 94 kg • Fits 1 to 3 tonne carrier classes.

RX 22 • Service weight: 1 500 kg • Ideal for 17 to 28 tonne carriers weight class.

Five new heavy breakers RX 26, RX 30, RX 38, RX 46 and RX 54 • Service weights: 1 800 to 4 200 kg • Fit 20 to 70 tonnes carriers • Ideal for heavy demolition, rock excavation and quarry applications

IMIESA September 2014

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CONSTRUCTION EQUIPMENT | VEHICLES

‘When the Bottom Line counts’

The importance of coolant in vehicle maintenance

‘Order your water meters from South Africa’s fastest growing water meter company with their stocks of NRCS TYPE APPROVED ASM LXH brass or 15 & 20mm plastic Brass water meters’

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T IS ESTIMATED that up to 40% of all engine failures are related to problems that stem from the cooling system. Coolants are thus of paramount importance when it comes to effective vehicle maintenance.

Cummins distributes a range of Fleetguard coolants which protect engine components from cooling system problems. The company’s technical sales manager for the mining division, Gerald Annandale, notes that coolant is composed of three components: water content, ethylene glycol and a chemical portion.

“The coolant is an integral part of vehicle engine maintenance. Its water content portion cools down the engine, while the ethylene glycol forms the anti-freeze portion of the mixture. The smallest, but arguably the most important, component is the chemical make-up of the coolant, which protects the internal sur faces of the engine,” he explains.

Cape Town: 021 510 4266 or 021 510 8408

Critical components The cooling system of a vehicle comprises a number of different types of metal, which results in sensitivity to corrosion.

“Aluminium is extremely sensitive to corrosion by chemical attack. In order to protect aluminium components in the engine, a silica compound forms part of the coolant formulation to specifically protect the surface of the aluminium. The foundation of the formulation is protection, cooling, antiboil and anti-freeze,” obser ves Annandale.

Annandale adds that although the radiator is an important component of the cooling system it is only able to do so much.

“With the radiator cap on, the system is pressurised, and the boiling point of the water rises slightly. When a high-quality coolant with a sufficient amount of ethylene glycol compound is used, it will only boil at 108°C, improving the boiling point of the water, as well as lowering the freezing point.”

Johannesburg: 011 609 4647 or 011 609 6336 ASM LXHS 15 & 20mm Plastic LEVEL 2

info@precisionmeters.co.za www.precisionmeters.co.za 74

IMIESA September 2014

Should the cooling system have not been regularly maintained, Restore will highlight any leaks or problems

Water makes up an extremely important part of a vehicle’s cooling system; however, if ordinar y tap water is used it could be detrimental to the life of the vehicle’s cooling system. “Chemicals such as chlorine are commonly added to water to make it safe for human consumption.

These chemicals not only disrupt the chemical make-up of the coolant, but also have the propensity to rust the different components of the cooling system. It is for this reason that long-life, pre-diluted coolants such as ES Complete were formulated,”states Annandale.

Some industrial operations even make use of borehole water, which is often calcium enriched or hard, leading to calcium deposits forming in the engine. These deposits form an insulation layer that separates the water from the engine component it should be cooling. A 3 mm buildup of calcium creates an equivalent heat barrier to that of 50 mm of extra steel.

Therefore, the necessar y heat transfer does not take place and results in dangerous levels of rising heat.

CONSTRUCTION EQUIPMENT | VEHICLES

ES Compleat Glycerin pre-diluted coolant This is a new and innovative heavy-duty engine coolant made with glycerin, a raw material derived from renewable energy sources, such as a by-product of biodiesel manufacturing.

Glycerin is used in place of ethylene glycol or propylene glycol, ensuring environmental responsibility with green products that continue to provide superior engine protection.

Good maintenance According to Annandale, a good vehicle cooling system maintenance programme should include regular testing of the coolant. It is recommended that a cooling system test is completed ever y 30 000 km in order to check the quality of the vehicle’s coolant and determine any contamination.

One of the most neglected parts of an engine system is the cooling system, and the only way to recover from a failure is to

overhaul the engine, which is immensely costly. Coolants can be tested effortlessly and accurately with either a refractometer or with coolant quality test strips, both of which are supplied by Cummins. The Fleetguard refractometer is a fast and easy way to determine the freeze-point protection of both ethylene glycol and propylene glycol coolants.

It is more accurate than most test strips and float-type hydrometers and it is also easy to use. A drop of coolant from the cooling system is placed on the refractometer window and the lid is shut. By simply looking through the eyepiece, you are able to record the freeze-point protection of the coolant.

Cummins-branded Restore alkalinebased cleaning fluid is designed to clean a vehicle’s engine and cooling system by removing all unwanted deposits and residue from inside the cooling system itself.

“In the event that the cooling system has not been regularly maintained, Restore will

highlight any leaks or problems detected.

If the cooling system has been properly maintained and the correct coolant has been used, Restore will ensure that the cooling system continues to operate in good working condition for a prolonged period.”

Cummins also supplies a wide range of Fleetguard coolant products, which protect engine components against corrosion, liner pitting, cavitation, scale and deposits and acidification. These include: ES Compleat OAT, ES Compleat, Fleetcool EX, Fleetcool and Fleetcool Recycled.

“The Cummins range of Fleetguard coolant products has been formulated for use in heavy-duty vehicles. Diesel engines today are highly efficient, but also stressed and need to be looked after. Coolant plays a vital part in this vehicle maintenance, as it is more cost-effective to buy a quality coolant than to replace an engine after a failure due to poor maintenance,” concludes Annandale.

IMIESA September 2014

75

IMESA Conference 2014 Pre-Conference Workshop Infrastructure Asset Management 28th October 2014 – Durban Country Club, KZN

“Using IMESA’s AMPLE and other tools to get started, and manage your valuable infrastructure portfolios through a structured and cost-effective, step-by-step asset management improvement programme”

WHAT IS AMPLE? AMPLE (Asset Management Program Learning Environment) is a webenabled knowledge management system which aims to present a means by which organisations and their staff can gain an understanding of: the principles of life-cycle asset management in a logical, costeffective, step-by-step process. the essential components of a state-of-the-art asset management programme. ‘how to do it’ information to drive their asset management improvement programme.

AMPLE is the result of over 20 years in the development of world-class asset management manuals and approaches

for successful AM improvement programmes that have delivered all aspects of best-practice AM for a full range of infrastructure services, especially local governments – metros and towns – using a ‘whole of city’ approach covering all infrastructure and physical asset types.

The objective of IMESA’s AMPLE is to provide a web-based asset management learning environment, which will assist all municipalities and their infrastructure-rich businesses to drive sustainable asset management improvement cost-effectively.

It provides a web-based knowledge management system that can be implemented to suit individual

municipalities to achieve a sustainable level of life-cycle asset management that delivers the required level of service at the lowest life-cycle cost.

WHO SHOULD ATTEND? This workshop will be ideal for all those who: are thinking about implementing infrastructure asset management but don’t know where to start. have started, but would like to see some smart ways to do it more cost-effectively, while deriving even greater benefits for your municipality. would like to know how IMESA can support you in your efforts.

YOUR WORKSHOP FACILITATOR Roger Byrne was the international manager of GHD’s Global Asset Management Group for over 30 years.

Based in Melbourne, Australia, and now semi-retired, he still works all over the world as a principal advisor/ mentor to clients. He has written many texts on asset management including many manuals, such as the IIMM and the development of the world’s first quality framework; associated AMPLE / TEAMQF web-based tools that are assisting infrastructure owners and managers around the world. Roger has helped develop innovative approaches including business value chains, confidence-level rating processes, the step-by-step approach and methods to identify what is best practice for different organisations and their assets. Roger is in the ‘legacy years’ of his career and is concentrating on really understanding the reasons or causes for AM failures and driving AM improvements collaboratively around the world.

TYPICAL TOPICS INCLUDED IN THE WORKSHOP PROGRAMME The workshop will follow the highly successful 10-box training programme now used across the USA and with municipal clients in Australia, New Zealand, UK, Canada and South America Asset registers, valuation, condition assessment and residual lives, levels of service, business risk exposure, optimal maintenance programmes, rehabilitation/ replacement/augmentation, asset management plans, future expenditure and funding models and stakeholder consultation Getting started – How did others do it: the different ways to get started Change management effective implementation programmes (EIP) – successful AM improvement programmes Building your first AMP and driving its improvement cost-effectively Gap analysis techniques and TEAMQF – Roger will demonstrate the Gap-Ex 1 web-based tool so that participants can then go and try it out with their organisation.

e All participants will be given a free toggle to use the tool The business case for improving yourr AM performance – asset managementt improvement programmes Organisational and people issues

ORGANISER The workshop is en-

IMESA

dorsed and organised by the INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA).

CO-HOSTED BY The eThekwini Municipality

CONTINUING PROFESSIONAL DEVELOPMENT Attendance at the workshop will ensure 1 CPD point. IMESA will issue a certificate of attendance to workshop participants after the event.

COST/REGISTRATION Online registration www.imesa.org.za

Risk management Data collection – smart techniques – Delphi group approaches Capital

investment

programmess

(CIP) justification/validation

Venue Durban Country Club Time 08:00 – 16:30 Payment before 17 October 2014

Strategic asset management planning Justifying and focusing existing budgetss Understanding the full economic// e whole-of-life/cost-of-service (triple bottom line – TBL) Asset valuation/depreciation/ economic cost Condition assessment process and d residual life estimates Asset

management

information n

systems, data and knowledge

Cost per delegate IMESA members R1 600.00 + VAT R224.00 = R1 824.00 Cost per delegate Non IMESA members R1 800.00 + VAT R252.00 = R2 052.00 For any query, please contact Erin – +27 (0)31 303 9852 Space at the workshop is limited and applications will be accepted on a first-come-first-served basis. Payment of the workshop fee includes full-day conference package.

YOUNG ENGINEERS

Achieving m Aqualibrium Aqualibrium, the exciting SAICE-Rand Water Schools Water Competition, strengthens initiatives to encourage learners to take mathematics and science, enabling them to pursue one of the top-priority scarce skills on Government’s list.

The competition – imitating reality

W

ATER DISTRIBUTION systems are important in suppying safe and clean drinking water. The teams are tasked with designing a model water-distribution network to distribute three litres of water equally between three points on the grid using two different diameter pipes and connection pieces.

They are then judged on how well they execute the task, working on a penalty-point system. The participants have an hour in which to design, construct and operate their network.

This competition exposes learners to the practical application of processes that influence their daily lives: how water gets to their homes. They are made aware of the intricacies involved in the design of water distribution networks and actual water deliver y to households.

The competition creates awareness regarding the issues surrounding water in South Africa. It spreads the message that

water is a precious commodity, the use of which should be reduced, recycled, reused, respected and conser ved.

Through this competition, SAICE and the Water Research Commission, currently the competition’s major sponsor, have undertaken to raise awareness that water should be used wisely, that infrastructure should be maintained and that new infrastructure should be created to provide potable water to those without it.

TOP The winning team from Brackenfell High School from left to right: Angelique le Roux, Stanford Mkhacane (SAICE President 2014), Aldo Siegling, Lefadi Makibinyane (Rand Water Board member and CESA’s CEO), Johan Nieuwoudt (educator) and Bennie van Eeden ABOVE Winnie Mandela Secondary School came second with team members Gugulethu Mokhwebane, Lerato Dhlamini and Collen Rapelego and educator Steven Ngwane at the back, second from the right, alongside representatives from Rand Water and SAICE

2014 champions The 2014 champions, with only 35 penalty points conceded, were Brackenfell High School from Cape Town with team members Angelique le Roux, Aldo Siegling and Bennie van Eeden.

Second place went to the Winnie Mandela Secondar y School from Tembisa, with 85 penalty points. The team members were Gugulethu Mokhwebane, Lerato Dhlamini and Collen Rapelego.

In third place, with 177 penalty points, was Dendron Secondar y School with team In the third place was Dendron Secondary School in Limpopo. The team members, Seokedzi Mothoka, Masuila Phihlela and Alvin Seakamela, with educator Vincent Mokobane, second from the right

78

IMIESA September 2014

members Seokedzi Mothoka, Masuila Phihlela and Alvin Seakamela. The three winning teams and their educators shared prize money of just over R17 000.

This year the winners of the regional competitions came to Johannesburg from Bloemfontein, Cape Town, East London, Port Elizabeth, Kimberley and Limpopo, to battle the local winners for top honours.

Awards finalist For a second successive year, the Aqualibrium initiative had the honour of being chosen as one of four finalists in the National Science and Technology Forum and BHP Billiton Awards – the oldest and most prestigious in South Africa – in the categor y where an individual or team is recognised for their outstanding contribution to science, engineering, technology and innovation through science communication and creating science awareness.

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

IMESA

AECOM vanessa.partington@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 Munitech info@boschmunitech.co.za Bosch Stemele bsdbn@boschstemele.co.za Brubin Pumps sales@brubin.co.za BVI Consulting Engineers marketing@bviho.co.za Civilconsult Consulting Engineers mail@civilconsult.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za CSIR Built Environment rbapela@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 leon.basson@elster.com Engcor Engineers masham@engcorengineers.co.za Fibertex South Africa (Pty) Ltd rcl@fibertex.com 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 INGEROP mravjee@ingerop.co.za Integrity Environment info@integrityafrica.co.za Jeffares and Green dennyc@jgi.co.za Johannesburg Water rtaljaard@jwater.co.za KABE Consulting Engineers info@kabe.co.za Kantey & Templer (K&T) Consulting Engineers info@kanteys.co.za Knowledge Base info@knowbase.co.za Lektratek Water general@lwt.co.za Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Malani Padayachee & Associates (Pty) Ltd admin@mpa.co.za Maragela Consulting Engineers admin@maragelaconsulting.co.za

Marley Pipe Systems info@marleypipesystems.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 Royal HaskoningDHV francisg@rhdv.com SABITA info@sabita.co.za SALGA info@salga.org.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 stolz.j@sna.co.za Sobek Engineering gen@sobek.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 VUKA Africa Consulting Engineers info@vukaafrica.co.za Water Institute of Southern Africa wisa@wisa.org.za Water Solutions Southern Africa ecoetzer@wssa.co.za Wilo South Africa tracy.vanderLinde@wilo.co.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

ADVERTISERS

INDEX TO ADVERTISERS Afri-Infra

80

Aggregate and Sand Producers Association of SA

21

Bagshaw Footwear

70

Beier Safety Footwear

68

DPI Plastics

55

DWA

14

ELB Equipment

46

ERWAT

22

Fiberpipe

44

Herrenknecht AG

38

Hall Longmore

52

Hydrodifusion Fittings

33

IMESA General

56

IMESA Workshop

76

Incledon

30

Joat Group

IFC

Komatsu

19

Krohne South Africa

18

Marley Pipe Systems

OFC

Maccaferri Southern Africa

72

MacSteel

49

MCI Measurement Control Instrumentation

66

Mr Stubman CC

32

National Asphalt

75

Pan Mixers South Africa

61

Precision Meters

74

Rescue Rod

45

Rocla

62

SA Readymix Association

65

Sasol Polymers

36

Sangio Pipe

54

SBS Water Systems

53

Sephaku Cement

58

Sizabantu Piping Systems

26

Standard Bank

17

The Bvi Group

12

The Concrete Institute

63

The Rare Group t/a Rare

34

Technicrete

64

Tosas

73

TT Innovations

42

Vermeer Equipment Suppliers

2

Water & Sanitation Services

OBC

Women in Engineering Convention

71

WRP

IBC

80

IMIESA September 2014

Your one-stop data acquisition solution for water utilities

WEB BASED DATA ACQUISITION, DISPLAY AND ANALYSIS SOFTWARE (PROUDLY DESIGNED AND DEVELOPED IN SOUTH AFRICA)

• GPRS/GSM based • Flow and Pressure Logging • Level Monitoring • Identification of leakage through MNF Analysis • Real time data monitoring • Identification of pressure problems • Automatic Meter Reading and Display • Provides live data to aid network management

Client:

Client:

Client Client

NTU

uS/cm

Purification Works

Turbidity

Conductivity

Daily Water Use

Critical Point Pressure Flow

Meter Reading

• Zednet can be linked to existing GSM and GPRS data logging systems.

• Updates immediately on receipt of data from data loggers.

• Data can be exported in any required format.

• Virtually any type of data can be captured eg. flow, pressure, TDS, conductivity, water levels etc.

Receive alarm notification on your standard cell phone via sms text, or e-mailed to your preferred IP address.

• Can be used to store and display all historical logging data.

http://www.zednet.co.za

Flow (m3/h)

Pressure P Press ressure ((m) m))

Meter Readings

Consumption (Kl)

Regulo PRV 01

Water and Sanitation Services South Africa (Pty) Ltd (WSSA) is a specialised provider of sustainable water services in Southern Africa