imiesa august 2014

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

INFRASTRUCTURE DEVELOPMENT • MAINTENANCE • SERVICE DELIVERY

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“Sasol’s needs are being met and so are government’s, so it is a real win-win situation” Maureen Mboshane, president of public and regulatory affairs, SasolMEDIA

in the HOT

SEAT

Open for business in the Western Cape

SPRAYPAVE

Cement and concrete

SARMA Readymix 2014

Civil engineering

State of the industry

Panel discussion

The road to excellence

HEAD OFFICE Unit 19 Alexander Park, 24 Alexander Road, Westmead, Pinetown, KZN, SA 3610 • Postnet Suite 23, Private Bag X4, Kloof 3640

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NATIONAL OFFICES • Pietermaritzburg • Port Elizabeth • Johannesburg • Cape Town • Shelly Beach

In response to this approach, JOAT has invested in wide-ranging

technology and partnerships that can be harnessed for the

benefit of municipalities. Flow metering solutions (permanent

or temporary, monitoring or revenue-generating), data manage-

ment solutions (data loggers, GSM data loggers), control valve

solutions (pressure-reducing valves, pressure controllers, surge

control), leak detection solutions (leak detection equipment

and service) and energy efficiency solutions (variable speed

drives and system optimising) are all available to be presented

into cost-effective, custom-made packages.

JOAT has also expanded into the optimisation of energy

consumption in the water cycle and has a number of in-house

experts that can undertake energy audits and design energy

efficiency solutions for pump stations and treatment works. This

forms part of its overall approach to making the distribution of

water as efficient as possible.

THE JOAT GROUP OF COMPANIES has moulded itself into an

efficient and market-leading solutions-orientated team that pri-

marily addresses the optimisation of water supply to consumers

through the minimisation of water losses, application of appro-

priate technology, revenue improvement and energy efficiency.

The group’s key focus areas of operation are consulting and

operations engineering (essentially the reduction of nonreve-

nue water and stabilising of water supply), product sales and

support, energy efficiency and mentorship. JOAT’s passion and

vision is to ensure that municipalities become as efficient as

possible in delivering water to consumers and has adapted its

approach towards an outcomes-based partnership that has

shared responsibility and accountability. The ultimate objective

of any successful partnership with JOAT is to provide water ser-

vice authorities with an efficient distribution system that they

are fully equipped and trained to continue to operate.

IMIESA August 2014 1

VOLUME 39 NO 8 AUGUST 2014CONTENTS

12 State of the industr y

16 Xonxa cement-lined steel water pipeline





in the HOT

SEAT


SPRAYPAVE

Cement and concrete

SARMA Readymix 2014

Civil engineering


Panel discussion


SprayPave’s newest branch in Cape Town is headed by branch manager Leslie Webb and is now fully operational, offering SprayPave’s full range of quality products, serviced by world-class plant and manufacturing facilities. P6

Sasol’s ground breaking PPP with two local governments is not simply delivering critical infrastructure; the need for sustainability is seeing this R800 million project evolve into an example of best practise and capacity building of the first order. Maureen Mboshane, Sasol’s president of public and regulatory affairs explains how in this edition’s Hotseat. P10

76 Island life – engineering connections

RegularsEditor’s comment 3

President’s comment 4

Africa round-up 8

Index to advertisers 92

Cover story

SprayPave: Quality uncompromised 6

Hot seatSasol – partnering with local government 10

Municipal projectXonxa cement-lined steel water pipeline 12

InsightState of the South African civil industry 14

Panel discussionConcrete Manufacturers Association 21

Aveng Infraset 23

Kaytech 25

Kerb-Master 27

Lafarge 29

Much Asphalt 31

Osborn 33

Sabita 35

Cement and concreteReducing CO2 footprint through new blends 40

Aiding the enhancement of cementitious materials – Part 1 42

Readymix to aid delivery 45

The cost of poor specification 46

in the HOT SEAT

Thriving in a challenging market 48

Missing the critical link 51

Roads: It don’t matter if they’re black or white 52

RoadsNew access tracks for Geelkrans Nature Reserve 54

Reclaimed asphalt paving 55

SANRAL roadsBenefits of Green Terramesh 58

Consulting engineeringEngineering a sustainable future 62

Coastal consulting 64

Water and wastewaterRealisation of renewable energy technology in SA 66

TrainingEngineering robust workforces 73

Construction vehicles and equipmentProject: Island life – engineering connections 76

Temporary power solutions for Southern Africa 81

Equipping for installation of solar PV support frames 83

Powerful, profitable, compact – new telescopic handlers 85

A new compact excavator 87

Hydraulic hammers – hit harder & last longer 89

Multipurpose telescopic handlers 91

EDITOR’S COMMENT


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.

@infrastructure4 Infrastructure News

PUBLISHER Elizabeth ShortenEDITOR Nicholas McDiarmidEDITORIAL ASSISTANT Danielle PettersonHEAD OF DESIGN Frédérick DantonSENIOR DESIGNER Hayley MendelowDESIGNER Kirsty GallowayCHIEF SUB-EDITOR Tristan SnijdersSUB-EDITOR Beatrix KnopjesCONTRIBUTORS Bo Barta, Tandi Breetzka, Raymond Campling, Ruby Estela Cardona, Concrete Manufacturers Association, Melinda Esterhuizen, Santosh Komal, Inga Loots, Carolina Giraldo, Dr Urishanie Govender, Juan Guillermo Morales, Claudia Rodriguez, Edgar Sabela, Frank Stevens, The South African Forum of Civil Engineering ContractorsCLIENT SERVICES & PRODUCTION MANAGER Antois-Leigh BotmaPRODUCTION COORDINATOR Jacqueline ModiseFINANCIAL MANAGER Andrew LobbanMARKETING MANAGER Hestelle RobinsonDIGITAL MANAGER Esther LouwADMINISTRATION Tonya HebentonDISTRIBUTION MANAGER Nomsa MasinaDISTRIBUTION COORDINATOR Asha PursothamSUBSCRIPTIONS [email protected] United Litho Johannesburg +27 (0)11 402 0571___________________________________________________

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

PUBLISHER: MEDIA No. 4, 5th Avenue, Rivonia 2056PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: [email protected] www.3smedia.co.za

ANNUAL SUBSCRIPTION: R550.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR.© Copyright 2014. All rights reserved.___________________________________________________

IMESA CONTACTSIMESA Administration Officer: Narisha SoganP O Box 2190, Westville, 3630Tel: +27 (0)31 266 3263Fax: +27 (0)31 266 5094Email: [email protected]: www.imesa.org.za

BORDER BRANCHSecretary: Melanie MatroosTel: +27 (0)43 705 2401Fax: +27 (0)43 743 5266E-mail: [email protected]

EAST CAPE BRANCHClarine ColtmanTel: +27 (0)41 505 8019Fax: +27 (0)41 585 3437E-mail: [email protected]

KWAZULU-NATAL BRANCHSecretary: Rita MatthewsTel: +27 (0)31 311 6382Fax: +27 (0)31 701 2935

NORTHERN PROVINCE BRANCHSecretary: Rona FourieTel: +27 (0)82 742 6364Fax: +27 (0)86 634 5644E-mail: [email protected]

SOUTHERN CAPE KAROO BRANCHSecretary: Henrietta OliverTel: +27 (0)79 390 7536Fax: 086 536 3725E-mail: [email protected]

WESTERN CAPE BRANCHSecretary: Erica van JaarsveldTel: +27 (0)21 938 8455Fax: +27 (0)21 938 8457E-mail: [email protected]

FREE STATE AND NORTHERN CAPE BRANCHSecretary: Wilma Van Der WaltTel: +27(0)83 457 4362Fax: 086 628 0468E-mail: [email protected]

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

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

LINDIWE SISULU is back as Minister of

Human Settlements and took the time

in her budget speech to reflect on what

she calls ‘the golden age’ of housing

delivery in South Africa, over which she pre-

sided as Minister of Housing until 2009. A lot

was achieved during that term: over one million

houses were delivered.

Sisulu’s speech moved quickly from pleas-

antries to cold facts: the loss of institutional

memory; a 30 per cent drop in delivery; the fact

that lack of housing accounted for 20 per cent

of all service delivery protests. Her remark that

these declines had been attributed by officials

in her department to so-called “blockages in

the pipeline; whatever that means” was well

publicised and criticised. It was unfortunately

lost on many that her phrasing indicated her

own intolerance of such a vapid explanation. It

is my opinion that Sisulu’s speech was on point,

and reason for hope. Here is a woman with a

track record, common sense and not given to

scoring political points. Her realistic approach

suggests that ‘blockages’ will no longer be an

excuse. From a policy perspective, Sisulu has

committed to creating legislation that covers and

coordinates all necessary elements, from land

reform to finance.

Given the range of infrastructure inherent in

delivering on human settlements, it was hearten-

ing to hear her say that “perhaps nothing short

of some kind of Marshall Plan will see us survive

this challenge.” Among her commitments are:

the revitalisation of mining towns; tackling back-

logs and red-tape currently clogging the issuing

of title deeds; the urgent completion of the N2

Gateway project; the implementation of megapro-

jects to capitalise on economies of scale and

handover of assets and responsibilities to local

governments; the revitalisation of Cosmo City;

re-establishing the role of banks, and much

else besides. Already, the flailing Social Housing

Regulatory Agency has been placed under admin-

istration and is likely to be absorbed into the

Department of Human Settlements.

The hope in all this lies in the fact the Sisulu

felt free to speak frankly and critically and pre-

sented a feasible, delivery-focused plan that has

ramifications way beyond housing itself.

The newly combined Department of Water

and Sanitation, under Minister Nomvula

Mokonyane, unveiled its R12.8 billion annual

budget, with a clear focus on bulk water and

sanitation. President Jacob Zuma signed in the

Infrastructure Development Act, establishing in

law the Presidential Infrastructure Coordinating

Commission and setting clear time frames for

the delivery of the NDP’s Strategic Infrastructure

Projects. Pravin Gordhan, now Minister of

Cooperative Governance and Traditional Affairs,

has announced an oversight strategy to bring

municipalities to accountability and – most

importantly – will establish an advisory commit-

tee to examine what is going on in procurement

and how to fix it.

Does this mean the projects are on their way?

Does it mean we might see an increase of pro-

fessional engineers in local government? Does

it mean that procurement will favour quality and

integrity? There is much pause for thought, but

after the pause, let’s see the action.

This edition of IMIESA introduces some chang-

es. We have launched a section dedicated to

construction equipment and vehicles in response

to demand from our readers, as without the right

equipment, projects are compromised. We have

also included a section on cement and concrete;

an area packed with innovation and potential. We

hope you enjoy this edition – it was a pleasure

to compile!

IMESA

The official magazine of the Institute

of Municipal Engineering of Southern Africa


A true revival TOSAS

RuralroadsMaintenance

now

I S S N 0 2 5 7 1 9 7 8 Vo l u m e 3 9 N o . 7 • J u l y 2 0 1 4 • R 5 0 . 0 0 ( i n c l VAT )

Trenchless

technology

Getting the most out

of innovations

Western

Aqueduct

Durban’s largest

pipeline

SARMA supplement

“We are reaching our ultimate milestone as the countdown to completion of

our flagship plant, Aganang, builds” Pieter Fourie, chief executive, Sephaku Cement

MEDIA

The new





in the HOT

SEAT


SPRAYPAVE

Cement and concrete

SARMA Readymix 2014

Civil engineering


Panel discussion


It’s been a month of budget speeches and political commitments,

Acts and policy announcements, and much of these ultimately

revolve around infrastructure – especially at local government level.

Promises and delivery

Nicholas McDiarmid

EIGHTEEN countries

were represented

with Israel, France,

Italy and Iceland

attending for the first time.

The usual format was

followed: a board meeting,

site visits and many useful

networking opportunities.

The board meeting at Perth’s municipal officesThere were a number of topics

presented and discussed

during the board meeting.

Though I cannot possibly cover

all the issues raised, there

are some I found particularly

interesting and would like

to highlight.

Under-use of debtChris Champion, CEO of IPWEA

(Institute of Public Works

Engineering Australasia), out-

lined a paper which he wrote

and in which he cautions that:

“Local government service

provision is asset intensive

and infrastructure assets have,

on average, long, useful lives.

In such circumstances, it is

impossible over time to finance

Frank Stevens, president of IMESA

the acquisition of new assets,

while at the same time financ-

ing warranted asset renewal,

without significant reliance

on debt.

Under-use of debt will result

in intergenerational inequity

in services and charging deci-

sions – and an inability to

accommodate needs for new

capital works and asset renew-

al. Local governments are gen-

erally debt averse. Many coun-

cils are likely to better serve

their communities by making

greater use of debt, and many

have considerable capacity to

deal with urgent asset-renewal

needs.” (Full article: www.

ipwea.org/DebtPaper).

Cahoot – CPDlive’s cutting-edge online education platformThis is a web-based CPD learn-

ing site developed at Stanford

and Harvard universities with a

membership of 5 million people

in 200 countries.

The courses offered usually

involve groups of 30 people per

expert facilitator and there is a

strong community ‘classmate’

atmosphere. A 95.2% comple-

tion rate is achieved.

An example of an offered

course would be the NAMS ISO

55/000 Asset Management

Standards course, which is

made up of eight modules

held over 10 weeks in 90

minute sessions.

Presentation to the Institute of Civil Engineers (ICE), Scotland.ICE (Scotland) held a one-day

municipal engineering seminar

titled ‘Innovation in Action’. I

was requested to present a

paper on IMESA, and fellow

IFME members from the USA,

Canada and New Zealand

also delivered presentations.

Sharing some insight into the

challenges and innovative

solutions related to munici-

pal service delivery in South

Africa, I found the enthusiasm

shown and questions asked by

the audience encouraging.

A fascinating paper on the

‘Nordic Link’ was delivered by

Dr Richard Blanchfield. This

project involves the laying of

two 500 kV cables a distance

of 650 km, below the seabed,

from Peterhead in Scotland to

the coast of Norway. This is to

form part of a European ‘super

grid’, which involves Scotland,

Ireland, Spain and several

Nordic countries at a cost of

£1.2 billion. Of particular inter-

est are the planned wind farms

that will feed into the grid and

the serious environmental

challenges of seabed protec-

tion while laying the cable in

300 m-deep fjords.

Site visitsIt has become an IFME tradi-

tion for the host country to

showcase interesting projects

of a municipal nature as part

of the programme. The visits to

projects in Perth and Edinburgh

proved to be very popular

and inspiring.

IFME and its value to IMESAI regard it as an honour to have represented IMESA at the recent International Federation of Municipal Engineers (IFME) board meeting held in Perth, Scotland.

4 IMIESA August 2014

“There were new acquaintances and networking opportunities to be made, illustrating that municipal engineers the world over are cut from much the same cloth”

FIGURE 1 19th century: Forth Bridge


IFME and its value to IMESA

criss-crosses the city of

Edinburgh. The system will be

integrated with train and bus

services offering hop-on and

-off tickets, and pensioners

and disabled people will travel

for free.

ConclusionAmong the meetings and tours,

there were new acquaintances

and networking opportunities to

be made, municipal engineers

the world over are cut from

much the same cloth. There

are benefits to IFME member-

ship, the foregoing has illus-

trated just a few of them.

The Perth flood-prevention schemeThe river Tay, which passes

through Perth, has the largest

peak flow of any UK river and

has a long history of flooding.

A site visit was carried out to

the six-phase project, which

was completed in 2002, and

involves walls, embankments,

flood gates, flood storage and

pumping stations at a cost of

£26 million.

Prior to the completion of this

project, a typical flood such as

the one in 1993, caused by

a combination of rainfall and

snowmelt, would flood 1 500

properties at a cost of £40 mil-

lion. During the project, spe-

cial attention was paid to the

landscape character, ecology,

archaeology and cultural herit-

age of the affected areas. There

has been no flooding since the

completion of this project.

Three centuries of span-ning the ForthIt must be every bridge engi-

neer’s dream to visit the three

iconic bridges spanning the

Fir th and Forth (Fir th being

the estuary and Forth being

the river). We spent a very

memorable half-day on-site,

basking in the splendour of

these structures.

• Forth Railway Bridge

The 2.5 km Forth Bridge

was built in 1883 using

65 000 tonnes of steel. At

its peak, 4 600 men were

employed on this project

and 200 000 litres of paint

were required to cover its

145 acre surface!

• Forth Road Bridge

Completed in 1964, this

2.5 km suspension bridge

caters for 24 million vehicles

per annum. An interesting sta-

tistic is that the suspension

cables, which weigh 6 350

tonnes, would stretch 1.25

times around the world.

• Queensferry Crossing

With a completion date of

2016, this cable-stayed bridge

is needed due to the dete-

rioration in the existing Forth

Road Bridge and its heavy

traffic load. Construction of

the three 210 m-high towers is

already underway.

Edinburgh TramsWe were taken on a trial

run of the new tram system,

which includes the airport,

Murrayfield Stadium and

FIGURE 2 20th century: Forth Road Bridge

FIGURE 3 21st century: Queensferry Crossing


COVER STORY

USING WORLD-CLASS plant and

equipment, SprayPave has the

ability to successfully take on

any project regardless of form or

magnitude. From the smallest rural road to

the biggest national route, no job is too big

or too small.

Established in 1981, and a proud member

of the Basil Read group of construction

companies since 2006, SprayPave is an

ISO9001 accredited company and Level 5

BBBEE contributor. Its head office is based

in Alrode South, Gauteng, and in 2010 it

expanded its footprint by opening a branch

in Bothas Hill, KwaZulu-Natal. The company

recently extended its reach even further, with

the opening of its Western Cape branch, in

Parow Industria, Cape Town.

The Western CapeSprayPave’s newest branch in Cape Town is

headed by branch manager Leslie Webb and

is now fully operational, offering SprayPave’s

full range of quality products, serviced by

world-class plant and manufacturing facili-

ties. “We are obviously proud that we have

already supplied such high-profile clients

as Martin and East/Zebra Surfacing and

H&I,” notes Webb. “We invite all current

and potential clients to visit our branches

and witness our commitment to quality and

service excellence first-hand.”

Bitumen reactor SprayPave Cape Town will also be the home

of a bitumen reactor, the first of its kind in

Africa and testament to SprayPave’s relent-

less drive to, through innovation, not only

maintain world-class standards, but pioneer

them. “Our bitumen reactor will be fully com-

missioned by the end of 2014,” explains Phil

Chirnside, SprayPave’s commercial manag-

er. “In essence, it will enable us to produce

various grades of bitumen not only for the

local market, but ultimately Southern Africa

as a whole. Typically, harder/more scarce

grades of bitumen have to be imported;

however, with our bitumen reactor, we can

not only produce these grades from more

readily available feedstock, but also engi-

neer inferior, poorer-performing products to

become superior, meeting all conceivable

specification requirements. Think of how this

will mitigate the risk of importing products

(should the need arise) as, very often, such

products end up not meeting local specifica-

tion requirements, therefore subjecting the

importers to catastrophic financial losses.

Now, with the reactor, we can simply re-

engineer these ‘off-specification’ products

and save many suppliers/contractors a lot

of time and money.” These are only a few of

Quality uncompromised

SPRAYPAVE

SprayPave is one of Southern Africa’s leading manufacturers, suppliers and applicators of bituminous road binders, emulsions, primes, pre-coats and modified binders, serving the road construction, maintenance and waterproofing industries.

LEFT One of SprayPave’s newest sprayers at work for H&I in the Western Cape

ABOVE SprayPave’s mobile plants are fully equipped with fitted laboratories


COVER STORY

the many benefits of having technology such

as this available to the local market.

The business of manufacturingHarnessing more than 30 years’ experi-

ence, SprayPave’s commitment to quality is

backed by its highly trained staff and state-

of-the-art facilities.

With impressive manufacturing and stor-

age capabilities for its vast product offer-

ings, SprayPave has successfully harmo-

nised quantity with quality and its product

range is now in the final stages of receiving

SABS certification.

Each branch also comes equipped with

its own fully fitted laboratory, all soon to be

SANAS accredited. Each and every batch of

product undergoes a strict array of testing

throughout the manufacturing process, and

is delivered to the client with corresponding

certificates of analysis. “Quality is at the

heart of everything we do,” says Steven

Single, SprayPave’s managing director.

“Whether the product is for the construction

of new roads, rehabilitation of existing roads

or simply minor maintenance, we consider

quality our chief contribution to the road con-

struction industry in Southern Africa.”

SprayPave offers all major forms of testing,

including binder content, softening points,

viscosity, elastic recovery, and so forth.

SprayPave Cape Town even has the ability to

go as far as testing the quality of bitumen on

a molecular level by way of SARA analysis.

Beyond bordersSprayPave’s footprint also extends beyond

South Africa’s borders. Its fleet of modern

road haulers not only ensures a smooth

supply, of both bulk and drummed products

to its customers throughout sub-Saharan

Africa, but through the many partnerships

forged throughout the years, the company

can also comfortably supply product via sea

freight, in bitutainers as well as even bagged

or pelletised bitumen.

Another key element of SprayPave’s ver-

satility and geographic reach is the compa-

ny’s state-of-the-art emulsion and modified

binder mobile plants, the establishment of

which includes feedstock, digestion and

end-product holding tanks. These self-pow-

ered plants are fully equipped and include

fully fitted laboratories, thus ensuring strin-

gent quality control standards, regardless

of location. Mounted on double-axle trailers

and able to reach the remotest of locations

and remain there for lengthy periods at a

time, each plant is capable of producing up

to 6 000 ℓ/h of product.

Recent projects deploying SprayPave’s

mobile plants include a 165 km stretch of

road in Gobabis, Namibia, as well the pro-

duction and supply of SS60 in Livingstone,

Zambia. “Our mobile plants can operate

independently for several months at a time

and provide our customers with the versa-

tility of on-site production at rates more

economically feasible than those employ-

ing long-distance haulage,” says Chirnside.

“This means you can control the qual-

ity of the end product, all of which can be

tested on-site. It further provides a high

level of on-site efficiency and quantity con-

trol, which can accommodate variations in

production schedules.”

Environmental and corporate responsibilityEnvironmental awareness and responsibil-

ity are intrinsic to SprayPave’s culture. “As

a company, we align ourselves with global

environmental objectives by conducting con-

tinuous research into, and development of,

alternatives to products traditionally used by

the industry,” explains Chirnside.

SprayPave promotes the use of environ-

mentally friendly products and conforms

to the current European legislation and

guidelines as laid down by the South African

Bitumen Association (Sabita), of which it is a

proud member.

For further information on SprayPave’s product

and service offerings, please log on to

www.spraypave.co.za

Interested parties are invited to contact the fol-

lowing personnel for enquires or site visits:

Cape Town

Leslie Webb – Branch manager

+27 (0)82 857 1604

[email protected]

Johannesburg

Philippe Chirnside – Commercial manager

+27 (0)74 141 4513

[email protected]

KwaZulu-Natal

Danashia Padayachee – Branch manager

+27 (0)76 755 2024

[email protected]

“We consider quality our chief contribution to the road construction industry in Southern Africa”

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


INFRASTRUCTURE NEWS FROM AROUND THE CONTINENT

AFRICA ROUND-UP

BURKINA FASO Sub-Saharan Africa’s largest PV plantBurkina Faso will soon play

host to the largest photo-

voltaic (PV) power station in

sub-Saharan Africa.

The government of Burkina

Faso has signed an invest-

ment support agreement with

Windiga Energy, a Canadian-

based independent renewable

energy power producer, appoint-

ing Windiga the first independ-

ent solar energy producer in

the country.

Siemens Energy Smart

Generation Solutions has been

selected to build and operate

the pioneering 20 megawatt

PV plant, which will be located

in Zina, Mouhoun province

and is scheduled for comple-

tion at the end of 2015. The

PV power plant is a project

that would include, among its

potential financiers, the African

Development Bank, the Frontier

Markets Fund Managers

and the Emerging Africa

Infrastructure Fund.

The agreement will finalise a

25-year power purchase agree-

ment with Société Nationale

d'électricité du Burkina

Faso, the country’s national

power supplier, for the pur-

chase of the facility’s entire

electricity production.

Edward Fast, Canada’s

Minister of International Trade

who was in Burkina Faso as

part of a trade mission to

Africa, congratulated Windiga on

the signing of the historic agree-

ment, stating, “This $50 million

project will help to meet the

country’s electricity needs.”

GHANA Big investments in potable waterThe government of Ghana aims

to increase urban water cover-

age from the current level to

85% by 2015 while taking rural

water coverage to 76% in order

to guarantee the availability of

potable water for all citizens.

According to the Deputy

Minister for Information and

Media Relations, Felix Kwakye

Ofosu, government has made

massive investments towards

achieving this.

The current demand of water

supply in the Accra Metropolitan

Area stands at 150 million gal-

lons per day, while total water

production from the Kpong and

Weija dams stand at only 93 a

shortfall of some 57 million gal-

lons per day.

In order to address the water

supply issue in the country,

the Kenyan government has

introduced the Kpong water

supply expansion project which

will supply 40 million gallons of

water a day to areas including

Adenta, Madina, Kwabenya,

Ashongman, North, East and

West Legon, Ashaley Botwe,

Haatso, Boi, Asofaa, Dome,

among others.

In addition, the Kpong Intake

Rehabilitation Project will

improve efficiency by replacing

all existing pumps.

As part of the project, a

3.3 million gallon per day

treatment plant is being built

to increase supply to Accra-

Tema Metropolitan Area. The

Accra-Tema Metropolitan area

water supply project, which

cost €56.5 million, involves the

installation of equipment for the

production of 9 million gallons

of water per day.

The construction of four res-

ervoirs at Adukrom, Dodowa,

Atimpoku and Akorley as

well as 92 km transmission

pipelines, when completed,

will improve water supply to

almost 70 communities in

both the Greater Accra and the

Eastern Regions.

Ofosu pointed out that about

a quarter of a million people in

these communities would have

access to potable water when

the project was completed and

would add a total of 65.3 mil-

lion gallons of water per day to

the existing production capacity

and bring total water supply to

the Greater Accra Metropolitan

Area to 158.3 million gallons

per day.

KENYA Opposition to construction levyThe Nairobi City County gov-

ernment has objected to

the Kenyan national govern-

ment’s 0.5 % construction

levy, arguing that it will scare

away investors.

In a letter addressed to

Charity Ngilu, the cabinet sec-

retary for lands, housing and

urban development, Nairobi

governor Dr Evans Kidero

said the regulations were

Ghana is constructing four new reservoirs

Burkina Faso will host the largest PV power station in sub-Saharan Africa


AFRICA ROUND-UP

prepared without consulting the

county governments.

“This levy affects the hous-

ing sector that falls within

the jurisdiction of the county

governments and it should

have been prepared with our

participation and concurrence,”

said Kidero.

The National Construction

Authority Act 2014 stipulates

that a construction levy of

0.5% of the value of any

contract for construction

works exceeding KSh5 million

(R600 000) will be payable

to the National Construction

Authority (NCA) by the owner of

the works.

The levy will have to be paid

before the commencement of

the contract works. However,

the NCA reserves the right to

consider the final value of the

completed works and assess

the amount of the levy afresh.

The NCA may suspend, can-

cel or revoke the registration of

a contractor who commences

construction works for which

the owner has not paid the

construction levy.

“This levy is bound to impact

heavily on housing as well

as push the cost of providing

urban technical services, which

would in turn impact negatively

on the ability of the county gov-

ernment to expand infrastruc-

ture services for socio-econom-

ic development,” said Kidero.

He noted that Nairobi City

County, as well as other coun-

ties, is currently experiencing

serious housing deficits and

infrastructure inadequacy. As

such, this levy would go against

the state’s obligation to provide

citizens with adequate and

affordable housing.

“There are already numerous

levies and charges imposed on

the housing and construction

sectors and this latest move

will only serve to discourage

investment in the sector.” The

Nairobi City County government

has been trying to engage

various potential developers

to interest them in investing in

large-scale housing and other

infrastructure projects in the

county, including the Eastlands

Urban Renewal project. Kidero

believes that the construction

levy will scare investors away.

The governor urged the

national government to revoke

the imposition of the construc-

tion levy, as he believes it

will adversely affect investor

enthusiasm and deny Nairobi

residents the right to adequate

and affordable housing

and infrastructure.

NIGERIAARM Infrastructure FundNigerian finance company

ARM’s infrastructure fund is

expected to close mid-August,

with the majority of the money

coming from pension funds.

The fund will be the coun-

try's first infrastructure fund

to invest in transport, energy

and utility sectors across West

Africa. The $250 million infra-

structure fund will invest equity

in road, airport, electricity, gas,

water, sewage and drainage

projects.

ARM managing director Opuiyo

Oforiokuma told Reuters that

there are various investors in

the fund, including the African

Development Bank. To meet

short-, medium-, and long-term

investor objectives, the fund

is structured in such a way

that will allow capital to be

raised from both Nigerian and

international investors. A paral-

lel legal structure will serve

this purpose.

The fund’s investment strat-

egy is based on carefully iden-

tifying and screening bankable

brownfield and greenfield infra-

structure assets, and on work-

ing with the relevant investee

management teams and other

investors to optimise returns

from those assets. The fund is

therefore focused on making

direct investments in entities

that primarily focus on the man-

agement, ownership, and opera-

tion of infrastructure assets.

TANZANIATSh140 billion to improve water supplyIn an effort to improve water

supply for industrial and domes-

tic consumption, the Tanzanian

government will spend

TSh140 billion (±R900 million)

on water projects in the Tanga

and Kilimanjaro regions.

According to Professor

Jumanne Maghembe, at least

38 villages in the Mwanga,

Same and Korogwe districts in

Kilimanjaro and Tanga will be

included in the project. The pro-

jects will involve tapping water

from Nyumbaya Mungu to those

villages, with the aim of solving

water shortage problems in.

A total of 23 contractors have

applied for a job and screening

is currently underway to pin-

point the three who will under-

take the projects. The projects

will commence in September

this year after qualified contrac-

tors are appointed.

TUNISIAThe South Tunisian Gas ProjectTunisia has received a

$75 million corporate loan for

the Entreprise Tunisienned’

Activités Pétrolières (ETAP),

the Tunisian state-owned

oil and gas exploration and

production company, to finance

part of the South Tunisian Gas

Project (STGP).

Also known as the Nawara

project, the STGP involves the

construction of gas transporta-

tion and treatment facilities to

bring stranded and associated

gas from the south of Tunisia.

It will comprise three parts: a

central processing facility that

will collect and compress gas

received from the Nawara; a

370 km pipeline for rich gas,

condensates and commercial

products with a design capacity

of 10 million m3 per day; and

a gas treatment plant that will

produce marketable products.

The project is being construct-

ed in a 50/50 joint venture by

ETAP and OMV Tunisia, a sub-

sidiary of OMV, the largest list-

ed industrial company in Austria

and the leading energy group in

Central and Southeast Europe.

More than 90% of Tunisia’s

power capacity is provided

through gas-fired power gen-

eration. Almost half of the gas

needed to generate electricity

is imported via gas pipeline.

In addition, the current exist-

ing pipeline linking the Sahara

region, where most of the hydro-

carbon resources are located, to

the industrial zone of Gabès has

reached its capacity limits. Thus,

the country’s energy deficit will

increase if no additional invest-

ment is made in infrastructure.

The Nawara project will help

reduce importation of gas and

also increase hydrocarbon

exports. More importantly, the

project represents the backbone

of a gas infrastructure network

and will lay the foundation to

develop hydrocarbon resources

for future energy sufficiency.

The project will add value to

local natural resources, reduce

current imports of gas in the

country, strengthen the energy

infrastructure of Tunisia, and

benefit local and national SMEs

through outsourced activities.

Nairobi governor Dr Evans Kidero has objected to the Kenyan government’s construction levy


THE PPP MODEL has

long been regarded

as one solution to

local government infra-

structure and service delivery

challenges, with enormous

potential especially for munici-

palities struggling with capacity.

Sasolburg and Secunda are

home to Sasol’s major facilities

and Project Ikusasa seeks to

satisfy both Sasol’s needs and

those of their respective munici-

palities. From project scoping

to sustainability, this work in

progress could well serve as

a template for PPPs in South

Africa as a whole.

This is an impressive project. How did it come about? MM There was

clear symmetry between the

Sasol partnering with local government

municipalities’ needs and

Sasol’s. Our needs are to at-

tract and retain skilled talent

– particularly young gradu-

ates – who have definite and

reasonable expectations of the

environments in which they

want to live. They want to know

that infrastructure is sound and

reliable, that there is sufficient

access to excellent educational

and health facilities for their

families, and that their environ-

ments are safe and attractive

to live in. The Secunda and

Sasolburg facilities and their

equipment are quite old and we

had to determine how to pro-

ceed in future. Do we maintain

our presence in these areas or

not? We took a deliberate deci-

sion to extend the life of our

operations in these regions.

What does Ikusasa mean and what were the first steps in establishing a working framework? Ikusasa is an isiZulu word for

‘hope’, with reference to the

future or tomorrow. The need

for the project emerged from

Sasol’s 2050 strategy and it

was launched in July 2011. By

October 2011, we were able to

define the scope of the project

by ascertaining the needs of

our employees and the broader

communities. This research pe-

riod also allowed us to assess

the impact and sustainability of

our established interventions.

Specifically, this is a PPP with

government, aimed at the two

municipalities that are home to

our operations in Secunda and

Sasolburg. Our engagement is

not limited to local government,

but also includes provincial and

national governments. We have

built excellent relationships

with these public entities, which

have been vital to the success

of our interventions.

A budget of R800 million was

set, with R100 million allocated

for each region for four years.

In identifying interven-tions, have you worked closely with the munici-palities? We have indeed. As

Sasol identified its particular

needs, specific reference was

made to the municipalities’

integrated development plans

to identify the placement of

particular projects, while at the

same time determining at what

stage the projects were. We

would then meet with the mu-

nicipality to indicate our needs,

find out their needs, and then

agree on the projects to priori-

tise. Sometimes it was a case

of meeting each other halfway,

but in all instances, there would

be mutual agreement. The prin-

ciple we follow for each project

is based on Sasol being able

to begin and complete projects

within identifiable objectives.

We take the responsibility to

handover completed projects.

How smoothly has this process gone? We are

now in the second year and I

am happy to say it has gone

HOT SEAT

Project Ikusasa is a groundbreaking public-private partnership (PPP) between Sasol, a giant in South Africa’s energy and chemicals sector, and the municipalities of Metsimahalo and Govan Mbeki. In the hot seat for this edition is Sasol’s

vice-president of public and regulatory affairs, Maureen Mboshane, who provides insight into the inner workings of this R800 million project.

LEFT Workers during the clean up campaign

BELOW Sasol emergency vehicles sponsored by Ikusasa


Sasol partnering with local governmentextremely well. Because we

are accountable for the project

planning and management,

we have been able to get to

the implementation stage

very rapidly. Throughout the

various project stages, we have

ensured that the municipalities

are involved. The municipal

engineers and technicians have

been very involved and this has

been of enormous value. There

is excellent cooperation from

the municipalities.

Within the context of this being a PPP, whose procurement processes are followed? The whole

project is managed within

Sasol’s governance framework.

We follow our own procurement

processes throughout. Where

necessary, we would appoint

service providers and contrac-

tors, while relying on Sasol’s

own engineers wherever pos-

sible. But ultimately it is about

completing projects according to

best practice. Sasol has a rich

supply of project management

skills and an ability to deliver on

time and on budget, so it makes

sense to use the expertise of

our employees.

Once each project is complet-

ed, it is then handed over in its

entirety back to the municipali-

ties for the benefit of the com-

munities and government. In

this way, Sasol’s needs are met

and so are government’s, so it

is a real win-win situation.

What processes have you followed when ap-pointing engineers? The

partnership and collaboration

between Sasol and government

almost goes beyond Ikusasa.

If government, in our regular

engagements, makes us aware

of existing challenges – be it in-

frastructure or simply a capacity

challenge within the municipality

– we can intervene. We recently

initiated a municipal capac-

ity building initiative that the

Mpumalanga premier requested

to be rolled out to all municipali-

ties in the province. We are cur-

rently reviewing this request.

What is Sasol’s approach to the sustainability of these projects? This is

probably the most important

element. We are in a process of

examination right now, looking

at what we have achieved and

figuring out how best to ensure

the sustainability of these

projects. While we don’t have

all the answers yet, some of

HOT SEAT

the capacity building measures

I just mentioned play into the

question of sustainability. We

need to upskill and share our

expertise in terms of asset

management and maintenance

and possibly come up with

maintenance programmes for

the municipalities.

How much impact has Ikusasa had on local job creation? In terms of both

implementing the projects and

the subsequent maintenance

work done, there has been a

lot of employment for locals.

There are also opportunities

for growth for officials as we

all learn together during the

implementation phase, so

that sense of ownership has

to be transferred as well, to

ensure the sustainability of

these projects.

The long-term objective is

improvement over time, and

this requires the municipalities

to take ownership. So far, we

are seeing signs that this will

be the case. Our relationships

are strong and we are working

extremely well together. The

success of our collaboration will

guarantee that cross-pollination

of best practice will be the

broader achievement.

www.sasol.com

Ikusasa is an isiZulu word for ‘hope’, with reference to the future or tomorrow

MUNICIPAL PROJECT


+27(0)860 482 [email protected]

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THE MAIN PURPOSE of this project

is to augment the current water

supply shortfall within the munici-

pality and open up the urgent-

ly needed supply of bulk potable water

to indigent areas within and surrounding

Queenstown. Without this project and its

components, service delivery as a whole

within the Lukhanji Local Municipality cannot

be extended to eradicate current service

delivery backlogs. The water supply short-

fall also has a major impact on the socio-

economic development within this region

Xonxa cement-lined steel water pipeline

The Xonxa Dam Transfer Scheme and Bulk Water Supply project comprises the augmentation of the Queenstown bulk water supply through the inter-regional transfer of raw water from the Xonxa Dam to the Queenstown Water Treatment Works. Nicholas McDiarmid profiles this Chris Hani District Municipality project.


MUNICIPAL PROJECT

and currently impacts greatly on the future

socio-economic growth and sustainability

within the municipality.

Esor Pipelines, a division of civil engi-

neering and construction group Esor, is

on schedule to complete the installation

of a 22.3 km DN600 cement-mortar-lined

steel water pipeline from the Xonxa Dam to

Queenstown Water Treatment Works.

Urgent supplyThis project, awarded in November 2012

by the Chris Hani District Council, is part

of the greater Xonxa Dam Transfer Scheme

and Bulk Water Supply project initiated by

the Chris Hani District Municipality in the

Eastern Cape to augment the Queenstown

bulk water supply.

Scope of projectEsor’s scope of work includes site clearance

for the new pipeline, connections to the

pump station delivery line intake and reser-

voir intake, as well as road and river cross-

ings. The route for the pipeline includes

two above-ground/surface sections. One

is a 900 m-long concrete-encased section

traversing along the base of the hill oppo-

site the Xonxa Dam, with the other portion

being only 100 m in length but going over

a mountainous rise. This 100 m piece of

the pipeline is to be supported on concrete

plinths. The difference in elevation from the

pump station to the top of the mountain sec-

tion is 400 m static.

Ian Foord, Esor Pipelines’ site agent,

says, “This is our first project for the Chris

Hani District Council and we’re delighted to

be partnering with such a progressive and

forward-thinking organisation on an impor-

tant project like this.”

Environment and safety challengesSpecial environmental requirements on the

project include demarcating and ensur-

ing the protection of two very old trees

and the preservation of a collection of

Bushman paintings on the rock faces near

the mountainous section and an ancient

Bushman stone tool factory at the top of

the mountain. Stringent safety procedures

have ensured that the project recorded

more than 253 530 LTI-free hours by

mid-March.

Supplementing the Esor project team of

30 skilled personnel, including operators,

coded welders, foremen and supervisors,

are 165 local labourers that have been

recruited and trained in various facets of

pipeline construction, where applicable.

Esor Pipelines operates mainly in the gas

and petrochemical, water, stormwater and

sewerage sectors. With specialist expertise

in laying and welding of steel pipelines as

well as in pipeline refurbishment, includ-

ing mechanical, linings and coatings, the

LEFT Esor Pipelines is on schedule to complete the installation of a 22.3 km pipeline from the Xonxa Dam to Queenstown Water Treatment Works

RIGHT The 22.3 km Xonxa pipeline will run from Xonxa Dam to the Queenstown Water Treatment Works

RIGHT The Xonxa pipeline project is part of the greater Xonxa Dam Transfer Scheme and Bulk Water Supply project initiated by the Chris Hani District Municipality in the Eastern Cape

division services both public and private

sector clients from top mining and industrial

groups to regional and municipal govern-

ment. A fully equipped workshop and yard to

support fleet maintenance operates on-site

at the business unit’s head office.

Esor expects to conclude the project this

coming September.


INSIGHT

CONDITIONS IN the South African

civil construction industry came

under greater pressure in the first

quarter of 2014, following a con-

traction of 10%, in real terms, during 2013.

Nominal turnover contracted by 12% on a

quarter-on-quarter (QOQ) basis, but because

of a particularly weak 1st quarter in 2013,

turnover increased by 18% year-on-year,

in real terms. However this is offset by a

notable deterioration in other indicators that

shows a growing dissatisfaction amongst

civil contracting firms regarding the outlook

for the civil industry.

A slow startThe unexpected slow start to the economy,

weakened by the relentless labour strike

action in the platinum industry and a con-

traction in the manufacturing sector, raises

fears that government will not be able to

deliver on its infrastructure expenditure pro-

grammes as was projected in the 2014/15

budget. Considering that the increase in

allocations over the next three years were

already below construction cost inflationary

expectations, here could be serious implica-

tions for the civil construction industry. The

budget was underpinned by economic growth

of 2.7% and inflation at around 6.2%, but

latest forecasts by the World Bank as well

as the IMF have been revised downward

to 2.0%. With growing speculation that the

economy may be in a technical recession

following the 0.6% contraction in the 1st

quarter of 2014, even a 2% growth outlook

may be regarded as too optimistic.

Strengthening financial stabilityContrary to historical trends, the civil indus-

try did not show any real benefit in the run

up to the election, which is normally accom-

panied by an unusually stronger increase in

tender activity. However, because this is nor-

mally followed by a contraction of between

10% and 15% in activity in a post-election

period, the nett result will simply imply a less

volatile working environment. The National

Treasury is serious about improving the

financial stability of the economy and this

includes reducing the deficit on the current

account, while the conditions to release

infrastructure-linked grants have been tight-

ened. Also, money not spent will simply be

reallocated elsewhere. It is therefore under-

standable that under these circumstances

tender activity did not react as usual within

an election period.

Interesting developments in Q2Employment increased on average by 2.5%

QOQ in the first quarter, as larger firms

provided increased employment opportuni-

ties that were offset to some extent by

medium-size firms who offered no additional

employment, and a reduction in employment

by smaller firms. This contradicts results

from the Q1 survey, which showed that it

was the medium- and smaller-size firms

that increased employment. The mobility

of staff is generally more favourable in the

first quarter, following the holiday and bonus

period in Q4.

Benefits of manageable contractsThe tide may be turning for medium-size

contractors in terms of the overall business

environment. In the last few surveys we noted

that medium-size contractors are benefiting

from the fact that contracts are broken down

into smaller, more manageable contracts,

generally implemented by provincial and local

authorities. Medium-size contractors however

seem to be under increasing pressure as

tendering competition has become keener

and tender prices pushed lower. This impacts

on profitability, which, according to Stats SA,

has moderated from an average of 6.5% in

the previous four quarters to 0% in Q4 2013.

Added to this, the survey has found that the

value of late payments has increased by

139% QOQ, which increased late payment, as

a percentage of turnover, from 11.1% in the

previous quarter to 15.6%.

Late payments also had an effect on large

contractors. The value of late payments to

larger contractors increased by 67% QOQ,

increasing the ratio of late payments to

State of the South African civil industry: Q2 2014In this quarterly review of the South African civils industry, the South African Forum of Civil Engineering Contractors reflects on developments within a strained environment.


INSIGHT

turnover from 11.5% to 12.0%. Contradictory

to medium-size contractors, there appears to

be a gradual improvement in the profitability

of larger firms. Late payments are nonethe-

less considered unacceptable in an industry

where government has committed to ensure

payment to contractors is made within the

30-day period.

Medium-size firms may therefore find them-

selves in a far worse position as their cash

flow may not allow them to carry the addi-

tional burden of late payments, alongside

deteriorating profitability.

A mixed third quarterAccording to the survey, medium-size con-

tractors experienced better than average

working conditions over the last few quar-

ters, but indicators are somewhat less opti-

mistic in Q2 2014. Only 37.5% of medium-

size firms reported ‘very busy’ working con-

ditions, down from over 70% in the previous

survey. None of the larger firms reported

busy conditions in Q2 (in line with expecta-

tions), compared to 25% in the previous sur-

vey. The outlook for Q3 2014 is mixed. While

a higher percentage of larger firms expect

State of the South African civil industry: Q2 2014to be busier (25%), fewer medium-size firms

expect busy conditions (down to 25%).

There was a slight improvement in opin-

ion regarding the awarding of tenders, and

although the nett satisfaction rate remains

negative it did improve from -82 to -22.5,

supported mainly by an uptick amongst

larger firms.

Opinions related to tender activity continued

to deteriorate, from -72 in Q1 to -87 in Q2,

while opinions related to the state of the

two-year forward order book also continued

to deteriorate from 91 to 11.4 and a negative

INSIGHT


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-0.2 over the last three quarters. An increas-

ing number of medium-size firms were of

the opinion that the value of order books

were low (63%) compared to 30% in the

previous survey.

The estimated value of tenders released

during Q1 2014 was 31% lower compared

to the 1st quarter in 2013, as fewer higher

CIDB-grade (7 and up) projects were put out

to tender.

Higher competition for smaller firmsIn Q3 2013, 91% of firms said competition

in tendering exceeded 10 bids per project.

Competition has eased somewhat with only

44% of firms reporting tendering in competi-

tion exceeding 10. Smaller firms experi-

enced the highest level of competition with

75% of firms reporting competition in excess

of 25 bids per project.

The opinions of firms related to profitability

have improved over the last few quarters,

although the nett satisfaction rate fell to

-13.4 in the current survey, from 15.4 in the

previous survey. Opinions are not as nega-

tive when compared to 2011 and 2012, and

are showing signs of stabilisation. Pressure

on profitability is nonetheless broad-based,

affecting all firm sizes, in spite of reports that

tendering in competition has eased over the

last few quarters. Both large and medium-size

firms were more pessimistic regarding profita-

bility, when compared to the previous survey.

Managing marginsProfit margins are normally influenced by the

level of tendering in competition, as contrac-

tors need to be more competitive in their

tender prices. Reduced tender prices, along-

side an increase in input costs (estimated at

between 6% and 8%), may pose a challenge

for contractors if not carefully managed.

According to Stats SA, the average profit mar-

gin in the construction industry moderated

from an average of 5.9% in Q3 2013 to 5.4%

in Q4 2013. The average profit margin for

larger firms improved to 4.5% in Q4, from an

average of 2.2% in the first three quarters of

the year, compared to an average of 4.8% for

medium-size contractors for the year 2013.

An increasing number of firms (21.4%)

reported that their overall assessment of

business conditions during the past quarter

was poor to very poor, yet 31% reported it to

be above average. The nett satisfaction rate

therefore improved from -15 in the previous

survey to 9, lifting the overall confidence

index from -25 to a -24 when smoothed over

the last five quarters. This supports our

view that conditions may not be deteriorat-

ing any further at the moment, but that any

real meaningful recovery also remains elu-

sive. Industry confidence was supported by

an improved outlook amongst medium and

smaller contractors.

Price pressures are expected to accelerate

in 2014 as currency volatility is expected

to impact on the cost of plant equipment

and fuel, while consumer inflation is also

expected to increase at a faster pace, aver-

aging 6.2% in 2014. Including the four main

drivers of construction input cost inflation

(plant, fuel, materials and labour), input costs

are expected to accelerate from an average

increase of 5.7% in 2013 to 8.1% in 2014.

Changing expectationsConsidering all the above, we are aware of

the growing risk to our original forecast, which

expected industry turnover to increase by

between 3% and 5% in real terms, or around

R5 billion in current prices. Our expectations

were supported by higher real growth in infra-

structure expenditure by government (includ-

ing central, provincial and local governments)

and a marginal increase in expenditure by

state-owned enterprises, while advancement

in renewable energy projects should also

support private sector spending in 2014. We

also expected some marginal improvement in

mining activity according to Nedbank’s infra-

structure project listing. However, economic

risks have intensified in the first six months

of 2014 as outlined in the first section of this

report, while the industry remains challenged

by the slow roll-out of projects, threats of fur-

ther strike action in the steel industry in July

2014, the deterioration in order books, low

industry confidence, combined with growing

economic uncertainty associated with emerg-

ing market jitters, capital flows, currency

volatility and growing inflationary pressures.

All these factors may result in a lower than

expected turnover for 2014 and a stronger

than expected slowdown in 2015.

The estimated value of tenders released during Q1 2014 was 31% lower compared to the 1st quarter in 2013

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INSIGHT

ACCORDING TO the department’s

strategic and annual per for-

mance plan, tabled at the brief-

ing, there are 173 089 km of

roads in “poor to very poor condition”, of

which 16 402 km are paved roads, and

156 687 km gravel.

By contrast, the country’s national roads-

which account for approximately for 40% of

the nation’s total roads are under the South

African National Roads Agency (SANRAL)

and in excellent condition.

So while there are two stories to be told

here, one thing is for sure: South Africa

has the expertise, the equipment and skills

to build world-class road infrastructure,

and that is what this Panel Discussion is

all about.

Eight leaders in the road industry pro-

vide the insights into the sector, ensuring

IMIESA’s readers are kept at the forefront

of the latest trends, equipment, materials

and techniques used in road building, repair

and maintenance.

PANEL DISCUSSION

constructionSouth Africa’s municipal roads need help. Latest figures indicate that more than 173 000 km of municipal roads are in very poor condition. Addressing Parliament’s transport portfolio committee, transport director-general Mawethu Vilana put the cost of repair at R149 billion.

Roads


Most people associate roads and

road building with asphalt. However, those involved with road design know that precast concrete also plays an indispensable role in road construction. Can you elaborate? JC Any

road, be it a suburban byway

or a national freeway, can be

built entirely with concrete and

suburban roads can be and

often are completely built with

precast concrete. There are

six product categories in which

precast concrete is used:

• paving and kerbs

• water management products

such as pipes, culverts, kerb

inlets, grating, manholes, and

embankment down drains

• columns, beams, slabs and

barriers for bridges

• retaining walls, security

walls, soundproofing walls

and barriers

• poles and masts for electric-

ity reticulation and lighting

• a general category for prod-

ucts such as such as bus

shelters, bollards, lay-bys,

security boxes and toilets.

Why is concrete such a ubiquitous road-building material? There are several

reasons for this. Unlike other

materials, which deteriorate

with age, concrete gains

strength, requires little, if any,

maintenance, and has a life

expectancy in excess of 50

years. Unlike asphalt, which

is imported and subject to

periodic shortages and rising

costs, the elements which

constitute concrete can all be

locally sourced.

Why precast concrete in particular? Perhaps

the biggest benefit of precast

concrete is that it is much

faster to use than its insitu

equivalent. Precast concrete

has the added advantage

of being manufactured in

controlled factory environ-

ments where SABS standards

and ISO 9000 management

systems ensure a consistently

high quality. The sourcing and

production of raw materials,

as well as the installation of

precast concrete products,

is labour intensive, which is

very important in South Africa.

Locally, there is an abundance

of the raw materials required

for its manufacture, as well as

more than enough installed

manufacturing capacity to meet

the demands of any accelerated

infrastructure programmes.

Gauteng’s freeway sys-tem recently underwent a major revamp. What role did precast concrete play in the Gauteng Freeway Improvement Project? During construc-

tion, SANRAL project manager

Hennie Kotze said that the

PANEL DISCUSSION

ROAD CONSTRUCTION, MANAGEMENT AND MAINTENANCE

John Cairns | Civil engineer | Concrete Manufacturers Association

Stormwater concrete piping, 1 350 mm in diameter, is installed under a section of the N12 westbound freeway in Gauteng


space for staging and shutter-

ing support was often extremely

limited, which meant that

the use of precast concrete

elements such as beams on

bridges was indispensable to

the upgrading process.

In addition, stormwater pipes

and box culverts had to be

extended under the freeways

and in instances where new

interchanges were built, new

culvert and stormwater sys-

tems using precast concrete

pipes and rectangular culverts

were installed. It was also the

first time that precast concrete

highway barriers were used

extensively, replacing W-section

crash barriers.

Precast concrete panelling-

was used for embankment rein-

forcing and facades. Precast

beams, which varied from small

I-beams to huge U-beams, were

also used on the project.

It appears that municipal engineers still tend to favour asphalt as their default paving material. However, an increasing number of roads are be-ing paved with concrete block paving (CBP). Why is this? Sustainability, pover-

ty alleviation and safety are the

main drivers here. CBP was first

introduced to this country 50

years ago when it was used to

pave roads in the Durban town-

ship of Chatsworth. However, it

was not until the advent of the

new millennium that CBP was

taken seriously as a suburban

road-paving alternative.

CBP is essentially mainte-

nance-free, provided it is laid in

compliance with best practice

standards – one of the main

reasons why it is finding favour

with local governments. What’s

PANEL DISCUSSION

more, the initial capital outlay

on CBP roads is only marginally

greater than an asphalt equiva-

lent, while the saving on main-

tenance is considerably more

substantial and quickly offsets

any higher capital spend.

How does CBP assist with poverty allevia-tion? Laying roads with CBP

is labour-intensive and offers

the unemployed an opportu-

nity of acquiring a marketable

skill and earning capacity. The

income earned has a multiplier

effect, stimulating economic

activity in other sectors of

local communities.

Could you describe how CBP contributes to greater safety? The

chance of aquaplaning on wet

surfaces is greatly reduced with

CBP roads. The two-to-three-

millimetre water sheet often

found on asphalt roads during

heavy downpours is vir tually

non-existent, especially when

the pavers are bevelled. One

may find an isolated water

channel crossing a CBP road

but not water sheeting over

an extended area. Permeable

paving installations, which are

specifically designed to soak

up stormwater, are even more

effective at dispersing surface

water and can be installed on

sections of road where water

channels are likely to form.

CBP also offers better brak-

ing owing to its rough texture

and broken surface. In addi-

tion, it provides better road

marking with coloured and

luminous concrete pavers and

offers constant and mainte-

nance-free signage.

CLOCKWISE FROM TOP

A typical precast concrete manhole

A box culvert, partially obscured by loose rock, at Reading Interchange on the N12 freeway

Concrete façade panels, 800 mm to 4 900 mm long and 1 980 mm wide,were used for the protection and aesthetic enhancement of several embankments and cuttings on the N1 freeway between Atterbury Road and the R21 Interchange. On this stretch of southbound freeway, the panels reach their maximum height. Concrete barriers, 1 m high, abut the panels at ground level, securing them firmly in position. Coping panels installed at the upper end of the façade panels add the finishing touch

One of several roads paved with CBP in Thembalihle, Phumelela (Vrede)

The precast concrete panelling on this Gautrain bridge serves the dual purpose of a safety wall and an aesthetically pleasing façade

A beany block stormwater drain

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INFR SET

Aveng Manufacturing Infraset produces a diverse range of precast concrete products to world-class quality standards and actively contributes to SADC infrastructure development. Our range includes concrete pipes, culverts, manholes, special precast products, various types of pre-stressed railway sleepers, turnouts, maintenance-free railway electrification masts and poles, paving blocks, retaining wall systems and roof tiles.

Aveng Manufacturing Infraset’s admired heritage is founded on innovation, technical and service excellence.

Aveng Manufacturing InfrasetSteeldale HouseTEL: +27 (0)11 876 5500FAX: +27 (0)11 872 1713EMAIL: [email protected]

PIPES • CULVERTS • MANHOLES: GAUTENG – TEL: +27 (0)11 876 5100CAPE TOWN – TEL: +27 (0)21 908 1156KWAZULU NATAL (PIETERMARITZBURG) – TEL: +27 (0)33 387 2236

RAILWAY SLEEPERS • POLES & MASTSNATIONAL – TEL: +27 (0)11 813 2340

INTERNATIONAL BRANCHESSWAZILAND – TEL: +2682 518 4236 | ZAMBIA – TEL: +260 21 131 1838

BUILDING DURABLE INFRASTRUCTURE WITH PRECAST CONCRETE PRODUCTS

PAVING • RETAINING WALLS • ROOF TILESROSSWAY (MIDRAND) – TEL: +27 (0)12 652 0000KWAZULU NATAL (EFFINGHAM) – TEL: +27 (0)31 569 6900


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INFR SET

Aveng Manufacturing Infraset produces a diverse range of precast concrete products to world-class quality standards and actively contributes to SADC infrastructure development. Our range includes concrete pipes, culverts, manholes, special precast products, various types of pre-stressed railway sleepers, turnouts, maintenance-free railway electrification masts and poles, paving blocks, retaining wall systems and roof tiles.

Aveng Manufacturing Infraset’s admired heritage is founded on innovation, technical and service excellence.

Aveng Manufacturing InfrasetSteeldale HouseTEL: +27 (0)11 876 5500FAX: +27 (0)11 872 1713EMAIL: [email protected]

PIPES • CULVERTS • MANHOLES: GAUTENG – TEL: +27 (0)11 876 5100CAPE TOWN – TEL: +27 (0)21 908 1156KWAZULU NATAL (PIETERMARITZBURG) – TEL: +27 (0)33 387 2236

RAILWAY SLEEPERS • POLES & MASTSNATIONAL – TEL: +27 (0)11 813 2340

INTERNATIONAL BRANCHESSWAZILAND – TEL: +2682 518 4236 | ZAMBIA – TEL: +260 21 131 1838

BUILDING DURABLE INFRASTRUCTURE WITH PRECAST CONCRETE PRODUCTS

PAVING • RETAINING WALLS • ROOF TILESROSSWAY (MIDRAND) – TEL: +27 (0)12 652 0000KWAZULU NATAL (EFFINGHAM) – TEL: +27 (0)31 569 6900

PANEL DISCUSSION


Coenraad Groenewald | Technical Marketing Manager: Construction Products | Aveng Manufacturing Infraset

What role does Aveng Manufacturing

Infraset play in road con-struction and infrastruc-ture? CG We provide products

for stormwater management,

and to this end supply a range of

concrete pipes, portal culverts,

manholes, various precast con-

crete channels and kerbs. We

also manufacture custom-built

precast products, concrete re-

taining blocks, and an interlock-

ing concrete paver, Uni-Ecolok,

which is used for permeable pav-

ing installations. Other road-re-

lated products include concrete

poles and masts for electrical

and telephonic reticulation.

How does permeable paving assist with water dispersement? Water pond-

ing on asphalt roads is common

during heavy thunderstorms. By

contrast, the two-to-three mil-

limetre water sheet often found

on asphalt roads during heavy

downpours is virtually non-

existent on roads paved with

concrete blocks. This is even

more evident with permeable

paving, which is specifically

designed to soak up and dis-

perse stormwater, and it can

be installed on sections of road

where water ponding is likely

to occur.

What innovations does your company bring to the roads, bridges and SMI construction indus-try? We cast a mammoth

12.8 tonne culvert forthe

construction of two buffer tun-

nels at Glencore’s Tweefontein

Optimisation Project near

Witbank last year. Although

not specifically designed for

roads, we believed it wouldn’t

be long before the culverts

were specified in stormwater

management applications.

This proved to be the case

earlier this year when they were

specified for the replacement

of a steel stormwater channel

that collapsed under Andre

Greyvenstein Road near O.R.

Tambo International Airport.

Having been eroded by

chemicals and other industrial

effluent, the collapse was a

gradual process and initially

the Ekurhuleni roads authori-

ties used premix as a stopgap

measure. However, the whole

section collapsed during particu-

larly heavy rains in November

last year and the road had to be

closed for the installation of a

new water channel.

Ndodana Consulting Engineers

was appointed to design the

new channel and decided to

widen and deepen the storm-

water channel under the road

to cope with the anticipated

increase of flooding. One design

option was to construct the

culvert using insitu concrete

and this would have been done

had our mammoth culverts not

existed. But because they were

available from our Brakpan fac-

tory, Ndodana chose to specify

them instead.

Was speed of construc-tion what motivated their choice? Yes. I estimate

that we saved approximately

one-and-a-half months by using

the culverts.

How big are these cul-verts? Each measures 3.5 m

(height) x 5.3 m (width) x 1 m

(depth) and contains 600 kg

of reinforced steel. The culvert

walls are tapered, with a

maximum thickness of 350 mm

at the top end narrowing to

300 mm at the base of each

foot. Six custom-made steel

moulds, which were designed

and supplied by local steel

fabricating company Mario

Meano Engineering were used

for the casting, which was

done horizontally.

Could you describe the installation process?A total of 32 culverts were low-

ered by crane onto a concrete

platform measuring 35 m x 6 m.

The internal dimension of the

culvert is 33 m x 4.8 m x 3 m.

The concrete platform comprised

500 mm of dump rock, two

150 mm layers of G7, a 50 mm

layer of blinding, and 350 mm of

reinforce concrete.

Concrete wing walls were at-

tached to the first culvert using

insitu concrete. We waterproofed

the culverts using a normal

concrete grout and also installed

110 mm subsoil drainage pipes

on the outside of the two culvert

walls to prevent water build-

up under the road. Once the

concrete work was completed,

we filled in with G7 material,

compacting as we went. Some

areas were too narrow for the

compacting equipment and in

these instances we filled in

with soilcrete.

What paving material will be used on the repair road surface? Normal

40 mm asphalt surface.

Were there any other pre-cast concrete elements used on this project? Yes.

We had to rehabilitate some

stormwater drainage leading into

the culvert and we used 450 m

of 600 mm-diameter concrete

piping supplied by Aveng

Manufacturing Infraset.

Are there any other road-related innova-tions in which Aveng Manufacturing Infraset is involved? Nothing strictly

road related, although we are

currently involved in the produc-

tion of culverts for a sewer that

forms part of the main line in

Newtown, Johannesburg. The

culverts for this project are

being cast with a chemical ad-

ditive which helps them better

withstand the gaseous sewer

environment.

BELOW One of the mam-moth culverts is lowered into position RIGHT The en-trance to the channel showing the wingwalls BELOW RIGHT The collapsed road above the stormwatwer channel on Andre Greyvenstein Road

With more than 500 000 km of roads in South Africa, the maintenance and development of this infrastructure requires critical strategic investment.

Kaytech will help you to limit construction and long-term maintenance costs of new roads, and extend the fatigue life of existing and damaged roads. From sealing and patching of cracks, potholes and edge breaks to the rehabilitation of substructures and the development of stable slopes or subsoil

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3843_kaytech_roads_ad_297x210_2.indd 1 2014/07/11 1:17 PM


PANEL DISCUSSION


Garth James | Technical Director | Kaytech Engineered Fabrics

What road construction-related services

do you offer? GJ Since the

mid-1970s, Kaytech has been

involved in the maintenance and

rehabilitation of South Africa’s

road infrastructure, offering

different geosynthetic solutions

to common problems facing any

ageing road network.

These primarily include subsoil

drainage systems and the

maintenance of our road pave-

ments through the use of our

specialist products. Our paving

fabric, Sealmac, with a suitable

bitumen impregnation, forms

a waterproofing, stress-relief

membrane upon which either

a spray seal or asphalt overlay

is applied.

In the late 1990s, asphalt

reinforcement interlayer technol-

ogy was initiated using a spe-

cialist polymeric-coated glass-

fibre geogrid called GlasGrid.

Kaytech also offers a composite

reinforcement interlayer geotex-

tile which effectively combines

the benefits of a paving fabric

like Sealmac with those of the

glass fibre to form a high-

strength, low-strain interlayer,

which, when impregnated with

bitumen, provides a waterproof

barrier and a stress-absorbing

underlayer, known as Sealgrid.

These technologies are in-

cluded in the national guideline

TG3 – Asphalt Reinforcement

for Road Construction.

What specialised tech-nology/equipment does you company bring to the market? Kaytech has

provided a solution to upgrad-

ing steep rural and township

roads using geocells and a

concrete infill.

Most of the roads used by

locals to access their homes

are constructed of gravel and

are often poorly maintained.

Paving these roads with asphalt

is not always viable due to the

steep gradients and prohibitive

costs of paving, so these steep

road sections are surfaced

with Multi-Cell of a 100 mm

profile filled with readymix

concrete. This system has been

successfully installed in the

past on a section of a district

road at Vulindlela and at Unit H

in Edendale.

More recently, Kaytech

worked on a section of the

Vulindlela district road D1125.

Working within tight budget

constraints, the regrading of

the 28% incline and widening

of the sharp horizontal curves

were particularly challenging. A

600 m section at 19% design

grade was constructed using

Multi-Cell geocells infilled with

25 MPa concrete.

The Multi-Cell system proved

to be the most economical tech-

nical solution, providing an ideal

opportunity for labour-intensive

construction techniques.

How do your products aid in the construction of roads, bridges and stormwater manage-ment infrastructure? The advanced glass-fibre

technology incorporated in our

GlasGrid asphalt reinforcement

interlayer grid is currently used

to strengthen the bitumen-

treated base on a section of the

Bakwena Platinum Corridor, on

the N1 between Pienaarsrivier

and Bela-Bela.

The technology prevents re-

flective cracking, enhancing the

pavement structure, and was in-

corporated in the design carried

out by the consulting engineers.

The added advantage is that

GlasGrid technology reduces the

need for deeper layer reha-

bilitation, saving both time and

money for the client.

What products does your company supply to ancil-lary roads infrastructure? The most critical aspect of road

pavement design is the preven-

tion of the ingress of water into

the load-bearing layer works.

Kaytech has been supplying

geocomposite drainage systems

to the road construction indus-

try since 1985.

The most commonly used

system is our Flo-Drain, which

is a find rain comprising a

FlowNet geospacer, wrapped

in a bidim drainage geotextile

jacket, which is connected to a

Geopipe collector. This system

offers savings through speed

of installation and by reducing

the need for expensive stone

aggregate used in conventional

subsoil drains.

The other system that offers

all these benefits, plus the

advantage of being a collector

conduit in one, is the Megaflo

system, which can be installed

within the pavement layers or

immediately adjacent to the

road shoulder to relatively

shallow depths.

Some locations demand that local materials be used – usually due to scarcity of conventional materials. How has your company approached such situations and what innovations have re-sulted? We manufacture our

bidim and Sealmac geotextiles

from 100% recycled polyester,

offering cost savings to the

end user and a reduced carbon

footprint. Millions of cooldrink

bottles have been collected,

processed and introduced into

our extrusion system to produce

our well-known geotextile range.

What specialties does your company bring to the discipline of road maintenance? Kaytech

brings over 40 years of experi-

ence to the table whenever the

road authority, pavement design

engineer or the roads contractor

are faced with challenges requir-

ing innovative solutions that

are cost-effective and relatively

simple to execute.

ABOVE GlasGrid 8511 laid onto the BTB, N1 Pienaarsrivier INSET Megaflo 300 being installed alongside a road shoulder

• Storm water Catch Pits• Concrete House

• Kerbstones• Rumble Blocks

• Street name kerbs• Culverts

• Concrete grids• Custom Slabs

• Concrete Palisade fence• New Jersey Barriers

• Tree rings• Pedestrian Blocks

• Wing Walls up to 750mm Pipe Draw Boxes

• Route Markers• Concrete Channels

• Pier Caps• Paving and Cladding

MANUFACTURERS AND INSTALLERS OF CONCRETE PRODUCTS

FOR ALL YOUR TECHNICAL AND PRODUCT QUERIES CONTACT

HEAD OFFICE WEST RANDTel: +27 (0)11 411 6901/2/3Sales & Financial Manager:

Hennie BezuidenhoudtCell: 083 759 8885

[email protected]

EAST RAND BRANCHSales Manager: Drienne Kruger

Tel: +27 (0)11 363 2886Cell: 081 501 4850

[email protected]

WWW.KERBMASTER.CO.ZA

Company Secretary: Ronel de BruynCell: 073 826 9661 • [email protected]

Marketing Manager: Ben MaraisCell: 074 329 5656 • [email protected]

Reception: Bernadine [email protected]


PANEL DISCUSSION


Coen Vermaak | Managing Director | Kerb-Master

What needs to be taken into consideration

when selecting stormwa-ter catch pits? CV When

we discuss stormwater catch

pits, we have to list the pros

and cons of each of them.There

are several factors that play

an important role and must be

considered. These are:

• price or cost-effectiveness

• exposed steel

• hydraulic design

• strength of units and covers

• safety for pedestrians, ani-

mals and motorists

• availability of spares

• adaptability to various

site conditions

• quality control

• speed of installation

• job creation or machine

installation

• length of KI

• modern and aesthetically

acceptable

• for domestic or industrial

use.

The Kerb-Master complies

with all these conditions

and all the criteria which will

be discussed.

Tell us about the costs Price is very important, but if

the catch pit is hydraulically

superior to other designs then

it can be made shorter and the

transitions can be made longer,

thereby cutting costs, but still

maintaining the same volume

of stormwater.

Should metal compo-nents be used? Steel

components, including man-

holes and grids, are targeted

by opportunistic criminals who

sell them for scrap. There is

no sense in installing steel

components that will be stolen

the next day.

Can you explain hydrau-lic effectiveness? The

hydraulic design consists of a

system of supports for the cov-

ers and also affects the velocity

of the water on the apron of the

catch pit. If the support system

deflects the water in storm

condition, then we have wasted

our money. Once the water is

inside the catch pit, it must

be discharged into the pipes

with very little turbulence. All

these factors play a role in the

hydraulic design.

How important is strength? The strength of

the catch pit is very important

because we design roads to

last 20 years. We also know

that most truck drivers have no

respect for our infrastructure

and they do use the sidewalks

as parking areas. You can

imagine when a 50 tonne truck

drives over a catch pit, there will

be very little left and another

R10 000 down the drain. Kerb

inlets should be so designed

that the repair costs are kept to

a minimum.

The Kerb-Master Storm Water

Catch Pit is designed so the

units can withstand a load of

60 tonnes and the covers a

load of 20 tonnes. The impli-

cation is that it is cheaper to

replace covers than the entire

catch pit.

Are there any particular safety measures to be considered? Safety is very

important for pedestrians,

motorists and cyclists, therefore

150 mm openings are the norm

and should not be exceeded.

Cover slabs should not protrude

higher than the paving level and

the catch pit should be moved

back from the kerb edge to stop

vehicles from driving into them.

This is especially valid at shop-

ping centres because motorists

drive right up to the kerbline

when parking. The Kerb-Master

is designed so that it is unnec-

essary to open the side inlet of

the catch pit.

How important is adapt-ability? Adaptability is key to

any catch pit installation. There

are numerous different site

conditions and a catch pit must

overcome all these obstacles.

It must be able to

be installed at any

length or depth,

to the left or right,

or at a low point,

and must fit on any

pipe size. Tar or

paving and operat-

ing at different heights should

not influence the installation.

What role does precast play in job creation? Job

creation is very important in

South Africa, but we have a situ-

ation where only temporary job

creation has been achieved in

the construction industry. There

have been expectations that

only local people should do criti-

cal work and riots have ensued.

Building lasting roads is a

specialised operation and

requires hiring competent peo-

ple. Contractors are often on

the receiving end when clients

reject poorly constructed catch

pits. In a factory environment,

quality control is done on an

hourly basis and very few con-

tractors accept substandard

products. These factories drive

job creation and produce quality

controlled products. We have a

skills shortage in South Africa

and, as a result, precast is the

way forward.

What about machine or TLB installation? Catch

pits should be handled safely

by hand and it should not be

necessary to use TLBs to exca-

vate or transport catch pits on

sites. Catch pit sections should

not weigh more than 150 kg

so that four men can handle

them safely.

What length should the kerb inlet be? The Kerb-

Master inlet can be installed at

any length. The longest so far

was 10 m with three outlets into

the pipe system. The design

should contain an outlet for

every 3 m of kerb inlet.

What products does Kerb-Master manufac-ture? Kerb-Master manufac-

tures the following:

• stormwater catch pits

• concrete housing

• kerbstones

• rumble blocks

• street name kerbs

• culverts

• concrete grids

• custom slabs

• concrete palisade fence

• new Jersey barriers

• tree rings

• pedestrian blocks

• wing walls up to 750 mm

• route markers

• concrete channels

• pier caps

• paving and cladding.

We also manufacture cutting-

edge retaining walls in various

colours. Kerb-Master can be

contacted at any time for fur-

ther product information.

Building lasting roads is a specialised operation and requires hiring competent people


PANEL DISCUSSION


Mike Fisher | Infrastructure Road and Rail Development Manager | Lafarge South Africa

What road construction-related services do you offer? MF Lafarge South Africa

provides the local construc-

tion industry with innovative

products, solutions and services

from our cement, aggregates and

readymix (RMX) lines. We supply

an extensive range of materials

to the road construction sector

made up of cement for stabilisa-

tion, base materials, including

stone for asphalt application,

and concrete for road structures.

What specialised tech-nology/equipment does your company bring to the market? For cement bulk

application, Lafarge has the

ability to bulk spread with a fully

automated system called Stoltz.

Our aggregates division offers

contractors a mobile crushing

solution if the project is far from

a commercial source. The same

offering can also be given from

our RMX division. We provide

contractors with mobile batch

plant operations.

What specialist techni-cal services does your company deploy? Lafarge

offers a complete materials solu-

tion, starting with an optimised

design for the road binder

needed for stabilisation, the

concrete design for all structural

requirements, and the specific

stone requirements for the as-

phalt used. This can all be done

through our SANAS-accredited

laboratory, Quality Department

Southern Africa.

We offer consultative services

to train and inform consultants

and role players on our offerings

as well as on the technical side

of specifying solutions.

How do your products aid in the construction

of roads, bridges and stormwater management infrastructure? As a

solutions-driven company,

Lafarge’s products and services

are a perfect fit for infrastructural

projects that incorporate the use

of Lafarge’s cement, aggregate

and concrete products. We

offer, among others, RoadCem,

spreaders, Agilia, durability

mixes, and Hydromedia.

RoadCemRoadCem is a highly effective

soil stabiliser that requires the

least concentration to meet the

specifications of a particular

road project. Lower spreading

concentrations equal a lower

product requirement and provide

reduced handling costs.

RoadCem’s workability has

made it especially popular with

contractors. It provides extended

open time, allowing longer appli-

cation runs and cost savings due

to better control over the work

schedule. RoadCem is also one

of a complete range of Lafarge

South Africa’s innovative, lower

carbon footprint cements.

Mobile RMX batch plantIn the event of the contractor not

being able to source concrete

from a commercial source, a

mobile RMX plant is the perfect

solution. The contractor can use

stone out of a borrow pit within

the contract itself and does

not have to worry about exces-

sive turnaround time on RMX

trucks. This gives the contractor

the ability to plan his concrete

pours far more effectively and

have better control over all

production plans.

Aggregate crushingThere are two main benefits

with contract crushing. First,

the installation cost of putting

up a mobile crusher is far more

cost-effective than a static

crusher. Second, the actual cost

of the material is a lot cheaper

because the contractor is saving

on haulage costs.

HydromediaLong-term maintenance and

stormwater management costs

are addressed by Lafarge’s

Hydromedia, a new, fast-draining

concrete pavement solution

that rapidly directs stormwater

off surfaces. Its cutting-edge

engineered design offers best-

in-class drainage, a surface

resilient to wear, and an indus-

try-leading aesthetic appeal and

increased ease of placement.

Training and informingDuring targeted involvement

in the conceptual and design

stages, we can assist in consult-

ing with the specific role players

in charge of the project on the

technical side of matters, ensur-

ing the correct specification fixed

for the contract. This prevents

variations on the contract after

tender stage.

How does your compa-ny’s service level agree-ments complement the intricacies of road and bridge construction, the materials worked with and the inherent maintenance requirements? Lafarge of-

fers a complete integrated roads

solution in which we can supply

and support key materials and

solutions to the contractor. By of-

fering these integrated solutions,

Lafarge removes a lot of risk for

the contractor, taking care of

the part of the contract that the

service provider specialises in.

The contractor can concentrate

on their main focus knowing

that materials supplied to site

would be within specification and

durability requirements.

What products does your company supply to ancil-lary roads infrastructure? Lafarge offers a range of decora-

tive concretes and a kerb mix

specifically designed for culverts.

Long-term maintenance and

stormwater management costs

are also addressed by Lafarge’s

Hydromedia.

The impressive Umgeni Interchange is scheduled to be completed in 2015

Lafarge's RMX and cement were used in the upgrading of the Gauteng Freeway Improvement Programme

The wave pattern of the Durban Beachfront Promenade was a combination of Lafarge's Artevia Colour and Artevia Exposed concretes

Much Asphalt is southern Africa’s largest supplier of an extensive range of hot and cold asphalt products.

Our products are supported by world class technology and expertise, extensive laboratory services and specialist advice. With 17 branches and state-of-the-art mobile plants, Much Asphalt offers services anywhere, any time, no matter how big or small the project.

ANYWHERE.ANY TIME. ANY PROJECT.

T: +27 21 900 4400F: +27 21 900 4468

E: [email protected]


PANEL DISCUSSION


Leon Alberts | Strategic Business Development and Marketing Director | Much Asphalt

As the leading as-phalt producer in the country, what

role is Much Asphalt playing in ensuring our roads are properly main-tained? LA Much Asphalt

aims to provide the most

appropriate and cutting-edge

technology to ensure that our

road surfaces meet global

standards. At the same time, we

have a responsibility to ensure

that SMMEs have access to ap-

propriate products and training

in order to be able to undertake

successful road maintenance.

What is the most appro-priate modern technol-ogy that we should be using for South Africa’s major road surfacing projects? The benefits

of warm-mix asphalt (WMA)

technology are well known in

the market and we continue to

upgrade all our plants around

the country to offer WMA

products. WMA decreases

carbon footprint by reducing

the temperature at which the

asphalt is mixed and placed on

the road, and provides other

benefits in both asphalt produc-

tion and paving. Higher recycled

asphalt content can be added to

a conventional WMA mix without

affecting the workability of the

end product or excessive emis-

sions, hence contributing to the

environmental benefits.

What is GB5? GB5 is an

alternative to high-modulus

asphalt –a mix designed to be

stiff by using very hard, 10/20

penetration grade bitumen.

This helps to reduce pavement

thickness, increase longevity

and decrease rutting.

The GB5 alternative uses

an SBS modified bitumen to

obtain the same high stiffness

modulus, while retaining good

fatigue properties. GB5 is a

cost-effective alternative to

high-modulus asphalt as the

binder content is lower and the

modified binder is locally availa-

ble, unlike the imported 10/20

penetration grade bitumen

required by the alternatives.

GB5 was developed by Eiffage

Travaux Publics in France and

Much Asphalt has acquired the

rights to manufacture GB5 under

licence in KwaZulu-Natal.

Plant trials have been com-

pleted in partnership with the

eThekwini metro and full-scale

paving trials will start soon on

a major harbour access route in

Durban. The product should be

ready for commercial use in the

near future.

What contribution does Much Asphalt make to an enabling environment for SMMEs in the asphalt paving sector? The future

of job creation in South Africa

lies with SMMEs and training

is essential to ensure these

businesses have the skills

and expertise to succeed and

be sustainable.

Much Asphalt provides free

workshops on best practice

in the placement of hot-mix

asphalt to assist SMMEs, lo-

cal and provincial authorities.

Thousands of individuals have

received this practical training

since 2006 and we believe

these kinds of interventions are

critical to getting the best out of

road maintenance programmes.

The aim of our workshops is to

establish a uniform, industry-

wide standard for high-quality

hand-laid asphalt. It is critical

to keep abreast of product in-

novations, combined with plant

technology advancements,to en-

sure we have the best asphalt

products. It is equally important

to invest in people so that the

right skills are developed and

applied in the workplace.

Our products undergo very

stringent testing procedures,

and most road-surfacing failures

are due to incorrect placement

of the product, particularly when

done by hand. This needs to

be remedied for the industry to

succeed as a whole and for our

roads to endure.

What value can you add for SMMEs with regard to asphalt products? We

produce bulk or bagged cold-mix

asphalt for the filling of potholes,

trench reinstatement, patching

of roadsurfaces and emergency

road repairs. Hot-mix asphalt,

however, remains the first choice

due to its ease of placement,

workability and long-term results.

We are currently in the ad-

vanced stage of implementing a

unique solution to the problem

of getting hot-mix asphalt to

paving sites. This will specifi-

cally help SMMEs transporting

smaller quantities of hot-mix

asphalt for road maintenance

projects, particularly getting the

mix to remote areas, without

compromising the integrity of

the product.

Technologies such as WMA

also benefit small asphalt pro-

jects as the time window for suc-

cessful compaction is extended

due to the workability of the mix

at lower temperatures. We have

joined forces with the CSIR to

research the use of WMA with

high recycled asphalt content for

labour-based township road up-

grades. This will go hand in glove

with appropriate training.

Much Asphalt strategic busi-ness development and mar-keting director Leon Alberts (front left) and Brian Mchunu, managing director of Much Asphalt subsidiary East Coast Asphalt (front right), hosted the first Hand Asphalt Workshop in Mthatha, in April this year, jointly with the South African Road Federa-tion. The workshop attracted 68 delegates

GB5 plant trials in Durban

Voyager full page ad.indd 1 2014/06/26 6:16 AM


PANEL DISCUSSION


Noel Bessler | Sales Director | Osborn Engineered Products

Mixing ZoneDrying Zone

RAP Collar outside the drum

Fire Shieldinside the drum

Long Burner Nose

UnifiedDrum™ Seethrough

What are key principles behind using recycled asphalt in road building? NB The idea is to reduce the

amount of virgin aggregate

required in road building and

road maintenance projects.

This is mainly for environ-

mental reasons and actively

reduces the carbon footprint

of each new project. The idea

is to remove old asphalt-paved

surfaces and return them to the

asphalt manufacturing plant,

introducing it alongside the

virgin aggregate. The recycled

asphalt is still bitumen coated

and requires special technolo-

gies to ensure it is reintroduced

in the best possible manner.

Generally, new road specifica-

tions call for certain ratios of

RAP. The South African road-

making industry now needs to

ensure it can accommodate this

requirement, and Osborn has

introduced the Astec Voyager

120 as an excellent solution.

What are the Astec Voyager 120’s key features? It is a highly

compact machine which has

been designed with portabil-

ity in mind. It is unique for a

product in this class as it has

the ability to run a guaranteed

30% RAP, though capable of up

to 40% RAP. It’s built around a

counter-flow drum that features

Astec’s unique V-flights. These

provide greater uniformity of

the aggregate veil during the

drying process, which results

in better heat transfer and a

significant reduction in fuel

use. Essentially, this minimises

heat loss and gets a lot more

of the material through the

heating gases more evenly

and consistently, resulting in

a better adhesion and mix of

bitumen throughout.

What should road con-tractors understand about Voyager? The 120 in the

name stands for 120 tonnes.

This is an unusually high capac-

ity for a portable asphalt plant

and extremely useful for the

road-building fraternity. Very

importantly, the Voyager 120 is

a continuous mix plant, which

means the mix can be modified

in real time, whilst continuously

feeding from the cold feed bins

onwards.

The Voyager 120 plant affords

the user a guaranteed 30%

RAP, which will be a require-

ment for road contractors. For

increased RAP percentages of

40% and 200 tph, the Portable

Voyager 200 Plant is available.

Alternatively for 40 to 60% RAP

and 300 to 350 tph, the Astec

Six Pack Portable Plant offers a

very viable solution.

The RAP functionality is obviously great for the environment; does the plant have other environ-mental benefits? Yes it

does – the Voyager 120 comes

equipped with a new generation

baghouse known as a reverse

pulse baghouse. A standard

baghouse collects the emitted

particulates and dust, and usu-

ally these are discharged into the

environment, or at the very least,

needs to be disposed of. The

reverse pulse technology actually

reintroduces these emissions

straight back into the drum.

While it can be (responsibly)

dumped or discharged, the ability

to reintroduce the particles is

obviously better practice, more

efficient and minimises waste.

So how exactly is the RAP introduced into the mix? The Voyager employs what is

known as UniDrum technology.

The drum is divided into two

sections, with virgin content

drying before the fire and induc-

tion, and RAP mixing with new

bitumen behind fire. RAP is intro-

duced through a collar directly

into the dryer and to avoid bitu-

men contact with fire, the RAP

falls behind the fire.

What other technologies drive the Voyager 120? It has excellent blending controls

in the shape of the MPIII control

system. This system allows the

user to create and store unlimit-

ed mix designs and has a highly

accurate diagnostics capability.

It allows for ultimate control.

The aggregate weigh system

enhances accuracy by using

a four-point system, which in-

cludes the adjustable feed gate,

weigh scales, S-type tracking

and gravity take-up.

Portability is obviously crucial too; how is this achieved? The Voyager

typically comes in two chassis –

12.2 metres and 18.9 metres.

The longer chassis can be split

in two for easier manoeuvrability

along narrow roads. All weight is

distributed on several axles al-

lowing the plant to remain within

maximum South African road

authorities limit.

The plant is entirely modular

in design and allows for flex-

ibility of bin selections and the

ability to use components of the

Voyager 120 to upgrade existing

plants. To enhance portability,

a hydraulically driven swing-out

drag and batcher can be set

up and ready to go in about 10

minutes. Other features include

a reverse-pulse baghouse, a

control cab with fully automated

PLC controls, gravity take-up

with direct drive, air-ride suspen-

sion – which easily raises and

lowers the drum into place – and

up to five cold feed bins and two

RAP bins. Separate chassis can

be offered as well.

QUICK SPECS – ASTEC 120 MTPH VOYAGER PORTABLE PLANT• Compact, highly

portable design• Ability to run a

guaranteed 30% RAP• Built around a counter-

flow drum featuring V-flights, which provide greater uniformity of the aggregate veil during the drying process, resulting in better heat transfer, fuel use reduction and increased productivity

• Hydraulically driven swing-out drag and batcher can be set and ready to go in about 10 minutes

• Other features include reverse-pulse baghouse, a control cab with fully automated PLC controls, gravity take-up with direct drive, air-ride suspension and up to five cold feed bins and two RAP bins


PANEL DISCUSSION


Saied Solomons | CEO | Southern African Bitumen Association (Sabita)

What is Enrobés à Module Elevé (EME) and what

prompted the research that resulted in its de-velopment? SS EME is a

hot-mix asphalt consisting of

hard bitumen blended at a high

binder content with good qual-

ity, fully crushed aggregate to

produce a fine-graded mix with

a low air voids content. EME is

designed to combine good me-

chanical performance with im-

permeability and durability. Its

key performance characteristic

is one of high elastic stiffness,

while meeting the requirements

for high resistance to perma-

nent (plastic) deformation and

high fatigue performance, while

also offering good moisture

resistance and good workability.

A few years ago, road authori-

ties began looking for long-life

pavement solutions that would

withstand the stresses of

heavy and heavily trafficked

routes. Sabita therefore initi-

ated a technology transfer

project in 2008 to adapt

the technology developed in

France in the early 1990s. The

performance testing and the

validation of the design, done

by the CSIR indicates that EME

is a durable solution to heavily

trafficked roads.

How was this project conducted? The research

was split into four phases:

• phase one: preliminary

assessment of viability

• phase two: preliminary

guidelines on mix and

structural design

• phase three: validation of

EME technology through

accelerated pavement design,

long-term pavement perfor-

mance and laboratory studies

• phase four: drafting of

guidelines and specifications

for EME.

An initial study was conducted

in France using materials

selected from South Africa.

The output was used by the

CSIR to fine-tune the design

requirements to South African

standards. The focus in par-

ticular was to deliver a mix that

combines superior permanent

deformation resistance with

high structural stiffness and

good fatigue performance.

When was this technol-ogy first applied in South Africa? In September 2010,

planning of the first full-scale

EME trials were underway on

a section of the heavily traf-

ficked South Coast Road near

Durban harbour. This ‘test bed’

was made available by the

eThekwini Municipality, and

used the mix design developed

by the CSIR.

The EME trial section select-

ed was on the northbound side

of South Coast Road, over a

length of approximately 300m

dual carriageway. Figure 1

shows the severely deformed

road as a result of the almost

continuous flow of heavy vehi-

cles – most of them heavily

laden with containers and other

goods destined for export.

Normal asphalt does not cope

well with this kind of extreme

loading, and the result is rut-

ting and mounding.

The trial section was com-

pleted in August 2011.

How has this trial sec-tion performed? As part

of the trial, regular six month

inspections were scheduled

for a two-year period to assess

performance. At the time of its

second inspection, the pave-

ment had been in service for

one full summer period. A visual

inspection was supplemented

by falling weight deflectometer

tests and profile measurements

carried out by VNA testing.

The CSIR reported that the

trial section had not changed

from the previous inspection,

and the overall condition of the

pavement was rated as good.

No distress was apparent aside

from localised surface distress

and flushing, derived mainly

from fuel spillages.

It was estimated that dur-

ing the two-year monitoring

period, the trial section car-

ried approximately nine million

E80’s without significant visual

or measurable forms of struc-

tural damage. This indicates

that EME does indeed provide

an optimum solution for heavily

trafficked roads. Construction

is currently underway using

EME on the upgrade of the N3

between Durban and Pinetown.

What is being done to disseminate the new technology? To ensure

that EME technology is readily

available to the road construc-

tion sector in general, Sabita

produced its Manual 33:

Interim design procedure for

high modulus asphalt (EME),

in January 2013 (available

from Sabita in CD format).

Ultimately, the design method

presented in the manual will be

integrated into a South African

Pavement Design Method

(SAPDM). The target perfor-

mance characteristics covered

tie in with those required as

inputs into the SAPDM being

developed under the auspices

of SANRAL.

Sabita fully expects that

EME will become an important

and widely used technology

in South Africa, and that its

durability will be recognised as

a cost-effective solution to the

maintenance and rehabilita-

tion of heavy and heavily traf-

ficked roads.

FIGURE 1 Avoiding severe pavement deformation demands the kind of fatigue resistance provided by HiMA

LEFT Figure 1(a): Severe rutting on the section prior to rehabilitation

RIGHT (b) Condition of the section after seven months

NEWS ARTICLES TECHNICAL PAPERS COMPANY NEWS ORGANISATIONS MULITMEDIA EVENTS

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Ruralroads

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Trenchless technology

Getting the most out of innovations

Western Aqueduct

Durban’s largest pipeline

SARMA supplement

“We are reaching our ultimate milestone as the countdown to completion of our flagship plant, Aganang, builds” Pieter Fourie, chief executive, Sephaku CementMEDIA

The new

The official magazine of the Water Institute of Southern Africa

Water & SanitationAfricaComplete water resource and wastewater management

The best way to promote sound water resources management principles is through working and sharing lessons with other

organisations. Phakamani Buthelezi, CEO of BGCMA P14


Sanitation

JulyJuly/August 2014 • ISSN 1990-8857 • Cover price R50.00 • Vol 9 No. 4

MEDIA

OPINIONManaging groundwater

through technology sharing

ODOUR CONTROLManaging plant odour

Promoting professional excellence in the water sector

IN THE HOT SEAT

THE HOT SEAT

THE HOT SEAT

Partnering change in Africa

WASTEWATERQuality and sustainability

in service delivery

RAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATER

Expert Opinion

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168

0-49

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• V

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6, N

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201

4

Promoting integrated resources management

The official journal of the Institute of Waste Management of Southern Africa

Institute ofWaste Managementof Southern Africa

Landfill Exposed geomembrane solar caps

Recycling Post-consumer PET

recycling

SustainabilitySolutions to emissions

reduction

Energy efficiencyTransforming waste

into power

is printed on 100% recycled paper

“Geotextiles offer a better alternative to conventional construction materials like sand and stone aggregate in landfills.” Cheri Scholtz of PETCO and Chris Els of Kaytech

Critical information on infrastructure development, maintenance and service delivery. Official magazine of the Institute of Municipal Engineering of Southern Africa (IMESA).

Stay current with new developments and technical information on the water and sanitation industry. Official magazine of the Water Institute of Southern Africa (WISA).

Comprehensive coverage on resource management, with a focus on waste management, cleaner production and waste to energy initiatives. Official magazine of the Institute of Waste Management of Southern Africa (IWMSA).

Join the INFRASTRUCTURENE.WS

community

RELATED MAGAZINES Hourly Follow the news or join the conversation: find and follow us on Facebook and Twitter.

Daily Visit the website for your daily infrastructure news: fresh stories are posted daily. You are in good company as this site receives more than 31 000 page views per month.

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Monthly, bi-monthly and quarterly Subscribe to the print or digital magazines for in-depth articles and expert analysis from industry experts and thought leaders.

STAY INFORMED

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[email protected]

www.infrastructurene.ws




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

Welcome to an IMIESA special edition…

NEWS ARTICLES TECHNICAL PAPERS COMPANY NEWS ORGANISATIONS MULITMEDIA EVENTS

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Ruralroads

Maintenance now

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

Trenchless technology

Getting the most out of innovations

Western Aqueduct

Durban’s largest pipeline

SARMA supplement

“We are reaching our ultimate milestone as the countdown to completion of our flagship plant, Aganang, builds” Pieter Fourie, chief executive, Sephaku CementMEDIA

The new


Water & SanitationAfricaComplete water resource and wastewater management

The best way to promote sound water resources management principles is through working and sharing lessons with other

organisations. Phakamani Buthelezi, CEO of BGCMA P14


Sanitation

JulyJuly/August 2014 • ISSN 1990-8857 • Cover price R50.00 • Vol 9 No. 4

MEDIA

OPINIONManaging groundwater

through technology sharing

ODOUR CONTROLManaging plant odour

Promoting professional excellence in the water sector

IN THE HOT SEAT

THE HOT SEAT

THE HOT SEAT

Partnering change in Africa

WASTEWATERQuality and sustainability

in service delivery

RAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATERRAND WATER

Expert Opinion

ISSN

168

0-49

02 R

50.0

0 (in

cl V

AT)

• V

ol 1

6, N

o 2,

May

201

4

Promoting integrated resources management

The official journal of the Institute of Waste Management of Southern Africa

Institute ofWaste Managementof Southern Africa

Landfill Exposed geomembrane solar caps

Recycling Post-consumer PET

recycling

SustainabilitySolutions to emissions

reduction

Energy efficiencyTransforming waste

into power

is printed on 100% recycled paper

“Geotextiles offer a better alternative to conventional construction materials like sand and stone aggregate in landfills.” Cheri Scholtz of PETCO and Chris Els of Kaytech

Critical information on infrastructure development, maintenance and service delivery. Official magazine of the Institute of Municipal Engineering of Southern Africa (IMESA).

Stay current with new developments and technical information on the water and sanitation industry. Official magazine of the Water Institute of Southern Africa (WISA).

Comprehensive coverage on resource management, with a focus on waste management, cleaner production and waste to energy initiatives. Official magazine of the Institute of Waste Management of Southern Africa (IWMSA).

Join the INFRASTRUCTURENE.WS

community

RELATED MAGAZINES Hourly Follow the news or join the conversation: find and follow us on Facebook and Twitter.

Daily Visit the website for your daily infrastructure news: fresh stories are posted daily. You are in good company as this site receives more than 31 000 page views per month.

Weekly Subscribe to the FREE weekly newsletter and enjoy news from the convenience of your own inbox.

Monthly, bi-monthly and quarterly Subscribe to the print or digital magazines for in-depth articles and expert analysis from industry experts and thought leaders.

STAY INFORMED

CONNECT NOWEditorial

Nicholas McDiarmid [email protected]

Advertising Jenny Miller

[email protected]

Subscriptions Trust Makina

[email protected]






CEMENT AND CONCRETE

RISING ON THE eastern perimeter

of the property on gently sloping

ground just above the Juksei

River, the wall forms a secure

boundary between what will become wooded

parkland and a new public road.

The project was a joint venture between

Echo Prestress, Encon and V-Con Civils

and the wall was built in two sections: one

540 m and 3.6 m high, the other 400 m

and 4.2 m high. This height variance is not

readily apparent to the naked eye, mainly

because there is no stepping and the wall

follows the natural slope of the land. To

facilitate this, ground-level panels were

cut trapezoidally, at the same angle as

the gradient.

The panels were secured between

H-section galvanised-steel columns, which

were bolted onto cast-in-situ concrete foun-

dations. The columns were spaced at 6 m

centres, which allowed for 25 mm installa-

tion tolerances on either side.

Echo Group marketing director Melinda

Esterhuizen says there are several advantag-

es to this type of walling – speed of construc-

tion and cost being major considerations.

“Eight to ten bays or 48 to 60 linear metres

were completed daily. A conventional mason-

ry wall would have taken two to three times

as long with no advantage gained in strength

or durability. In fact, because our panels

have a compressive strength of 50 MPa,

they are virtually indestructible.

Esterhuizen explains that the cost of build-

ing a security wall using prestressed hollow-

core slabs is considerably more economical

than an in situ wall offering the same prop-

erties. Moreover, precast walling requires

no shuttering or propping, on-site curing,

formwork or grouting.

The wall has added architectural features

such as gabion cladding on the inner-facing

steel columns, textured painting and the

attachment of electrical wiring on top of

the wall. The concrete slabs and steel

Echo security wall built at Waterfall EstateA huge security wall, just under one kilometre

long and up to 4.2 m high, has been built with

prestressed hollow-core panels manufactured by a

leading construction company. The wall is situated

at the 640 ha Waterfall Estate in Midrand,

currently under development.


ABOVE Electric security wiring was fastened to the steel supports

BELOW The northern end of the wall was built on a steeper gradient


Echo security wall built at Waterfall Estate

CEMENT AND CONCRETE

support columns are both 100% recyclable

and reusable. “The wall itself has a very

long lifespan, is maintenance free and,

ABOVE LEFT A section of the Waterfall Estate boundary wall showing the textured paint finish ABOVE RIGHT One of the foundation platforms on which H-section steel support columns were mounted RIGHT Cladding-steel support columns with gabions add aesthetic appeal

Case studies and thought leadership on new technologies, innovations and best practice in water management

Covering the major developments and application of water management in Southern Africa’s municipal sector and the mining industry.

WATER INFRASTRUCTURE MANAGEMENT

NEW EB

OOK

Major developments, application of water reuse and

management in Southern Africa’s municipal sector and mining industry.

Technology in engineering and water metering

Water in energy

Water in mining

Water in infrastructure

Water treatment

other than occasional cleaning, no other

maintenance is required. It can also be dis-

mantled and reused,” says Esterhuizen.

www.echofloors.co.za

CEMENT AND CONCRETE


Construction Vehicles

Johannesburg 011 316 4161 Durban 031 902 6443 East London 0861 901 901 Cape Town 021 948 4746 [email protected] www.tfm.co.za

TFM offers a market-leading range of specialised vehicle conversions, backed up with exceptional Aftersales Service on a National basis.

CEMENT PRODUCTION is respon-

sible for almost 10% of human

CO2 emissions, albeit one of the

most sustainable construction

materials. The École Polytechnique Fédérale

de Lausanne is leading the project, in

partnership with the Indian Institutes of

Technology and scholars from universities in

Cuba and Brazil. This new blend substitutes

up to half of the usual Portland cement used

to make concrete with highly abundant clay

and limestone, promising to reduce cement-

related CO2 emissions by up to 40%. Applied

globally, it could help bring down future

global CO2 emissions by several per cent.

The substitute challengeSubstituting a fraction of the Portland cement

used to make concrete is a well-established

way to cut emissions – understandably so,

considering that the production of each

tonne of cement releases up to 800 kg of

CO2. However, alternative materials that

allow the substitution of a large fraction of

cement have been hard to find. Industrial

waste products that are commonly used

today – such as slag from the steel industry

or fly ash from coal power plants – are not

available in large enough quantities to keep

up with demand.

Synergistic chemistryKaren Scrivener, the principle investigator

of the project, explains that the strength

of the combination of calcined clay and

ground limestone, which the researchers

call LC3 for limestone calcined clay clinker

cement, lies in its chemistry. When used

together, the aluminates from the calcined

clay interact with the calcium carbonates

from the limestone, leading to a less porous,

Reducing CO2 footprint through new blends

The Swiss Agency for Development and Cooperation has recently invested in the development and testing of a new blend of low-carbon cement. Nicholas McDiarmid reports on the potential of limestone calcined clay clinker cement.

CEMENT AND CONCRETE


KEY NUMBER school 4372 C

and therefore stronger, cement paste. In

the past, these materials have been used

individually to replace a small fraction of the

cement, but together they can replace up to

half without altering the performance of the

final product.

Limestone calcined clay clinker cementThanks to partnerships with industrial and

governmental partners, the researchers

hope to see LC3 become the new gold

standard of low-carbon cement, produced

by all major cement companies. Two indus-

trial scale pilot projects in India and Cuba

have already emphatically demonstrated the

robustness of their method and the ease

with which it can be integrated into existing

cement production lines. In the next phase

of the project, larger-scale production tests

are scheduled with industrial partners.

LC3 is designed to meet the needs of

both industry and users. It was developed

in close collaboration with industrial part-

ners and designed to integrate into existing

cement production lines. Clay and limestone

are available en masse in quarries around

the world and consumers will be able to use

it the same way they use ordinary Portland

cement today.

Time is of the essenceTime is of the essence, according to Karen

Scrivener, who heads EPFL’s Construction

Materials Laboratory. With global demand

for cement to double by 2050, driven by

growing demand in emerging economies

such as India, China, and Brazil, the need

for low-carbon cement is becoming more and

more pressing. The CHF4 million in funding

from the Swiss Agency for Development

and Cooperation will enable EPFL and its

partners to do the necessary research

and testing for the introduction and stand-

ardisation of LC3, so that it makes it to

the market as quickly as possible. “If we

want to have a real impact on the sustain-

ability of concrete – its cost, availability, and

environmental footprint – we have to act

before demand explodes in the emerging

and developing world.”

The primary raw material for cement clinker manufacture is limestone, which provides the kiln feed with kaolinite calcium carbonate


CEMENT AND CONCRETE

PUSHED BY ENVIRONMENTAL

issues and rising customer

demands in terms of quality and

new functionalities, the market

is imposing new challenges on cement

producers, demanding the development and

increasing use of more sustainable materi-

als. Cement producers therefore have to

know and examine the exact composition of

each of the raw materials more deeply, as

well as their effects, not only on the final

product, but also on the production process.

Modern X-ray diffraction (XRD), combined

XRD AND XRF:

Aiding the enhancement of cementitious materials

with X-ray fluorescence (XRF), is a powerful

tool for determining the elemental com-

position and the mineralogy of the materi-

als used in the production of traditional

Portland cement, as well as potential new

cementitious materials.

XRF provides detailed information for pro-

portioning raw materials and controlling the

main variables in the production process.

It also plays a significant role in the envi-

ronmental control of waste recovery, raw

materials, alternative fuels, analysis of trace

elements and chemical characterisation

of liquids such as additives and slurries.

XRD enables us to obtain a complete and

accurate identification and quantification of

the crystalline components of the material,

providing detailed mineralogical information

about them. This is very useful because the

performance of cement-based products is

determined more by its mineralogy than by its

elemental composition. As a result of better

knowledge about the science and engineer-

ing of materials, which is provided by tools

such as XRF and XRD, cement plant process

teams, supported by R&D departments, can

monitor, control and, in some ways, predict

the main parameters regarding the grindabil-

ity of raw materials and clinker, the burnability

of raw feed, the grindability of clinker and sup-

plementary cementitious materials, cement

setting times, strength development and the

final performance of cement-based products.

More sustainable cementOne of the main options for producing

cement with a smaller environmental impact

is, without a doubt, using less clinker in the

final product. In order to be able to do this, a

more detailed analysis of the materials and

processes has to be carried out to ensure

not only adequate amounts in the final for-

mulations, but also its performance in the

final application.

Less clinkerThe use of more reactive clinker: using

less clinker in cement requires the cement

producer to guarantee to the customer that

Within the cement industry, chemical and mineralogical control is one of the principal means of guaranteeing the quality of the final product and its optimum performance in the final application. By Juan Guillermo Morales, Claudia Rodriguez, Carolina Giraldo and Ruby Estela Cardona, Research and Development Department, Cementos Argos S.A.

PART 1

The cement production process


CEMENT AND CONCRETE

the product will have the same performance

when it is used in the final product. To

achieve this, R&D teams face the challenge

of increasing the reactivity of clinker. One

of the ways to do this is to identify the dif-

ferent polymorphous characteristics of the

C3S (tri-calcium silicates) and define the

best conditions to reach the most reactive

form. Without the use of technological tools

such as XRD and XRF, this analysis would be

almost impossible.

The use of more limestone: as a result of

more reactive cement, the use of limestone

as a mineral admixture is increasing in

many countries in order to obtain a more

environmentally friendly material. However,

it is known that limestone is more than just

a filler. Limestone, depending on its crystal-

line form, can react in different ways in the

cement hydration process, resulting in the

formation of products that have different

effects on the performance of cement.

These effects must be measured and XRD

tools allow us to identify the different com-

pounds that stem from the use of limestone

in cement hydration products.

The par tial replacement of clinker/

cement: supplementary cementitious mate-

rials (SCM), such as slags, fly ash and

pozzolans, are the main materials used to

replace clinker in cement production or to

replace cement in concrete production. For

many years now, these materials have been

used in the cement and concrete industry.

However, even though there have been

many studies seeking to understand their

reaction mechanisms and effects on the

final product, it is still not completely clear

how they work or what the main phenom-

ena are that determine their reactions with

Portland cement.

In addition, new technologies, such as

chemical activation, have been studied over

the last few decades in order to produce

new types of cement and/or to increase the

use of these materials in the cement indus-

try. Technical analyses like XRF and XRD are

tools that are fundamental to understanding

the main reactions and products of SCMs in

cement. Determining chemical species and

minor elements, such as alkalis, along with

their chemical structure, crystallography

and, at the same time, their reactive phase

(glassy, amorphous) is extremely important

in understanding the role of each species

and how they work during the hydration pro-

cess, in more detail. Finally, in the product,

after application, it is still very important

to identify the main compounds that these

materials formed or helped to form and

how these new products influence, either

positively or negatively, the performance of

the final application.

Part 2 will appear in the September 2014

edition of IMIESA.

Modern X-ray technologies can be a powerful tool in cement production

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6859 - EMA 2014 VISPROM IMIESA A4 AD Paths.indd 1 2014/06/19 12:18 PM

CEMENT AND CONCRETE

NEW TECHNIQUES, as well as

advances in cement technology

and admixtures, have allowed

readymix producers to tailor their

offerings more precisely, to produce afar

wider range of product choices than ever

before. This means that the types of con-

crete produced today are suitable for a

greater variety of uses and can be tailored

to suit exact project requirements.

Johan van Wyk, general man-

ager of the Southern Africa

Readymix Association (Sarma),

says that designers, builders

and specifiers need to be more

keenly aware of the types of

readymix that can be ordered

and encourages them work

more closely with readymix pro-

ducers in future. He adds that

Sarma’s Readymix Conference

is the definitive place to share ideas and

find out more about the characteristics of

modern-day readymix.

Global best practice“The conference is being held at Misty Hills

Conference Centre on the West Rand, on 13

and 14 August 2014, and will showcase the

ability of the readymix concrete industry. It

is the perfect opportunity for all disciplines

to see what is available and share ideas

with our industry’s professionals.

“Speakers will include international guests

with vast experience in the use of readymix.

They will also shed light on best practices

from all corners of the globe and provide

insight into alternative methods that can be

employed locally,” says Van Wyk.

“We will also be showcasing tilt-up con-

struction techniques with an actual demon-

stration of its ease of construction and sim-

plicity. Tilt-up construction has already been

widely mooted as a viable alternative to

speed up the provision of housing develop-

ments and is a cost-effective and fast meth-

od of constructing public sector buildings.”

Sustaining an industry“Readymix producers and suppliers to the

industry will also be able to shed light on

new products that are suitable for anything

fromroads, skyscrapers and dam walls to

lightweight chemical-resistant or ultra-dense

concrete for any other type of use. These

and many other products give profession-

als in the industry a number of choices

when it comes to concrete, and shows why

readymix is probably the most versatile

building material on earth today,” says

Van Wyk.

He adds that in addition to physical char-

acteristics of readymix concrete, it is also

good for sustainable developments, due to

its excellent thermal properties and local

availability of raw materials. Socially, it

empowers communities who are employed

full-time on-site and as a result is more

socially acceptable than site-mix.

Significantly, the confer-

ence is also taking place

in Women’s Month, which

also serves to highlight

the increasingly important

role that women are play-

ing in the manufacture and

specification of readymix

concrete throughout

the country.

“To further highlight the

role being played, the conference will fea-

ture a speaker on women in concrete, who

will give her views of the industry and add

spice to the already impressive panel of

high-profile speakers.”

Tools of the tradeDuring the conference, delegates will also

have the opportunity to view static and

working exhibits of the latest machines and

equipment available to manufacture, as well

as deliver concrete to sites. Admixtures that

enhance the characteristics of concrete will

also be shown.

“Sarma’s Readymix Conference is the definitive place to share ideas and find out more about the characteristics of modern-day readymix.” Johan van Wyk

Building professionals are being urged to harness the amazing characteristics of modern-day readymix concrete to build better structures and speedup the delivery of critical infrastructure throughout Southern Africa.

Readymix to aid delivery


CEMENT AND CONCRETE

ONE OF THE CMA’S technical con-

sultants, civil engineer and inde-

pendent paving consultant, John

Cairns, says that many of the

engineers and landscape architects who

design paved roads are not aware of the

most important specification criteria when

using CBP.

Tensile strength and abrasion“I participate in regular paving seminars and

workshops and am amazed at how many

professionals don’t know that the new CBP

standard, SANS 1058:2012, is based on

tensile strength and abrasion resistance

rather than the old standard of compression

resistance. Some are not even aware that

the standard has changed. Therefore it is

hardly surprising that so many professionals

are still specifying for CBP projects based on

compression strength,” says Cairns.

“In most instances, pavers fail either

by cracking and then splitting,or through

surface abrasion due to factors such as

particle distribution and binder percentages,

and these properties are addressed in

SANS 1058:2012. The old standard, SANS

1058:2006, was based solely on a single

compression test which measures resist-

ance to crushing.

“Paving blocks never crush under load,

which is why the compression test is not a

good performance indicator. In fact,pavers

can have a very high compressive strength

but poor abrasion resistance. This is why the

standard was changed.

Failed installations“This lack of awareness is resulting in failed

CBP installations and unnecessary remedial

expense. For instance,I was recently asked

to submit a report on a new car park paved

with CBP at an East London shopping mall.

Serious abrasion had taken place even

though the paved surface was barely six

months old. The reason for this was that the

pavers were simply specified on the basis

of compressive strength rather than the

SABS standard.”

Cairns says that most paving failures occur

in shopping centres, office parks and hous-

ing developments, where paved surfaces

tend to be regarded as simple, not requiring

an engineering design.

“By contrast, industrial CBP sur facing

is generally designed correctly, especially

where the paving provides a critical func-

tional element such as the working surface

of a container yard or steel mill.”

Construction loadingCairns adds that CBP roads can also fail when

they are not designed for construction loading.

The cost of poor specificationThe Concrete Manufacturers Association (CMA) warns that millions are being wasted on concrete block paving (CBP) roads, which fail due to poor specification. In many instances, paving is simply specified as being 25 MPa without any reference to the SABS mark.

ABOVE These pavers are not appropriate for heavy construction traffic

LEFT Pavers at an intersection in Randfontein have worn badly due to poor abrasion resistance


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GIBB 297x105.indd 1 2014/07/02 2:30 PM

CEMENT AND CONCRETE

“This often occurs on housing estates where roads are

designed to handle light traffic only. What normally happens is

that the roads are built before other construction takes place.

This means that they must then handle the heavy-duty trucks

and other construction equipment while the estate is being built

and this obviously causes damage. Further damage is caused by

the spillage of sand and stone, especially at traffic circles where

much braking and turning takes place.

It pays to wait“One way around this problem is to build road bases to handle

the construction and early resident traffic and only pave them

once the estate is close to completion. Not only will this save

the pavers from unnecessary wear but it will also ensure that the

road base has been constructed properly.

“However, in instances where it is deemed necessary to install

complete roads before the construction of the estate commenc-

es, they should be built with a paver that can handle heavy-duty

traffic. Once built, the contractor should ensure that the roads

are kept free of sand and stone. Then, if damage occurs, respon-

sibility for the repairs will fall to the contractor.”

CMA director Wally Armstrong notes that most CMA producer

members hold the SABS mark. This means they do regular batch

testing and manufacture with a recognised quality assurance

system in place.

Holding the mark“Some of our members and other CBP producers comply with the

standard but don’t actually hold the mark, which is also accept-

able. However, holding the mark is obviously first prize, especially

if there are comebacks due to poor specification.

“Most South African paving producers manufacture pavers with

two layers. The bottom and thicker layer provides the required

strength and the top layer can be coloured with pigments for

enhanced aesthetic appeal. Now that the new standard measures

abrasion resistance, this topping layer is also being designed with

excellent surface-wear properties. Even lower-grade blocks with

a good topping layer can offer high abrasion resistance, proving

that the topping layers do more than offer colour variation,” con-

cludes Armstrong.


HAVING HAD a

positive 12 months,

Nicholas McDiarmid

speaks to Quintin

Booysen, sales and marketing

manager, to learn more about

how a company thrives in a

challenging market.

How is the market far-ing? QB There is no doubt it

is a challenging market, but it

has been excellent 12 months

for PMSA. There are a number

of factors behind this success,

including our ability to strategi-

cally manage our highly varied

lead times on our plants, which

can range from one month to

six months. With good planning,

we have kept our order book

very stable. Our manufacture of

large machines is actually at al-

most full capacity right now and

we have enough on our books

for the next 12 months.

Where is demand originating from? Geographically speaking, we

have remained consistent

CEMENT AND CONCRETE

PMSA thriving in a challenging market

Pan Mixers Southern Africa has been supplying the cement and concrete market in Southern Africa for almost 40 years and is Africa’s largest manufacturer of concrete, block and paving machinery. It also supplies leading international brands of concrete pumps, mixers, batching plants and production pallets.

in the Gauteng region; the

Western Cape has also been

very good us – all this despite

the fact that some companies

in the brick-making business

are actually going under.

Companies using PMSA equip-

ment are most certainly thriving

and we pride ourselves on of-

fering top-class machines with

top-class support. Perhaps this

contributes to their endurance.

So the market isn’t contracting? Our clients

are running 24 hours a day in

the Cape. It appears to me that

they are capturing the gaps in

the market that have been left

by the struggling players. So

the reason for some companies

struggling must be fairly com-

plex: if their demise has simply

transferred demand, this would

suggest demand has not been

the only problem. Companies

using older technologies may

well be unable to compete

cost-wise with companies that

do make smart capex invest-

ments. Their productivity may

not be what it needs to be. Of

course, procurement of raw

materials is an issue and some

companies definitely have an

advantage ove others.

The Eastern Cape has also

been good for us. We have

just finished setting up our

largest brick-manufacturing

plant, the RE 1400. This is

the newest plant in our range

– it was developed in 2007

and since then we have been

setting them up. This is the

largest brick-making plant in

Africa, competing directly with

European imports. It is much

larger than any of our local

competitor machines, and also

allows us to compete with

European competitors.

How have environ-mental considerations impacted the industry? Carbon is linked to energy;

energy is linked to cost. It is

the prerogative of every client

of ours to bring down costs.

In a market like ours, bringing

down energy costs is crucial

to remaining competitive.

This has to be tackled in two

ways: efficient equipment and

best practice.

PMSA launched a series of

monthly seminars that have

been helping our customers

with cutting-edge techniques

with regard to issues like mois-

ture control and the maximisa-

tion of cement usage.

You seem to be very focused on technol-ogy, even beyond the machinery. Why is this? This year has been our technol-

ogy year, which is why we have

been bringing our suppliers to

provide seminars to the South

African industry. We have had

Manfred Ludwig from Frans

Ludwig moisture control; we

have had ABECE from Sweden,

who supplies roof-tiling ma-

chinery; we have had in-house

seminars for our Fiori, our

self-loading concrete mixers.

Technology is not always easy

to impart – it can require some

education. In terms of being as

competitive, efficient and eco-

nomical as possible, we have

seen how this type of education


CEMENT AND CONCRETE

has given our clients an edge in

the market.

Who attends these seminars? These are open

to anyone in the industry: from

leading concrete and precast

manufacturers to existing users

of our equipment. We invite

anyone in the industry with an

interest in better production to

attend, regardless of whether

they are a client of ours or

not. We have had a very broad

audience and the seminars

have been very well received.

We have between 20 and 40

participants per seminar and

sometimes we hold them over

two days, keeping the groups

small to ensure the seminars

are interactive and effec-

tive. We have had custom-

ers who have learnt some

game-changing practices for

their production.

Can you give an exam-ple of this? I mentioned

moisture control earlier. With

accurate moisture measure-

ment you get a better aggregate

to cement (A/C) ratio, leading

to more consistency and a bet-

ter quality product overall.

Before you can make a brick,

you need to know how much

moisture is in the sand. You

can control your mixes better

by having the measurements

and adjusting your ratio calcula-

tions. When it comes to mixing,

you then measure the moisture

in the drum and get perfect

water to cement ratios and per-

fect A/C ratios.

This practice leads to quality

and cost savings. Everyone is

concerned about saving the envi-

ronment and saving on costs at

the same time – the less energy

that goes into making product,

the better. Through moisture

control and moisture measure-

ment, we are able to gain more

consistent control over the mix,

and give the operator the ability

to use less cement by having a

consistent mix throughout the

time of production, regardless

of conditions.

Manfred Ludwig from Frans

Ludwig Moisture Control pre-

sented this workshop and

brought with him the latest

knowledge from Europe, giving

South Africans the ability to be

aligned with current internation-

al best practice. Combine this

knowledge with top equipment

and you have a recipe for stay-

ing competitive.

Has this expanded PMSA’s customer base? We have found that custom-

ers who had been considering

expanding their operations are

now choosing PMSA equipment,

due to what they have learnt at

our seminars. An acquisition of

one of our RE 1400s by a cus-

tomer in the Western Cape was

a direct result of our seminars.

We have two of these machines

going into the Western Cape, in-

cluding one to a customer who

has been using our competi-

tor’s equipment for the last 25

years. What interests people is

the level of backup and support

we with which we provide them.

How do you deliver this? Our teams are constantly on

the road, travelling throughout

the country and Namibia all

the time. Our investment in

technology-based solutions,

like brand-new laser-cutting

machinery, brand-new systems

and processes for our opera-

tions and business mean that

we are in better control of our

business, and can ultimately

charge a lower price. On the

technology side, we have

in-house electronics experts,

programmers, electrical con-

tractors and computer numeric

control operators.

What guides PMSA’s strategic decisions? You

need to be geared for market

conditions in the long term

and you need to be out there

in the market in an active

way. Our managing director’s

philosophy has been to invest

during the market downturn.

We took our ‘pre-crisis profits’

and ploughed them back into

the business. We invested

in the latest machinery and

technology and have spent the

last six years investing back

into our business, through

laser-cutting technologies,

and adding approximately

7 000 m2 of undercover area

to the business plus 4 000 m2

of open area. So where others

have been contracting, we

have been investing, because

when it does turn, we are

geared to provide better pricing

and services.

We anticipated the downturn

and, as a result, this year has

“Companies using older technologies may well be unable to compete cost-wise with companies that do make smart CAPEX investments.” Quintin Booysen,

sales and marketing manager, PMSA

®HOLLOW-CORE CONCRETE FLOORING


been a good year. We have

captured more customers and

shown them where to invest.

Companies that contract lose

trust. Customers purchasing

large machines are thinking

long term – 10 to 20 years

– and they know we are here

to stay and that we have long-

term faith in the industry.

As an importer from Europe, has that market influenced PMSA’s approach? We were in

Italy recently and visited one

of our suppliers to see how

CEMENT AND CONCRETE

“Our managing director’s philosophy has been to invest during the market downturn. We took our ‘pre-crisis profits’ and ploughed them back into the business.”

they have survived their tough

circumstances. The Italian

industry contracted by more

than 90% and their survival

demanded the implementation

of lean manufacturing

techniques, investing in the

business, looking at new

markets and gaining market

share from competitors.

We have definitely

streamlined our business

by cutting the non-critical

elements and strengthening

the critical ones. So where

customisation may have

been a dominant function,

now we focus on the 20

best designs and replicate

those strengths. This means

producing better plants more

efficiently and at lower costs,

without trying to capitalise on

perceived add-ons.

This has meant we can

produce better products

overall at a better economy of

scale. We have also sought

to simplify our business,

operational and manufacturing

processes and now we provide

better products across our

client-base with the support

and technology to back it up.

What about markets to our north? The backbone of

our business is hardware, and

we are now looking to expand

this into Africa. We believe

that finding suitable partners,

both in manufacturing and

distribution, is key. There

are much bigger knowledge

gaps in Africa as well, and we

have an opportunity to plug

these. Teaching people to

make higher quality concrete

will bring down cement

consumption and lower costs.

We see the need for training

and technology in Africa as the

key driver of our business. In

some regions, like Namibia, we

already dominate the market,

and we are identifying other

territories where we believe we

can add real value.

®HOLLOW-CORE CONCRETE FLOORING


CLOSER INVESTIGATION, however,

often reveals a different picture

in which blind trust was placed in

third-party suppliers whose prod-

ucts were incorrectly classified and did not

perform as they should have. Once delivered

on-site and accepted by the responsible

person, the rest of the crew would have no

reason to believe that a problem existed

and would continue unaware that a serious

breach had taken place.

According to Nico Pienaar, director of two

central industry associations responsible for

supplying concrete to construction sites, the

Aggregate and Sand Producers Association

(Aspasa) and the Southern Africa Readymix

Association (Sarma), such failures are most-

ly as a result of the “missing critical link”

between regulated and unregulated products

or scrupulous or unscrupulous suppliers.

Digging for answers“We refer to this as the missing link, in

which the construction firm is unwittingly

responsible for the failure. Even though in

their opinion they dotted every i and crossed

every t, they missed a step that led to the

eventual failure of a structure. In order to

prevent this, you need to look at the overall

integrity of the concrete that will be used to

build a structure.

“You have to ask yourself if the integrity is

in any way compromised or if you are unsure

at any point along the way. For example, is

the cement really from a trusted local sup-

plier that has met every requirement of our

cement regulations for quality? Is the sand

and aggregate being used by the supplier

traceable to a credible supplier (and source);

is its composition adequate and sized cor-

rectly? Is the chemical composition of admix-

tures, extenders and other components of

the concrete correct and are they being used

correctly? Is the readymix supplier a member

of Sarma with Sarma accreditation?

“Only once this has been established

should ordering commence, but this is by

no means a guarantee that the concrete

won’t fail. The next step is equally critical

and relies on procedurally correct sam-

pling and testing to be conducted to see

if it will indeed perform as expected,”

explains Pienaar.

Remedy at handHe says controls and systems are simple

to implement to ensure that a high level of

certainty can be built into concrete struc-

tures. It begins with procuring materials

from reputable suppliers that are audited

and accredited by their own industry organi-

sations, such as Aspasa and Sarma. Next,

materials should be correctly batched by

well-trained staff that know the exact speci-

fication and intended usage of the concrete

being prepared.

“Insist on quality cement products from

local suppliers and where possible steer

away from cheap imported cement and

cheap inferior extenders. Concrete is a very

sensitive product because it is made out of

aggregate, sand-cement, water and extend-

ers, and if the ratios and timing are not right,

it is – simply put – wrong.”

“If we are to build strong foundations for

the next generation to build upon, we need

to leave a legacy of quality construction

and infrastructure, as well as sustainable

development and the creation of jobs in the

local industry.

Sustainable development“By supporting local cement manufacturers

and suppliers of aggregate and readymix

that are accredited and from areas near the

construction site, we are guaranteeing qual-

ity and directly contributing to a sustainable

environment and the creation of jobs near

the construction area,” Pienaar adds.

He concludes that management and lead-

ers of construction firms are ultimately

responsible for the quality of work carried

out by their firmand therefore need to

ensure that all critical links are checked and

addressed to eliminate problems happening

in future.

Nico Pienaar, director of Aspasa

Experts are sometimes left perplexed in instances where a well-built concrete structure fails despite all evidence indicating that the correct materials and procedures were used in its construction.

Missing the critical link

CEMENT AND CONCRETE


CEMENT AND CONCRETE

WHETHER THE ROADS that are

eventually built are manufac-

tured from concrete or asphalt

will be irrelevant and should

not be of any consequence to national, pro-

vincial or local government. That is as long as

they meet existing and future requirements

and are durable enough to last for decades

with minimal maintenance requirements.

According to Johan van Wyk, general

manager of the Southern Africa Readymix

Association (Sarma), government

It don’t matter if they’re black or whiteSouth Africa has great need for durable paved roads that will allow communities in all regions to have equal access to services while allowing them to uplift other aspects of their lives. By Raymond Campling

decision-makers should concentrate on leav-

ing a quality road infrastructure legacy and

should entrust technical aspects to road

experts that will choose the right solutions

depending on traffic types and volumes,

as well as climate, underlying geology and

other factors that influence the eventual

durability of a road.

Delivery at all costs“With such a big backlog, it is more impor-

tant at this point in time to concentrate on

building quality, durable roads that won’t

need maintenance for years to come, rather

than limiting decisions based on cost or

personal preferences.

“Those responsible for constructing roads

have for many years argued and debated

whether blacktops (asphalt or tar) or white

(concrete) roads are more suited to South

Africa’s requirements. Decisions have often

been made on cost alone and this has per-

haps impeded the quality of roads delivered

and has impacted the pace at which delivery

is being driven,” says Van Wyk.

He continues that each has its own unique

strengths and weaknesses and both types

should form part of the arsenal used for any

road network in the country.

Lifetime costsConcrete roads provide a stronger sur face

for very heavy loads and are particularly

Roads:


CEMENT AND CONCRETE

good on up or downhill

stretches and steeply

inclined intersections.

They provide a long-last-

ing solution, but are gen-

erally more expensive

than blacktop surfaces.

Consequently, concrete

roads are mostly over-

looked by decision-

makers in the mistak-

en belief that cheaper

is better.

In many instances

residents need look no

further than their own

town’s road network to

see the shortcomings of

certain surfacing meth-

ods. In many areas,

trucks have caused

severe indentations and

rutting that is particu-

larly visible at intersec-

tions and traffic lights. This is as a result

of the forces generated when heavy vehi-

cles stop or accelerate and cause the

surface to surge and buckle under the

repeated stresses.

“This type of damage calls for continu-

ous maintenance and as a result it diverts

budget and manpower away from the more

important requirement to build new roads.

Similarly, it may be wasteful to use the

more expensive concrete construction

where there are vast open stretches of road

with only slight gradients and low incidents

of heavy loads.

Best of both“As a result, Sarma wants to encourage

those responsible for delivering our roads

to make use of solutions that are both cost-

effective and provide durable, long-lasting

surfaces. This requires concrete to be used

where it is most suited and asphalt where

it is best. Hybrid roads using both methods

may also be used to harness the best quali-

ties of each surface type.

“We can even draw from past examples

that exist in KwaZulu-Natal, where some

freeways were constructed with concrete

truck lanes and asphalt car lanes. This led

to the freeways requiring less repairs than

usual and allowed road crews to rather

focus their attention elsewhere.

“Many other successful examples exist

here and abroad and this leads us to

believe that the road industry should not

be divided between concrete and asphalt,

but should rather stand together in building

more quality roads – rather than arguing

over merits of the different types. All have

their merits and should be incorporated into

road designs right from the very beginning,”

Van Wyk explains.

Use it, don’t lose itWhile preferences and prices favour dif-

ferent techniques at different times, it is

important to always use the right material

for the job at hand. By simply favouring one

technique over the other, as a result of price

alone, the industry stands a real chance

of losing the skills required to construct

the other.

“It is important to remember that politi-

cians have a shelf life. If all they do is

build the cheapest roads for short-term

point-scoring then the very communities

that they serve will lose out in the long

run. Rather, we want to encourage our

politicians to leave a legacy that enables

the next administration to have funds and

manpower available to build upon the previ-

ous dispensation’s legacy.

“They should do it right the first time,

rather than having to repeatedly find funds

to do retroactive repair work. By using

concrete where concrete works best and

asphalt where asphalt works best, we can

build world-class roads and become known

as road builders, rather

than pothole repairers.”

Advantages of concreteWhile most roads in

South Africa are con-

structed with asphalt, it

is important to highlight

some of the advantages

of using concrete roads

as well. Overall, concrete

has a very low life cycle

cost and lower carbon

footprint than asphalt.

Materials are produced

locally and can be pro-

fessionally mixed by any

Sarma-accredited mem-

ber, with plants conveni-

ently situated throughout

the country to reduce

transport costs.

Concrete roads also

generally offer reduced friction, which

results in vehicles achieving better fuel con-

sumption and reducing tyre wear.

Surfaces are also cooler because the

lighter colour reduces warming effects on

the environment. Concrete roads are more

labour intensive and also support local

readymix outlets, as well as quarries and

aggregate suppliers.

“All in all, we believe that concrete roads

have a role to play in building our nation

and we therefore encourage all sectors of

the road building industry to work together

to deliver world-class roads,” concludes

Van Wyk.

While preferences and prices favour different techniques at different times, it is important to always use the right material


THE CLIENT, Cape Nature, was look-

ing for a permanent yet flexible solu-

tion for jeep tracks on deep sandy

substrates at Geelkrans Nature

Reserve, Stillbaai. It was vital to devise a

solution without the associated footprint

impacts of commonly used hard structures

such as asphalt or paving.

Mobicast, Terraforce licensee in the Garden

Route area, suggested the Terracrete paving

block – a permeable and interlocking eco-

surface paver that can be laid in different

patterns and may be used with or without

ground anchors for the lining of riverbanks,

roads and other areas subject to soil erosion.

Finding a versatile solutionThe blocks have been installed to form a

two-wheel jeep track as an erosion con-

trol and maintenance measure for existing

sand tracks.

Jean du Plessis, conservation manager

at Geelkrans Cluster and Stilbaai Marine

Protected Area, says, “We have a network of

maintenance jeep tracks that give us access

to the different sections of the reserve. The

substrate is mostly deep dune sand, making

it inadequate to surface with normal paving.

Putting down a road-base foundation or com-

pacting have been proven to be very costly

due to the nature of the substrate.

“Investigating alternative solutions pro-

duced the principle of putting down a ‘hard’

surface that is permeable for water and veg-

etation. The idea is also that the surfacing

material should then be able to move with

the substrate while keeping its shape and

integrity. We decided to use the Terracrete

blocks because of their permeable nature,

minimal impact on the environment and

cost-effectiveness.”

Low impact, low costThe blocks are relatively easy to work with

compared to other methods that involve

more sophisticated machinery and labour.

“About 2% of the blocks break during han-

dling, as the transport of the blocks to the

target areas requires a minimum of two load-

ing/offloading processes due to the nature

of the terrain, but on the whole the process

was straightforward, causing very little distur-

bance in the reserve, which is what we were

looking for. Another benefit is that the blocks,

if they do break, are easy to replace, making

maintenance of the tracks quick and easy,”

explains Du Plessis.

Construction commenced in March 2013

and is still ongoing. The tracks are installed

in stages of 250 m each, with 7 000 blocks

already laid down. To rehabilitate any desta-

bilisation that may have occurred during con-

struction, Carpobrotus edulis (Sour Fig) were

planted on the verges of the jeep track.

t +27 (0)21 465 1907

www.terraforce.co.za

New access tracks for Geelkrans Nature Reserve

Paving blocks have provided a flexible and environmentally friendly solution to sand tracks at the Geelkrans Nature Reserve.

THE INSTALLATION PROCESS SIMPLIFIED:• Blocks are transported to the

target area• The substrate is prepared by removing

10 cm to 15 cm and then levelled • Blocks are packed in the desired pattern• Binding wire threaded through holes in

the blocks to increase overall stability• After placement and threading,

substrate material is used to fill any gaps

ROADS: ADVERTORIAL


ROADS

THIS INTERNATIONALLY accepted

concept was first used in South

Africa by National Asphalt during

the successful completion of a

number of warm-mix trials for the eThek-

wini Municipality in Durban in 2009 and

2010. Krishna Naidoo, from the eThekwini

Road Rehabilitation Department, together

with Tony Lewis of Tony Lewis Consulting,

added invaluable input and assistance,

and ensured the successful completion of

these trials.

While focusing on the warm-mix technol-

ogy, the opportunity was used to intro-

duce up to 60% RA into a number of the

trial mixes.

The history of RAIn 2011, the National Asphalt plant at

Cliffdale, Durban, was upgraded using a

‘twin drum’ concept to accommodate the

introduction of 40% RA into the mix. Later,

together with eThekwini Municipality, a num-

ber of projects and trials were completed in

the region that also entailed the use of a

Reclaimed asphalt pavingThe benefits of introducing reclaimed asphalt (RA) into a road mix are numerous. Foremost among these is the ability to recycle an existing pavement layer that has a mix with inherently good aggregate and a certain percentage of bitumen that can be recovered. This ensures the sustainability of natural resources by reducing the volume of virgin aggregate required.

National Asphalt RA plant

ROADS


SETTTNG NEW TRENDS...

DURBANTee: (+27) 31 736 2146

Ceee: (+27) 82 3333 511/4 Fax: (+27) 031 736 1938

Lot AE 6616Ceiffdaee

PRETORRATee: (+27) 12 562 9500Fax: (+27) 12 562 960047 Graf Street, Bon AccordFor GPS: 1 Rosemary StreetBon Accord

CENTURRONTee: (+27) 86 146 6656 Fax: (+27) 86 549 3140

Buieding No 1 Highgrove Office park, 50 Tegee Avenue, Highveed, Centurion, 0169

[email protected] / www.nationaeasphaet..co.za

warm-mix technology. Further orders were

placed with Comar, a locally based asphalt

plant manufacturer in Pinetown, for the sup-

ply of three 120 to 150 tonne-per-hour twin

drum mobile asphalt plants.

In 2013, National Asphalt successfully

supplied the asphalt mix for the road

upgrade between the Vaal River and

Kroondal Plaza for SANRAL, using 40% RA

in the base mix and overlaying the base with

an ultra-thin friction course (UTFC).

First contractsNational Asphalt secured four more con-

tracts, three for SANRAL and one for the

Department of Transport in KZN using its

RA technology. The first project involves

maintenance of 57 km of the N2 from New

Guelderland to the Mtunzini Toll Plaza using

60 000 tonnes of an AP1-modified continu-

ously graded course bitumen treated base

with a 40% RA component, together with

63 000 tonnes of ULM, a proprietary UTFC

product manufactured under licence from

Jean Lefebvre.

The second contract is the supply of

asphalt mix for the rehabilitation of the

N2 between Murchison and Marburg out-

side Port Shepstone. This project involves

72 000 tonnes of an AP1-modified continu-

ously graded bitumen treated base, with a

40% RA component, together with 12 000

tonnes of ULM.

Introducing EME technologyNational Asphalt was also part of the first

officially recognised South African trials

using a high-modulus asphalt (HiMA) on a

section of the South Coast Road in KZN that

services the container terminal of Durban

Harbour in the Jacobs area. To avoid con-

flict of terminology, HiMA refers to a ‘highly

modified mix’, and reference is made to

EME-2 where harder penetration grade bitu-

men is used.

“In 2006, SABITA embarked on a technol-

ogy transfer exercise whereby the EME tech-

nology could be introduced to South Africa

as HiMA,” says Sean Pretorius, National

Asphalt’s managing director.

There are two grades of EME in French

specifications – EME Class 1 and EME

Class 2, with the Class 2 material hav-

ing significantly higher binder content, as

defined by a richness modulus, K.

National Asphalt’s third RA supply com-

bines both the EME and the RA technolo-

gies. The contract calls for 74 000 tonnes

of an EME Class 2 mix with 20% RA

for a SANRAL project on the N2 from

Paradise Valley to Candella Road, between

Pinetown and Durban. The binder used is a

10/20 penetration grade bitumen, which is

There are two grades of EME in French specifications – EME Class 1 and EME Class 2, with the Class 2 material having significantly higher binder content

INSIGHT


“We are proud to have successfully balanced environmental and heritage

sensitivities with strict technicalrequirements.”

TRANSPORT

Neil SlingersManager for Roads and Highways Western Cape

Upgrade of MR172 between Pniel and Johannesdal

Tel: +27 (011) 369-0600 Email: [email protected] Web: www.smec.com

National Asphalt’s 40% asphalt plant

imported in drums and stored in National

Asphalt’s two drum decanting units cur-

rently situated at the company’s plant.

Warm-mix technologyIn a first for the department, the fourth pro-

ject involves the use of National Asphalt’s

warm-mix technology together with a 25%

RA component. The supply is for the upgrad-

ing of the P255 Inanda Road outside

Hillcrest using National Asphalt’s foam-

ing technology for the manufacture of the

warm mix.

National Asphalt’s dual-purpose, environ-

mentally friendly additive, EcoNat, is manu-

factured from renewable raw materials and

can be used in the manufacture of warm,

low-temperature and cold asphalt mixes

and, as a powerful asphaltene dispersant,

it is used in the manufacture of RA mixes

where it rejuvenates the properties of age-

hardened bitumen.

ROADS


SANRAL ROADS

IN RECOGNITION OF the importance of

development, SANRAL has developed

a community development philosophy

and implementation model to bridge

the gap between the first and second econo-

mies of South Africa.

Positive developmentEmphasis is placed on the positive social,

economic and political change in a commu-

nity. Positive development requires skills,

institutions, local knowledge and experience

and this extends to the creation of wealth

through a consultative practice and should

not only address infrastructure provision,

but also social and economic development.

Community development is about devel-

oping the power, skills, knowledge and

experience of people as individuals and in

groups. It enables them to undertake their

own initiatives to combat social, economic,

political and environmental problems, and

to participate fully in a truly democratic

process. Interactive learning programmes

should address both concrete and abstract

human needs to create human develop-

ment, self-sufficiency and dignity.

Participation does not only mean physi-

cal labour, but includes being apart of the

decision-making process during and after

community assessment. SANRAL believes

that communities should receive a lifelong

benefit to enable a better life, whether it be

a safe road surface on a busy highway or a

bridge in a remote community to give access

to schools and clinics, a community devel-

opment approach ensures that the benefit

reaches all.

Mechanically stabilised earth wallsWith the above in mind, Hatch Goba approached

Maccaferri Africa as a specialist supplier to

provide the design for some mechanically sta-

bilised earth walls. These need to be a cost-

effective, rock-free and labour-intensive solu-

tion that would be environmentally friendly

and are intended to create steepened sloped

embankments for the community access roads

off the R61 at Tombo, just outside Port St John

in the Eastern Cape.

A solution of Green Terramesh was used

for four structures to create the embank-

ments ranging in heights from 2 m to 8 m.

Drainage was also provided to ensure that

the poor to good soils used for the structural

fills were kept dry. Very light loads of 5 kPa

were considered for the design. Maccaferri

Africa has designed this solution and taken

the professional indemnity on the internal

elements of the wall.

Benefits of Green TerrameshThe project required more unskilled than

skilled labour, and was therefore ideal for

3.00 m

Green Terramesh for community development

The South African National Roads Agency Limited (SANRAL) has been entrusted with the task of developing and maintaining the national road network.

SANRAL ROADS


A F R I C A

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

We now have 8 SAICE Accredited Complimentary CPD Lectures available. Visit www.maccaferri.co.za for information on lectures in your area.

In partnership with SANRAL focussing on community upliftment

R61 Section 8 Tombo Dual Carriageway & Modal Interchange - EASTERN CAPE

Mechanically stabilised earth wallsWith the above in mind, Hatch Goba approached

Maccaferri Africa as a specialist supplier to

provide the design for some mechanically sta-

bilised earth walls. These need to be a cost-

effective, rock-free and labour-intensive solu-

tion that would be environmentally friendly

and are intended to create steepened sloped

embankments for the community access roads

off the R61 at Tombo, just outside Port St John

in the Eastern Cape.

A solution of Green Terramesh was used

for four structures to create the embank-

ments ranging in heights from 2 m to 8 m.

Drainage was also provided to ensure that

the poor to good soils used for the structural

fills were kept dry. Very light loads of 5 kPa

were considered for the design. Maccaferri

Africa has designed this solution and taken

the professional indemnity on the internal

elements of the wall.

Benefits of Green TerrameshThe project required more unskilled than

skilled labour, and was therefore ideal for

3.00 m

SMME development programmes, job crea-

tion and skills development, which SANRAL

viewed as very important to support their

community development drive.

The no-rock solution of Green Terramesh,

together with the green front face, would

further improve the environmental benefits

and save costs, as rock was not available

close to the site, and the green front face

also makes for a more aesthetically pleas-

ing solution.

Green Terramesh is a modular system and

is perfect for accommodating tight-curved

roads in a community with minimum impact

on dwellings and farming land. Green

Terramesh units are manufactured from

double-twist hexagonal woven wire mesh to

SANS 1580:2005. The mesh is continuous

and provides both the reinforcing element

as well as, together with a welded mesh

panel, the front sloped face of the unit. The

front face is lined with an erosion control

blanket, which assists with the retention of

the topsoil and green provided.

Green Terramesh can be used together

with high tensile grids. This combination

allows for the reduction in reinforcement

used as the spacing between the primary

reinforcement (i.e. the grids) and the facing

Green Terramesh, which is the secondary

reinforcement, can be increased.

The project required more unskilled than skilled labour, and

was therefore ideal for SMME development

programmes, job creation and skills development

The workshop will follow the highly successful 10-box training programme now used across the USA and with municipal clients in Australia, New Zealand, UK, Canada and South America

Asset registers, valuation, con-dition assessment and residual lives, levels of service, business risk exposure, optimal mainte-nance programmes, rehabilitation/replacement/augmentation, asset management plans, future expend-iture and funding models and stake-holder consultation

Getting started – How did others do it: the different ways to get started

Change management effective implementation programmes (EIP) – successful AM improvement programmes

Building your first AMP and driving its improvement cost-effectively

Gap analysis techniques and TEAMQF – Roger will demonstrate the Gap-Ex 1 web-based tool so that participants can then go and try it out with their organisation.

All participants will be given a free toggle to use the tool

The business case for improving your AM performance – asset management improvement programmes

Organisational and people issues

Risk management

Data collection – smart techniques –

Delphi group approaches

Capital investment programmes (CIP) justification/validation

Strategic asset management planning

Justifying and focusing existing budgets

Understanding the full economic/whole-of-life/cost-of-service (triple

bottom line – TBL)

Asset valuation/depreciation/

economic cost

Condition assessment process and residual life estimates

Asset management information

systems, data and knowledge

IMESA

Pre-Conference Workshop Infrastructure Asset Management

28th October 2014 – Durban Country Club, KZN

“Using IMESA’s AMPLE and other tools to get started, and manage your valuable infrastructure portfolios through a structured and cost-effective,

step-by-step asset management improvement programme”

IMESA Conference 2014

WHAT IS AMPLE?

AMPLE (Asset Management Program Learning Environment) is a web-enabled knowledge management system which aims to present a means by which organisations and their staff can gain an understanding of:

the principles of life-cycle asset management in a logical, cost-effective, step-by-step process.

the essential components of a state-of-the-art asset management programme.

‘how to do it’ information to drive their asset management improvement programme.

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

YOUR WORKSHOP FACILITATOR

Roger Byrne was the international manager of GHD’s Global Asset Management Group for over 30 years. Based in Melbourne, Australia, and now semi-retired, he still works all over the world as a principal advisor/mentor to clients. He has written many texts on asset management including many manuals, such as the IIMM and the development of the world’s first quality framework; associated AMPLE / TEAMQF web-based

tools that are assisting infrastructure owners and managers around the world. Roger has helped develop innovative approaches including business value chains, confidence-level rating processes, the step-by-step approach and methods to identify what is best practice for different organisations and their assets. Roger is in the ‘legacy years’ of his career and is concentrating on really understanding the reasons or causes for AM failures and driving AM improvements collaboratively around the world.

TYPICAL TOPICS INCLUDED IN THE WORKSHOP PROGRAMME

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

The objective of IMESA’s AMPLE is to provide a web-based asset management learning environment, which will assist all municipalities and their infrastructure-rich businesses to drive sustainable asset management improvement cost-effectively. It provides a web-based knowledge management system that can be implemented to suit individual

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

WHO SHOULD ATTEND?This workshop will be ideal for all those who:

are thinking about implementing infrastructure asset management but don’t know where to start.

have started, but would like to see some smart ways to do it more cost-effectively, while deriving even greater benefits for your municipality.

would like to know how IMESA can support you in your efforts.

ORGANISERS

The workshop is endorsed and organised by the INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA).

CONTINUING PROFESSIONAL DEVELOPMENT

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

COST/REGISTRATIONOnline registration www.imesa.org.za

Venue Durban Country Club

Time 08:00 – 16:30

Payment before 17 October 2014

Cost per delegate IMESA members R1 600.00 + VAT R224.00 = R1 824.00

Cost per delegate Non IMESA members R1 800.00 + VAT R252.00 = R2 052.00

For any query, please contact Erin – +27 (0)31 303 9852

Space at the workshop is limited and applications will be accepted on a first-come-first-served basis. Payment of the workshop fee includes full-day conference package.

IMESA Preconf DPS.indd All Pages 2014/06/30 01:36:04 PM


CONSULTING ENGINEERING

THIS AND OTHER important con-

cerns were raised by Dr Urishanie

Govender, Gibb general manager of

environmental services, who was

invited to discuss the implications of the

Consulting Engineers of South Africa (CESA)

Sustainability Framework at a CESA Gauteng

South Branch breakfast meeting earlier

this year.

CESA Sustainability FrameworkGovender assisted in mandating the

Sustainability Framework, which was intro-

duced by CESA in November 2013. It

is aimed at guiding and assisting CESA

member firms with sustainability monitoring

and reporting.

She said that by reporting on sustainabil-

ity, engineering firms can see where they

Engineering a sustainable future

“Sustainability impacts the bottom line, and all industries ought to be acutely mindful of how they do business on a planet with fewer and fewer natural resources.”

are making a material impact. “Importantly,

reporting should not merely be about the

action of compiling a report or a tick box

tool. Rather, it needs to be a structured

medium to guide firms on sustainability –

how to define it on a firm-by-firm level and

how to understand and manage the identi-

fied material aspects.”

The engineering industry has a major

impact on the communities and environment

in which it operates. In addition, it is aware

of its role as a major job and employment

creation driver in South Africa.

Sustainability modelGibb has created its own sustainability

service line within the environmental ser-

vices sector and developed a practical and

informative sustainability model, which can

be applied on a project level. The purpose of

the model is to highlight the various tasks

and outcomes that relate to sustainability

and need to be considered from an early

project stage.

Gibb sustainability manager Karien

Erasmus said sustainability in engineer-

ing terms is all about achieving balance.

“There are a number of key issues on South

Africa’s development agenda that need to

be addressed. Sustainability is not just

about environmental and resource conser-

vation. The social component is becoming

increasingly important as it relates to com-

munity development, social upliftment and

skills transfer.

“The fact is, to contribute effectively

to South Africa’s National Development

Plan goals and objectives and achieve



sustainability on a national level, we need

to, amongst other things, get electricity

and water to people. We also need to

ensure that education and jobs are created.

Sustainability is not just about conservation,

it is about allowing growth, but doing so in a

responsible and future-considering manner.”

“The engineering sector needs to under-

stand the impact it makes with every pro-

ject it undertakes. In addition, it needs to

establish how it can contribute to the devel-

opmental agenda through the work it does,”

said Erasmus.

“One of our current projects relates to

renewable energy and linking it to grass-

roots skills development and sustained job

creation, which are key considerations at

the moment, especially in a country such

as South Africa where coal resources are

running low,” said Erasmus.

Inclusive growth in AfricaLegislatively, South Africa will be rolling out

carbon tax in 2015. “This will have a major

impact on the transport and logistics sector.

It will also impact the way we do business.

If we do not take carbon emissions into

consideration and look at international best

practice, the cost of business will continue

to rise,” warned Erasmus.

Africa is a dynamic business space, with

major opportunities. Govender said a num-

ber of international best practice policies

govern the way Gibb does business in Africa.

There are several externally developed char-

ters and sets of principles, such as the

Equator Principles and International Finance

Corporation Best Practice principles, that

will become entrenched in the next 10

to 15 years.

So, it makes

good business

sense to align ourselves with them now.

“Ultimately, the planet cannot sustain the

way we are developing at the moment. It’s

a bottom line fact. We have to find ways to

develop sustainably. We need to acknowl-

edge our past in South Africa and the way it

has impacted our development. We need to

find ways to give everyone access to equal

services and an improved quality of life.

This means we need the development, but

we need to take cognisance of the way we

develop,” commented Govender.

“Sustainability is not just about environmental and resource conservation. The social component is becoming increasingly important”Dr Urishanie Govender, Gibb general manager of

environmental services



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Vissershok Waste Management Facility Encapsulation Cell

Integrated Waste Management Plans Waste Disposal Strategies

Identification and permitting of landfill sites Design of General and Hazardous Waste sites

Design of Solid Waste Transfer Stations Design of Material Recovery Facilities

Optimisation of Waste Collection Systems Auditing of Waste Management Facilities

Development of Operational Plans Closure and Rehabilitation of Landfills Quality Assurance on Synthetic Liners

Waste Recycling Plans

HDPE Capping at Vissershok Waste Management Facility (H:H)

Highlands Material Recovery Facility

THIS WAS THE case recently when

a consulting team was appoint-

ed to prepare the Alfred Nzo

(Mbizana) Coastal Management

Programme (CMP) in terms of the National

Environmental Management: Integrated

Coastal Management Act, Act No 24

of 2004.

The Alfred Nzo District Municipality in the

Eastern Cape, South Africa, with only a

single coastal local municipality, identified

coastal zone management as one of three

aspects crucial to creating a conducive

environment for economic growth and bet-

ter access to services. The Mbizana Local

Municipality described its coastal environ-

ment as it’s “most prized natural resource.”

A CMP is intended to provide the policy

direction required with particular empha-

sis on establishing an agreement between

Coastal consulting

Despite living in the age of high technology and convenience, sometimes situations demand a more traditional approach to accessing essential information.



coastal communities, the local and district

municipalities as well as the relevant nation-

al departments. A CMP also provides a con-

sistent link and alignment with national and

provincial CMPs and the national estuarine

management protocol. It contains four key

components, namely: vision coastal manage-

ment objectives, priorities and strategies.

Specific components and focus areas need

to be prioritized and realistic implementation

action plans developed.

This CMP will be easy to read and compre-

hend and will employ spatial representation

of specific management requirements and

outcomes, and will build on the strength of

previous documents. Adaptive management

principles will be applied making the CMP

accessible and easily updated in the five-

year review period.

Inaccessible study areaRoyal HaskoningDHV’s project leader Tandi

Breetzka describes an unusual and physi-

cally challenging approach to gathering the

necessary information for this assignment.

“As a result of the relative inaccessibility of

the Mbizana coastal zone by vehicle, the site

visit to assess local conditions, to ground

true information and assess data, our team

needed to ‘think out the box’ and come up

with an innovative solution. We elected to

make use of the almost defunct Amadiba

hiking and trekking trails.

On foot and on horseback“Setting off before day break from Durban

we drove to the Wild Coast Sun hotel where

we hiked the initial 14 km from the north-

ern boundary, crossing two rivers via local

‘ferry’ and then via horse-back on Pondoland

ponies hired from local homesteads by trail

guide ‘sticks’. With innovative and somewhat

suspect tackle, we travelled the remaining

10 km to the southern boundary. The team,

including client representatives, spent the

night at the Mtentu Lodge, another local

tourism initiative, and rested our weary and

somewhat bruised bodies.

“The second day entailed more horse-

riding, this time going past the rocky shore

we had missed the day before, followed by

a three-hour trip by ‘wild coast taxi’ back to

the Wild Coast Sun. After a final look at the

beach we headed back to Durban.”

Comprehensive CMPBreetzke’s team will now report on the

status quo of the various sectors that

influence coastal management issues in

an inventory analysis. These include bio-

diversity, endemism, conservation, public

access and ecosystem goods and services,

will be prioritised. The drafting of the CMP

document follows and will be implementa-

tion focused, ensuring that the knowledge

generated by the inventory analysis compo-

nent will be incorporated into a decision-

making framework (among others). This

will provide a list of prioritised actions and

timeframes to achieve the identified goals

and objectives, identify funding opportuni-

ties and sources, as well as defining the

roles and responsibilities of various stake-

holders and decision-makers involved in

coastal governance.


WATER AND WASTEWATER

THE GENERATION output had been

envisaged to be extracted primar-

ily from the RE resources namely

as biomass, solar radiation, wind

and small-scale hydropower (<10 MW).

Ocean energy exploitation had not been

considered at the time. None of desired RE

technology means and products were read-

ily available in South Africa at the time of

the WP on RE introduction.

The Electricity Regulation Act (Act 4 of

2006) was promulgated in 2006 and led

to dissemination of the Regulation on New

Generation Capacity. In November 2010,

the Department of Energy (DOE) together

Realisation of renewable energy technology in SAThe development process of renewable energy (RE) resources in South Africa was spearheaded by the White Paper on Renewable Energy in November 2003. This document established a generation target of 10 000 GWh per annum from available non-coal energy resources by 2013. By Bo Barta and Inga Loots

with NERSA and National Treasury intro-

duced a new Integrated Resource Plan (IRP

2010-2030). The Government promulgated

the new IRP in May 2011 endorsing a widely

diversified future energy generation mix

aimed at reducing dependency on coal-fired

energy generation over next 20 years. At the

end of 2011, the DOE and NERSA issued

the first order of a 3 725 MW renewable

energy capacity, this time entirely allocated

to independent power producers (IPPs).

Embedded generationThe RE Independent Power Producers

Procurement (REIPPP) programme replaced

the internationally adopted REFIT procure-

ment programme, excluding all RE projects

below 1 MW in capacity. The REIPPPP has

been subsequently implemented in three

bidding windows and by now the whole RE

capacity allotment is fully allocated primar-

ily to the wind, solar PV and CSP large

projects. To date, the development of RE

small-scale projects is not supported by any

particular incentives. Banks are reluctant

to support small-scale developments below

1 MW in capacity. However, the so-called

embedded generation of hybrid configura-

tion (typically of solar, wind and hydropower)

small projects is taking place around South



Africa, mainly by these private developers

from their own financial resources.

The research, assessment studies and

training, in the development of embedded

generation small-scale projects and technol-

ogy implementation specifically focusing on

hydropower, are conducted at the University

of Pretoria. The university is engaged in

small-scale hydropower research in col-

laboration with the Tshwane Metropolitan

Municipality, Bloem Water and South Africa’s

Water Research Commission (WRC).

To date, the local government authorities

and water boards, due to their extensive

and demanding functions within the water

supply and sanitation chain (i.e. a complex

urban water services system), have been

finding themselves lacking in the develop-

ment of RE resources and application

of modern technology at their disposal.

However, the small-scale RE technology

options are rather plentiful for most munici-

palities and water boards, as well as inter-

ested IPPs.

Energy conservation, efficiency and RE generation programmesSince 2008, when serious shortages of

electricity from the national grid affected all

sectors of the economy, users of electricity

in South Africa, and particularly the munici-

palities, were tasked with the implementa-

tion of various programmes aimed at energy

conservation (EC), energy efficiency (EE)

and RE technology implementation.

EC national measuresConservation measures have already been

implemented for some time within the

municipal electricity supply systems. Timing

of electricity usage and new technologi-

cal measures have helped the conserva-

tion and individual users are tasked to

implement saving measures both in- and

outdoors.

EE measures within the urban water cycleThe EE measures are related more to the

optimisation of energy usage and the appli-

cation of advanced technology. Specifically

within the municipal water cycle chain,

the improvements in energy efficiency are

related to pressure management and leak-

age reduction, off-peak pumping, baseline

energy audit, solar heating and composting,

digester mixing optimisation, oxygenation

capacity and efficiency of algal oxidation

ponds, submersible versus self-priming

pumps, load-shedding and load-shifting,

and water distribution systems optimisa-

tion. Further substantial improvements in

energy efficiency may be obtained from

the CHP biogas-to-electricity, cost-benefit

model for biogas production, energy recov-

ery in desalination systems, recovery from

reverse osmosis, fine bubble diffused air

and air injection systems, hydropower gen-

eration in pressurised distribution networks,

and low-head hydropower generation.

Second National Energy Efficiency Strategy (NEES) The NEES review was instituted in July 2012

introducing the new measures through leg-

islation, incentives, standards and training

incentives as given below:

• South African NEES standards

• regulations for allowance on EE savings,

Section 12L of the Tax Amendment Law

Act, 2013

• national building codes and regulations

(e.g. SANS 204)

• minimum energy performance specifications

• EE policy recommendations adopted from

the International Energy Agency, focusing

on a seventh priority of energy utilities to

match the ESKOM incentives.

It should be noted that the above-listed

measures are to enable that the key goals

of the NEES – EC, EE and the demand-side

management – are implementable. The

municipalities and water boards should

become familiar with the impacts of new

measures on their energy usage within

relevant supply areas. The EC and EE meas-

ures, together with implementation of RE

technology, will reduce the demand for elec-

tricity from the national supply if all entities

as well as individual users were to imple-

ment such measures on a sustainable basis.

Complex urban water cycle system: energy demand and savingsThe Department of Water Affairs is a cus-

todian of the raw water resources from

where water is supplied either directly or

via a water board to the municipalities. The

municipalities are overseen by water servic-

es authorities that look after the day-to-day

operation, maintenance and future devel-

opment of sustainable water and electric-

ity supplies as well as sewerage services

provision and other important municipal

services (i.e. waste management, roads

and stormwater, housing). The municipali-

ties and water boards in South Africa are

also responsible for the rehabilitation and

upgrading of their water supply, waste-

water treatment and disposal infrastruc-

tural assets. Theoretically, although they

have a demand for energy, most of these

assets also have a potential for generating

energy at various processes and locations.

The energy demand for pumping within

the water supply process is much larger

than for pumping wastewater. The energy

demand from water supply and wastewater

processes are proportionally about 52% to

48% respectively. The institutional stake-

holders in the local water sector should be

concerned about the energy consumption

and in-house energy generation issues with-

in national, regional and municipal water-

cycle systems (Figure 2).

The electricity consumption encountered

by a municipality or water board in running

the complex water services systems (i.e.

FIGURE 1 Institutional hierarchy in the water services sector



abstraction/pumping, treatment/pumping,

storage, supply/distribution, collection/

pumping/treatment and disposal process-

es) amounts to a significant cost in the

overall municipal or utility budget (Table 1).

The amount of electricity required in the

operation processes of a water-cycle sys-

tem vary depending primarily on the extent

of pumping and treatment requirements.

The other factors that significantly influ-

ence electricity requirements are related

to the technological status of a system

and the quality of water and wastewater

being treated.

At present, practically all municipalities

and water boards are connected to the

national grid administered, on behalf of the

government, by Eskom. Although the situa-

tion is changing, there are only a few munic-

ipal and large industrial/mining electricity

users capable of generating green energy

within their own systems. Most existing

water services systems have components

where the energy usage can be reduced

or even discounted by rather generating

energy in a subsystem or a specific part

of the subsystem. Within a complex urban

water services system, the availability of

energy generation can be investigated by

two approaches: energy conservation (i.e.

demand-side measures) and energy genera-

tion (i.e. supply side measures).

Hydropower potential hidden within the urban water cycle systemsSouth Africa, a water-stressed country, has

developed extensive and complex bulk sup-

ply and distribution water supply infrastruc-

ture where significant hydropower potential

is hidden. If such potential is developed,

energy demand on the national grid will

be reduced.

Hydropower in surface and groundwater supply systemsMost of South Africa’s municipalities are

supplied with sur face water, abstracted

from either state-owned or their own

dams. There are several municipalities

entirely dependent on groundwater sup-

plies. Numerous municipalities are sup-

plied directly with potable water via some

twenty water utilities (e.g. Amatola Water,

Bloem Water, Magalies Water, Rand Water,

Sedibeng Water).

South Africa has some 4 500 dams of

various sizes. Only around 260 dams are

owned by local government administration

and only some 70 municipal dams have a

capacity over 1 million m3 (i.e. 1 000 Ml).

A few of these dams have good hydropower

potential (Table 2).

It should be noted that there are other

dams where small-scale hydropower

schemes can be installed. There are also

privately owned dams where small-scale

hydropower projects are currently in devel-

opment (e.g. new Bains and Boschendal

mini hydropower installations in the Western

Cape Province).

Bulk water supply and long conduit water distributionMany municipalities and some water boards

benefit from the state-owned inter-basin

water transfer schemes (WTSs). There are

now some thir ty such schemes built to over-

come imbalances between geographical

water availability and ever-growing demand

for water in locations without available

TABLE 2 Municipal dam impoundments with significant hydropower potential

DAMNAME

RIVER MUNICIPALITY (PROVINCE)

CAPACITY (MILLION M3)

LOCATION OF HYDROPOWER POTENTIAL

Bridle Drift Dam Buffalo Buffalo City Metro (EC) 73.5 From river releasesChurchill Dam Fish/Tsitsikamma Nelson Mandela Bay Metro (EC) 33.3 From both river releases and conduit supplyLake Mzingazi Mhlatuze Umhlathuze (KZN) 37.0 From conduit supplyMiddelburg Dam Olifants Steve Tshwete (MP) 48.4 From river releasesNgweba Dam Fish/Tsitsikamma Camdebo (EC) 46.4 From conduit supplySol Plaatjie Dam* Upper Vaal Dihlabeng (FS) 15.7 Already retrofitted with hydropower generationWitbank Dam Olifants eMalahleni (MP) 104.0 From both river releases and conduit supply*Note: The Sol Plaatjie Dam of the Dihlabeng LA was retrofitted with capacity installation of a 3 MW hydropower in 2009.

TABLE 1 Energy demand and possible gains within complex urban water services cycle

WATER SUPPLY CYCLE (CHAIN)

ENERGY-REQUIRING PROCESS

PROCESSENERGY DEMAND

POTENTIAL ENERGY SAVINGSWITHIN THE PROCESS

Raw/potablewater

Abstraction Pumping if not gravity – configuration depending

max 100 kWh/Mℓ Energy efficiency motors and pumps (up to 12%)

Treatment Pre-treatment, clarification, filtration, disinfection, etc.

150 to 650 kWh/Mℓ Between 0.014 and 0.021 kWh/m3 (by refurbishment up to 20% )

Distribution (consumption)

Pumping if not gravity – configuration depending

max 350 kWh/Mℓ Devices fitted: 0.91 kWh/m3 or 0.05 m3/day/household

Waste-water(sewage)

Collection Pumping if not gravity – configuration depending

approx. 100 kWh/Mℓ Heat pumps & in-sewer heat exchanges

Treatment processes Screening, grit, sedimentation, aeration, RAS, disinfection, tertiary/advanced treatment

200 to 1 800 kWh/Mℓ ASP Aeration: 0.063 kWh/m3

ASP nutrient removal: 0.291 kWh/m3 Disposal Pumping if not gravity –

configuration dependingminor within WWTW Energy recovery by hydro-turbines or

hydraulic screw (0.018 kWh/m3)Sludge handling Thickening, dewatering,

digestion, drying and disposalmainly from belt presses, centrifuges, etc.

Approx. 0.101 kWh/m3 (with efficient devices fitted, up to 23% )

Sources: British Compendium (UKWIR, 2010); DWA’s Green Drop water chain criteria and assessment approach



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natural water. Typically the raw water is

transferred from one river basin to another

by means of pumping or gravity via large

tunnels. If a municipality is not receiving

raw water directly, the raw water will be

conveyed by pumping or gravity to one of

the water boards to be treated, and the

bulk potable water will be distributed to

the municipalities, industries and mines via

service and distribution reservoirs. Several

WTSs have one or more locations where

small-scale hydropower generation plants

can be installed, mainly on the gravity

pipelines where it is required to reduce the

hydrostatic pressure.

The bulk water supply and distribution are

the most critical and costly components of

the urban water supply system. Thus the

savings in these areas through process

optimisation and retrofitting new technol-

ogy, can offer conservation results in water

supply and energy consumption. Most of

the operation pumping takes place within

the bulk supply.

Hydropower as pressure reduction in delivery pipelinesMost of the pressurised conduits (at both

pumping and gravity) operated by the water

utilities and municipalities are experiencing

excessive pressures at certain locations,

which must be typically curtailed by pres-

sure reducing valves (PRVs). At such loca-

tions, the installation of hydropower gen-

eration devices may be considered. PRVs

are typically installed before the inlet of a

reservoir or at the breaking point of a long

gravity pipeline. Table 3 illustrates current

hydropower developments taking place at

the foremost municipalities and water utili-

ties, utilising this approach in developing

available hydropower (Table 3).

Hydropower hidden in water distribution networks

Terminal consumer installationsTheoretically, every urban household having

an inflow pipe diameter of 20 mm and a

flow under at least 10 m head could gener-

ate some 50 W of electricity during each

tap opening. However, this energy will have

to be stored in a battery system and prefer-

ably fed also by a roof solar PV system or

another renewable energy technology appli-

cation in a hybrid configuration to obtain

significant household energy capacity.

Report No. KV 238/10 of the WRC con-

cluded that the flows of potable water

passing through the domestic water supply

piping during an average day may be utilised

for pico hydropower (<20 kW), primarily

for minor household energy uses. A flow

exceedance curve can be constructed to

assess the availability of the hydropower

that might be produced. It is also necessary

to determine the pressures in the water

supply pipelines.

Residual pressures in urban areasTo obtain the residual head at any point

in the reticulation network, the network

should be balanced using instantaneous

peak flows (IPF) and the fire flows. Table 4

TABLE 3 Water supply systems and potential sites of in-line hydropower development

WATER SUPPLY SYSTEM

CONSIDERED HYDROPOWERDEVELOPMENT

IDENTIFIED SITES WITH HYDROPOWER

POTENTIALBloemfontein Water (regional water utility)

Mini hydropower installations on the pressure Caledon-Bloemfontein pipeline

Uitkijk and Brankop reservoirs totaling almost to 1 MW (other options are investigated)

eThekwini Water and Sanitation Department

The installation of six mini hydro sets considered at various reservoirs

Sea Cow Lake, KwaMashu 2, Aloes, Phoenix 1 & 2, Umhlanga 2 totalling at about 750 kW

Tshwane Water Supply Area A pilot plant of 15 kW has been installed at Pierre van Ryneveld old Reservoir. Several other sites available

Estimated capacity of 8 MW is envisaged among 10 suitable city reservoirs

Rand Water (foremost water utility)

In-line hydropower has been evaluated at 13 MW of hydropower capacity. Another 40 to 50 MW capacity is envisaged to develop

Brakfontein Reservoir (1.8 MW), Hartebeesthoek Reservoir (2.2 MW), Klipfontein Reservoir (3.4 MW), Zoekfontein Reservoir (5.6 MW)

29-31 OCTOBER 2014

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29-31 OCTOBER 2014

Register & pay BEFORE 30 AUGUST 2014• Late Registration IMESA members@ R4725• Late Registration Non-IMESA members@ R5250

Register & pay AFTER 30 AUGUST 2014• Last Minute Reg IMESA Members@ R5200• Last Minute Reg Non-IMESA Members @ R5775

Theme - Balancing Service DeliveryEarn 2.5 CPD points by attending

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illustrates the variations in water head in

two different settings.

Potential energy gains from wastewater management The WRC study undertaken in conjunction

with the South African local government

Association established that there are

some 850 municipal wastewater treatment

plants (WWTWs) of various processing

capacities and treatment stages (i.e. from

preliminary to advanced treatment). It is

essential to any WWTW to have a sustaina-

ble and continuous supply of electricity. If a

WWTW is subjected to power interruptions

and pumping stoppages, untreated waste-

water is usually spilled directly into the

receiving river. To prevent this occurrence,

some of the WWTWs are installing suf-

ficiently large attenuation dams. Although

some plants that cater for advanced treat-

ment processes would be equipped with

some kind of stand-by, most small and

medium WWTWs do not have any backup.

Typically, the existing WWTWs in South

Africa are not designed to utilise energy

generation potential either at various pro-

cesses or from large quantities of released

treated wastewater.

Besides energy savings within the waste-

water treatment processes, hydropower can

be recovered on the outfall in front of the

plant and/or after the treatment processes

on the outfall into the receiving river ecosys-

tem. Taking into consideration the available

head configuration and the quantities of

treated wastewater, the type of water turbine

can be accordingly selected as per Table 5.

It should be noted that by per formance,

impulse runner-type turbines are more suit-

ed to high head applications whereas reac-

tion runner-type turbines are most suited to

low head hydropower installations.

Water conduit hydropower availability assessment procedureThe University of Pretoria developed, under

WRC/UP Project K5/2095, the conduit

hydropower assessment Decision Support

System (DSS) for the purpose of assessing

hydropower availability to assist munici-

palities and water utilities in administering

water supply systems.

Each phase, as illustrated in Table 6,

has its own process flow diagram linked

to the conduit hydropower potential tool.

Some of the inputs occur in more than one

phase and as the project progresses, more

detailed inputs are required.

The decision support system used to

identify conduit hydropower potential pro-

vides guidance for the development of iden-

tified potential sites. A systemic approach,

consisting of three phases, was developed

for the assessment of hydropower potential

in a water supply system to ensure that all

relevant factors are considered.

Legal and regulatory requirements in developing hydropower projectsThe development of renewable energy

resources is a relatively new activity and

untested ground for both the public and pri-

vate sectors in South Africa. In reality there

are no firm guidelines for the implementation

of development stages in creating municipal

renewable energy assets. However, most

physical infrastructural assets created in

South Africa are developed along pre-pro-

curement stages as follows:

• project planning/inception stage

• project pre-feasibility stage

• project feasibility stage leading to the

compilation of a bankable study.

Municipalities have to find their own ten-

dering or PPP implementation approach

based on suitable contractual procedure,

as they will need hydropower consulting

services. Hydropower development is a

rather specialised field in the design of both

the installation and procurement. There are

several options available to potential IPPs in

negotiating with national departments, para-

statals and local government authorities to

arrange for access to the resources and

infrastructure which are effectively owned/

administered by the state.

The general regulatory environment is

guided by the Constitution via Parliament,

the courts and tribunals. Key regulatory

instruments relevant to the water resources

and energy development sectors are to

comply with:

• National Water Act (Act 36 of 1998)

• Electricity Regulation Act (Act 4 of 2006)

• National Environmental Management Act

(Act 107 of 1998).

All three pieces of legislation have direct

influence on the development of renewable

energy resources and the implementation of

technological choice within the urban/rural

water services system context. Within the

municipal and water board context, the DOE/

NERSA standard conditions for small-scale

(up to 100 kW) embedded generation within

entity boundaries, allows RE projects to be

implemented. The licensing requirements to

be observed during the process of renew-

able energy capacity development at the

local government and water board levels are

illustrated in Table 7.

Each municipality must match the gen-

eral legal and regulatory requirements with

their local municipal by-laws and regulations

TABLE 5 Basic turbine type selection criteria

Turbine runner High head Medium head Low head Ultra-low head> 100 m 20 m – 100 m 5 m – 20 m < 5 m

Impulse TurgoPelton

Crossflow Turgo Multi-jet Pelton

Crossflow Turgo Multi-jet Pelton

Water wheel

Reaction Francis turbine as pump

Kaplan propeller Propeller Kaplan propeller

Note: More detailed information on the selection of suitable hydropower generation equipment for wastewater outfalls is available from the WRC/UP project K8/1017.

TABLE 4 Standard head and flow provision at terminal water installations

Minimum and maximum water head at the house connection

Type ofdevelopment

Min. head under IPF (m)

Max. head under zero flow (m)

Dwelling house connection 24 90

Dwelling house yard tap + tank 10 90

Typical discharge rates for domestic taps

Tap diameter Discharge (litres/minute)

5 m head 10 m head

60 m head

15 mm16

23 54

20 mm 22 31 70



integrating the environmental, energy gen-

eration and water services legislation.

Municipal integrated development plans are

perhaps one existing mechanism into which

renewable energy development proposals

should be incorporated.

Concluding remarksThe key objective of IRP 2010-2030 for

South Africa is to develop a sustainable

future energy-generation mix, significantly

reducing coal-fired generation. The EC and

EE programmes, together with develop-

ment of available RE resources (i.e. par-

ticularly solar radiation, small-scale hydro-

power from existing infrastructure, wind

and marine energy where suitable), have

become national priorities as the margin

between power demand and supply from

the national grid is very narrow. Fortunately,

most of the enabling mechanisms are in

place to allow for orderly development.

On the international scale, South Africa is

ranked as the twelfth-highest carbon-emit-

ting nation in the world (our electricity sec-

tor contributes 45% of our total emissions).

However, with the abundance of solar radia-

tion in most regions of South Africa, togeth-

er with the positive implementation results

of the REIPPP programme, the country is

now widely recognised as a future leading

renewable energy investment destination.

The country is on the threshold of signifi-

cant growth in all spheres of RE technology

industries, with PV municipal rooftop sys-

tems being the strongest component.

Although energy generation from solar

sources is most suitable for development,

particularly within the municipal context,

the hydropower potential hidden within

municipal and water board water services

systems is another viable renewable and

sustainable option open to the administra-

tors of these systems. The future upgrade

and optimisation of existing water ser-

vices systems in South Africa are likely to

gravitate towards a combination of solar

and hydropower technologies (following

international tendencies).

Research and assessments to gauge the

potential for development, particularly of

small-scale embedded generation hydro-

power, supported and financed by the

WRC, are being conducted at the University

of Pretoria, in collaboration with Tshwane

Metropolitan Municipality and Bloem Water.

The University of Pretoria can help the

municipalities and water boards assess

energy savings and hydropower potential

within their water services systems.

TABLE 7 Essential licensing requirements

Regulatory/legal requirements

Usage optionsOwn use Islanded use Municipal grid Eskom gridFor own use + from grid; but not into grid

Completely independent

Feeds into Feeds into

Environmental ROD If < 20 MW: BA ito S1 activities (GN544);If > 20 MW: EIA ito (amendment to original build’s EIA or BA; or new)

Water use licence (i) Repair/rehab/upgrade (i.e. public or private ownership): Not required unless an increase of water flow is required

(ii) Augmentation of existing infrastructure (e.g. pipelines, canals, etc.): Water permit not normally required if not a state asset (i.e. municipal or private infrastructure)

(iii) Retrofitting hydropower to non-powered dams: Water permit is required subject to possible exemption (i.e. for socio-economic/environmental reasons) (iv) Development of greenfield hydropower (not associated with existing infrastructure): Water use permit is

required on all accounts together with a basic assessment or environment impact assessmentElectricity generation licence

If < 1 MW: None If for non-commercial: None

If < 100 kW: None If > 100 kW: Yes Yes (only IPPs through REIPPPP )

TABLE 6 Layout of DSS for assessment of hydropower in water supply conduits

PHASE ESSENTIAL INPUTS DESIRED OUTPUTSPhase 1:Pre-feasibility

Average daily flow First order power analysisAverage pressure head (or static head)

Initial estimate of net present value

Distance to grid connection (if applicable)

Initial estimate of internal rate of return

Power demand (if applicable) Initial estimate of payback periodProject design life Optimum design flow and head

Phase 2:Feasibility

Measured flow records Initial turbine selectionMeasured pressure records Flow rating curveEnvironmental studies Net present valueRegulatory assessment Internal rate of return and

payback periodPhase 3:Detailed design

Similar to Phase 2, but with additional data

Final turbine selection

All project costs Detailed drawingsAll expected income Net present valueOperational criteria Internal rate of returnDetailed design of all civil and electro-mechanical components

Payback period

NB: A fourth phase, dealing with operation and maintenance aspects (outside the scope of this study) is also an important phase to consider when designing a conduit hydropower facility.

The future upgrade and optimisation of existing water services systems in South Africa are likely to gravitate towards a combination of solar and hydropower technologies


TRAINING

The wheels of service deliv-

ery and the broader economy

demand not only more engineer-

ing graduates, but more regis-

tered engineering professionals, able to

take responsibility and make decisions

independently, while ensuring the highest

level of quality and safety. It is for this

reason that organisations need to work

towards developing all engineering staff

towards professional registration with the

Engineering Council of South Africa (ECSA).

Making staff more valuableIt is not difficult to see why the process of

getting registered makes employees more

valuable to a company. Apart from the

positive end-result, they learn a wide range

of essential skills.

Candidates must demonstrably become

masters in developing engineering solu-

tions, in addition to being able to analyse

problems.

They must understand and apply

advanced knowledge, including general

principles and specific aspects of their

jurisdiction and local area.

What is critical for business is that staff

manage engineering activities and com-

municate clearly with others in the course

of doing this. Taking a broad and forward

view of what they are doing is also vital:

they must develop forward thinking, and

address the social, cultural and environ-

mental impact of their projects — as well

as the legal requirements and health and

safety aspects.

Engineering robust workforcesTraining is the ‘soft’ side of your business, right? Wrong. The right training, guidance and mentoring will empower your engineering staff to take more responsibility and take on more work, adding directly to your bottom line and their job satisfaction.

TRAINING


ECSA also requires candidates demon-

strate ethical conduct and take responsibility

for the engineering decisions they make. All

these demands raise the calibre of candi-

date in the workplace, uplifting the profile of

your company and instilling confidence in the

employee’s ability.

Better returns, lower riskThe skills learnt in the lead-up to profession-

al registration create a strong foundation

for the candidate. Engineering companies

can rely on this for years to come, knowing

that their staff is legally and professionally

capable of tackling complex projects independently, or actively

contributing to project teams. This means less time-consuming

management, lower risks, and better returns.

Supporting development towards registration ensures that there

is a continuous cycle of skills transfer, and experience within the

business. This ensures that the expertise can be built up over

the years and effectively passed down from one generation to the

next, enabling businesses to remain sustainable and retain their

competitive edge.

“It is possible to launch a small entrepreneurial firm, grow expo-

nentially and achieve incredible results through investing in people.

As a result of our mentoring ethos, the skills

and services of our staff members are

highly sought after all over the world,” says

Dempsey Naidoo from Mott McDonald, final-

ist in CESA Mentoring Company of the Year.

Developing the professionThe reality is that the engineering profession

is one that is at risk. The development of

engineering graduates to the point of reg-

istration has therefore been identified as a

national priority which requires targets, policy

and funding.

The SETAs are being encouraged to make

discretionary funds available to support companies in their efforts

to provide structured workplace experience to graduates. ECSA has

been lobbying the Department of Higher Education and Training to

set national targets, not only for graduation, but for candidacy pro-

grammes and to fund the candidate phase. Calls for expressions of

interest from SETAs are increasingly reflecting support for graduate

internships or candidate programmes.

Candidate programmes are no longer simply nice to have, but

are fast becoming key to addressing South Africa’s ever-increasing

demand for engineering professionals. Candidates are also quick

to see where organisations will invest in them and move there as

soon as an opportunity arises.

Organisational commitmentAddressing the problem starts with an organisation’s commitment

to fill their engineering workforce with registered professionals as

well as supporting graduates to get registered and stay registered.

“Research has confirmed that companies that invest in struc-

tured training and mentoring of their graduates record higher lev-

els of productivity from their graduates when compared with their

counterparts whose training and mentoring is not structured,”

says Edgar Sabela, acting CEO of ECSA.

Organisations should start by registering a Commitment and

Undertaking with ECSA, ensuring that their graduates register as

candidates and providing them with appropriate projects, supervi-

sors and a mentor to oversee and monitor progress.

The sooner companies invest in this process, the quicker candi-

dates can pick up the workload and take responsibility.

Registration with ECSA is just one step in the continuous devel-

opment of engineering staff that will allow your business to retain

them and plan ahead for succession. Knowing that there is a plan

for their advancement also encourages younger staff to contribute

fully to the business – if they regard themselves as part of the

business’s future, you can rely on their commitment.

Edgar Sabela - Acting CEO of ECSA

Candidate programmes are no longer simply nice to have, but are fast becoming key to addressing South Africa’s ever-increasing demand for engineering professionals

&CONSTRUCTION VEHICLES

EQUIPMENT


CONSTRUCTION VEHICLES AND EQUIPMENT

Island life Engineering connectionsSt Helena, discovered in 1502 and one of the most geographically isolated islands in the world, is upgrading its ports infrastructure, from air to sea. Nicholas McDiarmid spoke to the lead engineer, the contractor and the equipment supplier about building something in the middle of nowhere.

The ship was the first ever to unload directly onto St Helena Island

LOCATED approximately 1 950 km

from the south-west coast of Africa

and 2 900 km from South America,

the only access to the island has

been by sea on the British mail ship,

the RMS St Helena. Landing infrastruc-

ture on the island has also been limited,

with no breakwater or mooring facilities

at Jamestown on the seafront. Cargo is

transported ashore using towed barges and

passengers are ferried to and from the ship

by small launches.

WorleyParsons, one of the world’s largest

engineering, procurement and construction

management businesses, is approaching

the end of its task as lead design engineer

on the iconic St Helena Airport project

— an undertaking that has provided an

exceptional showcase of many of its design

engineering skills.

Building horizonsThe construction of a modern airport and

the establishment of a permanent wharf

herald a new era for the island by providing

employment, creating opportunities for the

local ‘Saints’ to learn new skills, stimulat-

ing the expansion of support industries and

boosting the island’s economic growth with

the increased tourism that will follow.

“The St Helena Airport project incorpo-

rates many unique and unusual features

that have required advanced engineering

ingenuity and thorough planning,” says

Graham Isaac, technical director special pro-

jects at WorleyParsons. “The remoteness

of the island, its size, material supply

logistics, unique geology, topography and

climate, endemic biodiversity with sensi-

tive environmental heritage, ethnic diversity

and history called for real innovation in the

design of specific aspects of the project

infrastructure. The design also necessi-

tated careful consideration to ensure ease

of constructability and programming of

design delivery, calling for close integration

between the members of the design and

construction teams.”

Working alongside main contractor Basil

Read, WorleyParsons’ scope of work has

covered a full spectrum of infrastructure

design aspects for the airport project, nota-

bly, land-side engineering, air-side design

and the airport buildings, including a bulk

fuel storage facility for 6 million litres of Jet

A-1, diesel and gasoline fuels, and a winding

14.5 km access road rising over 300 m in

the first 5 km.

A precious habitatApart from the varying geographical features

of the island, the airport site presented a

unique challenge in terms of the setting and

history of St Helena. There were protected

slave burial sites and archaeological finds to

contend with, apart from the site being close

to the breeding area of the wirebird, indig-

enous to St Helena. The site is also in close

proximity to some 40 species of inverte-

brates that can only be found on the island.

Environmental protection is being guided by

Basil Read’s Environmental Management

Plan and the independent Landscape and

Ecology Mitigation Programme (LEMP), a

four-year initiative that will focus on habitat

restoration and landscaping.

Filling the gorgeOne of the biggest project challenges has

been filling the Dry Gut gorge with 8 mil-

lion m3 of blasted rock to a height of over

100 m, with a width of 750 m, to create

an embankment that will form part of the

runway. Fill material is sourced from the site

area as the landscape and hills are levelled.

When completed, the 2 km-long concrete-

surfaced runway will provide an effective

1 550 m available landing distance.

Isaac says the predictions of Dry Gut’s

potential settlement and the construction

method are among the biggest risks on the

project. The rock-fill has been designed for

stringent final-level tolerances (6 mm in 3 m

straight edge) in supporting the concrete run-

way pavement. The strength and settlement

characteristics of the rock-fill determine the

side slopes and service performance of the

embankment, drawing on WorleyParsons’

extensive international experience in design

principles from rock-fill dams. Settlement

monitoring instrumentation has been

designed and installed at strategic stages

in the fill matrix to enable assessments of

settlement during construction.

Safe landingOn the aviation side, the WorleyParsons

team had to take the remoteness of the

island into account when engineering an

innovative airport design capable of ensur-

ing that aircraft would be able to land safely,

with sufficient fuel to return to the originat-

ing airport.

The terrain on the island made positioning

of the airport runway difficult, particularly

when remaining in the bounds of cost and

environmental impact.

“WorleyParsons RSA’s response to the

exacting requirements of this unique project

underpinned this project,” Isaac concludes.

“For the bulk fuel facility, for instance, we

drew on our world-renowned, in-house hydro-

carbons design expertise and, in terms of

the design of the 14.5 km access road,

bulk earthworks, concrete runway, structural

components of the terminal buildings and


LEFT The Basil Read ship, NP Glory 4, pictured in Cape Town shortly before making its historic first voyage to St Helena, laden with equipment and materials for building the island’s airport

RIGHT James Bay, St. Helena



2014_VOLVO_G940_CEN_297X210

05 May 2014 03:59:06 PM



related services, we drew on our core in-

house skills in the built environment.”

Environmental protection is being guided

by Basil Read’s Environmental Management

Plan, which covers flora, fauna and heritage

issues. In addition to these environmental

considerations, Basil Read is fully sup-

portive of the LEMP, which is required as a

result of the airport construction and sup-

porting infrastructure activities. LEMP will

carry on after all construction activities have

ceased and will provide alternative habitats

and landscape treatments to reduce and

offset the permanent direct loss of habitat

and the direct and indirect impacts on the

landscape that might have arisen from

construction works.

Fitting out the islandThe supply of heavy equipment, for both

the airport and wharf, was undertaken

by Babcock.

The project director, Basil Read’s Jimmy

Johnston, says with 60% of the airport

now complete, the equipment supplied by

Babcock – primarily Volvo heavy construc-

tion vehicles – has per formed reliably,

with good fuel efficiency and high produc-

tivity. Once the airport and wharf have

been completed, this heavy construction

equipment, previously unobtainable on the

island as a result of the challenging ship-

ping logistics, will be available for future

infrastructure development.

Shipping the yellow metalBabcock has supplied the necessary con-

struction equipment in batches, beginning

with shipments on the RMS St Helena,

which included a Volvo EW140C wheeled

excavator, a BL61 backhoe loader and a

DD24 2.5 tonne double drum vibration com-

pactor. Since August 2012, Basil Read’s

flat-deck shallow-draft cargo ship, the NP

Glory 4, has brought the balance of the

equipment to the island. Other shipments

have included a high-discharge 2 tonne

Winget site dumper and a hydraulically oper-

ated, heavy-duty Winget concrete mixer.

Later shipments brought a Volvo G940B

grader, as well as four colossal 70 tonne

Volvo EC700 C-Series crawler excavators

and one Volvo MC115C skid steer loader.

World-renowned Volvo articulated dumpers

were also aboard, including an A30E and

brand-new A40F articulated dump trucks

with 30 to 40 tonne payloads. This equip-

ment was necessary to perform more rigor-

ous and heavy-duty site work, as well as

the necessary bulk excavation and rock-fill

in the most cost-efficient manner. Adding

to the growing Babcock/Volvo fleet on the

island are an EC480 excavator, an EC380

excavator and four SD200DX compaction

rollers, among other machines.

30 000 tonnes of cargoThe project began with the construction of

a temporary landing facility at Rupert’s Bay

to accommodate the NP Glory 4, which, in

July 2012, was the first ever ship to unload

cargo directly onto St Helena Island. Since

then, the volume of material shipped to the

island underscores the scale of the opera-

tion. Around 30 000 tonnes of cargo has

been moved so far, including 500 tonnes of

sand from Namibia, more than 120 items

of construction equipment, 900 containers

and 1 200 tonnes of reinforcing steel. By

the end of the project, more than 20 mil-

lion litres of diesel fuel, 5 000 tonnes of

explosives, 27 000 tonnes of cement and

pulverised fuel ash, and 20 000 tonnes of

miscellaneous cargo have been moved.

Building the building to buildTo enable the transport of equipment and

material from Rupert’s Bay to Prosperous

Plain, where the airport site is situated,

Basil Read has built a 14 km-long haul road

Settlement monitoring instrumentation has been designed and installed at strategic stages

in the fill matrix to enable assessments of settlement during construction

Babcock supplied Volvo heavy construction vehicles


W: www.basilread.co.za | E: [email protected] | T: +27 11 418 6300

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

BUILDINGLEGACIES

1705

7 te

naka

.co.

za


that rises more than 500 m in the first 5 km

– quite an engineering challenge in itself.

Volvo equipment is being heavily deployed

on the construction of the airport runway,

which involves filling the Dry Gut gorge,

thereby creating an embankment that will

form part of the runway. As at February

2014, the Dry Gut fill was 65% complete

with more than 5 million m3 of material

placed through a 24-hour operational cycle.

Fill material is sourced from the site area

as the landscape and hills are levelled. The

Dry Gut fill, taking 24 months to complete,

should be completed by September 2014.

Work has also commenced on the

1 950 m-long concrete runway, a taxiway

and apron. This is due for completion in

May 2015. Construction of the terminal

building, combined air traffic control and fire

department, is progressing well and is on

schedule. Installation of aerodrome ground

lighting, navigational aids and air traffic

control equipment will begin in August 2014

and will completed and tested by mid-2015.

Construction includes a bulk fuel installation

for 6 million litres of diesel, petrol and avia-

tion fuel in Rupert’s Valley and an airport

fuel facility at the airport site.

The airport will be connected to the

island’s electrical, communications and

roads infrastructure. All construction work

and certification will be completed and

ready for the first flight in early 2016.

The St Helena Airport project incorporates many unique and unusual features that have required advanced engineering ingenuity and thorough planning

Fill material being sourced from the site area



THE NEW JOHANNESBURG office

will serve as a hub for the com-

pany’s sales and operations in

Southern African.

Altaaqa Global will bring its expertise, inno-

vative technologies, industry-proven reliabil-

ity and rapid deployment to the region, which

is largely known for its thriving oil and gas,

industrial manufacturing, and mineral and

coal mining industries. Peter den Boogert,

general manager of Altaaqa Global, says

that the company would provide Southern

Africa with the most advanced power plant

packaged systems, remote monitoring, and

fuel-efficient gas, diesel or dual-fuel-powered

generators. “Altaaqa Global and its sister

company in Saudi Arabia have a total com-

bined fleet of 1 400 MW rental power plant

generation readily available to serve the

Southern African region.”

One of the flagship innovations that

Altaaqa Global will offer is the flexible

Temporary power solutions for Southern Africa

operational mode that can switch from island

to grid mode in mere seconds. Furthermore,

Altaaqa Global’s energy rental dynamic pack-

age allows its power plants to hook directly

to the grid without the need for a substation.

In line with its avowed corporate social

responsibility programmes that aim to alle-

viate the social needs of its immediate

environs, Altaaqa Global will also continue

to provide job opportunities, extend imme-

diate assistance for school children, and

conduct educational campaigns on energy

conservation and environmental stewardship

in Southern Africa. Meyrick continued, “One

of the pillars of our sustainable business

model is employing and training local profes-

sionals in areas where we operate, and we

are excited to extend that commitment to

Southern Africa.”

Majid Zahid, strategic accounts director of

Altaaqa Global, says, “Southern Africa has

a promising economic outlook within the

energy, engineering, production, oil and gas,

and mining sectors, and we are delighted to

open our new office in Africa to provide our

wide range of highly innovative interim power

plants. We are determined to serve various

industries, such as oil and gas, petrochemi-

cals, mining, electric power utilities, indus-

trial manufacturing and maritime.”

Altaaqa Global has been aggressively mak-

ing inroads into the African market with the

opening of branch offices in several key

locations in the continent. “We have also

recently opened an office in East Africa,”

says Den Boogert. “We have appointed a

highly competent management team to over-

see our African operations.”

Hendrick Mtemeri has been appointed

as the regional director for the entire sub-

Saharan region, and Paul Heyns, a power

equipment engineering expert based in

Pretoria, and Oduor Omolo, power generation

professional based in Nairobi, have been

appointed as sales managers for Southern

and East Africa, respectively. “Under their

leadership, we will reinforce our presence in

Africa and ensure that we maintain close ties

with our customers.”

The economy of Southern Africa is largely

driven by the precious stone, mineral and

coal mining industry. South Africa, a leading

economy in the Southern Africa region, is

ranked as an upper-middle income economy

by the World Bank, and is touted to be the

largest African economy ahead of Nigeria.

Though still reeling from the effects of

its recent economic setbacks, the African

Economic Outlook expects South Africa’s

economy to moderately accelerate in 2014.

Angola’s economy, after experiencing slow

growth due to the recent oil and financial

crises, is also predicted to be on the

rebound and is expected to grow by 7.8% in

2014. Furthermore, Mozambique’s economy

is forecast to maintain its upward trend,

predicted to grow by 8% in 2014. Agriculture,

manufacturing, oil and gas, in addition to

mineral and coal mining, significantly con-

tribute to these countries’ GDP, as well as to

their employment rates.

A global leader in temporary power solutions has chosen Johannesburg as its location for its Southern African ventures, which will cater to a number of SADC countries, including South Africa, Angola, Botswana, Mozambique, Madagascar,

Malawi, Namibia, Zambia and Zimbabwe.



OVER THE LAST two years, we

have witnessed the arrival of solar

photovoltaic (PV) projects as the

government’s Renewable Energy

Independent Power Producer Procurement

Programme (REIPPP) has been rolled out.

The first and second packages saw the over-

seas providers arrive with European thinking

and equipment. The speed and volume of

installation needed for some of the larger

75 MW projects also saw a demand on

production figures that was uncomfortable

for local contractors. The IPPs themselves

did not expect the difficult dry and hard

rocky terrain that our more arid areas offer.

Hence installation of beam/pole supports

for the PV support frames proved challeng-

ing, says Cousins.

The hard formation on many sites required

pre-drilling through calcrete formations. Most

of our local drilling equipment was geared

around larger and deeper rock drilling and

proved in some cases expensive and not

within budgeted installation costs.

The small Orteco pile driver/drill rig

has evolved from use in the European

guard-rail installation industry into one

of the leading brands of solar-PV-post

installation equipment.

This small 4 t unit is highly versatile for

driving short steel sections into the ground

using a strong 1 000 J hydraulic percussion

hammer and having the capacity for shallow

Equipping for installation of solar PV support framesPilequipSA is a leading

supplier of geotechnical

and piling equipment in

South Africa. Established

in 2003, we have seen

the growth and changes of

demand for various types

of geotech equipment

within South Africa says

owner Boyd Cousins.

drillings of up to 3.5 m and 4 m using a DTH

hammer and small-diameter auger.

Pilequip has been actively supporting some

of the units currently in South Africa. From

this knowledge basis and from our strong

history of drilling equipment, we are the ideal

sales and support agent for Orteco.

Meeting with owner Segio Tessenrari at his

Italian Orteco factory, situated just outside

Bologna, was a pleasure, says Cousins. This

family-run business has been in operation

for over 20 years. Sergio has taken a very

simple rig idea and developed it himself into

a versatile solar unit that focuses on this

recently developed world market.

The Orteco units can be converted to do

many applications such as driving, drilling,

coring and even extraction of misaligned

beams. The rigs are ordered to match cus-

tomer requirements and can be built to run

remotely for improved operator safety.

Orteco has even developed a com-

plete GPS remote system whereby preset

installation-pole patterns can be prepro-

grammed into the control box and, with

aid of local survey base stations, the rig is

completely automated.

Pilequip is confident that this unit is ideal

for many of our solar projects and for other

applications such as fence-post installa-

tions, core drilling, mini piles and even short

screw piles for light loads. “We are confident

that soon we shall establish a few units here

for rental,” concludes Cousins.

ORTECO HD 1000 unit on solar PV project

H/OFFICE: 14 Atlas Road, Anderbolt, BoksburgTel: (011) 306-0700 • Fax: (011) 918-7208e-mail: [email protected] • Website: www.elbequipment.com

BRANCHES & DEALERS RSA AND EAST AFRICA: BRITS: (012) 250-1565 • CAPE TOWN: (021) 933-2383DURBAN: (031) 464-6522 • EAST LONDON: (043) 748-1469GEORGE: (044) 878-0874 • KIMBERLEY: (053) 841-0040 MIDDELBURG: (013) 246-2312 • NAIROBI: (00254) (0) 20 807 0728 NELSPRUIT: (013) 755-1003 • POLOKWANE: (015) 293-1978 PORT ELIZABETH: (041) 451-0232 • WOLMARANSSTAD: (018) 596-3032

BRANCHES & DEALERS SOUTHERN AFRICA: BOTSWANA: (00267) 240-4320 • LESOTHO: (00266) 2831 3926 MOZAMBIQUE: (00258) 219-00469 • NAMIBIA: (00264) 61-234-052 SWAZILAND: (00268) 518-5348 • ZAMBIA: (00260) 212-210-642 ZIMBABWE: (00263) 448-5771/5

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and

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CONSTRUCTION DIVISION:• Compaction Equipment• Backhoe Loaders• Chain Trenchers• Trenchless Technology• Mole Pneumatic Piercing Tools• Mini Excavators• Skid Steer Loaders• Telescopic Handlers

EARTHMOVING DIVISION:• Excavators • Front-end Loaders• Bulldozers

MINING AND QUARRYING DIVISION:• Mobile Crushers• Mobile Screens• Washing Plants• Rock Drills• Conveyor Belting• Minerals Processing Systems• Static & Modular Crushers & Screens• Blockmakers• Hydraulic Breakers• Telescopic Conveyor Systems• Optical Belt Scales• Modular Plants• Excavator Attachments• Heavy Duty Static & Mobile Rotary Barrel Screens



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second story of a building. Often they will

reverse, and start lowering the boom at the

same time. Very quickly, the machine moves

into an overloaded zone and the boom lower-

ing is cut by the machine’s electric system.

With any other machine, the operator will

have to stop lowering, retract the boom

manually until the machine is out of the over-

loaded zone, and then continue lowering the

boom. This is repeated a few times before

the load is actually low enough for the opera-

tor to drive the machine. Our machine is

different: when ‘stacking mode’ is selected

on the smart handling system, it allows the

boom to be automatically retracted if it gets

into an overloaded zone while lowering, and

then continues with manual control once the

machine is in a safe zone. All automatically,

every time! What this means is that our

customers enjoy an automatically continual,

safe and controlled workflow, even if the

operator puts the machine into an overload

situation,” says Brown.

The telehandlers complement Wacker

Neuson’s comprehensive range of excava-

tors, skid steer loaders, dumpers, wheel load-

ers and telewheel loaders. “Our machines

get the job done fast, effectively and effi-

ciently, while operating costs are kept to a

minimum. In other words, maximum results

with minimum input,“ concludes Brown.

Wacker Neuson telescopic handlers of 6 m lifting-height class have an innovative lift-arm control system


THE ZERO TAIL swing excavator EZ38 from Wacker Neuson

scores with its compact dimensions as well as a spacious

and ergonomic cabin.

Tight job sites are no problem for the EZ38. The com-

pact machine from Wacker Neuson with zero tail swing is charac-

terised by flexibility in use and a great deal of manoeuvrability. For

contractors, this means a variety of application areas and a high

level of economic efficiency. Operators benefit from the comfort of

the completely revised cabin.

Operational comfort and safetyThe EZ38 is compact on the outside, and spacious on the inside

– a combination that every operator enjoys. For narrow or com-

plex job sites, as is often the case in urban areas, the operator

does not have to worry that he could damage the machine while

working or block traffic. The rear of the compact EZ38 excavator,

with an operating weight of 3.8 tonnes, never projects over the

excavator’s undercarriage. At the same time, the cabin interior

is designed to be spacious and ergonomic – with clear thought

given to an intuitive design arrangement, safety and operating

comfort. A particular added comfort is the flat spacious foot-

well of the EZ38 excavator that can also be expanded through

fold-down accelerator pedals. It is more than just the operator

A new zero-tail-swing excavator offers ergonomic sophistication, flexibility and great manoeuvrability.

Zero tail swing, lots of play

ABOVE Wacker Neuson EZ38 compact excavator with zero tail swing

Vermeer, the Vermeer logo and Equipped to Do More. are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries. © 2014 Vermeer Corporation and Equipment Suppliers (Pty) Ltd. Southern Africa. All Rights Reserved.

WE LOOK FORWARD TO WELCOMING YOU TO OUR

NEW, PURPOSE-BUILT PREMISES EARLY 2015!

NO. 1 BRETT PARK, 11 JERSEY DRIVE, LONG MEADOW BUSINESS PARK EAST

JOHANNESBURG, SOUTH AFRICA

Equipment Suppliers (Pty) Ltd.Southern Africa

VERMEER.CO.ZA | +27 (0)11 608 0893

VERMEER HELPS MEET YOUR TOUGHEST UNDERGROUND CHALLENGES.

THIS IS WHERE THE NAME ON THE MACHINE MATTERS MOST. Whether you’re facing a tight, congested urban setting or a remote river crossing, Vermeer and ourglobal dealer network will be right beside you. We know the conditions you work in are demanding – it’s why we make equipment that’s up to the task. We offer the industry’s most complete lineup of horizontal directional drills, tooling, and accessories designed to take on your installation challenges. So when it’s tough going out there – look to Vermeer – the trusted name for proven equipment and reliable support.



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Head Office: 12 Commercial Road, Wadeville, Germiston, 1422 Tel: 011 323 2000 Fax: 011 902 1112 Email: [email protected] Branches: Spartan: 011 974 1971Bloemfontein: 051 435 0214 / Worcester: 023 342 0609 / Vryburg: 053 927 2209 / Namibia: 0026 (46) 722 1942 / Botswana: 00267 391 4957

We Supply:● Anionic and Cationic Emulsions● Modified Bitumen Binders● Pen Grade Bitumen ● Bitumen Primes ● Bitumen Rubber

Products are sold in 200ℓ drums or in bulk. Distribution, as well as application teams.

Leading manufacturer,supplier and applicator oftop quality bituminous roadbinders and emulsions.

Largest fleet of bitumendistributors south of theSahara at your service.

who benefits from these advantages; the

machine owner can also be assured that

his employees have the ideal environment

for fatigue-free, focused work. This is the

best prerequisite for high productivity and

satisfied employees.

With up to three auxiliary control circuits,

the excavator offers connection options for

a variety of attachments and therefore more

flexibility for the contractor. Thanks to the

standard fitted additional section on the

manifold block for the second and third con-

trol circuits, retrofitting with minimum effort

is possible. This makes the compact exca-

vator even more productive and provides for

versatile application areas in the long term.

Easy maintenanceLow clearance heights are also not an

obstacle: the cabin or the canopy can easily

be removed by loosening four screws. The

EZ38 is quickly ready for use again at the

site of operation. Maintenance of the zero

tail EZ38 is also extremely user friendly. The

tiltable cabin directly uncovers the underlying

components. All maintenance components,

such as fuel, air, oil and hydraulic oil filters

as well as the water and hydraulic coolers,

are easily accessible thanks to the laterally

placed engine. In addition, the side panels

are easy to remove. Necessary service work

can be carried out directly on-site easily and

in a time and money-saving manner – that’s

practical and service friendly.

The opening system for the front wind-

shield is also extremely practical. Thanks to

a front windshield mechanism, the operator

has the option of securing both the lower

as well as the upper part of the window

beneath the cabin roof. This not only facili-

tates the ventilation of the cabin, but the

separate removal and cumbersome storage

of the lower front window is also omitted

and the windows are better protected from

damage. In addition, this system offers vari-

ous opening versions, such as the ventila-

tion position or dialogue position, in which

the lower window is pushed under the upper

window portion, thereby ensuring fresh air

in any weather.

FlexibilityThe compact design with zero tail swing

makes the EZ38 excavator by Wacker

Neuson the ideal device in urban narrow-

ness, because it can also be used without

any separation to buildings. The optional

vertical digging system (VDS) – the inno-

vative revolving superstructure tilting by

Wacker Neuson – gives the machine addi-

tional flexibility in use.

Even on uneven surfaces, inclines and

declines of up to 27% can be compen-

sated for at the push of a button. VDS

not only provides greater safety, but also

increased efficiency.

Through exact vertical digging, the end

user saves up to 25% in material and time

when excavating and filling. The ergonomics

also pay off here, because the upright seat-

ing position relieves the back and allows

the operator fatigue-free work. As the only

manufacturer in the compact excavator seg-

ment, Wacker Neuson has been offering the

revolving superstructure tilting function for

over 20 years.



AN EFFECTIVE SERVICE structure

can make or break a project,

especially when it comes to down-

time. To meet increasing demand,

EPH Plant Hire has increased their offerings

as well as their support.

“To meet increasing demands in the hire

industry, we have increased our rental fleet

with the purchase of eight new Komatsu

PC200 excavators, which have been fit-

ted with Atlas Copco MB1700 hammers,”

states EPH Plant Hire’s Enzo Chiocchi.

Across bordersEnzo explains that EPH Plant Hire was

established in 2004 to accommodate the

demand in the hire market for quality exca-

vators with hammers. “We are situated

in Centurion, Gauteng, but our hire foot-

print covers the entire country, as well as

Lesotho and Mozambique.”

EPH Plant Hire’s specialised fleet of exca-

vators, fitted with hammers/peckers or

buckets, comprises 30 machines ranging

from 5 tonne mini excavators to wheeled

excavators up to 30 tonnes. The com-

pany purchased the first hammer from Atlas

Copco in 2007 and due to its outstanding

quality and performance over the past six

years, it made sound financial sense to

continue supporting the Atlas Copco brand.

The 1700 and 2200 hammers are ideally

suited to their fleet and can be fitted to EPH

Plant Hire’s carriers, which include 20 to

35 tonne excavators.

Low maintenance, high uptimeThe MB1700 hydraulic hammers also boast

a number of operator and maintenance

friendly features such as the self-greasing

and auto control systems. “A consequence

of low maintenance is increased uptime

and productivity,” remarks Chiocchi. “Atlas

Copco hammers hit harder and last longer

so when it comes to hydraulic hammers,

Atlas Copco remains our hammer supplier

of choice.”

Discussing the current market climate,

EPH Plant Hire sales manager Brendan

Badenhorst says there are numerous chal-

lenges in this highly competitive market.

“One of our main challenges is the fact that

many sites are located in remote areas.

Customers rely on the reliability of our equip-

ment because they simply cannot afford

downtime. It takes time to reach outlying

areas and to address this challenge, our

main focus is on long-distance service and

maintenance. We have developed an effec-

tive service structure that includes multiple

service teams to keep our machines running

smoothly so that we can keep our custom-

ers’ downtime to a minimum, regardless of

their location.”

In closing, Badenhorst says, “To pro-

tect our reputation as a supplier of hire

equipment that delivers maximum perfor-

mance and reliability, we purchase only the

best brands, like Atlas Copco, to reduce

the risk of equipment failure and unplanned

downtime for our customers. This gives us a

competitive edge.”

Hammering it homeAtlas Copco Construction Technique, one of

four business areas within the Atlas Copco

Group, supplies portable compressors and

generators, road construction equipment,

construction tools and all related services.

“Our wide range of world-class construction

equipment meet the stringent demands of

the construction industry across diverse

applications including demolition, compac-

tion, levelling, screening, recycling, rock

drilling and concrete surfacing,” says Atlas

Copco business line manager: Construction

Tools Division Neville Stewart. “Our ham-

mers, engineered to ensure maximum per-

formance and rugged reliability, incorpo-

rate features that protect the customer’s

investment as well as the environment,”

concludes Stewart.

Hydraulic hammers hit harder and last longerWith many construction sites in South Africa situated in remote areas, being in the business of construction equipment hire comes with very specific challenges.

One of EPH Plant Hire’s eight new Komatsu PC200 excavators fitted with an Atlas Copco MB1700 hammer

Performance and efficiency originals.www.wackerneuson.comHead Office: Johannesburg: 011 672 0847 Branches: Cape Town: 021 981 2197, Durban: 031 569 1200

ECOlogy + ECOnomy =

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SA

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IMESA

AECOM [email protected] Broom Road Products [email protected] SA [email protected] [email protected] Manufacturing Infraset [email protected] Africa Group Holdings [email protected] Consulting [email protected] Bosch Munitech [email protected] Stemele [email protected] Brubin Pumps [email protected] Consulting Engineers [email protected] Consulting Engineers [email protected] Corrosion Institute of Southern Africa [email protected] Built Environment [email protected] Bank of SA [email protected] Plastics [email protected] Engineers [email protected] Kent Metering [email protected] Engineers [email protected] South Africa (Pty) Ltd [email protected] [email protected] Consulting [email protected] Goba [email protected] [email protected] Technology [email protected] Enterprises [email protected]@Consulting [email protected] Consulting [email protected] [email protected] Environment [email protected] and Green [email protected] Water [email protected] Consulting Engineers [email protected] & Templer (K&T) Consulting Engineers [email protected] Base [email protected] Water [email protected] Narasimulu & Associates [email protected] Padayachee & Associates (Pty) Ltd [email protected]

Maragela Consulting Engineers [email protected] [email protected] Macdonald PDNA [email protected] Asphalt [email protected] Consulting [email protected] Engineering Systems [email protected] [email protected] [email protected] HaskoningDHV [email protected] SABITA [email protected] [email protected] [email protected] Water Systems [email protected] Consulting [email protected] Lines [email protected] SA [email protected] Water Company [email protected] [email protected] [email protected] Sobek Engineering [email protected] African Society for Trenchless Technology [email protected] Consulting [email protected] Pumps Wastewater [email protected] Syntell [email protected] Engineers East London [email protected] Consulting [email protected] Consulting [email protected] [email protected] VIP Consulting Engineers [email protected] VOMM [email protected] VUKA Africa Consulting Engineers [email protected] Institute of Southern Africa [email protected] Water Solutions Southern Africa [email protected] South Africa [email protected] [email protected] [email protected] Group Africa [email protected] Surfacing [email protected]


Performance and efficiency originals.www.wackerneuson.comHead Office: Johannesburg: 011 672 0847 Branches: Cape Town: 021 981 2197, Durban: 031 569 1200

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BOBCAT TELESCOPIC handlers

are built for precise position-

ing of bulky and heavy loads

and combine best-in-class lifting

capacity (even at maximum reach) and out-

standing stability for efficient, easy, reliable

and safe work performance anywhere on a

job site.

TransformativeBy adding a full range of dedicated attach-

ments, the telescopic handler is trans-

formed into a multipurpose material han-

dling machine. With no less than a quick,

tool-free attachment change, the telescopic

handlers can operate as a man platform,

a crane or a concrete placing machine,

accessing locations that are normally

impossible for ordinary man platforms or

cranes to reach.

Shift on the flyThe hydrostatic transmission, in two drive-

speed ranges, helps to maintain accurate

and precise machine control even in small

or restricted work areas. The inching pedal

allows for smooth manoeuvring at very

low speed and provides maximum stability

and braking precision, regardless of the

load. Shift on the fly ensures smooth gear

changes and reduces wear while dynamic

braking gives a smooth, safe ride.

SafetyThe aggravating movements arrestor (AMA)

offered in all Bobcat telescopic handlers

prevents dangerous movements during

operation of the machine. The longitudinal

movement indicator, which complements

the AMA, clearly displays the machine’s

longitudinal stability.

Multipurpose telescopic handlersA new range of telescopic handlers packs a powerful punch with optimum performance, precision, reliability and safety all in one compact machine.

Bobcat tele-handler TL360 with bucket attachment for construction industry


INDEX TO ADVERTISERS

sa

2014 GAUTENG

IAIAsa 19TH ANNUAL NATIONAL CONFERENCE

SUSTAINING DEVELOPMENT FOR LIFE IN SOUTHERN AFRICA

27 - 29 AUGUST 2014TO REGISTER GO TO:

www.iaiasaconference.co.za or email: [email protected]

MetsiWATERamanzi

matimadi

IAIASA 19TH ANNUAL NATIONAL CONFERENCE

2014 GAUTENG

www.iaiasaconference.co.za

INDEX TO ADVERTISERS Afri-Infra 63

Afrisam OBC

AMMANN Construction Machinery SA 18

Aveng Manufacturing Infraset 22

Babcock 78

Basil Read 80

Bell Equipment 86

Concrete Manufacturers Association 20

Corobrik 2

Echo Prestress 50

ELB Equipment 84

Electra Mining 44

Esor 17

Gibb 47

IMESA Conference 60

International Association of Impact Assessment 92

Jan Palm Consulting 64

Joat Group IFC

Kaytech 24

Kerb-Master Stormwater Systems 26

Lafarge Industries 28

Maccaferri Southern Africa 59

Model Maker Systems 74

Much Asphalt 30

National Asphalt 56

Noshcon 2014 65

Osborn Engineered Products SA 32

Pan Mixers South Africa 43

Pilequip 82

PPC 16

Precision Meters 69

Sabita 34

Sasol 10

SBS Water Systems 12

SMEC South Africa 57

Spraypave OFC

Terraforce 54

TFM Holdings 40

The Concrete Insitute 41

Tosas 88

Vermeer Equipment Suppliers 87

Wacker Neuson 91

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