IMIESA November/December 2023 by IMESA

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

INFRASTRUCTURE DEVELOPMENT • SERVICE DELIVERY • ROADS • BUILDING • MAINTENANCE • ENERGY • WASTE

APE Pumps & Mather+Platt The art of predictive and preventative pump maintenance

MUNICIPAL FOCUS: MANGAUNG A data-driven approach to infrastructure management IMESA 86TH CONFERENCE REPORT Teamwork, innovation, and excellence TRENCHLESS TECHNOLOGY The business case for CIPP

ENVIRONMENTAL ENGINEERING Designing retaining structures that work

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INSIDE

VOLUME 48 NO. 10 NOV/DEC 2023

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

INFRASTRUCTURE DEVELOPMENT • SERVICE DELIVERY • ROADS • BUILDING • MAINTENANCE • ENERGY • WASTE

Editor’s comment President’s comment Index to advertisers

3 5 52

Cover Story The art of predictive and preventative pump maintenance

APE Pumps & Mather+Platt

The art of predictive and preventative pump maintenance

IMESA

al handling solutions.

itoucentre.co.za

IMESA 86th Conference Report IMESA elects new Fellows and Honorary Fellows Celebrating the IMESA CESA 2023 Excellence Awards

MUNICIPAL FOCUS: MANGAUNG A data-driven approach to infrastructure management IMESA 86TH CONFERENCE REPORT Teamwork, innovation, and excellence TRENCHLESS TECHNOLOGY The business case for CIPP

ENVIRONMENTAL ENGINEERING Designing retaining structures that work

ON THE COVER

8 13 14

Leading Projects Human-centred engineering is the key to sustainable infrastructure development

Trenchless Technology Mahatma Gandhi trunk sewer line rehabilitation showcases innovation

Pipe Systems

At the heart of every fluid transfer system are the pumps that drive the overall process. These are mission critical items, and their operations and maintenance (O&M) are an exact science. IMIESA speaks to John Montgomery, general manager for group companies, APE Pumps and Mather+Platt (the Group), about how investments in technology have placed this world-class original equipment manufacturer (OEM) at the cutting edge of service delivery since 1952. P6

TRENCHLESS TECHNOLOGY

Leak detection for energy transition The importance of standards for HDPE piping sustainability

22 23

Environmental Engineering The cost of restoring our beaches Soil retention is key for structural integrity and the environment

24 26

Waste Management Managing shutdown waste streams and contamination spills

31 31 32 34

Transportation South Africa’s path to e-Mobility needs to accelerate

Bitumen & Asphalt SAT members step up at CAPSA 23

Spatial Development & Planning Westown forms the nucleus for the Shongweni catalytic rollout

Municipal Focus A data-driven approach to infrastructure management in Mangaung

Vehicles & Equipment Lifting new capacities with Liebherr’s LR 1400 SX crane Konecranes’ technology cuts fuel consumption and emissions by 25% Bell expands its offering with new Heavy Industries division

45 46 47

Cement & Concrete Concrete construction significantly improved by admixtures AfriSam prioritises skills development

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Awards 29

Water & Wastewater Retrofitting for water conservation: transforming the future

Community sanitation The IDRA Desalination and Reuse Handbook 2023-2024 How to evaluate water data solutions Swimming Sustainably. How can you make your pool more water wise?

Honorary Doctorate awarded to Professor Kevin Wall

Renewable Energy & Electrification 30

ENVIRONMENTAL ENGINEERING

Digitisation is changing the power landscape

SPATIAL DEVELOPMENT & PLANNING

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Engineering Revolutionised

06 - 08 November 2024 CAPE TOWN | GRANDWEST

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IMESA ORGANISER

THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA)

EDITOR’S COMMENT EDITOR Alastair Currie Email: alastair@infraprojects.co.za DESIGNER Beren Bauermeister CONTRIBUTORS Max Ihring, Chetan Mistry, Reudebaker Nel, Bryan Perrie, Sibusiso Mjwara, Daniel Vogt DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS Email: IMIESAdistribution@infraprojects.co.za ___________________________________________________ ADVERTISING SALES KEY ACCOUNT MANAGER Joanne Lawrie Tel: +27 (0)11 234 0825 / +27 (0)82 346 5338 Email: joanne@infraprojects.co.za ___________________________________________________

PUBLISHER IMESA (Pty) Ltd P O Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Email: info@infraprojects.co.za ANNUAL SUBSCRIPTION: R600.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2023. All rights reserved. ___________________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Email: imesaec@imesa.org.za

oing into 2024, sustainable energy remains an overarching priority for South Africa as Eskom strives to end loadshedding and embrace the shift to green power. It’s a mammoth task, and one that needs major funding support, which was recently given a boost in November 2023. This follows the conclusion of bilateral loan agreements between the South African government and the World Bank (approximately US$1 billion), Kreditanstalt für Wiederaufbau (around €500 million) and the African Development Bank ($300 million) to support the country’s Just Energy Transition. That’s great news for renewables and downstream industries – and a future stabilised power grid that maintains optimum thermal power station performance in the interim. However, this needs to form part of an integrated approach where all priority infrastructure – from ports and rail to roads, pipelines, and sanitation – receive equal attention, mobilised through a renewed focus on government’s Infrastructure Fund initiative. The latter hinges on proactive public and private partnership (PPP) investment. Plus, there are still funds allocated at municipal level that continue to remain unspent and returned to National Treasury each year. So positive gains can be made here for new construction and maintenance. However, even where the money has been allocated, and implementation is possible, current challenges surrounding procurement legislation and project approvals remain a constraining factor. This requires further coordination and streamlining to remove unnecessary red tape.

Excellence prevails

KWAZULU-NATAL Secretary: Narisha Sogan Tel: +27 (0)31 266 3263 Email: imesakzn@imesa.org.za

In the meantime, project excellence prevails, as showcased in the 2023 IMESA CESA Excellence Awards published in this edition, along with the 86th IMESA Conference Report, which highlights how innovation, technology and dedication are positively changing the infrastructure landscape. Achieving this is practice requires a unified approach and bringing the community on board. This was the message carried across to the conference audience by keynote speaker, Dr Imtiaz Sooliman, founder and head of Gift of the Givers, who stressed the importance of pooling skills and resources. It’s about winning through teamwork.

NORTHERN PROVINCES Secretary: Debbie Anderson Tel: +27 (0)83 326 3050 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Olivier Tel: +27 (0)79 390 7536 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7112 Email: imesawc@imesa.org.za

Winning goals One of the signature moments in this respect is the outcome

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

of the Rugby World Cup France 2023 tournament where South Africa walked away with the winning trophy. What a fantastic achievement, and one that truly reinforces the value of teamwork and commitment in achieving a common goal. It’s a model we need to replicate in the way we plan and implement service delivery across our multifaced frameworks, matching the right expertise with the end objective.

Following the money In the meantime, the updated game plan for engagement in the public arena was presented on 1st November 2023 by Finance Minister Enoch Godongwana during the Medium-Term Budget Policy Statement (MTBPS) speech. A key emphasis is on stabilising public finances and reforming the economy. Mobilising more effective PPP and procurement frameworks were also highlights. Setting the scene, the minister stated that in terms of projections, “…gross debt rises from R4.8 trillion in 2023/24 to R5.2 trillion in the next financial year.” And by 2025/26, it will exceed the R6 trillion mark (around 77% of Gross Domestic Product). That places extra emphasis on irradicating inefficiencies in the system and targeting expenditure effectively. A key element here was the MTBPS’s reference to division of revenue and the equitable allocation of funds. Godongwana stated that, “Over the next three years, government proposes allocating 48 % of available noninterest spending to national departments, 42.1% to provinces, and 9.9% to local government.” Supporting local government is a core strategy, especially in terms of improving service delivery in critical areas like water and wastewater treatment. Changes proposed include, “reconfiguring of grants and revising the grant conditions, to align them with the Green Drop, Blue Drop, and No Drop assessments…” So, it’s a performance-based approach. That’s the right strategy going into 2024, along with a concerted focus on building technical engineering centres of excellence within each municipality. Now, more than ever, South Africa needs a more coherent and empowered mandate for infrastructure execution.

Alastair

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

All material herein IMIESA is copyright protected Paving the and waymay not be reproduced without the prior written permission of for TOMORROW the publisher. The views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

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

INFRASTRUCTURE DEVELOPMENT • SERVICE DELIVERY • ROADS • BUILDING • MAINTENANCE • ENERGY • WASTE

APE Pumps & Mather+Platt

Cover opportunity

The art of predictive and preventative pump maintenance

In each issue, IMIESA offers advertisers the opportunity to get to the front of the line by placing a company, product or service on the front cover of the journal. Buying this position will afford the advertiser the cover story and maximum exposure. For more information on cover bookings, contact Joanne Lawrie on +27 (0)82 346 5338.

MUNICIPAL FOCUS: MANGAUNG A data-driven approach to infrastructure management IMESA 86TH CONFERENCE REPORT Teamwork, innovation, and excellence TRENCHLESS TECHNOLOGY The business case for CIPP

ENVIRONMENTAL ENGINEERING Designing retaining structures that work

IMIESA Nov/Dec 2023

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PRESIDENT’S COMMENT

IMESA

ON THE FRONTLINE OF INFRASTRUCTURE DELIVERY As municipal engineers we intimately understand the challenges and opportunities to address the need for world-class service delivery within our towns and cities.

ur engineers, technologists and technicians work tirelessly at the coalface in conjunction with consulting engineers and key government entities to devise the most cost-effective and technologically sustainable solutions. Achieving implementation in practice requires navigating a complex regulatory system, including motivating for the necessary funding. However, at times this has slowed down the place of project delivery, which has been acknowledged and is being addressed by national government. There is no doubt that when policies and practice are in sync, backed by proven proficiency, as well as commitment in all areas – particularly finance, administration, and engineering – the results speak for themselves. As IMESA our role is to support our members in terms of mentorship and training so that they are professionally equipped to execute their mandate.

Municipalities in transition “Dysfunctional” is not a term any person or organisation wants to be labelled with. Within the municipal arena, it’s been used to refer to a percentage of municipalities, but across the board there are pockets of excellence, and work in progress to ensure that all local government organisations perform optimally. The most recent State of Local Government Report for 2022 provides an overview of the status quo, with municipalities categorised as either Dysfunctional, Medium Risk, Low Risk or

Sibusiso Mjwara, PrTechEng, MIMESA, MSAICE, MWISA, MIPET

Stable. Compared to 2021 there’s a definite although marginal improvement. In 2021, the percentage of municipalities falling into each of these respective categories was 64, 111, 66 and 16. For 2022, that changed to 66, 107, 57 and 27. Congratulations go to those municipalities that transitioned to Stable: a great achievement and a benchmark for the rest to follow. Driving this positive change is a multi-pronged approach by government.

Multi-pronged approach Speaking in November 2023, in reference to the latest results, Thembi Nkadimeng, Minister of Cooperative Governance and Traditional Affairs (CoGTA) outlined key developments in terms of municipal support and interventions. These encompass reforms that more effectively empower municipalities to execute their duties and mandates. Examples include the introduction of the Municipal Staff Regulations (2021). The latter lays down what the Minister describes as a “robust foundation to professionalise local government by setting essential standards.” Then there’s the Circular 88 Introduction (2017) initiated by CoGTA in collaboration with National Treasury. As the Minister states, “This circular aligns with the Municipal Systems Act and the MFMA requirements, ensuring coherence between planning and reporting instruments such as the Integrated Development Plan, the Service Delivery and Budget Implementation Plan, and the Annual Report.” The current pilot of Circular 88 is being applied across South Africa’s eight metros, with plans for broader implementation across all municipalities in future. In terms of other key initiatives, CoGTA has also established a Results Management Office staffed by multi-disciplinary experts to assist those entities most in need, namely dysfunctional municipalities. Backing this is the ongoing role of the Municipal Infrastructure Support Agent. The latter’s responsibilities include championing the development of Infrastructure Asset Management Plans, technical expert

deployment, supporting the implementation of the Community Work Programme, and ongoing infrastructure condition assessments. To date that includes assessments on the bulk water and sanitation infrastructure of 117 out of 144 Water Service Authorities (WSAs).

Strategic partnerships Throughout all these endeavours, IMESA forms an integral part, with our members represented across all spheres of government – we’re the implementers of outcomes on the frontline of municipal engineering. It’s an exciting time to be a municipal engineer because we are the change agents and our Institute’s role is growing stronger by the day.

An outstanding IMESA conference That was underscored at our recent 86th IMESA Conference in October 2023, where some 800 delegates attended. The conference was a resounding success, enabling delegates to meaningly debate how policies are applied in the real world. Our next conference will be held in Cape Town between 6th and 8th November 2024 under the theme “Engineering Revolutionised” and we anticipate that there will be a record turnout. Abstract topics are welcomed from all engineering and related built environment professionals across ever y municipal engineering field. More details can be found at www.imesa.org.za.

In closing It’s been a tough year for the local and global economy, and 2024 will cer tainly require everyone to put their best foot forward. We know that the seemly impossible is possible with everyone on board, and I’d like to thank our members, the construction sector in general, and our government stakeholders for uniting in a common cause. My best wishes go to you and your families over the festive season, and I look forward to engaging with you all in 2024.

IMIESA Nov/Dec 2023

COVER STORY

The art of predictive and

preventative pump maintenance

COVER STORY

At the heart of every clients to assist them in optimising their fluid transfer system are the fluid transfer processes on its OEM pumps that drive the overall process. supplied solutions. These services include remoting monitoring of These are mission critical items, and system health, plus in-field their operations and maintenance (O&M) inspection and maintenance are an exact science. IMIESA speaks services to confirm that every to John Montgomery, general manager Group pump installed is running at its correct duty by testing for for group companies, APE Pumps and aspects like alignment, vibration, Mather+Platt (the Group), about how temperature, and flow dynamics. investments in technology have placed Pump calibrations occur at this world-class original equipment recommended OEM intervals. manufacturer (OEM) at the Current SLA contracts include work for Eskom, national water utilities, cutting edge of service municipalities, and private industry. delivery since 1952. End-user cost optimisation

orming part of leading multinational, WPIL Limited, APE Pumps and Mather+Platt celebrate their 72nd anniversary in 2024 as a Proudly South African company, with their turnkey design, manufacturing and commissioning capability backed by their 8 ME (Mechanical Engineering) grading as a contractor in terms of the Construction Industry Development Board. “The key differentiator that has made us a leader in our field is attention to every detail in our multifaceted manufacturing processes. That starts with our record keeping and we’re proud to state that the technical drawings for every single pump we’ve ever produced since 1952 is on file and can be extracted to execute assessments, repairs, refurbishments or a complete rebuild,” Montgomery explains. “Those aspects include details like metallurgical materials, the designed duty, and impeller trims.” “Our record keeping is a vital ser vice for our public and private sector end-users, some of whom may no longer have an institutional knowledge of our pumps due to organisational and/or ownership changes, as well as gaps in in-house technical knowhow,” Montgomer y continues. In recent years, the Group has entered into service level agreement (SLA) contracts with

6 IMIESA Nov/Dec 2023

“Given the tough economic times locally and globally, cost optimisation has become of paramount importance for end-users, along with the need to ensure that their pumps – typically running around the clock, every day of the year – perform without unscheduled breakdowns. For any sector, from power stations to municipal wastewater treatment plants and water utilities, this is a nonnegotiable requirement. So, our goal is to ensure that our pumps run at their Best Efficiency Point (BEP),” Montgomery continues. One of the value-added services offered by the Group in this respect is to analyse enduser networks. Often these undergo upgrades and modifications over time. Examples would include the addition of smaller or larger pipes, or additional valves and bends that affect the originally installed operational parameters of existing pump systems. Following a detailed inspection, recommendations might include the installation of a larger impeller, or an increase or reduction in the pump speeds. Supporting the Group’s SLA and general project work is its Stores Department, which holds a multi-million rand inventory of general as well as major components to ensure lead times are kept to the minimum. “We do have access to WPIL entities across the world based in countries that include Australia, the UK, India,

and Italy. However, to date we have remained completely sufficient,” Montgomery explains.

Adherence to quality From a quality perspective, pump design and fabrication are completed and verified in-house – the exception being the pump foundry castings. To this end, the Group recently enhanced its capabilities in September 2023 with investments in new equipment that include a state-of-the-art 3D laser scanner that takes geometric accuracy and on-site lidar surveys to an unprecedented level. “It’s an amazing enhancement to traditional 2D techniques that can be used for verification of pump geometries during manufacturing and assembly, as well as in terms of correct pump installation and commissioning,” Montgomery continues. As a longstanding OEM, the Group is one of the few in its field to retain a traditional pattern making department. To this day, predominately

COVER STORY

“From a capital equipment perspective, pumps are high value items. However, the mission critical roles they perform for utilities and industries is far greater. One single component flaw overlooked could lead to a catastrophic failure costing millions. The same is true for incorrect pump set-up and operation. For municipal clients, for example, the cost considerations are far outweighed by the downstream impacts of interrupted potable water delivery or the inability to process and treat domestic or industrial effluent,” Coetzee continues. Adds Coetzee: “The use of non-destructive testing technology serves two purposes: firstly, it ensures total quality assurance, and secondly it provides the customer or end-user with verification of all the steps taken to achieve this.”

The importance of asset management wooden patterns are still painstakingly crafted by hand to create the moulds that are sent to the foundries for pump casting – and there’s zero margin for error. “Imagine the possibilities now to take this a step further with 3D scanning technology. It’s pinpoint precision. For example, we can verify the impeller vanes against the pattern to ensure they match up and that the hydraulics are 100% correct,” says Montgomery.

Repair and refurbishment With planned and preventive maintenance, APE and Mather+Platt pumps will last for decades, with many examples of installed units running for 50 years or more without the need for a major overhaul. However, at some stage every pump will reach a point where it’s no longer economical to repair. “Any pump that comes out of service from the end-user will be stripped, cleaned and assessed visually,” explains Tian Coetzee, who heads up the Group’s Stripping and Non-Destructive Examination Department. Thereafter, an extra layer of quality control is applied using various non-destructive testing (NDT) techniques and specialist equipment. Examples of NDT processes include ultrasonic examination and magnetic particle inspection, the latter used to check for surface or subsurface cracks in pumps made with ferrous metals. Another common NDT technique employed by the Group is dye penetrant inspection – used to detect casting,

forging and welding defects. The Group is also currently considering the addition of positive material identification testing equipment. “Our ultimate goal is to use our technical expertise to extend every pump’s life and to repair components where practical. Following every inspection, we generate a detailed report based on an evidence-based analysis that is shared with the client’s engineers, along with the recommended repair or replacement solution,” Coetzee continues. The same rigorous approached is applied on components and pump repairs, which have to pass strict quality control tests in terms of all materials used, including repair polymers and protective coatings.

In the end, optimum pump performance boils down to predictive and preventative maintenance – the essential foundation being an up-to-date asset management register. As Montgomery points out, only once you know the status and system health of your fluid transfer network can you start drawing up realistic budgets for effective O&M, instead of working in a reactive maintenance environment. “Customers want their plants to work and run at the best possible cost. And that can only happen with expert OEM partnerships. Since 1952, APE Pumps and Mather+Platt have been committed to achieving this, which is why we’re market leaders in fluid transfer and pump innovation,” Montgomery concludes.

www.apepumps.co.za www.matherandplatt.com

IMIESA Nov/Dec 2023

IMESA 86 TH CONFERENCE REPORT

The 86th IMESA Conference was attended by approximately 800 delegates from across South Africa, making it one of the most successful events since the pre Covid-19 era

RESILIENCE IS THE FUTURE,

AND IT STARTS NOW

IMESA has been the beacon for excellence in municipal engineering since its founding and this was again underscored at its 86th Annual Conference. Held between 25th and 27th October 2023 in Gqeberha (formerly Port Elizabeth) at the Boardwalk Hotel, approximately 800 delegates from across South Africa attended, making it one of the most successful events since the pre Covid-19 era. By Alastair Currie

his year’s conference was themed “Resilience is the future”, with a pressing need to find and implement sustainable infrastructure solutions within the context of climate change, increasing urbanisation – formal as well as informal – and population growth. Data-driven intelligent asset management and proactive operations and maintenance (O&M) were central themes, focusing on the need to maintain critical services driven by technology and innovation. This comes at a time when many municipalities face infrastructure backlogs, with technical skills and funding thin on the ground. Equally central to the presentations and panel discussions was the vital need for more effective coordination between national, provincial, and local government in implementing infrastructure development programmes. As at previous conferences, municipal engineering leaders at the coal face again interacted with key stakeholders like National Treasury

8 IMIESA Nov/Dec 2023

and CoGTA’s Municipal Infrastructure Support Agent (MISA) on administration bottlenecks that continue to hamper funding applications and procurement processes. “Now more important than ever, the need for much greater public and private sector collaboration was universally acknowledged within our increasingly austere budgeting environment,” said Sibusiso Mjwara, IMESA President. “Our role as IMESA is to facilitate an enabling environment by supporting municipal engineering personnel through to ECSA registration, as well as the provision of training and workshops for members. Local government delivery is the key to enabling growth and prosperity in South Africa and our ongoing engagement with all applicable stakeholders is critical to achieving this.”

Gift of the Givers – the impossible is possible One of the most remarkable speeches was the keynote address on the opening day of the

conference. Delivered by Dr Imtiaz Sooliman, a medical doctor by training, as well as founder and head of Gift of the Givers, his presentation inspired the audience with examples of how the seemingly impossible is possible. This is well demonstrated by his organisation’s selfless and dedicated mission of helping those in need at home and abroad in times of crisis. For the past 30 years, the Gift of the Givers has filled the gap, leading relief missions in more than 45 countries, including South Africa, with a key focus on providing emergency assistance. Local

Dr Imtiaz Sooliman, founder and head of Gift of the Givers, presenting at the conference

IMESA 86 TH CONFERENCE REPORT

BEST SINGLE EXHIBITION STAND

BEST DOUBLE EXHIBITION STAND

Dynamic Fluid Control

Sizabantu Pipe Systems

and global disasters where they’ve been involved range from earthquakes, tsunamis and droughts to famines, hostage release negotiations, and aid to victims in war torn zones. Major international natural disasters where they’ve been involved include the Bosnian conflict in the 90s, the Haiti earthquake in 2010 that wiped out some 220 000 people, and the earthquakes in Turkey during 2023 which affected some 15 million people. In both of the latter two countries, poorly constructed civil infrastructure and buildings were exacerbating factors. However, compared to many of the countries he’s visited, Dr Sooliman says South Africa is far better off, despite the fact that local citizens experience the daily frustrations of loadshedding and failing infrastructure, which actually remains relatively world class. However, he said that doesn’t mean the issues inhibiting South Africa’s socio-economic advancement can be ignored, with political conflict being a root cause.

On a positive note, he said that the South African government is now reappraising itself to fix shortfalls in the system, especially at municipal level. This includes tackling the endemic issue of corruption. However, as he

BEST PAPER BY AN IMESA MEMBER

BEST PAPER BY A NON-IMESA MEMBER

Paper 16: “Bulk Water Journey: The Development & Diversification of NMBM’s Water Supply” by Chandre Barnard, Deputy Director, Nelson Mandela Bay Municipality (NMBM)

Paper 12: “Data Modelling and Infrastructure Profiling in Local Municipalities” by Christopher Chinonge, Asset Management Engineer, IMQS Software

Geoff Tooley presenting at the Knowledge Bar within the exhibition hall. Tooley is IMESA’s Vice President: Operations Portfolios and Senior Manager: Catchment Management at eThekwini Municipality

stated, “government itself is not corrupt, there are corrupt people in government, and the same is true within parts of the private sector. So that has to change.”

Morality and ethics “The key issue is one of adhering to moral and ethical best practice in all sectors, proactive collaboration, as well as a return to faith and spirituality, because through that comes positivity and hope. As the Gift of the Givers, we are the instruments of that faith, and we serve unconditionally.” Dr Sooliman pointed out that what sets South African society apart from other nations is its amazing resilience, a deep sense of patriotism where people from all walks of life stand together in times of crisis. Examples include the devastating floods in 2022 – particularly in eThekwini – where the rebuilding process is still ongoing. “So South Africa is far from becoming a failed state, because of citizen unity, and if it was going to burn, it would have done so in 1994

IMIESA Nov/Dec 2023

IMESA 86 TH CONFERENCE REPORT

point being the KwaZulu-Natal floods where we also provided assistance,” said Dr Sooliman. “We need that type of commitment at every level of society.” In recognition of the Gift of the Givers’ exceptional work, the organisation was presented with a R25 000 donation at the conference – jointly funded by IMESA’s Executive and the IMESA Eastern Cape Branch – this year’s Local Organising Committee.

Differing viewpoints The IMESA Head Office team

IMESA President Sibusiso Mjwara

during the country’s democratic transition. But it didn’t. It was a peaceful and signature moment – despite our turbulent past – and as President Nelson Mandela stated, ‘the people have spoken’.” “But that level of unity and social cohesion must be maintained. Every South African aspires more or less to the same thing, namely health, education, employment, food, security, housing, electricity, working roads, water, and sanitation. The only way to achieve this is together, and as the Gift of the Givers we’re there wherever practical,” stressed Dr Sooliman.

Responding to a city in need Prime examples include the Gift of the Giver’s support for the Nelson Mandela Bay Municipality (NMBM). In May 2022, the call went out. The metro was facing a worsening drought and the real prospect of “Day Zero” when the taps would run dry. The mayor, the city’s engineers and the business chamber were in crisis. “Sitting with the NMBM team, we had a common problem to face so we sat together as South Africans, designed a plan, and drilled 50 boreholes to help save the city,” Dr Sooliman explained.

10 IMIESA Nov/Dec 2023

Then at the beginning of December 2022 another call went out from NMBM. A major fire had broken out, fed by strong winds, which threatened to engulf parts of the CBD and surrounds. In addition to being constrained by water shortages, the city was unable to respond effectively due to factors such as a shortage of fire trucks and personnel. In response, the Gift of the Givers immediately sent in two helicopters, two planes, extra fire trucks, water tankers and firefighting personnel. In five days, the fires had been extinguished. Another recent example was in Citrusdal in the Western Cape. A key bridge connecting the town had been swept away during a major flood and helicopters couldn’t fly due to the high winds. Again, everyone came together – engineers, municipal leaders, and the community. A potential farm bridge was identified some 30 to 40 km away, but water was flowing over the deck. The municipality’s engineers assessed the bridge as potentially safe to cross, but with a degree of risk. The Gift of the Givers’ truck drivers didn’t hesitate. “Our organisation is on standby 365 days a year, since most of the time you never know when a disaster is going to happen, a case in

Infrastructure service delivery is clearly multifaceted and exists in a realm where engineering, politicians, legislation, and procurement co-exist. Where disconnects occur, a meeting of the minds is essential to troubleshoot issues between policymakers and the engineers that apply these policies in the practical world of construction. These were among the topics raised during the conference’s panel discussion entitled, “South African Resilience: Fostering Sustainable Solutions for an Uncertain Future,” facilitated by Pule Tarafara Setai, National Treasury Chief Director: Provincial and Local Government Infrastructure (Intergovernmental Relations). Joining the panel were Regina Ravele, MISA Provincial Head in Limpopo; Barry Martin, Director: Water and Sanitation at NMBM; Dr Sooliman; and Chris Campbell, CEO of Consulting Engineers South Africa (CESA). In opening, Campbell said that the objective of delivering sustainable infrastructure must factor in its O&M costs at the inception of the design so that asset owners can plan and budget accordingly. Rather than viewing infrastructure delivery as a goods and services transaction, with the objective of achieving the Flowtite South Africa was the Diamond Sponsor for the 86TH IMESA Conference

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Scholars from local schools were invited to the conference to gain exposure to the world of municipal engineering, as well as careers in this multi-faceted field

lowest cost, he said the emphasis must be on the most cost-effective option from a lifecycle perspective. This also assumes that adequate technical skills are in place. Without effective O&M, municipalities may end up installing services they can’t afford. To ensure effective implementation, MISA’s mandate is to provide technical support to municipalities and to help build in-house engineering capacity. As Ravele stated, this includes assisting in the development and implementation of asset management plans, with funding support from the Development Bank of Southern Africa, among other initiatives. It’s a highly commendable work in progress, but as Dr Sooliman stated, as end users the man in the street simply wants the services he paid for. He said rules and policies without implementation were meaningless, and that “urgency, emergency and disaster” must be central to all intergovernmental responses. To illustrate the point, communities within parts of eThekwini went for months without potable water or waterborne sanitation in the aftermath of the 2022 KwaZulu-Natal floods, which caused extensive infrastructure damage. The availability of funds or expertise was not the main impediment: the timeline for execution was just too long because of the intense administrative process required. Adding to the panelists’ comments, Martin acknowledged the importance of effective project management tools. However, it all starts with effective planning. To underscore the point, he said NMBM’s planning dating back to around 2005 is what saved the city

from a “Day Zero” scenario – including the location of all the boreholes that were drilled – with some R700 m invested in the process. But he said there must be an enabling legislative environment, which remains a practical challenge for municipal engineers. The timeline for implementation is the deciding factor. The environmental impact assessment alone, for example, can take up to 18 months, which then has to be factored into the final design. “So, in the current framework, when a natural disaster hits, a quick repair response is very challenging,” he said. This was the case for eThekwini after the 2022 floods. The city submitted a storm damage claim to National Treasury signed off by four or more professional engineers employed by the metro. In response, National Treasury employed a consultant to verify these claims, causing additional costs and delays. In January 2023 National Treasury then approved some R1,2 bn for remediation works over a three-year period. In February 2023, that timeframe was subsequently adjusted to one year for design, procurement, and construction. However, some of the bridges that need to be rebuilt take around 18 months. When it comes to project execution, teamwork is key. That applies to every single engineer from a design and project implementation perspective, as well as the qualified trades so essential for routine O&M. A key ingredient is the need to plan, verify and then install the most workable and sustainable solution that works for the community and industry. “Essentially, a problem shared is a problem halved,” said Martin.

Dr Imtiaz Sooliman (left) from Gift of the Givers, accepts a R25 000 donation from Lyle Francis, head of this year’s IMESA Eastern Cape Local Organising Committee and Deputy Director: Water Demand Management at NMBM, together with IMESA President Sibusiso Mjwara

In closing Ending off the conference, IMESA’s President thanked the delegates for their dedication to making municipal engineering in all its facets – public and private – the catalyst for a socioeconomically stronger and unified South Africa, with a special thanks to the exhibitors and sponsors for their major contribution to the success of this event. “There will always be challenges, but from the wide range of exceptional papers and talks at this conference, it’s very clear that with innovation, collective participation and hard work, nothing is insurmountable,” said Mjwara. “Work has already begun on the 87th Annual Conference, which will take place in Cape Town between 6th and 8th November 2024. In the meantime, IMESA’s commitment and engagement will continue to push the boundaries of what is possible in South African municipal engineering, benchmarking ourselves against the best in the world,” Mjwara concluded. To download all the papers presented at the IMESA 86th Conference, visit www.imesa.org.za.

IMIESA Nov/Dec 2023

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IMESA ELECTS NEW FELLOWS AND HONORARY FELLOWS Like most voluntary associations registered with the Engineering Council of South Africa, IMESA’s Executive Committee (EXCO), Council and regional branches are composed of member volunteers who are employed full-time as engineers and allied professionals either in the public or private sector.

hrough their applied experience addition, have distinguished themselves in and knowledge within the the community, are or have been intimately municipal engineering arena, engaged with infrastructure engineering and deserve the honour for exceptional and every IMESA member strives to make a dif ference and fur ther the important services in connection with the objectives of the institute. Institute’s vision and mission. The During the 86th IMESA Conference, six encapsulating mandate is to promote IMESA members were honoured. excellence for the benefit of municipalities and their communities. This is achieved through platforms that Elected as Fellows • Christo Swar t, Deputy Director: Project include branch events and seminars, training workshops, por tfolio committees, Management, Cape Winelands District and the annual IMESA conference, which Municipality, and IMESA EXCO Technical Director: Environment. enable members to discuss contentious engineering issues, debate best practices • Emmarentia Stipp, Senior Professional and promote knowledge sharing. Allied Officer: Pavement, Roads Infrastructure & Management, City of Cape Town and IMESA to this, IMESA and its members ser ve Council member. on a wide range of representative industr y stakeholder bodies within the built environment. All of New IMESA this takes time, dedication Fellows and Honorary Fellows (from left): and commitment. Bhavna Soni (Honorary The highest recognition Fellow); Christo Swart of outstanding ser vice (Fellow); Professor Emmarentia Stipp is the conferring of Jakobus (Kobus) du Plessis from the City of Cape (Honorary Fellow); Town (Fellow) Fellow and Honorar y Jeanine du Preez (Honorary Fellow status. IMESA Fellow); and Johan Basson Branches are encouraged (Honorary Fellow) during the year to identify and nominate members who demonstrate exceptional commitment. The nominations are submitted to EXCO and Council for evaluation and award. Fellows are corporate members of the Institute, registered as engineering professionals, who have been members for at least five years and either hold or have held a senior executive or senior professional position in the field of infrastructure engineering. They will have been of service and value not only to the institute but also to the infrastructure engineering profession. Honorar y Fellows are persons who, in

Elected as Honorary Fellows • Bhavna Soni, Deputy Head: Water and Sanitation Unit, eThekwini Municipality. Soni was IMESA President for the 20202022 term and currently holds the position of Deputy President • Professor Jakobus (Kobus) du Plessis, Depar tment of Civil Engineering, Stellenbosch University, and IMESA EXCO Technical Director: Training and Skills Development • Jeanine du Preez, District Manager: Roads and Stormwater, City of Cape Town, and IMESA EXCO Operations Director: Marketing and Communication • Johan Basson, Function Manager: Urban Development, SMEC South Africa, and IMESA EXCO Technical Director: Infrastructure Comments Sibusiso Mjwara, IMESA’s President for 2022-2024: “The IMESA EXCO and Council would like to congratulate our new Fellows and Honorar y Fellows and thank them for their continued service. Their exemplary roles have and continue to make a positive difference.”

IMIESA Nov/Dec 2023

IMESA

Celebrating the IMESA CESA 2023 Excellence Awards Hosted every two years, the IMESA CESA Excellence Awards provides a platform to showcase exceptional project execution within the public infrastructure arena.

peaking at the opening of the awards ceremony on 24th October 2023, Consulting Engineers South Africa (CESA) President Olu Soluade emphasised the crucial role of engineers as gamechangers in creating a better and more sustainable world. “Excellence is not a static destination, but an ongoing journey, with a major emphasis on the need for perpetual innovation and for ward thinking,” he stated, stressing the need for the design and construction of infrastructure that optimises lifecycle utilisation and leaves a positive legacy.

Geoff Tooley, the master of ceremonies and IMESA’s Vice President: Operations Por tfolios, concurred, stating that “IMESA is proud of its partnership with CESA. Together, we make the difference in promoting professional engineering excellence within municipalities and the communities they ser ve. The planning, design, construction, and maintenance of infrastructure are all key to achieving this.” This year there were 14 entries, competing for an award in one of three categories.

Community Upliftment and Job Creation Category Winner. From left: CESA President Olu Soluade; Balan Govender from eThekwini Municipality Roads Provision – Design Department; and IMESA President Sibusiso Mjwara

CATEGORY 1 Community Upliftment and Job Creation Winner Pedestrian Bridge over Mbokodweni River Client: eThekwini Municipality Roads Provision – Design Department Submitted by eThekwini Municipality

2nd Place The construction of a conventional brick and mortar school at Melibuwa Senior Primary School in the Eastern Cape Province Client: Mbhashe Local Municipality Submitted by BTKM Quantity Surveyors EC

3rd Place Brandwacht Pedestrian Bridge Client: Mossel Bay Municipality Submitted by Royal HaskoningDHV

CATEGORY 2 Environment and Climate Change Winner Ceres Material Recovery Facility Client: Witzenberg Municipality Submitted by Zutari

2nd Place eThekwini Flood Early Warning System Client: eThekwini Coastal Stormwater Catchment Management Department Submitted by eThekwini Municipality

3rd Place Laingsburg Clean and Green Client: Laingsburg Municipality Submitted by Laingsburg Municipality

CATEGORY 3 Engineering Excellence in Structures and Civils Winner CATEGORY 1: WINNING PROJECT The Mbokodweni River has historically served as a boundary of the Durban Metro, resulting in two very different communities on each side of it. The construction of this bridge creates the first and only formal connection between the two communities, with no other way across the river. It provides the only direct access for the Emansomini community to schools, transport and shops, and replaces a bridge that was built by the community members themselves, but which was dangerous or unusable during heavy rains. The bridge is a 100 m long semi-integral reinforced concrete pedestrian bridge without prestress. It is designed with highly optimised, flexible structural sections to allow even the shortest piers to move with the deck’s cyclical expansions, and to absorb the effects of any construction defects. The overall design principal is thus a structure that is unusually tough and highly durable, with minimal maintenance and lifecycle costs.

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Groote Schuur Estate Client: Department of Public Works and Infrastructure Submitted by Zutari

2nd Place Mahatma Ghandi Road Truck Sewer Rehabilitation Phase 2 Client: eThekwini Municipality Water and Sanitation Unit Submitted by eThekwini Municipality

3rd Place Umdloti Storm Damage Rehabilitation Client: eThekwini Municipality Submitted by eThekwini Municipality

IMESA

CATEGORY 2: WINNING PROJECT Located in the southern outskirts of Ceres, the new Material Recovery Facility aims to help consolidate the Witzenberg Municipality solid waste operation. The building orientation and final layout design was influenced by the existing site slope and the prevailing wind directions, while ensuring heavy vehicle manoeuvrability, site drainage, ergonomics, efficient usage of space and public workforce safety. Natural ventilation and lighting were encouraged to cut down on power requirements. Large louvres and translucent cladding panels were installed to aid in this regard. The prevailing seasonal wind direction were also considered in the building orientation and door placement to mitigate refuse being swept away on windy days. The facility is designed to be upgradable in the future when the area’s needs increase.

CATEGORY 3: WINNING PROJECT Zutari was responsible for upgrading electrical and civil infrastructure within the 52-hectare Groote Schuur Estate. Ageing water, stormwater and sanitation infrastructure presented a par ticular challenge, resulting in exorbitant maintenance costs and unsustainable practices. The team radically improved the entire water system including the fire and domestic water, irrigation water, stormwater, and sewerage system. Sewer pipes were relined or replaced using innovative trenchless technology methods to avoid disruptive excavations. A mix of sustainable and renewable water resources were exploited to meet the Estate’s irrigation demands, and an irrigation reserve and sophisticated telemetry system now control this infrastructure. Zutari drew on sustainable urban drainage principals, and used digital simulations, to design optimal stormwater solutions, utilising natural systems such as wetlands to attenuate, polish and release cleaner water into the rivers. The project was delivered on time and within budget.

Our purpose is to co-create an engineered impact that enables environments, communities and economies to thrive. As an engineering and advisory practice, we believe infrastructure has unparalled potential to create an enduring impact. Never more relevant, this potential can be realised only if we plan, design, deliver and manage infrastructure in ways that maximise its value. At Zutari our people connect differently, work smarter, and stay rooted. We reliably deliver impact through infrastructure, making the world a better place - one project at a time.

Environment & Climate Change Winner. From left to right: Joseph Barnard (Director: Technical Services, Witzenberg Municipality), Ferdie van Zyl (Engineer’s Representative, Zutari) and Chris van der Walt (Project Engineer, Zutari)

Engineering Excellence in Structures and Civils Winner. Andre Kayser from Zutari together with CESA President Olu Soluade and IMESA President Sibusiso Mjwara

LEADING PROJECTS

Human-centred engineering is the key to sustainable infrastructure development Human-centred engineering design focuses on creating infrastructure that not only meets immediate needs, but also considers the long-term implications of projects. Such an approach delivers enduring assets in line with sustainable infrastructure development. This is according to Chris Van der Walt, a Civil Engineering Associate at leading consulting engineering and infrastructure advisory firm Zutari.

an der Walt is professionally registered with 22 years’ experience in project management, civil engineering design and construction supervision of various mixed-use and municipal infrastructurerelated projects.He has been involved with diverse projects from South Africa to Ethiopia, Seychelles, Kenya, Tanzania, Malawi, Angola, Rwanda, Cameroon, and Ghana, relating to all aspects of civil engineering. “One of the key ways that we deliver resilient systems is by prioritising sustainability in our engineering solutions. By using sustainable materials and practices, we have created durable, long-lasting, and environment-friendly infrastructure. It not only reduces the impact of infrastructure on the environment but also minimises maintenance costs over time, making it more resilient in the face of unforeseen disruptions,” comments Van der Walt. Zutari provides global engineering, management, specialist technical and advisory services for government and private sector clients. It is committed to the application, regular review and continual improvement of its sustainability and resilience approach.

Case studies that define best practice An example of two diverse, successful projects undertaken by Zutari that embed sustainable infrastructure development and resilience considerations into its skills, services and project

Chris Van der Walt, Civil Engineering Associate, Zutari

16 IMIESA Nov/Dec 2023

deliverables are the Groote Schuur Estate refurbishment and the Ceres Material Recovery Facility (MRF), both in the Western Cape. Sustainable infrastructure development encompasses a myriad of factors, from health and safety to environment, corporate social responsibility (including B-BBEE), ethics and integrity, diversity and inclusion, project sustainability and resilience and regular reviews to indicate performance improvements. Zutari was appointed civil and electrical engineer and provided principal agent services at the Groote Schuur Estate refurbishment project, which involved upgrading and refurbishing existing civil and electrical infrastructure, explains Gehardt Müller, a professional civil engineer and associate at Zutari. Müller has 19 years’ experience in civil engineering design, project management and site supervision on mixed-use land developments in Southern Africa, Nigeria, the Middle East, Southeast Asia and water engineering in Australasia. The R160 million project included labourintensive construction (LIC) methods, Expanded Public Works Programme (EPWP) and National Youth Service (NYS) programmes and appointing and developing

small, medium and micro enterprises (SMMEs). Young EPWP learners underwent classroom and on-site training as part of the government’s NYS initiatives to create jobs and facilitate training and skills development. Socioeconomic impact is an integral aspect of sustainable infrastructure development. Therefore, the SMME development target for the Groote Schuur contract was set at 40 % of the total construction value. The contractor appointed local SMMEs to undertake most of the LIC work to empower small black-owned companies and facilitate their growth to achieve higher CIDB gradings. “During the design period, we spent a lot of time walking around the 50 ha site to try to understand the existing services, natural resources, and the general layout of the land. The extent of the historic site and myriad of services, some known and some unknown, drove us to walk many kilometres exploring unused and forgotten areas for years,” says Müller. Zutari had to devise creative ways to salvage some materials or retrofit the existing dilapidated infrastructure. Old stone terraces, channels and walls were exposed and worked into the designs. “We made a concerted effort to maintain the heritage elements, look and feel of the site and worked hand in hand with the landscape and heritage architects to get it right,” says Müller. Quality products that would endure were specified. This manifested in simple details like the doors at the pump station being solid wood from a good supplier instead of being left to the contractor’s discretion as is usually the case. Natural resources found on-site were utilised, from building rubble to natural Table Mountain sandstone. “All of this meant that we had to rethink how we applied stock-standard details. Almost all the designs were designed specifically for

Gehardt Müller, Civil Engineer and Associate, Zutari

LEADING PROJECTS

purpose within the constraints of the existing landscape,” notes Müller. He adds: “It is gratifying to walk around the site to see the difference this project has made, not only functionally but also aesthetically. By taking a long-term view of sustainable infrastructure development, we ensured that the project delivers good value for many years.”

Resilient and future-proof Sustainable infrastructure development recognises the need to balance economic growth, including the financial viability of the companies involved, with social development and protecting the environment. “We integrate the principles of sustainability and resilience into our culture,” says Müller. “We assist our clients, partners and stakeholders to meet their sustainability commitments and advise them on increasing their resilience and crisis preparedness with foresight. An example of this approach was the Ceres MRF identified in terms of the larger Witzenberg Municipality and Cape Winelands District Municipality’s waste management strategy and development plan,” says Van der Walt. The project included initiatives to maximise local labour and local content that promoted new job opportunities and facilitated training and skills development. During the planning stage, Jospeh Barnard, Director: Technical Services of Witzenberg Municipality, requested Zutari to ensure the project is planned to be future-ready. The facility is therefore designed to allow for the municipality’s future needs and population growth by allowing it to expand with a second conveyor line. Currently the MRF is

An external perspective of the Ceres Material Recovery Facility

Groote Schuur Estate: stormwater channels made with stones found on site

operated as a wet/dirty MRF which can be converted to a dry/clean facility as the public awareness adapts. Waste from Ceres, Wolseley, Tulbagh, Prince Alfred Hamlet, and Die Dorp op die Berg will be processed at the Ceres MRF, whereafter it will be recycled and tailings consolidated and transported to the regional Worcester Landfill Facility. A site was identified across the bridge at the end of Lyell Street in Ceres, adjacent to the Ceres wastewater treatment works, that met all the accessibility, financial and ecological criteria. While conventional construction methods were used to build the Ceres MRF, the building orientation and final internal layout design were influenced by the existing site slope and prevailing wind directions. This was prioritised to create an efficient design needing minimal earthworks and to afford proper protection for the workforce at the facility.

A site layout was developed in conjunction with the municipal engineering team, which went through various revisions until an optimal solution was found to accommodate factors such as heavy vehicle manoeuvrability, site drainage, ergonomics, efficient usage of space and public and workforce safety. “The Witzenberg Municipality has developed and implemented a public awareness and education campaign about waste avoidance and reduction at source. The campaign highlights how the public can avoid or prevent waste generation and suggests alternatives to high wasteproducing products and activities. Measures to reach the public locally are also being explored,” notes Van der Walt. “For example, refuse skips have been placed at the facility, while the community is encouraged and financially incentivised to bring recycled material to the local hub. The Ceres MRF forms part of a far larger plan to provide a better level of service throughout the Witzenberg Municipal area,” says Van der Walt. Sustainable infrastructure development also refers to smart infrastructure that improves liveability and reduces the carbon footprint. Zutari has the multidisciplinary resources to develop and deliver sustainable infrastructure for a range of clients in both the public and private sectors. It provides these clients with access to strategic advice, technical expertise, and advanced data analytics while focusing on project delivery, regulatory compliance, and community acceptance.

IMIESA Nov/Dec 2023

TRENCHLESS TECHNOLOGY

Mahatma Gandhi trunk sewer line rehabilitation showcases innovation

The employment of cured-in-place pipe (CIPP) lining technologies to rehabilitate a 1 350 mm diameter trunk sewer pipeline in Durban Central underscores the advantages of trenchless techniques to repair critical infrastructure in dense urban areas. At the time of construction, it was the longest and largest diameter of CIPP liner installed in Africa, winning the 2021 Award of Excellence from the Southern African Society for Trenchless Technology. By Reudebaker Nel, Pr Eng*

he existing 1 350 mm diameter concrete trunk sewer pipeline in Mahatma Gandhi Road was constructed in 1954 with a total length of 1 850 m. As a strategic sewer pipeline, the pipe carries most of the central region of sewage catchment in Durban.

18 IMIESA Nov/Dec 2023

In recent times, cracks and subsidence appeared on the road surface above the pipe, which the eThekwini Water and Sanitation Unit suspected was due to the concrete sewer line. They carried out a detailed inspection using closed circuit television (CCTV) cameras and found that the pipe

Plan showing overall scope of work

was severely corroded and close to collapse, requiring immediate attention.

Phase 1 Work was started on Phase 1 of the project for a length of 640 m. However, due to budget constraints, only 560 m was completed. Here the scope – using open trench construction methodologies – entailed the installation of a new 1 250 mm diameter structured wall HDPE pipeline at a depth of 7,7 m at its deepest point, located well below sea level, with the water table being 1,1 m below the road surface. Therefore, the construction approach required sheet metal shoring and extensive dewatering to work at these depths. The new pipeline was constructed parallel to the old pipeline, enabling minimal disruption to the sewage flow in the existing pipe until the new pipe could be connected into the existing

TRENCHLESS TECHNOLOGY

tie-in manholes. It was a slow process due to the ground conditions and it affected traffic and the surrounding business significantly during the 18-month construction duration.

Phase 2 Phase 2 of the project set out to complete the work started in Phase 1 (80 m of open trench method construction). However, using the lessons learnt from Phase 1, and to avoid major disruption to the public, a trenchless approach was chosen using CIPP to rehabilitate the existing concrete pipeline. The rationale behind this was that CIPP liner – cured using ultra violet (UV) light – would cost less when compared to open trench construction for the equivalent length and be completed much faster. This was especially the case given the pipeline’s location in a road reserve with many underground services and in close proximity to businesses, as well as variances in pipeline depths of 5 to 7,7 m in waterlogged conditions (high water table) below sea level. In addition to the 1 350 mm diameter concrete trunk sewer pipeline, rehabilitation of a 210 m long 300 mm diameter asbestos cement (AC) pipe using CIPP thermal curing was also part of the Phase 2 project scope. This AC pipe, situated in Mahatma Gandhi Road between Browns Road and Camperdown Road, was broken in places, and needed to be replaced in sections and rehabilitated. Due to the proximity of an existing large diameter water main and other services, the relatively cheaper cost of CIPP rehabilitation was selected.

CIPP characteristics and project benefits Essentially, CIPP entails the use of a fabric Evidence of corrosion inside the existing 1 350 mm diameter concrete pipe

tube reinforced with glass fibres impregnated with polyester or epoxy resin. Thermal cured tube liners are composed of needled polyester felt fibre material, while UV cured liners use a glass fibre reinforced tube liner material. The tube is inserted into an existing pipeline and inflated by compressed air against the pipe wall, then cured either by hot water or steam (thermal cure) or by UV light to cure the resin to form a new pipe inside the existing pipe. The liner is designed to take the loading of the pipe as if the host pipe was not there. Additionally, the smooth inner surface of the CIPP liner results in a low hydraulic roughness, ensuring better flow through the pipe. For this project, a UV cured liner was selected for the 1 350 mm diameter concrete pipeline for the following key reasons: • The construction footprint is relatively smaller than the thermal method, thus causing less disruption to the public. During installation one vehicle lane width was used. • The liner strength and the flexural modulus of a UV cured liner is higher than a thermal

On-site ovality measurement after flow diversion and pipe cleaning

cured liner, which was the essential criteria considering the pipe depth of 7m. • Due to the pipe’s large diameter of 1 350 mm, a UV cured liner thickness will be thinner, thus allowing for more pipe capacity and lesser weight for each liner, which has a practical installation advantage. • In terms of construction, the UV liner has an advantage over thermal cured CIPP in that the installer can see the liner that has been pulled in place before it is cured, thus ensuring better quality control. • UV CIPP requires minimal energy and water consumption during the curing process and refrigeration of the uncured liners is not required as per thermal cured CIPP. CIPP liner being inserted into a manhole using a conveyor belt for the UV curing stage of the project

IMIESA Nov/Dec 2023

TRENCHLESS TECHNOLOGY

• UV cure time is much faster than thermal cure. • Cure time for a section of a liner occurs once a light train passes at a programmed speed, as opposed to thermal cure where the entire length must be brought up to temperature for cure to occur. • UV cured liner can be installed during the day, as opposed to a thermal cured liner, which can only be installed in the night, which presented a programme advantage. • UV cured liner has a significantly longer shelf life than a thermal cured liner, which was essential for this project in terms of ordering of materials ahead of installation to match the installation programme. The required CIPP liner thickness was calculated using ASTM F1216 (Standard practice for rehabilitation of existing pipelines and conduits by the inversion and curing of a resin impregnated tube, Appendix X1.2.2). The thickness calculated was then checked for each length of pipe between manholes for loading at invert, minimum thickness for ovality measured on site and for hydraulic, soil and live loads at the top of the pipe, which is generally the check that governs the required thickness. The ovality of the pipe was obtained by physical measurement on site and proved critical in the design process. Largest ovality observed from physical measurement was 5% and the liner thicknesses installed varied from 10,8 mm to 14,9 mm. The UV cured liner selected was imported from the supplier in Germany.

Diversion of existing flow for rehabilitation A major constraint of the project was the diversion of sewage flow and the critical sequence of the flow diversion. Ahead of the works, the existing flow was required to be diverted into the adjacent trunk sewer pipes, namely Shepstone Road Trunk Sewer (860 mm diameter) and Quayside Road Trunk Sewer (1 050 mm diameter).

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AC 300 mm diameter pipe refurbishment: CIPP liner being installed by the inversion process

An investigation of the sewage flow in the adjacent pipelines and the existing 1 350 mm diameter pipeline was carried out using an ultrasonic level transducer located inside different manholes. The flow results indicated that the adjacent pipelines had sufficient reserve capacity to cater for the diverted flow of 410 ℓ/s peak flow from the existing 1 350 mm concrete pipe, subject to the removal of silt from these pipelines. The cumulative amount of silt that was removed during the project was 437 m3, which equated to approximately 20 % of the volume of the pipe. Since the affected pipelines were not desilted for a long period of time, the silt in the pipe was compact and cementitious in consistency – thus difficult to remove – which posed a challenge to the contractor during construction. The nearest waste management facility that would accept the silt material was the Dolphin Coast Waste Management Facility located some 50 km from the site.

CIPP liner installation challenges Numerous challenges were experienced during installation of the CIPP liner inside the existing 1 350 mm diameter concrete pipe, mainly due to the weight of the liners (up to 15 tonnes). Existing manhole shaft top slabs needed to be removed to facilitate the installation of the liner and limited space in these manholes made working conditions very difficult. In some cases, sheetpiled shoring had to be deployed to get access to the manhole reducer slabs. In preparation for installation of the liner, it was required that all sewage flow had to been diverted, ensuring there was no water/liquid in the existing pipe, and that

the pipe had been cleaned sufficiently to identify any obstructions/intrusions, which could otherwise obstruct or damage the liner during installation. The liner was transported to site by truck, still in its protective packaging. Thereafter, it was inserted into the receiving manhole using a conveyor unit with a roller installed to guide the liner inside the manhole and then pulled into the pipe using a winch. Once placed, the liner was inflated slowly to position it. Thereafter, the pressure was released, and the UV light train inserted. Once the light was activated, it was then pulled through the liner at a nominal speed depending on the strength of the light source and as per manufacturer’s recommendations. A total of 17 liners were installed. And to ensure additional quality control during construction, specialist installation technicians from the supplier were also on site. During the hardening process the pressure, position, and progress of UV light, plus the functioning of the UV tubes and reactive temperature, were recorded. Once fully cured, samples were cut, labelled, and sent for testing to an approved materials laboratory in Germany.

AC section For the 300 mm diameter AC section, point repair replacement was carried out by open trench construction. Once these

UV light train equipment ready for deployment

were completed and the sewage diverted by bypass pumping, the pipeline was rehabilitated by the CIPP thermal curing method. As with the concrete pipe, the liner was designed for fully deteriorated gravity pipe condition. This liner, measuring 6 mm in thickness, was fabricated in Cape Town, transported to Durban, and fully installed in one night.

Conclusion With many technical and practical on-site challenges, the overall project was a great learning curve, and serves as an excellent case study for municipal engineers when considering the implementation of trenchless techniques for pipeline rehabilitation. On the Mahatma Gandhi trunk sewer line project, timeous implementation of the programme by the contractor was crucial considering that sewage diversion, pipe cleaning, ordering of liners from Germany, cash flow management and installation all had to follow a well-timed sequential path. Thanks to everyone involved, the project was a great success, and completed on time and within budget. *Chief Civil Engineer and Acting Area Project Manager: South & West Regions, eThekwini Water & Sanitation Unit Typical UV light train inside the pipe during curing

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Fully installed CIPP liner cured by UV light

This is an edited version of the paper entitled “A case for Trenchless Technology – Mahatma Gandhi Truck Sewer Rehabilitation Phase 2” presented at the 86TH IMESA Conference held between 25th and 27th October 2023. The full paper can be downloaded at www.imesa.org.za.

More information about PipePatrol: krohne.com/pipepatrol

Acknowledgments The author hereby acknowledges the valuable inputs of Rob Van Vuuren and Hannes Coetzee from the Tuboseal Services/CSV Construction Joint Venture.

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PIPE SYSTEMS

Leak detection for energy transition With a shift from fossilbased systems to renewable energy sources also comes a shift in terms of transportation. This is equally true for pipeline leak detection systems. By Max Ihring* and

Daniel Vogt**

ome pipelines transport 100% hydrogen while others a blend with natural gas. Carbon dioxide (CO2) can be transported as gas, liquid or in supercritical state. As a result, the leak detection system needs to be able to work with these different mixtures and phases. For classical leak detection systems this is a problem. Negative Pressure Wave leak detection systems are affected due to damping in gas. Classical statistical systems are affected due to compressibility and linepack changes. This leads to long detection times or high thresholds. The systems will react with a loss of sensitivity or in the worst case with false alarms. This is a typical application for Real-Time Transient Model (RTTM) based systems, which try to consider all the different products and pipeline properties in its calculations. However, if the fluid cannot be accurately modelled by the system this leads to false results. With Extended Real-Time Transient Model technology (E-RTTM) these disadvantages are compensated by Signature Analysis. Signature Analysis makes the system less sensitive against inaccuracies in RTTM calculations. Thus challenging pipeline conditions, product parameters or mixtures, e.g. hydrogen blends, leading to inaccuracies become less important. In PipePatrol the RTTM is used for filtering purposes and leaks are detected by pattern recognition techniques.

E-RTTM explained KROHNE, a manufacturer of measuring technology and established supplier of systems to the pipeline industry – with more than 35 years of experience in leak detection and localisation systems – developed E-RTTM. An E-RTTM leak detection system creates a virtual image of a pipeline and uses standard process instrumentation for flow, temperature and pressure

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Basic functional principle of E-RTTM

Process scheme: leak detection on a CO2 pipeline from LNG plant

PIPE SYSTEMS

measurements. The hydraulic profiles along the virtual pipeline are calculated from the measured pressure and temperature values. The model compares the calculated flow values with the actual values from the flowmeters. If the model detects a discrepancy, the leak signature analysis module determines whether it was caused by changing pipeline operation, an instrument error or a leak.

THE IMPORTANCE OF STANDARDS FOR HDPE PIPING SUSTAINABILITY In a recent webinar hosted by the Southern African Plastic Pipe Manufacturers Association (SAPPMA), the spotlight was firmly placed on high-density polyethylene (HDPE) as a sustainable and durable piping material.

Leak detection system for hydrogen The leak detection system was installed on a Power-to-Gas project, which was the world’s first demonstration plant for storing wind energy in the natural gas grid. As the leading leak detection system provider in Germany, KROHNE had been recommended by an independent third-party authority to be the supplier for the leak detection system. The E-RTTM technology was selected due to its ability to measure a product even in small leak quantities. This was the first Powerto-Gas Application equipped with a PipePatrol leak detection system in 2013. Since then, PipePatrol has been installed on more hydrogen pipelines.

Leak detection system for carbon capture Another case study serving to demonstrate KROHNE’s E-RTTM technology is the Gorgon gas field in Western Australia. Natural gas from the Gorgon gas field contains around 14 % naturally occurring CO2. Prior to converting the natural gas to LNG, the CO2 is removed. To minimise the environmental footprint, the separated CO2 is injected in a storage formation. A 7 km long pipeline transports the CO2 from the LNG liquefaction plant to the CO2 injection wells. The requirement was to provide a pipeline leak detection system that provides timely and accurate leak information for the pipeline segments between the LNG plant and drill centres. The project involved unique conditions, such as the properties of CO2 in supercritical phase and flow measurements done by orifice plates with limited rangeability.

HDPE pipe

eorge Diliyannis, employed in marine outfall senior application applications specialist at Safripol, delivered a compelling presentation that highlighted both the virtues of HDPE and the pivotal role of standards in ensuring its lifespan. A key aspect of Diliyannis’s presentation revolved around ISO 4427 and its role in guaranteeing the durability of HDPE piping. “The standard forms the backbone of HDPE material properties, establishing the foundation necessary to endure the stresses and demands of extended service life. By complying with the specifications laid out in ISO 4427, HDPE piping systems can achieve design lifetimes of 50 years or more. This standard is therefore not just an option, but a critical tool that ensures the reliability and longevity of HDPE systems,” says Diliyannis.

Summary KROHNE, a manufacturer of measuring technology and established supplier of solutions to the pipeline industry, with over 450 installations and more than three decades of experience in pipeline leak detection and localisation systems, provides extended PipePatrol E-RTTM, a leading technology for monitoring of pipelines. Through the possibility to adapt the model to the different requirements of applications, the overall result is better. Due to the Signature Analysis, the system is less sensitive against inaccuracies in the process and modelling of the fluid. The technology is industry proven for liquid, gas and slurry applications. Smallest detectable leak rates are typically 0,5% and below, with leak detection time in seconds, and confirmation within minutes. It has an exceptionally low false alarm rate due to optimisation. And leak localisation is best-in-class. *P roduct Group Manager, Pipeline Management Solutions, KROHNE ** Business Unit Manager, Pipeline Management Solutions, KROHNE

The significance of CEN TS 12201-7 Fur thermore, the webinar also delved into the significance of CEN TS 12201-7, which focuses on conformity assessment procedures for HDPE piping systems. CEN TS 12201-7 goes beyond just the materials themselves: it encompasses the evaluation of compounds, products, joints, and assemblies, emphasising a holistic approach to HDPE system performance. The standard also recommends quality management systems and certification procedures. “Only when manufacturers, authorities, and professionals adhere to both product and process standards as outlined in these documents can HDPE piping systems confidently achieve design lifetimes of 50 years or more,” Diliyannis concludes. For more information, visit www.sappma.co.za George Diliyannis, senior application specialist at Safripol

IMIESA Nov/Dec 2023

ENVIRONMENTAL ENGINEERING

The cost

of restoring our beaches

A Terraforce seawall installed at Herolds Bay formed part of a reconstructed system after a section of the existing structure collapsed. During subsequent unprecedented swells, the Terraforce wall held back the storm and has continued to function optimally

During September 2023, South African beaches again suffered considerable damage from a seasonal winter storm. A combination of high spring tide and strong onshore winds – with waves of up to 9,5m high – affected 50% of the southern coastline.

rom year to year, events of this nature occur in various levels of intensity. Some experts claim that man-made climate change is to blame, while others say these storms are part of normal phenomena which has influenced weather patterns since the dawn of creation. It is also safe to assume that infrastructure development, encroaching into the coastal zone beyond the high-water mark, is a contributing factor toward the damage suffered. “Be that as it may, we will have to respond in a measured and sustainable manner,” says Holger Rust, founder and head of Terraforce, a leading inventor and manufacturer of precast concrete hollow core block systems. An invaluable research and reference work is the Informing Coastal Erosion Decision Making Guideline published by the Western Cape Government’s Department of Environmental Affairs and Development Planning, which can be downloaded from their website. The guide refers to “hard techniques” to counter erosion that include revetment and retaining walls, alongside other measures.

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Within the design mix, concrete block retaining walls have been well proven – when professionally designed and installed – as highly effective remediation and mitigation measures within marine environments. Here Terraforce® blocks have played a key role on a broad range of beach stabilisation projects, often in combination with allied methodologies.

Designs must meet legislative requirements An important point to note is that Section 15 of the National Environmental Management: Integrated Coastal Management Act 24 of 2008 stipulates that all proposed erosion protection measures in a coastal zone must be planned and approved through the prescribed channels. “This has the benefit of ensuring that only the best systems are selected for these crucial interventions to preserve existing ecosystems,” Rust continues. For heavy duty protection works, it’s not uncommon to use solid concrete walls – either precast or cast in-situ – to create vertical or

sloping structures. However, these methods (often combined with extra heavy rock rip rap) are not always possible due to their prohibitive cost or the lack of solid founding conditions, so alternative solutions need to be identified. Where good rock foundations occur, or on sandy beaches that can accommodate foundations (installed below lowest scour profile) concrete retaining blocks are often the preferred route, subject to a detailed site assessment. The extent of direct or indirect wave action is one of the key considerations.

Laguna Beach: a case study A prime example of a well-executed retaining system is the Laguna Beach project on Durban’s seashore near the Umgeni River mouth. Completed in 1986, this 6 m high concrete retaining block wall is one of the oldest installed in South Africa, and it’s still securely in place – screened by its succulent vegetation. Seashore protection at The Point, Mossel Bay

ENVIRONMENTAL ENGINEERING

A technical cross section of the Laguna Beach retaining wall

The wall was designed by consulting engineers, Campbell Bernstein and Irving, with construction carried out by Goldstein Civils (Natal) with the purpose of retaining beachfront recreational facilities that include kiosks and paddling pools. Key design factors to consider included: • Anticipated depth of scour and erosion protection at foundation level • Dissipation of hydrostatic pressure by means of effective backfill design and drainage measures, and • Providing a solid buffer with enough mass and rigidity to withstand occasional direct wave attack. Prior to the construction of the wall, the beach had eroded down to foundation level on a number of occasions when big storms hit.

Construction approach A minimum Terraforce element mass of 38 kg (790 kg/m2 constructed mass including topsoil) was specified. Furthermore, for durability in this aggressive coastal environment, a cement content of 300 kg/m3 concrete was used in making the Terraforce units.

After excavating the beach to its foundation level (1.5 msl and also the level of the water table) a 1 100 mm long x 250 mm deep foundation of 25 MPa concrete was cast. Thereafter Terraforce elements filled with 15 MPa concrete – hot dip galvanised dowels locking individual rows together – were installed to a height of approximately 3 m to reach beach level. Selected coarse backfill and weepholes were provided. Then as a front line of defense in case of severe beach erosion, a gabion mattress apron was placed at the toe of the concrete foundation, topped with sand backfill (4 % cement mix composition) to the level of the retaining block founding units. With this phase now finalised, the contractor then proceeded to construct the stepped back wall to its full height of 6 m above foundation level, with the individual blocks filled with plant supportive topsoil.

Composite retaining wall with foundation under sea level in Ajman, Dubai

An erosion control structure constructed using Terraforce retaining blocks at Laguna Beach, Durban. The structure is curved to match the radii of the paddling pools that were built above, and an existing stormwater outfall was incorporated to form a functional yet attractive spillway onto the beach

Currently the wall is almost completely buried by sea sand, deposited there by waves and currents. “This phenomenon, referred to as beach filling/nourishment, has possibly been helped by groynes – hard structures of heavy rock at right angles to the beach – that were installed further west, since 1986,” adds Rust. “What is certain is that when employed as a fit-for-purpose solution, concrete retaining block walls will withstand the elements and help preserve sensitive coastal environments for many decades,” Rust concludes.

www.terrforce.com

IMIESA Nov/Dec 2023

ENVIRONMENTAL ENGINEERING

Soil retention is key for structural integrity and the environment

Kyloe Village Dam Project: The repaired spillway featuring a mass gravity gabion structure, safeguarding the downstream side, while gabion mattresses provide vital protection in the horizontal zone behind the vertical wall. The concrete vehicle crossing, fortified with a concrete overlay over the gabion mattresses, ensures long-term stability in the face of erosion challenges

For any structure, a sound foundation is the basis for its longer-term integrity, with the geotechnical elements a core part of this process. This is especially true for mass gravity retention systems designed to retain the soil and counter erosion on walls, embankments and riverbanks. IMIESA speaks to Louis Cheyne, managing director of Gabion Baskets, about why gabion wire systems are among the most sustainable options.

orking across South Africa and Southern Africa, Gabion Gaskets is a specialist manufacturer of gabion and related environmentally engineered systems, dovetailing with which is a comprehensive suite of design

recommendation ser vices, installation training, project and construction management solutions. Headquartered in Johannesburg with branches in Cape Town and Durban, the network is further supported by dealers in all main centres of South Africa and key SADC countries.

The spillway breach has been restored, with ongoing construction focusing on shaping and excavating for the horizontal mattress base and mass gravity gabion structure

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“For an uninformed observer, the globally manufactured and standard hexagonal doubletwisted Class A galvanised wire products employed predominately for civil engineering gabion applications may seem ‘flimsy’, but their tensile strength is actually extremely robust and will withstand the elements for decades. Once filled with rock, they can, for example, comfortably serve as abutments for bailey-type bridges, lowvolume river ford crossings, plus a wide range of retaining structures,” Cheyne explains. Gabion Baskets specialises in custom, preassembled gabion panels for specific projects, as well as standard “off-the-shelf” products that are generally acquired by contractors. Options include standard wire lacing to tie individual baskets together, or the employment of hog ring clips using specialist pneumatic guns or manually equivalent tools for fast and efficient connections.

The magnitude of erosion becomes evident when contrasting the 1 m central segment of the check dam with the upper edge of the donga, illustrating the impact of flooding on erosion

The comprehensive project is encapsulated in this image, including the construction of a gabion mass gravity structure, the installation of Check Dams 1, 2, and 3, and the strategic placement of a 2 m high cut-off wall between Check Dams 2 and 3. This intervention was specifically aimed at mitigating cut bank formation on the outer bend where water with the highest velocity presented a significant challenge

CASE STUDY: KYLOE VILLAGE DAM In February 2023, a momentous meteorological event unfolded in the vicinity of the renowned God’s Window, situated between Graskop and Bushbuckridge, which experienced an astounding 754 mm of precipitation. This climatic occurrence wreaked havoc on various critical infrastructure elements, including Sappi’s Kyloe Village Dam, which was one of the most severely impacted. The spillway of the dam bore the brunt of the damage, succumbing to complete erosion. Additionally, this meteorological episode led to the formation of a donga, measuring approximately 100 m in length, 20 m in width at its widest point, and with a depth reaching around 5 m. Recognising the gravity of the situation, Hannes Vosloo, Sappi’s forestry manager overseeing civil engineering projects, swiftly acknowledged the need for external expertise. He turned to Fanie Joubert of Civil, Structural, and Eco-Engineering, based in Nelspruit, which is also Gabion Basket’s agent for Limpopo and Mpumalanga. Given the area’s delicate ecological equilibrium, it was imperative to exercise the utmost care and precision to minimise disturbances both to the surrounding environment and the newly formed donga. Gabion erosion and stabilisation structures Following a thorough examination and an in-depth topographical sur vey of the affected site, Joubert conceived a comprehensive proposal centred on the creation of gabion erosion and stabilisation structures. The rehabilitation endeavour entailed the procurement and utilisation of approximately 600 t of gabion rock and 600 m3 of filling material to reinstate and fortify the spillway. Furthermore, the project encompassed the strategic construction of three check dams within the confines of the donga. Careful calculations were made to determine the spacing between these check dams and the spillway’s base, ensuring a minimum water depth of 300 mm. This precise configuration was crafted to induce a calming effect on the water flow, thereby facilitating sedimentation in the area. Additionally, a 2 m high gabion wall was erected between Check Dams 2 and 3, targeting areas where erosion had been particularly severe. Having clinched the contract for execution of the project, Civil, Structural, and Eco-Engineering commenced construction activities on 29th August 2023 with a dedicated workforce of six individuals. In support, a 24 t excavator was employed for 14 days and a backhoe loader utilised for 20 days. Despite the formidable scale and demanding timeline of the project, the team achieved an admirable feat by successfully completing all assigned tasks by 20th September 2023. Their remarkable efficiency ensured compliance with the mandated completion date of 30th September 2023. The key is ensuring their correct rock-fill composition within the integrated design (river or land-based – a much higher material wear needed for the former given constant scourer conditions). It is imperative that hydraulic elements are well understood and factored in, which requires professional verification. Gabion systems have up to a 35 degree of permeability – controlled to a greater or lesser extent by woven or non-woven geotextiles, depending on the soil characteristics. For

example, clayey soils are water retainers, so woven systems are preferred for controlled drainage. On the other hand, sandy soils need full retention with non-woven systems.

The importance of stormwater management “Either way, though, the design must always consider the need for additional drainage systems when it comes to erosion control. For mass gravity concrete retaining block

ENVIRONMENTAL ENGINEERING

(CRB) wall systems this is a fundamental requirement because they don’t benefit from the advantages of overall gabion permeability,” Cheyne continues. “Without adequate drainage systems, hydraulic pressure build ups could eventually lead to a wall collapse.” A recent example is a design recommendation, supply and project management contract secured by Gabion Baskets for the replacement of a collapsed CRB wall at Silver Star Casino in Krugersdorp, Gauteng. The reinstated wall height ranges from 9 m down to 4 m, with a length of 40 m, with the works completed over a two and a half month timeframe. The scope entailed the supply of some 900 m3 of gabion baskets, with an average daily work rate of around 20 to 30 gabion baskets installed daily. “As testimony to the importance of secure founding conditions, during initial site preparation, the site team identified a major

SILVER STAR CASINO Gabion Baskets recently secured a design recommendation, supply and project management contract for the replacement of a collapsed mass gravity CRB wall at Silver Star Casino in Krugersdorp, Gauteng.

crack in the ground, right above the area where the new gabion retaining wall was planned for construction. To remediate this, the team excavated up to this crack and then commended the preparation of the concrete foundation for the wall,” Cheyne explains.

Riverworks Outside South Africa, Gabion Baskets has secured new work in Zambia, entailing gabion supply for the construction of a 300 m long river erosion wall alongside the Zambezi River to combat seasonal flooding. Another project in the pipeline is the reinstatement of a failed river wall some 1 to 2 km further away. “The original mattress extending into the river on the failed section requiring reinstatement was too short. The wall was also too close to the river. This meant that the water was seeping through underneath, creating an erosion cavity into which the original wall settled, detaching from the bank. During reinstatement, the excavation will go deeper into the riverbank to accommodate a longer mattress footprint reaching to the toe of the embankment, and the original retaining wall will then be rebuilt in its new position. Clearly, this project underscores the vital requirement to accurately estimate river flow conditions when installing a gabion mattress foundation,” explains Cheyne.

Allied erosion and barrier systems As a leader in its field, Gabion Baskets also supplies allied erosion control systems for temporary and permanent works. These include FiberRock geosynthetic sand containers for beach erosion control and protection, as well as gabion barrier systems used for applications like flood countermeasures or berms. Gabion barrier systems consist of square-shaped, high strength geotextile bags framed by wire mesh panels that are laced together. These bags can be filled rapidly using a backhoe loader or excavator with any on-site material. Plus, an added benefit is that the systems can also be reused.

Responding to climate change “Climate change has resulted in an unprecedented increase in extreme weather conditions, resulting in the widespread increase of devastating floods. Coupled with this is the increased use of land for agriculture, building and infrastructure. Where natural land is disturbed, it needs to be retained to prevent soil losses and the potential for structures being undermined, dams being silted up, and riverine zones being compromised. That’s where gabions come it as a cost-effective and environmentally engineered interface,” Cheyne concludes.

Clean-up operations in progress

A collapsed section of the CRB wall at Silver Star Casino

Gabion wall foundation being established

Work in progress on the new mass gravity gabion retaining wall

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WASTE MANAGEMENT

MANAGING SHUTDOWN WASTE STREAMS AND CONTAMINATION SPILLS Carrying out essential preventative maintenance shutdown activities is a vital part of ensuring sustained plant operations by routinely checking the condition of critical components such as pipes, pumps, and tanks.

For all its specialist solutions, EnviroServ’s teams verify the correct disposal method required, as well as which waste streams can be recycled

Hazardous clean-up services

longside this is the need for the safe removal and disposal of any residue waste streams, an area where EnviroServ has extensive experience in managing the tight schedules required to fast-track shutdown turnaround times. “We employ safety officers and skilled workers for the task that needs to be completed on site to ensure the shutdown is being run according to SHEQ standards, operational efficiencies and avoid any lost time injuries because people’s lives come first,” says Hugh Khumalo, EnviroServ’s regional commercial manager: Inland South. Sometimes, for example, workers are required to enter a tank to manually remove sludge build-ups. During tank entry, the EnviroServ team manage risks to ensure there is sufficient oxygen and no poisonous gases. They also verify whether additional equipment, such as airlines masks, must be utilised for tank entry and safe execution of the planned work.

The critical planning steps “We engage with our customers during the planning phase as they know their plants better than we do, such as the potential for fires and what hazardous materials are in their plants. We then determine

the correct PPE that should be worn,” Khumalo continues. The second step after a safety analysis is to cost a shutdown. “We establish what waste can be recovered or recycled and what has to be landfilled. We list our method as part of our costing, and determine the staff complement needed for day and/or night shifts,” he explains. With sustainability increasingly important to EnviroServ’s customers, the amount of recycling gets recorded for reporting purposes. “We always conduct a postmor tem to see what positives were achieved, such as if we saved a customer money by completing our clean-up early and look at what could have been done better.”

EnviroSer v also offers industr y leading pollution preventative products, containment concepts and clean-up solutions matching international standards. “Our focus is on reducing environmental risk – we walk our customers through the applicable waste legislation to ensure total legal compliance,” says Henco Swar t, EnviroServ’s industrial services manager. “We assist with planned project cleanups for chemical and hydrocarbon spills, and sell spill kits containing our absorbent range, which allow customers to manage and clean-up these types of smaller spills on their own.” The company provides basic training on how to use the products. “Booms of 2 to 4 m in length are deployed in conjunction for spill containment and clean-up to contain and control the waste body. An absorbent fibre is then applied to the surface to absorb the spill,” he adds. In turn, EnviroSer v has a range of environmentally friendly degreasers, which are used after the waste has been absorbed and the absorbent products have been removed. In addition, the company conducts rehabilitation and remediation projects, removing contaminated soil and formulating remediation plans, either in-situ or ex-situ. “The remediation process is tracked through laboratory analysis to ensure the goal has been achieved,” Swart concludes.

During routine plant shutdowns, EnviroServ conducts an in-depth risk assessment in conjunction with the customer to identify all known hazards. The correct PPE is then specified to meet the requirements of each clean-up operation

IMIESA Nov/Dec 2023

WATER & WASTEWATER

RETROFITTING FOR WATER CONSERVATION: TRANSFORMING THE FUTURE

Rand Water is dedicated to suppor ting both industries and communities in becoming conscientious water consumers. This commitment is exemplified, in par t, by its Water Wise brand. Beyond educating on various facets of water conser vation, the brand delves into pioneering methods and techniques for promoting responsible water usage.

n 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. Water Wise considers the significance of retrofitting in water conservation and its potential to reshape the way we interact with this vital resource. Retrofitting, in the context of water conservation, refers to the process of enhancing or modifying existing water systems and infrastructure 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

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. 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. 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.

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Adapting to climate change: As climate change leads to more erratic weather patterns, retrofitting can make water systems more resilient. Water-saving technologies help mitigate the impact of droughts and water scarcity. 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 to 18 litres of water per minute, while a water-efficient tap, equipped with flow regulators, reduces the usage to six 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 to 25 litres of water per minute, whereas water-efficient shower heads, retrofitted with flow regulators, bring the usage down to six to eight 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 to 13 litres of water per flush, while more recent ones utilise nine litres of water. Choosing a dual flush system further reduces water consumption to three to six 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 watersaving 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. Be #WaterWise

www.randwater.co.za

WATER & WASTEWATER

Community sanitation Precast concrete manufacturer, Rocla, is in the process of supplying 2 866 Twin Eco Leach Pit sanitation units to eThekwini Municipality as par t of the metro’s ongoing ser vice deliver y programmes.

o ensure optimum utilisation, these standalone precast concrete toilets have been purpose-designed so they can operate in twin leach pit configuration, as well as being upgradable for waterborne connections. The unit is supplied complete with an Agrément approved high quality, polymer pivot door and Rocla’s proprietary 40 ℓ grey water cistern. To ensure the reuse of water as a scarce commodity, it is fitted with a practical mini basin and an Agrément approved 10 ℓ clean water hand wash apparatus. This allows the waste water to drain into the 40 ℓ cistern for flushing use. To add to this system, the toilet structure comes standard with a Rocla proprietary rainwater harvesting system that further adds to keeping the 40 ℓ cistern filled and ensuring that the system as a whole is sustainable and user-friendly. “The leach pits themselves are also available as polymer options for difficult terrain or can be manufactured from concrete to create the maximum of employment opportunities and these are then supplied together with the toilet unit. This provides a system in line with the Water Research Commission’s findings for a cost effective and viable on-site waterborne system,” explains Andre Labuschagne, product development manager at Rocla.

Job creation During the installation process, Rocla’s unique “Community Cast” system creates jobs at all levels from casting right through to erecting. The units themselves comprise only eight panels that make up the complete structure, while offering a relatively large interior (900 mm wide x 1 100 mm deep x 2 000 mm high). “The sanitation units are easy and quick to install, and members of the community can be upskilled to self-install,” Labuschagne concludes.

Each unit is supplied complete with an Agrément approved high quality, polymer pivot door and Rocla’s proprietary 40 ℓ grey water cistern, among other key elements

The IDRA Desalination and Reuse Handbook 2023-2024

n partnership with the International Desalination and Reuse Association (IDRA), Global Water Intelligence’s (GWI’s) desalination and reuse market analysts have designed the IDRA Desalination & Reuse Handbook 2023-2024 to help utilities and industrial endusers find the right strategies and partners to help them combat water scarcity and drought as effectively as possible. With detailed profiles and references from EPC contractors, engineers, systems integrators, technology and equipment suppliers, the handbook provides a clear picture of how the challenges associated with water scarcity are being handled and by whom. The challenges are very real. By 2050 water scarcity will affect the lives of 5 billion people. Demand for freshwater is increasing rapidly, and the combination of climate change, the legacy of the Covid pandemic, a volatile energy market, and global supply chain issues only looks set to amplify this scenario. Within this context, desalination and water reuse will both play a vital role in combatting water scarcity and in the delivery of Sustainable Development Goal 6: Safe drinking water and sanitation for all.

Economies of scale Surging demand, population growth, and the economies of scale achievable for larger projects are fuelling the construction of desalination megaprojects. While activity is currently centred in traditional markets such as Saudi Arabia, the UAE, and China, major initiatives are also emerging fast in countries such as Egypt, Algeria, and Morocco. GWI’s desalination team expect to see record-breaking capex spending and contracted capacity figures between now and 2028 as a result. Simultaneously, the water reuse market is thriving, having grown by 41% over the past five years, compared to only 25% for desalination. Regulations mandating water reuse are becoming increasingly widespread, with increasing demand particularly from the agricultural and industrial markets, which are continuing to drive significant uptake in water reuse technologies.

A valuable reference Published annually, the IDRA handbook is circulated to a tailored group of utility and industrial end-users, showcasing a wealth of high-value insights from those on the frontlines of water security. By drawing knowledge and innovations from those who have faced similar challenges, it provides water professionals with the tools they need to drive the industry forward and foster a sustainable approach to water management. The handbook is available as part of a Water Desalination Report subscription. Visit https://www.desalination.com for more information.

IMIESA Nov/Dec 2023

WATER & WASTEWATER

How to evaluate water data solutions During the Covid-19 pandemic researchers had to find ways to track the disease. They quickly turned their attention to water. This valuable resource touches all levels of society; using modern data analytics, the researchers could build accurate models around the disease’s spread and behaviour. By Chetan Mistry

his approach isn’t new: researchers have been using water data to track diseases, pollution, and even food and drug consumption. Water carries a lot of valuable information, and this is particularly true for managing water itself. Municipal and private sector experts can use modern analytics with historical and current data to manage water and wastewater systems, enhancing strategic visibility and creating 360 Performance. Data is radically improving water management without removing or invalidating established systems. To help inform water and wastewater managers’ decisions, Xylem Africa recommends asking the following questions to evaluate water data analytics and management solutions: • What are the administration features? • What are the integration options? • How quick is the user training? • Are there consolidated and customisable dashboards? • Does the service consolidate data? • Can the service offer customised alerts? • Does the system support predictive analytics? • Is the solution cloud-based? • Is the solution secure? The following is Xylem Africa’s viewpoint in response:

What are the administration features? Modern administration systems should provide granular, role-based user access and privilege controls, and grouping of devices and billing cycles. Their management tools must offer a menu of continuously updated reports that instantly summarise information for improved productivity, visibility and decision-making.

What are the integration options? The best data solutions do not rip and replace existing systems. They integrate Chetan Mistry, strategy and marketing manager, Xylem Africa

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into established equipment such as SCADA software, Advanced Metering Infrastructure and Automated Meter Reading. They should also support established and future sensors and Internet of Things (IoT) devices and incorporate historical data.

How quick is the user training? If it takes months of training before staff and partners can use the data systems, you are wasting your time. Training should happen within weeks, based on an operations-aligned change management strategy, and backed by additional information sources and selflearning opportunities.

wide to specifics such as temperature, voltage, leaks, tampering, and other flags – delivered via SMS, e-mail and phone call.

Does the system support predictive analytics? Analytics discover and use new insights by studying historical and current data. The best water management platforms use machine learning to identify trends, facilitate audits, generate histories, and enable deeper exploration for strategic planning and predictive maintenance.

Is the solution cloud-based? Though some managers are sceptical about cloudbased software, the cloud is much more flexible, secure and cost-effective than older technologies. Cloud-based water management provides access to information on any device (PC, tablet, mobile phone, etc.), incorporates security and data loss prevention, and ensures authorised staff can manage water requirements anywhere.

Is the solution secure? Are there consolidated and customisable dashboards? Generic dashboards won’t cut it; the system must offer customisable dashboards that consolidate different data sources. These dashboards should be secure yet accessible on multiple devices and shareable between authorised users. Users should be able to drill down into individual events, understand usage history and trends, identify anomalies, and set custom alerts to track specific issues.

Does the service consolidate data? Disparate and conflicting data will severely limit the effectiveness of any analytics and insights platform. Water data solutions should consolidate different data sources into a single truth, but without compromising the integrity of the sources. Consolidated data helps create assets such as single billing files, ad hoc reporting, and reliance on accuracy, not estimates.

Can the service offer customised alerts? Time is crucial when something goes wrong; a top water management solution provides customised aler ts targeted at specific stakeholders along the value chain. It must offer custom alerts – from system

Data security is a genuine concern and not to be taken lightly. Leading water management solutions invest in cybersecurity, including ISO 27001 certification, and they help their clients run cyber-safe workplaces. Additionally, cloudbased secure platforms increase data protection and business resilience. Xylem Africa is the leading provider of “fourth industrial revolution” water data solutions for a more rational and sustainable management of water resources. Our 360 Performance services are defining what it means to manage legacy and modern water operations with digital and data assets, including Xylem SAM PRO real-time asset condition monitoring and management, the Sensus Cordonel® ultrasonic metering solution, the Xylem optimyze™ predictive maintenance monitoring module, and the Xylem Avensor pump station monitoring system. Digital data systems add enormous benefits to any water site – old or new, public or private. Add intelligence, gather information from current sensors, harvest historic data, and use the convenience of the cloud for secure remote access and dashboards for effective insights. Whatever your water management challenges, consider how water data solutions can offer effective, affordable and immediate results. Our future relies on water, and the future of water relies on data-driven intelligence. Manage both effectively, and you control the future of your water operations.

Profitability on board: hi-tech instrumentation for the rough seas VEGA sensors measure level and pressure in tanks and containers with exceptional accuracy and reliability. Our compact sensors for level measurement, full or empty alarm and pressure measurement in vessels fulfill all the needs of the modern shipbuilding industry. They offer highest reliability, have all necessary approvals and guarantee long operating periods without maintenance.

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WATER & WASTEWATER

SWIMMING SUSTAINABLY

HOW CAN YOU MAKE YOUR POOL MORE WATER WISE? As summer looms, water forms an essential part of our lives – how then do we save water during a season of high demand? An answer to this lies in how we view our swimming pools. A swimming pool can be defined as a structure that has been designed to hold a volume of water, particularly for the sole purpose of swimming.

he climate in South Africa, specifically its long summers that are characterised by high temperatures, are what make having a swimming pool so appealing. However, these are the same conditions that lead to excessive water evaporation. The average home with a swimming pool uses more than double the amount of water outdoors than a home with no swimming pool – a cause for concern for a semi-arid country like South Africa that receives less than half the amount of average rainfall in relation to the global average. A typical swimming pool can hold volumes ranging from 20 000 to 80 000 litres of water, dependent on the size, depth and design. In a semi-arid country like South Africa, the average evaporation rate during the summer season is between 6 to 10 mm daily. For a 4 x 3 m pool, that translates to around 2 800 litres of water evaporated per month, which is 33 600 litres lost every year – if you consider a 50 litres limit per day per

individual; the amount lost to evaporation alone could be sufficient for a person’s usage for one year, eight months. Should we still consider having pools in our households? Perhaps with a few considerations, we can still enjoy our pools in a water wise way.

Here are some tips to have a water wise pool: • Invest in a pool cover – it is an effective method to minimise evaporation and maintain the pool’s cleanliness by keeping debris out. • Consider har vested rainwater and be mindful when filling your pool with water. Instead of using a hose without control, use a timer to avoid wasting water if you forget to turn it off. An eco-friendly option is to use rainwater collected from your gutter system to top up your pool, reducing the need for additional water from other sources. • Minimise the use of water features: inadequately designed water features

Visit www.randwater.co.za and click on the Water Wise logo or contact us on: 0860 10 10 60 34 IMIESA Nov/Dec 2023

can result in substantial water wastage. To limit water loss through such features, place them in shaded areas and choose designs that deliver maximum impact with minimal size. • Create an artificial wetland for backwashed water: backwashing can consume more than 30 % of your pool’s water. Since this water contains chemicals, it’s not suitable for direct garden disposal. Instead, consider channelling your pool’s backwash through large pebbles and hydrophytes to create a “bubbling rapids” effect, which effectively neutralises the chlorine and makes it safe for plants. Always be #WaterWise

CMY

Liebherr crawler cranes. The art of lifting

www.liebherr.com

Liebherr-Africa (Pty.) Limited Vlakfontein Road, Springs 1560 Phone: +27 11 365 2000 E-mail: info.laf@liebherr.com www.facebook.com/LiebherrConstruction www.liebherr.com

TRANSPORTATION

SOUTH AFRICA’S PATH TO E-MOBILITY NEEDS TO ACCELERATE Accenture’s Greg Cress contends that loadshedding could be the catalyst for the decentralisation of the countr y’s green energy rollout and may fuel the shift to e-Mobility.

peaking at a conference for supply chain professionals co-hosted by the Professional Body for Supply Chain Management (SAPICS) and the South African Association of Freight Forwarders (SAAFF), Cress said that it was critical to put the gas on – without the gas – in the race to net zero carbon emissions. He stressed that South Africa needed to focus its electric vehicle (EV) transition not just on private cars, but also on trucks, light delivery vehicles and buses. According to the International Energy Agency, road transport (cars, trucks and buses) account for 28% of global CO2 emissions. Cress, who is the sustainable energy and e-Mobility lead at Accenture, outlined two possible e-Mobility scenarios in South Africa’s future. In the “Beetle” scenario, the country will continue on the status quo path, only investing in manufacturing and exporting internal combustion engine vehicles, and not transforming facilities to make and assemble EVs. “If this plays out, South Africa will become irrelevant on the global stage. Demand for our exports will decline, unemployment will rise, and large original equipment manufacturers (OEMs) may exit South Africa’s automotive manufacturing sector,” he asserted.

“Charged-Up” scenario He stressed that South Africa needed to pursue the “Charged-Up” scenario, in which the country’s assembly plants have been transformed for EVs, 60 % of which are expor ted. Expanding on this scenario and the benefits, Cress said: “Consumers will have transitioned towards green and sustainable technologies and adopted EVs. Cities, OEMs and independent power producers will have created an ‘energy alliance’ to offset the dependence on Eskom for EV charging infrastructure. Understanding the benefits of an EV future, government will have made tremendous progress in removing all the red tape that hampers EV adoption. South Africa’s economy will have recovered, the GDP will be growing and unemployment dropping in this scenario.”

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Cress said that the retail logistics and supply chain sectors have a critical role to play in the move to sustainable mobility and achieving a “Charged-Up” future for South Africa. He noted that globally, many logistics companies are transitioning to EVs. These include FedEx, UPS and DHL. Heavy commercial OEMs like Volvo are focusing on EVs, and CocaCola, which is switching to electric trucks, aims to have transformed its fleet to 100 % EVs by 2030. Meanwhile, in California Volvo and Shell Recharge have partnered to build an “Electrified Charging Corridor Project” for medium and heavy duty EVs. Volvo’s first electric truck sold in South Africa was delivered to KDG Logistics earlier this year, while Woolworths is the first South African retailer to embark on an extensive rollout of electric panel vans in partnership with DSV and Everlectric, Cress said.

Energy diversification and decentralisation He stressed that the diversification and decentralisation of energy generation are national imperatives for South Africa right now, and that both small-scale and large-scale generation projects have roles to play. “More EVs will lead to more decentralised (and mobile) energy storage. It is also critical to establish a viable EV batter y recycling value chain in South Africa,” he noted, and said that the Global Battery Alliance, which has leading mining companies among its members, is leading the way on this front.

46th Annual SAPICS Conference Sustainability and the shift towards e-Mobility are among the impor tant topics that will be explored at the 46th Annual SAPICS Conference, which takes place in Cape Town from 9th to 12th June 2024. This impor tant conference is the leading education, knowledge sharing and networking gathering for the African supply chain community. In 2024, it will be held under the theme “Supply Chain Metamorphosis” and hosted by SAPICS in association with SAAFF. More information can be obtained by visiting https://conference.sapics.org/

BITUMEN & ASPHALT

SAT MEMBERS STEP UP AT CAPSA 23 The Society for Asphalt Technology’s (SAT’s) iconic green, blue, and white logo and colours stood out strong and proud at the CAPSA 23 conference in the Drakensberg in October.

Herman Marais (AECI Much Asphalt), Past President of SAT, presents on Balanced Mix Design at CAPSA 23, with session leader Joanne Muller (AECI Much Asphalt), Vice President of SAT, and Wim Hofsink (WHCES) looking on.

hile at least 20 SAT members were directly involved in the success of CAPSA 2023, serving on the executive committee, chairing and presenting sessions, or leading workshops, among other functions, quite a number of the conference delegates were also SAT members. Many of the more than 550 conference delegates no longer ask SAT, “Who Are You?”; now they ask, “What can you do for me?” and “What can you do for our industry?” and “What can I do for you?” “That’s what we want to hear and numbers of CAPSA delegates who showed their interest in joining the SAT family at our stand reiterated this,” said SAT Operations Manager, John Onraet. At the SAT stand (from left): Aly Moloobhoy (Director, Richmond Group); Herman Marais (AECI Much Asphalt and Past President of SAT); Ané Cromhout (Kubu Consulting and Chair of SAT Central Region); John Onraet (Operations Manager, SAT); and Bob Khan (General Manager – Commercial, Richmond Group)

Several SAT Exco stalwarts, including Past President Herman Marais and Honorary Secretary Duncan Mason (also a CAPSA Exco member), found time to be present at the stand. John Onraet and his SAT colleagues caught up with longstanding SAT members, reminiscing as well as probing current thinking in asphalt pavements. SAT has a responsibility to engage with industry in the interests of its members, and the event provided an opportunity to quiz suppliers on their latest products and test methods and the industry in general on what’s hot and what is not. “These exchanges gave us ideas for future events that will certainly benefit our members and the industry,” said Onraet. One recurring theme was the issue of young professionals leaving South Africa for what they perceive to be better opportunities abroad. SAT will address this as a matter of concern for the local industry. Nik Berning, SAT’s Eastern Cape chair, added that the topic of cold mix asphalt

and emergency road repair, as well as the advantages of warm mix asphalt, featured strongly and will be driven further by SAT in the coming months.

Treasure hunt

A treasure hunt jointly hosted by SAT and ROMH Consulting offered a prize of two tickets to attend the 8th E&E Congress 2024 in Budapest, Hungary, worth R30 000. This attracted 42 entrants, who had to visit various exhibitors’ stands at CAPSA to collect clues to solving a puzzle. In addition to SAT and ROMH, these included the Western Cape Government, Ingevity, Tosas, Roadlab, Ammann, AECI Much Asphalt, and Specialised Road Technologies. “The idea was to involve all aspects of building an asphalt-surfaced road – the client body, consulting engineers, material suppliers, laboratory, equipment manufacturers, asphalt manufacturers, and various individuals,” Berning explained. This also increased traffic to the participating stands. Among others, SAT President Krishna Naidoo met with the Improved Asset Management Focus Area presenters at the SAT stand. He was also pleased to welcome some National Department of Transport colleagues. In addition to visits from across the South African asphalt and bitumen spectrum, International Society for Asphalt Pavements (ISAP) colleagues from Brazil paid their respects. This was an excellent conference and a fertile breeding ground for brainstorming and new ideas to take the industry into 2024 and beyond. SAT has taken away many learnings and will engage with the industry to ensure that the conversation does not stop there. From left: Zongile Radebe (Nexor); John Onraet (Operations Manager, SAT); Sthabile Sibiya (Naidu Consulting); Nana Dlomo (Naidu Consulting); and Leslie Johnson (National Department of Transport)

IMIESA Nov/Dec 2023

SPATIAL DEVELOPMENT & PLANNING

WESTOWN FORMS THE NUCLEUS FOR THE SHONGWENI CATALYTIC ROLLOUT Westown – the New City of the West positioned off the N3 between Pietermaritzburg and Durban – is located on a vast 100 ha site, with contractor, Stefanutti Stocks, heading up the construction works on the Westown Square retail experience and the trigger project in this landmark development. Westown represents the first phase of the Shongweni Urban Development – a catalytic project spearheaded by eThekwini Municipality.

he piling, earthworks, retaining structures and columns are virtually all complete and the walls of Westown Square – the 50 000 m² retail experience – are now progressively going up. Working in parallel are much-needed and critical road and infrastructure upgrades funded by the eThekwini Municipality in partnership with developers Fundamentum Property Group (Fundamentum) to the tune of R730 m. Stefanutti Stocks is the appointed contractor for the first piece of this work, which is the Kassier Road upgrade. Contracts for the remaining infrastructure, set to come on stream at the end of 2024, are in the process of being awarded. This includes ar terial access roads, bulk water, and wastewater infrastructure.

The Westown development promotes an interconnected space for mobility

38 IMIESA Nov/Dec 2023

Mixed-use evolution Over time, Westown will become a mixed-use precinct of lifestyle, retail, business and recreational activities located within a managed urban environment. In place are secured and approved development rights of approximately 520 000 m² of bulk floor area. The activation of these rights began when the first sod was turned for the construction of Westown Square in August 2022. Westown Square itself is a high street retail environment designed by MDS Architecture in a joint venture with Booger tman and Par tners KZN to “prioritise the movement of people, social spaces and lifestyle,” says Donald McGillivray, MDS Architecture par tner. “The design is open, permeable and accessible, which encourages connection and interaction as par t of the retail experience.” For Fundamentum, Westown is a landmark achievement. “Westown Square moves away from the ‘mall concept’ and brings together shopping, dining and recreation in a setting that reflects the character of Shongweni,” says Fundamentum’s CEO, Carlos

Correia. “It’s an aspirational offering for all ages, that will reach the Outer West community and beyond, with a national tenant mix complemented by local niche offerings.” Anchor tenants already committed include Checkers Hyper (the Shoprite Group), Pick n Pay, Woolwor ths, Dischem, Edgars (Retailability), Mr Price, and Clicks, each bringing their latest generation, premium stores to the underser ved Outer West for the first time. Fur ther top-tier and local tenant announcements are imminent. “The show is definitely on the road and KZN is the place to be as far as investment goes,” continues Correia. “It’s incredibly exciting to be a par t of this catalytic project, with full suppor t across all three spheres of government, surrounding communities, and local businesses. So far R1,5 billion has already been committed and this investment is set to double within the next couple of years.”

Enabling infrastructure Suppor ting the progress on site, the surrounding road infrastructure upgrades include two new bridges and

SPATIAL DEVELOPMENT & PLANNING

a total makeover of the existing twolane Kassier Road across the M13 and N3 into four lanes, with a new loop ramp and bridge over Kassier Road providing direct access into Westown. Phase 1A, covering the 3 km section from Alverstone Road to Milky Way (MR559), is due for completion in March 2024. Meanwhile, Phase 1B from the N3 Shongweni interchange heading north to the Hillcrest Hospital/ Alverstone intersection will open in advance of the of ficial opening of Westown Square in March 2025. Thereafter, the West Private Hospital, Westown’s warehousing and logistics sub-precinct and the first tranch of residential units will be phased in. “As this massive new investment comes out of the ground, interest from across a wide spectrum of markets increases, demonstrating the versatility of the Westown offering,” says Ror y Wilkinson, Westown head of development and planning.

share of contribution to GDP in the city. That has presented both a challenge and an oppor tunity for public and private sector investment, something the Westown developers have responded to. Westown’s warehousing and logistics oppor tunities, for example, are all strategically located with seamless access – just 1,5 km to the N3 highway national corridor. Referred to as the National Strategic Integrated Project 2 (SIP 2), this logistics and industrial corridor between Durban, Free State and Gauteng is defined as a route with investment and development oppor tunities in accessible nodes.

An artist’s impression of the unfolding Westown vision

Within KwaZulu-Natal, Keystone and Cato Ridge are two such nodes that have been slowly developing, leaving Shongweni as the next logical, and closest, new industrial development node to the Por t of Durban.

Central to this view is an artist’s impression of Westown’s West Private Hospital, which will form part of the advanced phases of the overall development

So why the Outer West? Why Shongweni? KwaZulu-Natal is the second largest economic contributor to South Africa’s Gross Domestic Product (GDP) after Gauteng. It also has the second largest population and is home to the countr y’s busiest container and bulk cargo ports. Yet as one of eThekweni Municipality’s five main industrial areas, the Outer West (Shongweni, Hammarsdale, Cato Ridge) has historically had the lowest

IMIESA Nov/Dec 2023

MUNICIPAL FOCUS

A DATA-DRIVEN APPROACH TO

INFRASTRUCTURE MANAGEMENT IN MANGAUNG In the heart of South Africa’s Free State province lies the Mangaung Metropolitan Municipality (MMM), a dynamic urban centre comprising Bloemfontein and its surrounding towns. Established as a metropolitan entity in 2011, MMM’s jurisdiction expanded in 2016 when it merged with the Naledi Local Municipality to form the current municipal boundaries. MMM covers 9 887 km2 and comprises three prominent urban centres, which are surrounded by an extensive rural area.

he metro’s ageing water, sewer and stormwater infrastructure network has resulted in frequent burst pipes, leaks and water loss across the region, with the Minister of Water and Sanitation, Senzo Mchunu, previously stating that the metro's loss of about 46% of its water was due to water pipe leakages. The non-payment of water services has placed immense strain on the metro’s capacity to provide essential water resources to its residents; while the availability of manpower to tackle existing sewerage spillages and burst pipes is limited. The lack of budget for repairs and maintenance and the prioritisation of the maintenance of existing infrastructure over new infrastructure has resulted in constraints relating to the timeous repair of breakdowns.

Exacerbating the situation is the lack of comprehensive operational and maintenance plans for water, sewer, and stormwater infrastructure. This, coupled with a lack of evidence regarding the condition of problematic pipelines in the network, has hindered the metro’s ability to ensure sustained operations and plan for the replacement of ageing infrastructure that is past its design life. With 2 615 km of sewer pipes, 3 906 km of water pipes and 885 km of stormwater infrastructure, the metro recognised the urgent need for a solution to ensure the sustainable provision of vital services to its burgeoning population and appointed SMEC South Africa to develop operational and maintenance plans for its ageing water and sanitation infrastructure. The Water, Sewer and Stormwater Network Condition Assessment, Impairment Investigation and Maintenance Plan Programme Development project included the following spatial towns within MMM: Bloemfontein, Soutpan, Botshabelo, Thaba Nchu, Dewetsdorp, Wepener and Van Stadensrus.

Van Dyk Van Rooyen, Project Manager and Section Manager, Management Services, SMEC South Africa

40 IMIESA Nov/Dec 2023

Prioritisation Model SMEC South Africa's scope of work encompassed the development of comprehensive data-driven operational and maintenance plans for water,

sanitation and stormwater infrastructure within each of these areas, providing the metro with clear guidance on the required maintenance to ensure infrastructure longevity and reliability. A key innovation introduced by SMEC was the creation of a Prioritisation Model designed to identify and plan the replacement of old infrastructure. The model per forms a condition-based risk assessment of each pipeline in order to anticipate its condition, remaining lifespan and risk of failure. The pipelines are then prioritised according to their Risk of Failure Score (RFS), which is calculated by the model. A pipeline with a high RFS is given a higher priority for replacement, while a pipeline with a low RFS is given a lower priority for replacement. This enables the municipality to prioritise and plan which pipelines require replacement or maintenance in advance. A Pipe Replacement Model, linked to a Geographic Information System (GIS) within Microsoft Excel, pinpoints the exact location of the pipe/infrastructure and categorises it as ‘high risk’ or ‘high priority’. The result is a strategic framework for infrastructure management that optimises resources and ensures critical components within the network receive the attention required, thereby allowing the metro to work proactively to minimise the number of pipe breakages and improve service delivery. The Prioritisation Model is a live system that can be updated daily as old infrastructure is replaced – a function that is driven by the Technical Department of the metro to ensure longterm sustainability. The SMEC team utilised CCTV equipment (push rod and crawler type cameras) to inspect problematic sewer and stormwater pipes to verify the structural integrity of the pipe and/or any defects or blockages, as well as acoustic leak detection equipment to identify problematic/ leaking water pipeline sections. These problematic pipe sections were identified

MUNICIPAL FOCUS

through Delphi Sessions with the metro and this information was also populated into the Pipe Replacement Model. SMEC South Africa’s Van Dyk Van Rooyen (Project Manager and Section Manager, Management Ser vices) says that it was very important from the onset of this project that the tools wouldn't burden the metro with additional yearly fees relating to the upkeep and maintenance of software. In response to this need, the team focused on using open source software for the GIS, such as QGIS, that will enable the metro to continue operating without expensive licencing requirements when the project is completed. “The tools that have been completed to date for MMM’s sewer and water network have provided comprehensive solutions to the metro’s infrastructure and asset management challenges. While we are still working on the completion of the stormwater network tools, the anticipated outcomes across all three networks (water, sewer and stormwater) include improved maintenance planning, better asset management practices, and enhanced data-driven decision-making on infrastructure replacement/upgrading planning,” Van Rooyen explains. “The tools will empower the metro with the data required to not only address its immediate challenges relating to its ageing water, sewer and stormwater infrastructure, but build a more resilient and sustainable future for the communities within MMM through the reduction of water loss and contamination in what is already a water-scarce region.” The operational and maintenance plans for the sewer and water networks were completed by SMEC in June 2022, and it is anticipated that the operational and maintenance plan for the stormwater network will be completed in mid-2024.

Acoustic leak detection equipment was used to identify problematic/leaking water pipeline sections

Sewer pipe replacement model in GIS showing the High Priority Pipelines

Computer Vision Models SMEC is currently developing an innovative solution to incorporate Artificial Intelligence (AI) into its workflow processes. Instead of reviewing thousands of hours of CCTV footage manually, the team will train several computer vision models for different types of infrastructure analysis to automatically extract relevant details from footage (video and images). “Following the success of these completed models, we are in the process

Water pipe replacement model in GIS showing the High Risk Pipelines

IMIESA Nov/Dec 2023

optimyze™

CONDITION MONITORING

TO OPTIMIZE YOUR BOTTOM LINE

At Xylem we are 100% about water, including delivering transformative solutions across the entire water cycle. We are pioneering our approach through 360 Performance solutions, delivering source-to-tap support, products, engineering expertise, and more for real value, efficiency, and lasting performance. Let’s Solve Water is more than a slogan, it is our mission! Discover 360 Performance, the cornerstone for a sustainable water future. At its heart, Xylem optimyze™ is a condition monitoring module that harnesses the power of predictive maintenance analysis and advice for rotating and fixed assets - a 360 Performance game-changing feature that forecasts trends and maintenance needs, optimising efficiency and reducing downtime.

PREDICTIVE ANALYSIS CONDITIONING MONITORING SCALABLE

Find out how we can solve water together.

MUNICIPAL FOCUS

TABLE 1: An example of the data pushed to the database

FIGURE 1: An example snapshot of the visual output of the trained computer vision mode

A typical example of a broken sewer pipe

of training a model to automatically identify the locality and severity of irregularities in stormwater and sewerage pipes from previous project data. This approach reduces human error and optimises time allocation, allowing our team to focus on more complex tasks,” says Van Rooyen. Figure 1 displays an example of the results from the preliminary model, with the output generated through the following process: The in-office user selects the CCTV file or folder directory of multiple files and initiates the model. The model then runs without human supervision through each video frame and searches for any irregularities learned during the training stage. If the model identifies an object (irregularity), the model outputs the following data subject to a threshold confidence level: (a) If the confidence of the detection is high, the model outputs the data shown in Table 1. In addition to this output, the model can retrieve any

metadata from the video file, as requested by the client. For example, if the drone is GPS enabled, then the X and Y GPS coordinates of the identified irregularity can be extracted. (b) If the confidence of the detection is low, the irregularity is identified as an edge case and the model trims the video for later inspection by the inoffice technician. The model then pushes the extracted data to a database, or the like, for record keeping.

Once the model is complete, the inoffice technician needs only review the CCTV footage of objects identified by the model with low confidence (edge cases), thereby substantially reducing the time required for the review. As the model is used, the reviewed low-confidence detections are used by the SMEC AI team to improve the accuracy of the model. Thereafter, the Project Engineer can assess the structured data to make data-driven decisions on the pipe replacement or point repair requirements.

1 2 3

Sewer investigation site work in progress. This included the use of CCTV equipment (push rod and crawler type cameras) to inspect problematic sewer and stormwater pipes to verify the structural integrity of the pipe and/or any defects or blockages

IMIESA Nov/Dec 2023

cfaoequipment.co.za

VEHICLES & EQUIPMENT

Liebherr’s LR 1400 SX crane impresses with a range of safety features, including Ground Pressure Visualisation, Boom Up-and-Down Assistant and Gradient Travel Aid

Lifting new capacities with Liebherr’s LR 1400 SX crane With the new LR 1400 SX – Liebherr’s biggest multipurpose crawler crane to date – customers can now expect to lift capacities of up to 400 tonnes (t). The first LR 1400 SX in Africa will be commissioned in Angola later this month. After successfully working with three LR 1250.1 units at its Malongo base, Cabinda Gulf Oil Company will add this new model to its operations.

or a long time, the LR 1300 – with a lifting capacity of 300 t – was the best-selling Liebherr crawler crane. But as loads continuously get bigger and heavier, so are the market needs, prompting Liebherr to respond with the 400 t LR 1400 SX. Apart from the larger capacities, the crane impresses with a range of safety features, including Ground Pressure Visualisation, Boom Up-and-Down Assistant and Gradient Travel Aid for maximum safety. Lukas Sturn, General Manager for Liebherr Maritime Cranes and Construction Machines responsible for Sub-Saharan Africa, says customers in Africa can also expect more flexibility through radio remote control. “Liebherr paid particular attention to the safety concept while designing the crane. One highlight is the Gradient Travel Aid for the safe negotiation of slopes. The crane’s control system automatically calculates the centre of gravity and warns the operator before the crane leaves the safe area. While travelling, the operator constantly receives information about the permissible and actual gradient, and the crane’s overall centre of gravity. If necessary, the boom angle can be adjusted so that the machine remains in the safe area,” explains Sturn. Additional safety is guaranteed through the Ground Pressure Visualisation feature, which calculates the current ground pressure

of the crane in real-time and compares it with the specified safety limits of the relevant position. The ground pressure is displayed in the operator’s cab. This means the operator is permanently aware of where the machine is situated, or whether it is approaching a critical area.

Another feature of note is the radio remote control, which gives the crane operator a high degree of flexibility and additional safety during operation. Operating the crane from outside the cab allows for a better overview of the construction site and helps avoid blind spots. Depending on the application, a second person will not be required to assist with hand signals during lifting operations.

Ease of transport While the crane boasts larger lifting capacities, its compact transport weight of only 46 t makes it easy to transpor t between jobsites. Platform and railings remain attached to the uppercarriage during transportation and only need to be folded down. Due to the crane’s self-assembly system, the boom sections, carbody counterweight, crawlers and hoist winches can be easily assembled and disassembled without the need for an auxiliary crane. “The flexibility and mobility of the crane can be seen when space is restricted. The four crawler drives make it easier to manoeuvre the LR 1400 SX on jobsites where space is tight. Thanks to the track width adjustment, access on narrow roads is simplified,” concludes Sturn.

Ground pressure reduction plates “The ground pressure of the crane can also be reduced using the ground pressure reduction plates. During lifting work, the operator can lower these plates to significantly increase the crane’s ground contact area. Thus, the ground pressure under the crane can be reduced by more than half. This safety feature is also particularly useful when lifting long booms from the ground,” adds Sturn. The Boom Up-and-Down Assistant is also part of the safety concept. When erecting or lowering the boom, this assistance system indicates the approach to the tipping border and automatically stops operation before the operator enters an unsafe zone. The operator is no longer required to move the winches of the main boom and luffing jib separately. Controlled folding of the luffing jib begins at the press of a button. The speed of the laying down procedure is controlled with a single joystick. The BoomUp-and-Down Assistant chooses the safest method for laying down the jib.

The Liebherr LR 1400 SX crane offers a maximum hoist height of 178 m and a maximum radius of 130 m

IMIESA Nov/Dec 2023

VEHICLES & EQUIPMENT

KONECRANES’ TECHNOLOGY CUTS FUEL CONSUMPTION AND EMISSIONS BY 25% Frequent downtime, high fuel consumption and excessive emissions are the bane of equipment operators in the material handling market. The total time interval between when a machine goes down to when it is fully operational can be financially crippling, especially when the downtime causes shipping delays and demurrage is charged in dollars.

ncreased fuel consumption can directly impact profit margins and elevated levels of pollution can compromise an equipment’s environmental performance. Therefore, any advancements to equipment to reduce overhead costs and emissions are most welcomed by material handling companies. Konecranes range of lift trucks, which has a long history of working with leading container ports and terminals, promises peace of mind with the latest technology to keep the wheels turning, reduce running costs, and ensure compliance with emission regulations. Lenny Naidoo, Acting National Operations Manager for Heavy Lift, a division of CFAO Equipment SA that sells heavy forklifts to container handlers and the ports industry, says that for over 80 years, Konecranes has been the industry-leader in the lifting sector, offering reliable and resilient container lift trucks, reach stackers and forklift trucks for shipyard, port and terminal applications. “From the start, Konecranes has invested in research and development to continually improve the safety, productivity and cost-effectiveness of equipment. The new technology enables us to give every one of our customers fit-for-purpose solutions for their own set of circumstances. Added to this, our service-minded attitude makes all the difference,” says Naidoo.

Flow Drive cuts costs and emissions The Konecranes Lift Trucks Flow Drive concept not only significantly cuts down fuel consumption and emissions by up to 25%, but also enhances the driver experience and increases active operation time. “Flow Drive, a Konecranes innovation, uses hydromechanical variable transmission (HVT) to limit power at low speed, lowering wear, fuel consumption and emissions on a heavy-duty engine that maintains full performance. With greater intervals between refuelling and less maintenance, it can significantly increase productivity. It’s a solution that brings concrete benefits to everyday operations and an increase in overall productivity,” says Naidoo.

Active preventive maintenance Konecranes active preventive maintenance programme also plays a crucial role in improving productivity and safety. Since preventive maintenance can reduce downtime and increase reliability, Konecranes CheckApp for daily inspections is an easy-to-use app for crane users to quickly and easily record their findings when performing pre-shift and/or pre-lift inspections. CheckApp allows for intuitive and reliable auditing of performed daily inspections. The easy-to-use

mobile app assists with timely recognition of potential asset-specific safety or production risk issues. Furthermore, it can also capture videos and photos for uploading to the cloud where it can be accessed by service personnel. Inspection results can also help to identify potential asset-specific safety or production risk issues and identify workplace improvement opportunities and operator training needs. “The most important reason to perform daily inspections is safety. Even with regular inspections and maintenance, issues can arise for a variety of reasons including continuous or heavy use, operator behaviour, overloads and more. A daily inspection helps to spot obvious damage, excessive wear or other deficiencies and enables operators to know whether the crane is working correctly before a load is lifted,” says Naidoo.

Cabin designed for safety and comfort Konecranes has carefully designed its cabins for driver comfor t and safety. Controls, displays, ventilation, and seating work to boost driver productivity. There is excellent visibility in all directions. This is made possible by very large, lowered windows with no corner posts, thin but very strong roof crossmember, and curved panels. Sightlines to

Lenny Naidoo, Acting National Operations Manager for Heavy Lift, a division of CFAO Equipment SA

46 IMIESA Nov/Dec 2023

VEHICLES & EQUIPMENT key working areas are clear in the front, to the sides, and to the rear. Another safety consideration is that there is also more space for operating the foot pedals. The positioning of the instrumentation improves operating ergonomics. With an excellent seat, powerful cabin heating and ventilation, and air conditioning, the driver is provided with every possible comfort. This aids in eliminating harsh braking and sudden stops. Konecranes also provides for its cabins to be customised for exact operational needs.

Remote monitoring of equipment usage Konecranes lifting equipment also benefits from TRUCONNECT remote monitoring service to enable tracking of the real usage of the lift trucks. TRUCONNECT collects condition, usage and operating data from control systems and sensors on a machine and provides alerts of certain anomalies. Remote monitoring data is used in maintenance planning and in predicting possible component or equipment failure. Collected data typically covers condition and expected service life of critical components, running time, lifted loads, motor starts, work cycles and emergency stops. Safety alerts are delivered automatically by email or text message to notify designated contact personnel of selected safety risk events.

New or pre-owned? The choice of new or used Konecranes equipment is dependent on affordability. There are also 60-month rental and cash outright options available from CFAO Equipment SA, which sells new and pre-owned units, rental options, and value-added services. A wide range of quality pre-owned equipment sourced from short to long-term rental fleets is available. All pre-owned equipment is inspected and repaired using genuine parts. Warranties and load test certificates are offered with all pre-owned equipment and service agreements available on request.

After-sales support Naidoo says all Konecranes products and offerings are supported by CFAO Equipment SA’s aftermarket service. “Our after-sales service is our key selling point and differentiator in South Africa and the rest of Africa. Underpinned with a promise of Trusted Quality Service, we are committed to offering exceptional support, and providing quality service delivery and superior workmanship. This is aimed at reducing downtime and getting your operations back on track as quickly as possible,” concludes Naidoo.

Bell expands its offering with new Heavy Industries division With almost seventy years of demonstrated expertise in complex engineering, heavy fabrication, and machining for its own range of material handling equipment, Bell Equipment (Bell) is now offering these specialist services to all industries in the country through its newly formed division, Bell Heavy Industries (BHI).

ell’s group business development director, Stephen Jones, emphasises the current scarcity of companies providing these vital services locally. “South Africa has seen a huge reduction in engineering companies and in response we have strategically positioned our South African manufacturing facility to fill this void by providing project engineering and contract manufacturing through BHI,” he explains. “The growth of Bell as a well-established mining, earthmoving, and agriculture equipment manufacturer, both domestically and in terms of exports around the world, is a testament to the skills available and the quality of products that we make in Richards Bay. We’re confident in our ability to expand into other industries and believe this will benefit not only the manufacturing sector but the whole country.” Bell’s 45 000m² undercover manufacturing area in Richards Bay complies with the ISO 9001:2015 Quality Management System and welds to the internationally recognised ISO 3834-2 Appendix 10 standards. It is well equipped with specialist machines including both horizontal and vertical CNC (computerised numerical control) machining centres, 5-axis boring machines, laser cutters, high-definition oxyfuel and plasma cutters, bending

The Bell team in Richards Bay of over 800 machinists, welders, and assemblers is among the best in the country thanks to the company’s own training centre, which plays a crucial role in internally developing world class skills from the surrounding community

brakes, and advanced welding technology. A blasting plant, phosphating tanks, sealed spray booth, galvanising bath, and an automated powder coating installation are available to take care of surface treatments.

Expert technical skills The Bell team in Richards Bay of over 800 machinists, welders, and assemblers is among the best in the country thanks to the company’s own training centre, which plays a crucial role in internally developing world-class skills from the surrounding community. “This is complemented by our highly skilled team of welding, quality, and industrial engineers, along with on-site calibration facilities, equipment to perform material checks, and a number of highly specialised co-ordinate measuring machines,” Jones continues. Together with its strong focus on process development, BHI can guarantee consistent quality to customers. “BHI can also tap into a wealth of group resources, notably a team of over 100 South African design engineers, enhancing its suitability for local manufacturing across diverse industries,” he adds. “We have always maintained that manufacturing has massive transformation potential for the South African economy and employment, so we are optimistic about this new division and will be actively engaging with those looking for the expertise we now offer outside of our traditional market segment,” Jones concludes. Three robotic welders are used to optimise the quality of long, continuous welds at Bell’s Richards Bay facility

CEMENT & CONCRETE

CONCRETE CONSTRUCTION SIGNIFICANTLY IMPROVED BY ADMIXTURES Admixtures have in the past few decades become an integral part of the concrete mix because they can significantly improve the properties and performance of concrete in construction. Here Bryan Perrie, CEO of Cement & Concrete SA (CCSA), outlines the rationale for and type of admixtures most commonly found in the mix.

dmixtures are chemicals added to the concrete mix to modify some of the properties of the mix. However, they should never be regarded as a substitute for good mix design, sound workmanship, or use of the correct materials. The most common reasons for using admixtures in concrete are: • To increase workability without changing water content • To reduce water content without changing workability • To achieve a combination of the above • To adjust setting time • To reduce segregation and/or bleeding • To improve pumpability • To accelerate or retard the rate of strength development at early stages • To improve potential durability and reduce permeability • To reduce the total cost of the materials used in the concrete, and • To compensate for poor aggregate properties

The various types of admixtures include plasticisers, superplasticisers, airentrainers, accelerators, and retarders, which are discussed below.

Plasticisers When added to a concrete mix, plasticisers (water-reducing agents) are absorbed on the surface of the binder particles, causing them to repel each other and deflocculate. This results in improved workability and provides a more even distribution of the binder particles through the mix. Plasticisers usually increase the slump of concrete with a given water content and can reduce the water requirement of a concrete mix for a given workability by about 10%. The addition of a plasticiser makes it possible to achieve a given

Bryan Perrie, CEO of Cement & Concrete SA (CCSA)

strength with a lower cement content, and they may also improve pumpability. However, some plasticisers contain a retarder and can cause problems if overdosed. While some entrain varying amounts of air, others are reasonably consistent in the amount of air they entrain. Where plasticisers are used to increase workability, shrinkage and creep will invariably be increased.

Superplasticisers These admixtures are chemically different from normal plasticisers and their action more marked. When used to produce flowing concrete, a rapid loss of workability can be expected and therefore they should be added just prior to placing. Superplasticisers are used to best advantage in areas of congested reinforcement, and where a self-levelling consistence facilitates placing. For highstrength concretes, they decrease the water:cement ratio by reducing the water content by 15 to 25%. Special mixes must be designed for superplasticisers and their use carefully controlled. Their effect varies between 30 minutes to six hours or more, depending on the admixture used.

Built in 2003, the towering pylons of the Nelson Mandela Bridge in Johannesburg were filled with self-compacting concrete based on an admixture supplied by Chryso SA

CEMENT & CONCRETE Air-entrainers An air-entraining agent introduces air in the form of minute bubbles distributed uniformly throughout the cement paste. Uses include where improved resistance of hardened concrete to damage from freezing and thawing is required; to add workability, especially in harsh or lean mixes; and to reduce bleeding and segregation, especially when a mix lacks fines. Air-entrainment may reduce the strength of concrete and overdosing can cause major loss of strength: 1 % air may cause a strength loss of 5 %, so it is important that the percentage of air entrained during construction be monitored. Because dosages are typically small, special dispensers and accurate monitoring are required. Different types and sources of cement/cement extenders may result in the entrainment of different amounts of air for the same dose and mix proportions. A change in cementitious content in the grading or proportions of the fine fractions of sand will normally alter the volume of air entrained. The amount of air entrained may depend on the source and grading of sand in concrete. Forced-action mixers entrain larger volumes of air than other types, while increasing ambient temperatures tend to reduce the volume of air entrained. The use of ground granulated blast furnace slag and fly ash will reduce the amount of air entrained, and the duration of mixing can also affect air content.

Accelerators These admixtures speed up the chemical reaction of the cement and water and so accelerate the rate of setting and/ or early gain in strength of concrete. Shotcrete accelerators react almost instantaneously, causing stiffening, rapid setting and hardening of the shotcrete. Accelerators’ uses include where rapid setting and high early strengths are required (e.g., in shaft sinking) where rapid turnover of moulds or formwork is needed, and where concreting takes place under very cold conditions. All chloride-based accelerators promote corrosion of reinforcing steel and should not be used in reinforced concrete, water-retaining structures, prestressed concrete, and steam-cured concrete. Overdosing with these materials can cause instant setting of the concrete, resulting in equipment damage. Accelerators work more effectively at lower temperatures.

Retarders These admixtures slow the chemical reaction of the cement and water leading to longer setting times and slower initial strength gain. They are mainly used when placing concrete in hot weather, particularly when the concrete is pumped, to prevent cold joints due to duration of placing, and for concrete that has to be transported for a long time. If a mix is overdosed beyond the limit recommended by the supplier, retardation can last for days. Retarders also often increase plastic shrinkage and plastic settlement cracking, and delayed addition of retarders can cause extended retardation. For more information, download the leaflet on Admixtures for Concrete by CCSA at www.cemcon-sa.org.za.

AfriSam prioritises skills development

o stay ahead in the industry’s war for talent, AfriSam has over the years placed skills at the forefront of its people development initiatives. With its several training programmes, the company has successfully created a pool of talent, not only to the benefit of its operations, but the industry at large. Glenn Johnson, General Manager Construction Materials at AfriSam, believes it is fundamental for the construction materials industry to develop people. The industry, he says, needs strong technical skills at the core of its operational excellence. With that in mind, AfriSam has over the years invested significantly in its in-house training initiatives, namely the Engineer-In-Training, Artisan Learnerships, Trainee Works Manager programmes and general operational training. This has recently been expanded with the introduction of the Trainee Operational Managers programme for the readymix business unit. Johnson explains that the Engineer-In-Training is a structured training programme for young graduates who have come through AfriSam’s bursary pipeline. “Selected individuals – those who demonstrate the best aptitude for the aggregates and readymix businesses – are integrated into the programme with the aim of developing a pipeline of electrical, civil, mechanical and mining engineers,” he says. AfriSam has a two-pronged approach to developing its Engineer-In-Training graduates further. They are either given a chance to move into line management or to stay in their chosen technical discipline, be it mechanical or electrical engineering, or a multifunction of the two disciplines. The Trainee Works Manager programme exposes candidates to all the critical aspects of works management on aggregate operations, including legal training, blasting certificates, financial management and, more importantly, people management amongst others. The Trainee Operations Manager programme follows the same pattern, but with a specific focus on readymix concrete production, including technical specifications, product application and customer interface. Candidates are also exposed to the financial and operational aspects of the readymix business. The Artisan Learnership Programme targets candidates who have completed their National Qualification Framework (NQF) courses, be it internal employees (18.1 learners) or external candidates (18.2 learners). “AfriSam has recorded massive success with these programmes,” Johnson says. “To provide context, since 2012, a total of 83 artisans – both 18.1 and 18.2 learners – came through the system.” Despite the recent challenges brought about by the Covid-19 pandemic and the continued downturn in the construction sector, Johnson says the company continues to show the resolve to develop people. “I also urge other industry players, who have generally lagged behind, to play Glenn Johnson, General their part in developing skills the industry needs, Manager Construction Materials at AfriSam now and well into the future,” he concludes. IMIESA Nov/Dec 2023

IMESA

IMESA AFFILIATE MEMBERS PROFESSIONAL AFFILIATES

AECOM siphokuhle.dlamini@aecom.com AFI Consult banie@afri-infra.com ARRB Systems info@arrbsystemssa.com Asla Construction (Pty) Ltd johanv@asla.co.za BMK Group brian@bmkgroup.co.za Bosch Projects (Pty) Ltd mail@boschprojects.co.za BVI Consulting Engineers marketing@bviho.co.za CCG puhumudzo@ccgsytems.co.za / info@ccgsystems.co.za Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za Dlamindlovu Consulting Engineers & Project Managers info@dlami-ndlovu.co.za EFG Engineers eric@efgeng.co.za Elster Kent Metering Mark.Shamley@Honeywell.com EMS Solutions paul@emssolutions.co.za ERWAT mail@erwat.co.za ESCONGWENI BPH ENGINEERS (PTY) LTD info@escbph.co.za Gabion Baskets mail@gabionbaskets.co.za GIBB marketing@gibb.co.za GIGSA secretary@gigsa.org GLS Consulting info@gls.co.za Gorman Rupp Cordeiro@gormanrupp.co.za Gudunkomo Investments & Consulting info@gudunkomo.co.za Hatch Africa (Pty) Ltd info@hatch.co.za HB Glass Filter Media info@hardybulkinglass.com Herrenknecht schiewe.helene@herrenknecht.de Huber Technology cs@hubersa.com Hydro-comp Enterprises info@edams.co.za Infrachamps Consulting info@infrachamps.co.za INFRATEC info@infratec.co.za IQHINA Consulting Engineers & Project Managers info@iqhina.co.za iX engineers (Pty) Ltd hans.k@ixengineers.co.za Izinga Holdings info@izingalabezi.co.za JBFE Consulting (Pty) Ltd issie@jbfe.co.za JG Afrika DennyC@jgafrika.com KABE Consulting Engineers info@kabe.co.za Kago Consulting Engineers kagocon@kago.co.za Kantey & Templer (K&T) Consulting Engineers ccherry@ct.kanteys.co.za Kitso Botlhale Consulting Engineers info@kitsobce.co.za KSB Pumps and Valves (Pty) Ltd salesza@ksb.com KUREMA Engineering (Pty) Ltd info@kurema.co.za Lektratek Water general@lwt.co.za Loshini Projects muzi@loshini.co.za Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Mariswe (Pty) Ltd neshniec@mariswe.com Martin & East gbyron@martin-east.co.za M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za Mhiduve adminpotch@mhiduve.co.za MPAMOT (PTY) LTD mpumem@mpamot.com Mvubu Consulting & Project Managers miranda@mvubu.net Nyeleti Consulting naidoot@nyeleti.co.za Odour Engineering Systems mathewc@oes.co.za Prociv Consulting & Projects Management amarunga@prociv.co.za Rainbow Reservoirs quin@rainbowres.com Re-Solve Consulting (Pty) Ltd maura@re-solve.co.za Ribicon Consulting Group (Pty) Ltd info@ribicon.co.za Royal HaskoningDHV francisg@rhdv.com SABITA info@sabita.co.za SAFRIPOL mberry@safripol.com SAGI annette@sagi.co.za SALGA info@salga.org.za SAPPMA admin@sappma.co.za / willem@sappma.co.za SARF administrator@sarf.org.za.co.za SBS Water Systems marketing@sbstanks.co.za Silulumanzi Antoinette.Diphoko@silulumanzi.com Siroccon International (Pty) Ltd admin@siroccon.co.za SiVEST SA info@sivest.co.za Sizabantu Piping Systems (Pty) Ltd proudly@sizabantu.com Siza Water (RF) Pty Ltd PA@sizawater.com Sky High Consulting Engineers (Pty) Ltd info@shconsultong.co.za SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za Smartlock jp.alkema@smartlock.net SMEC capetown@smec.com SOUTH AFRICAN VALUE EDUCATION Sabiha@savegroup.co.za Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Star Of Life Emergency Trading CC admin@staroflife.co.za TPA Consulting roger@tpa.co.za V3 Consulting Engineers (Pty) Ltd info@v3consulting.co.za VIP Consulting Engineers esme@vipconsulting.co.za VNA info@vnac.co.za 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 Zutari Rashree.Maharaj@Zutari.com

AWARDS

Honorary Doctorate awarded to Professor Kevin Wall

evin Wall, an extraordinary professor at the University of Pretoria’s Department of Construction Economics, was earlier this year conferred with an honorary doctorate. A civil engineer and town planner, he is a Fellow of IMESA, a Fellow of the South African Academy of Engineering and past President of the South African Institution of Civil Engineering (SAICE). During his career, he has received both the SAICE Gold Medal and the Lifetime Award of the National Science and Technology Forum. The latter is the highest honour that can be bestowed by the science, engineering, and technology community. Until 2022, Professor Wall was a non-executive board member of the Ekurhuleni Water Care Company. He has served on several other municipal entities’ boards and was ministerial appointee and deputy chairperson of the Council of King Hintsa Technical and Vocational Education and Training College. Much of his work over the last two decades has focused on the effectiveness of government spending on infrastructure and ways to improve the quality, reliability, and sustainability of that infrastructure. In this respect, he led the research team for the four SAICE “report cards” on the infrastructure condition in South Africa (2006, 2011, 2017 and 2022) and drafted the National Infrastructure Maintenance Strategy, which Cabinet approved. Since leaving the Council for Scientific and Industrial Research as a Built Environment Fellow, he has consulted widely. Recent appointments include his role as infrastructure advisor to a branch of the National Treasury, member of a team evaluating the Government Technical Advisory Centre, and capital programme and project appraisals for German foreign aid agency, GIZ, as well as advisory services for the City of Cape Town. He researches and publishes extensively, usually on topics related to enabling engineering and service delivery to take place rather than on engineering itself.

From left: Emeritus Justice Sisi Khampepe, Chancellor of the University of Pretoria; Professor Kevin Wall bestowed with his D Eng (honoris causa); and Professor Wynand Steyn, Dean of the Faculty of Engineering, Built Environment and Information Technology

IMIESA Nov/Dec 2023

RENEWABLE ENERGY & ELECTRIFICATION

In times of crisis, it’s essential that South Africa explores a disruptive approach, says Taru Madangombe, Vice President: Power and Grid for Middle East and Africa at Schneider Electric.

peaking at the Association of Municipal Electricity Utilities’ (AMEU’s) 69th Convention in October 2023, Madangombe told delegates that it is not only South Africa’s current energy crisis that is driving disruption, but a multitude of industry related trends. These range from new utility revenue models, climatic impacts, and cybersecurity risk, to the rise of energy prosumers and the proliferation of renewable energy sources. “The overall electricity value chain (generation, transmission and distribution) is like an orchestra and each new instrument, whether it’s a distributed energy resource or prosumer, requires the reimaging of a well-known symphony to ensure the music remains harmonious and recognisable, and thus the smar t grid becomes the conductor or master of this orchestra,” Madangombe explains.

DIGITISATION IS CHANGING THE POWER LANDSCAPE Playing an important role in ensuring harmonious grid operations is digitisation, which is rapidly becoming the driving force behind the evolution of the energy landscape. “We need to consider the entire energy value chain, from energy efficiency measures within homes to innovative grid solutions. Technology, particularly coupled with software digitisation, is key to creating more energy-conscious and flexible energy infrastructure,” he continues. Utilising digitisation as part of the recomposed energy landscape offers the following benefits: • Digital technologies enable smar ter grid management. Grids equipped with sensors and communication systems can detect issues, adapt to changes in demand, and optimise the energy flow. • Predictive analytics and forecasting help grid operators manage the intermittency of renewable energy, ensuring a stable energy supply. • The decentralisation of energy generation: smallscale renewable energy installations, such as rooftop solar panels, can be integrated into the grid with ease. This democratises energy production and reduces reliance on centralised power plants. • It plays a role in extending access to energy in remote or underserved areas: microgrids and off-grid solutions that incorporate digital technologies can provide reliable energy sources to communities that were previously off the grid. “The energy trilemma is even more unique in the African context, as reliability, sustainability, and affordability are significant challenges. To overcome these, we must look at energy efficiency, electrification, and digitisation as a combined solution,” Madangombe concludes.

Taru Madangombe, Vice President: Power and Grid for Middle East and Africa at Schneider Electric

INDEX TO ADVERTISERS APE Pumps | Mather+Platt BVi Consulting Engineers CFAO Equipment Envitech IMESA

52 IMIESA Nov/Dec 2023

OFC, 6 IBC 44 27 2, 50

Sizabantu Piping Systems

IFC

4, 35

Vega

OBC

Xylem

Zutari

Krohne

Liebherr Manitou Southern Africa Rand Water

BVi

BVi DOES IT AGAIN

BVi RECEIVED THE DIAMOND PMR AWARDS FOR THE FOLLOWING CATEGORIES: CIVIL, ELECTRICAL, STRUCTURAL, & MECHANICAL ENGINEERING

AWARDS WE APPRECIATE THIS PRESTIGIOUS RECOGNITION FROM THE INDUSTRY.

A BIG THANK YOU TO OUR CLIENTS AND INDUSTRY PROFESSIONALS FOR THE POSITIVE FEEDBACK WHICH MADE THIS POSSIBLE.

BVi won the Business Excellence awards and the Job Shadow poster awards category at the CESA AON awards held at Vodaworld on the 16th August.

Diamond Arrow 2023

National Survey on

Diamond Arrow 2023 National Survey on

Consulting Engineering Firms

BVI Consulting

➢ Mechanical Consulting Engineers

➢ Electrical Consulting Engineers

➢ Civil Consulting Engineers

➢ Structural Consulting Engineers

Engineers

101-399 employees

Outstanding – 1st overall

Rated by a random, national sample of 150 respondents comprising of 35 architects, 50 respondents representing construction companies, 25 developers and 40 quantity surveyors

SAICE AWARDS HELD ON 7TH SEPTEMBER 2023

Nadine de Mink won in the category: Geometric Design Technologist.

Massiquini Tembe Top 3 finalists for category: Graduate Technologist of the Year

At BVi Consulting Engineers, we are grateful and humbled to have received numerous prestigious awards that underscore our unwavering dedication to excellence in the field of engineering. These accolades serve as a testament to the hard work, innovation, and commitment of our exceptional team. We extend our deepest gratitude to our talented and passionate staff, whose relentless efforts and expertise have been instrumental in achieving such remarkable recognition. Their dedication to pushing the boundaries of engineering solutions has not only elevated our firm but has also contributed significantly to the industry. We look forward to continuing our journey of delivering cutting-edge solutions that make a positive impact in our communities.

OVER 55 YEARS OF ENGINEERING EXCELLENCE

BIG ENOUGH TO MAKE A DIFFERENCE. SMALL ENOUGH TO CARE

Paving the way for TOMORROW

Versatile material handling solutions.

www.manitoucentre.co.za Tel: +27 10 449 4800 Email: info.centresa@manitou-group.com