IMIESA November December 2024

www.imesa.org.za

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

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

INDUSTRY INSIGHT NJ Bouwer

CEO of Emi Koussi Investments

APE Pumps & Mather+Platt Strategic acquisition fuels group’s growth

How Emi Koussi Investments integrates infrastructure for a sustainable future

ENVIRONMENTAL ENGINEERING

ROADS & BRIDGES

Welded mesh adds a novel gabion dimension

Upgrading the strategic Montrose Interchange

IMESA 87TH CONFERENCE REPORT Municipal engineering: the catalyst for building a shared future

IN THE HOT SEAT

Delivering world class water quality is our primary objective, working within the challenges and constraints presented by global warming and climate change. Foremost, that requires technological innovation to ensure consistent supply and to bridge gaps in infrastructure capacity.”

Ofentse Nthutang, Acting CE of Magalies Water I S S N 0 2 5 7 1 9 7 8 Vo l u m e 4 9 N o . 1 0 • N o v e m b e r / D e c e m b e r 2 0 2 4 • R 5 5 . 0 0 ( i n c l . VAT )

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INSIDE

VOLUME 49 NO. 10 NOV/DEC 2024

42 www.imesa.org.za

Regulars

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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

INDUSTRY INSIGHT NJ Bouwer

CEO of Emi Koussi Investments

Editor’s comment

3

President’s comment Index to advertisers

5 52

APE Pumps & Mather+Platt Strategic acquisition fuels group’s growth

How Emi Koussi Investments integrates infrastructure for a sustainable future

ENVIRONMENTAL ENGINEERING

ROADS & BRIDGES

Welded mesh adds a novel gabion dimension

Upgrading the strategic Montrose Interchange

IMESA 87TH CONFERENCE REPORT

IN THE HOT SEAT

Delivering world class water quality is our primary objective, working within the challenges and constraints presented by global warming and climate change. Foremost, that requires technological innovation to ensure consistent supply and to bridge gaps in infrastructure capacity.”

Ofentse Nthutang, Acting CE of Magalies Water

Strategic acquisition positions the APE Pumps Group for growth

6

Harnessing the synergy between water, sanitation and energy. How Emi Koussi Investments integrates infrastructure for a sustainable future

10

I S S N 0 2 5 7 1 9 7 8 Vo l u m e 4 9 N o . 1 0 • N o v e m b e r / D e c e m b e r 2 0 2 4 • R 5 5 . 0 0 ( i n c l . VAT )

ON THE COVER

The fluid transfer leaders since 1952, APE Pumps and Mather+Platt’s (the Group’s) key ingredient for success is its investment in technology and human capital, backed by an ongoing diversification strategy.

This includes the acquisition of class leading companies that complement the Group’s turnkey manufacturing and contracting approach. IMIESA speaks to John Montgomery, the Group’s General Manager, about recent developments. P6

IN THE HOT SEAT South Africa’s Water Boards are leading the charge in addressing service delivery gaps and building future capacity. IMIESA speaks to Ofentse Nthutang, Acting CE of Magalies Water about their unique approach to environmental sustainability and clean water. P14

30

WATER & WASTEWATER

Hot Seat Magalies Water sets a high standard for sustained supply

14

Environmental Stewardship Alternative water sources

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87th IMESA Conference Report Engineering Revolutionised. Municipal engineering is the catalyst for building a shared future

Spatial Development & Planning

IMESA elects new Fellows and Honorary Fellows

18

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Trenchless Technology Developments in the design, construction and rehabilitation of sewers: Part 2

ROADS & BRIDGES

Concrete Retaining Wall Systems Aiming for the sky with hollow core concrete blocks

42

Information & Communications Technology 45

Vehicles & Equipment Smart lubrication solutions for future e-mobility applications Astec’s class leading cold planer debuts in South Africa

46 48

The ultimate readymix solution for modern construction Sika® Ucrete® polyurethane cementitious hybrid flooring systems Admixtures critical in durability of water-retaining structures

49 49 51

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Pumps & Valves

Water & Wastewater Can municipalities keep the water flowing?

Widening of National Route R22 Section 5 through kwaNgwanase town 34 A case study in digital engineering.

Upgrading the strategic Montrose Interchange 36 The installation of the New Wear Footbridge 40 Mpumalanga unveils its road maintenance management system 41

Cement & Concrete

Environmental Engineering Welded mesh adds a novel gabion dimension

Roads & Bridges

The environmental responsibility of AI

IMESA

34

29 30

A conscious approach to smart urbanisation 33

Cover Story

Industry Insight

Municipal engineering: the catalyst for building a shared future

Is your building prepared for the upcoming rainy season?

Can water help Africa reach net zero?

28

Pump donation revives Nama Khoi water infrastructure

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INDUSTRY INSIGHT As a developing nation, South Africa faces growing service delivery gaps as population expansion and rising urbanisation trends place pressure on resources and ageing infrastructure. IMIESA talks to NJ Bouwer, CEO of Emi Koussi Investments about how their financing, technology and training solutions are providing an innovative response in the water and sanitation segment, driven by sustainable power demand. P14

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EDITOR’S COMMENT EDITOR Alastair Currie Email: alastair@infraprojects.co.za DESIGNER Beren Bauermeister CONTRIBUTORS Alaster Goyns, Chetan Mistry, Geoff Tooley, Karin Johns DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS Email: distribution@infraprojects.co.za _________________________________________________ ADVERTISING SALES KEY ACCOUNT MANAGER Joanne Lawrie Tel: +27 (0)82 346 5338 Email: joanne@infraprojects.co.za _________________________________________________

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ANNUAL SUBSCRIPTION: R805.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2024. 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 KWAZULU-NATAL Secretary: Narisha Sogan Tel: +27 (0)31 266 3263 Email: imesakzn@imesa.org.za NORTHERN PROVINCES Secretary: Zurika Louw Tel: +27 (0)82 322 5208 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Oliver 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 FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Email: imesafsnc@imesa.org.za All material herein IMIESA is copyright protected and may not be reproduced without the prior written permission of the publisher. The views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

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Putting money to work

or many South Africans, 2024 has been another roller coaster year where most households have continued to face financial constraints within an economy that has been slow to rebound from the Covid era.

Perhaps one of the greatest indicators of this are the two million plus people who have so far decided to take advantage of the Savings Withdrawal Benefit option in terms of the new Two-Pot Retirement System. The latter came into effect on 1st September 2024 and allows retirement fund members to make partial withdrawals from their savings pot component prior to retirement.

That can help meet immediate financial needs, but the downside is that withdrawals are taxed at the individual’s marginal rate. Longer-term, the implications can also be negative as individuals may not have sufficient funds on retirement. (Based on available statistics only around 6% of South Africans can retire comfortably.) Plus, if the motivation for withdrawal is offsetting debt, then only short-term relief is achieved.

Collective investment Hopefully, as the South African Reserve Bank begins to implement more interest rate cuts, this will ease widespread domestic debt pressures, reducing the ensuing temptation to borrow to keep afloat, as this has a direct and indirect impact on macroeconomic performance. For instance, indebted consumers will inevitably struggle to pay for municipal services, creating a vicious cycle.

The end goal is to increase the national tax base to stimulate growth (not ideally fuelled in part by cashing in pension savings) and create employment, with an emphasis on higher-earning skills development. That can only be achieved through business expansion, supported by personal and corporate savings invested, which banks can leverage to fund value-based loans. This includes infrastructure projects in terms of public-private ventures.

In fact, overall research proves that countries with higher gross domestic savings rates tend to experience faster economic growth. That in turn means greater prosperity and buying power during an upturn.

Public sector expenditure trends Public sector capital expenditure remains the primary catalyst. The good news here is there’s a general upward

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. www.imesa.org.za

IMESA

IMESA

imesa_za

imesa

www.imesa.org.za

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

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

INDUSTRY INSIGHT NJ Bouwer

CEO of Emi Koussi Investments

APE Pumps & Mather+Platt Strategic acquisition fuels group’s growth

How Emi Koussi Investments integrates infrastructure for a sustainable future

ENVIRONMENTAL ENGINEERING

ROADS & BRIDGES

Welded mesh adds a novel gabion dimension

Upgrading the strategic Montrose Interchange

The ABC logo is a valued stamp of measurement and trust. IMIESA is ABC audited and certified.

trend, as reported by Statistics SA, with a weighting towards infrastructure. Their recent report reveals that in 2023, the country’s 749 public sector institutions injected some R233 billion into the economy, up 10,9% compared to 2022. This was also the second successive increase after a five-year slump impacted by the pandemic. However, capital expenditure in 2023 still remained below the 2016 peak of R283 billion.

As would be expected, spending by public corporations dominated in 2023, amounting to R87 billion. Eskom accounted for the lion’s share at R39 billion – a core portion spent on high-voltage transmission lines. It was also great to see Rand Water and uMngeni-uThukela Water both expending R2 billion respectively during the period.

In parallel, key state-owned entities like SANRAL continue to add value. A case in point is the R9 billion invested during 2023 on development and maintenance projects nationally.

In turn, provincial government departments spent around R35 billion during 2023. Infrastructure examples include R3 billion expended by the Western Cape Department of Transport and Public Works, and R3 billion by the KwaZulu-Natal Department of Transport.

Then from a local government perspective, the statistics show that municipalities incurred around R62 billion in capital expenditure during 2023. In terms of infrastructure spend, a standout example is the City of Cape Town, which invested R7 billion, mainly on water and sewerage upgrades. However, in general, municipalities have not recorded significant budgeted year-on-year increases. For example, municipal budgeted capital expenditure only increased by 1,8% to R77,4 billion in 2024/25 compared to the original budget allocated for 2023/24, estimated at R76 billion based on the final tally.

Overall, though, the prospects going into 2025 are encouraging, driven by South Africa’s Government of National Unity, which investors and society in general are banking on to make a difference.

Political certainly and public-private collaboration are the key to unlocking real value so we can collectively build a sustainable future that works for the common good.

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

IMESA 87TH CONFERENCE REPORT Municipal engineering: the catalyst for building a shared future

IN THE HOT SEAT

Delivering world class water quality is our primary objective, working within the challenges and constraints presented by global warming and climate change. Foremost, that requires technological innovation to ensure consistent supply and to bridge gaps in infrastructure capacity.”

Ofentse Nthutang, Acting CE of Magalies Water I S S N 0 2 5 7 1 9 7 8 Vo l u m e 4 9 N o . 1 0 • N o v e m b e r / D e c e m b e r 2 0 2 4 • R 5 5 . 0 0 ( i n c l . VAT )

IMIESA Nov/Dec 2024

3

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PRESIDENT’S COMMENT

IMESA

Introducing our new President This is my first comment as the incoming IMESA President for the 2024-2026 term and I’m excited and honoured to take on this instrumental role. My thanks to the IMESA EXCO and Council for their support and faith in electing me to this vital position.

E

ngineering has always been in in shaping much of the future approach to civil my blood and from an early age I engineering solutions in my department. enjoyed building things. As I grew to understand the significance of civil Sihlanzimvelo Programme engineers in society, I knew this was the career for One of the defining projects in my career has been me. Encouraged by my teachers, I came to realise the Sihlanzimvelo (“we clean the environment”) that mathematics is a fascinating subject and a programme. The seeds of this can be found in practical tool for creating the civil structures that another groundbreaking initiative, the Zibambele (“get a hold of yourself”) project, which in turn was surround us.

Having obtained a BSc Civil Engineering adapted from the Kenyan Lengthman model.

In a nutshell, Sihlanzimvelo is a poverty degree in 1987 from the University of Natal (now UKZN), I joined the eThekwini Municipality alleviation programme. It contracts a co-operative after graduation. This was the start of a career rather than an individual or company to maintain with eThekwini which has spanned close to four a stretch of river/stream. The objective is to help decades. If anything, my passion has grown active members lift themselves out of the poverty stronger – especially in terms of how green and cycle, while simultaneously improving their traditional grey infrastructure complement each environment via the rivers/streams they clean other. Climate change, of course, has taken this up. The downstream benefits are reductions in to a whole new level of significance. the volume of vegetative material and solid waste At the starting point of my career, I worked debris, which in times of flood negatively impacts in the materials laborator y doing soil and on road and stormwater infrastructure.

Presenting the work done in Durban on the concrete tests, which served as an excellent foundation. I then joined eThekwini’s Major Sihlanzimvelo project to the C40 CFF workshop in Drainage section, which became the Drainage Berlin was a definitive personal milestone. and Coastal Engineering Department and then finally the Coastal, Stormwater and Catchment My philosophy Management Department.

Essentially, I’m an optimist, which allows me to After registering as a professional in 1998, and see opportunities even in the face of adversity. spending a few years in the stormwater design In this respect, I believe that there is a growing section, I was appointed to my current post as understanding that we need to look the Senior Manager: Catchment Management for different solutions. Covid and the Engineering Unit responsible for the rivers and 2022 KZN riots underscored that floodlines of the city. being active in our communities An important early engagement was the work and working together at all levels completed with Dr Debra Roberts, currently head is essential for alignment and of the Sustainable and Resilient City Initiatives commitment.

From my experience, there’s Unit at eThekwini. Endeavours focused on the threat of climate change in the water sector, which a massive amount of led to the development of Municipal Adaptation goodwill that exists Plans (MAP) within the water, Geoff Tooley, Pr Eng Hon FIMESA health and disaster sectors.

IMESA President: 2024-2026 This work was fundamental

in our communities. Like riverine restoration projects, this can be reinforced by practical actions. We need to show how well-planned infrastructure and service delivery go hand in hand to improve living conditions. Each success increases the willingness of the community to step up and assist in improving the resilience not just of eThekwini, but all South African towns and cities.

As the ultimate end of the Covid shutdown illustrated, the environment can bounce back if given a chance. However, there were painful lessons learnt, and it’s clear that we need to change the trajectory if we want to collectively map out a sustainable future. Let’s not get overwhelmed by trying to tackle the problems in one go. It’s an incremental process.

My IMESA mandate I’m now leading the charge as IMESA President, and in my closing for the 2024 IMESA Annual Conference in November, I reiterated my call to action. Firstly, as members of the engineering profession we need to stand up against corruption and rebuild the professionalism we experienced in the past.

Secondly, you are not alone. As President, I promise to lead IMESA in supporting every single technical municipal staff member and consulting engineer in delivering service to the large and small municipalities across our country. It will only be through standing steadfastly together that we will achieve President Ramaphosa's promise to the nation of building a capable developmental state that places infrastructure at its centre.

So, together, let’s work to regain the trust of our residents and restore the professional status of the municipal engineer.

IMIESA Nov/Dec 2024

5

One of the Group’s most complex projects completed to date entailed the refurbished of a 650 MLD Mather+Platt unit at Rand Water’s Lethabo raw water abstraction pump station

Strategic acquisition positions the APE Pumps Group for growth The fluid transfer leaders since 1952, APE Pumps and Mather+Platt’s (the Group’s) key ingredient for success is its investment in technology and human capital, backed by an ongoing diversification strategy. This includes the acquisition of class leading companies that complement the Group’s turnkey manufacturing and contracting approach.

IMIESA speaks to John Montgomer y, the Group’s General Manager, about recent developments.

A

major milestone celebrated in September 2024 is the Group’s 100% acquisition of South African multidisciplinary contractor, Eigenbau. As a Group entity, the latter now forms part of the multinational WPIL Limited corporation, headquartered in Kolkata, India.

Originally established as Johnston Pumps India in 1952, WPIL Limited was founded in 1996 and has since established an extensive global footprint spearhead by its original equipment manufacturing (OEM) companies – all class leaders in the design, fabrication, commissioning and servicing of pumps and related systems. Key OEM subsidiaries include Sterling Pumps, based in Australia; Mathers Foundr y Limited in the UK; APE

6 IMIESA Nov/Dec 2024

Pumps and Mather+Platt in South Africa; and Gruppo Aturia in Italy. Collectively, they support WPIL’s international growth into Asia, Africa, Europe and Oceania. Eigenbau is WPIL’s first construction company acquisition.

“As the South African arm, APE Pumps and Mather+Platt have a long-established footprint locally, as well as in the Southern African region, providing a complete in-house OEM solution, as well as comprehensive contracting services, backed by our rating as an 8 ME (Mechanical Engineering) contractor in accordance with the Construction Industr y Development Board (CIDB) grading system,” Montgomery explains.

APE Pumps and Mather+Platt specialise in manufacturing fit-for-purpose fluid transfer solutions for all industries.

Shown here is a horizontal two stage split case pump

COVER STORY

APE Pumps and Mather+Platt’s engineering team employ sophisticated 3D scanning technologies to perfect their installation designs

“Our ongoing investments in machiner y and technology, combined with specialist technical and engineering recruitment, places the Group in a unique position to partner with clients to improve their process performance – either for existing or greenfield construction projects. So, we’re far more than just a pump company,” he continues.

Predictive and preventative maintenance is key. However, as Montgomer y points out, so too is the need to build new capacity to replace ageing infrastructure and keep pace with population growth.

Since 1952, APE Pumps and Mather+Platt systems have been installed extensively within South African municipal water and wastewater plants, so the Group has an indepth understanding of current and future requirements. For example, based on Group records, around 30% of the larger municipalities currently have the Group’s screw pumps installed at their wastewater treatment works as the critical primar y process interface.

“We work with our municipal clients and Water Boards to map out their maintenance and replacement needs, frequently supported

by Service Level Agreements where our teams manage the operations and maintenance elements on our installed systems,” Montgomery explains.

refurbishment. Removed from its housing in three sections at the end of July 2024, the pump was refurbished and reinstalled within two months.

To perfect their methodology statement, APE Pumps and Mather+Platt’s technical team executed a full 3D scan of the entire pump station layout to ensure that the removed pump could be reinstalled precisely. Once commissioned and tested during a future scheduled shutdown, the Water Board will then proceed with the phased refurbishment of the other three pumps at this critical facility, which abstracts a major portion of Gauteng’s downstream potable water.

Meanwhile, in the Western Cape, the Group was recently awarded a contract to supply new vertical dewatering pumps at the Palmiet Pumped Storage Scheme. The Group’s scope entails the installation and commissioning of four pumps, plus the supply of two spare units.

The four pumps installed will replace older non-Group OEM units. “Our pumps met the

All components for the Group’s pump systems are designed and fabricated in-house

client requirement for increased head capacity.

The challenge for us is the need to install our larger pumps in the existing tight space.

Plus, the pump chambers reach a depth of around 80 m. Therefore, to ensure a perfect fit, our technical team again harnessed the benefits of 3D to complete a comprehensive survey,” Montgomery explains. He adds that during a shutdown in December 2024, the first two pumps will be installed, tested and commissioned.

Eigenbau acquisition adds a new dimension “The Water Boards are leading the way when it comes to system optimisation. However, across the board, South Africa’s growing water scarcity, compounded by a sharp decline in municipal water and wastewater quality due to plant failures, and ensuing pollution, has reached a critical point. We urgently need to reverse this trend through exper t OEM interventions,” Montgomery asserts.

“Therefore, to address the challenge from treatment and distribution perspectives, the Group has embarked on an acquisition drive to bring onboard leading pump OEMs that will further expand our range and capabilities to deliver.

“In parallel, is the identification of specialist contractors to support our project build plans, which include the construction and operation of modular treatment plants.

In this respect, the recent addition of Eigenbau is a landmark development that takes our Group’s total solutions offering

Group projects One of the Group’s most complex projects completed to date entailed the refurbished of a 650 MLD Mather+Platt unit at Rand Water’s Lethabo raw water abstraction pump station. Originally commissioned in the 1980s, it operates alongside three identical Mather+Platt pumps – each weighing around 44 tonnes – that were installed at the same time.

This is the first time since their installation that one of these pumps had been removed and sent to the Group’s factory for a complete

IMIESA Nov/Dec 2024

7

COVER STORY

The first major challenge was engaging with the previous sub-contractors involved that had been left stranded by the business rescue process. “You can imagine the multitude of loose ends we needed to identify and resolve,” says Healing. “In each case, we analysed the progress made by the previous main contractor and sub-contractors, verified if the work was correct, and then put in place action plans for completion.”

The ultimate result is an outstanding project that also includes a 2 MLD pilot reuse plant, designed to treat wastewater to potable water standards.

Supporting South Africa’s socioeconomic goals Fire pumps ready for despatch to an industrial client

to a whole new level. However, Eigenbau will also continue to operate as an independent contractor in its own right on the open market,” Montgomery explains.

Established in 1981, Eigenbau initially entered the market as a civil engineering contractor specialising predominately in concrete structures. Subsequently they evolved into a civil and electromechanical constr uction company focusing on the construction of dams, run-of-river hydroelectric plants, as well as water and wastewater infrastructure.

“In addition to their track record for excellence, what made them a per fect fit is their performance driven culture, expert personnel and turnkey methodology, which includes in-house component fabrication. We have been in discussions with their directors for a number of years and we’re thrilled to have now concluded the deal. There are tremendous synergies and opportunities,” says Montgomery.

Currently, Eigenbau is graded as a 7EP (Electrical Engineering Works – Infrastructure), 8 ME and 8 CE (Civil Engineering) and has successfully completed an extensive range of contracts over the past 43 years. In addition to South Africa, other countries where Eigenbau has executed works include Botswana, Swaziland, Namibia, Mauritius, and the Seychelles.

Getting the job done “As a multidisciplinary project house, Eigenbau has built its reputation both on engineering excellence and technological innovation,” says Shane Healing, project director at Eigenbau.

“Years of experience have proven what works best for us and the client in practice.

That includes in-house bespoke mechanical fabrication for specific projects, like dam sluice gates. Whatever the challenge, we’ll find the solution and get the job done.”

A prime example is the Darvill Wastewater Treatment Works in Pietermaritzburg, Kwazulu-Natal, which is owned and operated by uMngeni-uThukela Water on behalf of the Msunduzi Local Municipality.

The original contract to expand the plant from 65 to 100 MLD was awarded to Group Five at a contract value of around R800 million. However, Group Five subsequently went into business rescue, leaving the project around 80% complete and stalled for up to two years. Eigenbau successfully bid for the completion of the project at a contract value of around R200 million. This was awarded in May 2020 at the onset of the Covid pandemic.

“Eigenbau’s long-term vision is to grow to the CIDB 9 level – and take on mega infrastructure projects in South Africa and Africa. The same vision holds true for APE Pumps and Mather+Platt as a class leading OEM and turnkey fluid transfer specialist,” adds Montgomery.

“It’s a quantum leap that is now possible for both par ties thanks to this exciting acquisition development, backed by the financial strength of the Group and the broader international WPIL family. We are investing in South Africa’s future with the skills, technologies and capabilities essential for our sustainable development goals,” Montgomery concludes.

The impeller design for a circulating water (CW) pump

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

8 IMIESA Nov/Dec 2024

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INDUSTRY INSIGHT

An artist’s impression of a community on-site VIP cooperative sanitation scheme, which includes onward sale of waste byproducts that can be used for applications like fertiliser

HARNESSING THE SYNERGY BETWEEN WATER, SANITATION AND ENERGY

HOW EMI KOUSSI INVESTMENTS INTEGRATES INFRASTRUCTURE FOR A SUSTAINABLE FUTURE As a developing nation, South Africa faces growing service delivery gaps as population expansion and rising urbanisation trends place intensified pressure on available resources and ageing infrastructure. IMIESA talks to NJ Bouwer, CEO of Emi Koussi Investments (Emi Koussi) about how their financing, technology and training solutions are providing an innovative response in the water and sanitation segment, driven by sustainable power demand.

A

Level 2 BBBEE entity, the Group’s portfolio encompasses Servelec, Sizwe Amanzi Investments (SAI), and The Water Academy, which collectively integrate to provide a holistic response in meeting modern municipal infrastructure demands.

“The overall focus is on enhanced resilience and efficiency by matching fit-for-purpose solutions with the essential skills required by client personnel to optimise processes,”

explains Bouwer. “From our perspective, investing in essential public infrastructure makes business sense, and is also a socio-economic priority.”

“A core component of this response is a publicprivate partnership framework that encompasses both our in-house and external private equity funding mechanisms for Build Own Operate (BOO) and Build Own Operate and Transfer (BOOT) projects, as well as operations and maintenance (O&M) services for municipal water and wastewater plants using our modular systems.”

How BOO and BOOT models work In water and wastewater treatment, municipal clients often face financial constraints that limit

NJ Bouwer, CEO of Emi Koussi Investments

their ability to invest in essential infrastructure.

In response, Emi Koussi’s BOO and BOOT models provide a flexible financial framework that ensure municipalities can access advanced treatment solutions without significant upfront capital investment.

“Under the BOO model, our company designs, constructs, and maintains water and wastewater treatment facilities. We retain ownership of these systems for the operational term. Municipal clients benefit from our expertise in running complex treatment processes, while paying for the service as an operational cost rather than a capital expense,” Bouwer continues.

“This arrangement allows municipalities to redirect limited capital funds toward other critical needs, such as emergency services or community development projects. Once the operational period concludes, municipalities can purchase the systems, transitioning to ownership when funds become available.”

The BOOT model builds upon the benefits of BOO, but with a significant difference: ownership of the system is ultimately transferred to the municipality after a predefined operational term. “Initially, our company handles the design, construction, and operation of the facility, ensuring that it meets the highest standards of efficiency and effectiveness.

Municipal clients benefit from reduced risk

INDUSTRY INSIGHT as we manage ongoing O&M during the initial period. This model is particularly advantageous for municipalities developing their treatment capabilities without immediate capital expenditure.

Once the term concludes, the system is transferred to the municipality, empowering them with a fully operational facility to integrate into their budget,” says Bouwer.

“Through our BOO and BOOT models, we are committed to helping municipalities enhance their water and wastewater treatment capabilities while navigating the An example financial challenges that come of a typical modular with infrastructure development. treatment plant designed, built and These innovative approaches commissioned by Emi provide immediate operational Koussi Investments for these solutions are provided by relief and position municipalities the community for sustainable growth and improved Servelec, a CIDB graded turnkey environmental stewardship.” electrical contracting specialist established in 1952 with over 70 years of Proactive engagement experience in medium and low voltage installations, Central to Emi Koussi’s approach is proactive automation, instrumentation, and maintenance.

Located in Newton Park, Gqeberha, with a satellite engagement with municipalities to research and develop feasible system designs that have longer- office in Paarl, Servelec handles significant projects term commercial viability. Working with the client, across the Eastern, Western, and Southern Cape this includes collaboration with public officials and regions, where its reputation for reliability and municipal engineers, in conjunction with community efficiency has positioned the company as a trusted leaders, to map out all the requirements. At the partner among consulting engineers, municipal municipal level, that incorporates a knowledge engineers, architects, and contractors. This applies and skills assessment aligned with the proposed to greenfield projects, as well as upgrades to technology process put forward. outdated electromechanical plant that pose a risk “To maximise trust and transparency, our in terms of intermittent or ultimate failure. methodology also includes setting up pilot plants “Servelec’s expertise in motor control centres to trial and prove the proposed concept, so it’s a (MCCs), medium voltage (MV) switchgear, and win-win for all concerned,” Bouwer continues. “It all custom PLC programming underpins the reliability comes together through the dovetailing of our three of power infrastructure essential to support water treatment and distribution systems. The company’s business lines.” client-focused approach ensures these systems Servelec: Expertise in are durable, energy efficient, and Servelec, electrical infrastructure optimised for long-term functionality,” a CIDB graded turnkey Within the mix, energy Bouwer explains. electrical contracting Either as an off-grid solution, demand management is specialist established in 1952, has over 70 years of or as a power demand buffer, key in terms of municipal experience in medium and Servelec’s parallel focus is on system performance and low voltage installations, meeting an upsurge in demand cost optimisation, as is automation, instrumentation, and maintenance for solar PV micro-grid installations. power quality. As a group,

Another trend is the growth in self-contained residential and commercial developments where installed renewable power stations supply the energy for dedicated on-site water and wastewater treatment plants that are not connected to municipal services.

As Bouwer points out – aside from the green power benefits – this trend is also being driven by existing municipal network constraints where developers face challenges in gaining building approval to add large-scale projects that could potentially overload existing municipal plant process capacities.

“From an overall energy perspective, plans are in place to provide renewable power requirements to run an entire small town, and not just individual components, like pump stations and treatment plants, via concluded Power Purchase Agreements,” says Bouwer.

Sizwe Amanzi Investments: A holistic approach to water management In turn, Sizwe Amanzi Investments (SAI) drives Emi Koussi’s water strategy, offering advanced water treatment and management solutions for residential, municipal, industrial, and agricultural applications. Beyond treatment, SAI oversees the entire water lifecycle – purification, distribution, maintenance, and compliance. This comprehensive approach ensures each solution is adaptable and able to meet evolving needs. Plus, there are unique

IMIESA Nov/Dec 2024

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INDUSTRY INSIGHT An internal perspective of a modular water purification plant under construction

services (QMS) that help municipalities deliver reliable water services. This strategy forms part of Emi Koussi’s broader goal of partnering with its stakeholders to enable high-quality water and dignified sanitation for their communities.

On-site sanitation

wastewater plants under development designed to facilitate reuse for downstream applications like community-based agriculture – especially well-suited for more arid regions.

SAI’s water purification and wastewater management systems rely on sophisticated filtration, disinfection, and reuse technologies, adaptable across applications. Remote monitoring enables continuous performance and compliance checks, while advanced sensors provide accurate, real-time water quality data. SAI also emphasises ongoing maintenance, with a dedicated O&M team to support system performance and reliability.

A municipal case study A standout example of Emi Koussi’s integrated approach is its most recent municipal project in the Eastern Cape, where SAI and Servelec collaborated to meet community water and power needs. SAI deployed a water treatment system with advanced purification and modular design, integrating seamlessly with the municipality’s existing infrastructure. This adaptability allows for future scalability as the community grows.

Then from an energy perspective, Servelec provided the power infrastructure critical to the municipality's ongoing operations, including MCCs, MV switchgear, and custom automation to optimise energy efficiency. This support ensures consistent power, even during peak demand periods.

“The project showcases Emi Koussi’s commitment to sustainable, community-focused infrastructure, setting a standard for future initiatives,” says Bouwer.

The Water Academy: Building knowledge for sustainable infrastructure To achieve a sustainable return on investment, however, the right skills need to be in place to provide municipalities with the ability and confidence to embrace BOOT and/or BOO models. In parallel, there’s a clear necessity to ensure that municipal plant personnel in general have the necessary knowledge and experience. Here, The Water

12 IMIESA Nov/Dec 2024

Academy plays an essential role in Emi Koussi’s sustainable vision, providing specialised training for water and wastewater treatment professionals.

Accredited by EWSETA to offer multi-level training – from short courses to full qualifications – The Academy prepares industry professionals to manage critical infrastructure effectively up to NQF Level 5. Courses cover water and wastewater treatment operations and demand management (pressure and flow) in terms of theory and practice, with trainers equipped to host in-person training sessions nationally.

Currently, The Water Academy is transitioning its learning material to align with the new Quality Council for Trades and Occupations (QCTO) style of education.

Beyond training, The Water Academy also supports process engineering and quality management SAI’s water purification and wastewater management systems rely on sophisticated filtration, disinfection and reuse technologies, adaptable across applications

While a high percentage of South Africans live in dwellings connected to waterborne sanitation, there’s a growing informal settlement community that is not currently serviced, instead relying on VIP toilets. The same issue often applies for remote rural villages. Given fiscal funding constraints, the best interim alternative is an on-site sanitation model that meets health and environmental standards, as well as promoting SMME opportunities through community-based partnerships.

Emi Koussi has extensive experience in this area and is exploring the implementation of suitable models in collaboration with affected communities.

The latter include the establishment of cooperatives for the collection and transfer of VIP generated waste for treatment.

“Similar to the waste picker recycling concept, cooperative members would be paid a set rate for VIP waste delivered to dedicated collection points for onward transit to a purpose-designed Emi Koussi treatment plant. We plan to implement our first pilot plant in the Western Cape to prove the business case, subject to approvals and permitting,” explains Bouwer.

Aside from reuse benefits at the plant, saleable byproducts from the treatment process can be used for commercial applications like charcoal and fertilisers, which can be distributed through local spaza shops and agents. This helps foster a circular economy within communities while providing access to affordable resources.

Conclusion “Irrespective of the scale or complexity, and based on our proven track record and expertise, our Group is well positioned to help solve South Africa’s multifaceted water, sanitation, energy and related skills challenges,” adds Bouwer.

“We are proud of our problem-solving culture, and extensive knowledge base. We also have the financial and risk management acumen to partner with municipalities to develop solutions that are commercially viable, thereby enhancing municipal service delivery,” Bouwer concludes.

www.emikoussi.co.za

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abstracts

CATEGORIES Buildings, Structures and Housing

Water and Sanitation

Electrical and Electronic

Transport, Roads and Stormwater

Financial, Legal and Regulatory

Ecological, Environmental and Social

A B S T R AC T S S U B M I T T E D BY 10 April 2025

marketing@imesa.org.za | tel +27 (0)31 266 3263

Contact Melanie Stemmer for an entry form or download it from the website.

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IMESA ORGANISER

THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA)

HOT SEAT

Magalies Water sets a high standard for sustained supply South Africa’s Water Boards are leading the charge in addressing service delivery gaps and building future capacity. IMIESA speaks to Ofentse Nthutang, Acting CE of Magalies Water about their unique approach to environmental sustainability and clean water.

Magalies Water’s Scientific Services Laboratories building houses state-of-the-art technologies to track and ensure compliance with key industry standards that include SANS 241:2015

What are some of the key milestones achieved in terms of meeting the National Development Plan 2030 (NDP 2030) targets?

In 2014 Magalies Water commenced with the crafting of its Master Plan to address water challenges within the region in response to the NDP 2030 objectives. This resulted in the planning and implementation of a series of projects that include the upgrading of the Vaalkop Water Treatment Plant (WTP) to 270 ML/d, as well as the Kilpdrift WTP to 42 ML/d, plus associated distribution networks in both cases.

Both incorporate counter-current dissolved air flotation/filtration (COCODAFF), as well as a chlorine dioxide system for algae treatment.

These projects have provided water to approximately 140 000 households, in the process giving access to water-poor communities and the previously disadvantaged. These projects have also increased the availability of water for Platinum Group Metals mines within the Bojanala District, thus stimulating regional socio-economic growth.

Delivering world class water quality is our primary objective, working within the challenges and constraints presented by global warming and climate change. Foremost, that requires technological innovation to ensure consistent supply and to bridge gaps in infrastructure capacity. A prime example is our current project at the Klipdrift WTP in Hammanskraal, where a 50 ML/d emergency package plant is being installed to supplement existing capacity. This fast-tracked project will be commissioned in Q4 of 2024.

[namely the Department of Water and Sanitation (DWS)], detailing the key deliverables, and established regulatory frameworks – specifically SANS 241:2015. This benchmarking process helps to identify areas needing improvement, establish achievable goals, and ensure that the company is aligned with its objectives for sustainable growth.

Our performance has been over 90% for the past five years in terms of our KPIs. We have also been ranked in first place as South Africa’s top Water Board for the past three years. In terms of the Auditor-General’s audit opinion for the past five years, Magalies Water achieved a clean audit, only regressing to an unqualified audit opinion in the past two financial years. We are addressing this.

How does Magalies Water benchmark its performance?

To respond comprehensively to the question, it is important to provide a brief background of the merger and the transition process. The former Minister of Water and Sanitation, as the Executive Authority and Shareholder of Water Boards on behalf of the government of South Africa, took a decision for the institutional reform and realignment of Water Boards. As a result of this decision, Sedibeng Water (SW), which operated

Magalies Water evaluates its performance by comparing its operational processes, financial results, and other key performance indicators (KPIs) against the Shareholder’s Compact Ofentse Nthutang, Acting CE of Magalies Water

14 IMIESA Nov/Dec 2024

Has Magalies Water’s absorption of Sedibeng Water been a positive development?

HOT SEAT

in parts of North West, Free State and Northern Cape, was disestablished. Its operations, staff, assets, and liabilities in the North West province were incorporated into the Magalies Water Board.

SW had operated on a decentralised model, whereby each region had its own support staff in terms of human resources, finance, information technology and stakeholder management. For the period post the merger and during the transition period, there were challenges relating to people management issues due to resistance to change.

This had a temporary impact on service delivery, particularly in the Far West Region (Magalies Water’s newly acquired area of operation).

Stakeholder expectations also needed to be addressed. Historically, SW was perceived to have a poor track record for service delivery and customer ser vice. We have successfully addressed this, with positive gains for communities and industry.

Do you think that Water Boards should directly manage municipal WSAs to ensure Green, Blue and No Drop compliance?

Given the relevant resources and political influence, yes. The Water Services Act provides a clear legislative framework in terms of the designation of roles and responsibilities for Water Ser vice Authorities (WSAs) and Water Service Providers.

Some of the benefits in terms of directly managing the entire water ser vices value chain are: Standardisation and Oversight: Water Boards can establish uniform standards and regulatory oversight to ensure municipal WSAs consistently meet regulatory standards, promoting equitable water access.

Technical Expertise: With their specialised knowledge, Water Boards can ensure best

practices in managing complex water systems and maintaining municipal infrastructure to prevent inefficiencies.

Integrated Planning: A central governing body can manage water resources regionally, enhancing resilience, optimising resource use, and minimising water loss. Cross-municipal systems are easily managed as a centralised system, allowing for benefits in terms of order of magnitude.

Focus on Compliance: Direct management by Water Boards can enhance compliance with environmental regulations and enforce water conservation measures effectively.

However, implementing such a management model necessitates a careful consideration of the advantages of centralisation alongside the imperative for local flexibility and responsiveness to the unique needs of individual communities. A hybrid model may prove to be the most effective approach, wherein local WSAs retain a degree of autonomy, while being closely guided and monitored by Water Boards.

What percentage of North West’s residents are currently serviced by water and waterborne sanitation?

Nor th West province is a semi-arid area with few rivers running annually. According to Stats SA (2019), 29% of households in the province have access to good quality water, 27% are served but need some improvements,

36% are served but have significant challenges in terms of reliability of supply, while 7% have no basic supply.

In 2022, post the disestablishment of SW and its incorporation within the Magalies Water network, we appointed a consultant to undertake a water and sanitation masterplan.

Some of the key projects which are being refined through technical feasibility studies include the provision of bulk water supply to Ngaka Modiri Molema District Municipality and Dr Ruth Segomitsi Mompati District Municipality through the Bloemhof Bulk Water Supply Scheme.

Other key projects that are still at conceptual stage include utilising spare capacity from the Midvaal Water Treatment Works located in Klerksdorp to supply Lichtenburg, Zeerust, Madibogo and Mahikeng.

Another planned project is the Pilanesberg Phase III development. This will involve upgrading the Vaalkop WTP from 270 ML/d to 450 ML/d.

Has Magalies Water been able to make a difference in reversing river and dam contamination within its footprint?

Magalies Water, serving as both a Water Service Provider and an Implementing Agent for the Har tbeespoor t Dam, has made significant progress in restoring this vital reservoir. The organisation has adopted a comprehensive, multidisciplinar y approach for the dam’s remediation, which includes ongoing manual har vesting of alien invasive species, the application of advanced technological inter ventions, and continuous monitoring of water quality to facilitate improvement.

The raw water basin has also demonstrated notable improvements, attributable to the successful implementation of the remediation programme.

What are some of the key findings of Magalies Water’s Scientific Services Laboratories?

Magalies Water boundary

Our water treatment plants and distribution networks generally meet operational standards. However, the organisation faces ongoing challenges, including deteriorating raw water quality, water loss, infrastructure maintenance, and occasional adjustments in chemical dosing practices.

Regarding effluent quality and environmental compliance, the treatment facilities comply with most regulatory requirements, showcasing strong per formance. Nonetheless, cer tain

IMIESA Nov/Dec 2024

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HOT SEAT

reduce the need for additional capital investment in new conventional treatment facilities and promote efficient resource utilisation.

The Vaalkop Water Treatment Plant

Work at an advanced stage on the 50 ML/d emergency package plant being installed at the Klipdrift WTP in Hammanskraal to supplement existing capacity. This fast-tracked project will be commissioned in Q4 of 2024

regions, especially rapidly urbanised areas, industrial zones and agriculturally active areas require more rigorous monitoring and enforcement to ensure adherence to environmental standards and localised by-laws. The main issues affecting environmental compliance include nutrient loads in effluent, pollution resulting from industrial discharges, and localised impacts on nearby inefficient water bodies.

Does the Hammanskraal 50 ML/d emergency intervention project present a business case for the rollout of similar plants?

By investing in these innovate package plants, water service delivery challenges can be fasttracked. However, as with any project, due processes still need to be followed, like the Environmental Impact Authorisation, Water Use License Authorisation, servitude approvals and registration. Coordinated inter-governmental relations is also key to ensuring ef fective project execution.

Package plants align with the principles of sustainable infrastructure development. They

16 IMIESA Nov/Dec 2024

What are some of Magalies Water’s major projects for 2025 and beyond?

Dam to 360 ML/d, including linking of the raw water system and the supernatant system to the new centralised inlet works; construction of a new 90 ML/d water treatment module, plus the upgrading of the associated high-lift pump stations.

We have an exciting infrastructure programme in the pipeline. Key ones include the following projects: Moretele North (Klipvoor) Bulk Water Supply Scheme – R 5,2 billion (blended funded project) This project entails the construction of a new pipeline system, a water treatment plant, as well as the development of a groundwater source at Ngobi. The Moretele North-Klipvoor Bulk Water Supply Scheme will serve the Moretele North region in North West, as well as the Bela-Bela, Modimolle-Mookgophong, and Mogalakwena local municipalities in Limpopo.

Upgrade of the Kort Begrip to Modikwe/ Bethanie bulk pipeline, including the pipeline link to Makolokwe in Rustenburg The project scope consists of the construction of 13,4 km of 560 mm diameter gravity bulk line linking Kort Begrip Reservoir with the Modikwe Reser voirs in RLM. Thereafter, it continues for another 9,3 km of 400 mm diameter gravity bulk pipeline to the point of sale (RLM) of Bethanie Reser voirs. The project fur ther entails the construction of a new pipeline to Makolokwe village.

Pilanesberg Phase 2 Bulk Water Supply Project – R 2.9 billion (blended funded project) This project is divided into five components, detailed as follows: Component 1: Construction of infrastructure works to meet the long-term demands of Rustenburg Local Municipality (RLM) and the Royal Bafokeng Administration (RBA). The scope entails the construction of a 30 ML reservoir at Tlhabane; a bulk pipeline from Mafenya pump station to Tlhabane reser voir, including the interconnection to RLM reservoirs; construction of the off-take to Madubu/Serone, including the construction of a 10 ML reservoir and associated pump station; construction of the bulk pipeline to the Bakubung reser voir in Ledig, including construction of a new 20 ML Bakubung reservoir; and upgrading of the bulk pipeline from the Vaalkop WTP to the Evergreen Junction.

Component 2: Construction of a 54 km bulk pipeline from Padda Junction to Thabazimbi to augment the current infrastructure.

Component 3: Construction of a 7,5 km bulk pipeline from La Patrie to Moruleng to satisfy demand in the area.

Component 4: Construction of a new gravity pipeline from La Patrie to Sandfontein, which will replace the current pipeline to meet existing and future water demands.

Component 5: Construction of a new pipeline connecting the Padda Junction to the Swartklip area, where the two pipeline routes separate to replace the stressed and aged existing pipelines.

Pilanesberg Phase 4 – Upgrade of Vaalkop WTP from 270 to 360 ML/d This exciting project entails the upgrade of the raw water abstraction pumping capacity at the Vaalkop

Is PPP funding an essential component in accelerating the change we need to see in water?

Public-private par tnerships (PPPs) can be attractive to both Water Boards and the private sector in many ways. In the case of Water Boards, unlocking private financing can support increased infrastructure investment without immediately adding to the entities’ borrowing and debt. At the same time, more skilful management in the private sector, and its capacity to innovate, can lead to increased efficiency; this in turn should translate into higher quality and/or lower cost services. PPPs can therefore offer better value for money while accelerating service delivery.

Traditionally, PPPs have been concluded in the development of economic infrastructure mainly due to high economic rate of returns; the involvement of the private sector in constructing and providing principal services in relation to infrastructure; and lastly because the services are provided directly to end users, and they are directly charged.

Social infrastructure such as water is different in that the social returns are high and there are often low economic returns. Innovation to attract private sector investment will therefore involve adopting approaches such as blended funding, and aggressive improvement on revenue collection.

www.magalieswater.co.za

ENVIRONMENTAL STEWARDSHIP

ALTERNATIVE WATER SOURCES South Africa’s water security is under increasing pressure due to climate change, urban expansion, and rising water demand. To meet these challenges, embracing alternative water sources is key to reducing dependency on conventional supplies.

W

hether you’re landscaping for commercial spaces, public parks, or private homes, adopting these alternatives can make a transformative dif ference.

1 Rainwater Harvesting

Maximise seasonal rainfall by installing rainwater tanks and guttering systems to capture and store runof f. This water can be used for irrigation, cleaning, and even potable use with proper filtration. Benefits: Reduces municipal water use, especially in the dr y season. A cost-effective solution for garden irrigation.

2 Greywater Systems

Water from baths, showers, washing machines, and sinks (excluding those in the kitchen) can be reused for landscape irrigation. Greywater systems filter and direct this water to lawns, ornamental plants, and even vegetable gardens, reducing overall water consumption.

3 Borehole Water

Tapping into underground aquifers via boreholes provides a steady water source, especially in regions with depleted sur face water supplies. While installation can be costly, borehole water can supplement garden irrigation or even domestic use if treated properly.

5

Desalination Desalination can offer a crucial alternative in coastal regions where freshwater is scarce.

This process turns seawater into usable water for irrigation and non-potable purposes.

WATER WISE TIPS • Use greywater for gardens and landscaping but avoid using it on edible plants unless properly treated.

• Ensure water from boreholes or rainwater tanks is stored in sealed containers to prevent contamination.

• Limit greywater usage to non-edible plants and avoid spraying it directly on leaves.

• Prioritise alternative water for irrigation, cleaning, and flushing to reduce potable water consumption.

THE WATER WISE APPROACH Sustainability goes beyond sourcing water – it’s about using it ef ficiently. Always incorporate water-saving irrigation techniques such as drip irrigation, mulching, and smart irrigation controllers to ensure that every drop is used effectively.

By exploring these alternative water sources, we can build more resilient landscapes that thrive under water-scarce conditions. Whether you’re a homeowner, landscape architect, or urban planner, adopting these practices today will shape the sustainable landscapes of tomorrow.

4 Treated Wastewater

Effluent from wastewater treatment plants can be treated and reused for landscape irrigation. This source, typically used for larger commercial landscapes and municipalities, offers a reliable, eco-friendly water solution.

Always Be #WaterWise

IMIESA Nov/Dec 2024

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87 TH IMESA CONFERENCE REPORT

ENGINEERING REVOLUTIONISED More than 700 delegates from across South Africa attended the 87th IMESA Annual Conference

Municipal engineering is the catalyst for building a shared future Between the 6th and 8th November 2024, stakeholders from across the private and public sector built environment came together for the 87th IMESA Annual Conference, held this year at the GrandWest in Cape Town. Hosted under the theme “Engineering Revolutionised”, the conference ser ved as an invaluable platform for debating, sharing experiences and presenting solutions in addressing South Africa’s infrastructure challenges.

T

The opening function marked the end of Sibusiso Mjwara’s term as President for the 2022-2024 term, with the chain of office officially handed over to Geoff Tooley as the incoming President for 2024-2026

18 IMIESA Nov/Dec 2024

his was also one of the best attended IMESA conferences in recent years – with the venue booked to full capacity – underscoring the impor tance of the Institute’s role in effecting positive gains within the local government arena. Pressing issues covered at the conference centred on developing sustainable outcomes for both urban and rural communities within the context of climate change, plus resource and funding constraints – all of which place increasing pressure on existing infrastructure.

Topics covered included roads and stormwater, catchment management,

87 TH IMESA CONFERENCE REPORT

Nhlanhla Ngidi, Head of Energy and Electricity Distribution at SALGA outlined the scope and challenges for smart city evolution, emphasising the vital need for interconnected, intelligent infrastructure

responses to flooding, pollution, asset management, financial mechanisms, ICT, countering social ills in poor communities prone to vandalism, water and sanitation – all of which are interrelated in establishing a functioning society.

The opening function marked the end of Sibusiso Mjwara’s term as President for the 2022-2024 term, with the chain of office officially handed over to Geoff Tooley as the incoming President for 2024-2026.

“Collaboration is the key, and during my time in office, IMESA has made strong gains in terms of its recognition and inclusion within all spheres of government, along with a growing IMESA membership base as we expand our representation across all 257 South African municipalities. As a voluntar y association, IMESA’s focus is on professionalisation and capacity building at all levels and it has been an honour to serve as head of this prestigious organisation.

My hear ty congratulations go to Geoff as he takes for ward these vital initiatives,” says Mjwara.

Responding during his acceptance speech, Tooley saluted the contributions made by Mjwara, and said the groundwork achieved was remarkable, suppor ted by IMESA’s EXCO, Council, and Head Office team. “As IMESA, we have a proud histor y extending back to our establishment in

1961. Each successive President has been a dedicated municipal engineer instrumental in helping shape today’s towns and cities, as well as in providing and maintaining municipal ser vices for its communities,” he explains.

“Ever y Past President has raised the bar, and it’s a great privilege to build on the exceptional standard set to date. The role of the municipal engineer has never been more impor tant in closing pover ty and inequality gaps, thereby ef fecting meaningful socio-economic gains,” Tooley continues.

“In the past decade, we have seen the undermining of professionalism within our municipal structures. My key mandate is therefore to lead the Institute in meeting the Government of National Unity’s objective of building an ethical and capable developmental state – in our case founded on engineering excellence. In this respect, the value and impor tance of professional registration with the Engineering Council of South Africa (ECSA) is of paramount impor tance and IMESA has forged a proactive alliance with ECSA as part of our concerted professionalisation drive.”

Conference opening address Enabling partnerships are key to achieving these goals and the role of the South African Local Government Association (SALGA) is an integral par t of the process. Speaking on behalf of SALGA’s leadership, Nhlanhla Ngidi, Head of Energy and Electricity Distribution, expressed the organisation’s full support for IMESA’s mandate.

“Rapid urbanisation, infrastructure backlogs and climate change pressures are testing our systems to the max. The upside is that these challenges are enforcing a mindset change hinging on innovation and the reimaging of how future municipal ser vices frameworks work, spurred on by practical for ward-thinking policies which can turn challenges into oppor tunities,” he explains.

“The essential backbone is smar t infrastr ucture to create intelligent interconnected systems that monitor and optimise ser vices in real-time. The benefits are reduced operational costs and wastage, and enhanced efficiencies.

Renewable energy will also become increasingly integrated. And across the board, skills development is the foundation for infrastructure implementation, with

an emphasis on youth development and mentorship to successfully navigate a changing world.”

Keynote address: City of Cape Town One of the leading municipalities in taking forward this vision is the City of Cape Town, with keynote speaker, Deputy Executive Mayor Alderman Eddie Andrews outlining elements of the metro’s extensive new build programme. Andrews also ser ves as the Mayoral Committee Member responsible for the city’s Spatial Planning and Environment portfolio.

Backing the city’s strategy is an approximately R120 billion capital expenditure programme being implemented over a ten-year period from 2024 that will primarily be allocated to infrastructure development. A core component focuses on water and sanitation upgrades – amounting to some R82,28 billion – as well as af fordable housing, green infrastructure, public transport, roads and waste management to meet burgeoning urbanisation expansion.

“The starting point for our vision is to build a city that positively impacts and shapes the lives of future generations to come,” say Andrews. “Within this context, we also need to ensure that historical inequalities are positively addressed at a time when the demands on the city’s infrastructure are unprecedented. Our capital expenditure programme prioritises this.”

Currently, Cape Town ranks as one of the world’s most popular tourism destinations, suppor ted by a proactive ease of doing

Cape Town’s Deputy Executive Mayor Alderman Eddie Andrews was the conference’s keynote speaker

IMIESA Nov/Dec 2024

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87 TH IMESA CONFERENCE REPORT

Richard Raphiri, Director: Development, Procurement and Delivery Improvement at the CIDB, presents at the Knowledge Bar on developments in terms of the Public Procurement Act. Looking on are (from left) Chris Campbell, CEO of CESA, Pule Tarafara Setai, National Treasury Chief Director: Provincial and Local Government Infrastructure, and IMESA President, Geoff Tooley

business policy approach that continues to crowd in local and international investment.

However, a percentage of the city’s residents are still socially vulnerable, in part due to an influx of unemployed job seekers who add to Cape Town’s expanding informal settlements.

“In 2018 we commissioned our human settlements strategy to better understand the constraints and requirements. The ensuing studies revealed the financial strain many households are facing – both within formal and informal communities,” Andrews continues.

The studies showed that, on average, some 54% of Cape Town’s households generated an estimated income of R10 000 or less per month, while 17% earned a monthly income ranging between R10 001 and R20 000. At the other end of the scale, 13% of households enjoyed an income of R40 000 and above per month.

Clearly, this impacts on affordability and the ability to pay for services and accommodation for more than 70% of the city’s population within the context of a growing housing backlog. One city initiative in place within the informal segment is the approval of a fund to assist micro-developers in building accommodation in terms of the Small-Scale Rental Programme. In addition to providing housing, this initiative also formalises building permissions and provides a clearer indication of downstream service requirements.

“So, we cannot lose sight of the contextual reality in our current and future infrastructure planning. Going for ward, that requires critical public-private partnerships to realise sustainable responses in co-designing a shared future that enhances livelihoods in what we refer to as the ‘City of Hope’,” Andrews continues. “Collectively, value-based decision-making is key in identifying projects that uplift communities, which speaks directly to the right municipal organisational cultures and skillsets.”

20 IMIESA Nov/Dec 2024

For all households and industr y, energy security remains an overriding priority and Cape Town has placed major focus on renewables as an optimal alternative to fossil-fuelled power – both from greener and future lower-cost standpoints. As Andrews emphasises, cheaper energy is a fundamental catalyst for real growth.

“Ever y municipality in South Africa should be enabled to make the right choices for its constituents within existing legislative frameworks. So impor tant in this respect is an enabling policy, bylaws and procurement environment. One of the proactive examples for Cape Town is our Development Application Management System. This is an online por tal designed to fast-track building approvals, as well as lowering administrative costs.”

Adds Andrews: “In all respects, transparent engagement is vital, so that all stakeholders – especially the community – buy-in to current and future public works.

As municipal engineers, review the hand you’ve been dealt with, and ask yourself the question, what type of town or city do you want to create?”

questions than answers. At the conference, the floor was opened to delegates following a panel discussion entitled “Public Procurement Bill: Implementing Changes for Successful Outcomes”.

Hosted by Pule Tarafara Setai, National Treasury Chief Director: Provincial and Local Government Infrastructure, the panellists comprised Chris Campbell, CEO of Consulting Engineers South Africa (CESA), Geoff Tooley as IMESA President, and Richard Raphiri, Director: Development, Procurement and Deliver y Improvement at the Construction Industry Development Board (CIDB).

In terms of background, the PPA was signed by the President of South Africa on 23rd July 2024 but is not yet in force pending ensuing stakeholder consultation. Once this

Public Procurement Act (PPA) Ef fecting change and transitioning to implementation remains a burning issue for the construction industr y in terms of public procurement. Generally, the opinion is that excessive red tape filtering down from national government level continues to put a brake on “shovel ready” projects – and project approvals in general. This has been acknowledged and is being addressed at the highest levels of government.

Pending legislation, like the Public Procurement Act 28 of 2024 (PPA), is intended to streamline processes – both for construction and other industr y sectors – but many feel it raises more

Edmund Nxumalo, Executive: Regulatory Services and International Relations at the Engineering Council of South Africa (ECSA) underscored the importance of professional registration for all practitioners conducting engineering work

2024

IMESA

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87 TH IMESA CONFERENCE REPORT Best Double Exhibition Stand: Precision Meters

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extensive process is completed, findings will then be submitted to parliament for final review in 2026.

Questions raised from the floor included, what happens in the interim and what are the implications of the PPA’s ultimate regulation enforcement parameters in terms of alignment with national and municipal integrated development plans?

And can South Africa successfully effect an online tendering system based on global benchmarks?

Other concerns included how existing contractual disputes will be handled within the legal domain. Plus, greater clarity is required on how specific tenders – par ticularly those below economic cost – still win awards within the Bid Evaluation Committee and Bid Adjudication Committee process, par ticularly where non-engineering members make these decisions.

Best Paper by an IMESA Member

Paper 15: “A practical and proven guide to municipal water SCADAtelemetry systems.”

Author: Matthew Hills, Nelson Mandela Bay Municipality

22 IMIESA Nov/Dec 2024

The end goal is to ensure fair, ethical and corruption-free equitable transactions as governed by the National Treasur y’s Public Procurement Of fice. Plus, the BBEEE agenda remains key in terms of transformation. However, many feel that the current PPA doesn’t provide a clear qualifying criteria framework. This therefore needs to be resolved – both from an infrastructure industr y stance in terms of winning work, as well as from an ultimate community empowerment and UN Sustainable Development Goals (SDG) standpoint.

What is clear is that the PPA is a work in progress and a groundbreaking development. Ultimately, though, the obser vation is that South Africa has some of the world’s most advanced legislation, but when it comes to best practice execution, ever yone must be clear on the rules for engagement. As demonstrated by Best Paper by a Non-IMESA Member

Paper 14: “Addressing vandalism and water issues in low-cost, high-density housing projects.”

Authors: Karen King and Hanry Neethling, Royal HaskoningDHV

the Cape Town example, city legislative developments enable locally, but national macroeconomic policy is what truly builds a successful nation where no one is left behind.

In closing “As IMESA, we’d like to thank our presenters, delegates, exhibitors and sponsors for enabling this exceptional conference. The takeaways are invaluable as together we forge a long-term vision for South Africa’s infrastructure landscape.

As in the Cape Town example, our goal is to ensure that ever y municipality becomes a centre of hope. This can only be achieved by revolutionising our methodologies to ensure that ever y rand spent makes a difference,” adds Tooley.

“There’s an exciting road ahead, and we look for ward to working with all our industry partners and members in creating a sustainable strategy. On that note, work is already under way for our 88th IMESA Conference, which will be held next year in East London between 29th and 31st October 2025. The theme is ‘Sustainable Engineering Solutions’ and our wish is that we’ll be able to share the traction gained by industr y in moving towards our SDG objectives,” Tooley concludes.

The digital version of the 87TH IMESA Annual Conference Proceedings is available online. Visit https://issuu.com/imesa/ docs/imesa_conference_ proceedings_2024 to view and download.

IMESA

IMESA ELECTS NEW FELLOWS AND HONORARY FELLOWS At the 87th IMESA Annual Conference in November 2024, special recognition was conferred on members of the Institute of Municipal Engineering of Southern Africa (IMESA) – either as Fellows or Honorary Fellows – for their exceptional dedication and service.

D

uring each calendar year, IMESA’s national branches are encouraged to identify and nominate members who have demonstrated outstanding commitment. The nominations are then submitted to the IMESA EXCO and Council for evaluation.

In terms of criteria, elected Fellows must be corporate members of the Institute who are professionally registered with the Engineering Council of South Africa. They also need to have been an IMESA member 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 remain in service or continue to add value to the industry.

Honorar y Fellows are persons who, in addition, have distinguished themselves in the community. They are currently or have been intimately engaged with infrastructure engineering and deser ve the honour for exceptional and impor tant ser vices in connection with the objectives of the institute.

During the 87th IMESA Conference, the following IMESA members were honoured, Fellows and Honorary Fellows who were present at the 87th IMESA Conference receiving their awards 1 Outgoing 2022-2024 IMESA President, Sibusiso Mjwara congratulates Geoff Tooley, IMESA’s incoming 2024-2026 President for his recognition as an IMESA Honorary Fellow 2 IMESA Fellow Balan Govender, Pr Tech Eng, Senior Manager: Engineering Unit, eThekwini Municipality 3 IMESA Fellow Jannie Koegelenberg, Pr Eng, Director: Civil Engineering Services, George Local Municipality 4 IMESA Fellow Lyle Francis, Pr Tech Eng, Deputy Director: Water Demand Management, Nelson Mandela Bay Municipality

with the certificates bestowed by Sibusiso Mjwara, IMESA’s outgoing President for the 2022-2024 term:

1

Elected as Fellows - B alan Govender, Pr Tech Eng, Senior Manager: Engineering Unit, eThekwini Municipality - Michael Greatwood, Pr Eng, Specialist Advisor to Msunduzi Local Municipality - Marius van Jaarsveld, Pr Tech Eng, Technical Director, Zutari - Joseph Tsatsire, Pr Tech Eng, Director: Water Distribution, Nelson Mandela Bay Municipality - Lyle Francis, Pr Tech Eng, Deputy Director: Water Demand Management, Nelson Mandela Bay Municipality - Jannie Koegelenberg, Pr Eng, Director: Civil Engineering Services, George Local Municipality - A ndré Keyser, Pr Tech Eng, Technical Director/Office Manager, Zutari.

2

Elected as Honorary Fellows - Ivor Berrington, Pr Tech Eng, consulting engineering contract, Nelson Mandela Bay Municipality - Gerrie van der Merwe, Pr Tech Eng, Manager: Water & Sanitation, AfriCoast Consulting Engineers - Drikus Bester, Pr Tech Eng, Consultant: Nelson Mandela Bay Municipality -- Barry Martin, Pr Tech Eng, Senior Director: Water & Sanitation, Nelson Mandela Bay Municipality - Geoff Tooley, Pr Eng, Senior Manager: Catchment Management, eThekwini Municipality.

“The IMESA EXCO and Council would like to congratulate our new Fellows and Honorary Fellows and thank them for their continued ser vice. Their exemplar y roles have and continue to make a positive difference,” Mjwara concludes.

3

4 IMIESA Nov/Dec 2024

23

ENVIROMENTAL ENGINEERING

WELDED MESH ADDS A NOVEL GABION DIMENSION The traditional role of gabions in constructing engineered systems, like mass gravity retaining walls, is now increasingly crossing over into parallel applications outside the mainstream civils industry that include landscaping and architecture. IMIESA speaks to Louis Cheyne, managing director of Gabion Baskets, about current trends.

Welded mesh wall elements installed on a concrete base for a residential complex

O

ne of the key drivers locally and internationally is the ongoing refinement of square welded mesh panels, which provide a flat finish particularly well suited for wall cladding and feature walls,” explains Cheyne. “The natural appeal of the rock fill used to form gabions has also been a key influencer for landscapers and architects, along with durability and aesthetic benefits.”

Conventional hexagonal double-twisted woven mesh gabion systems can achieve the same effect, but their performance characteristics are different. Welded mesh is intentionally rigid,

whereas woven mesh is designed to flex. The latter is particularly important for applications like submerged riverine retaining walls, where welded mesh would fail. However, both woven and welded mesh can be specified for land-based mass gravity retaining walls, but choosing the hexagonal woven mesh option is the logical choice given the lower cost at scale, unless there’s a specific design requirement.

Dimensional wire tolerances Therefore, the starting point for choosing a woven or welded option is dependent on the application and thereafter the ultimate result

The gabion elements for this project were designed to enhance an old boundary wall originally composed of brick pillars and palisade fencing. The latter was removed and replaced with 50 x 50 mm welded mesh baskets bolted onto the brick pillars and filled with grey rock

required, which comes down to the accepted dimensional wire stretch tolerances.

Welded mesh panels – given their intentional rigidity – must comply to industry standard tolerances in a range from 0,5 mm to 0,10 mm. However, with woven mesh the acceptable variance is greater at a threshold of around 5%. The reason for this is the need to make provision for the inherent nominal expansion and contraction of woven mesh systems when bracing and tensioning baskets during installation.

“In our view, however, 5% is too high, and our woven mesh systems and design recommendations make provision for a maximum 2,5% variability,” Cheyne continues.

“This of course is dependent on correct installation and rock filling techniques. When perfectly executed, the geometry all comes together, whether it’s a gabion staircase, a weir or a retaining wall. For predominately nonengineered structures, welded mesh takes this a step further.”

Welded mesh diversification Historically, Gabion Baskets first entered the welded mesh market with a 75 mm x 75 mm panel product composed of 3 mm diameter Class A galvanised wire. This was followed by 50 mm x 100 mm, and 50 mm x 50 mm panels to meet growing demand. In all cases, products

24 IMIESA Nov/Dec 2024

ENVIROMENTAL ENGINEERING

1 can now be specified either with 3 mm or 4 mm diameter wire within a tensile strength range of 350 to 550 MPa. “A thicker wire specification provides far greater rigidity and lends itself to the creation of new product lines. For, example, our new gabion barrier systems – employed for tasks like flood emergency mitigation and military protection – use a 75 x 75 mm panel with a 4 mm wire. Lined with a geotextile basket sock, these barriers can be filled with any material, including sand, and are quick to deploy thanks to their prefabricated modular concertina design. Since they fold flat into a compact space, they are also easier to transport and store,” Cheyne explains.

Another key advantage is that welded mesh gabion wire panels may be rigid in term of tolerance dimensions, but that doesn’t stop them from flowing with the curves. “Rounded shapes and corners are a major trend globally, and we’re adding our own unique interpretation

2

3

1 This gabion welded mesh feature wall for a commercial client measures 2,7 m high and 0,3 m wide and incorporates angle iron framing along with internal steel tubing supports to ensure its structural integrity 2 An example of a gabion barrier wall, with provision made for plants 3 A freestanding boundary wall constructed for a residential development. The structure was built using 50 x 50 mm welded mesh panels, filled with multicoloured rock to create a unique effect

locally through an upgrade in our manufacturing lines,” says Cheyne.

Growing entry points Either way, whether it’s for a commercial, industrial or residential project, Cheyne says the rising volume of welded mesh enquiries from built environment professionals, as well as private clients, is remarkable. These include enquiries for garden terraces, boundary walls, freestanding walls, barrier protection, building cladding, as well as commercial signage. The latter is one of Gabion Baskets’ new product lines.

“Climate change impacts are a constant reminder that our fragile ecosystems are under increasing threat and need to be countered with greener initiatives.

Gabions are a natural response from an environmentally engineered perspective, as well as from a sustainability standpoint, plus there’s tremendous comfort in being interconnected with natural stone – whether it’s ultimately a welded or woven solution,” adds Cheyne.

“Full engineering design and on-site practical installation training is offered to assist in using these product lines,” Cheyne concludes.

These external and internal cladding elements were installed using 100 x 100 mm welded mesh gabions filled with a light brown sandstone. The external wall cladding measures 9,8 m in height and was bolted at intervals into the underlying structure, as were the internal elements

IMIESA Nov/Dec 2024

25

TRENCHLESS TECHNOLOGY

Developments in design, construction and rehabilitation of sewers: Part 2 There are several practical factors in terms of sewer performance, materials and installation that are often not considered at the design and construction stage.

However, when evaluating a sewer’s condition prior to rehabilitation these become apparent in hindsight.

By Alaster Goyns, Pr Eng*

E

FIGURE 1 Siliceous aggregate concrete

FIGURE 2 Dolomitic aggregate concrete

i t h e r w a y, b e f o r e a n y rehabilitation takes place, it is essential that the sewer’s hydraulic per formance and condition are assessed, and that all underlying causes of corrosion have been identified.

Historically, many of the sewers installed during the 1960s to 1990s in South Africa’s urban areas used dolomitic aggregate.

Generally, these systems have met their planned 40 year plus lifespan and now need to be replaced or rehabilitated.

The starting point is to conduct a CCTV camera inspection along the whole length of the sewer, or at least along a reasonable length and not over a short section between a few manholes.

Evaluating the sewer’s hydraulic performance and longitudinal gradient along its whole length is essential. This needs to be determined by combining the gradients given by the CCTV inspections between each manhole, which is seldom done.

The output from a basic hydraulic analysis will indicate whether or not there are any performance problems and whether there is a variation in the hydraulic performance between different sections. The CCTV inspections will also indicate which sections of the sewer need cleaning before assessing their condition; where there are localised problems needing repair; and where there is an overall problem requiring rehabilitation.

When there is a need for localised repairs these should be done before any rehabilitation of the conduit in general. This means that there should be a clear distinction between addressing any underlying causes, doing localised repairs or rehabilitating the total section of sewer.

Industry research findings FIGURE 3 Large sewer half full of silt

26 IMIESA Nov/Dec 2024

Here the findings of a Council for Scientific and Industrial Research (CSIR) study published

in 1959 provides valuable background information. Entitled “Corrosion of Concrete Sewers”, the problems identified were addressed from three dif ferent angles, namely: the microbiological aspect of how the production of sulphuric acid attacks the concrete; the technical (hydraulic) aspects of sewer design that cause corrosion; and construction materials that tend to be more resistant to corrosion.

Of significance was the practical approach based on the materials being used in the CSIR research compared to international research. Although this covered all three angles mentioned above, the most significant was the choice of material to improve sewer performance despite corrosive conditions.

When an alkaline aggregate such as dolomite was used, for example, the study showed that both the aggregate and the cementitious binder would be corroded by sulphuric acid.

However, when an iner t usually siliceous aggregate was used, it was just the alkaline cementitious binder that would corrode.

Significantly, the combination of binder and aggregate both being alkaline resulted in a more unform corrosion of the pipe surface and a significantly slower loss in wall thickness.

(Figures 1 and 2 show the difference between the corroded surfaces of concretes made with these two different aggregates.)

Effect on pipe performance Therefore, aggregate selection clearly has a direct bearing on longer term pipe performance.

In the case of non-alkaline siliceous aggregates, as cementitious binder corrosion intensifies, the coarse aggregates (the stones) start to protrude from the pipe wall, making the wall rougher. This will reduce the velocity during peak flows. Eventually, the stones will fall out of the binder, leaving gaps in the pipe wall.

Due to the size of the stones, the velocity in the sewer will be unable to move them, so they will collect on the invert, gradually making it rougher and changing the pipe profile. This will cause the collection of finer material, increasing the amount of silt and reducing the sewer capacity.

There have been cases on large diameter sewers where they are half full of silt (as shown in Figure 3). This means that at peak

TRENCHLESS TECHNOLOGY

flows manholes can overflow into the streets.

Under these conditions, the slower flow will also result in more hydrogen sulphide (H2S) being formed. When this escapes into the sewer atmosphere, the amount of sulphuric acid (H 2SO 4) produced also increases, resulting in greater corrosion.

In comparison, when a dolomitic aggregate is used, the stones corrode and become rounded and will not cause an increased roughness on the pipe walls. Although there may well be some aggregate fall out, it will not be as serious compared to where siliceous aggregate is used.

Variable gradient considerations Inevitably, corrosion is directly impacted by variable gradients. When there are flat gradients and the velocity is very slow – for example, lower than 0,6 to 0,8 m/s – there is a lack of oxygen in the effluent. The bacteria in the slimes layer then extract this from the sulphates, and hydrogen sulphide is produced. This accumulates in the effluent and at a certain concentration will escape into the sewer atmosphere.

H2S generated

H2S released

Flat slope

Downstream corrosion

Steep slope Flat slope Gradient’s impact on H2S generation and release

Should there be a change to a steeper gradient, however, the velocity will increase, and the hydrogen sulphide will be stripped out at a faster rate. This is why it is so important to look at the hydraulic performance over the whole length of a sewer.

Action plan A comparison of the information gained from the hydraulic assessment and the CCTV condition assessment will shape the future rehabilitation plan. When there is a

clear correlation between the two, this will in general indicate whether or not rehabilitation using lining or on-line replacement is required.

In turn, the lessons learnt from this combined assessment approach will prove invaluable for future new sewer designs by optimising the gradient to minimise corrosion, combined with the selection of the best pipe material to match the site conditions. *Board member, Southern African Society for Trenchless Technology (SASTT)

Part 1 in this two-part series was published in the September 2024 edition of IMIESA.

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WATER & WASTEWATER

CAN MUNICIPALITIES KEEP THE WATER FLOWING? The pressure is on, and the vice is tightening around water management.

VEGA can ensure a reliable and sustainable water supply for metros.

A

s urban populations in South Africa grow rapidly, the demand for water infrastr uctur e intensifies, making sustainable water management essential. A reliable water supply is closely tied to social stability, and disruptions can undermine community well-being and environmental sustainability.

Monitoring and managing pressure within water systems is therefore vital to ensure consistent water delivery but also to help achieve sustainability goals by minimising resource waste, lowering consumption, and protecting infrastructure. VEGA’s pressure instrumentation equips water utilities and municipalities with reliable sensors that support efficient, resilient water management.

Sustainable water management extends beyond delivering a steady supply; it encompasses wastewater management and careful resource use.

In a move toward greener practices, water utilities recognise the operational and environmental benefits of precise pressure monitoring.

Reliable pressure sensors can prevent pipe bursts, prevent costly leakages, optimise water flow, and ensure accurate readings that reduce both energy use and resource waste.

Inconsistent data from less reliable sensors can lead to inefficiencies, equipment wear, and higher maintenance costs, which ultimately strain environmental and financial resources.

Standardising pressure instrumentation with VEGA’s solutions simplifies the adoption of sustainable practices and provides facilities with a comprehensive approach to environmental management. VEGA’s sensors are designed for

durability and minimal resource demand, allowing treatment plants to streamline operations while reducing their environmental footprint.

Sensor accuracy Beyond initial costs, reliability, accuracy, and robustness in instrumentation are essential to avoid hidden expenses. Inaccurate pressure readings can damage infrastructure and disrupt water supply, affecting end users and, in turn, damaging the utility’s reputation and trustworthiness. VEGA has provided reliable, cost-effective water pressure solutions globally for over 40 years, helping facilities safeguard their operations and environmental impact.

VEGA’s pressure solutions, like the VEGABAR 38, allow utilities to remotely monitor tanks and chemical systems, conserving time and resources.

With IO-Link communication, the VEGABAR 38 integrates smoothly into automated operations, offering an energy-efficient LED light ring and userfriendly VDMA menu that enhances usability while cutting operational costs and energy consumption.

For extreme environments, the VEGABAR 82 pressure transmitter features a resilient ceramic measuring cell designed to minimise maintenance needs. Ideal for challenging settings like sewerage and pipeline systems, the VEGABAR 82 supports continuous, efficient operation, reducing environmental strain through resource-conscious design. The VEGABAR Series 80 sensors can be connected to provide electronic differential pressure measurements, expanding the possibilities for water and wastewater applications.

Precise influent and effluent flow measurement is essential, and the VEGADIF 85 differential pressure transmitter ensures accurate readings critical for effective flow management. Its overload diaphragm withstands pressure fluctuations, and its multivariable sensing capabilities provide precise data, supporting informed decisionmaking. This durability and precision make the VEGADIF 85 invaluable for consistent performance across various fluid measurement conditions.

The VEGAWELL 52, designed for hydrostatic level and pressure monitoring, offers a robust solution for continuous measurement in deep wells, reservoirs, and other challenging settings. Its durable construction and energyefficient design make it a sustainable option that supports informed water management and resource allocation, ideal for both surface and sub-surface applications.

VEGA’s commitment to innovation also enhances connectivity, facilitating sustainable monitoring.

With Bluetooth-enabled sensors and the VEGA Tools App, facilities can remotely configure, manage, and troubleshoot, reducing the need for on-site intervention and lowering emissions linked to travel.

Through VEGA’s advanced pressure monitoring systems, water and wastewater facilities can improve sustainability efforts, optimising real-time resource usage and operational efficiency. VEGA’s solutions not only enhance daily functionality but also promote an approach that aligns operational success with ecological preservation, supporting both local communities and ecosystems reliant on clean water.

VEGA instruments offer reliable measurements in the most challenging environments

VEGAWELL 52 is suitable for continuous level measurement in deep wells, reservoirs and rivers

Increase water treatment efficiency with VEGA pressure sensors

WATER & WASTEWATER

Is your building prepared for the upcoming rainy season?

As we may be aware, Gauteng is currently facing significant water challenges due to high demand for various needs in our buildings and construction sites. With the rainy season approaching, now is the perfect time to adopt sustainable practices that can help alleviate the pressure on municipal water resources. Investing in rainwater harvesting not only prepares your building for the season ahead but also supports a more sustainable future for Gauteng.

R

ainwater, a freely available source, can be captured in many ways around your building. Take for instance an office with 50 employees. If each employee flushes the toilet four times a day, the daily consumption is bound to accumulate. By implementing a rainwater harvesting system, you can significantly reduce reliance on municipal water for non-potable uses, such as toilet flushing, landscape irrigation, and even washing vehicles. This approach could lead to substantial financial savings.

To put the potential financial savings into perspective, each flush uses around 6 litres of water, equating to approximately 1 200 litres per day of water just for flushing! Therefore, capturing the rain to service these needs can lead to substantial savings and have a positive environmental impact of reducing stormwater runoff and relieving pressure on our already stressed water supply.

Beyond financial savings, rainwater harvesting can enhance your building’s sustainability profile. This demonstrates a commitment to environmental stewardship and can improve your organisation’s public image, attracting tenants or clients who prioritise sustainability.

Rainwater har vesting systems come in a variety of forms, each with special characteristics that are appropriate for certain applications and architectural styles.

These are a few typical choices:

1

Rain Barrels: Easy and affordable, rain barrels gather water from rooftops through gutters and store it for cleaning or gardening purposes. They are quick to set up and perfect for small-scale requirements.

Consulting with an expert is a smart way to find a system that best meets your needs.

2 Permeable Pavements: Rainwater can

• Harvested rainwater can be used

percolate through permeable pavements instead of creating runoff – albeit this process is more indirect. The water is filtered naturally and stored in underground reser voirs for later use by plants in the landscape.

DID YOU KNOW? to flush your toilet, wash your cloths and dishes, and even water your plants.

• Just one small rain shower of

25 mm on a 10 m x 10 m roof can provide you with 2 500 litres of fresh clean rainwater.

3 Green Roof Systems: These systems

integrate rainwater collection with a green roof, which is a vegetated area that absorbs and filters rainfall. After that, the water can either be put back into storage tanks or used again.

They also enhance the quality of the air and offer insulation.

4 Gravity-Driven Systems: These systems

use gravity to send water to specific locations within the building from an elevated tank, saving energy and money when used for flushing or irrigation.

5 Underground Storage Tanks: Built to hold

Uphold the values of using water efficiently and stay informed by contacting our Rand Water, Water Wise website or follow us on our social media platforms for more water conservation tips.

Act now – Save water – Let’s make ever y drop count!

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enormous amounts, these tanks are placed underground to conserve space and are linked to the building's plumbing systems for nonpotable usage. They are perfect for homes or businesses that use more water.

IMIESA Nov/Dec 2024

29

WATER & WASTEWATER

CAN WATER HELP AFRICA REACH NET ZERO? Carbon neutrality is an oppor tunity to accelerate Africa's water modernisation, writes Chetan Mistry, Strategy and Marketing Manager at Xylem Africa, citing a range of globally applied examples.

Chetan Mistry, Strategy and Marketing Manager at Xylem Africa

H

uman activity is substantially increasing carbon levels. NASA's regular carbon dioxide measurements show an alarmingly upward trajector y. Its researchers estimate that modern civilisation has elevated atmospheric carbon levels by 50%, slowly raising average global temperatures. Even marginal shifts in that benchmark have already led to disastrous results, such as large forest fires, prolonged droughts, excessive rainfall, and aggressive heatwaves.

Rising carbon levels create tumultuous ripples in our planet's complex weather ecosystem, hur ting communities – especially in Africa. Even though the continent contributes 4% to global carbon levels, it's considered the most vulnerable to climate change's impact. According to the African Development Bank, Africa is home to seven of the ten countries most vulnerable to climate change, and 95% of

30 IMIESA Nov/Dec 2024

the globe's rain-fed agriculture is in subSaharan Africa, making local crops ver y vulnerable to shifting rainfall.

The problem has many aspects, such as Africa's massive reliance on combustible fuels and oil economies, or reluctance to fund African decarbonisation. But one area deser ves more attention: water.

Water is climate change's canar y.

Excessive rainfall and prolonged droughts relate to changes in water systems.

Civilisations primarily rise around water, so changing water behaviour is a bellwether for sustaining the modern world.

Net Zero: The Race We All Win Water also offers opportunities to tackle carbon generation and usher nations closer to Net Zero status, negating the greenhouse gases they produce. Xylem consulted international experts to design a strategy that will help public water utilities and large water consumers

adapt their systems to reduce carbon generation. The strategy, Net Zero: The Race We All Win, is a four-step approach: set realistic targets, optimise existing assets, prioritise capital planning, and plan for the future.

Public utilities often have stockpiles of data – modern data analytics tools are helping them use that information for future planning. We can set realistic data-backed targets to incrementally make appropriate adjustments for a given site. For example, Chile's Aguas Andinas is using data-backed planning to significantly reduce its carbon output by 2030 through renewable energy.

Asset optimisation is also crucial. Utility sites must last for decades, and sweat their pumps, pipes, mixers, bioreactors, and oxidisers. However, strategically modernising those systems delivers dramatic energy efficiency and carbon reduction improvements. Numerous utilities are using Net Zero plans to cut

WATER & WASTEWATER

energy and maintenance costs. For example, variable-frequency pumps require less energy and maintenance, and many models work on solar energy. Scottish Water used this approach to reduce energy usage by 40% and maintenance costs by 99%.

As utilities stabilise their energy and maintenance requirements, they can prioritise capital planning. This step urges us to both focus on urgent requirements and maintain long-term carbon reduction.

According to Belgium's De Water Groep, this approach helps protect sites from continually making radical adaptations in response to extreme environmental shifts.

Part of its process is to vet future projects on their energy-neutral and climate-neutral aspects, a space it can explore while it achieves greater asset optimisation.

All three of these steps feed into the four th step: planning for the future.

Ultimately, aiming for Net Zero is an opportunity to revisit how we run our water systems. Some strategies include buying renewable grid energy and generating onsite renewable energy. New Zealand's Watercare is helping lead the way. It has launched several solar sites, including the countr y's first floating solar farm, and integrated its capital and operational strategies for better per formance.

Incremental upgrades How can African utilities benefit from these steps? Our water management sites can star t with specific and incremental

upgrades rather than attempt massive overhauls. Some solutions are faster to deploy, such as UV and ozone disinfection that complement chlorine systems while reducing the latter's storage and pollution risks.

Smart meters and in-line leak detection improve monitoring and data collection and reduce costly non-revenue water waste. Modern aeration systems are more energy-efficient than their predecessors, and new sludge management systems substantially reduce carbon release.

These examples apply to public utilities and industrial water systems at mines, factories, and farms. They help enterprises manage their Environmental, Social and Governance (ESG) requirements, lower costs, and improve energy resilience. They also reduce carbon output and extend control over carbon and environmental risks.

Water can help African communities reach Net Zero status. It offers many quick wins and long-term victories to ensure we look after our planet and future.

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BIENNIAL PROJECT EXCELLENCE AWARDS

CALL FOR ENTRIES To recognise outstanding achievements in municipal infrastructure, we are calling for entries that showcase projects that demonstrate the best of civil engineering as a science and how engineering enhances the lives of the local communities, through excellence in:

1

ENGINEERING EXCELLENCE IN STRUCTURES & CIVILS E.g. Projects demonstrating engineering science, use of alternate materials, innovative construction processes, etc.

2

Planning and design Construction methods Innovation and originality Meeting social and technical challenges Contributing to the well-being of communities

COMMUNITY UPLIFTMENT & JOB CREATION E.g. Projects demonstrating labour-intensive construction, skills development, community awareness/participation, etc.

3

ENVIRONMENT & CLIMATE CHANGE E.g. Environmental rehabilitation, renewable energy, drought solutions, coastal initiatives for rising sea levels, pollution control, educational/ technical initiatives, etc.

CLOSING DATE FOR SUBMISSIONS 03 July 2025

Only projects that have reached practical or substantive completion by 30 June 2025 will be accepted for the Excellence Awards.

Adjudicators reserve the right to reallocate entries in the 3 categories.

ENTRY FORMS AND AWARD CRITERIA Available for download on the website: www.imesa.org.za

IMESA THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA)

QUESTIONS Contact Debbie Anderson on +27 (0)83 326 3050 or email conference@imesa.org.za

SPATIAL DEVELOPMENT & PLANNING

A CONSCIOUS APPROACH TO SMART URBANISATION In Sub-Saharan Africa, where roughly 60% of people still live in rural areas, urbanisation is occurring faster than anywhere else in the world. The temptation to build new cities on greenfield sites away from existing city centres is enormous.

G

iven the available land, it’s far simpler to develop new, state of the art urban environments from scratch,” notes Alison Groves, Director and Discipline Lead: Built Ecology at WSP in Africa. “However, overlooking the critical importance of retrofitting existing urban centres could inadvertently have a negative impact.”

This observation is underscored in WSP’s Retrofitting+ paper, which points out that retrofitting will be the global proper ty and building sector’s greatest contribution to avoiding catastrophic climate change and transforming cities into healthier, happier, more resilient places.

Currently, the built environment is responsible for just under 40% of global energy-related emissions. For example, in 2022 operating buildings generated nearly 10 billion tonnes of carbon, and construction a further 2,5 billion of embodied carbon.

“Retrofitting therefore ser ves a dual purpose,” expands Hlologelo Manthose, Built Ecology Sustainability Consultant at WSP in Africa. “Firstly, it improves the energy efficiency of existing buildings and incorporates key sustainable practices like water efficiency, and secondly it repurposes underutilised or redundant buildings to ser ve a new purpose – such as conver ting old office buildings into housing.”

WSP’s Built Ecology team believes that making adaptive reuse of existing buildings the default for meeting new demand – rather than demolition – is just as impor tant in the African context as it is internationally.

The embodied carbon of the materials that were used to build existing building stock has already been realised. In turn, for ever y cubic metre of concrete that is not poured there’s a CO2e saving of approximately 474 kg.

Alison Groves, Director and Discipline Lead: Built Ecology, WSP in Africa

Hlologelo Manthose, Built Ecology Sustainability Consultant at WSP in Africa

“This global retrofitting movement is an opportunity to reflect on and re-envision how and where we want to live, and to shape our urban reality to match this vision,” Groves continues. “Perhaps even more importantly in our African social and economic context, retrofitting represents an opportunity to overturn entrenched inequities that stifle economic and human potential.”

Bringing central business districts back to life In the global context, this means giving people a reason to return to urban centres, especially with return to office full-time being more the exception than the rule. A post pandemic impact that has resulted from the remote and hybrid work approach is the appreciation for the reduction of the daily commute. For commercial buildings, the continuing hybrid work style means smaller office footprints, which also opens avenues for possibly redundant office space to be reconfigured and retrofitted into residential spaces and other amenities.

“This could be a catalyst for realising the 15-minute city vision,” says Groves. “A 15-minute city is an urban planning concept that emphasises the role of neighbourhoods in promoting climate, social and economic resilience. It centres on the principle that people would have access to the essential services they need – workplaces, schools, affordable food shops, public transport, healthcare and green space – within a 15-minute radius of where they live.”

In the African context, retrofitting therefore presents a key opportunity to work towards Net Zero, address the housing crisis, as well as connect communities within a safe and sustainable urban environment.

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WIDENING OF NATIONAL ROUTE R22 SECTION 5 THROUGH KWANGWANASE TOWN The town of kwaNgwanase is a gateway to Mozambique and is a renowned tourist attraction area forming part of the iSimangaliso Wetland Park, recognised as a World Heritage Site. The town is also the main business hub serving a population of about 500 000 people.

Improved accesses including entrance to local municipality offices (left)

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ue to poor town planning and rapid growth in the number of businesses (formal and informal), it led to a significant decline in the level of service along Road R22 within the town.

The main challenges faced by the town included: • Heavy delays through town due to illegal U-turns and parking on the road; • Poor access to the hospital and clinic; • Influx of illegal traders with solid structures within the road reserve; • Damage to the drainage system along Road R22 by informal traders; and • Conflict between pedestrians and vehicular traffic.

The design contract for rehabilitation and widening of Route R22-5 through kwaNgwanase town was awarded to BVi Consulting Engineers

by SANRAL in 2018. BVi appointed BSP Consulting Engineers as the Targeted Enterprise on the project. Leomat Construction was awarded the construction contract.

The project covers a 3.9 km section of national road located in the KwaZulu-Natal province and included the construction of street lighting, new stormwater systems and a 2.83 km long bypass road (IYK Road). Other works included in the scope were the construction of access roads, pedestrian sidewalks and two community development projects.

The design included widening the rural portions of Road R22-5 to a cross section consisting of one lane per direction with 0.9 m surfaced shoulders.

Several private properties with direct access onto Road R22 were situated along the eastern rural portion of the project with no alternative access. In

order to reduce the number of direct accesses onto Road R22, the design included separate parallel concrete access roads with limited direct access to Road R22. Due to safety concerns guardrails were introduced between the R22 and concrete access roads.

The design along the urban section through town allowed for one lane per direction as well as parallel parking on both sides of the road.

Paved (concrete) sidewalks were included to accommodate pedestrians.

Geometric design The geometric design of the road was guided by the existing road, road reserve and the development of properties close to the road reserve. The vertical alignment generally followed the existing alignment while the horizontal alignment was adjusted to suit the new cross section. This required earth retaining structures to fit within the existing road reserve.

IYK Bypass Road The design of the IYK Bypass Road was prepared

by BSP Consulting Engineers under the guidance of BVi. The Bypass Road was identified by the local municipality with the intention of providing an alternative route while the town section of the R22 was being constructed. The cross section of the

Construction of retaining wall and drainage infrastructure while traffic is accommodated along completed widening

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R22-5 urban section

Bypass Road consisted of one lane per direction as well as kerbs and paved shoulders.

During the construction phase of the project, BVi was instructed to revise the design to allow for two lanes per direction compared to the original design of one lane plus parallel parking. The revised design included standard intersections replacing roundabouts as per the original design and required additional retaining walls.

Community development projects As par t of SANRAL’s contribution to the improvement of local communities, new market stalls were constructed next to an existing market. In addition to this, an animal pound was constructed for the municipality. These projects were designed by BSP Consulting Engineers and were completed by three local sub-contractors under supervision by the main contractor.

Market stalls The market stalls project was constructed under two sub-contracts with a total value of R3.5 million (excl. VAT). The market provides covered stalls for 50 vendors, each with their own lockable storage facility. The purpose of these stalls was to reduce the number of vendors along the road.

An area next to Road R22 within the urban portion was identified by the municipality to ensure close proximity to the road as this provided the most exposure for the vendors. Concrete block paving was provided to ensure improved accessibility during inclement weather and to allow for drainage.

Goat pound

Market stalls

Animal pound Construction of an animal pound for goats and a kraal for cattle was requested by the municipality with the objective of providing them with a facility to house stray animals collected along Road R22.

SANRAL agreed to the project, which will have the benefit of reducing the number of animals within the road reserve, thereby improving safety for the travelling public.

The goat pound comprises an elevated covered structure consisting of steel beams and columns together with a timber floor. Also included as part of the project was an administration building, borehole for water supply and fencing of the property boundary. The total cost of this facility was R6.1 million (excl. VAT).

The project achieved its objectives of improved mobility and safety and provided much needed benefits to the community. Besides the two community projects, the community benefitted from improved infrastructure and access with the upgrading of the Bypass Road, employment opportunities to 40 local sub-contractors and over 200 people. In addition, over R1 million was invested in training and support to local schools and beneficiaries.

The contractor and supervision team maintained a good relationship with the local community, including representatives from the Tribal Authority, which assisted in a relatively smooth project without any undue work stoppages or protests.

Conclusion Collaboration and teamwork The project was completed successfully, albeit over an extended construction period. Teamwork and in particular stakeholder engagement played a key role in this success. The public liaison officer (PLO) together with the site teams proved effective in ensuring that the local municipality, Tribal Authority, business owners and the community were continuously informed and engaged on project matters. Key in this process was the SANRAL project manager, Mr Andrew Ssekayita’s dedication and involvement as PLO chair.

Challenges during construction included: • Material quality within the area; • Mixed-in-plant BSM versus in-situ recycling; • Stormwater; and • Extreme climatic conditions.

Animal pound administration building

The widening and improvement of Road R22-5 through kwaNgwanase town provided improved mobility for the travelling public, improved safety for pedestrian traffic, upgraded infrastructure for the local municipality, improved access to the community and business owners and various smaller infrastructure improvements benefitting the community.

www.bvi.co.za Cattle kraal area

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CASE STUDY IN DIGITAL ENGINEERING

Upgrading the strategic Montrose Interchange The original layout of the Montrose Interchange, which dates back to the 1970s

The Montrose Interchange is a vital link on the sole eastwest route connecting South Africa, Mozambique in the east, and Botswana in the west. The original 1970s intersection design could no longer keep pace with rising traffic volumes along the Maputo Development Corridor.

Trans African Concessions (TRAC) launched the Montrose Interchange Upgrade Project as one of the projects earmarked to address some of these issues and enhance safety and mobility on the route.

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RAC, a privately-owned company formed in 1996, manages the N4 Toll Route from Solomon Mahlangu Drive Interchange in Tshwane (Gauteng) to the Por t of Maputo in Mozambique in terms of a 30-year Build, Operate and Transfer concession contract, in par tnership with the South African National Roads Agency Limited (SANRAL) and its Mozambican counterpar t Administração Nacional de Estradas (ANE). In addition to operations and maintenance, TRAC’s focus includes ongoing enhancements to the approximately 570 km route, funded via toll fees at its ten plazas.

36 IMIESA Nov/Dec 2024

Both from a mobility and safety perspective, the Montrose Interchange Upgrade Pr oject was a cr ucial requirement in terms of current and future planning, requiring an innovative reconfiguration approach driven by SMEC as the lead designer.

The cost-effective solution devised needed to ensure efficient traffic flow between eMalahleni (Witbank), Mbombela (Nelspruit) and beyond via the Montrose Interchange node. This could only be achieved by replacing the existing at-grade T-junction with a new grade-separated, free-flow interchange at the intersection of N4-6Y (N4 via Schoemanskloof) and N4-7X (N4 via Elands Valley).

An intensive 69-month construction programme was completed in September 2023. The scope of works included realigning 600 m of the existing Schoemanskloof road to facilitate the construction of four new interchange ramps; 1 800 m of new directional ramps to facilitate freeflow movement in all directions; and widening the existing Crocodile River Bridge from two to five lanes.

Additionally, two new signature deckstiffened arch bridges – anchored into the natural rock – were built to cross the existing Elands Valley section of the N4 and accommodate two new ramps (A and D) of the upgraded interchange.

Eleven 25 m high energy efficient lighting masts were also installed to illuminate the interchange, enhancing visibility and road safety.

Future-proof design The design of the Montrose Interchange was carried out to consider not only the immediate needs but also the future function of the N4-6Y as the main N4 route. To fulfil this future role, an additional bridge across the Crocodile River will need to be constructed. Early indications showed that the only way to achieve free-flow traffic in all directions and two lanes from Mbombela to Schoemanskloof would be to construct this second bridge as par t of the current project.

However, this new bridge was estimated to cost around R350 million, which was more than the cost of the entire interchange designed

by SMEC and exceeded the available budget. Therefore, SMEC conducted an intensive engineering investigation to determine how the existing Crocodile River bridge could be repurposed to meet immediate needs and align with future requirements.

The result is that the cur rent interchange is an interim stage of the future enhanced Montrose Interchange.

Eventually, this will facilitate two lanes per direction at a design speed of 100

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A rendered image of the Montrose Interchange during design development

km/h when it becomes necessar y to upgrade the N4-6Y to a dual carriageway freeway standard. This interim solution is a cost-ef fective way to provide functionality and capacity that will ser ve the users of the N4 for many years.

Transforming project efficiency with digital tools In terms of terrain, the Montrose Interchange is uniquely situated at the confluence of two steep valleys car ved by the Crocodile River and Elands River in the Drakensberg Mountain range.

With nine geometric alignments af fecting constr uction planning, pavement engineering, minimum lighting requirements and tight structural tolerances, design changes had to be ef fectively managed and well-communicated throughout the project lifecycle. All digital design information was hosted in a common data environment of SMEC’s own design to ensure that ever y discipline was always working on the latest information through a single source of truth. This principle aligns with the imminent implementation of the SANS 19650 Information Management Standard.

Digital twinning With limited time and budget to conduct a traditional detailed or aerial sur vey of the project location during the concept development phase, SMEC turned to Bentley’s iTwin Capture software. This software uses advanced photogrammetric methods to create a

realistic 3D digital twin of the site using only drone-acquired photos.

SMEC acquired the software and used their own drone operators to gather the necessar y data, saving approximately three months on the project timeline and reducing the initial feasibility sur vey cost drastically by approximately 85%.

The resulting reality mesh provided the SMEC team with a deeper understanding of the unique challenges posed by the terrain and existing infrastructure. Four conceptual designs were modelled in 3D, using the reality mesh as a foundation to test the feasibility of each option and to visualise the finished product as if it were already present in the real world.

Other technological innovations included creating reusable roadway templates in Bentley’s OpenRoads Designer, significantly reducing the time required to develop alternative 3D-modelled options compared to the initial model.

Through the smar t and efficient use of digital software, the SMEC team accelerated the project schedule, reduced material costs, enhanced productivity, improved workflows, and elevated the quality of deliverables within a Building Information Modelling (BIM) environment.

Crocodile River Bridge The existing Crocodile River Bridge, spanning 160 m across the river from constructed fills on either side through the historical Montrose Pass, posed a complex challenge to

the geometric team. Not only was it positioned extremely close to the existing intersection, but it was originally designed with ver y complex geometr y.

The horizontal alignment included both a circular cur ve and a por tion of a spiral transition cur ve, and the ver tical alignment had a low point positioned on the bridge deck with two ver tical points of intersection along the length of the bridge. The superelevation development also happened par tly along the bridge, var ying from 6 to 9.6% crossfall.

The new alignment needed to be smooth and geometrically sound, uniformly of fset from the original alignment while accommodating the tapering of the exit to Ramp A within this complex transition. The complexity of the new alignment’s design may go unnoticed by the average road user, but it was intentionally crafted to ensure the smoothest possible transition.

The existing bridge had to be open to traf fic 24/7 throughout the construction period, making stitching of the deck widening to the existing bridge challenging. The demolition and removal of the existing parapets from heights approaching 15 m required extensive saw cutting and the use of cranes.

The existing frame abutment has ver tical and inclined reinforced concrete columns that are directly embedded into hard granite, with a seating beam connecting these columns. The widening required avoidance of any differential settlement between the existing and the widened abutment and this was achieved by extending the seating beam onto percussion drilled odex piles, into the existing boulder filled road prism.

Arch bridges that blend with the terrain As new structural elements, the two arch bridges spanning the Elands Valley were specially designed to blend in with the surrounding environment. Their rendition was inspired by the Maillar t Arch Bridges of Switzerland, designed

by Swiss engineer Rober t Maillar t in

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the early 20th centur y. His designs are celebrated for their structural simplicity, aesthetic appeal, and ability to integrate harmoniously with their natural surroundings.

In elevation, SMEC’s arch bridge designs have visually slender elements to enhance their transparency. The arches have a ver y flat span-to-rise ratio of 11.3. The result is a shallow, deck-stiffened arch bridge form, which spans using both arching and flexural action. The bridges were designed as jointless, with expansion joints eliminated for ease of maintenance and improved riding quality.

Typically, arch bridges are placed on straight geometr y in plan. However, the Montrose arch bridges’ form was designed to express the free-flowing, cur ved ramps of the new interchange.

They follow the sweeping, parallel cur ves of the ramps on radii of 162 m and 172 m, respectively. This unique design creates a dramatic visual interest at the grade separation,

with the cur ved decks contrasting with the arches below, which span perpendicular to the rock cut faces.

The bridges’ form combines a variety of geometric shapes along the cur ved decks. Wide deck cantilevers overhang inclined spandrel walls on the arches below. The arches var y in width from 4 m to 6.8 m, with one edge forming a reverse cur ve between the cut faces and the other following the cur ve of the road. This arrangement resists centrifugal forces from traffic loads and helps restrain torsion in the cur ved deck.

Arch bridge foundations The arch springers were founded on hard rock porphyritic granite. Detailed finite element geotechnical analysis of the slopes (including rock joint locations) was carried out in the design stage. This analysis determined that rock bolts were required to deal with fracture planes identified in the rock mass. SMEC partnered with PeraGage

to leverage their geotechnical exper tise to manage the transfer of loads into the natural rock safely.

The rock bolts enabled the large arch-foundation’s thrust forces to be safely transferred into the rock mass with minimum displacement, despite the jointed rock mass. Additionally, due to the jointing in the rock at the arch springer foundations, ver y carefully controlled blasting/rock excavation techniques were specified.

During the construction excavations at the arch springers, substantial variation in the founding rock condition was discovered. Founding variation included zones of softer weathered granite and fur ther joints/ fractures, which would af fect the resistance to arch thrust forces at the springer foundations.

To deal with the variable rock stif fness and jointing encountered during construction, the rock bolt arrangement had to be modified and included bolts actively prestressed

The completed Montrose Interchange in the direction of Schoemanskloof

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through the springer foundations, as well as ver tical prestressed bolts behind the springers. These ensured that, despite zones of softer weathered granite and more adverse jointing, safe bearing stresses were maintained under all load combinations. The modified rock bolting fur ther ensured that the Factor of Safety for slope stability, as well as the subgrade modulii (stiffnesses) were consistent with the design intent.

By utilising the natural hard rock for suppor t and employing innovative design and construction techniques, the Montrose Interchange arch bridges stand as a remarkable example of moder n engineering excellence.

The same is equally true for the project as a whole, which stands as a testament to SMEC, TRAC and SANRAL’s commitment to advancing infrastructure, fostering socio-economic development and preser ving the natural beauty of the region.

Fur thermore, the Montrose Interchange Upgrade had a positive community impact, creating over 350 jobs for local labourers and engaging more than 20 local subcontractors.

Additionally, the project suppor ted the development of small and medium enterprises (SMMEs) and provided extensive training oppor tunities.

As a pathfinder in digital design innovation, the project has also received industr y recognition in the following competitions: • Selected as one of three finalists in

the international 2023 Bentley Going Digital Awards in Singapore • Winner of the “Projects with a value between R50 million and R250 million” categor y at the 2024 CESA Aon Engineering Excellence Awards

• Winning the Most Outstanding Civil Engineering Project at the 2024 SAICE SANRAL National Awards, and • Winning the 23rd Construction World Best Projects Award 2024 in the categor y Consulting Engineers.

The interchange illuminated at night

The completed upgrade on the Crocodile River Bridge

One of two arch bridges constructed to facilitate interchange access

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heavy lift of the final centre section, which was 300 t heavier than the other parts. The alternative would have been to erect the bridge in five sections, which would have lengthened the project schedule.

Crawler crane mobilisation Delivering one of the bridge sections via a barge in the Wear River

The installation of the New Wear Footbridge The New Wear Footbridge will play a key role within the evolving Riverside Sunderland precinct development, connecting pedestrian and cyclist traffic from the city centre to the Stadium of Light – home of Sunderland AFC – across the River Wear.

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ituated on a 32-hectare footprint, Riverside Sunderland is one of the UK’s most ambitious city centre regeneration projects – steadily transforming the site into a dynamic, carbonneutral mixed-use urban quarter.

As an expert in efficient bridge installation projects and smar t site management, Mammoet was appointed to oversee the smooth delivery and heavy lifting of the four sections that form the 250 m long footbridge structure. The latter were fabricated in Ghent, Belgium by Victor Buyck Steel Construction and in total weighs 1 150 t.

Working closely with Belgium-based marine heavy-lift specialist HEBO, Mammoet arranged for the four bridge sections to be shipped via two voyages spaced a month apar t. This just-in-time approach allowed

enough space for the operations team at Mammoet to install the first two sections and prepare for the arrival of the remaining two.

The team was first mobilised on the north side of the River Wear, ready to receive and lift the first two sections from a barge using an LR 11350 crawler crane. The first two bridge sections were lifted from the barge onto concrete plinths close to the water’s edge.

The team then dismantled the crane and relocated to the south side of the river, ready to receive the second deliver y. One more bridge section was placed on plinths; then the final and largest section, measuring 105 m, was lifted from the barge using strand jacks connected to the previously installed sections.

Strand jacks were necessary as the crawler crane didn’t have the capacity to perform the

The bridge installation programme at an advanced stage of construction

The crawler crane came directly from another project at the Port of Nigg, Scotland. Its parts were transported to Sunderland using 50 conventional trailers, which caused a challenge in scheduling.

“During assembly of a crawler crane, you need to bring in each section as you would build it,” explains Richard Gatenby, Project Manager at Mammoet.

“We needed to make sure that as the crane was coming from Nigg, the trailers were arriving in the right order and there was no breakdown in communication. We sent the client our transport schedule and plan, so they were aware of what was moving and when.”

There were other challenges the team overcame during the project. For example, the barges could be positioned in a general mirroring spot in the middle of the river, but due to the changing water heights there were limited opportunities to move them to the river’s edge. This was managed carefully to ensure the waterway was kept as clear as possible.

The bridge’s curved bottom also posed a challenge. When the sections were placed flat on conventional trailers, their angled tops meant one end sat higher than the other. Therefore, during the heavy lift, careful jacking was needed to rotate them and get them into the correct position.

With all phases successfully completed, however, the ultimate result is an iconic new landmark and a strategic non-motorised conduit for the Riverside Sunderland community.

Strand jacks were necessary as the crawler crane didn’t have the capacity to perform the heavy lift of the final centre section, which was 300 t heavier than the other three bridge sections

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MPUMALANGA UNVEILS ITS ROAD MAINTENANCE MANAGEMENT SYSTEM An innovative road Maintenance Management System (MMS) has been implemented by the Depar tment of Public Works, Roads and Transpor t (DPWR&T) in Mpumalanga, developed in collaboration with leading consulting engineering and infrastructure advisor y practice, Zutari.

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he road MMS assists the department to manage maintenance activities by facilitating task planning, allocating tasks to teams, tracking work completion and generating reports.

“It is a comprehensive tool for managing road maintenance activities across the entire road network in the province,” explains Dr Chris von Holdt, Zutari Director: Asset Management.

In addition to having a web-based interface for the DPWR&T’s operational staff, the MMS incorporates a pothole logging web application that can be accessed by the public and allows them to report any issues they encounter on the road.

Work order management Essentially, the system focuses on comprehensive work order management. “We are talking about capturing maintenance issues, whether they are publicly reported or identified through inspections, and then moving through the process of planning

Dr Chris von Holdt, Zutari Director: Asset Management

The task team from the Department of Public Works, Roads and Transport (DPWR&T) in Mpumalanga

and executing the work,” explains Mr Bheki Walter Shabangu, Senior Project Manager: Transport Infrastructure Roads Planning.

“It also covers executing the work, recording it, and incorporates features such as job card inspections on work done for approval. In addition, we have developed a mobile app specifically for foremen working on-site to reduce paper usage by digitising the work process and capturing evidence, such as photos, of completed tasks,” Shabangu explains.

The MMS also tracks fuel and materials expenditure and provides a detailed view of maintenance costs, both in the shor t and long term.

A dashboard offers full visibility of operations across the province, allowing managers at different levels to monitor maintenance activities.

It is a substantial and important task, involving

28 call centres and several hundred people working daily on maintenance.

“The introduction of the road MMS is a transformative step for DPWR&T,” adds Mr M.C. Morolo, Head of Department. “I am excited about how this system will streamline our maintenance operations and improve our responsiveness to public repor ting of road issues.”

Depar tment MEC, Mr Thulasizwe Thomo, concurs: “Our collaborative efforts with Zutari epitomise our commitment to improving road maintenance, ensuring safety and reliability for all road users.”

“I firmly believe that this initiative not only addresses current maintenance challenges, but also sets a benchmark for similar projects across the nation, enhancing overall transport infrastructure in our province,” Thomo concludes.

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CONCRETE RETAINING WALL SYSTEMS

HKS Law Gibb designed a 7,5 m high and 90 m long Terraforce retaining wall at 65 degrees to support the fill section of the approximately 2 020 m³ cut and fill earthworks for a new home in Bishopscourt, Cape Town

AIMING FOR THE SKY WITH HOLLOW CORE CONCRETE BLOCKS In the past, it was common knowledge that retaining walls “had” to be poured, reinforced concrete. Even though concrete retaining blocks (CRBs) have been on the market for decades, there are still some who think blocks (especially hollow core units) cannot do the same job as poured concrete, especially for structures more than 4 m high. That's simply not the case. By Karin Johns*

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s an engineered structure, concrete block retaining walls offer extensive flexibility at a range of heights and in varied soil conditions when designed by experts in this complex field. The question of how high these structures can go is relatively governed by design engineers with the expertise to push beyond conventional boundaries.

A prime example is Simon Knutton, a professional engineer and consultant with over a quarter century of experience in this field, both locally and internationally (as well as being the author of the first design guidelines for gravity walls in South Africa).

The latter includes the first Palm Jumeirah Island in Dubai, where Cape based

42 IMIESA Nov/Dec 2024

international precast concrete licenser, Terraforce, supplied its locally designed hollow core, vertically interlocking retaining block system.

Commenting on the benefits of the Terraforce system, Knutton says: “The closed face of the Terraforce minimises the risk of erosion induced failure and the contact area from block to block is better on Terraforce than any other similar product.”

Another advantage is that the wall angle is most easily changed from near vertical to flatter slopes, and features such as stairs are easily incorporated.

Although composite Terraforce walls have been built to a height of 11 m with a single skin facing, it is important to point

out that there are cer tain limitations, and as a rule of thumb, any wall (with or without extra reinforcing) exceeding 8 m and with a wall angle of more than 65 degrees will require either a double layer or concrete filled blocks at the base to increase crushing strength, which will avoid potential pressure cracks.

Terracing Knutton also warns that terracing a wall can seem like a tempting solution – he remembers successfully reaching heights of up to 25 m in this way – as terraces effectively reduce the slope angle that the wall is resisting. However, the temptation to use them can make a situation worse

CONCRETE RETAINING WALL SYSTEMS

rather than better since the foundation load from the upper wall can surcharge the lower one.

This does not mean terracing can never be considered for achieving greater wall height. Silvio Ferraris Pr Techni Eng, from Remacon Products, a Gauteng based CRB manufacturer, feels that it can be a good option, especially when space allows for it. As a basic guideline, the lower terrace must be approximately one third of the total wall height and the distance between terraces depends on overall wall height and overall horizontal space available. Generally, geofabric reinforced lower terraces will offer greater overall wall stability. Most impor tantly, says Ferraris, the overall slope angle must be considered at the design stage.

When building composite walls of any significant height, it is of crucial importance to consult with an experienced engineer.

Ferraris stresses that the law is very strict on these matters: “The NHBRC requirement is that one can build a wall to a height of 1.2 m without consulting an engineer, but as a general rule 1.5 m for walls no steeper than 70 degrees is also possible. Any steeper, and especially load carrying walls, must be designed by a qualified engineer, even if only 1.2 m high.”

The Cloverleaf Salwa Interchange project in Qatar, lined entirely by Terraforce block terraces and exquisitely planted

There are a variety of methods of building high, composite retaining walls using hollow core, interlocking blocks and each of these will have to be carefully evaluated to establish suitability for any given situation.

Double skin Double skin effectively doubles the gravity mass of the wall and increases the lever arm for overturning moments. The wall mass can be further increased by spacing the front and back skins using a stabilised fill and a geotextile or grid to hold the two faces in juxtaposition. It is not always necessary to take the second skin to the full height of the wall.

to counter this force and to intersect the slip plane with sufficient depth to resist “pull-out” when forces in the soils are activated. The choice of fabric is important and is determined by the nature of the fill material, i.e. coarse free draining or high fines content, possibly high PI with clays.

The last row of geofabric, usually three rows from the top, is mainly a needle punched fabric placed to carr y and

An 11 m high, 106 m long, 70 degree incline retaining wall constructed at Woodinville Athletics Club in Washington state, USA. Installed in 2004, the project is a classic example of effective largescale earth retention

Geofabric The use of horizontal, tensile layers increases the maximum height of the Terraforce wall significantly. The basis here is to determine the force of the “active” soil, then place enough fabric

Every terrace wall has its own foundation (founded in cut/5% cement stabilised soil), a drainage system, cement stabilised sand infill and geofabric reinforcing. On this project, reinforced steel was used inside the blocks for the bottom terraces. (Design by Terrasafe: Fred Laker, Icos Engineering)

BUILDING METHODS

A 20,5m high Terraforce round face finish wall stabilising cut and fill slopes for a road project

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CONCRETE RETAINING WALL SYSTEMS if circumstances require, or “wick” drains placed at between 1 m to 2.5m centres and at 45 degrees against the slope face.

Ferraris adds that in all cases, although this is mostly ver y difficult, all soils should be tested by a soils laborator y to determine the internal shear strength of soils, their cohesion, the percentage of fines and the plasticity index of both backfill soils and retained soils.

Montecasino: a case study

Terraforce L13 blocks placed on a 25 MPa concrete foundation and built to an average height of 9 m in chainages of about 60 m at Montecasino in Fourways, Gauteng

distribute “line” loads close to the top of the wall and to limit stormwater damage.

While the design is sometimes complex, the application is straightforward enough.

BS8006 is considered the “Bible” when it comes to geosynthetic slopes and there has been a move away from geotextiles in favour of higher tenacity products such as grids.

Concrete infill Concrete fill has a similar ef fect to double skin in as much as the mass of the wall is increased per square metre.

The concrete also improves shear resistance from block to block and boosts crushing strength. It is also possible to reinforce the concrete infill with steel or to incorporate ver tical RC pillars or horizontal RC beams into the blocks.

Steel reinforcement When considering the use of steel reinforcement in a concrete-filled wall, the block effectively gets considered to be a combination of a shutter as well as a spacer. The use of reinforcement would require structural input to assess the efficacy of the whole system.

Interlocking keys Concrete keys would only have value

44 IMIESA Nov/Dec 2024

where there are higher than usual shear forces in a wall. They can either be plain coarse gravel infill, cement stabilised soil infill or concrete keys. The soil inside the blocks should be tamped, leaving a 50 mm gap. Once the next row of blocks is placed, the soil is tamped through into the 50 mm recess, effectively keying in the blocks.

Regardless of the methods described above, there are a few basic guidelines that need to be adhered to during the construction of a very high CRB/Terraforce wall, and Ferraris is very clear on how he would proceed.

“A level foundation and an accurate first row is just the first step in many to ensure a safe and stable wall. Angled profiles need to be set up so the wall angle will keep to the design slope and compaction must be 93% mod AASHTO or more,” he explains.

“If possible, use soil material with less than 15% passing a 0.075 mm sieve, and if not possible, intermediate soil blanket drains and/or water transmissive geotextiles with adequate strength, as well as drains both at the base of the wall against the cut face, as well as at intermediate heights need to be considered,” he explains.

Drains should be placed against cut faces using either continuous sheets,

Never theless, each situation can call for a different solution and over the years many interesting and challenging Terraforce projects have been completed in South Africa and abroad. One such extensive retaining wall, completed within 4 months at Montecasino in Four ways near Johannesburg, boasts a face area of 2 700 m² and average height of 9 m. In this case, Terraforce L13 blocks were placed on a 25 MPa concrete foundation and built to full height in chainages of about 60 m.

The bottom twelve rows of blocks were filled with a cement stabilised load bearing mix, while the fabric reinforced backfill was made up of 5% cement stabilised soil (mixed with a TLB and placed with a telescopic loader) and compacted to 93% mod AASHTO. Light and heavy grades of woven geofabric were specified depending on their position within the wall. In-situ concrete shear keys were installed ever y row and ever y other block, including rows with fabric layers. All geotextiles were pre-tensioned in warp direction before placement of backfill material took place.

Conclusion Fred Laker from Icos Engineering, who has completed many successful Terraforce designs for Terrasafe (a Terraforce professional design service), and in his independent professional capacity, sums up: “While Terraforce blocks offer remarkable flexibility and strength, the expertise of experienced engineers is crucial for ensuring safety and stability in high walls. From seismic challenges to complex designs, Terraforce has proven its ability to meet and exceed expectations in various environments.” *Director of Marketing & Business Development, Terraforce

INFORMATION & COMMUNICATIONS TECHNOLOGY

The growth and proliferation of artificial intelligence (AI) shows no signs of slowing down, and with it an increasing demand for computing power, says Ben Selier, Vice President, Secure Power, Anglophone Africa at Schneider Electric.

M

ost AI research today focuses on achieving the highest levels of accuracy, with little attention to computational or energy ef ficiency.

Leaderboards in the AI community track which system per forms best on tasks like image recognition or language comprehension, prioritising accuracy above all else.

However, deep learning – based on neural networks with billions of parameters – is inherently computer intensive. The more complex the network, the greater the need for high-performance computational power and extended training times.

For example, studies by OpenAI researchers Dario Amodei and Danny Hernandez show that since 2012 the computing power used for deep learning research has doubled every 3,4 months. This equates to a 300 000-fold increase from 2012 to 2018, far exceeding Moore’s Law, which states that processing power doubles every two years. Therefore, as AI usage grows – especially with consumer applications like ChatGPT – energy consumption escalates further.

In this respect, the University of Massachusetts (Strubell et al., 2019) highlighted the environmental impact of AI, analysing the computational demands of neural architecture searches for machine translation.

Five years ago, it was already projected that the carbon cost of training such models was around 280 tonnes of CO₂, equivalent to 125 roundtrip flights from New York to Beijing.

The good news Despite these statistics, there’s an upside for AI in helping to drive down greenhouse gas emissions (GHG). For example, a 2019 study by

THE ENVIRONMENTAL RESPONSIBILITY OF AI Microsoft and PwC predicted that responsible use of AI could reduce GHC by 4% (equating to 2,4 gigatonnes) by 2030.

In fact, AI is already being used to optimise energy consumption in industrial and residential sectors, forecast supply and demand, manage autonomous transportation, and reduce carbon footprints. For instance, Google has improved the energy efficiency of its data centres by 35% using machine learning technology developed

by DeepMind.

AI is also helping to minimise waste in green energy production – predicting the output of solar, wind, and hydro energy – and optimising water usage in residential, agricultural, and manufacturing areas. Furthermore, algorithms have improved agricultural processes, such as precision farming, ensuring that crops are picked at the right time and water is used efficiently.

Data centre efficiencies At present, according to the Shift Project, the ICT sector accounts for around 4% of global carbon emissions, with its contribution to GHG surpassing that of the aviation industry by 60%.

Furthermore, as more businesses adopt AI to drive innovation, the demand for cloudoptimised data centre facilities will rise, accounting for around 33% of global ICT electricity consumption going forward.

Therefore, to minimise their carbon footprint, companies must ensure that their data centres are equipped to handle high-density compute demands efficiently. Unfortunately, at present, up to 61% of systems run by corporate data

centres are running at low efficiency, according to ScienceDirect.

Location is another factor. Cooling data centres is expensive, especially in warmer climates, but more than 80% of hardware does not need to be near the end user in terms of latency.

As an example, tech giants like Google are investing in data centres in Nordic countries for better energy efficiency. Plus, in countries like Iceland, natural cooling reduces energy usage, with renewable geothermal and hydroelectric power ensuring cleaner operations.

The future The future of AI must focus on sustainability.

Here, the World Economic Forum suggests a four-step process to balance AI’s benefits with its environmental impact.

Firstly, select the right use case since not all AI optimisations lead to significant carbon reductions. Secondly, choose the right algorithm as the energy consumption of an AI system depends largely on the algorithm used. Thirdly, predict and track carbon outcomes. In terms of the latter, implementers must include carbon footprint estimates in cost-benefit analyses and use sustainability as a key performance indicator for AI projects.

Then, last but not least, organisations must utilise green energy sources to power AI models. Google, for instance, has committed to powering its data centres with renewable energy, achieving net-zero carbon emissions since 2017 – an excellent example of sustainable ICT in practice.

IMIESA Nov/Dec 2024

45

VEHICLES & EQUIPMENT

SMART LUBRICATION SOLUTIONS FOR FUTURE E-MOBILITY APPLICATIONS Highly efficient and sustainable e-mobility solutions rely on lubrication. Therefore, to develop smart lubrication solutions for future mobility applications, FUCHS Lubricants South Africa draws on its in-depth knowledge and extensive experience in various mobility sectors.

C

ustomers benefit from the company’s long-standing collaboration with exper ts in the automotive industr y.

An innovative technology that covers nearly all solutions under one umbrella is FUCHS BluEV, which results in greater efficiency and optimised costs.

FUCHS is the number one lubrication par tner for e-mobility applications. As mobility continues to evolve, the market is slowly switching from combustion engine to electric power. Bridging between these two technologies, hybrid powered vehicles combine both combustion and electric power.

“These are an increasingly popular choice of vehicle in South Africa as they offer dual benefits and provide a transition for consumers,” comments Hayley Arnesen, National Sales Manager, Automotive Aftermarket.

The FUCHS BluEV Technology range builds the bridge between existing and new products and their application in conventional vehicles with combustion engines as well as hybrid vehicles.

Selected engine oils, transmission oils and ser vice fluids from FUCHS will be labelled with BluEV Technology, explains Wiedaad Emeran, Automotive Product Manager at FUCHS. “Pure electric vehicles (EVs) are not expected to take off in South Africa for a few years, which is why hybrid technology is ideal for our market,” adds Arnesen. FUCHS is positioning itself to take advantage of this sector as it grows and is already offering advanced products for this space.

There are many complex applications for specialised lubricants in electric and hybrid vehicles to reduce friction and secure the requisite service life. Thermal fluids also play an increasingly impor tant role in electric vehicles, as established coolants

46 IMIESA Nov/Dec 2024

TITAN ATF 6400 BluEV Technology is a premium performance automatic transmission fluid with reduced viscosity, specifically formulated for automatic transmissions of Japanese, European, and American manufacturers

offer only limited suitability for use in drive and battery systems, mainly due to their electrical conductivity. Protecting the sensitive components from environmental influences represents another challenge, with FUCHS providing the correct solutions for any vehicle both reliably and flexibly – no matter whether for lubrication, cooling, or protection.

The interaction between the combustion engine and electric motor in hybrid vehicles, as well as the frequent startstop behaviour, place new and additional demands on the engine oil. FUCHS’ BluEV Technology engine oils address these exact requirements and ensure full protection against wear caused by this arduous duty cycle. Three premium performance engine oils for combustion powered vehicles can also be used in selected hybrid vehicles, depending on the OEM specifications.

TITAN GT1 FLEX 5 SAE 0W-20 BluEV Technology is a premium per formance

engine oil with XTL® technology. It is specifically designed for highly stressed downsized engines with maximum power output, providing extreme fuel economy characteristics and reduced CO2 emissions. Other features are excellent cold star ting behaviour, ver y fast oil circulation, and outstanding performance reserves.

TITAN GT1 FLEX C23 SAE 5W-30 BluEV Technology is a premium per formance fuel-economy engine oil with optimum cold start ability and outstanding performance reserves. It is ideal for modern passenger cars and light commercial vehicles with or without extended service intervals. In addition, it is applicable in hybrid vehicles of different manufacturers such as Audi or Mercedes-Benz.

TITAN GT1 PRO C-3 SAE 5W-30 BluEV Technology is a premium per formance

TITAN GT1 FLEX C23 SAE 5W-30 BluEV Technology is a premium performance fuel economy engine oil with optimum cold start ability and outstanding performance reserves

VEHICLES & EQUIPMENT

engine oil for modern cars and vans. It has been especially developed for BMW, VW, Porsche and Mercedes-Benz vehicles with exhaust gas after treatment and turbochargers. Features include excellent cold-start properties, low oil consumption, and reduced emissions.

Gear oils As vehicle manufacturers rely on the same or related designs of automatic, continuously variable, dual-clutch or even axle transmissions for hybrid vehicles, gear oils needed are often based on already established specifications. FUCHS’ BluEV Technology gear oils are therefore suitable for most modern hybrid vehicles.

TITAN ATF 6400 BluEV Technology is a premium per formance automatic transmission fluid (ATF) with reduced viscosity, specifically formulated for automatic transmissions of Japanese, European, and American manufacturers.

It is licenced according to DEXRON VI and MERCON LV and is suitable for use in hybrid applications from various manufacturers.

TITAN ATF 6008 BluEV Technology has reduced viscosity to optimise the performance of specified six and eightspeed ZF automatic transmissions, including hybrid applications.

TITAN ATF 6009 BluEV Technology optimises the performance of specified eight and nine-speed ZF automatic transmissions, including hybrid applications.

Service fluids Due to their modern technological status, newly developed hybrid vehicles require service fluids that meet the latest requirements. Service fluids include brake fluids, coolants, and power steering fluids.

BluEV Technology brake fluids offer the best protection against steam bubble formation due to their high wet and dry boiling points.

The low viscosities of these brake fluids enable excellent brake response times, ensuring maximum safety. “The BluEV Technology label on our coolants confirms the excellent heat rejection from internal combustion engines in hybrid vehicles, but also from indirect cooling of the electric

motor and battery,” highlights Emeran.

TITAN CHF 202 BluEV Technology is a premium per formance power steering and central hydraulic fluid with a wide application and approval profile for various manufacturers.

“We have great products in place to suppor t the EV and hybrid markets, including a full list of OEM approvals.

Efficiency and fuel savings are the top priorities for consumers, along with reducing CO2 emissions. Our products are designed to meet these requirements. We also offer extended drain intervals for some products, which is important to reduce downtime and maintenance costs,” says Emeran.

Adds Arnesen: “We are well-prepared to suppor t the transition to EVs and hybrids. This is such an important sector to focus on.”

“With our many years of experience and in-depth automotive expertise, we develop lubricant solutions to meet the needs of our customers both today and in the future and are therefore cementing our vision of being first choice,” Arnesen concludes.

VEHICLES & EQUIPMENT

ASTEC’S CLASS LEADING COLD PLANER DEBUTS IN SOUTH AFRICA The Astec RX-600ex cold planer features two control stations, enabling machine operation from either side

initiating a cut, rather than requiring the operator to do so manually. It ensures that the drum connects with the pavement at the required depth and angle for the milling task.

Saunders states that the simplified controls also allow for easy operation from either side of the platform. “With multifunctional joysticks and accessible controls, operating the cold planer is clear and intuitive. Furthermore, the controls are designed to be operated with one hand to allow for truck signalling,” he adds.

Rock to Road

The South African launch of the Astec RX-600ex cold planer sets a new standard for per formance in the local construction sector, with the first unit sold deployed for the rehabilitation of a section of the R21 highway in Gauteng.

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owered by a 630 horsepower Cummins QSX 15 Tier III engine, the Astec RX-600ex has a 2 007 mm wide QX1 asphalt milling drum with 16 mm tool spacing.

Its key features include a dust extraction system, hydraulically folding conveyor, Astec’s ACE Grade and Slope Automation with auto-cut entry, dual water spray bars and bolt-on track pads – all of which are standard on the machine.

It also boasts an Astec QX1 quick change cutter drum, and an integrated dual operator platform with simplified intuitive controls.

The dust extraction system removes dust and debris from the milling operation through a hydraulic fan at the primary conveyor. The dust is then ejected at the end of the secondar y conveyor into the leading dump truck.

“The folding secondar y conveyor available on the Astec RX-600ex as standard simplifies transport and loading. A boost function, also offered as a standard feature on the machine, temporarily speeds up the conveyor should it become overloaded,” explains Philip Saunders, product sales manager for Astec’s Materials and Infrastructure Solutions divisions.

He notes that the cold planer’s Astec QX1 cutter drum improves access for bit and insert

48 IMIESA Nov/Dec 2024

removal. “It has notches in the seating face, which allows for the use of a small wedge to remove inser ts. Notches in the nose are for front bit removal with a fork tool. Shorter base blocks provide additional space at the end rings, while the machine’s shorter shank allows for easier bit removal from the rear of the shank,” Saunders continues.

Automatic precision On the move, the ACE Auto-Cut Entry system automatically controls the drum's depth when

The RX-600ex is par t of Astec’s expansive Rock to Road range, which includes equipment for every phase of road building – from quarrying, crushing and processing the aggregate to concrete production and road construction. Astec supplies more than 100 products to a global customer base in the aggregates, construction, infrastructure and mining sectors, and offers worldwide training, education, service and support.

The group’s operations are divided into two primar y business segments. Materials Solutions includes aggregate and other material handling and processing solutions, including crushers, screens, apron feeders and rock breakers. In turn, Infrastructure Solutions include road building, asphalt and concrete plants, thermal and storage solutions.

Combined, the products in these two business segments are designed and proven to deliver on demanding infrastructure projects across the globe and in Africa.

Astec cold planers like the RX-600ex have two independent spray bars to inject water in the cutter housing. The front spray bar is primarily for dust suppression, while the rear spray bar cools the drum

CEMENT & CONCRETE

Sika® Ucrete® polyurethane cementitious hybrid flooring systems

The ultimate readymix solution for modern construction

A

friSam Starmix ®, a premium readymix concrete solution, answers the need for high quality, reliable and efficient building materials. Available from leading construction materials company, AfriSam, this product is designed to cater for a wide range of construction applications.

This versatile, high per formance readymix concrete combines the finest raw materials with advanced technology to ensure superior quality and consistency. It is specifically formulated to meet the stringent demands of modern construction projects, of fering unmatched durability and strength.

One of the standout features of AfriSam Starmix® is its exceptional workability. The mix is designed to flow easily and settle smoothly, making it ideal for a variety of applications. This improved workability also reduces the time and effort required for placement, ultimately speeding up the construction process.

Another key advantage of AfriSam Starmix® is its versatility. The product is highly adaptable and can be customised to meet specific project requirements.

Starmix ® is also designed with environmental considerations in mind, incorporating eco-friendly materials and production methods that minimise the carbon footprint. This aligns with AfriSam's br oader commitment to sustainability and responsible construction.

S

ika® Ucrete® offers a range of high-performance flooring solutions that stand out for their durability, mechanical strength, and chemical resistance, all while delivering costeffective, low-maintenance advantages. With environmental benefits and resurfacing options available, Sika® Ucrete® is an adaptable solution ideal for heavy-duty applications across industries.

Its unique core technology blends a resilient resin binder with cementbased fillers, providing resistance to high temperature fluctuations and even thermal shocks in specific designs. Unlike other options, Sika® Ucrete® can be installed directly on damp concrete surfaces, saving installation time and reducing project delays.

Typical installations include light or heavy anti-slip finishes for wet areas, or full mortar builds to withstand the toughest environments. For dry areas, Sika® Ucrete® offers a smooth or lightly textured finish for added aesthetic and functional versatility.

The latest addition to the Sika® Ucrete® family is Sika® Ucrete® Gloss, featuring a glossy finish that significantly simplifies floor cleaning. With a smooth surface in low to medium thickness, Sika® Ucrete® Gloss can also serve as a viable alternative to certain Sikafloor® MultiDur products.

Common applications of Sika® Ucrete® flooring include: • F ood and beverage processing facilities • Professional kitchens • Cold storage areas •H eavy-duty wet processing areas This solution is designed for South African projects demanding resilience and longevity in tough conditions, maximising both time and cost efficiency while enhancing environmental sustainability.

Technical support Alongside product excellence, AfriSam also offers exceptional customer support and service.

The company’s team of experts is available to assist with mix design, technical advice and on-site support to ensure that ever y project runs smoothly and efficiently.

One of the standout features of AfriSam Starmix® is its exceptional workability

IMIESA Nov/Dec 2024

49

IMESA

IMESA AFFILIATE MEMBERS PROFESSIONAL AFFILIATES

T O T A L

P I P E L I N E

W W W. U L T R AVA LV E S . C O . Z A

V A L V E T E L :

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+ 2 7

( 0 ) 1 1

4 5 2

6 5 1 4

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 Civtech Engineers (Pty) Ltd admin@civtech.biz Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za Dlamindlovu Consulting Engineers & Project Managers info@dlami-ndlovu.co.za EFG Engineers info@efgeng.co.za Elster Kent Metering Mark.Shamley@Honeywell.com EMS Solutions paul@emssolutions.co.za ENsync Engineers info@ensync.africa ERWAT mail@erwat.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 HSA Technology (Pty) Ltd cs@hubersa.com info@edams.co.za Hydro-comp Enterprises IMQS Software (Pty) Ltd shemine.adams@imqs.co.za Infrachamps Consulting info@infrachamps.co.za INFRATEC info@infratec.co.za Institute of Waste Management of Southern Africa iwmsa@iwmsa.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 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 salesza@ksb.com KSB Pumps and Valves (Pty) Ltd KUREMA Engineering (Pty) Ltd info@kurema.co.za Lektratek Water general@lwt.co.za muzi@loshini.co.za Loshini Projects 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 amarunga@prociv.co.za Prociv Consulting & Projects Management Rainbow Reservoirs quin@rainbowres.com maura@re-solve.co.za Re-Solve Consulting (Pty) Ltd Ribicon Consulting Group (Pty) Ltd info@ribicon.co.za francisg@rhdv.com Royal HaskoningDHV info@sabita.co.za SABITA mberry@safripol.com SAFRIPOL SAGI annette@sagi.co.za info@salga.org.za SALGA 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 admin@siroccon.co.za Siroccon International (Pty) Ltd 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 capetown@smec.com SMEC Sabiha@savegroup.co.za SOUTH AFRICAN VALUE EDUCATION Southern African Society for Trenchless Technology director@sasst.org.za jomar@srk.co.za SRK Consulting Structa Group info@structatech.co.za Superior Filtration (Pty) Ltd info@superior-filtration.com TPA Consulting roger@tpa.co.za Ultra Control Valves peter@ultravalves.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 charmaine.achour@zutari.com

CEMENT & CONCRETE

CHRYSO admixtures are ideal for no-fines concrete, ensuring water flows away while maintaining stability in large water-retaining structures

Admixtures critical in durability of water-retaining structures

C

oncrete per formance and durability underpin the value to society of water retaining structures such as water treatment plants and storage reservoirs – and admixtures make all the difference.

Challenges, including cracking and permeability, can undermine the strength and longevity of these structures, according to Michelle Fick of CHRYSO Southern Africa’s Concrete Aesthetics Business Unit.

“Cracking of concrete, for instance, often calls for urgent and costly maintenance of water related infrastructure,” says Fick. “In addition to leakage, cracks can undermine the strength of a structure due to corrosion of the steel reinforcing.”

She highlights the importance of reducing shrinkage in concrete to avoid cracking, using admixtures such as CHRYSO® Serenis. By reducing the volume changes that occur during the curing process, this admixture helps to prevent cracking. It works by decreasing capillary tension, protecting concrete against moisture transmission, chemical attack and corrosion of reinforcing steel.

There are also waterproofing agents, like pore blockers such as CHRYSO® Fuge B that further enhance concrete’s resilience against chemical attack and reduce permeability, she adds.

“Another waterproofing agent is crystalline admixture such as CHRYSO® CWA 10,” she says. “This reacts with moisture to form crystals deep within the pores and capillary tract of the concrete structure.”

Plasticisers and super plasticisers Admixtures such as plasticisers and super plasticisers are critical in ensuring workability of concrete, which is especially vital to heavily reinforced structures like reservoirs, adds Patrick Flannigan, Technical Manager of the Concrete Business Unit at CHRYSO Southern Africa.

“Water in the concrete mixture must be kept to a minimum to ensure strength and density, which could hamper its workability,” says Flannigan. “However, admixtures allow the concrete to continue to flow into the cavities between the steel reinforcing, which is often extensive to ensure strength in these large water-related structures. Secondary reinforcing can be achieved through the application of macro-fibres and micro-fibres, which can reduce the amount of steel while also further reducing the risk of cracking.”

Another aspect of water retaining structures to consider is their weight, so the ground underneath them must be well drained if they are to remain stable.

“To ensure water does not collect, a pervious base layer usually needs to be installed,” he says. “This is constructed from no-fines concrete, which allows water to flow away without eroding the sub-base material.”

He notes that an admixture like CHRYSO® Easy Drain is ideal for no-fines concrete, as it coats the coarse aggregate to ensure a stronger bond between these particles and the cement-water mix.

IMIESA Nov/Dec 2024

51

PUMPS & VALVES

Pump donation revives Nama Khoi water infrastructure A public-private sector collaboration among residents, companies, Nama Khoi Municipality, and KSB Pumps and Valves has brought desperate relief for affected communities.

Louis Harper of Springbok Municipality and Adriaan Augus of Nama Khoi Municipality inspect the Etanorm pump donated to the municipality

Some of the participants in the Nama Khoi pump station projects include Louis Harper of Springbok Municipality; Adriaan Augus of Nama Khoi Municipality: Martin Fourie of KSB Mining; Mayor of Nama Khoi Municipality, Rodney Kritzinger; and KSB Upington branch manager, Andre Jonker

F

or Nama Khoi Municipality, a key challenge was the need for vital equipment upgrades that were being impacted by budget constraints. In response, KSB Pumps and Valves stepped in to help alleviate the problem by donating a KSB Etanorm pump. This unit is renowned for its efficiency, reliability and ability to handle a wide range of applications, including drinking water supply.

According to KSB Pumps and Valves’ Upington branch manager, Andre Jonker, the donation was part of a collaborative project to restore the Overberg potable water pump station after a pump failure and other issues caused the station to nearly grind to a halt. The remaining pump had been struggling to operate at full capacity, leading to water shortages.

“The donation of the pump not only restored water services, but also ensured a more durable and energy-efficient solution, which

will benefit the community for years to come.

This joint effort highlights the power of collaboration between local businesses and municipal authorities. Several companies and experts joined forces with municipal experts to bring the pump station back online. It is an admirable achievement considering that all parties contributed their time, resources and expertise at no cost,” says Jonker.

Following the successful restoration of water services, Mayor Rodney Kritzinger expressed his heartfelt gratitude: “On behalf of the residents, the Nama Khoi Mayor would like to express his sincere thanks to all the role players who helped save almost R1 million by applying their expertise and businesses to get the Overberg pumping station up and running again.”

The Mayor also extended special thanks to the following individuals and businesses: • Abri van Niekerk and Tiaan van den Heever

of Novatec for supplying and installing a new panel.

• Thinus van Schalkwyk and his team from Copper 360 for repairing the refurbished pump’s axles and supplying a new impeller.

• Kobus Zandberg for his organisational support.

• Nico Moore of Springbok Motor Rewinds for rebuilding critical components.

• Andre Jonker, Mar tin Fourie and the management team from KSB Pumps and Valves for their donation of the KSB Etanorm pump, which was vital to the project.

Jonker added that the restoration of the Nama Khoi pump station exemplifies how public-private partnerships can solve critical infrastructure challenges in South Africa.

“We are proud that KSB Pumps and Valves continues to play a vital role in safeguarding South Africa’s most precious resource – water,” Jonker concludes.

INDEX TO ADVERTISERS

APE Pumps & Mather+Platt Astec BVi Consulting Engineers CESA

52 IMIESA Nov/Dec 2024

OFC, 6 47

EMI Koussi Investments IMESA

10 2, 13, 32, 50

Rainbow Reservoirs Rand Water

34, OBC

Liebherr-Africa

4

Sizabantu Piping Systems

27

Magalies Water

14

Xylem

31 17, 29 IFC 9

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