Driving water infrastructure innovation: A 4.0 approach
HEALTH & SAFETY
Updated legislation enhances H&S practices
CONCRETE RETAINING WALL SYSTEMS Designing for sloping terrain
Across the globe, Ammann Group Holdings AG (the Ammann Group) – a leading Swiss multinational OEM founded in 1869 – is dedicated to providing bestin-class solutions for the road construction market, serving more than 100 countries via a network of over 200 dealers and partners. P6
EDITOR Alastair Currie
Email: alastair@infraprojects.co.za
DESIGNER Beren Bauermeister
CONTRIBUTORS Claire Deacon, Christian A. Mulol, Devesh Mothilall, Geoff Tooley
DISTRIBUTION MANAGER Nomsa Masina
DISTRIBUTION COORDINATOR Asha Pursotham
SUBSCRIPTIONS
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ADVERTISING SALES
KEY ACCOUNT MANAGER Joanne Lawrie
Tel: +27 (0)82 346 5338
Email: joanne@infraprojects.co.za
Creating a healthy Balance of Trade where everyone benefits
Sparring within the international community over tariffs has sent shock waves throughout the global economy, forcing long-term trading partners to revisit current and future alliances. There are no easy solutions in sight, but hopefully the collective wisdom of the G20, among other country groups like BRICS, will restore a sustainable equilibrium.
Either way, there’s a new evolving engagement platform, which is certain to reshape modern economic history, with trade diversification being a key influencing factor.
There’s always going to be a quid pro quo because no country wants to be and should be a net importer. The latter would indicate negative under-performance in terms of their Balance of Trade.
Positively, in South Africa’s case, we do have a strong export base – thanks to sound agricultural, industrial, manufacturing, mining, IT, tourism, and financial services sectors, among others. Plus, we already have local centres of excellence that enable foreign investors to obtain a sound return on their investment in areas like automotive, renewable energy, minerals, and data centres.
All material herein IMIESA is copyright protected and may not be reproduced without the prior written permission of the publisher. The views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.
On the global stage, South Africa currently ranks around 40th in terms of nominal Gross Domestic Product (GDP) (based on World Bank Group 2023 statistics), positioning the country as a strong developed and developing economy with competitive advantage.
Opportunities in Africa
South Africa also ranks in the top three in Africa, with major opportunities to grow its market penetration through the evolving African Continental Free Trade Area (AfCFTA) framework agreement. Connecting 55 countries, the AfCFTA – launched in 2021 – provides an enabling platform for the sale of goods and services.
Currently, the top five economies in Africa comprise Algeria, Egypt, Ethiopia, Nigeria, and South Africa, all of whom serve as potential changemakers, helping to facilitate mutually beneficial growth in neighbouring more under-industrialised countries.
For all parties, the benefits are far reaching, providing crucial platforms for technology exchanges and localised skills development in new high-tech segments that foster SME growth. Whether in Germany or South Africa, SMEs are one of the core pillars for GDP prosperity and employment.
In South Africa’s case, as much as 25% of SME activity falls into the informal category. Therefore, transitioning these enterprises to the formal economy through investment and training makes business sense. It would also increase tax revenue flows to the fiscus.
Quid pro quo
Proactive public-private partnerships (PPPs) – internally and country-to-country – are essential for meeting the UN Sustainable Development Goals. This requires an equitable and universal approach.
Additionally, we have a world class construction sector, which is already present in parts of Africa and the Middle East for a range of services that include consulting engineering, contracting and OEM solutions. A current prime example of excellent country-tocountry collaboration is the Lesotho Highlands Phase II development – a multi-faceted global initiative in terms of funding and implementation.
Renewed focus on water and energy efficiencies
However, for South Africa to grow its GDP to 3% plus annually, there are fundamental requirements. Foremost, we must get on top of our water, sanitation, and energy infrastructure backlogs.
A positive development in terms of the latter is a concerted drive by Eskom to improve system availability and eradicate loadshedding. To date unplanned outages have been significantly reduced due to a commendable maintenance drive.
As part of its longer-term Just Energy Transition strategy, Eskom has also recently released a tender to establish a separate independent renewable energy business unit. This opens a new door for local and international PPP engagement via “green financing” within a sector that has already demonstrated best-in-class execution on locally commissioned solar PV and wind projects.
Measurable improvements in all infrastructure services transmits the best possible message for investors and taxpayers. With a unified response, everything is possible for South Africa in conjunction with its global trading partners.
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• free exhibition stands
• complimentary delegate registrations
• brand representation at the event, promotion of your company in the conference proceedings magazine and online
• free entry for guests at the social evening and much more.
Asset management: the enabling tool for efficient infrastructure performance
New infrastructure builds are essential catalysts for socioeconomic growth, whether it’s an airport or port, a major national route upgrade or a greenfield smart city development.
In parallel is the vital need to manage existing infrastructure – both in terms of daily highfunctioning utilisation, as well as optimum lifecycle return on investment. There’s a uniform asset management (AM) requirement for all public works endeavours, spearheaded at town and city level by municipal engineers. We must collectively work towards combatting underinvestment on maintenance.
Within the mix, adequate budget allocations and efficient expenditure are essential. We also need to be far more cognisant of climate change impacts in terms of how we design new works and retrofit older ones to maximise sustainability. In areas like Green Building, this has the added benefit of saving on energy costs from conventional coal-fired power, while contributing to global Net Zero emission targets.
The same principle applies to methane waste-toenergy initiatives in areas like landfills, wastewater treatment plants, and organic waste energy conversion. The ongoing changeover from energy intensive older metal halides to energy efficient LEDs for streetlighting is another example of effective AM in practice.
IMESA and IFME collaboration AM and sustainability form integral components of IMESA’s objectives, with a key emphasis on knowledge exchange via our membership of the International Federation of Municipal Engineering (IFME). This network, which continues to grow, provides an essential platform for collaboration in solving common challenges faced within municipalities globally.
Irrespective of whether it’s a developed or developing country, there’s a common IFME and IMESA priority focus on ensuring that governments – as the predominate source of infrastructure funding – plus communities, have a full understanding of why investment in municipal engineering capacity is so essential in terms of meaningful service delivery engagement. It also provides an opportunity for extensive outreach programmes.
These include educating all stakeholders on the role that civil engineers play in society, as well as promoting understanding and acceptance of conservation programmes. Prime examples are effective water consumption practices and eradicating litter in our catchments, which impacts everything from river water quality to blocked stormwater drains that exacerbate flooding risks.
For any country, and especially water stressed nations like South Africa, demand management and longer-term security of supply is in the spotlight. These issues where reemphasised at the 2025 Water and Sanitation Indaba held on the 27th and 28th March 2025 at the Gallagher Convention Centre in Midrand, Gauteng.
The overriding objective is to ensure complete No Drop, Blue Drop and Green Drop compliance within every municipality, all of which requires proactive AM – managed by qualified personnel as an essential requirement.
Currently, 105 out of 144 Water Services Authorities are experiencing a delivery crisis. At the Indaba it was also highlighted that South Africa’s “average consumption of water per capita per day is 218 l/c/d, compared to an international average of 173 l/c/d”. It’s too high and comes back to the need for a universal acceptance for sustainable water utilisation.
Intelligent infrastructure
Thanks to advancements in information technology (IT), we have a whole new suite of tools at our disposal to intelligently collect, analyse and interrogate infrastructure systems data, due to software advancements powered by Artificial Intelligence (AI). This has a direct bearing on operations and maintenance (O&M) improvements, as well as new design and
Tooley, Pr Eng Hon FIMESA
IMESA President: 2024-2026
construct programmes within the rapidly evolving 3D BIM environment.
The latter provides a collaborative IT platform for the execution of all infrastructure installations from inception through to their effective end of life. Locally and around the world, the private and public sector – utilities, consulting engineers, contactors and OEMs – are at various stages of universal adoption and it’s revolutionising how municipal engineers can maximise AM interventions.
AM training initiatives
IMESA recognised the need for AM benchmarked practices in South Africa more than 10 years ago. A forerunner was the introduction of the AMPLE (Asset Management Programme Learning Environment) software tool, following a licensing user agreement concluded in August 2012 with GHD’s Global Asset Management Group.
We are now in discussions with our IFME partner based in Australia – the Institute of Public Works Engineering Australasia (IPWEA) – to explore new partnership opportunities. IPWEA is a major changemaker within the AM sector at home and abroad, fielding a comprehensive suite of training programmes in accordance with the latest international guidelines. Locally, this potential collaboration could result in online IPWEA training being made available for our engineering practitioners.
Ultimately, enabling municipal infrastructure drives economies, and AM is at the heart of the process, backed by best-in-class supply chain management. This requires capable and committed engineers, together with an informed and supportive municipal management framework. Both must be equally accountable for deliverable outcomes.
With these two key elements in place, we have the essential ingredients to effect cost-efficient and effective sustainable development that nurtures a healthy and prosperous society.
Geoff
CELEBRATING 156 YEARS OF EXCELLENCE IN 2025
AMMANN’S SOUTH AFRICAN ARM EXPANDS ITS ASPHALT PLANT FOOTPRINT
Across the globe, Ammann Group Holdings AG (the Ammann Group) – a leading Swiss multinational OEM founded in 1869 – is dedicated to providing best-in-class solutions for the road construction market, serving more than 100 countries via a network of over 200 dealers and partners.
With more than 280 products available –encompassing both construction machines, asphalt and concrete mixing plants – there’s a fit-for-purpose solution for every customer and project, from major highways to urban resurfacing.
Within the Sub-Saharan Africa region, the Group is represented by its wholly owned subsidiary, Ammann Kenzam South Africa, based in Brakpan, Gauteng, which is also the
Perspectives of the ABC ValueTec 140 batch plant, which is designed to produce a broad range of asphalt mixes. Compared to competitor OEM plants in this segment, the ABC ValueTec claims the lowest product lifecycle cost
Ammann Group’s first fabrication centre on the African continent. This followed the acquisition of Kenzam Equipment in 2022, which was previously appointed as Ammann South Africa’s asphalt plant dealer in May 2020. Kenzam Equipment is a leading OEM in its own right for asphalt industry complementary products that include containerised emulsion
plants, bitumen drum decanters and bulk bitumen storage solutions.
Prior to that, Ammann South Africa first entered the local market in 2000 as the direct customer interface for its asphalt plant range, and from inception has been headed by Rocco Lehman as managing director. An asphalt industry veteran, Lehman has
worked on road projects in South Africa, as well as internationally during his career, and has a comprehensive understanding of what works best in practice – region by region.
“Roads are the essential backbone for any country in accelerating socioeconomic development. Here the Ammann Group’s solutions are designed to match local operating conditions and requirements. A case in point is the formation of Ammann America and the establishment in March 2024 of a new state-of-the-art facility in Columbia, South Carolina to exclusively serve the North American region,” says Lehman.
“Based on extensive industry research, Ammann developed the new ACP 300 ContiHRT continuous asphalt plant – which is being manufactured in the USA – specifically to meet North American customer requirements. This type of attention to detail is why Ammann remains a class leader.”
Solutions for Africa
For the African region, the bulk of the plants supplied are sourced from Ammann India’s facility in Ahmedabad to meet the requirements of developing markets –particularly in terms of tailoring solutions for the growing SMME contractor segment.
Here there’s an emphasis on simplified operations and maintenance, as well as rugged durability, but with a no-compromise approach to asphalt quality in meeting local and international pavement construction standards.
An ACC 120 CounterMix continuous mixing plant. This unit was custom built by Ammann Kenzam for legal on-road transport between construction sites
“Ammann has identified Africa as a major growth market. In response, the Brakpan facility was expanded in 2023 to boost our fabrication and service capabilities, including stores inventory. We’ve also focused on the recruitment of additional technical personnel to ensure that all customers – whether in South Africa or cross-border – receive the same after-sales support,” Lehman expands. “As a Group, we also recognise the vital importance of supporting start-ups and existing SMMEs in terms of technical advice and training services.”
As one of the top three economies in Africa (the others being Egypt and Nigeria) South Africa has the most extensive network on the continent – ranking 12th in the world and covering some 750 000 km (of which 158 124 km is paved). Egypt and Nigeria are currently ranked 24th and 34th respectively, so these are all high potential regions for Ammann.
“However, across the board, there’s a massive need for all African countries to keep place with intensified urbanisation trends, with a major emphasis on transportation engineering to unlock meaningful development,” Lehman continues.
“As for South Africa, the first priority should be to maintain and extend the life of existing road infrastructure, and in parallel to construct new
roads that link towns and cities, and connect core industries like mining, manufacturing and agriculture with local and export markets. Kenzam Equipment already had a wellestablished presence across Southern Africa and East Africa, and we’re leveraging this to our advantage.”
West Africa is a new frontier for Ammann Kenzam, which recently supplied and commissioned its first plant in Guinea. This included the supply of a 10-tonne constant output emulsion plant and a 55-tonne containerised bitumen storage tank facility.
Closer to home, over the past three years Zimbabwe has been one of Ammann Kenzam’s best cross-border markets, thanks to major local government funded infrastructure projects. In response to customer requests, orders have included the supply of trailermounted Ammann ACC 120 CounterMix continuous mixing plants, custom designed and configured at the Brakpan facility for legal on-road transport between construction sites.
“However, mobility comes at an added cost. It speeds deployment between sites, but unless that is a specific requirement, most customers opt for static plant set-ups,” says Lehman.
Positive market gains
Plant sales to date in or outside South Africa predominately comprise either ACC 120 CounterMix continuous mixing plants or ABC ValueTec 140 batch plants. Both are manufactured at Ammann’s Ahmedabad facility.
In total five asphalt plants were delivered to Southern African customers during 2024, making it one Ammann Kenzam’s best recent trading years. The first plant order for 2025 (an ABC ValueTec 140) was delivered in Q1 to a South African company based in Rustenburg for a project in Mooinooi. The deal includes the supply of a containerised emulsion plant.
For customers in South Africa and Africa, the ACC 120 CounterMix and ABC ValueTec series provide a class-leading value proposition. The ACC CounterMix range (available with outputs of 90 or 120 tonnes per hour) produces mix at a lower cost than traditional parallel-flow drummix plants and requires less energy to heat materials, contributing to reduced emissions.
From a batch plant set-up perspective, the ABC ValueTec comprises four models, with respective output capacities of 80, 140, 180 and 260 tonnes per hour and the capability to produce a broad range of asphalt mixes. Compared to competitor OEM plants in this segment, the ABC ValueTec claims the lowest product lifecycle cost.
Upgrades that optimise long-term utilisation
An additional benefit is that all Ammann plants can be refurbished, upgraded and retrofitted with the latest Ammann process technologies. Here, however, effecting the best return on investment hinges on ensuring that the refurbishment costs are 100% in line with future production needs.
Globally, there are many examples of Ammann plants 25 years and older that remain productive assets. As Lehman points out, the key to longevity is a rigorous maintenance regime, an area where Ammann provides expert technical advice and recommendations on the optimum timing for plant upgrades.
New developments like Ammann’s Connected Worksite solution now also provide an intelligent way to seamlessly integrate all phases of asphalt road construction with realtime tracking and reporting.
Upgraded facilities at the Ammann Kenzam fabrication centre, based in Brakpan, Gauteng, include extra cranage, new working platform areas, machinery and stores warehousing
SA public works projections
“Going into 2025, we’re highly optimistic that there will be intensified local demand for new and refurbished asphalt plants as South Africa enters a new era of buoyant construction activity,” says Lehman.
This viewpoint is supported by a positive spike in Ammann plant sales enquiries from the onset of the New Year, bolstered by the recent 2025 Budget speech delivered by Minister of Finance Enoch Godongwana. Over the next three years, the South African government has committed to spending more than R1 trillion on public infrastructure, with R402 billion allocated for transport and logistics. Breaking it down further, SANRAL has been allocated some R100 billion, while funding support will be allocated to provincial roads departments to reseal over 16 000 lane-kilometres.
“Whether as an asphalt producer, contractor, or both, partnering with the right OEM is interlinked to their business success and we are here to ensure that our asphalt plants deliver,” adds Lehman.
“That fact that Ammann can claim a track record of excellence for close to 16 decades speaks volumes. We’re invested in every country where we operate and committed to building long-lasting customer relationships,” Lehman concludes.
Bitumen storage tanks designed and manufactured by Ammann Kenzam
BIENNIAL PROJECT EXCELLENCE AWARDS CALL FOR ENTRIES
To recognise outstanding achievements in municipal infrastructure, we are calling for entries that showcase projects that demonstrate the best of civil engineering as a science and how engineering enhances the lives of the local communities, through excellence in:
1
ENGINEERING EXCELLENCE IN STRUCTURES & CIVILS
E.g. Projects demonstrating engineering science, use of alternate materials, innovative construction processes, etc.
Planning and design
Construction methods
Innovation and originality
Meeting social and technical challenges
Contributing to the well-being of communities
2
COMMUNITY UPLIFTMENT & JOB CREATION
E.g. Projects demonstrating labour-intensive construction, skills development, community awareness/participation, etc.
3
ENVIRONMENT & CLIMATE CHANGE
E.g. Environmental rehabilitation, renewable energy, drought solutions, coastal initiatives for rising sea levels, pollution control, educational/ technical initiatives, etc.
CLOSING DATE FOR SUBMISSIONS
03 July 2025
Only projects that have reached practical or substantive completion by 30 June 2025 will be accepted for the Excellence Awards.
Adjudicators reserve the right to reallocate entries in the 3 categories.
ENTRY FORMS AND AWARD CRITERIA
Available for download on the website: www.imesa.org.za
QUESTIONS
Contact Debbie Anderson on +27 (0)83 326 3050 or email conference@imesa.org.za
BUILDING SAFE, SUSTAINABLE AND DURABLE ROADS WITH AFRISAM
Whether it’s a rigid or a flexible pavement, every structure requires a fit-for-purpose design in accordance with strict engineering standards. IMIESA speaks to Nithia Pillay, Regional Product Technical Manager at AfriSam about the exact science of optimum material selection as an essential component.
Road construction projects require carefully specified materials to ensure longevity and performance. From AfriSam’s perspective, how important is the correct selection of cement and aggregates in road construction, and what are some of the common mistakes made when these materials are not correctly specified?
Road construction relies on the mechanical, chemical and physical properties of cement and aggregates to create the necessary structural integrity, allowing the road to withstand the required loads and environmental conditions. Incorrect selection of these materials will directly affect road performance, leading invariably to premature failure, increased maintenance costs and reduced lifespan.
Concrete roads, for instance, will have very different cement requirements to the more
common asphalt roads. Among the key factors for engineers to consider in the selection of cement are compressive strength and reaction rates. For instance, AfriSam Rapid Hard Cement gains strength very quickly, while our road stabilising cement, AfriSam Roadstab Cement, enhances certain properties necessary for competent subbase layers.
Cement selection depends on the environmental conditions; it is important to consider the material’s resistance to sulphate attack and alkalisilica reactivity as well as the risks of shrinkage and cracking. In the application of rigid pavements, the workability and curing requirements are also fundamental considerations. Technical mistakes in cement specification can lead to premature failure by way of aggressive environments, inappropriate cement content specification, ignoring supplementary cementitious materials which improve durability, and finally inadequate curing practices result in surface blemishes, cracking and strength deficiencies.
Aggregate selection will encompass wading through a vast array of specifics – shape and angularity, durability and hardness, moisture content and contaminants are a few of them. The desired end-result may detrimentally defer if gap graded aggregates are used, which lead to poor interlocking, reducing strength. Low crushing resistance of aggregates will lead to premature failures while aggregate associated with poor durability leads to excessive polishing, reducing skid resistance. High moisture content will lead
to water sensitive failures such as stripping in asphalt pavements. Lack of compatibility of aggregate to cement and aggregate to bitumen may lead to alkali-silica reaction with cement, while bitumen stripping can occur if aggregates have a high water affinity.
AfriSam takes a keen interest in ensuring optimal material selection by producing highperformance cements with tailored properties for road construction. Producing premium aggregates with validated properties ensures required specifications are surpassed. AfriSam also conducts on-site testing while providing technical support for the vast array of construction materials that it produces. AfriSam also prides itself on creating custom solutions for challenging environments. Significantly, all quarterly measured properties are documented in archives available on request. A technical reference guide is also available as a free download from the AfriSam website to aid the selection of suitable cements, aggregates and readymix concrete.
Adhering to technical standards and specifications is crucial for building roads that withstand traffic loads and environmental conditions. How does AfriSam ensure that its products align with industry standards, and what risks do construction professionals face when they deviate from these specifications?
AfriSam applies rigorous quality management and process control systems to ensure that its cement, aggregates and readymix concrete meet technical specifications, which underpin optimal road durability and performance. Building on AfriSam's
Road construction relies on the mechanical, chemical and physical properties of cement and aggregates to create the necessary structural integrity
ISO accreditation and the SANAS-certified Centre of Product Excellence, our Construction Materials business, which includes aggregates and readymix, will also soon be SANAS-accredited.
In addition to our own facilities, we use external SANAS accredited laboratories for specialised testing, giving road engineers added comfort in the integrity and accuracy of our test results. Our proficiency testing regime includes regular comparisons between our laboratories and outside SANAS-accredited facilities – to ensure alignment with best industry practices. In addition, our process control focuses on continuously testing the output from our cement, aggregates and readymix production facilities.
Proprietary products such as asphalt play an important role in road building, and AfriSam provides certain bespoke products for specific customers. We work with the customer to develop a solution in terms of the aggregate size or shape, for instance, which best suits their requirements. This applies to readymix solutions too where we partner with customers, such as piling and flooring companies, to develop and supply a concrete product that matches their equipment and product specification.
Deviation from specifications carries significant risks such as premature structural failures and the compromising of integrity and safety of roads. Non-compliance with requirements can also result in legal and financial repercussions, including potential lawsuits, project delays and reputational damage.
Emerging technologies, such as nanotechnology and advanced material processing are influencing modern construction methods. What innovations is AfriSam seeing in cement and aggregate production that could enhance road construction quality and sustainability?
AfriSam has pioneered the use of composite cements – which incorporate supplementary
cementitious materials such as ground granulated blast furnace slag (GGBFS) and fly ash. These materials not only reduce reliance on milled clinker and cut down on carbon emissions, but also enhance performance characteristics by improving the durability and workability of concrete.
One of our key developments has been AfriSam Roadstab Cement, a high quality composite cement engineered to improve soil stabilisation by reducing plasticity and enhancing strength. This gives road builders a more durable road base as both asphalt and concrete roads are highly reliant on the strength of their base for their longevity. Our concrete mix designs are also increasingly focused on enhancing sustainability, so we are constantly pushing boundaries in replacing clinker levels with other cementitious material. This allows road projects to reduce their overall carbon footprint as clinker is a highly energy-intensive element of concrete.
The construction industry is under increasing pressure to adopt more sustainable practices. How does AfriSam view the role of in-situ recycling and alternative material use in road projects, and what challenges need to be addressed to ensure compliance with technical standards while achieving sustainability goals?
AfriSam’s sustainability efforts include recycling initiatives such as incorporating returned concrete
www.afrisam.co.za
into construction materials for sub-base layers. Returned concrete can be treated in its fresh state, where it can be washed and separated out into its constituents. The aggregate can be reused, while the cementitious slurry can be reintroduced into the concrete batching process, as the cement particles remain active for a short period of time.
In its hardened state, concrete can also be recycled. At AfriSam, this material is recrushed for incorporation into G5 to G9 sub-base – thereby ensuring that waste concrete is repurposed rather than discarded.
Readymix plants use considerable volumes of water, mainly in the rinsing of readymix truck drums after concrete is delivered to customers. We channel this water carefully through a series of settlement ponds – allowing us to re-use this water in our concrete batching process. This has the dual benefit of recycling water containing cementitious material while also reducing the volume of potable water drawn from the municipality.
While the adoption of in-situ recycling and alternative materials offers significant environmental benefits, challenges in balancing sustainability with technical standards is always a reality. Recycled materials can exhibit variability in properties that may affect the end-product performance. The latter can be overcome, to an extent, by applying rigorous testing and adherence to established standards. Regulatory compliance and ongoing collaboration with regulatory bodies is key to update and develop guidelines that accommodate innovative materials without compromising safety and performance. AfriSam addresses these challenges via comprehensive quality management systems, continuous research and development, and active stakeholder engagements with industry.
AfriSam’s Roadstab Cement enhances certain properties necessary for competent sub-bases
Concrete mix designs are increasingly focused on enhancing sustainability
AfriSam works with customers to develop a solution in terms of aggregate size or shape to best suit their requirements
NEXOR SA
SHAPING A SUSTAINABLE FUTURE THROUGH INTEGRATED INFRASTRUCTURE MANAGEMENT
The built environment and road infrastructure sectors in South Africa stand at a critical juncture, facing a complex interplay of challenges that demand innovative and integrated solutions. Inadequate planning, misalignment with community needs, cost overruns, and a lack of datadriven decision-making are just some of the issues hindering economic growth, community development, and public safety. IMIESA speaks to Bongani Ndaba, Director at Nexor SA, about proactive engineered responses.
What’s the primary starting point for a turnaround strategy?
Addressing the challenges requires a paradigm shift towards effective infrastructure asset management, underpinned by credible data, stakeholder collaboration, and a commitment to sustainable development. Nexor, a multidisciplinary built environment firm, is dedicated to leading this transformation, guiding road authorities toward a future where infrastructure serves as a catalyst for progress and prosperity.
What are Nexor’s core areas of specialisation?
Nexor specialises in delivering comprehensive, full-lifecycle services tailored to the evolving
demands of large-scale infrastructure projects. As a multi-disciplinary built environment firm, our core areas of expertise include Infrastructure Delivery Management Services (IDMS), Programme and Project Management Office (PMO) Services, Turnkey Professional Services, Civil Engineering, and Principal Agency Services. Our mission is to assist road authorities in enhancing the condition of road infrastructure networks to better serve community needs. By leveraging advanced technologies and scientific data, we collaborate with stakeholders to provide realistic analyses and solutions. This ensures adherence to national regulations and policies, such as those stipulated by National Treasury, while delivering optimal service levels to communities. Our approach aligns with the principles of City Infrastructure Delivery Management Systems (City IDMS), which emphasise integrated planning, execution, and maintenance of infrastructure assets to achieve sustainable outcomes.
What are some of the key challenges of implementing an effective infrastructure asset management programme?
A critical challenge in infrastructure asset management is the credibility of data. Traditional methods, such as visual condition assessments, are often subjective, prone to human bias, and limited in scope. These methods fail to detect
Bongani Ndaba, Director at Nexor SA
subsurface issues, are time-constrained, and lack standardised evaluation criteria, leading to inconsistent reporting across regions. Additionally, visual inspections pose safety risks to inspectors, particularly on busy or hazardous roads.
To address these limitations, Nexor advocates for the integration of advanced technologies, including non-destructive testing and remote sensing through ground penetration radar. These innovations enhance the accuracy, efficiency, and safety of infrastructure assessments, ensuring data-driven decision-making.
How important is digitalisation?
Digitalisation is pivotal in managing and designing modern transportation networks. Our experience with institutions adopting automated data collection mechanisms demonstrates its transformative impact. Digital tools enable effective planning by providing reliable, scientific data, leading to cost savings, enhanced efficiency, and improved project quality. By leveraging digital, web-based, and cloudbased technologies, Nexor facilitates real-time monitoring of compliance, project progress, and road conditions through its trademark software, IDMS Plus.
In addition, Nexor’s strategic partner, ARRB Systems, has developed platforms for Bridge Management Systems and Pavement Management Systems through strong user analytical interfaces that can be used to provide a basis for utilising road condition data to inform meaningful maintenance management plans and strategies. This aligns with the City IDMS framework, which emphasises datadriven strategies to optimise infrastructure performance and ensure long-term sustainability.
What technologies does Nexor employ?
Nexor invests in innovative systems to empower professionals and ensure compliance with design standards and construction regulations.
Our digital platforms enable real-time monitoring of project lifecycles, gate progression, and road condition data. These tools enhance safety by identifying and addressing potential issues promptly, such as traffic conditions, structural health of bridges, and road surface integrity.
How can technology improve road safety?
Road safety is a cornerstone of Nexor’s asset management strategy. We partner with entities implementing the International Road Assessment Programme (iRAP), a global initiative that evaluates and rates roads based on safety features. iRAP’s Star Rating system provides objective assessments and practical tools to create safer roads, reducing the risk of traffic injuries and fatalities.
Nexor recognises that road safety is a shared responsibility. While road authorities play a critical role, public adherence to safety regulations is equally essential. Our efforts align with IDMS and C-IDMS principles, which prioritise safety and inclusivity in infrastructure planning and execution.
What does the future hold for Nexor?
As a trendsetter in infrastructure delivery and management, Nexor remains committed to innovation and excellence. Our focus is on enabling road authorities to improve network conditions through advanced data collection and analysis. This ensures the effective planning and execution of priority projects that meet community needs while adhering to national policies and industry standards.
By integrating IDMS and C-IDMS principles into our services, Nexor aims to enhance compliance, accountability, and sustainability across all levels of infrastructure management. Our expertise ensures that we continue to deliver impactful solutions that drive economic growth, community development, and longterm resilience.
What does a legacy of progress mean in practice?
The roads we build are more than just pathways; they are arteries of progress, connecting communities, driving economies, and shaping the very fabric of our society. Yet, the challenges we face in infrastructure development demand a new vision, one that transcends traditional approaches and embraces the power of data, innovation, and collaboration.
At Nexor, we believe that infrastructure should not only be functional but also sustainable, equitable, and a source of pride for the communities it serves.
Nexor is a next generation organisation driving a legacy of progress. We aim to transform our infrastructure landscape with strategic partners, creating a future where roads are not just conduits for transportation but also symbols of opportunity, safety, and resilience for a brighter tomorrow. The time for transformative action is now.
www.nexorsa.com
PREVENTATIVE MAINTENANCE THRESHOLDS
THE DRAWBACKS OF POTHOLE FILLING PROGRAMMES
South Africa’s secondary and tertiary road network continues to deteriorate at an alarming rate, with a growing maintenance backlog that will cost hundreds of billions to remediate.
By Christian A. Mulol*
Widespread pothole repairs have become a necessity as a short-term safety measure, but this doesn’t address the root causes, which include inadequate technical capacity within provincial and municipal roads departments. Either way, pothole repairs cost money and need to be efficient, which requires a correct assessment and repair methodology.
TABLE 1: List of case study roads Road
Road 1 KwaZulu-Natal / King Cetshwayo
Pothole repairs delay the inevitable, and an early intervention can extend pavement life at a fraction of the cost of a new road if done correctly. However, sometimes a deep rehabilitation is the best and only recommended approach.
To prove the point, members of the CSIR’s Smart Mobility: Pavement Design and Construction team conducted studies on five actual rehabilitation and maintenance
projects within KwaZulu-Natal and Limpopo (as shown in Table 1). These were all Category B roads as per the TRH4 classification.
The roads were investigated for their visual conditions following the TMH9 (1992) guidelines by mapping of all their surface and structural defects’ respective degrees and extents at 20 m intervals. Potholes with degree of failure greater than three were selected (where a degree of five is the worse level of failure severity). The falling weight deflectometer (FWD) deflection bowl parameters strip map to determine the road layers structural conditions rating criteria, shown in Table 2, were superimposed to the mapping of the selected potholes and repair patches from previous maintenance interventions.
The deflection bowl parameters considered for the analyses were the maximum deflection (Y-Max), the base layer index (BLI), the medium layer index (MLI), and the lower layer index (LLI). For this specific study, the MLI and the LLI were not considered. The approximate locations within the selected subgrade (SSG) horizon, corresponding to the MLI, and within the subgrade location (SG), corresponding to the LLI, were found
to have less probability of interfering with pothole repair excavations.
The Y-Max measures the total pavement deflection from the pavement surface, while the BLI captures the deflection parameters within the pavement base layer horizon. In this scenario, the pothole repair activities are likely to be concentrated within the surface, wearing course, or the base layer of a distressed pavement.
Following the deflection bowl parameters criteria provided by Table 2, the structural conditions of the roads were evaluated. For each location corresponding to a FWD measurement, the condition of the pavement was rated as being in a sound condition, a warning condition, or a severe condition.
It should be noted that the FWD measurements were undertaken for each travelling direction or lane. As such, the overall measurements of each deflection bowl parameter corresponded to the worse
reading between the different travelling directions for the given location or chainage.
Effect of old patches on pavement performance
Before the future anticipated performance of any pothole repair could be predicted, the performance of the old patches was evaluated. As shown in Figure 1, it was often observed that these generally incorrectly constructed patches invariably performed
poorly – worse than the older pavement structure they were intended to improve.
This is often the case due to substandard construction techniques, and the use of different materials than those initially used within the adjacent older pavement structure, leading to differential settlement, or differential consolidation.
The study showed that the pothole repairs were often confined, making the uniform compaction of the patched area difficult to
FIGURE 1: Patch performing worse than adjacent older road
achieve. As depicted by Figure 2, there was also an issue with new patching adjacent to older pothole repairs. In many cases the newer patches had also failed. If the older pothole repair had been efficient, this would have helped in preventing a new pothole repair.
Patches, potholes, and FWD parameters mapping
The observations illustrated by Figure 1 and Figure 2 were further confirmed by analysing the condition of the roads based on the FWD deflections. For ease of comparison, the older pothole repairs, based on the evidence provided by the old structural patches observed through the visual assessment of the road, were superimposed on the FWD strip map. Both the old and new patches
as well as the potholes to be repaired were superimposed on the FWD strip map.
For some sections of Road 1, it was evident that previous years’ pothole repairs (current old patches) did not prevent the severe deterioration of the road. The same pattern was observed for Road 3, Road 4 and Road 5. This being an indication that repairs on the surface did not address deepseated problems that ended up requiring resurfacing.
The same conclusion was arrived at with Road 2 with the only difference that the Y-Max and BLI deflection bowl parameter readings had a warning rating instead of severe.
Even if the maintenance teams had meticulously followed the recommended
FIGURE 2: Older patch indicating poor performance
repair standard, the evidence shows that the repaired potholes were destined to fail again. This is because the locations of the identified potholes were within sections that were already showing severe distress both regarding the Y-Max or the BLI parameters. In other words, the low-lying layers were already failing and there was little chance that a surface patch was going to slow down the deep-seated failures.
Correct methodology
This shows that for any pothole repair to be effective within the uniform section of severe Y-Max and BLI deflection destress, the pothole repair will need to be carried out by extensive excavation or stabilisation that is deeper than the base layer. In other words, a heavy rehabilitation approach rather than a pothole repair might be the most effective intervention. One of the drawbacks of such localised heavy rehabilitation is the difficulty of working within a confined area, making the compaction of layers difficult to achieve. Another drawback is the “chasing after pothole repairs syndrome”, whereby the whole road is not attended to, but rather an isolated area dictated by the presence of potholes. This will result in the introduction of non-uniformity of the pavement structure. Such a non-uniform section will present further challenges in terms of trustworthy condition assessment for future maintenance and rehabilitation works.
As was alluded to earlier, the biggest drawback of “chasing after pothole filling syndrome” is that such repair would bandage over a deep-seated problem if not done properly. On the other hand, the absence of potholes does not mean the absence of deep-seated defects. During the analysis, severe conditions of deflections were sometime recorded over areas without any pothole formation. Other road defects were more competent in highlighting deep-seated problems than the presence of potholes. It is therefore not true that a direct relation exists between pothole formation and road deterioration.
In some instances, potholes are only the symptoms, and the source of the problems lies deeper within the pavement. Such deeper problems are the reason why poorer Y-Max and BLI scores are still recorded even in the absence of potholes. This also means indirectly that shallow pothole repairs will not
necessarily eliminate the underlying and deepseated source of the problem.
Such deep-seated problems have the tendency of resurfacing at a later stage by reflecting the defects through the shallow pothole repair. In the long run there is a risk of investing scarce financial resources only to end up with a similar result as the ones depicted in Figure 1 and Figure 2. Hence, pothole repairs are not guaranteed to always yield the desirable outcome, especially when the repairs are not undertaken appropriately.
Conclusion
It could be concluded from the results of the analyses that the previous maintenance patches, which probably resulted from previous pothole filling interventions, did not necessarily improve the reading of the Y-Max and BLI deflection bowl parameters of the respective roads. In most cases, the location of the patches still corresponded to the location of severe Y-Max and BLI deflection bowl readings.
It was also observed that the sections with patches did not necessarily perform better
This is an edited version of Paper 10: “Drawbacks of pothole filling programs as a preventative maintenance measure: Study based on non-intrusive pavement defects investigation” authored by Christian A. Mulol and presented at the 87 th IMESA Conference in November 2024. The full paper, including references, can be downloaded at www.imesa.org.za
than those without patches. In many cases, other identified surface and structural defects were shown to be equally critical in influencing the deterioration of the pavement Y-Max and BLI deflection parameters.
Therefore, selective emphasis on pothole repairs runs the risk of ignoring other defects that could be more revealing about the poor pavement layer conditions. Additionally, when pothole filling is implemented in isolation, one runs the risk of adopting a “cheaper” preventative maintenance intervention where a minor or major rehabilitation approach would
have been the optimal solution and more costeffective longer-term solution.
To confirm the best approach, any pothole filling initiative should always be combined with other intrusive or non-intrusive evaluations of the underlying layers of the road pavement. And in all respects, the findings and recommendations must be made by a qualified and experienced pavement engineering practitioner.
*Research Group Leader, Smart Mobility: Pavement Design and Construction at the CSIR
GREYWATER REUSE A PROMISING METHOD FOR FOSTERING WATER CONSERVATION IN GREEN BUILDINGS
Water scarcity is becoming a worldwide issue rather than a remote concern. This is exacerbated by continuous strain on the limited supply of water due to urbanisation, population growth, and the increasing effects of climate change.
According to the International Water Management Institute, urban water consumption is forecasted to increase from 1995 to 2025 by 62%. It has therefore become imperative that we find adaptable solutions where we can maintain existing water resources while seeking methods that reduce potable water demand. Greywater reuse is receiving more traction as a solution to urban water management as it offers a straightforward on-site but effective option to shift our water-use patterns.
What is greywater?
Greywater is used water collected from bathtubs, showers, washing machines, even sinks and can be reused/recycled for other purposes. Greywater makes for as much as 70% of all residential buildings’ water use.
Although greywater and blackwater are typically combined, separating the two, greywater on its own provides several reuse opportunities such as toilet flushing, and garden irrigation. This can additionally assist in lowering potable water use in arid areas by up to 30% for households and up to 60% for corporate buildings. Furthermore, saving money on garden irrigation through reuse can boost household savings by 40%.
Greywater can be collected from the source by installing a plumbing system from an outlet of a bathroom/kitchen to a garden or for toilet
Sources:
flushing. To this, a greywater treatment system such as green walls can be installed to help filter large particles, nutrients and pump treated water through irrigation pipes. Blackwater on the other hand, is toilet water that contains faecal matter and urine. Faecal matter is a breeding ground for harmful bacteria and pathogens that can cause diseases.
Advantages of using greywater for green buildings
• Water conservation: The use of greywater provides us with an opportunity to use an average of approximately 35 – 234 litres (per person per day, depending on lifestyles) of greywater which can be repurposed for garden irrigation or toilet flushing where little human contact is achieved.
• Enhancing the EDGE (Excellence in Design for Greater Efficiencies) standard: The incorporation of a greywater reuse system can play a pivotal role in diminishing the reliance on potable water, consequently elevating the overall EDGE score of the green building.
• Cost-effective: The use of greywater is inexpensive and for this reason water bills can be drastically reduced while investing in a greener future.
• Lush landscapes: Watch your garden flourish! Greywater provides essential nutrients such as total nitrogen (2.75 to 21.00 mg/ℓ) and total phosphorus (0.062 to 57.00 mg/ℓ) that mainly
originate from the kitchen (kitchen residues/ waste) and hand basins (soap), respectively (Gholami et al., 2023). These nutrients nourish our soil and plants, promoting healthier growth and vibrant blooms.
• Resilience to drought: Water-efficient measures (greywater reuse) make green buildings more resilient to water scarcity and drought conditions, ensuring continued operations during challenging times.
Safe and sustainable use of greywater
• Greywater containing potentially infectious pathogens should not be used for overhead irrigation. This includes water used to wash nappies or soiled sheets.
• To reduce odour and bacteria, greywater should be used within 24 hours of collection.
• To avoid waterlogging and prevent root damage, it's critical to disperse greywater uniformly in your landscape (and not just in one spot).
• When irrigating with greywater, it is not advisable to use spray irrigation. This is primarily due to the increased risk of exposing people to greywater.
• Where possible, greywater should not be used for an extended period in the same area. This may result in the accumulation of different components found in greywater that may negatively impact the plant’s health.
Rand Water is upholding its commitment to encourage water saving behaviours among its supporting clients in its service region by using the Water Wise brand.
Gholami, M., O’Sullivan, A.D. & Mackey, H.R. (2023) ‘Nutrient treatment of greywater in green wall systems: A critical review of removal mechanisms, performance efficiencies and system design parameters’, Journal of Environmental Management, 345, p1-18.
Greywater can be collected and stored from the source by installing a plumbing system from an outlet of a bathroom/kitchen
A small-scale greywater system
Green walls can be installed to help filter large particles, nutrients and pump treated water through irrigation pipes
As South Africa faces rising energy costs, water shortages, and growing investor pressure for assets that meet Environmental, Social, and Governance criteria, the property industry must adapt with sustainable responses.
Contrary to common misconceptions, green buildings are not inherently more expensive. In fact, they deliver long-term financial and environmental benefits, often at little to no extra cost.
The Green Building Council South Africa (GBCSA), an independent third-party verifier, defines a green building as one that reduces its environmental impact across multiple areas, including energy and water efficiency, material use, waste, indoor air quality, transport access, and socio-economic benefits.
“People often assume green buildings are about extravagant add-ons like solar panels,” says Lisa Reynolds, CEO of GBCSA. “In reality, they prioritise efficient design – reducing resource consumption while enhancing occupant well-being and long-term sustainability.”
To underscore this viewpoint, according to the MSCI South Africa Green Annual Property Index (2023)*, over eight-years, green-certified buildings used 7% less electricity and 21% less water per square metre.
“The greatest energy saved is the energy never used,” says Reynolds. “Energy efficiency is the ‘first fuel’ – it should always come before adding solar panels or high-tech solutions. Simple design choices like passive cooling, insulation, efficient lighting, responsible material selection, and water and waste reduction strategies can dramatically lower a building’s environmental footprint while keeping costs in check.”
From a construction perspective, a 4-star Green Star-certified commercial building costs about the same as a conventional one. “You can build a ‘Ferrari’ of a green building if you want to, but you can also achieve certification at industry-standard costs by applying best practices,” says Reynolds.
Green buildings: Simple, resilient, and cost effective
GBCSA’s 2022 Cost of Green Report* found that the average “green premium” for office projects was 3.15% for projects certified between 2019 and 2021, with steady decreases year-on-year. Fast-forward to 2025, and you’re looking at negligible cost differences.
Financial performance:
Green buildings outperform Green-certified buildings studies also prove that sustainability can be profitable through their better financial returns. In this respect, the MSCI Index reports that green-certified offices in South Africa delivered a total return of 5.8%, outperforming similar non-certified offices by 1.5 percentage points. Net operating income per square metre was also 30% higher for green-certified offices.
“The data proves that certified buildings attract higher rental yields, lower vacancy rates, and offer stronger returns,” says Georgina Smit, Head of Technical at GBCSA.
Furthermore, certified green buildings attract additional financial benefits such as lower risk profiles for investors, sustainabilitylinked financing, green bonds, and preferential loan rates.
The Visual Arts Building at Stellenbosch University, a heritage structure constructed in 1905, has achieved a prestigious 6-Star Green Star rating from the GBCSA under the Existing Building Performance (EBP) version 1 tool
The Hasso Plattner School of Design Thinking Afrika (d-school Afrika) at the University of Cape Town exemplifies world-class sustainability with its 6-Star Green Star rating from the GBCSA
For existing buildings, retrofitting is the key to achieving sustainability goals. This can be achieved through simple upgrades such as LED lighting and insulation. In addition, smart building management systems can cut energy use by 30-50%, with payback periods as low as 3 to 7 years.
“One of the easiest ways to improve a building’s energy efficiency is by shading windows to reduce heat gain. It’s more costeffective than retrofitting double glazing,” says Reynolds.
Mitigating greenwashing
However, as demand for sustainability grows, so too does the risk of companies making unverified environmental claims known as ‘greenwashing’. GBCSA provides accountability through independent, third-party verification, ensuring that green buildings meet measurable performance benchmarks rather than selfdeclaring sustainability.
GBCSA also drives systemic change beyond certification. As a not-for-profit organisation, it collaborates with relevant stakeholders such as the Presidential Climate Commission, municipalities, and the private sector to shape green building regulations and financing solutions.
“The evidence is clear. Green buildings perform better than their counterparts and cost the same (or less) in the long run. They are the only viable way forward as energy and water costs rise,” Reynolds concludes.
*A new Cost of Green Report and MSCI Green Property Index are set to be released later in 2025.
MANAGING BI-DIRECTIONAL FLOWS FOR RENEWABLE GROWTH MODERNISING THE POWER GRID
Modernising South Africa’s power grid to manage bi-directional flows is essential for enabling renewablepowered economic growth, following the crippling effects of prolonged periods of load shedding.
Even though South Africa has experienced a protracted spell without load shedding, electricity outages persist due to network overloading. This is largely due to load reduction efforts to protect transformers from excessive demand and electricity theft.
“The impact of loadshedding on South Africa's economy has been severe, particularly in key sectors like mining, which has experienced significant operational challenges due to unreliable power supply,” says Nishan Baijnath, Systems Architect, Power Systems at Schneider Electric.
“Beyond mining, other sectors such as manufacturing, transportation and construction have also been severely impacted. The lack of reliable energy has resulted in decreased production capacity, increased costs and lost economic opportunities. For example, in the food sector, the energy crisis
Nishan Baijnath, Systems Architect, Power Systems at Schneider Electric
has contributed to inflation, affecting both producers and consumers.”
Renewables uptake
Baijnath points out that in 2023, the installed capacity of solar panels in commercial, industrial and residential sectors exceeded 3.2GW, with renewable energy sources accounting for 8.8% of the country’s electrical energy.
“Because businesses, households and industries needed to get through multiple stages of rolling blackouts, they installed sufficient capacity to do so. However, this now means they are generating more electricity than they need and this additional capacity can essentially be sold or exported back into the grid,” Baijnath continues. This has resulted in the energy flow becoming bi-directional, rather than just the one-way flow from the utility or municipality to the consumer. In response, this shift has necessitated a robust framework for managing these resources effectively via a Distributed Energy Resource Management
System (DERMS). The latter is the software platform that manages and optimises the operation of Energy Resource (DER) systems that include PV solar installations.
“Utility control centres are primarily designed for real-time operations. However, with DER management, we incorporate metadata to gain a predictive perspective,” he explains.
“This allows utilities to forecast production based on weather data for specific areas. As they look ahead, they can develop both future projections and real-time constraint management. This helps them understand the energy available for deployment now and what could be available later.”
Future projections
Baijnath notes that the challenges lie in managing these resources while recognising the inherent flexibility in the system. Some customers can participate in demand response programmes, opting to reduce their load because they have alternative energy sources for their operations. Utilities must effectively address these challenges by measuring and managing DERs as a complete, integrated system.
“DERMS can introduce a completely new energy model that incorporates time-of-day usage, which is effective because you can predict both potential load and generation at specific times, enabling energy trading capabilities. DERMS essentially allows for orchestration across the grid, managing individual distributed energy resources as a single system,” he expands.
Baijnath states that adopting digital solutions, primarily software platforms, is crucial for effectively managing electrical networks. These solutions provide access to vast amounts of data, which is essential for efficient network management.
“In power systems, everything revolves around mathematical calculations based on load and generation, which are constantly changing. Without the ability to process and analyse this data, it's impossible to manage the electrical network effectively or efficiently,” Baijnath concludes.
UNDERGROUND CABLING PROJECTS ENHANCE
EFFICIENCIES
The City of Cape Town’s R6 million underground electricity cabling project in Sea Point is nearing completion and is one of the city’s interventions to combat crises level electricity infrastructure vandalism across the metro. In total, approximately 2 000 m of overhead electricity conductors will be removed and replaced in targeted areas of Sea Point.
The project commenced in 2024, with the city’s teams removing 22 electricity poles and electricity cabling in five roads within Sea Point. The next phase covers a further four streets, with the overall programme scheduled for completion in May 2025.
Other allied interventions city-wide have also been completed or are in progress. For example, in the previous financial year (2023/2024), the city completed major overhead to underground infrastructure projects in areas that include Bonteheuwel, Kewtown, Kensington, Pinelands and Woodstock.
As one of the city’s vandalism and theft deterrents, the city utilises aluminium cabling for streetlights and for its low voltage (LV) and medium voltage (MV) networks due to the material’s lower resale value compared to copper.
In addition, the decision to switch to underground cable infrastructure passes on benefits that include reduced susceptibility to weather related faults, such as storms and falling trees. Underground cabling also reduces the risk of electrical accidents from people, cars and animals coming into contact with power lines. Furthermore, eliminating poles and overhead power lines greatly improves urban aesthetics.
Comments Alderman Xanthea Limberg, Cape Town’s Mayoral Committee Member for Energy: “The city’s transition to underground electricity cabling is a key component of our long-term vision to modernise and enhance the reliability of our infrastructure and network. We are committed to investing in our electricity infrastructure to ensure it remains resilient and reliable to support the prosperity of our communities.”
The City of Cape Town’s R6 million underground electricity cabling project in Sea Point will help combat infrastructure vandalism
SIKA: BUILDING BRIDGES TO A STRONGER FUTURE
Sika offers a comprehensive range of world-class products and systems designed to tackle the unique challenges of bridge construction and maintenance. From concrete admixtures to watertight joint systems, Sika ensures superior performance, durability, and safety for all bridge projects.
OUR TAILORED SOLUTIONS INCLUDE:
High-performance concrete admixtures
Advanced watertight joint systems
Liquid-applied waterproofing membranes
Reliable concrete repair and corrosion
protection systems
Post-tensioning and structural strengthening
Call us for more info: 031 792 6500 www.sika.co.za
UPDATED H&S LEGISLATION AFFECTING THE CONSTRUCTION SECTOR IN 2025
The Department of Employment and Labour (DEL) has made some significant legal changes over the past few years. This includes recent amendments to the Occupational Health and Safety Act (OHSA) No. 85 of 1993, which place a key emphasis on mandatory risk identification and management.
By Claire Deacon, PhD (Construction Management)
To date in 2025, three new regulations have been promulgated, as well as a draft of the Construction Regulations (CRs), last updated in 2014. Regulations which have been promulgated have brought the issues dealt with into a more modern era, and we discuss some of them and their implications in practice. The key question is, relative to the CRs, are the proposed changes adequate in terms of voluntary versus prescriptive health and safety (H&S) adherence?
Legal compliance versus better practice
It is a common view by organisations and management that one only needs to worry about the law to be compliant. This perception could not be further from the truth. The
legislative framework is just that, a framework to be built on and not prescriptive in every detail. There are areas that are implied, rather than specifically stated, such as promoting and maintaining a positive safety culture.
The OHSA and its amendments – although prescriptive in parts – is meant to enable employers to proactively develop and build their own unique H&S solutions within the legal parameters enacted. This requires a comprehensive approach beyond merely identifying risks relative to the type of work done. Examples include factors such as building codes, standards, and registration criteria for professionals.
In my view, legislation becomes more prescriptive when employers don’t apply their minds with respect to risk identification and management.
Common elements of the updated legislation
In line with the employer being responsible for a healthy and safe (H&S) workplace, virtually every part of the existing framework, risk assessments, management, mitigation and training are required. The updated regulations continue, if not more strongly, on the need to use risk assessments as the pri mary driver for compliance.
Consultation and engagement with H&S representatives, and the H&S committee is required. This includes comprehensive training about the subject (including refresher training), controls to be placed and medical surveillance.
Dr Claire Deacon, Director: Association of Construction Health and Safety Management (ACHASM)
Physical Agents Regulations
Formerly known as the Environmental Regulations for Workplaces, 1987, the new Physical Agents Regulations (PAR) cover a much broader range of risk categories in the workplace, such as cold and heat stress, radiation, vibration, and illumination.
The PARs are managed by the employer and in most cases will be monitored by an Approved Inspection Authority (AIA). AIAs are highly trained occupational hygienists approved by the DEL.
AIAs can specialise in what they monitor, whether asbestos, dusts, chemicals, vibration, etc. AIAs are specially trained to follow measuring standards, using calibrated equipment and accredited laboratories. Results from such surveys guide employers in managing their H&S programmes, as well as medical surveillance. Results indicate compliance with standards and whether employees have any signs and symptoms of occupational diseases.
Medical surveillance requirements are extensive and prescriptive. Reputable and professional Occupational Health services used on a regular basis would be the best approach to compliance.
Vibration is the new kid on the block. Hand arm vibration (HAV) and whole-body vibration (HBV) have implications for designers, manufacturers and employers. Consideration for the type of plant and equipment, maintenance, etc., have a direct impact on employee health. Vibration is likely to affect hearing loss, increasing the risk. Therefore, the Noise Exposure Regulations (NERs) need to be referred to.
General Safety Regulations (GSRs)
The GSRs have also been amended. Additional factors to the current regulations include fire safety, requiring, among others, evacuation routes and multiple fire exits that are
appropriate for the number of people likely to use the building.
Flammability of materials and combustible materials must be considered for both building materials and also what is kept in the area. Flood risks must also be considered, and appropriate warning provided.
Workplaces need to allow for at least 2,25 m 2 of floor space per person. While the floor space was always required, it was formally in the Environmental Regulations. There are overlaps that relate to the Ergonomics and Construction Regulations. The designs relating to fire and flammability, working space and flooding now need to be considered during design of spaces, or when doing refurbishments.
The Noise Exposure Regulations (NERs)
The NERs have also brought updated practice into play. Hearing protection products are now referred to as hearing protection devices (HPDs). Designers, suppliers, importers and manufacturers must meet strict requirements, expanding on Section 10 of the OSHA. Workplace noise levels must be measured at least twice yearly and are covered in the PARs.
The NERs link to multiple factors, including where there are chemicals that can cause hearing loss, and whole-body vibration referred in the PARs. The Hazardous Chemical Agents Regulations (HCARs) were also recently updated.
Duties of employees have also become quite prescriptive relative to following instructions, training, and provision of HPDs including the wearing thereof.
The draft Construction Regulations (DCRs)
There are a number of semantic and “cleanups” in the DCRs. The exemption passed in 2014 relating to the H&S categories has been
included. Terms such as contractor, ergonomics, project and pre-construction information are some of the updated changes and additions to the definitions. However, is what is being proposed adequate, or a damp squib?
Focus is on lifecycle in terms of scope. There are changes to the permit requirements. This applies to projects now exceeding a year, CIDB grades 7 and above, and where structures are more than two storeys above ground. Changes are similar to the other regulations updates and aligns requirements with other standards and South African National Standards (SANS) codes. In my view more could be done, given that in many countries construction accounts for among the highest levels of accidents, fatalities, and occupational diseases. Clients and designers are overall responsible for designs and therefore “inherent risk”. For this reason, increased responsibility is needed at this end of the life cycle approach.
In conclusion
Most of the changes brought about in the now promulgated regulations bring the legislation into the current era. Alignment with international practice and updated standards and codes are also noted. Most significant are the enforced foundations relating to risk identification and management. As noted, however, legislation itself cannot manage risks that are created by an organisation and how it operates.
The DCRs are still open for comment until the 9 th June 2025 and should be reviewed by organisations and professionals alike to comment if needed. Our voluntary association, the Association of Construction Health and Safety Management (ACHASM), will be putting groups together to comment collectively on the DCRs. Ultimately, changes will reduce accidents, fatalities, and occupational diseases, making the workplace a safer place for all.
DESIGN AND PRODUCT INNOVATION DRIVE GABION GAINS
Taking a two-pronged approach, Gabion Baskets is making strong gains in the civil engineering and architectural markets with the introduction of new products that complement its current offering. A ramp-up in its training division is also creating greater awareness and appreciation within the construction industry for gabion systems as an environmentally engineered response to growing climate change threats.
Across South Africa erosion – exacerbated by extreme drought and flood cycles –has increased the demand for engineered gabion systems exponentially, with our project teams working nationally, and especially within KwaZulu-Natal where cyclical storm damage is undermining embankments, properties and riverine systems,” explains Louis Cheyne, managing director at Gabion Baskets.
In addition to manufacturing a full suite of gabion products, the company provides
technical design recommendations, subcontractor training, as well as turnkey programme management services for projects in South Africa and Africa. Prime examples of the latter include recent river embankment stablisation and mass gravity retaining wall installations for private developments in Zambia. Towards the end of 2024, Gabion Baskets also completed its first order for a mining client in Chad. This entailed the production and delivery of 25 tonnes of galvanised hexagonal double-twisted woven mesh gabion baskets.
Other cross-border work includes an order secured in April 2025 for the supply of standard and gab-tail gabions (the latter designed for added soil reinforcement applications) for a property development in Eswatini. In addition to providing a design proposal, the scope includes project management supervision.
The roads segment – traditionally a core market for gabion systems – is also gaining traction. Orders locally include the ongoing supply of gabion systems for the South African government’s rural bridges
CASE STUDY: DUNDEE REGION, KWAZULU-NATAL
1 This property near Dundee was exposed to an unstable boulder strewn slope, which presented a serious landslide risk
2 Extensive earthworks were required to remove loose rock materials and then reshape the embankment
3 Establishment of the 1 m high gabion wall at the top of the embankment
4 Construction in progress on the 2,5 m high mass gravity retaining wall at the base of the slope
5 Both walls at an advanced stage of completion
6 The remediated slope was covered with a soil filled and seeded geocell layer as an additional erosion protection measure. Once the plants are established, the slope will blend in naturally with its surroundings
programme, which is being rolled out nationally.
The most recent order in January 2025 was for four bridges within the Free State. These are bailey-type bridges, where the gabion component forms the abutments for the structures, as well as river-scour protection, where applicable.
Unstable slope stabilisation
A particularly challenging ten-week project was completed by Gabion Basket’s teams in January 2025 for a residential property near Dundee, KwaZulu-Natal. The scope entailed extensive slope stabilisation behind the property to counter soil movement and tumbling boulders that posed a growing hazard, with the potential for a major landslide.
Following a geotechnical investigation, the solution comprised a 1 m high bench cut mass gravity gabion retaining wall at the top of the embankment, and a 2,5 m high mass gravity gabion wall at the base of the slope
Gabion Basket’s design recommendation was in accordance with SANS 1200DK, with a comprehensive site plan developed to guide all aspects of the stabilisation process, ensuring safety and precision execution. Preparing the site required extensive earthworks to remove approximately 19 000 m³ of in-situ material, including boulder removal – the latter accounting for some 4 000 m3. For this phase, a rock barrier was constructed in-front of the dwelling to protect it from any rolling boulders dislodged during the excavation. In parallel, the sub-contracting team progressed with the assembly of the woven mesh gabion baskets that were used for the retaining structures. In total, some 410 tonnes of gabion rock-fill 3 4 5 6
immediately behind the property. Both the top and bottom gabion structures incorporate V-drain stormwater channels behind the walls, which are designed to divert runoff to soak pits. These in turn facilitate groundwater recharge.
was required and some 546 m2 of geotextile. The latter was installed behind and below the gabions to provided controlled permeability.
For the compacted and now stabilised slope, the client appointed a separate contactor for the installation of an earthfilled geocell covering layer with seeding to enable the growth of vegetation. Once these plants are established, the slope will blend in seamlessly with its surroundings.
“This challenging project is a great example of how a well-designed gabion intervention can solve the most complex erosion issues, in addition to providing a climate resilient solution,” says Cheyne.
Architectural penetration
Alongside recent civil engineering developments that include its barrier systems for flood and military defence, Gabion Baskets is progressively expanding its line of architectural products, which are formed using welded mesh gabions. As for its woven mesh solutions, welded mesh materials are manufactured and supplied by Gabion Baskets’ sister entity, Barnes Fencing Industries, using locally sourced steel wire. These welded mesh product designs cater for elements like freestanding walls,
GABION SIGNAGE
To reinforce the sustainability message, Gabion Baskets has launched a signage range fabricated using the same welded mesh employed to construct gabion systems like building cladding, staircases and retaining structures
boundary walls, landscaping, building cladding, and integrated steps and staircases – with provision for fixed lines and curvatures. “We recently went a step further and launched our welded mesh signage line, which has really taken off as clients immediately identify with the sustainability message,” Cheyne expands.
The boundary wall range was further extended recently with the introduction of a 2,4 m high and 76 mm thick welded mesh slimline fence product. This is designed to be filled completely or partially in sections with 19 mm aggregate in various colour options.
Anchored into a concrete base, the typical spacings between pillars is 3 m and clients have the option of a standard galvanised, powder coated or PVC finish. The latter provides the best longer-term durability.
SLIMLINE PERIMETER FENCES
Gabion Baskets has introduced a 2,4 m high and 76 mm thick welded mesh slimline fence product designed to be filled completely or in sections with 19 mm aggregate
“A key trend is an increasing request from clients for a fully integrated ‘green’ set-up. That often includes elements like gabion retaining walls and welded mesh gabion perimeter fencing to complete the engineered and aesthetic effect,” says Cheyne.
Knowledge sharing
“Building awareness forms a core part of our marketing strategy, which includes the facilitation of SMME sub-contractor development as the implementation arm for our solutions. Here we provide a range of comprehensive training programmes that are industry certified,” Cheyne continues.
“In parallel, we’ve decided to extend these initiatives by reaching out to the built environment industry at large through a series of webinars, entitled ‘Rock Solid Solutions.’ Delegate responses have been revealing – either showing a comprehensive understanding of gabion construction, or a limited exposure.
“However, in both cases, the feedback has been unanimous: gabions need a far more renewed focus, especially in terms of public works where they dominated in the past,” he adds.
“Aside from the environmental advantages, there’s a clear benefit in terms of their largely labour-intensive construction approach, opportunity for enterprise development and employment,” Cheyne concludes.
Enhancing public sector cyber resilience
As governments around the world face increasingly sophisticated cyber threats, the need for robust cyber resilience is more urgent than ever, writes Graham Brown, Country Manager for South Africa/SADC at Commvault.
Government entities often rely on basic antivirus solutions that, while helpful, are no longer sufficient to defend against modern cyberattacks. As threat actors become more sophisticated – utilising AI-driven tools to orchestrate attacks – the public sector is finding itself increasingly vulnerable.
The expansion of the attack surface is a key factor. As more government functions move to the cloud and hybrid cloud environments, the potential for entry points increases. Simple errors like poor configuration or reliance on legacy systems can provide cybercriminals with a foothold. Many government agencies are also still using outdated security methods, such as relying solely on firewalls or signaturebased detection, which simply cannot keep pace with the speed and complexity of today’s cyber threats.
Cleanroom technology
While the situation may seem daunting, it is important to recognise that the right technologies can make a significant difference. A prime example is cleanroom technology. In many cases, when systems are affected by a cyberattack, the recovery process can
be prolonged as organisations struggle to identify which systems have been affected. Cleanroom technology ensures that when data is recovered, it is done so in an environment that is guaranteed to be secure.
However, while countermeasure technologies are available, one of the key issues for public sector entities is budget constraints, coupled with a shortage of skilled cybersecurity professionals. This makes it challenging to adopt and implement the necessary security measures.
One solution is to shift from capital expenditure to operational expenditure by adopting cloud-based platforms that provide both flexibility and scalability. These platforms can reduce the need for large upfront investments, enabling governments to allocate resources more efficiently. Furthermore, by outsourcing certain cybersecurity functions or collaborating with third-party providers, governments can access the expertise they need without the burden of hiring large teams of specialists.
Embracing compliance
Looking ahead, the upcoming Joint Standard on Cybersecurity and Cyber Resilience, which takes effect in June 2025, will
impose new compliance requirements in South Africa. Going forward, governments will need to adopt minimum cybersecurity standards, including robust risk management, incident response, and data protection protocols.
By addressing the evolving threat landscape with innovative technologies and a focus on proactive, strategic resilience, the upside is that the public sector can safeguard itself against cyber threats while ensuring that essential services continue uninterrupted.
Graham Brown, Country Manager for South Africa/SADC at Commvault
LOCAL AND INTERNATIONAL PARTNERSHIP TARGETS BCMM WATER UPGRADES
A comprehensive feasibility study is underway to enhance the Umzonyana water supply system for the residents of Buffalo City, East London, aimed at improving overall water quality.
Spearheaded by the Buffalo City Metropolitan Municipality (BCMM), the project is being executed in partnership with the German Federal Ministry for Economic Cooperation and Development, which is co-funding the initiative, with South African consulting engineering firm, GIBB, appointed to co-manage local implementation.
This initiative forms part of a broader partnership between the City of Oldenburg and the United Nation’s Water Operator Partnership formed between BCMM and two German Water Boards, namely, Oldenburgisch-Ostfriesischer Wasserverband (OOWV) and Wupperverband.
The Umzonyana water supply system consists of the Umzonyana raw water dam and Umzonyana Water Treatment Works (WTW). In terms of the
current network, water is released from the Bridle Drift Dam into the Buffalo River after which it takes around 10 hours to reach the Buffalo River Pump Station (BRPS) weir. The raw water is then pumped through the BRPS rising main to the Umzonyana raw water holding dam. From there, water is fed from the raw water holding dam to the inlet structure of the Umzonyana WTW for treatment to potable water standards.
The feasibility study includes the following scope of works:
- The construction of an intake tower for the Bridle Drift Dam. Currently, this dam only has an outlet pipe constructed at the dam invert. The purpose of the intake tower is to extract the best quality water at variable depths, which varies depending on the seasons of the year.
- The installation of a new pump station and rising main from the Bridle Drift Dam outlet to the Umzonyana holding dam to:
i. Reduce water losses
ii. Eliminate the 10 hours delay of supply to the pump station, and
iii. Reduce the pumping height to save pumping costs
- Optimise and upgrade the capacity of the WTW for future water supply demands.
With substantial experience and broad expertise on both sides, the responsibilities for this project have been divided, with the German team focusing on the Bridle Drift Dam and intake tower, and water quality, while the local team headed by GIBB concentrates on optimising existing infrastructure and water movement.
A Google Maps perspective of the Umzonyana water supply system An overview of the Umzonyana Water Treatment Works
Effective cooperation between the parties is essential in order to share local expertise and exchange technology to achieve better project outcomes. GIBB’s insights have been particularly beneficial in adapting European methods to local conditions.
Pollution concerns
The team is in the process of formulating critical strategies aimed at optimising water quality to reduce turbidity and algal issues linked to thermal stratification.
According to Wiero Vogelzang, Infrastructure Water and Sanitation Services Technical Executive, and Victor de Wet, Technical Executive at GIBB, another critical aspect is the catchment area. The latter is facing pollution from nearby residential settlements and inadequate wastewater treatment, which adversely affects water quality.
Buffalo River Pump Station
In addition, complications arising from the BRPS have arisen. Any problems with the pumps can lead to significant delays in water supply. The solution being explored is the development of a pipeline that bypasses the pump station, potentially reducing the need for extensive pumping and improving long-term financial sustainability, as it could save about 10% of water lost through evaporation and infiltration during droughts.
The team is also addressing the efficiency and capacity of the water treatment and pumping systems serving the Greater Buffalo City area. Vogelzang notes, “Significant energy savings will be achieved by reducing the pumping head requirement at the BRPS from 120 to 80 metres, which would lower power consumption. However, concerns remain regarding potential pump failures leading to downtime, despite the improvements in efficiency.”
De Wet adds that the initial feasibility study did not adequately account for downtime costs associated with pipeline expenses. “As mentioned, there is the possibility of building a pump station and taking gravity lines into account. However, the topography may affect potential savings in the pumping head, with a limited reduction of about 40 metres identified over 50 years.”
Improved treatment capacity
The Umzonyana WTW is crucial as it supplies approximately 80% of the urban area's water, while additional supplies come from the smaller Nahoon Dam WTW. The current capacity of the Umzonyana WTW is reported as 120 Mℓ per day,
but a study reveals it effectively operates at only 100 Mℓ, due to factors such as limitations in settling tank performance.
The original water treatment plant was built in the 1920s, so the team has to address the challenges associated with an ageing plant, although some improvements have been made to the plant over time.
To meet the increased demand, the plan is to upgrade the existing plant capacity to 160 Mℓ. Identified issues with the plant include the efficiency of flocculation and high surface loading rates in the filtration system, which need to be addressed to improve operations.
Vogelzang notes, “We have the additional problem of concerns about high organic carbon concentrations in the water affecting taste and odour. We are considering solutions such as UV disinfection combined with chlorination to enhance water quality.”
De Wet underscores the need for environmental assessments and cost estimates for feasibility, as well as the consideration of social impacts, despite time constraints that limit comprehensive studies. “The upgrades will also include optimisation of the poly-electrolyte dosing for effective coagulation, flocculation and sedimentation, the introduction of new sedimentation tanks, increasing the effective filtration capacity required and the potential need for granular-activated carbon filters, as well as adding the essential tertiary process of UV disinfection,” he says.
The current capacity of the Umzonyana Water Treatment Works is reported as 120 Mℓ per day, but a study reveals it effectively operates at only 100 Mℓ, due to factors such as limitations in settling tank performance
This milestone project involves weighing various competing socio-economic and developmental needs, ensuring water supply security, and delivering services to communities in a manner that is both cost-effective and environmentally sustainable. With GIBB’s commitment to achieving this objective in conjunction with its German counterparts, not only will Buffalo City’s residents be able to enjoy a better life, but other similar projects could become possible in the future.
Members from the local and international project team
The Umzonyana raw water dam
ADMINISTRATION, FINANCE AND ENGINEERING EXCELLENCE DRIVE ERWAT GAINS
Demonstrating its adherence to consequence management, ERWAT (Ekurhuleni Water Care Company) received a clean audit for the 2023/2024 financial year – its first in ten years – after embarking on an intensive internal review. IMIESA speaks to Kennedy Chihota, ERWAT’s Managing Director, about the success factors, as well as future developments.
What were the key audit interventions required and how were they achieved?
Foremost, I’d like to acknowledge ERWAT’s board of directors, my senior management and their teams for adopting a unified approach to quality and operational excellence. Our concerted commitment to financial discipline is the key to unlocking the full value of our 19 water care works (WCWs) within the City of Ekurhuleni, backed by an exceptional team of in-house engineers, technicians and artisans. We have the distinction of being the only dedicated public wastewater treatment provider on this scale nationally.
It’s been a long road since our last clean audit from the Auditor-General South Africa (AGSA) in 2010. When I was appointed as MD effective
1 st September 2022 the most prominent concern flagged in the past centred around supply chain non-compliance, and more specifically irregular expenditure. This was in the range of R70 to R80 million per annum, so it presented major non-compliance issues on the allocated operations and maintenance (O&M) budgets required to run our WCWs network, which has a combined treatment capacity of 623 mℓ daily
As the new MD, it was clear from the onset that this high level of irregular expenditure had to be addressed urgently. For me, the starting point was to go back ten years and analyse each AGSA report on ERWAT’s outcomes so we could establish an evaluation checklist. We developed a three-pillar approach covering our policies and processes, our people, and our system.
From there we were able to drill down into the data and action previous audit shortfalls, thereby reducing irregular expenditure to around R20 million in 2022/2023.
This massive reduction was achieved through internally established probity committees in financial and technical areas. Once their findings had been concluded, they were subjected to additional scrutiny by an overarching probity evaluation committee.
The latter’s role – then and now – is to doublecheck aspects such as documentation, correct tendering processes, pricing (too high or too low), and evidence of collusion, and from there to make recommendations to ERWAT’s Managing Director. In the first few months of this process, we were able to reject some 90% of supply chain bids that weren’t compliant. Additionally, we recently embarked on a comprehensive forensic audit dating back to 2016 so we can – through the board and Council – write-off some of the historical irregular expenditure.
In terms of our WCWs, we’re proud to say that the O&M expenditure adopted was verified as fully compliant by technical experts
ERWAT operates 19 water care works within the City of Ekurhuleni
appointed by the AGSA as part of achieving our 2023/2024 clean audit.
How important is accountability?
It’s essential and non-negotiable. In terms of the AGSA’s requirements, every public auditee must adhere to a strict consequence management protocol to root out transgressions and non-performance in terms of the Public Finance Management Act and allied legislation. This essentially means that accounting officers and officials must take full responsibility and act immediately when irregular transactions are identified. The same approach applies to wasteful expenditure. It’s vital that decisionmakers are ethical and competent to ensure that all capital and operational expenditure is fit-for-purpose and adds value.
ERWAT has fully embraced this with a zerotolerance approach that sends a clear message throughout the organisation.
ERWAT achieved an excellent overall score in the 2022 Green Drop Awards. How are things progressing in terms of 100% compliance?
There’s no doubt that the Department of Water and Sanitation’s (DWS’s) Green Drop Certification Programme is a vital initiative – both in recognising excellence, as well as in ensuring that all wastewater treatment plants operate to the highest efficiencies and environmental standards.
To win a Green Drop, the minimum overall score is 90% based on five criteria, namely capacity, environmental, financial and technical management, as well as quality compliance.
In 2022 there were 23 Green Drop Certification Awards out of close to 1 000 wastewater treatment plants audited across South Africa. We led the country with 7 Green Drops. Six of these were for ERWAT plants – the seventh being the Ratanda WCWs within Lesedi Local Municipality, which ERWAT managed at the time in terms of an O&M agreement. Two of our other ERWAT plants were Green Drop Contenders, meaning they scored 89% overall, respectively, but fell short of the mark. This was primarily due to being overloaded in terms of capacity – an aspect beyond our control and influenced by seasonal factors like rainfall variations.
At present, our average compliance for all 19 ERWAT WCWs is 84%. And for the 2026 Awards we’re expecting at least 6 of our WCWs to be Green Drop Certified, but hopefully more.
For the wastewater sector as a whole though there’s still much that needs to be done to ensure that all wastewater plants are universally compliant. The biggest concern is the
approximately 350 plants that were classified as in a critical state in the most recent Green Drop Report.
What are ERWAT’s current priority projects in terms of its WCWs facilities?
Some of the older plants date back to the 1950s and 1970s and need upgrading to meet future demand. The ultimate goal is to mothball older and smaller plants and consolidate the network by expanding our larger facilities. Currently, we serve an estimated population of some 4,2 million within the City of Ekurhuleni and parts of Johannesburg, which includes a growing industrial segment.
Recognising the importance of engineering input in determining viable future socioeconomic infrastructure priorities, the city has developed a Capital Investment Framework model. In terms of this, project motivations submitted for approval require a score of 100. While the political imperatives are evident, they only represent 5 points in terms of the approval process. The other 95 points are allocated for technical merit in terms of obtaining funding approval.
In terms of our funding going forward, the great news is that the city – in its draft budget – has doubled our capital budget in terms of the Medium Term Revenue and Expenditure Framework (MTREF) for the 2025/2026, 2026/2027 and 2027/2028 period. Over this term, ERWAT will receive R1 billion, of which some R500 million will be allocated for WCWs upgrades. The plan is to boost overall infrastructure capacity by some 30 Mℓ
Does ERWAT have the capacity to assist other municipalities in addressing gaps in process efficiencies?
In terms of our constitution, our legal mandate is limited to the City of Ekurhuleni. However, legislation permits us to provide services to
any municipality on request. We currently have O&M agreements with two municipalities, namely Mogale City in Gauteng, and Dipaleseng Local Municipality in Mpumalanga.
Is ERWAT’s commercial business division gaining traction?
We regard this division as an important part of our diversification strategy. At this stage we’re fielding enquiries from private sector clients within the industrial segment, but have not concluded any deals so far, but the outlook is promising.
In the meantime, we’ve concluded a Memorandum of Understanding with Rand Water to potentially work with them on their projects in terms of our wastewater capabilities.
However, our niche market currently is the municipal sector nationwide in assisting them to retore and optimise their wastewater and allied water treatment facilities. From socioeconomic and environmental perspectives, this is a top priority. At present there are too many technical gaps within municipalities so outsourcing O&M is the most viable option in meeting immediate needs. Over time, the upskilling of municipal personnel and the implementation of the correct
Kennedy Chihota, Managing Director at ERWAT
systems will enable them to become selfsufficient once more. ERWAT has the capacity to make this happen in practice.
How is ERWAT contributing to sustainable practices?
Our Green Drop Awards reinforce our commitment to positively influencing the hydrological cycle, but we can’t do it in isolation. A case in point is the fact that 16 of our WCWs discharge into the Vaal River with fully compliant treated effluent. But it’s well known scientifically that pollution is still finding its way to the Vaal River via other sources.
Stretching for some 1 200 km, it is South Africa’s second longest river. So, the downstream impacts where municipalities release untreated effluent poses both a serious environmental hazard and adds to the costs of treating abstracted water for potable purposes. We must restore the cycle collectively.
Reuse is also a core part of our sustainability drive. Currently, we supply a portion of our
MINING
INDUSTRY
treated effluent for reuse by industrial clients predominately in the mining sector, as well as to a nearby residential golf estate for their landscaping requirements. As opposed to say R10 per Kℓ for potable water, these clients only pay around R3 per Kℓ, passing on major savings. We also have the technologies in place to take this a stage further for potable use.
MUNICIPAL
AGRICULTURE
We also plan to reduce the energy costs at our plants, which have a current total installed capacity of around 24 MW. In total, we pay around R180 million per annum to Eskom, and the tariff costs keep rising. Responses include potential waste-to-energy projects, and the widespread adoption of solar PV, both of which will help to lower our carbon footprint.
And in closing?
The increased MTREF allocation provides a significant boost for ERWAT in meeting its expanded mandate, keeping pace with our 2% effluent growth targets annually. There’s also a major potential for increased municipal reuse projects driven by the Development Bank of Southern Africa’s proposed blended finance Water Reuse Programme.
Then of course, we look forward to achieving another clean audit for 2024/2025 based on our successful turnaround strategy. At ERWAT we recognise that quality and compliance are the two key ingredients for sound governance and service delivery.
FOOD AND BEVERAGE
FIRE
Retrofitting for water conservation Transforming the future
In a world where water is an increasingly scarce resource, finding sustainable solutions to conserve and manage our water supply is paramount. Retrofitting, a technique gaining momentum in the water conservation context, offers a powerful and innovative way to address this pressing global concern.
Retrofitting, in the context of water conservation, refers to the process of enhancing or modifying existing water systems and infrastructures to improve their efficiency and reduce water waste. This can encompass a wide range of upgrades, from installing water-saving fixtures in homes to overhauling industrial water processes. Retrofitting is a continual process and a cornerstone of sustainable water management.
Whether you're a homeowner, an architect, an engineer, a landscape architect, a business owner, manager, or a policymaker, you have a role to play in championing water conservation through retrofitting.
Why retrofitting matters
1 Preserving precious resources: The world's fresh water supply is finite, and retrofitting ensures that we use it wisely. By reducing water waste, we safeguard this precious resource for future generations.
2 Economic benefits: Retrofitting can lead to substantial savings in water bills for both individuals and businesses. In the long run, it is a smart financial decision that often pays for itself through reduced consumption.
3 Environmental impact: A lower demand for water means less stress on ecosystems and reduced energy consumption for water treatment and transportation. This translates to lower carbon emissions and a smaller environmental footprint.
4 Adapting to climate change: As climate change leads to more erratic weather patterns, retrofitting can make water systems more resilient. Watersaving technologies help mitigate the impact of droughts and water scarcity.
5 Continual improvement: As new information, designs and technology become available, this affords us ongoing opportunities to design, replace and implement these responsible water initiatives.
Applications of retrofitting
Introducing water efficiency programmes, such as retrofitting at domestic, commercial, and industrial levels, can lead to savings of up to 40% in water consumption. Various retrofitting technologies, ranging from low to high-cost interventions, can be employed:
• Taps: Taps in dishwashing areas, sinks, and bathrooms can account for up to 30% of domestic water usage. A standard tap typically consumes 15 – 18 litres of water per minute, while a water-efficient tap, equipped with flow regulators, reduces the usage to 6 litres and less of water per minute. For commercial and industrial settings, push-button (self-closing) taps that automatically shut off after each use can further contribute to water conservation.
• Showers: Conventional shower heads use 15 – 25 litres of water per minute, whereas water-efficient shower heads, retrofitted with flow regulators, bring the usage down to 6 – 8 litres of water per minute. This adjustment doesn't compromise water pressure.
• Bathtubs: Showers and bathtubs collectively make up around 20% of household water consumption. Opting for a smaller bathtub with a reduced water capacity of 150 litres of water, compared to larger ones holding up to 300 litres, can significantly contribute to water conservation.
• Toilets: Toilet flushing constitutes approximately 20% of household water usage. Older cisterns use 10 – 13 litres of water per flush, while more recent ones utilise 9 litres of water. Choosing a dual flush system further reduces water consumption to 3 – 6 litres of water per flush.
• Rainwater harvesting: This involves collecting, storing, and utilising rainwater from roofs or paving. Rainwater can be directed into storage tanks through gutter and drainage systems, reducing reliance on municipal water by up to 40%. Monitoring the tank's water level with a water level monitor ensures efficient usage.
Championing water conservation through retrofitting
1 Embrace innovation: Stay updated on the latest water-saving technologies and practices. Invest in them to reduce water consumption and waste.
2 Educate and advocate: Promote water conservation within your community and organisation. Encourage others to adopt retrofitting measures. Work with water utilities, environmental organisations, and other stakeholders to develop and implement water-saving strategies.
In conclusion, retrofitting in the water conservation context is a transformative approach to tackling the global water crisis. It offers a path to responsible sustainability, economic benefits, and environmental preservation. By embracing retrofitting, we can secure a brighter and more water-efficient future for all.
Water Wise challenges you to retrofit today for a greener, more prosperous tomorrow.
Always Be #WaterWise
www.randwater.co.za
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REGISTRATION OF PROCESS CONTROLLERS WILL IMPROVE WATER SECURITY REGULATION 3630
The deadline to professionally register water process controllers by 30th June 2025 may seem like yet another onerous layer of red tape, when it’s in fact a critical step towards improving accountability and setting standards in South Africa’s water sector.
Regulation 3630 of the National Water Act mandates that all water and wastewater works be managed by qualified professionals to ensure compliance and best practice – by registering all plant supervisors at the Water Institute of Southern Africa (WISA). This will benefit ordinary water users and businesses in South Africa while also empowering a professional designation that has historically not received the recognition that its vital role deserves.
Essential part of the water chain
“Process controllers essentially run the water and wastewater treatment plants across the country by monitoring, operating and managing all the required processes,” says Dr Lester Goldman, CEO of WISA. “Being a key part of the water chain, process controllers will now see their responsibilities aligned like those of engineers and natural scientists, in whose shadow they have operated.”
This lack of visibility is rooted in history. Process controllers started out as “operators” with minimal qualifications, often ending up in water treatment plants as a form of demotion or punishment. “It used to be an undesirable job, so instead of being dismissed for whatever reason, you would be sent to that ‘stinky’ place situated somewhere on the outskirts of the municipality,” says Goldman.
However, over the past six decades, their role has significantly evolved along with the increasing complexity of water purification, and the understanding that water and wastewater go through some key processes, which need to be monitored – with many of these now automated.
Mandatory registration
Nowadays, the designation of process controller requires a minimum NQF 6 qualification and several years of work experience. “They are the unsung heroes who ensure that everything functions in the provision of our most precious natural resource,” says Goldman. “Regulation 3630 clearly states that the supervisor of every licenced water or wastewater treatment plant in South Africa must now be a senior process controller and be professionally registered.”
This means that even municipalities with capacity issues can’t opt out of registering their process controller or simply register one of their engineers or scientists instead, as either scenario would make them non-compliant.
The reason for specifying “senior process controller” is that experts in engineering or natural science are highly specialised, but don’t necessarily have the competency to manage the water treatment processes and run the actual plant itself.
Raising the bar Regulation 3630 will go a long way towards professionalising the roughly 4 000 process controllers in South Africa. The standardising of their education and training will raise the bar and produce better qualified process controllers. It should also inspire new entrants into the profession and encourage continuous upskilling for those already on this career path.
“As the Blue Drop and Green Drop reports show, there is a positive correlation between the number of trained professionals and performance in the water sector,” says Goldman, hinting at improvements in water quality and availability for residential and commercial users.
Furthermore, setting compulsory national standards for process controllers will also strengthen accountability in the daily operations of South Africa’s water and wastewater treatment works. This, in turn, should lead to more transparency, better local governance, and ultimately to an improvement in water service delivery.
“The mandatory registration of process controllers should not be a grudge purchase,” concludes Goldman. “Public and private Water Service Institutions need to budget and fasttrack training for this registration, because it’s a crucial investment in the water security of South Africa.”
Dr Lester Goldman, CEO of WISA
VANDALISM: AN OVERLOOKED FACTOR IN SOUTH AFRICA'S WATER CRISIS
South Africa's ongoing water crisis has been primarily linked to inadequate infrastructure, climate change, and governance issues. However, an increasingly significant yet frequently ignored contributor is vandalism, which plays a major role in exacerbating water shortages and causing infrastructure failures nationwide, says Sagren Narasimulu, Managing Director at Makhaotse, Narasimulu & Associates (MNA).
Narasimulu points out that, alongside the disruption caused by aging pipelines and load shedding, vandalism has emerged as a destructive element. The theft of water meters, pipes, and electrical cables for resale – often fetching as little as R20 – can incapacitate entire communities for several days.
“Previously, vandalism was predominantly perceived as a rural issue. However, it is very prevalent in urban areas as well, where daylight theft of pipes and cables has become commonplace. This type of criminal behaviour not only hampers water supply but also imposes additional financial strains on municipalities, which must repeatedly replace stolen or damaged assets,” he explains.
The ramifications of vandalism go beyond immediate disruptions in service. The theft of essential components undermines entire water systems, compelling municipalities to reallocate funds from routine maintenance and infrastructure improvements to urgent repairs.
“The inconsistent nature of these repairs means we are not addressing the core issues,” Narasimulu highlights.
According to a report by the Helen Suzman Foundation, from July 2024, South Africa's water infrastructure is already under significant pressure, with many pipelines exceeding 70 years in age and suffering from inadequate maintenance. Vandalism worsens these challenges, hastening the deterioration of an already vulnerable system.
Countermeasures
Initiatives aimed at reducing vandalism include the adoption of non-metallic materials for infrastructure components, thereby lowering their resale value. Some municipalities have also heightened security patrols and surveillance, though stricter enforcement is needed.
“There is an urgent call by both the public and private sectors for stricter law enforcement and enforced and serious penalties. Addressing vandalism is a vital yet often overlooked element. Enhanced law enforcement, investment in vandalresistant materials, and community outreach initiatives could help alleviate these disruptions,” Narasimulu continues.
While vandalism is a contributing factor to South Africa's water sector challenges, it coexists with other critical challenges. Climate change has intensified the occurrence of droughts and floods, further straining water availability, while load shedding disrupts water treatment processes, leaving reservoirs depleted and wastewater untreated.
According to the Department of Water and Sanitation's 2023 No Drop Report, South Africa's non-revenue water losses have risen to 47%, primarily due to leaks, illegal connections, and poor billing systems. These losses far exceed the international average of 30%, underscoring the urgent need for infrastructure improvements and better management practices.
Moreover, Good Governance Africa has explained in a report from June 2024 that South Africa is expected to face a 17% gap between water supply and demand by 2030, underscoring the urgency for strategic intervention. This projection aligns with the findings of the National Water and Sanitation Master Plan from 2018, which identified a similar water supply deficit by 2030.
Safeguarding existing systems while building capacity
Narasimulu asserts that confronting South Africa's water crisis necessitates a comprehensive strategy. He advocates for a change in approach: “Rather than concentrating solely on expanding infrastructure, we must also focus on safeguarding our existing systems.”
Without prompt action, the combined effects of theft, climate change, and mismanagement will only exacerbate the crisis, continuing to jeopardise water security for millions of South Africans.
The recent floods in KwaZulu-Natal have served as a stark reminder of South Africa's ongoing water crisis. Despite numerous warnings and extensive discussions over the years, the fundamental issues facing the country's water sector remain unresolved.
Narasimulu describes how decayed systems lead to severe flooding, a problem exacerbated by poor maintenance practices. Regular clearing of stormwater networks, once commonplace, is now a rarity.
“There is an urgent need for increased accountability in water management. We cannot allow for infrastructure decay and vandalism to persist unchecked. As South Africa nears the brink of physical water scarcity, immediate action is imperative,” Narasimulu continues.
To address these challenges, solutions such as community-based monitoring, can play a crucial role in safeguarding water infrastructure. “By actively involving local communities in oversight efforts early detection of leaks, illegal connections, and vandalism can be improved. Additionally, the use of technical advancements can also enhance water security. For example, the implementation of smart water meters enables real-time monitoring of water usage, helping to detect anomalies and reduce wastage, while surveillance systems provide an added layer of protection against theft and vandalism,” he adds.
“Protecting infrastructure from vandalism must be prioritised alongside maintenance, climate adaptation, and technological advancements. Without a concerted effort, the socioeconomic repercussions of water shortages will continue to escalate, affecting both communities and businesses,” Narasimulu concludes.
Sagren Narasimulu, Managing Director at Makhaotse, Narasimulu & Associates (MNA)
Driving water infrastructure innovation: A Water 4.0 approach
As we stand at the intersection of digital transformation and critical infrastructure management, Water 4.0 represents not merely a technological upgrade but a fundamental rethinking of how we value, manage, and protect our most essential resource. This paradigm shift can revolutionise water management in South Africa, creating systems that are not just smarter, but more resilient, equitable, and sustainable for generations to come.
By Devesh Mothilall
The water infrastructure challenges we face today are unprecedented in scale and complexity. Consider this: in many South African municipalities, non-revenue water losses exceed 35% due to ageing infrastructure – that's water literally disappearing before reaching consumers. Meanwhile, our urban population is projected to grow by an additional 10 to 15 million people by 2035.
These aren't just statistics. They represent a critical inflection point that demands innovative thinking beyond traditional engineering approaches. The question before us isn't whether we need to transform our water systems, but how quickly we can implement solutions that address both immediate crises and long-term sustainability.
Water 4.0 represents the fourth revolution in water management – from the Roman
aqueducts to modern treatment plants, and now to digitally integrated systems. But unlike previous evolutions that took centuries to develop, we're experiencing this transformation in real-time. These technologies aren't futuristic concepts – they're available now and being implemented globally.
What makes Water 4.0 transformative is how it connects previously siloed systems into an intelligent network that can learn, adapt, and optimise in ways human operators alone cannot achieve. For South Africa, with our unique water challenges, this isn't just about technological advancement – it's about leapfrogging decades of incremental improvement to create resilient systems that can withstand climate volatility and demographic shifts.
Smart water technologies in action
Let me put this in perspective: a single undetected leak in a major distribution pipe can waste more than 20 million litres of treated water per year – enough to supply hundreds of households.
that helps utilities identify usage patterns, optimise pressure management, and target conservation efforts where they'll have the greatest impact. The predictive maintenance systems we're implementing today are fundamentally changing the economics of infrastructure management, shifting from reactive repair to proactive optimisation.
A case study in successful implementation
When the City of Johannesburg implemented acoustic sensors and AI-driven leak detection some four years, sceptics questioned the return on investment. However, this initial pilot –funded by the Water Research Commission and executed in collaboration with Joburg Water and the University of Johannesburg – has proven the business case.
Traditional leak detection relies on visible evidence or customer complaints, often weeks or months after the problem begins. With acoustic sensors and Artificial Intelligence (AI) algorithms, we're now detecting leaks within hours, and in some cases, predicting weaknesses before they fail.
Similarly, smart meters aren't just about automated billing – they're providing granular consumption data
Six months after implementation, the system had identified over 200 previously undetected leaks, some as small as 0.5 litres per minute. The 25% reduction in water loss translated to approximately R15 million in annual savings –a payback period of less than two years. More importantly, the system in its current format continues to improve as its algorithms learn from each detection event.
The role of SMEs in Water 4.0
However, large-scale infrastructure innovation isn't solely the domain of major corporations or utilities. In fact, the agility and specialisation of SMEs make them critical innovation partners in the Water 4.0 ecosystem. From sensor manufacturing to specialised analytics, SMEs are often better positioned to develop and deploy
SMEs play a crucial role in implementing Industry 4.0 in the water sector
targeted solutions. Consider that in countries like Germany and Singapore, SMEs contribute more than 40% of water technology innovations despite representing a smaller percentage of the market.
In South Africa, we have an opportunity to develop a vibrant water technology sector by creating pathways for SMEs to collaborate with utilities and engineering firms. This isn't just good technical strategy – it's sound economic policy that can create high-skills jobs while addressing critical infrastructure needs.
Data-driven decisions:
The AI hierarchy of needs
But before we get seduced by the promise of AI and machine learning, we must acknowledge a fundamental truth: even the most sophisticated algorithms are only as good as the data that feeds them. This hierarchy illustrates the critical progression from basic data collection to advanced AI applications.
Many water utilities attempt to implement advanced analytics without addressing fundamental data quality and flow issues, leading to disappointing results. The starting point is therefore to establish robust data collection infrastructure with proper sensor networks and IoT devices. Each step in this pyramid must be solidly established before moving to the next level. Ask yourself: where does your organisation currently sit in this hierarchy, and what's your strategy for climbing to the next level?
Shaping the future of water:
A collaborative approach
The most successful water innovation ecosystems globally share four common characteristics.
the City of Johannesburg
Firstly, they integrate sustainability metrics into every aspect of system design and operation. Secondly, they utilise data analytics not just for operational efficiency but for long-term planning and climate adaptation. Thirdly, they leverage public-private partnerships to accelerate innovation and implementation. And finally, they foster knowledge sharing through formal and informal networks. The question for us is not which of these approaches to adopt, but how to implement all four simultaneously to create a uniquely South African model of water innovation.
Addressing future challenges and implementation
Implementation is where vision meets reality –and where many digital transformation initiatives falter. Let's be candid about the challenges: our current digitisation efforts in South Africa often suffer from fragmentation, with sensors and smart meters deployed without integration into comprehensive management systems. Real-
time data capture remains minimal in many utilities, and the digital skills gap presents a significant barrier to adoption. However, these challenges also present opportunities to design integrated systems from the ground up rather than retrofitting legacy approaches.
In response, we need to establish working groups that bring together technical experts, policymakers, and financial stakeholders to develop implementation roadmaps tailored to different contexts within South Africa, from major metros to rural water systems.
When we embrace digital technologies, we're not simply adding sensors to pipes – we're creating intelligent infrastructure capable of selfdiagnosis and optimisation. When we prioritise data-driven decisions, we're transforming water management from an art to a science. And when we champion sustainability, we're acknowledging that efficiency and environmental responsibility are not competing priorities but complementary imperatives.
However, the transition to Water 4.0 requires investment – not just financial capital, but human capital. The way forward demands forwarding thinking engineering professionals. As catalysts for change, they need to invest in the latest digitalisation trends and prepare the next generation of Water 4.0 professionals.
The time for incremental change has passed. The climate crisis, demographic shifts, and infrastructure deterioration demand bold action now. Every day we delay implementing these solutions means more water is lost, more resources are wasted, and more opportunities are missed. That’s why we urgently need to build a community of best practice around water innovation in South Africa.
SHAPING THE FUTURE OF WATER: A COLLABORATIVE APPROACH
Devesh Mothilall, Head of Digitalisation: Smart City Office, and Head of Knowledge Hub: ECOE at
CREATIVE LANDSCAPING
Designing for sloping terrain at a Cape lifestyle estate
Nestled against the picturesque slopes of the Tygerberg Nature Reserve, De Plattekloof Lifestyle Estate stands as a testament to innovative terracing. With breathtaking views of Table Bay, Cape Town’s City Bowl area and Table Mountain, this five-star retirement estate offers a wide range of accommodation, amenities and care facilities.
The estate’s sloping terrain has been converted into a luxurious living environment through the construction of some 2 300 m² of gravity walls using Terraforce L12 and Decorwall blocks. The walls have not only created stable platforms – linked with staircases (Terraforce 4x4 Step Blocks) and ramps – for the construction of elegant homes, apartment and community buildings, but have also carved out serene, verdant garden terraces.
Delivering striking aesthetic appeal and remarkable versatility, the success of De Plattekloof’s landscaping project was buttressed by the judicious selection of Terraforce Rock Face blocks in combination with the Decorwall blocks. Besides creating terraces for estate gardens, retaining garden walls were built at the front of individual homes.
The estate walls were built in three phases. Phase 1 began in 2016, and Phase 3 is still in progress. Wall heights, which were determined by the site’s natural topography and structural requirements, vary from 1 m to 6m.
The retaining wall blocks were supplied by Klapmuts Concrete and Decorton Retaining Systems used them to build the walls. The latter were designed by Freddie Laker of iCOS Engineers and were landscaped
Built on a piled concrete beam, this L12 Rock Face retaining wall supports a wheelchair path
Some of the retaining walls built with Terraforce L12 Rock Face blocks
seamlessly into the estate by Intebe Landscaping. This included selecting suitable vegetation to stabilise the slopes, enhance aesthetics, and ensure long-term sustainability of the walls.
PROJECT TEAM
Engineer: Invictus Engineering Services
Retaining Wall Engineer: Fred Laker, iCOS Engineers
Main Contractor – current: Mastec Construction
Sub-Contractor: Decorton Retaining Systems
Landscaping: Intebe Landscaping
Construction methodology
“One of our main challenges was adapting our design to the site conditions and switching from the originally specified L11 blocks to the lighter L12 blocks. Moreover, some walls were constructed using a cut-and-fill technology, while in others engineered fill was used to build up levels. The latter ensured proper compaction and stability,” explains Laker.
“The foundations varied based on ground conditions, with some sections requiring reinforced concrete bases, while others were supported on existing concrete retaining walls. Some of the higher walls needed additional structural support in the form of starter bars and concrete infill to enhance their load-bearing capacity and improve overall stability, particularly in high-stress sections of the walls.”
SP van Blerk, managing director of Decorton Retaining Systems, says that geogrid reinforcement was placed at every second layer of block intervals.
“This extended from 750 mm on the lower walls to as much as 2 000 mm behind the higher walls. Geogrid reinforcement was introduced from a wall height of approximately 2,5 m and above, depending on the specific engineering requirements,” he expands.
Drainage was incorporated behind all walls, irrespective of wall height, to prevent pore pressure from building up behind the walls and to ensure long-term durability. The drainage system included perforated pipes placed at the base of the
A paved garden path fringed with L12 Rock Face walls
walls, backed by drainage aggregate, and covered with geotextile fabric to prevent clogging. Weep holes were also integrated into the design to allow water to escape.
“One of the retaining walls was constructed on a piled concrete beam. The wall, which supports the load of a wheelchair access ramp above it, required precise alignment and additional structural reinforcement to maintain longterm stability,” adds van Blerk.
A green response
Terraforce managing director, Karin Johns, says Terraforce blocks are designed to create one of the most energy-efficient segmental retaining wall systems.
“Being hollow yet strong they require less concrete to do the job when compared to solid block systems. They are also plantable, and if an irrigation system is properly installed, a Terraforce wall can be completely covered in vegetation,” Johns concludes.
ABOUT TERRAFORCE
A Concrete Manufacturers Association (CMA) member for over three decades, Terraforce has maintained a strong foothold in the South African retaining wall market for over 40 years. And during the past decade the company has seen a steady expansion into the international retaining wall market with a footprint extending to Australia, Canada, Egypt, Ghana, India, Lesotho, Morocco, Namibia, Nigeria, Spain, Eswatini, and United Arab Emirates.
A planted wall built with Decorwall blocks
A staircase built with Terraforce 4x4 Step Blocks integrates seamlessly with a Terraforce wall
Paarl bridges widened with precast concrete beams
Led by UDS Africa, the upgrading of Bergriver Boulevard and Oosbosch Street in Paarl was commissioned by the employer, Drakenstein Municipality in 2013. The first phase, which included the upgrading of Bergriver Boulevard from Lady Grey Street to Optenhorst/Oosbosch Street, was started in 2016 and completed in 2018.
of the partially constructed river bridge
This phase included the construction of the abutments and piers for the subsequent widening of the 100 m long Oosbosch Street bridge over the Berg River.
The bridge widening project commenced in August 2019 for scheduled completion in August 2021 and included the allied widening of the 20 m long Oosbosch St rail bridge. The latter traverses a railway line some 600 m from the Berg River bridge. Both bridges were widened using precast concrete beams manufactured by Concrete Manufacturers Association (CMA) member, Cape Concrete. Members of the bridge-widening professional team included main contractor, Martin and East, AECOM SA, Empa Structures and Mowana Engineers.
These bridges were first built as beamand-slab structures in the 1960s. The river bridge has now been transformed from two to four traffic lanes, whereas the rail bridge, which was originally built as a narrow fourlane thoroughfare, has been widened on either side to accommodate new pedestrian walkways and to allow the full width of the original bridge to be used solely for traffic.
The original river bridge was constructed with post-tensioned beams – a building technology which was considered for the current project. However, UDS finally approved the contractor’s proposal for pretensioned precast beams as being the more cost-effective and time-efficient option and Cape Concrete was commissioned to cast 20 T beams, 26 m apiece.
The rail bridge extension required four 10 m reinforced concrete beams and balustrades to be cast as single full sections by Cape Concrete. Two of these beam/balustrade units were placed on either side of the bridge. By casting the beams and balustrades as a
Elements
single unit no staging was necessary, saving much valuable time. Moreover, the use of precast elements meant that the manufacture of the beams for both bridges and the precast permanent shuttering for the river bridge could take place during the early stages of the project and be run concurrently with other construction work.
Both bridges were designed by AECOM SA. AECOM SA engineer, Jacobus Kritzinger, said having extended abutments and piers for the river bridge already in place saved further construction time.
Tight tolerances
“In addition, the benefit of several construction activities taking place simultaneously reduced pressure on the programme and yielded savings for the client and all parties involved. In order to achieve uniformity throughout the new river bridge structure, we adopted the same type of cross section profile we found in the original design but, of course, using pretensioned rather than post-tensioned beams,” said Kritzinger.
“It was essential that the structural behaviour of the new beams mirrored the structural behaviour of the existing posttensioned beams as closely as possible because construction tolerances were very tight. This meant we had to model and analyse
the deflections and the induced moments of the pre-tensioned beams to match that of the existing beams as closely as possible,” Kritzinger continued.
Creep and shrinkage
Allowing for creep and shrinkage in this alternative beam design proposed by the contractor entailed some specialist engineering input, which was why consulting engineers, Mowana Engineers, were appointed to design the pre-tensioned concrete beams.
Edward Smuts, Mowana Engineers bridge engineering director, said that there was evidence that considerable creep had taken place on the river bridge over its 50-year lifespan.
“Armed with the concrete and section properties of the old bridge structure, we were able to simulate theoretical deflections in order to match the behaviour of the new beams as closely as possible with the performance of the original beams. Part of this exercise involved calculating instantaneous and long-term creep. Based on these calculations we compiled a report which was submitted to AECOM in the first instance, and once approved by them, to Cape Concrete,” said Smuts.
Post-to-pre-tensioned conversions
Cape Concrete factory manager, Johan Nel, said that as a result of Mowana’s calculations, some additional detailing was required in casting the river bridge beams, and this aspect was handled by Mowana.
“We have done numerous post-to-pretensioned conversions with Mowana Engineers, and they get involved with the prestressing and checking procedures,” Nel explained. “The river bridge beams were specified as W40 MPa and the rail bridge beams as a W50 MPa mix. However, we used the W50 mix for the river bridge beams as well because it covers ASR durability issues as well. We have used this formula historically on other bridge projects with very satisfactory results.”
“Steam-cured, the river bridge beams reached the desired de-tensioning strength after 18 hours. However, we only de-tensioned on the third day because earlier de-tensioning leads to greater hog and deflection issues. It was essential that we controlled the deflection of the beams very carefully so that they matched the camber alignment of the existing bridge beams.”
Empa Structures was appointed by Martin and East to handle the actual construction
The underside of the newly constructed river bridge showing the T beams and the permanent concrete shuttering
One of four precast concrete beam/balustrade units being lifted off the truck bed and lowered into position on the rail bridge
The river beams were cast with bend-out bars for attachment to the diaphragm beams. They were also cast with seven 50 mm PVC ducts at the point where they crossed the diaphragm beams to enable Y25 continuity rebar to be installed along the full length of the diaphragm beams for additional strength. This required a high level of precision in casting the precast beams because the ducts had to run parallel to the slope of the diaphragm beams.
“Once all the precast beams were placed, we started with the in-situ casting of the diaphragm beams. The river bridge has 28 diaphragm beams at seven beams per span, which resulted in a massive and extremely strong monolithic bridge structure. The main diaphragm beams were installed at each abutment end and at each pier. As each diaphragm beam has six sections, the bridge required 196 diaphragm casts,” Dos Reis continued.
Workers involved with attachment of a precast concrete beam/balustrade unit to the rail bridge of both bridges. Work on the river bridge involved the installation of bearing pads, beam placement, cross bracing with in-situ cast diaphragm beams and casting a reinforced concrete deck on reinforced concrete permanent shutters. It also involved demolishing the old balustrade above the midpoint of the new bridge structure and replacing it with an in-situ cast safety barrier between the two sets of traffic lanes, as well as the construction of a new outer balustrade. Unlike the river bridge, the abutments and centre pier of the rail bridge had to be extended under extremely constrained conditions. Once this was accomplished, the precast beam/balustrade units were placed on the bearing pads and attached to the existing bridge structure. Subsequent works included the demolition of the two original balustrades, the construction of new pavements, and resurfacing the road.
Jose Dos Reis of Empa Structures said the river beams were placed on the bearing pads using two mobile cranes. “Because the bridge has a high mid-point, the abutments and piers were sloped for stormwater drainage. This meant that when the bearing pads were installed, they had to be offset with epoxy to attain a level resting position,” he explained.
“Two of the spans are positioned above the river and we had to comply with very strict environmental conditions; we used long through ties to support a gangway below the diaphragm beams. As soon as the diaphragm beams in each span were completed, we immediately installed permanent concrete shutters between the precast beams. We had cast 1 500 on site and some of them needed trimming because we were working to very tight tolerances. Any gaps of 3 mm or more were sealed with multibond epoxy. This was done to prevent any grout loss when we poured the deck concrete.
“Once the deck shuttering was in position, we installed the rebar for the deck slab, which took about a week to a week-and-half to do. We then inserted our level rails and cast the deck to a thickness of 125 mm. Each span took 40 cubes of concrete and once the screeding and floating was done, the deck was watercured for seven days. This process was repeated for each span.”
Rail bridge
Dos Reis said that before the beams could be placed on the rail bridge a colossal amount of preparation work went into widening the central pier and the abutments.
“What made it tricky was that we were working above and under two 3 kV power lines and three live fibre lines running right next to
the one abutment. In addition, we had to found 3 m below natural ground level within 1 m of the live track and then tie the new abutment and pier superstructure into the existing structure,” he explained.
“We had to apply to Transnet for occupation permits, which gave us a very limited time to do the work. The extension of the abutments and centre pier took approximately 30 working occupation permits. This was extremely challenging. For example, we had to cast the 3 m deep foundation base over a weekend, starting on Friday evening and finishing on Sunday afternoon. To accomplish this and to meet other targets we had to double up on all our plant and equipment and human resource capacities,” he continued.
“The foundation trench had to be retained, and we had to steel fix, place the formwork and pour the concrete, which had to set within our allotted 72 hours. Scaffolding and drilling into the existing structure to insert the rebar followed. All of this work was done under occupation permits which take roughly 28 days to be granted. So, if one fell behind with anything due to a freak thunderstorm or some other event, one would have had to reapply and wait another 28 days before work could resume.
“Empa is fortunate in having a great team and we managed by working on multiple fronts. We first began working on the side of the bridge where occupation permission was not required. It provided a valuable learning curve that enabled us to properly plan our working schedules for the ‘live’ side. We conducted time-and-motion studies, and we actually beat our targets through every site occupation. During one of our working windows there was a massive storm when 90 mm fell in one day. We had to erect temporary roofs on our scaffolding so our team could continue working.”
Once the precast beams were placed on the bearing pads, they were held in position with push-pull props until they were permanently attached to the rail bridge. This was done by drilling into the existing bridge and inserting rebar, which was then tied to the exposed rebar of the new beam. Concrete was poured over the rebar and when it was set the push-pull props were removed. After that the old balustrades were demolished, and new raised pavements were cast by Martin and East using premix.
Dos Reis concluded by observing that despite the challenging nature of the project, everything was well executed, due essentially to all the members of the professional team working extremely well together.
In his State of the Nation address on 6th February 2025, President Cyril Ramaphosa outlined government’s intentions to provide more housing in South Africa’s city centres, reclaim hijacked buildings and transform our cities into economic hubs.
As a leader in impact investment with an affordable housing outcome, TUHF supports this move as a vocal advocate for investing in affordable housing that promotes urban densification.
Housing, as part of the real economy, is crucial to transforming our cities and stimulating the growth President Ramaphosa wants to achieve,” says Paul Jackson, CEO of TUHF.
A report by Harvard’s Growth Lab – released in November 2023 – points to tackling persistent spatial exclusion of the country’s most vulnerable as one of two key areas that can make a positive impact on the country’s persistent growth and equality challenges.
Affordable housing development in South Africa – the crucial component of addressing spatial exclusion – has followed a simple principle since 1994: build as many houses as possible, as affordably as possible, to accommodate as many people as possible in decent homes. This well-intentioned approach has led to housing developments being built on the periphery of cities, where land is cheap and building costs can be kept low.
However, it has also inadvertently resulted in uniquely extreme patterns of low density and fragmented city structures – or urban sprawl. “Cities are built the way they’re financed,” Jackson quotes Bertrand Renaud. “So, when housing investment focuses on achieving the lowest possible upfront cost in the annual budget, without accounting for fiscal and economic impacts in the longerterm, urban sprawl is inevitable.”
AFFORDABLE HOUSING INVESTMENT NEEDS DIRECTION
“It is ultimately the most expensive way to provide housing, and exacerbates social, economic and spatial exclusion of the poor, with negative impacts both on the economy overall, and on the fiscus,” Jackson explains. “TUHF’s own research and 21 years’ on-the-ground experience supports this view.”
For a housing development to be built on the outskirts of a city, new infrastructure – physical, social, and administrative – must follow, increasing the real costs that are not accounted for in the financial accounting model. Furthermore, people living on the outskirts remain impoverished. They have little access to employment – whether formal or informal – and struggle to pay for utilities.
“Distant, low-density residential areas simply cannot support social and small business opportunities that generate growth,” Jackson continues. “In contrast, TUHF’s in-fill project approach to affordable housing development stimulates both social and economic activity around our buildings.”
He advocates for a thorough government-funded economic cost/benefit analysis together with a comprehensive medium-term fiscal analysis, to understand the role of urban densification in stimulating real economic growth, local government and fiscal sustainability, and a more inclusive South African society.
Paul Jackson, CEO of TUHF
“The research must include a demand analysis, i.e. what people want and need,” Jackson explains. “For example, public and private sector developers assume that larger housing is preferred even if it is located far from economic hubs. But TUHFs experience suggests that people will happily live in smaller, quality accommodation if it provides access to economic opportunities – whether business opportunities, formal jobs, or self-employment. The continued growth of informal settlements – despite being unsafe and lacking access to services – also suggests that what people want and what is being provided may not align.”
TUHF’s urban densification drive TUHF has long been a champion of urban densification and its ability to uplift individuals and communities. This is why the company has expanded its areas of finance beyond the inner cities to include any urban area that can benefit from densification.
“We support entrepreneurs who want to invest in areas with multi-sector local or micro-economies, and where affordable housing would stimulate increased economic and social action,” Jackson concludes.
Over the last two decades, TUHF has provided finance for affordable residential rental properties in all major metropolitan areas of South Africa, totalling over R8,3 billion and encompassing over 50 000 units since its inception in 2003. In doing so, TUHF has supported hundreds of successful entrepreneurs in achieving their commercial property goals by running sustainable residential rental businesses.
Mobilising for sustainable development
South
At the heart of this year's Consulting Engineers
Africa
(CESA)
Infrastructure Indaba is a powerful call to action: bring South Africa’s engineers back home to contribute to our nation’s growth.
Held on the 18 th and 19 th March 2025 at the Indaba Hotel in Fourways, Johannesburg, the theme was “Engineering the Future We Want: Mobilising for Sustainable Development.”
This set the stage for action-oriented discussions aimed at advancing South Africa’s infrastructure through collaboration, innovation, and strategic investment.
During the opening session, Honourable Minister of Public Works and Infrastructure,
Dean Macpherson, highlighting the critical need for skilled professionals in the country. He made an impassioned plea for engineers working abroad to return and play a role in rebuilding South Africa. “Engineers are the midwives of construction in SA. I want engineers to come back to South Africa and contribute to our projects,” he said.
CESA CEO Chris Campbell added, “The Indaba is not just a talk shop; it is a platform for action. We need to ensure that our
engineers feel valued, have opportunities for growth, and are empowered to drive meaningful change in South Africa.”
Further, Minister Macpherson, speaking on the importance of restoring confidence in the infrastructure sector, remarked: “A key indicator of success would be seeing the stock prices of the Big 5 construction companies returning to their previous levels. We want the construction industry to thrive and become a cornerstone of employment in South Africa. Our goal is to revitalise existing construction companies and foster the emergence of new ones, which will lead to more engineers being employed across the nation.”
Minister Macpherson also emphasised that the time for action is now: “The time for talk is over; now is the time for action. We have the plans in place and are implementing the difficult decisions necessary to turn South Africa into a thriving ‘construction site’,” he declared. He emphasised the critical role of partnerships between government and the private sector, stating, “We will never achieve our infrastructure goals unless we partner with experts in the private sector – the key to unlocking our economic potential.”
CESA CEO Chris Campbell, the Honourable Minister of Public Works and Infrastructure, Dean Macpherson, and CESA President David Leukes at the CESA Infrastructure Indaba
CESA President David Leukes concurred: “Collaboration is the backbone of sustainable development. By working together across disciplines and sectors, we can ensure that our infrastructure is not only resilient and future-ready but also inclusive and transformative. This Indaba is about mobilisation and action. It's about moving from plans and policies to implementation, from ideas to impact." He urged stakeholders to ensure investments translate into real progress.
Economic insights
Annabel Bishop, Chief Economist at Investec, provided insights into South Africa’s economic outlook, stating: “We expect the first interest rate cut this year, after January’s in July, with another possible cut later in the year. A lot depends on what the Reserve Bank anticipates and what happens in international markets.”
“The ultimate goal is to accelerate inclusive economic growth and boost the employment rate. Last year, business confidence was not in a good space, but now, with private sector investment accounting for 74% of fixed investment, there is real hope for improvement.”
“If we achieve operational improvements and swiftly mobilise private sector investment, we could see GDP growth reach 3.3% by the end of 2025. This would provide a crucial uplift from the baseline. Higher taxes are not the solution for funding problems in South Africa; in fact, they have weakened the economy. Cutting back on non-critical expenditure is key," Bishop added.
Another key session entitled “Procurement Strategies and Delivery Models: Opportunity for Industry and Economic Growth” was facilitated by Naomi Naidoo, CESA Board Member and Managing Director of Pink Africa Consulting Engineers. Speakers included Tintswalo Masia, Deputy Business Unit Leader at the Auditor-General South Africa; Dr Ron Watermeyer, Board Member of FIDIC Credentialing Limited; Thobeka Mgobozi, Senior Banker at Absa Corporate and Investment Banking; and Chuene Ramphele, Group Executive at the Infrastructure Delivery Division of the Development Bank of Southern Africa.
Transportation engineering
The second day of the Indaba continued to drill down into key issues, including the
need for a vibrant transportation network facilitated by proactive public-private partnerships.
A key insight in this respect was provided by Hishaam Emeran, Group CEO of the Passenger Rail Agency of South Africa (PRASA). He shared PRASA’s progress in recovering rail corridors, noting that with passenger trips projected to exceed 60 million this year, partnerships are essential to achieving PRASA’s target of 116 million by 2025/26 and 600 million by 2030. Emeran was speaking during a session on “Mandates for Economic Growth: Role of State-owned Entities” facilitated by Logashri Sewnarain: CESA Board Member and CEO of SMEC South Africa.
Emeran further emphasised PRASA’s vision to position rail as the backbone of an integrated transport network. “We are not just rebuilding; we are modernising the system to serve as a foundation for economic growth and social development,” he added.
Sandile Magenuka, General Manager for Network Asset Maintenance at Transnet Rail Infrastructure Manager (TRIM), also called for stronger collaboration to combat theft and vandalism in the rail sector. He acknowledged progress but stressed the urgent need for more effective law enforcement. “We need more crime intelligence as we track how this criminal activity shifts from one community to another and from town to town. We have seen improvements, but there is still a long way to go.”
Adding his input from a roads perspective, Progress Hlahla, Regional Manager transitioning to Provincial Head for Gauteng at SANRAL, encouraged delegates to view infrastructure challenges as opportunities for innovation. “All the challenges surrounding infrastructure development in South Africa are opportunities for professionals, including engineers, to solve together,” he remarked.
Meanwhile, other key sessions included a focus on “Technology and Engineering Innovation” facilitated by Dr Gift Mphefu, co-chairperson of the CESA Transformation and Development Committee and MD at Med-TechEngineers. Speakers included Devesh Mothilall, Head of Digitalisation: Smart City Office at the City of Johannesburg, and Richard Matchett: founding member of BIMCommunityAfrica.
We need to ensure that our engineers feel valued, have opportunities for growth, and are empowered to drive meaningful change in South Africa. ”
A dedicated session also focused on “Infrastructure and Water & Energy Security,” which was facilitated by Sechaba Kou, a CESA Board member and MD at Isao Consulting. Speakers included Mzila Mthenjane, CEO of the Minerals Council South Africa; Geoff Tooley, President of IMESA; and Aubrey Jabulani Nxumalo, Senior Manager Master Planning at Rand Water.
Conclusion
Summing up the 2025 Infrastructure Indaba, Chris Campbell, CEO of CESA, said: “The Indaba has made a clear call to action: collaboration is not just beneficial –it is imperative. By leveraging partnerships between government entities, private firms, engineers, and communities, South Africa can unlock new opportunities for sustainable growth and modernisation in infrastructure development.”
For more information about the CESA Infrastructure Indaba visit www.cesa.co.za/indaba.
Water Institute of Southern Africa wisa@wisa.org.za
Wam Technology CC support@wamsys.co.za
Wilo South Africa marketingsa@wilo.co.za
WRCON ben@wrcon.co.za
Zimile Consulting Engineers info@zimile.co.za
Zutari charmaine.achour@zutari.com
Drain blaster keeps conduits clear VEHICLES
Makabongwe Nomatye, director at Sojaji, says his business is booming and growing faster than ever now that he’s invested in the right equipment for his needs – a Werner Pumps trailer-mounted drain blaster. This four-cylinder jetting trailer assists Sojaji with its core business of drain and stormwater blockage solutions in East London.
“We handle everything from unblocking sewerage and stormwater pipes to CCTV camera inspections and industrial high-pressure cleaning,” says Nomatye.
Nomatye has plans to expand the business to service the Eastern Cape coastline, from Port St Johns through to the Wild Coast, East London, Port Alfred, and Gqeberha, as well as inland regions. He’s thrilled with the performance of the Werner Pumps trailer, having found the company online after being let down by other suppliers in the industry before.
“My main client was battling manganese blockages on their drainage lines and with the Werner Pumps specifications of high flow and low pressure, the trailer’s penetration is more effective with no hassle, especially with top end ENZ nozzles,” Nomatye explains.
Nomatye says Sojaji has built a reputation for reliability and professionalism. “We proudly serve both residential and commercial clients, ensuring that every job, big or small, receives the same attention to detail and quality service.”
Product specifications
In terms of performance, Werner Pumps’ drain blaster units are diesel-driven with a 600 litre breaker tank and hydraulic hose reel with 120 m hose, all fitted on a high-speed road ordinance trailer. There are models available for every need, ranging from 70 litres per minute to 500 litres per minute, with pressures from 130 Bar to 205 Bar and power from 35 kW to 135 kW. Werner Pumps builds all trailer units to order.
Sojaji team members clearing a pipeline blockage
BASF and Sika revolutionise epoxy coatings with sustainable hardener
BASF and Sika have introduced Baxxodur ® EC 151, a groundbreaking amine-based curing agent for epoxy resins, now available under BASF's Baxxodur ® brand. Designed for high-performance flooring applications, it is ideal for production plants, storage and assembly halls, and parking decks.
Baxxodur® EC 151 enhances epoxy flooring solutions by improving viscosity and flow properties, ensuring easy application and a smooth, even finish. Unlike conventional hardeners, it requires significantly less thinner, cutting volatile organic compound (VOC) emissions by up to 90%. This allows for the development of ultra-low VOC formulations, making it a game-changer for environmentally conscious construction projects.
The hardener also enables the greater use of mineral fillers, reducing overall costs while enhancing sustainability.
Reliable curing in challenging conditions
Baxxodur ® EC 151 ensures quick and
thorough curing across a broad temperature range, making it particularly effective in colder conditions. Unlike standard hardeners, which struggle at 5-10°C, this innovative solution cures rapidly, cutting drying time by up to twothirds. As a result, floors can be walked on soon after application, increasing efficiency on construction sites.
Durability and aesthetic excellence
Epoxy coatings formulated with Baxxodur® EC 151 offer a glossy, colour-stable finish without the clouding or hazing (“blushing”) commonly seen with conventional hardeners. The result is a long-lasting, visually appealing surface that withstands mechanical and chemical stresses while minimising maintenance costs.
Innovative collaboration for a greener future
This breakthrough is the result of a strong collaboration between Sika and BASF. Sika developed the amine building block to optimise epoxy formulations, while BASF engineered and scaled up the manufacturing process.
“Baxxodur ® EC 151 demonstrates our commitment to supporting customers in their green transformation,” says Vasilios Galanos, Senior Vice President, Intermediates Europe, BASF. “Our collaboration with Sika combines expertise in chemistry and scalable, costefficient processes to deliver sustainable innovations.”
“This development is a major step toward resource-saving construction,” adds Urs Burckhardt, Head of Research at Sika. “By working closely with BASF, we have created a solution that helps our customers meet their efficiency and sustainability goals more effectively.”
Baxxodur®: A trusted portfolio for high-performance applications
BASF’s Baxxodur® portfolio provides highperformance curing agents for epoxy and polyurea applications across industries including wind energy, electrical, composites, adhesives, and flooring. With the addition of Baxxodur® EC 151, BASF strengthens its offering, delivering high-performance, low-emission solutions tailored to modern construction demands.
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