april 2014 constructionworld - crown publications · economy’ thela stated that the national...

Waterfall – Africa’s FASTEST-GROWING URBAN NODE

SAFCEC CHANGES ITS NAME

Massive water TRANSFER SCHEME IN BOTSWANA

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WORLDAPRIL 2014

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http://www.lafarge.co.za/

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CONSTRUCTION WORLD APRIL 2014

> CONTENTS

COVER STORY

04KEY TO gROw ThE ECOnOmY Sustaining consulting engineering is key says CESA president.

6 RESiliEnT pERfORmanCE Despite difficulties, the Aveng Group is solid.

12SETTing ThE STandaRd Standard Bank’s Rosebank offices sets benchmark for green building.

18EnViROnmEnTal COnSidERaTiOnS The balance between projects and the integrity of environments.

20dRiVing afRiCa’S faSTEST-gROwing uRban nOdE Waterfall City has recently been launched to market.

22iSland ViEw bERTh 2 upgRadE This forms part of the ongoing Port of Durban upgrade.

28bOTSwana’S maSSiVE waTER SChEmE Scheme to ensure water for industry growth.

30CEnTRaliSing TO a nEw wORld-ClaSS faCiliTY Atlas Copco invests further in Africa with new head quarters.

34TRiplE bOTTOm linE SuSTainabiliTY The Bivane dam has had a remarkable impact on the community.

38pRECaST ingEnuiTY aT impumElElO Innovative method could well herald a new era for large structures.

44 EffiCiEnT dEliVERY The Jeffreys Bay Wind Farm is a fast tracked project.

36 pOmOna ChallEngE Piling for a new warehouse in Kempton Park.

52maChinE hEalTh and lOCaTiOn: iT paYS TO KnOw The Barloworld Equipment Monitoring Bureau.

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REgulaRS

Marketplace

Environment

Property

Project Profile

Projects & Contracts

Equipment

Products & Services

Diary & Appointments

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The geotechnical division of Stefanutti Stocks, based in Gauteng, offers the design and construction of various types of piles, geotechnical investigations and reports, lateral support, rock anchoring, shot-crete, void fill/compaction grounding and specialist grouting.

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COMMENT

EdiTORWilhelm du Plessis [email protected]

adVERTiSing managEREugene Botha [email protected]

laYOuT & dESignLesley Testa

CiRCulaTiOn Karen Smith

paid CiRCulaTiOn:(Fourth Quarter ’13)

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fREE CiRCulaTiOn:(Fourth Quarter ’13)

4 645

TOTal CiRCulaTiOn:(Fourth Quarter ’13)

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publiShERJenny Warwick

publiShEd mOnThlY bYCrown Publications ccP O Box 140BEDFORDVIEW, 2008Tel: 27 11-622-4770 • Fax: 27 11-615-6108

pRinTEd bYTandym Cape

The views expressed in this publication are not necessarily those of the editor or the publisher.

The GBSCA customised a rating system for local use that is based on the Australian Green Star rating system. It uses this to set standards for green buildings and provides clear guidelines as to what ‘green building’ is.

In South Africa it is a voluntary rating system that allows the commercial property sector to have their developments inde-pendently rated and certified. The tool for new developments obviously encourage developers to minimise the future environ-mental impacts of developments.

These include buildings with lower energy and water consumption and lower operating costs.

In 2013’s survey by McGraw and Hill called ‘World Green Building Survey’, it is stated that 51% of South African companies will build green by 2015. This will most notably be in the commercial markets and implies that outside investors, developers and owners will have an increasingly important role to play in the growing green building industry.

As the built environment is responsible for about one third of all carbon emissions an increased focus on green building becomes more important for government, developers and the general public. In South Africa it is encouraging to see that government, by far the largest land owner and operator of land,

is leading by example and accelerating sustainability in the built environment. From 2012, nine government build-ings have achieved Green Star SA status.

Organisations within the financial sector are increasingly recognising the long term benefits of green building: increased rental rates, asset value, reduced risk of depre-ciation, and higher tenant attraction and retention rates. Banks are increasingly building green – Nedbank, Old Mutual, Standard Bank and Firstrand Bank are leading the way.

In addition various businesses are also going the green route because of the obvious benefits. This is partly due to the fact that developers are now keeping increasing utility costs, potential carbon taxes and stricter regu-lations in mind. In addition most developers have realised that green building can more easily retain tenants for longer than conven-tional buildings.

South African tenants now require buildings that provide healthier and more productive environments while buildings must be such that they can reduce energy resources.

Green building has three big advantages: for developers it holds bottom-line benefits, it has clear environmental advantages and for users of such buildings it has obvious advan-tages – from an operational and a health and productivity point of view.

The green building Council of South africa (gbCSa) recently certified its 50th building. This an indication of the growth in green building in South africa and also a compliment to the gbSCa which (after just six years) has activated widespread support for such buildings in the commercial sector.

Green building is increasingly being supported by government, business and financial institutions. From top to bottom: The Department of Environmental Affairs, Portside and the Deloitte Building.

wilhelm du plessis

EdiTOR

Twitter: @ConstworldSa

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http://www.komatsu.co.za/

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overnment, through the NDP, has identified infra-

structure development as key to the socio economic development of the country. Thela believes that the NDP and

its objectives will never

Pipeline key CESA is pleased that Government has prioritised infrastructure development as a key component of accelerated economic development. In his 2013 medium term budget policy statement Minister Pravin Gordhan allocated R827-billion to infra-structure for the three year period ending 2015/16. They welcome this announcement but are concerned government has not yet revealed the project pipeline going forward. The industry needs this information to commit to long term planning and invest-ment in more resources. Although there were delays in implementation since the NDP which was adopted at the end of 2012, the organisation is looking forward to an acceleration of this programme in 2014.

With Government’s plan to grow the economy and triple GDP by 2030 the consulting engineering Industry has a significant role to play in achieving this growth through infrastructure develop-ment. Thela stated, “The consulting engi-neering industry is facing a number of challenges but by far the most challenging is how consulting engineering services are currently procured, as it is stifling the industry”.

Quality key for procurementWhile CESA does not oppose competitive bidding, which is a constitutional impera-tive, they do not believe that price should be the determining basis.

The organisation believes that it should be based on quality taking into account the bidder’s qualifications, experience, capa-bility and innovation.

The bulk of infrastructure cost lies in construction and maintenance with the cost of consulting engineering only being 1 - 2% of the project lifecycle cost. So it makes perfect sense that a procurement system that takes the entire project life

cycle into account should be implemented when procuring consulting engineering services. Consulting engineers need to go back to their very important role of being trusted advisers to the client providing advice on planning and design and its impact on construction operating and main-tenance costs.

As an interim measure CESA calls on Government to reintroduce quality as part of the total procurement points calcula-tion alongside price and BBBEE points. At the same time they challenge Govern-ment to conduct a comprehensive research and review of the current procurement system to determine its impact on the consulting engineering industry and infra-structure development in the country.

Access to opportunities There is a strong outcry from emerging and small consulting engineering firms, particularly those who are not specialist, over the lack of access to large projects from government and public entities. These firms provide an important vehicle for empow-erment within, and transformation of, the industry. CESA believes that the participa-tion of emerging and small firms in large projects can be best facilitated by using targeted procurement procedures by either specifying minimum participation goals as a percentage of the contract amount or spec-ifying portions of services which must be subcontracted to targeted enterprises.

Infrastructure investmentKPMG estimated an infrastructure spending gap of R6,5-million between the planned MTEF and PICC infrastructure spending and the infrastructure spending based on the NDP target of 10% of GDP. Part of this spending gap will have to be funded by the private sector. The NDP also intends to raise the private sector infrastructure contri-bution from 10% to 20% of GDP to drive the intended growth. CESA states that a

to GROWKEYthe economy

Consulting Engineers South Africa’s (CESA) newly

appointed President, Abe Thela, recently presented his presidential message

and theme for the year at a function held in

Johannesburg. With the theme of ‘Sustaining

Consulting Engineering is Key to Growing the

Economy’ Thela stated that the National Development

Plan (NDP) was created in order to develop South

Africa’s economy.

Consulting Engineers South Africa’s newly appointed President, Abe Thela and its CEO, Lefadi Makibinyane.

come to fruition unless there is involvement of consulting engineers at the forefront of this development.

Consulting Engineering, although a relatively small sector, has a large multiplier effect on the development of infrastructure as consulting engineers are the designers that create the large scale infrastructure projects that employ large numbers of people during the construction, operation and maintenance phases of infrastructure.

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clearer project pipeline, more standardisa-tion of deal structures, policy stability and better information about the performance of projects at their various stages would all encourage infrastructure debt invest-ment. SA business has further identified regulatory uncertainty, inclusive growth, education and skills and labour relations as affecting investor confidence.

CESA is committed to working with Government to address these constraints where they affect the consulting engi-neering sector. The potential of PPPs to entice private sector investors into infra-structure development is not fully appreci-ated in SA. Government must address regu-latory constraints to unlock this potential.

Call for changes CESA supports BBBEE as necessary to transform business and contribute to the eradication of inequality – a NDP objec-tive. However, the current requirement for

a consolidated/joint BBBEE scorecard for joint ventures discourages the formation of joint ventures which are crucial for skills transfer between large and small firms, international and local firms as well as for creating critical mass between smaller firms to enable them to handle larger projects. CESA proposes that a formula be devel-oped to enable calculation of consolidated BBBEE scorecards of two or more entities forming a JV.

With projects getting bigger and some taking more than three years to implement from design to construction completion, CESA urges Government to review and align the Municipal Finance Management Act and Municipal Systems Act. This will sort out the issue when appointments are made for consulting services for a fixed three year term and the project runs over this period.

CESA is also lobbying to have consulting engineering alongside other built envi-ronment professions designated as a local

Attending the event, various high-pro-file guests, including champions of the infrastructure industry, government

officials, engineering clients from both the private and public sectors, as well as SAICE members were challenged by the global figures of 780 million people living without access to safe water and the 2,5 billion who lack adequate sanitation. Diseases caused by unsafe water, inadequate sanitation and accompanying lack of hygiene kill more than 5 000 people each day.

In his address titled Taking Civil Engi-neering to the remote and marginalised areas of South Africa and beyond – forward with Civilution, which was motivated by his background, Mkhacane discussed the seven ‘crocodiles’ hindering the delivery of services. These include diminishing technical capacity specifically in state institutions, quality of engineering education, corruption in the engineering profession, engineers’ effective participation in the National Development Plan, technical leadership and learned society, awareness of what engineering professionals actually do, and career guidance schools.

Mkhacane challenged all engineering practitioners, “These days it is a common thing to see communities toy-toying to register unhappiness with poor service delivery.

You may ask, what are we doing wrong? I say we because as civil engineering profes-sionals, how can we dissociate ourselves from

service to receive preference over interna-tional companies, who do not have a pres-ence in South Africa, when bidding for work.

Infrastructure needs a cadre of engi-neers focused not only on planning, design, tender specification, evaluation and adju-dication but also on maintenance and operation – localisation needs to be looked at carefully as you cannot create employ-ment and address inequality unless South African companies are utilised to their maximum capacity.

Lack of technical capacity An added challenge is the serious lack of technical capacity within Government. In order for tender documents to be effective they need to be prepared, and subsequently tenders need to be evaluated, by competent engineers in Government or a consulting engineering consultant with input from

Forward with CIVILUTIONThe South african institution of Civil Engineering (SaiCE) inaugurated its 112th president, Stanford mkhacane, at the SaiCE presidential inauguration and gala dinner recently.

infrastructure provision, especially when a six year old child dies in one of the pit latrines still used in 11 450 of the 26 000 schools across the country? In the eyes of society civil engi-neering may be seen to be failing.”

As a civil engineering practitioner, born and bred in Mhinga in Limpopo Province, he shares his views on what it would require from the civil engineering fraternity to ensure that learners in the remote and marginalised areas within urban municipalities receive the necessary career guidance for making decisions on following civil engineering as a career. He suggests that individuals or groups

The South African Institution of Civil Engineering (SAICE) recently inaugurated its 112th president, Stanford Mkhacane.

The 2014 SaiCE Civilution CongressThis congress will be held at Emperors Palace from 6 to 8 April 2014 and will address many of the issues facing engineering, including those raised in Mkhacane’s address. Civilution is a new era for engineering professionals motivating engineers of all disciplines to conduct business differently. It is also where engineers play the role of history makers bringing about transformation, diversity, leadership and evolution in our local and global society for its betterment and of the quality of life, with collaboration between communities and government. It aims to highlight the important role that engineers can play in this sphere. Engi-neers are innovators and through innovation economic competitiveness arises. Civilution will direct engineers along this path of intellectual revolution where they have the power to impact communities and create awareness of the need for our pivotal engineering skills.

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of professionals should infiltrate schools by adopting them and then spending time influencing learners’ early subject choices towards engineering.

Mkhacane concluded his thought-pro-voking address, “I am calling upon all civil engineering professionals – from Limpopo to the Western Cape, from Mpumalanga to North West, from the Eastern Cape to the Northern Cape, from KwaZulu-Natal to the Free State and Gauteng. Let us together embrace the spirit of Nelson Mandela; let us intone the spirit of Mahatma Gandhi; let us emulate the spirit of Beyers Naude; let us follow the courage of FW de Klerk; let us put our thoughts and energies together and take civil engineering to all the corners of our country and beyond – forward with CIVILUTION.”

Continued on page 6

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Commenting on the results Aveng Group CEO, Kobus Verster said, “The second half of 2013 was as challenging as the first, with no

material improvement in infrastructure spending in South Africa and Australia. Market conditions, particularly in South Africa, remain difficult but optimisation programmes have delivered pleasing cost benefits across the Group.”

Notwithstanding the challenges expe-rienced, a significant improvement was achieved in the performance of the Construc-tion & Engineering: South Africa and Rest of Africa segment when compared with the immediately preceding six month’s result ending 30 June 2013.

Operating performanceThe trading conditions experienced by the South African and Australian Construction & Engineering businesses remained chal-lenging, with the Group’s performance adversely impacted by labour disruptions contract execution and claim challenges in the first half of the year.

The Manufacturing & Processing part of the business performed well in a relatively soft market, which was also affected by labour disruptions.

Construction & Engineering: Africa and Rest of Africa saw revenue increased by 11% to R4,2-billion. This improvement is mainly due to the start of major contracts at Aveng Grinaker-LTA and increased activity on renew-able energy projects at Aveng Engineering.

started to lay the foundation from which the Group can strengthen its focus and optimise its performance. We nevertheless still have a way to go to drive delivery of the full poten-tial of our diverse business. The Aveng Group strives to ensure that the companies within its portfolio become leaders in the industry based on market share and profitability. The focus in 2014 will remain on further strength-ening our capabilities within the Construc-tion and Engineering operating groups.”

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>Despite Aveng Grinaker-LTA having an oper-ationally disappointing year in 2013, the operating group increased revenue by 10% to R3,8-billion from R3,4-billion in the compara-tive period. However the execution of current projects at lower margins, together with the still high level of fixed costs resulted in a net operating loss. Various initiatives have been implemented to improve the performance of Aveng Grinaker-LTA, including strengthening of management capabilities.

The segmental revenue from Aveng Mool-mans and Aveng Mining Shafts & Underground decreased 9% to R3,5-billion, while net oper-ating earnings were 24% lower at R295-mil-lion. Aveng Mining Shafts & Underground performed below expectations largely due to a combination of margin slippage at some South African projects and problems experi-enced on a mining contract in Chile. This was marginally offset by continued strong results at Aveng Moolmans, although it did not reach the levels of the comparative period due to the loss of a contract in Zambia.

Order book and prospectsThe order book is marginally down compared to June 2013, at a still-strong R36,7-billion (June 2013: R37,4-billion).

The Group anticipates improved trading conditions in the second half of the year against its comparative period.

Kobus Verster said, “The past six months have been characterised by consolidation and repositioning of the Aveng Group.

Through various interventions we have

Government’s supply chain. Minister of Finance, Pravin Gordhan, acknowledged that consulting engineers are key, and the exception, to Government’s ban on the use of consultants. Government does not have the capacity and this is particularly poor at Provincial and Local Government level.

CESA has made a number of proposals to partner with Government to assist with capacity. CESA member firms have the skills and the capacity to assist Government in unlocking infrastructure development.

The biggest issue is that the working environment for engineers in Government needs to be improved. Properly qualified and experienced individuals need to be appointed to critical Government technical posts and their contracts need to be based

RESILIENTThe Aveng Group interim results for the six months ended

31 December 2013 were released recently. Aveng Group CEO, Kobus Verster.

Key features • Revenue improved by 11% to

R27,6-billion (2012: R24,9-billion).• Net operating earnings down by 8%

to R503-million (2012: R544-million).

• Headline earnings per share down 21% to 82,1 cents compared with 104,5 cents in 2012,reflecting a substantial improvement against the immediate preceding six months ended 30 June 2013.

• Net cash position remained stable at R2,4-billion.

• Mining and Construction & Engineering: South Africa and Rest of Africa operating segments’ order books increased by 18% and 22% respectively from June 2013.

on their performance of technical work.

Eradication of corruptionCESA is committed to fighting corruption in procurement processes and has increased its capacity and ability to do so by recently creating a litigation fund and also forming partnerships with other corruption fighting organisations.

Basic education key Education is another challenge facing the industry. Basic education is key to the development of mathematics and science capabilities within the country forming the foundation required for the development of engineers. Teaching must be made to be a career of choice and attractive to top

achievers by paying salaries comparable to those of other professions. When looking at investment in a country the level of skills that the country has to offer is one of the many factors considered.

CESA ready to assist CESA fully supports the NDP but imple-mentation is key and this is where Govern-ment falls short and CESA and its member firms are able to assist. CESA is ready to engage and partner with Government to address these challenges. The organisa-tion has been lobbying Government for years on these issues and more recently with National Treasury who are reviewing procurement regulations following CESA’s interaction with them.

PERFORMANCE

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www.afrisam.co.za

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SAFCEC goes back to 1939 when it was founded as the South African Federation of Civil Engineering

Contractors, supporting established and emerging contractors, irrespective of their company’s size.

Times have changed, and it has grown leaps and bounds. Forum now better describes its way of business – SAFCEC presents a united voice on issues affecting the civil engineering contracting industry.

This name change could not have come at a better time. In 2013 SAFCEC was presented with am opportunity to strengthen the organisation through restructuring to ensure it is well placed to improve service delivery to members and to enhance transformation efforts internally as well as in the civil engi-neering contracting industry. It sees the name change as a significant symbol to illustrate all the changes and achievements to date as it celebrates its 75th anniversary.

He decl ined to present the programme of action for the current financial year, stating “that

programme will be presented by the new government after the elections.

“While the construction industry is grateful for the contribution the govern-ment has made, it is disappointed that there are no plans, as yet, for it to continue in this vein,” says Rob Johnson, executive director of the Master Builders Association of the Western Cape (MBAWC), a registered trade association for employers in the building industry.

“The industry is still recovering from the effects of the global recession and needs to have some measure of reassurance that the government, regardless of whether it remains in the hands of the ANC or is taken over by another party, will continue to support it. Government is in the best position to deliver a consistent workload to the construction sector and thereby reduce the effects of economic cycles. Our industry has the capacity to absorb large numbers of unemployed people, and thus enable the development of skills, if a steady workflow can come from government,” he continues.

“In terms of training and skills devel-opment, we commend the government’s achievements, particularly the increase in the number of enrolments at tertiary level,

NAME ChANgESafCEC has announced that an aspect of its name has changed. it is now registered as the South african forum of Civil Engineering Contractors (SafCEC).

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about SafCECSAFCEC is the leading voluntary employ-er’s organisation for the Civil Engineering Contracting industry in South Africa registered under the Labour Relations Act. Although the industry is united by profes-sionalism and the desire to collaborate, SAFCEC offers its members different areas of expertise and outlook.

SAFCEC acknowledges that its members are diverse. It supports them by meeting their individual needs for training, trans-formation, SHERQ, HR and labour rela-tions, economic affairs and contractual advice, irrespective of their size, so that they can stay informed and operative in an ever changing demanding environment. SAFCEC finds that its members stay and flourish in an environment that allows them to be their very best. SAFCEC enables its members to deliver a professional construc-tion service by assisting them in taking care of their employees’ safety and welfare, the environment and the community so that they can provide a foundation for our country’s development.

BEyONd 2014 in his recent State of the nation address, president Jacob Zuma said, “in 2012 we unveiled the national infrastructure plan, led by the president through the presidential infrastructure Coordinating Commission. we have subsequently invested one trillion rand in public infrastructure over the past five years. many of the projects are completed or are nearing completion.”

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the much-improved matric pass rate and interventions aimed at bettering maths and science. We also applaud their efforts to make further education more accessible both through the National Student Finan-cial Aid Scheme and the construction of additional FET Colleges,” says Johnson.

“We will continue to support govern-ment’s efforts through our artisan, skills and bursary programmes. However, these can never be on the scale required to service the industry as a whole,” adds the executive director.

“It is our hope that the party elected on 7 May 2014 will continue to build on the foundations laid by the current govern-ment,” concludes Johnson.

MBAWC executive director, Rob Johnson.

about the master builders association (mba)

The Master Builders and Allied Trades' Association of the Western Cape is a registered trade association for employers in the building industry. Its membership comprises some 400 companies in the Western Cape, most of whom are either builders, building subcontractors, building merchants or manufacturers of building products. The Association was founded in 1891 and is the oldest organisation of its kind in South Africa. It

is affiliated to MBSA, the Master Builders South Africa, but is totally autonomous.

The MBAWC's primary objec-tive is to ensure that the repu-tation of members in this area remains high and that invest-ment in building is therefore attracted to it. It does this by insisting that Members work to the highest possible standards, aesthetically, technically and ethically – in short, that they conduct their business in a thor-oughly professional manner at all times. Membership of the MBAWC is on a voluntary basis. Its members handle some 70% of all the building work in Cape Town and employ a similar percentage of the total building industry workforce.

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New York Stock Exchange listed Hill International, which is the global leader in managing construction,

mining and general industry risk, last year acquired local company, Binnington Cope-land & Associates which provides commer-cial and contractual and training services.

At the launch in Sandton, Hill Interna-tional chairman, Irv Richter said the slow-down in industry is resulting in an increase in disputes as margins become so tight that contractors find it difficult to absorb even minor losses which the may have absorbed in the more buoyant conditions of the past.

“The acquisition of Binnington Copeland coincides with an increase in demand for our traditional services such as construction claims support and all forms of alternative dispute resolution including adjudication and arbitration as well as commercial and contractual advisory services in sub Saharan Africa where we have not previously oper-ated,” said Richter.

CONSTRUCTION WORLD MARCH 2014

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ENhANCINg ITS OFFERINgbinnington Copeland & associates has been officially launched as a hill international company.

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Richter went on to say that the poor economic climate worldwide places greater pressure on contractors to ensure that they are equipped with the highest levels of expertise and knowledge. “Some African companies have withdrawn from international markets or are being more selective in the projects they undertake due to the reduced margins and increasing competition and this in turn results in greater competition for local work. This scenario often results in an increase in disputes as companies cannot absorb even minor losses. There is therefore an advantage in consulting Hill International through its subsidiary Binnington Copeland before such problems arise.”

Although Binnington Copeland has assisted clients for over 25 years the compa-ny’s acquisition by Hill will enhance the local company ‘s ability to find experts in any discipline and extend its service to clients wherever in the world they may be working. Chris Binnington, who will remain managing director of Binnington Copeland, says that with Hill’s over 3 800 professionals in more than 100 offices around the world Hill’s unmatched global footprint means that

the company can offer its clients local knowledge and international expertise to effectively manage their risk.”Similarly BCA staff will have an opportunity of gaining international exposure by being seconded to other Hill offices around the world.”

BCA specialist company, BCA Training will also benefit from the transaction by gaining access to an enlarged group of trainers and resources thereby offering local clients’ staff training in local and international contract issues. In keeping with Hill’s international policy of retaining local expertise and personnel and adding to these as required the local board will be retained with the addition of Irv Richter and Dave Richter from Hill.

www.basilread.co.za

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Commenting on the results, Group Five CEO Mike Upton said, “The sentiment in our markets is gradu-ally improving, with South African

demand still comparatively weak and the timing of a recovery remaining uncertain. The rest of Africa and Eastern Europe are demonstrating more visible opportunity.

In terms of the Competition Commis-sion findings of anti-competitive behaviour in the construction sector, Upton said, “As previously communicated, the group secured conditional leniency from the Commission in terms of the Commission’s Corporate Leni-ency Policy in return for full disclosure of all matters that the group was able to uncover during its internal investigation process. In late June 2013, it came to the group’s attention that the Commission is seeking a proposed administrative penalty on four projects in which the group was implicated and for which no leniency was granted. The group did not have sufficient evidence of its collusive involvement upon which to admit liability and could thus not responsibly accede to the penalties and chose not to settle hastily.

Looking forward, Mr Upton said, “The group’s total secured contracting order book, which represents the Construction and Engineering & Construction order book, stands at R14-billion.

Financial overviewGroup revenue from continuing operations increased by 55,7% from R4,9-billion to R7,7-billion, as a result of increased activity in all of the group’s businesses.

Headline earnings (HEPS) of 204 cents per share represents an increase of 40,7%

and fully diluted HEPS (FDHEPS) of 201 cents per share an increase of 39,6%, compared to restated HEPS and FDHEPS of 145 cents per share and 144 cents per share respectively for the comparable reporting period.

Operational overviewThe group’s underlying businesses – outside of the Civil Engineering segment – performed in line with management expectations and in accordance with the market guidance provided in November 2013. The Civil Engi-neering segment was affected by a decrease in profit recognition following management’s more cautious view on the estimated final completion margin on two contracts, one of which will be completed during F2014.

Investments and Concessions – 5,4% of group revenue Investments and Concessions consists of transport concessions and property developments.• Investments and Concessions delivered

another strong performance despite weak concessions markets

• Revenue, which consists primarily of fees for the operation and maintenance of toll roads, increased by 27,5% from R334,7-million to R426,7-million

Engineering & Construction – 20,2% of group revenueThe E+C business was established to deliver technology-based EPC, multi-disciplinary project management and construction, as well as operations and services solutions to selected growth sectors such as power, oil and gas and water. It continues to expand rapidly off a burgeoning order book in power and oil and gas.

Manufacturing – 6,8% of group revenueManufacturing consists of fibre cement building products business, Everite, as well as steel fabrication businesses BRI and Group Five Pipe.

Construction – 67,5% of group revenueConstruction continued to be the largest cluster in the group and its revenue increased by 37,4% from R3,9-billion to R5,3-billion.

Building and HousingBuilding and Housing revenue increased by 46,1% from R1,5-billion (91% local) to

R2,2-billion (98% local). The segment reported a 57,6% increase in core operating profit from R30,3 million to R47,8 million.

Civil EngineeringCivil Engineering reported a 40,7% increase in revenue from R1,5-billion (61% local) to R2,1-billion (54% local)

Civil Engineering experienced record revenues, with the underlying business generating margins as guided in the group’s November 2013 update to stakeholders. However, margins have been impacted by management’s more cautious view on the estimated final completion margin on two contracts

ProjectsRevenue increased by 16,8% from R872,7- million (19% local) to R1-billion (28% local)

The secured one-year order book stands at R1,2 billion. The full secured order book stands at R1,5 billion.

SOLID RESuLTSdespite challenging markets

In a year that mark’s Group Five’s 40th year as a listed group,

earnings demonstrate an improved performance over the

comparable reporting period and were delivered following the

corrective action taken in the last two years, specifically with regard

to the Construction Materials cluster and the group’s Middle

East operations.

Group Five CEO, Mike upton.

• Order book: maintained despite weak markets

∗ good sector spread ∗ geographically diverse, but

still value weighted to South Africa

∗ significant African traction expected in H2 in power, mining and transport

• Revenue: growth achieved in target sectors

• Profitability: in line with expectations, excluding Civil Engineering

• Cash: pleasing retention of cash balance in tough market

• BBBEE certification: reaffirmed as Level 2 contributor at 89,5%

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www.doka.co.za

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ENVIRONMENT

ome 4 000 parking bays have been provided in a basement consisting of five underground levels. A one hectare land-scaped piazza provides

a pleasant approach to the entrance and a green breakaway environment for the staff.

The project has been awarded a 5 Star GBCSA rating for sustainability.

Structural phaseThe structural phase of the project comprised a combination of 185 000 m2 of suspended, normally reinforced concrete flat and coffer slabs on a column grid of 8,4 m and a further 25 000 m2 of surface bed. The below street level parking slabs were generally flat slabs while the office floor levels incorporated an off-shutter exposed raking slab edge that was used to make up the depth of the raised access floor void and coffer slabs on the atrium bridge links. The walls of the fire escape stair shafts were constructed of in-situ concrete and these

provide the structural stability required in the two office blocks.

Pioneering green technology Pioneering technology such as floor to ceiling triple glazed façades has been provided to project natural light into the deep space using clear glass. A ‘responsive’ unitised façade was developed in collabo-ration with German experts to control heat, glare and sunlight. A single outer skin and a double glazed inner skin envelops a sealed air-conditioned cavity.

Motorised, custom designed, aluminium blinds within the cavity serve to harvest light by reflecting it into the space while protecting it from direct sunlight. The blinds respond automatically to the external illumination and climatic condi-tions via sensors that track the sun.

The building generates a portion of its own electricity from an Egoli gas main adja-cent to the site via a ‘Tri-generation’ plant in the basement. Also known as a CCHP (combined cooling, heating and power

12


A new landmark has emerged at the edge of

Rosebank’s urban district. WBHO commenced

construction of Standard Bank’s new Rosebank

offices in June 2010 and achieved Practical

Completion in May 2013. The 65 000 m2 of offices

now houses a workforce of 5 000 in two buildings

of nine and 11 floors that are connected by a

central glass atrium.

SETTING THE

13


ENVIRONMENT

generation), this plant produces heating, cooling and electrical energy simultane-ously from a single source, by using the rejected heat to warm and cool the building thereby providing a further saving on the use of electricity from the grid. Natural gas has the advantage of significantly lowering carbon emissions and the heat that is rejected in the process is captured by an absorption chiller which converts the energy into air-conditioning.

The plant’s current 1 MW capacity covers the buildings basic needs as it cannot be switched off at night but the capacity can be expanded to potentially supply surplus power back into the national grid in future.

A set of five Dynamic/Rotary UPSs have been installed to provide for the client’s requirement of three days autonomous full electrical supply. These Dynamic UPSs act

13


as normal standby generators and largely replace the need for a static UPS system and thereby obviate the need to replace and dispose of the batteries at the end of their life cycle. There is also no requirement for power factor correction equipment.

Other energy saving devices used include a DALI or digitally addressable lighting system for the automated switching and dimming of lights. (The the quantity of natural light demands a much lower degree of artificial lighting for most of the day resulting in a lighting power density of below 2,5 W/m2 per 100 Lux.)

Escalators are designed to be power saving by slowing to a crawl when not in use, while air-conditioning that incorpo-rates 50% more fresh air than conventional systems, and uses a combination of 40% air-cooled and 60% water-cooled chillers to provide the best balance between efficiency and water dependency.

Automated fabric roller blinds provide protection from direct sun in the three multi- level atriums.

Saving waterVarious water saving measures reduce the building’s water dependency by up to 50%. A large underground tank collects water harvested from the basement subsoil drainage system as well as rain-water harvested from the buildings atrium glass roofs. This water is used for irrigation and non-potable applications. All sanitary fittings were selected to meet the highest water efficiency criteria. Drip irrigation has been installed throughout the landscaped piazza to keep the 400 trees moist with minimal evaporation.

A building management system moni-tors consumption via multiple water and electricity meters and the like allowing for the quick detection of faults in the system, manages the operating efficiency of multiple systems as well as managing the operational integration of these systems.

In line with the GBCSA rating require-ments, extensive use has been made of

AboVE LEFt: A set of five Dynamic/Rotary uPSs have been installed to provide for the client’s requirement of three days autonomous full electrical supply.

Continued on page 14

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ENVIRONMENT

> The facility has been supplying electrical power to the regional grid since late November 2013. MWVS

wind farm will sell renewable energy to ESKOM for the next 20 years in accordance with the terms of the Power Purchase Agreement concluded between the parties in November 2012.

The 27 MW wind farm is situated in the Nelson Mandela Bay Municipality in the Eastern Cape Province. Nelson Mandela Bay is renowned for its excellent wind resource and is home to South Africa’s ‘windy city’, Port Elizabeth.

MWVS wind farm is 100% South Afri-can-owned, with 35% attributed to Black Economic Empowerment (BEE). A portion of the project is owned by the Metrowind

Community Trust which was established by the project developers as a vehicle to deliver their Corporate Social Investment (CSI) programme. In addition to the divi-dends payable to the community trust, 2,1% of the facilities annual revenue is being channelled into socio-economic develop-ment and enterprise development within the community.

MWVS wind farm has been under development since 2006. It was selected preferred bidder in terms of the Department of Energy’s Renewable Energy Independent Power Producer Procurement Programme (REIPPPP). Construction of the R550-million project started in November 2012 and is the first commercial wind farm operating under REIPPPP.

COMMERCIALLy OpERATIONAL

The directors and Shareholders of the metrowind Van Stadens (mwVS) wind farm, announce that on 2 february 2014 the facility completion milestone was achieved and the 27 mw wind farm has commenced commercial operations.

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green and recycled materials. Over 85% of all site generated waste and rubble has been recycled, thereby reducing the impact on landfill sites.

Minimising its impactPrior to commencement of construction, Standard Bank appointed an independent consultant to develop an Environmental Management Plan for the project. This plan was implemented and monitored inde-pendently by an Environmental Control Officer throughout the project duration. The project team undertook a pre-com-mencement noise and dust survey to assess the possible construction impact on local residents and businesses. Noise and dust levels were monitored and controlled over the duration of construction. Vehicle traffic, particularly trucks delivering materials to and leaving site, were restricted to the main routes and were not permitted to travel through residential areas.

There was an existing filling station on a portion of the site, prior to demolition, that had caused a considerable amount of contamination of the area around the fuel tanks. This contaminated material was removed to a hazardous waste site and the area rehabilitated.

Corporate Social InvestmentThe numerous site activities commencing with the construction of the concrete structure through to the basic wet trades, the services and finishes installation and through to the highly technical final building commissioning and integration created in excess in 8 000 jobs on site. Satis-fying both Greenstar and CSI opportunities, waste and offcuts of timber used during the construction phase was donated to four

Project information• Name of project: Standard Bank

• Project start date: June 2010

• Project end date: May 2013

• Client: The Standard Bank of South Africa

• Main contractor: WBHO Construction

• Architect: Grosskopf Lombart Huyberechts & Associates

• Prinicpal agent: Grosskopf Lombart Huyberechts & Associates

• Quantity surveyor: Norval Wentzel Steinberg

• Consulting engineer: Pure Consulting

churches in the Tembisa and Delmore areas to be used to provide cooking and heating facilities at their premises. Bricks were donated to a church in Mpumalanga that was in the process of undertaking reme-dial work to their buildings. Various mate-

rials and management time was provided from the site to assist with the construction of the Simunye Safe Haven, a safe haven for abused women and children, in West-onaria. The facility was officially opened in November 2012.

www.franki.co.za

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CONSTRUCTION WORLD APRIL 2014CONSTRUCTION WORLD MARCH 2014

ENVIRONMENT

SOLuTIONSCall for sustainable

Home improvement solutions for the low income housing market, that are innovative, affordable and use green

technology, could soon be available locally. This follows the call for entries to the Better Living Challenge (BLC)

competition that opened in February.

There are three entry categories: Structural home Innovative prod-ucts and materials to construct safe, sustainable homes. This could include components and systems for new, self-built homes, or systems that add bulk to an existing footprint in an affordable way. Fire-proofing, sanita-tion and flooding are key challenges that could be addressed.Comfortable home Products used to create enjoyable interiors. These could be affordable modular and space-saving furniture ranges; products that enhance temperature control and light, energy and water efficiencies; and systems offering privacy within multi-purpose spaces. Connected home This category calls for products and services that connect a home to its surroundings and beyond, digitally or physically. They could include food production and waste water systems, for example.

Jenny Cargill, who leads 110% Green, said, “The challenge differs from the usual design contests. It encompasses innovative marketing to test consumer acceptance of the designs and products on show, hopes to encourage financial institutions to provide new financial products to support self-improve-ment, and follow-up business support to award winning manufacturers and designers in the subsequent year.”

New Rest, Dunoon, Cape Town. (Photo: David Harrison)

The BLC is part of the Western Cape Government’s 110% Green initiative, which encourages organ-isations to commit to the Green

Economy. The competition is intended to take powerful ideas to market and to provide a platform for consumers to experience and interact with innovative solutions.

Designers and innovators, inventors and creators, students and professionals, manu-facturers and retailers (local and beyond SA’s borders) are all encouraged to enter.

Three winners will each receive support worth R500 000 to commercialise their home improvement solutions. Students will compete for a R40 000 cash prize.

The rollout will be project managed by the Cape Craft & Design Institute (CCDI), an organisation established in 2001 to promote and grow the economic sustainability of the Western Cape craft and design sector. This competition (WDC#204) is one of seven CCDI

projects selected for the Cape Town World Design Capital 2014 (WDC2014) programme.

CCDI executive director Erica Elk said, “Millions of South Africans live in dire condi-tions in informal settlements, backyard shacks and RDP houses. The need is much greater than the capacity and resources of government to deliver.

“We need to find solutions for home improvements that are affordable, result in better living conditions and quality of life, and provide people with the choices and resources to help themselves at their own pace. There are many needs and also many opportunities.”

Entries of new or existing prototypes and products can be submitted from 1 March - 31 May (www.betterlivingchallenge.co.za).

Winners will be announced in November 2014 and will receive tailored business and product support, starting the following year (2015).

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www.barloworldpower.com

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ENVIRONMENT

The Global 100 is an annual project and inclusion on the list is limited to a select group of the

top 100 large-cap companies in the world. The Global 100 is recognised as the gold standard in corporate sustainability analysis and ranking. Companies named to the Global 100 are the top overall sustain-ability performers in their respective indus-trial sectors.

“Our selection is due to the hard work of our 170 000 employees around the globe who recognise the importance of sustainability in their work,” said Alex Molinaroli, chairman and chief executive officer of Johnson Controls. “Sustainability is at the heart of what we do for our customers and the communities we serve.”Johnson Controls has been added to this elite list four times since inception in 2005.

There have been significant developments in the way envi-ronmental considerations have been managed over the past 20 years, however, implementing environmental legal frameworks within complex political, economic and social

contexts remains a challenge.According to GIBB’s environmental licensing unit manager, Suken-

drie Paras, environmental concerns need to be properly considered from the beginning of any infrastructure development strategy.

With 10 years of experience in the industry, Paras specialises in strategic environmental management and manages all environmental licensing work secured by GIBB. Her expertise specifically lies in under-taking all legislated environmental authorisation processes including EIA’s, water use licenses, waste management licenses and air emis-sions licenses.

“We have seen the implementation of an array of impressive envi-ronmental legislation throughout major African counties, not only aimed at conserving natural resources but also to ensure sustain-able economic growth. The challenge that exists however is not in the formation of legislation, but in the thorough implementation and enforcement thereof,” said Paras.

Executing an EIA in countries with a broad range of cultures and political systems requires a skilful and systematic approach. Paras has completed many projects on the African continent including coun-

gOLd STANdARd IN CORpORATE

SUSTAINABILITyJohnson Controls, a global multi-industrial company with established core businesses in the automotive, building, and energy storage industries, has announced that Corporate Knights has again put the company on its 2014 global 100 most Sustainable Corporations index.

>

Managing ENVIRONMENTAL considerations

The fine balancing act between developing major public and private projects in

a manner that does not significantly jeopardise the integrity of the environment is a key focus for environmental scientists.

tries such as, Nigeria, Lesotho, Zambia and Botswana, where she has gained extensive experience in overcoming the various obstacles that hinder effective environmental conflict resolution.

Paras stresses that the key to managing successful projects is in the development of strong client relationships.

“The most efficient projects are those where there is a meeting of minds between the client and the Environ-mental Assessment Practitioner (EAP). While environmental constraints exist, it is important to consider the devel-opment context in Africa, and instead of hampering potential developers’ (public and private) goals, EAPs must be resourceful enough to apply relevant best practice methods and solutions to achieve both the client’s goals and mitigation of deleterious environmental impacts,” explained Paras.

“Good governance – information,

transparency, accountability and responsibility to resolve potential or existing conflicts is equally important,” she continued.

Of further importance to managing successful projects is stake-holder engagement. When executing projects outside the country, GIBB makes use of local social specialists to assist with communi-cation to raise a better understanding of the project and to ensure compliance with the relevant environmental regulations.

“In South Africa and Africa as a whole, community buy-in can either make or break a project. Participation by the public is crucial to the EIA process, and we therefore need to be aware of the various social and cultural differences that exist within a particular country,” said Paras.

“GIBB has poised itself with key local partnerships to break into the African market and ensure that development projects are assessed in an environmentally sustainable manner. Our aim is to deliver projects that are not only compliant to all minimum environ-mental legislative requirements, but that also meet environmental best practice standards.”

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www.gunite.co.za

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The Waterfall mixed-use precinct is the largest urban concept development in South Africa – a

city superbly situated between Johannes-burg and Pretoria. Atterbury is driving the commercial development elements across the entire node.

Waterfall City is at the heart of Water-fall Business Estate, Atterbury’s staggering 1,6 million square metre mixed-use commer-cial development. The exciting 800 000 m2

mixed-use Waterfall City comprises around 60% of the entire Waterfall Business Estate.

Leading JSE-listed capital growth prop-erty company Attacq is the major investor in Waterfall Business Estate, including Waterfall City, with an 80% stake.

“This ground-breaking development is a highlight in our portfolio. The continued roll-out of Waterfall Business Estate supports Attacq’s sustainable growth and perfor-mance. It has gained excellent market trac-tion and is making pleasing progress,” says Morne Wilken, CEO of Attacq.

The tailor-made 330 ha new Waterfall City will feature everything expected from a vibrant modern city. It embraces integrated, new urban living to the fullest with retail, offices, homes, hotels, a hospital, parks, dining, entertainment and more.

“Waterfall City is the whole package. It is more than a city, it is a truly connected, fully-integrated lifestyle,” says Atterbury Pro- perty Developments MD James Ehlers.

“Its design is inspired by the principles of walkable, energised, mixed-use environ-ments to create a truly trailblazing city.”

PROPERTY

>Under construction at the nucleus of Water-fall City is the super-regional Mall of Africa. At 120 000 m2, this is South Africa’s largest single-phase shopping mall development to date. The R3,5-billion, two-level mall is set to commence trading in April 2016.

Waterfall City Netcare Hospital is already fully operational. And, in November 2014, a 4 100 m2, 150-bed City Lodge Hotel will welcome guests to the city. Atterbury has the rights to develop 1 200 urban residential units in Waterfall City and Waterfall’s resi-dential developer, Century will build on this in the future.

In addition to premium-grade corporate offices, Waterfall City will also accommo-date tenant-driven low-density office devel-opments, including Maxwell Office Park, as well as motor dealerships and other busi-nesses hand-picked to benefit those who come to Waterfall City to work, live, shop, stay and play in the fastest growing urban node in Africa.

“Waterfall city is a unique proposition. Not only does it offer a vibrant mixed-use environment and convenient contemporary lifestyle, but it also has a great location and its more affordable than other main nodes, such as Sandton and Rosebank,” says Ehlers.

For business, Waterfall City – like the rest of Waterfall Business Estate – offers the flexibility to respond to specific tenant requirements, creating efficient, tailor- made premises.

The list of leading companies to recognise the impressive benefits of offices in Waterfall City is already impressive, and growing.

Novartis has concluded a deal for new corpo-rate offices at Waterfall City spanning some 7 000 m2, for occupation in April 2015. From December 2014, Covidien will operate its distribution centre of 11 000 m2 at Waterfall City. Atterbury began construction on both premises in February.

It has already commenced work on offices of 4 700 m2 for Dräger, 4 500 m2 for Angle Shack, 7 500 m2 for Westcon and 4 000 m2 for Premier Foods.

And, so far, four large projects have been completed in Waterfall Business Estate: the 44 200 m Cell C Campus, the 26 286 m2 premises for MBT Technologies, the 23 139 m2 head office for Group Five and the 6 198 m2 head office for Golder and Associ-ates. In addition, Mall of Africa is attracting top international, national and bespoke retailers to Waterfall City.

Besides having everything needed for safe, quality everyday living right within walking distance, Waterfall City is linked to public transport both within and around the precinct. It also enjoys easy access to major routes and benefits from detailed planning for effective traffic flows stop.

Waterfall City also connects seamlessly with the outdoors, featuring refreshing green spaces and parks. And the design also takes cognizance of the environment, making it both green and efficient.

“Waterfall strives to promote an inte-grated, eco-friendly environment which provides good quality of life. Waterfall City will embody this,” says Ehlers.

With all this, it is no surprise that Waterfall is poised to become one of the strongest and most successful nodes within the Gauteng market and in South Africa, with positive and far-reaching socio-economic benefits.

“This vibrant city, with a modern new urban framework, is growing to become an exciting contemporary landmark at the forefront of development and lifestyle,” says Ehlers.

Driving Africa’s FASTEST-GROWING uRBAN NODE

Atterbury Property Development and Attacq recently launched the mixed-use Waterfall City to market,

marking the next wave of its ambitious commercial development at the landmark Waterfall Business Estate.

(ABOVE) Morne Wilken, CEO of Attacq.Atterbury Property Developments MD, James Ehlers.

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Finished product and not just vacant stands will now also become available with construction of the first six cluster homes currently being built in Le Jardin, the first phase in Avianto Lifestyle Estate, a 250 hectare development situated along the Crocodile River, just 3 km from the new 75 000 m2 Cradlestone Mall and with easy access to Fourways, Pretoria, Sandton and Lanseria via the N14.

Avianto Estate, which already includes the well known Avianto Village Hotel, will include residential freehold stands, clusters and sectional title erven and a retirement development, along with

office parks, a medical centre and business nodes – all centred round extensive sports and leisure facilities. The residential component will comprise a total of 1 800 opportunities, reports Neville Lang, an agent for Pam Golding Properties, marketers of stands on the estate.

Importantly, Maragon Private Schools has secured the rights for a new school on the estate, which will offer first language education in both English and Afrikaans from pre-primary school up to Grade 12. The pre-school is scheduled to open in 2015 and organic growth will take the school to its final, total capacity of 1 500 students.

Le Jardin consists of 90 freehold residential stands and 24 luxury freehold cluster units. Buyers may use their own architect and builder to create their dream home, working within the architectural guidelines, and building packages are also available. The first six cluster homes which are under construction each comprise from 288 m2, with three bedrooms en suite, lounge, dining room, kitchen and study, guest toilet plus upstairs TV lounge and two garages.

Avianto’s architecture, which has European influences, is developed from the existing appealing architecture of the hotel, with the use of natural materials such as stone, true-colour plaster and flush-plastered clay brick in the same colours, and timber in dark and neutral tones. Home owners at Avianto are encouraged to build energy efficient homes, while a focus on indigenous landscaping will reduce water consumption and encourage bird life. A fully-integrated security system with control room provides residents with peace of mind, while affordable, high-speed data packages using fibre to the home connections are available to all homes and offices within the estate.

Says Trevor D’Oliviera, CEO of Avianto Estate: “Designed to offer residents the peacefulness of indigenous forests and parklands, Avianto Estate incorporates picnic areas right next to the Crocodile River. Walking, jogging and mountain biking trails are available to enjoy, as is the Avianto Sports Club and its public amenities which include a soccer field, qolf (action golf) course, tennis courts, swimming pools and a clubhouse.”

D’Oliviera says the recent completion of Cradlestone Mall, on the corner of the N14 highway and Hendrik Potgieter Roads, is a welcome addition to an area that has experienced burgeoning residential growth in recent years, driven by numerous upmarket and middle market residential developments. “Avianto is well positioned in an area which is developing into a strong residential and commercial node offering a live, work, play concept. In addition, Tsogo Sun recently announced a R480-million refurbishment of its Silverstar casino which is expected to change the face of entertainment on the West Rand and is due for completion in August 2014.

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NEW WEST RANDDEVELOPMENT

www.catrental.com

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he proposed upgrades due to be completed in 2019 forms part of the complete Port of Durban upgrade which

incorporates; Point MPT and Ro-Ro (roll-on roll-off) Terminal, Maydon Wharf, Bayhead Park, Durban Container Terminal Pier 1 & 2, Island View Liquid Bulk Precinct, Bluff – Dry Bulk Terminal, North Quay berth deepening, Pier 1 expansion with Salisbury Island infill, Island View Berth Reconstruc-tion and Point Passenger Terminal.

Dolphin Design DataUpon inspection of the approximately 20 m x 20 m existing structure, it was quite apparent that the precast concrete piles in particular and overall structure in

general was in a state of disrepair, having already been upgraded and strengthened approximately

20 years earlier. Transnet National Port Authority (TNPA) therefore required a complete reconstruc-

tion of the existing Dolphin structure to ensure a common Design Life for the entire Berth 2

structure. Further inspections and review of as-built drawings and client require-

ments brought about additional design challenges in the form of lateral berthing

and mooring loading imposed by ship-ping as well as earth loading on the

landside of the structure imposed by

Situated on the inland side of the Bluff Ridge, Island View Bulk Terminal has been scheduled to form part of continual upgrades over the course of the next seven years, with three years of upgrades having already been completed.

the rock revetment. It became apparent during

the construction sequencing that an additional factor would

influence the construction methodology, Health Safety

and Environmental. This came about from TNPA’s

requirement for the existing Dolphin to

be demolished.

Island View Berth 2’s exisiting Dolphin in 2012.

The Kobelco crane on the temporary jetty.

Pitching the 813 mm pile casing.

23


ISLAND VIEW BERTH 2

PROJECT PROFILE

uPGRADE

But again it was proven that the design proposal could allow for the existing struc-ture to remain intact during the construc-tion process.

Project designRCE Consultants proposed a structural design that incorporated 20 813 mm x 16 mm WT x 42 m long reinforced concrete piles and eight precast concrete buttress units cast monolithically into the new deck slab. To reduce the environmental impact, it was decided to use the existing structure as a soffit for the new deck.

RCE laid out a construction sequence in conjunction with Stefanutti Stocks Marine (SSM) which illustrated the demolition of the top slab, partial chamfering of the up-stand beams and breaking of the joint between the Phase I Deck and existing Dolphin.

Following installation, mucking out and concreting of the piles, new haunches would be formed within the existing coffers and tapered to tie in the 813 mm piles.

To isolate the new structure from the old, void forming hardboard backed 50 mm expanded polystyrene was placed over all existing concrete surfaces.

TNPA had also requested that a Foam Fire Fighting Tower be constructed on the Southern corner of the deck as per previous design specifications.

Prior to design approval, (as with most Marine Structures) the required dura-bility of the concrete and the stringent mix

design parameters would play a major role in both the Environmental and Quality control measures.

Upon design approval, TCP awarded SSM site access in December 2012. Given a deadline date of August 2013 (which was non-negotiable due to shipping require-ments) SSM immediately moved onto the new Berth 2 deck to set-up camp and commence construction. Berth 2 could not be fenced off as per the Construction Safety Regulations due to the fact that it is a working Berth and a shared resource and it was therefore decided that only the site camp would be set-up to avoid any partial construction/demolition resulting in tagging out and safety implications over the December shutdown period. All long lead materials were procured, mainly the Steel Pile casing and Roq-Tuff Pile shoes.

QualityIn January 2013 a Strategic Planning and Risk Reduction meeting was held between the site management staff. It was clear that this project would be used as a form of advertisement to the client (TCP/TNPA), but as well as an opportunity to hone already proven construction methods within SSM and train a young labour force for future projects.

Concluding the Strategic Planning and Risk Reduction meeting it was decided that for each sphere of the project a target goal must be achieved and a potential bonus scheme would be employed (for labour

force only). For each sector it was decided: a minimum of 95% for client audit scores for both Health & Safety and Environmental Audits; Zero Quality Non-conformances (both internal and client) and completion must be achieved both on time (31 July) and under budget.

Island View Berth 2 was selected as one of only two sites to be audited at the end of the first quarter of 2013.

Corporate Social InvestmentStefanutti Stocks Marine’s recently formed Employment Equity committee also took it upon themselves to roll out the Divisional Employment Equity plan which aims to not only encourage training within the work place, but also improve the socio-economic status of the employee.

A relatively young group of employees was hired with the vision to continue the training of these employees on future projects, ensuring sustainable mutually beneficial employment.

Acting in accordance with the TCP and SSM HSE requirements, baseline risk assessments were conducted of the area and potential hazards were identified. The most abundant hazard was the presence of work over or near water. Due to the limited construction area and loading constraints on the new Berth 2, SSM constructed a Piled Temporary Jetty comprising of 6 914 mm steel pile casings, steel pile caps and longi-

Project information• Main contractor: Stefanutti Stocks

Marine• Project start date: December 2012• Project end date: July 2013• Project team: Transnet• Project manager: Stefanutti

Stocks Marine• Consulting engineer: RCE

Consultants• Project value: R23-million

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It was decided to focus all resources on completing

(mucking out and Tremie pour) one half of the deck

allowing for the concrete team to commence work

on the buttress unit installation, dry pack

and void forming, deck steel and

concrete and the foam

tower.

tudinal & capping beams. This structure had the capability of supporting the SSM owned 180 t Kobelco crane (including lifted load) for the duration of the project.

The Issue Based Risk Assessments made it clear that imme-diate training was required to instil awareness among the labour force (suspended loads, crane movements, hydro-carbon spills over water). Banks-man and Spill response/prevention training was scheduled at a site level. Offering training of this nature meant that the entire labour force understood the crane/load movements at all times and were available and trained to respond/prevent hydrocarbon spills.

Health & SafetyBased on the success of the training and the high quality of HIRA (both Safety and Environmental) and in conjunction with Daily Safety Task Instruction, Toolbox talks and correct use of PPE, the project managed to record zero LTIs. Due to the excellent work ethic of the labour force, a weekly award was presented to ‘The most Health & Safety, Environmentally and Quality driven employee of the week’, voted for by the labour force.

ConstructionWith all design, safety, environmental, quality, budget and labour force constraints in place, the site was split immediately into two teams: on-shore works and marine

works. The on-shore team had the task of co-ordinating a 20 t excavator to carry out the partial demolition of

the top deck slab without compromising the up-stand beams or the entire Dolphin structure. The marine

works team was mobilised to site along with a SSM barge on which a SSM Manitowoc 110 t crawler

An aerial view of Island View Berth 2.

Concreting pile casings with a tremie pour.

Casting of deck and foam tower.

25


PROJECT PROFILE

crane was made available along with the 914 mm pile casings and a SSM owned PTC 50 Vibratory hammer.

The initial stage of the construction process incorporated constructing a Tempo-rary Piled Jetty, capable of supporting a Kobelco 180 t Crawler crane for the dura-tion of the project. For this Manfred Kloos (WML Coast) adapted a previous design from the original Berth 2 Phase I, Manitowoc 110 t temporary jetty. The Marine crew went about installing 6 914 mm pile casings to an average depth of 30 m and confirming solid embedment by ‘setting’ the pile casing using a 4 t drop weight allowed to free fall within a dolly hammer placed on top of each pile casing (similar methodology to be used to confirm set for the 813 mm casings).

The I-section crane mats were then bolted onto the capping beam and two sheet piles were welded to the structure and bolts to the concrete deck to act as lateral bracing (as well as a walkway). The Transnet 200 t Floating Crane was then employed to transport SSM’s pre-commis-sioned Kobelco 180 t. Once fully commis-sioned at IV2, the Kobelco with its 52 m long boom would service the entire project performing piling installation, airlifting and jetting, pile casing welding, reinforcing steel installation, buttress unit installation and other minor tasks.

Piling commenced immediately using steel channel-section guide frames to support the pile casings. The ten 1 400 mm pile positions along the revetment were of utmost importance as it was not clear during the early stages of the project what the duration required to clear the 1 400 mm casing of rock by means of Casagrande Grab (‘fish mouth grab’) would be. It was there-fore essential that a night shift be under-taken to allow for piling and welding during the day and pile casings mucking out at night. It was at this point that the labour force was given a bonus target to complete the installation of the pile casings before the end of April (which was achieved).

The mucking out of the casings was conducted using a combination of an H-sec-tion Air/Water Jet column and a 6-inch Airlift steel pipe (in various sections) down to a depth of 15 m below seedbed level (varied from -15 mCD to -26 mCD).

Due to the delays to the completion of the mucking out of the 813 mm casings

(cohesive clay conditions resulted in prolonged airlifting per casing), the preceding concrete activities, concreting of pile shafts by means of Tremie pour, deck concrete and foam tower were at risk of delaying the completion of the project due to a late start. It was decided to focus all resources on completing (mucking out and Tremie pour) one half of the deck allowing for the concrete team to commence work on the buttress unit installation, dry pack and void forming, deck steel and concrete and the foam tower.

Working nearly 24 hours, both day and night shift managed to prepare 10 casings for tremie pour concrete placement. A concrete boom pump truck was used to deliver the 40 MPA concrete having a slump of 200 mm to the hopper of the tremie pipe.

The completion of the first 10 casings allowed the concrete team to commence construction of the deck slab.

The client specification called for a wooden float finish which meant that the pour duration ran beyond 14 hours. The second half of the deck followed the same methodology. Of particular concern at the coast is wind shear and rapid moisture lost due to a combination of high temperatures and prevailing winds. The deck was there-fore water cured by laying hessian over the entire deck and setting up a sprinkler system to ensure that a constant supply of water was maintained.

Following the results of the four-day concrete cube tests (purely as an indi-cator) the construction of the Foam Tower commenced which was split into four pours; base, 1st column lift, 2nd column lift and the final lift incorporating the precast platform.

Of utmost importance during this phase was co-ordinating with RME with regards to installing the pipe and pressure testing. Once installed, plumbed and tested, the pipe became the responsibility of SSM. Once cast, the Foam Tower was completed with access ladder and safety hand-railing. The ‘Foam Cannon’ was later installed along with a maintenance platform.

To complete the project an oil/hydro-carbon catchment drain was constructed along the landside end of the structure and directed into the existing oil separator tank (to be commissioned at a later date) and paving was tied into the deck from the existing entrance.

ConclusionThe Stefanutti Stocks Marine took it upon themselves to offer this project to a rela-tively young construction team. With the average age of the staff at approximately 26 years, it created the potential for a severe learning curve. The project team not only took it upon themselves to excel, but refine previous in-house construction methods and report back to the company with improved and efficient methods for future projects within Durban Port. The project was completed both on time and under budget, but the true reflection on the success of the project was the upliftment of a labour that previously had no knowledge of marine piling and the resounding praises received from the client (TCP).

Driven 813 mm pile casings.

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PROJECTS AND CONTRACTS

“We are keen to ensure that we have continuity of work to safe-guard these skills into the future,” Dave Heron, managing director at

Murray & Roberts Western Cape, says. “Our company is in a good position, having entered 2014 with a positive outlook on our future order book. Our mood is definitely more positive than in previous years, despite the fact that there has been a lull in the recent tender market. We remain optimistic that there will be new opportunities to be engaged going forward.

“Our primary focus in this market is on the longer term projects, underpinned by the relationships being forged with key customers in the market place through the provision of consistently world class services. This key customer focus is aligned with the Murray & Roberts Group initiatives. Currently these customers tend to have opportunities in three business hubs – Century City and the Waterfront, which are development hubs for commercial, retail and residential construc-tion, and the general Cape Town CBD that offers predominantly commercial develop-ment opportunities.”

March will see the final handover of the prestigious Portside building constructed by Murray & Roberts Western Cape for joint venture Employers Old Mutual and the FirstRand Group. The process of client occupation has begun prior to final hand-over, with the project completed in line with revised schedules.

Another sizeable contract being executed in the Cape Town CBD is the refurbishment of existing tower blocks and the establish-ment of a new car park between the towers at Merriman Square, formerly the Standard Bank buildings. Here Murray & Roberts Western Cape is adding completely new glass and aluminium façades to both tower blocks and refurbishing certain areas of the internals. This is the first major project the company has carried out for Redefine Prop-erties in recent times.

A new build and alteration project at Kingsbury Hospital in Claremont is scheduled for completion in June 2014. This contract was awarded last year by the Life Health-care group and involves an extension to the existing hospital by the construction of a new four-storey building, as well as alterna-

With several prominent construction projects in progress, notably the landmark Portside building in Cape Town’s city centre, Murray & Roberts Western Cape has clearly

demonstrated to the market that it is capable of offering the major project management and implementation

skills critical to the local building sector.

tions and additions to the additional facilities to improve areas such as operating thea-tres, private doctor suites and the canteen. Heron comments that the main challenge on this project has been ongoing co-ordi-nation of activities with hospital personnel, since the facility has had to remain operational at all times. Murray & Roberts Western Cape successfully completed a contract for improvements to the Vincent Pallotti hospital in Pinelands some time ago for the same client.

Also proceeding within budget and on schedule for handover by year end is the construction of the new eTV headquarters building in Roeland Park for Sabido Prop-erties, comprising six levels of offices and studios and four levels of basement parking.

At Century City, Murray & Roberts Western Cape has been contracted to build a new office development and car park for the Rabie Property Group, which is in a joint venture with Growthpoint Properties for this project. Construction began in December 2013 and is on track for completion in early 2015.

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AboVE: Dave Heron, managing director at Murray & Roberts Western Cape.

mAIN pHoto:March saw the final handover of the prestigious Portside building constructed by Murray & Roberts Western Cape for joint venture Employers Old Mutual and the FirstRand Group.

A POSITIVE OuTLOOK

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The SMEC rail division offers a variety of specialised services, ranging from planning and feasi-bility studies, to managing design

and construction. SMEC functional head of rail Johan Stander indicates that PRASA's new rolling stock will have a direct bearing on stations, which need to be upgraded in order to accommodate the new fleet and enhance the overall passenger experience.

"Under the current appointment, we are fortunate in the sense that the majority of our work is strategic advice to PRASA, and the ultimate cost of a new depot is defined by the technicalities involved in the design of that facility. At this stage, SMEC is not involved in design itself, however it does have a design review function," he explains.

SMEC boasts more than 30 years of expe-rience in railway engineering consultancy services in South Africa.

The company is able to supply a turnkey package tailored to suit the specific needs of a client due to its excellent capabilities. The SMEC rail division specialises in the construction of buildings, track and geotech-nical services, as well as electrical and elec-tronic engineering and communications.

According to Stander, SMEC has expanded its rail capacity locally over the past three years. “We now have 65 employees spread through our regional offices in South Africa that have expertise at numerous levels in the various disciplines required by the rail industry.”

Stander points out that SMEC has been involved with several major rail projects, one of which was the 21 km addition to the Erme-lo-to-Richard’s Bay line from 1980 to 1990. He adds that many of the junior engineers who worked on this project are still with SMEC today. “Some of the engineers who were juniors at that time are still with the

company and now form the senior manage-ment echelon.”

More recently, SMEC has been involved in furthering the aims of broad-based black economic empowerment (BBBEE) by increasing participation in the industry of those who were previously excluded. Stander stresses that SMEC recognises the impor-tance of fostering new talent in the industry, and he highlights the company’s commit-ment to developing skills and to maintaining assets once they have been constructed.

GROWTH TRACKOn aDecades of in-depth

experience and industry successes have resulted in the rail division of internationally

recognised consultancy firm SMEC being selected to undertake a number of high

profile projects, including the Passenger Rail Agency

of South Africa (PRASA) Rolling Stock Fleet Renewal

Programme.

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“It is our joint and individual responsibility to ensure that Africa benefits from our history and experience. At SMEC we have built up the experience and capability to offer unparalleled expertise to Africa’s rail networks,” he concludes.

AboVE: The SMEC rail division offers a variety of specialised services, ranging from planning and feasibility studies, to managing design and construction. bELoW: SMEC boasts more than 30 years of experience in railway engineering consultancy services in South Africa.

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For the last five years, ILISO Consulting’s Environmental Management business unit, together with Botswa-na-based Water Resource Consultants, has been involved in the massive Chobe/Zambezi Water Transfer Scheme.

The scheme was commissioned by the Botswana government as part of its national water management strategy. To date, ILISO Consulting has successfully completed both the pre-feasibility and feasibility studies; it is now working on the preliminary design of the R12-billion (BWP10-billion) project.

Once established, the scheme will be used to meet the ever increasing agricultural, industrial and urban demand for water, creating sustainability in water supply – it will also contribute to Botswana’s GDP and create further employment.

Sourcing potential“Botswana has two major river systems, the Okavango and Zambezi,” explains Martin van Veelen, director of environmental management, ILISO Consulting. “From preserving tourism to maintaining sound political ties with its neighbours, the Botswana government are natu-rally reluctant to touch any part of the Okavango Delta to ease water supply, especially with its delicate eco system.”

The other viable option, he points out, was identified as the Zambezi River. Botswana owns only 200 metres of riverfront riparian to the Zambezi, but has some rights to water from the Zambezi as the catchment of the Chobe River, a tributary of the Zambezi, is partially situated in Botswana.

“The Chobe is an unreliable source of water, but it does make a contribution to the average flow in the Zambezi,” Van Veelen says.

The Zambezi Commission (ZAMCOM) has approved the use of 495 million cubic metres per year of raw water from the Zambezi/Chobe scheme. “Botswana needs this water delivered for irrigation use at

Pandamatenga and for industrial and domestic use in the southern parts of the country,” he says.

Seizing opportunities“Botswana has the oppor-tunity to make the most of their coal production and to use their carbon credits more effectively with this project,” says Van Veelen. “In Francistown and the Selebi-Phikwe mines, we are seeing massive coal-

field developments. The country can either export the coal or, more astutely, use it to generate and sell power to other countries. However, in order to commoditise their resources, they need water.”

At present, the country has only groundwater in these areas, but no river water as a resource. In terms of the Chobe/Zambezi Transfer Scheme, 150 million cubic metres of water will be carried south of the country, and 345 million cubic metres of water will be used for irriga-tion in Pandamatenga.

ILISO expertise on pipelineTo carry this influx of raw water requires a pipeline of significant proportions; it also demands innovative engineering expertise. Initially, ILISO was appointed by the Botswana Department of Water Affairs to put together an environmental impact study on the proposed pipeline, which would run 550 km south, starting at Pandamateng and ending at Selebi Phikwe. ILISO was subsequently appointed to conduct an engineering feasibility study, and was then tasked to draw up the preliminary design for the scheme. Subsequently ILISO was also made responsible for the first 80 km of 3,5 m diameter pipeline, two 12 MW pump stations and two major reservoirs that constitute Phase I of the scheme that was previously designed by others.

Meeting logistical challengesThe logistics of the project present a daunting engineering challenge, he points out. To mitigate the risk of pipes deforming during transpor-tation, steel sheets will be taken to site. Spiral welding will be used to manufacture the pipes, which will then be placed in the trenches – trenches deeper and wider than an average conference room – and then backfilled.

“For ILISO Consulting, it has been highly gratifying to take this contract into the design stage,” comments Van Veelen. In effect, this means that ILISO will play a critical role in the construction of the Chobe/Zambezi Transfer Scheme for the next three to four years. “We will have to pre-select contractors and suppliers with care, as this is a highly specialised process,” he adds. However long the process, there is no mistaking that this is one of the most prestigious and ambitious contracts ILISO Consulting has taken on. “It is an engineer’s dream come true,” says Van Veelen. “If you are lucky, a project like this comes along once in a lifetime,” he concluded.

WATER SCHEMEBotswana’s massive

ILISO Consulting has proven itself an integral part of a water solution for neighbouring

Botswana. An ambitious water project, acknowledged as one of the largest in the

engineering world, will ensure the country has enough water to sustain industrial and mining

development in the future.

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www.oconbrick.co.za

www.technicrete.co.za

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The world class, state-of-the-art facility occupies a total land area of 78 000 m2 and is strategically located in Jet Park, east of Johan-

nesburg, within close proximity to O.R. Tambo International Airport.

South Africa was the Atlas Copco Group’s first step onto the African continent in the mid 1920s. Development into other African countries started in the 1950s and today the Group’s extensive African footprint includes operations across the continent. “As a specialist supplier of compressors, construction and mining equipment, power tools and assembly systems, the successful growth and development of Atlas Copco South Africa meant that we outgrew our old Witfield head office which simply became too small to accommodate all our business areas and divisions,” says Atlas Copco South Africa’s vice-president, Bernie Hanaray. “The construction of Atlas Copco House now brings us all together under one roof which will help build synergies between our four business areas – Mining and Rock Excava-tion Technique, Construction Technique, Compressor Technique and Industrial Tools – as well as Atlas Copco Business Services and Atlas Copco Holdings.”

According to Hanaray, the initial concept of an ‘Atlas Copco House’ in South Africa dates back some years. “This substantial investment made by our Sweden-based parent company into the establishment of Atlas Copco House not only shows strong commitment to South Africa but also confi-dence in business, mining and industry across our borders.” Following project approval in September 2011, breaking ground and site works commenced in November 2012. A short 12 months later, in December 2013, the offi-cial handover was made to Atlas Copco South Africa, “and”, says Hanaray, “our ‘big move’ took place January 2014.”

“AC House is testimony to our continued focus on customers, employees and the environment,” continues Hanaray. “Careful consideration went into the bespoke design and layout of the entire complex, which consist of an office administration building, a warehouse, workshop, a training facility and a spacious yard area with ample parking. The result is a practical, functional, comfort-able and efficient facility that meets our current needs with sufficient flexibility to address future expansion requirements.”

The distinctive glass and rock architec-ture of the 6 100 m2 office building presents an aesthetic contrast to the massive steel clad Distribution Centre (DC) which comprises a 9 600 m2 warehouse and a 7 600 m2 workshop.

Hanaray says that the DC supports all business areas as well as national and regional activities including regional work-shops and he highlights some of the advan-tages of centralisation. “The consolidation of the warehouse and logistics will enhance customer service experience across the board. Centralised logistics will streamline operations for all the business areas and the large stock holding capabilities of the ware-house will improve availability and turna-round times for customers.” Hanaray adds that centralising stock will further enhance customer service as the branches will be able to draw from a larger parts supply at the central DC and not have to live off their own shelves. “Moreover, by having our prod-ucts and capabilities all under one roof will improve our abilities to assist many of our customers who use products and equipment across our business areas.”

The site also offers heavier lifting capacities (up to 30 t), a compressor testing facility (up to 500 kW), spray booth facilities and wash bays. Access to these resources will enable the respective business areas to add value to their customer service offerings.

NEW WORLD-CLASS FACILITYCompany centralises to a

Atlas Copco South Africa now operates from

Atlas Copco House, a new, purpose-built,

multi-faceted facility. This strategic move in

January 2014, centralises the business areas and divisions of this global

industrial Group for the sustainable and

streamlined delivery of end-to-end product and

service solutions to South and Southern African mining and industry.

Ronnie Leten group president & CEO Atlas Copco AB (left) and Bengt Kvarnback, chairman of the board South Africa.

The ribbon cutting ceremony at the opening of Atlas Copco House in February.

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The 1 100 m2 state-of-the-art Academy is fully equipped with modern lecture rooms to address a wide range of operator, tech-nical and dedicated computer based training. The workshop has been specially equipped with separate training bays to address the practical hands-on training experience. The enlarged facility also presents plentiful scope for customer training.

A number of significant processes were implemented throughout the project in line with the Atlas Copco Group’s SHEQ and sustainability initiatives.

During construction, surplus mate-rial excavated from the site was recycled.

Atlas Copco South Africa's new world class facility – Atlas Copco House.

The building incorporates features aligned with Atlas Copco’s focus on the environment. The buildings are carefully positioned to allow maximum natural light access.

The use of solar energy water heating, lower energy lighting and a building manage-ment system to monitor electric power, air-conditioning systems, fire protection, etc. help to reduce demand on the national power grid. The warehouse and workshop are insulated for efficient thermal management, noise and dust reduction. The attenuation pond required for rain water run-off will be developed into an attractive park-like area to attract local bird life. Atlas Copco House’s

state-of-art safety and security elements create a secure and comfortable environ-ment for employees and visitors.

“We are exceptionally proud of Atlas Copco House which reflects Atlas Copco’s values of innovation, interaction and commit-ment. With customers always at the centre of our attention, we will use all the capabilities offered by our new facility to full capacity to deliver world-class product and service solu-tions for sustainable productivity.

The move makes 2014 a pinnacle year for Atlas Copco South Africa and we look to the future with great confidence and optimism,” concludes Hanaray.

www.jch.co.za

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SASFA director John Barnard says that, in the main, the survey showed that the mass of steel used in South Africa to profile LSF sections increased by 6% during 2013, compared

with the previous year. However, exports declined by 30% largely due to the establishment of manufacturing capacities in the neighbouring countries, while the local market for LSFB grew by 21%, considerably more than the 7% growth recorded for the building industry (floor area of buildings completed) in South Africa.

“As the volume of steel used purely for light steel roof structures remained fairly constant, all the growth came from steel used for complete LSF buildings, almost doubling the previous year’s figure for this sector!” Barnard says.

Building industry statistics The floor area of all buildings completed in South Africa during 2012/13, including additions and alterations, is reported to be 10 million m² – showing a growth of 7% compared with the perfor-mance of the previous year. New residential buildings (including alterations) made up 68% of the area of all buildings completed, and showed a 3% growth on the previous year. The largest sector in the residential market was dwellings of more than 80 m², followed by flats and townhouses. A significant 24% of all buildings (residential and non-residential) completed, comprised of “Additions and Alterations”.

Industrial buildings and warehousing formed the major sector in the non-residential market, with 40% of the floor area, followed by office buildings (32%). The latter sector showed massive growth during the past year, more than doubling the floor area completed during the previous year.

“Based on building plans approved, we can look forward to a 16% growth in building activity during the next 12 to 18 months, keeping in mind that there is a lag of some nine months between plans approved and buildings completed,” says Barnard.

LSFB performanceSASFA’s annual survey, which aims at quantifying the level of light steel frame building (LSFB) activity in the market, was again carried out

rises

dram

atica

lly

An industry survey by the Southern African Light Steel Frame Building

Association (SASFA) has revealed a dramatic increase in the use of the

light steel frame building (LSFB) method in South Africa.

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out during 2013. Barnard explained that, as in the past, SASFA approached the South African manufacturers of light steel framing to determine the volume of thin gauge high strength galvanized steel sheet they had processed during the past year, as a measure of the building activity in the industry.

The manufacturers reported throughput of 24 200 tons of high strength galvanized steel sheet, reflecting 6% growth compared with production in the previous year. “Supply into the local market increased by an astounding 21%, while exports from South Africa into Sub-Saharan Africa declined by 30%. This decline can be ascribed to profiling capacity that is being installed in the neighboring countries, as well as the increase in local demand,”

Barnard says.During 2013, LSF roof trusses used with

masonry or in industrial buildings consti-tuted 54% of locally sold LSF. Roof structures

covering a total floor area of 1,31 million m² was produced, on par with that during the previous

year. “Based on Statssa figures for buildings completed in 2012/13 (excluding low cost housing),

light steel roof trusses captured 13% market share during the period, Barnard says.

He adds that based on industry feedback, complete buildings – wall panels with roof structures – covering a

total area in excess of 500 000 m² were built in LSF in South Africa during 2012/13, which is an 80% increase on the

2012 performance. “This growth in demand is remarkable, as the official

building statistics supplied by Statssa indicates a growth of only 7% in total floor area of new buildings completed during 2012/13.

This underlines the rapidly growing acceptance of LSFB by archi-tects, engineers, builders and clients,” Barnard says.

But LSFB does not only consist of steel. Based on average ratios of wall area to floor area, LSF has in 2013 resulted in a demand for• 0,6 million m² of external cladding (typically fibre

cement board), • 0,9 million m² of bulk insulation (typically glasswool), • 1,3 million m² of internal lining or gypsum board, and• 0,6 million m² of vapour permeable membrane used in

external walls.Barnard says the total LSF market (local and export, trusses and complete buildings) is forecast to grow by 15% during 2014, compared with 2013. “The SASFA manufacturing members report good demand for middle and upper income housing, schools and classrooms, and roofing structures for low cost housing projects - including a large affordable housing project in the Cape, which is being built using LSF,” Barnard says.

He adds that LSFB is increasingly being used for external (and internal) walling of multi-storey office and commercial buildings while a growing volume of additions to existing buildings is also reported. In addition, a number of project enquiries from neigh-bouring countries have been received.

“The encouraging fact that the government recently announced that innovative building technologies, such as LSFB, will increasingly be preferred for new schools, clinics and student accommodation, will add additional growth potential,” says Barnard. “In view of all the above, the forecast 15% growth in the use of LSFB in 2014 may in time prove to be conservative,” he concluded.

www.rescuerod.co.za

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CONSTRUCTION WORLD MARCH 2014

Completed in 2000, the double award-winning Bivane Dam was a major success achieving all its primary goals in providing

continued benefits to its communities. A plaque unveiling ceremony was held

in February to honour the Dam Committee’s four members; the late Piet Marais, late Louis du Preez, Esuan Höll and Quartus Botha, who

the dam created an estimated 900 more jobs as well as the opportunity for 47 emerging farmers west of Pongola to farm sugar cane.

These farmers are now contributing an annual 53 000 tons of cane to the Pongola mill. The R300-million project cost has been justified by the 16 200 ha irrigated area’s increased land value to R1,3-billion.

Walter Visser, vice chairman of the Pongola Sugar Cane Growers Association, said investment in the dam had stabilised the supply of irrigation water to the area and was an unmitigated success.

“Over the last 14 years the dam level had never dropped below 10% (even during a severe drought in 2003) and it was able to supply agricultural and domestic demand, and provide for the environmental releases required by the Operating Rule,” he said.

Johann Boonzaaier, CE of Impala Water User Association, said, “The project’s sustain-ability and associated socio-economic bene-fits are a credit to the four Dam Committee members and our engineering team, lead by Bosch Stemele in association with BKS (AECOM) at a time when sustainability has become a global buzz word that engineering projects strive to achieve.”

Sid Turner, Bosch Stemele national oper-ations director, said, “We are proud to have been associated with the Impala Water User Association on this 115 million m3 dam flag-ship project and it is even more satisfying to see the project delivering triple bottom line sustainability in terms of economic, social and environmental benefits 14 years down the track.”

The 72 m high Bivane Dam will be a life-long value-adding monument to the whole Pongola community from which many future generations will benefit.

From left: Esuan Hőll (Bivane Dam Committee), Sid Turner (Bosch Stemele project director), James Perkins (Department of Water Affairs chief engineer), Piet Viljoen (AECOM resident engineer) and Quartus Botha (Bivane Dam Committee).

SuSTAINABILITY

Delivering triple bottom line

In the mid 1990s, Bosch Stemele was appointed by the Impala Irrigation Board to provide the engineering services for a

much-needed large dam for the Pongola community.

successfully obtained the authorisation from Water Affairs and directed the planning and construction of the project.

Besides supplying potable water to 48 000 people, the dam also supplies irriga-tion water for 16 200 ha of Pongola farmland. It will ultimately supply a further 260 000 people with water.

Because of sustainable irrigation supply,

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6.

5.

4.

The Coega Development Corporation (CDC) welcomed the onset of site clearing and construction. “We are incredibly excited to welcome Afrox to the Coega IDZ,” said Christopher

Mashigo, Coega Development Corporation (CDC) Business Devel-opment executive manager.

“Already a supplier to a number of our investors, including DCD Wind Towers, Agni Steels and Dynamic Commodities, their positioning and establishment in the IDZ means they will be able to service their established customer base while moving into new markets.”

Afrox will establish a 150 ton per day air separation unit (ASU) in the IDZ to service customers throughout the Eastern Cape. The investment will see the supply of a variety of industrial gases used in the automotive, food processing and medical sectors.

Afrox managing director Brett Kimber said: “The new R300-mil-lion investments at the Coega came as a result of CDC continuous assistance in wanting to make this investment work. Their assistance has seen a culmination of business coming together with industry.”

Afrox has an established customer base in the Eastern Cape, servicing the automotive and medical sectors in particular, but the company also indicated that it is focused on broadening its focus.

“Afrox’s air separation unit is important to us not only as a new investor but as an enabler. It enhances our value proposition and also provides a foundation for Afrox’s own growth,” added Mashigo. “Gas is a critical part of industrial processes and we are happy to see demand equate into supply through the establishment of two air separation units in the IDZ.”

The Afrox ASU will come online in the first quarter of 2015. Air Products, also an industrial gas company, is well underway with construction at the site of their ASU plant and is due to come online in the third quarter of this year.

R300-MILLIONINVESTMENTnot one but two gas companies will be under construction in the Coega industrial development zone (idZ) after a R300-million investment deal with industrial gas company afrox saw the company break ground on their site in zone 3.

Christopher Mashigo, Coega development Corporation Business devel-opment executive manager, and Brett Kimber (right), Afrox managing director, breaks ground at their sod-turning event.

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www.roclaproducts.co.za

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GEOTECHNICAL ENGINEERING

The main contractor for the 9 100 m2 warehouse project in E.P. Malan Road is Bruce Kirchmann Construction. Martin Eygelaar, contracts manager of Gauteng Piling, said the contract calls for 152 auger piles.

Auger piles are deep foundation elements that are cast-in-place, using 450 mm, 500 mm or 600 mm diameter flights. The process is carried out by auger drills that excavate the piling holes drilled into the soil to pre-designed depths, which for the Value Logistics project vary between 8 to 10 metres.

“After reaching the required depths, the auger hole is cleaned, and concrete is place directly into the hole from the ready mix truck. Rein-forcing steel is then lowered into the wet concrete.

The finished foundation element resists compressive loads. The technique is been globally popular and is been used to support towering buildings, tanks, towers and bridges,” Eygelaar explains.

Gauteng’s heavy summer rains – coupled with underground mois-ture – posed an early unexpected challenge for Gauteng Piling at Pomona. “After extensive pre-piling geotechnical soil tests, we were prepared for a relatively high level of moisture in the soil but, of course, none of the preliminary soil tests could predict the heavy summer rains

that followed and led to the underground water table rising much higher than expected.

“Eventually, we had to revert to the traditional ‘drill and cast’ piling method instead of auger piling because the pile bore could not be sealed against water ingress. ‘Drill and cast’ operations call for a concrete truck to be on standby right next to the drill rig. When the rig has reached the required depth, the operator immediately lifts the extracted soil to the surface, and concrete is then cast – within seconds – to prevent water ingress and the piles from collapsing,” he states.

Another major challenge on site was exceptionally stringent health and safety standards imposed by the contractors and designers. This involved certification of lifting equipment, provision of maintenance record of auger rigs, and regular inspection of the rigs and other similar health and safety standards. “Although far more stringent than the norm on most building projects, Gauteng Piling actually welcomed this exceptional emphasis on health and safety as it reinforces our own company’s philosophy. As members of the Master Builders Association North, we value our staff’s safety above financial profits,” Eygelaar says. “In fact, we would like to help the contractors and professional teams lift this project to award-winning status in a future MBA North safety competition.”

Bruce Kirchmann, MD of Bruce Kirchmann Construction, commenting on the Pomona project, praised Gauteng Piling’s profes-sionalism. “The company has always provided us with a cost-effective product, delivered professionally and within deadline,” he states.

Established in 1996, Gauteng Piling (led by MBA North immediate past president, Hennie Bester), has completed close to 1 500 major piling contracts. The company has attained 135% BBBEE recognition and is strongly committed to the future development of emerging contractors in all facets of the building industry. Simon Linakane, Gauteng Piling’s Quantity Surveyor, was recently elected to serve on the executive committee of MBA North.

Gauteng Piling has a fleet of 23 straight shafted augercast machines, three cranes, four bore rigs and six Grundo hammers (mainly used for residential foundations), as well as three machines for lateral support.

The company recently completed the contract for the piling for the construction of southern African’s largest single-phase retail centre, Mall of Africa, which called for over 400 piles. Other recent contracts

CHALLENGE>

Leading piling company, Gauteng Piling, has been awarded the

contract for the piling for a new large-scaled warehouse for Value

Logistics in Pomona, Kempton Park.

POMONA

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handled by Fourways-based Gauteng Piling include the piling for the Fire & Ice Hotel in Pretoria, The Grove Shopping Centre in Pretoria, and the Bon Accord Police Station, also in Pretoria. The company also handled the piling requirements for a new FAW auto dealership in Croydon in Ekurhuleni, to name just some of its recent work.

Gauteng Piling is using two auger rigs for the Value Logistics warehouse project: an MF and LDH machine – both chain-and-sprocket machines. The rigs provide exceptionally high drilling speed which allows sufficient time to place the concrete and also helps to remove the risk of collapse and ingress of water inside the bore.

www.smec.com

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CEMENT AND CONCRETE TECHNOLOGY

Innovative new systemAlthough widely used in Europe for many years, precast construction methods have not been very popular in South Africa in past decades. However, based on the supe-rior constructability of precast elements in combination with in-situ components demonstrated in the implementation of the 15 000 t Impumelelo coal bunker, as well as other smaller bunkers, this innova-tive method could well herald a new era for large, heavy loaded industrial structures where quality, cost effectiveness and speed of construction are high priorities.

The innovative 15 000 t coal bunker being constructed by Concor Civils at Sasol Mining’s greenfields Impumelelo colliery in Secunda, Mpumalanga, has

mooted this composite system as an inno-vative and viable option for future similar applications, offering great potential for speed of construction, safety, savings and a high quality end product. This form of construction, involving the precasting of key elements, uses fewer resources than conventional methods and is proving economical, fast and efficient on site.

Impumelelo is scheduled to start supplying coal to Sasol Secunda in the last quarter of 2014.

Project backgroundThe civils package on the Impumelelo bunker was subcontracted to Concor Civils by ELB Engineering (who is executing the materials handling package) in July 2012

PRECAST

An aerial view of the 15 000 t bunker and stockpile area.

at Impumelelo

Project information• Project start date: 4 July 2012• Project end date: April 2014 • Client: ELB Engineered Services• Main contractor: Concor Civils• Principal agent: ELB Engineering• Quantity surveyor: ELB

Engineering• Contract value: R149-million

(exclusive)

The on-site precast yard positioned next to the 15 000 t bunker. The on-site crew.

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main structural elements are precast. The foundations, columns and diaphragm walls are cast in-situ.

Precasting wall panels has a clear advantage over the conventional cast in-situ operation as it leads to a superior quality of finish offering a significant advan-tage in improved material flow, as well as resistance to abrasion. Monolithically connecting the ends of the precast wall panels promotes continuity over supports which leads to greater structural stability and economy.

System heralds new era• Composite system of precast

and in situ elements presents an innovative and viable option.

• The system offers great potential for speed of construction, safety, savings and a high quality end product.

• Precasting of coal bunker wall panels has a clear advantage, as it leads to a superior quality of finish and offers a significant advantage in improved material flow and abrasion resistance.

• The composite system of precast and in situ construction has allowed for a concrete saving of approximately 35%.

• Absolute precision was applied throughout the design phase demonstrating excellent workmanship, a high level of skills and allowing for the production of quality moulds.

refined for the 15 000 t bunker project. For the 15 000 t bunker project, Concor Civils appointed Lyonell Fliss & Associates, in joint venture with Logiman, as industrial civil/design consultants.

Constructed from concrete with overall dimensions of 80 metres long by 18 metres wide, the bunker has a coal handling capacity of 15 000 t. Precast components comprising various elements tip the scales from 5 to 10,5 t.

The use of both precast and in-situ concrete makes connecting the various elements to each other considerably simpler than conventional in-situ construc-tion alone. Various lifting frames have been designed to lift the precast elements at stra-tegic points and handle the elements from the manufacture, transport and installation stages. These are being hoisted into place by a Liebherr 280 EC-H tower crane from the Concor Civils fleet.

Using an innovative system of locating pins cast into the elements accurate place-ment of precast elements is achieved.

The bunker has 10 discharge chutes located between 11 concrete frames at 7,5 metre centres. These discharge chutes will feed coal to a reclaim conveyor located underneath. Provision for an extended funnel flow has been built into the bunker’s geometric design with advantages that include a reduction in excessive wall abrasion to minimise wear and tear and eliminate the need for a steel lining. In addition, the design promotes the reli-ance on the abrasion resistance of high strength concrete.

To meet the demands of an extremely tight construction programme, as well as quality and economic requirements, the

and will run for 20 months. This project is part of a materials handling system that will transport coal from an underground surge bunker at the Impumelelo Mine by means of an incline conveyor to the surface. The system will then extract the coal on a continuous basis from the 15 000 t surface based coal bunkering system and transport it to a 4 000 t bunker from where it will be fed onto the main coal supply conveyor to the Sasol plant.

The original civils subcontract called for conventional in situ construction of the 15 000 t bunker and although the Concor Civils team submitted pricing for this execution method, an alternative precast option was also proposed which was ultimately preferred by Sasol Mining and ELB Engineering.

A new methodConcor Civils was the first to introduce this method of construction based on a concept originated by Lyonell Fliss and Associates to the South African mining industry, when it successfully built the 8 000 t coal bunker in 2005 for Anglo American and Sasol Mining at the Isibonelo Colliery in Mpumalanga.

In addition to the 15 000 t bunker, the scope of the Concor Civils subcontract includes a stockpile tunnel, foundations for a 120 metre reclaim conveyor and an over-land conveyor to transport the coal to the Sasol plant and a 4 000 t bunker (also being constructed using the precast method). Concor Civils is laying the foundations for this overland conveyor, manufacturing precast sleepers all along the route.

The original concept for a bunker constructed by a composite system of precast and cast in-situ elements was

Precasting of the P2 elements for the bunker. Stacking of the P1 elements at the precast yard.

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This form of construction, involving the precasting of key elements, uses fewer resources than conventional methods and is proving economical, fast and efficient on site.

The precast elements are being manufac-tured on site, while in-situ construction proceeds simultaneously. Erection of the precast beams followed shortly after the casting of the first columns.

Stringent quality controls are imple-mented at the precast yard. These meas-ures ensure that the high performance concrete is moulded to tight tolerances. The steel moulds used in the construction of the bunker were designed by pre-form using 3D computer aided modelling to meet the exacting demands of the complex geometry and to facilitate the precise location of the protruding reinforcements.

Stitching concrete is used to structur-ally connect the gaps between the precast concrete elements. The gaps are being filled with a specially designed 60 MPA concrete. Abrasion resistance tests have proved this concrete to be totally adequate for the application. In fact, the steel abrasion tests resulted in less than 0,5 mm of this concrete being abraded.

The concrete was batched by AfriSam at its Evander readymix plant and trucked to the Impumelelo site. The composite system of precast and in-situ construction has allowed for a concrete saving of approx-imately 35%, compared to constructing the bunker fully in-situ. The surface of the precast units is coated with a sodium sili-cate surface hardener. This contributes to the surface abrasion resistance and negates the requirement for steel liner plates.

The unusually high level of construction excellence being achieved at Impumelelo reflects attention to detail in design and construction and the quality of the precast product. Concor Civils has harnessed global best practice to offer the local construction arena an enormously attractive alternative. The success of this project could create other opportunities for a composite system to be applied to other types of structures.

This technique has immense poten-

tial for projects in other parts of Africa, particularly those in remote areas. Instead of shipping up hundreds of tons of support gear and equipment, only precast moulds need to be moved to the site, simplifying construction and reducing costs.

However, it is important to note that the main benefit of precast construction is to be found in design and construct contracts where project designer and contractor are involved from the early planning stages and throughout the project, particularly solving together the constructability aspects.

QualityAmong the many advantages of precast construction is the quality of the construc-tion elements produced. Instead of having to navigate challenging in-situ conditions, repetitive precasting is carried out in the controlled environment at ground level in comfortable casting positions of the precast yard. This enables better production control, better quality and better mecha-nisation. Here it is possible to monitor all stages of production including adequate curing, compaction, reinforcement fixing (the most difficult operation of the cast in-situ system), quality and depth of cover concrete, and ensure that products comply fully with strength requirements.

The test of precast quality is the level of precision achieved. In the realm of precast construction, tolerances are higher than those required for conventional construc-tion methods because it is effectively an assembly line process and all the elements must fit together perfectly.

To ensure a smooth assembly phase and milli metrically fitting elements, 3D modelling was applied in the design phase using AutoCAD and Solid Edge software. Precast moulds were manufactured to a very high tolerance by a pre-form in an engineering environment and the moulds were checked for correct tolerances during

and after manufacture. Absolute precision was applied throughout the design phase demonstrating excellent workmanship, a high level of skills and allowing for the production of quality moulds.

The correct tolerances for the in-situ work were achieved by using purpose made shutters and templates.

Risk managementWith precast construction, the risk is focused on during the design and planning phase. The use of 3D modelling in designing the Impumelelo coal bunker ensured that the key connections would fit perfectly together. The software enabled the design and construction teams to build the struc-ture virtually in the actual sequence of the construction programme and this has been key to the success of the project allowing any clashes to be identified and addressed during design and significantly mitigating the risk during actual construction.

Cost savingsThe composite system successfully applied on this contract has achieved significant cost savings on materials, site labour and time on site.

Health and safetyA major factor in the design of the bunker is the safety of the personnel. Most of the construction work is conducted at ground level and only a few people are required aloft to direct precast elements into posi-tion. The precast wall panels are fixed in place in the bunker at 50° to the horizontal, eliminating the need to work on site under difficult and dangerous conditions.

Without the necessity for steel plate liners, the discharge performance of coal bunker is far better than conventionally constructed structures of this nature. No coal is trapped inside the bunker, which would require personnel to shovel it out at regular intervals.

Concor Civils has provided ongoing training of site personnel, with particular emphasis on working at heights. To date zero LTIs have been recorded.

Precast elements placed in their final position.

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A first of its kind in our market, SupaSet takes only 10-15 minutes to set compared with up to two days for a

conventional concrete mix. SupaSet comple-ments the company’s wide range of innova-tive, designed-for-purpose products, which are contributing to the company’s vision of helping to build better cities with more desir-able environments for all our people.

SupaSet is an essential product for DIY enthusiasts and small contractors involved in erecting poles (wooden, concrete, metal or plastic), whenever and wherever there is a need for a rapid, reliable method of setting poles in the ground. Typical applications include small to medium size gateposts; decking poles; rotary washing lines; signposts; carports and lapas; domestic, farm or general fencing; advertising boards, and crash barriers.

The unique formulation of SupaSet is an example of how Lafarge South Africa focuses on understanding the needs of its customers and applying its unparalleled technical strength to provide user-friendly, quality solutions. Solutions that contribute to the elimination of some traditional building steps, promoting faster working, enhanced productivity and cost optimisation. Apart from the speed, why buy all the ingredients for a traditional mix and waste most of them, when there is the convenience of SupaSet?

SupaSet is available from major building material and hardware stores in 25 kg bags, or in two ton palletised loads of 25 kg paper bags from Lafarge’s Kaalfontein Depot in Gauteng or the company’s Lichtenburg Cement Works in the North West Province. The product

offers users, even homeowners without any previous experience, convenience and zero wastage. Formulated to have a remarkably high rate of early strength development, SupaSet maximises productivity on pole installation work.

Using SupaSet is extremely easy. Manual mixing and the use of concrete mixers are specifically excluded. After digging a hole of the correct depth and width for the size of pole, the pole is inserted and the hole filled between one third and half-full with water. SupaSet is then spread evenly around the pole to completely cover the surface of the water. More water is sprinkled evenly on top of the powder.

The pole must be immediately adjusted to ensure it is vertical and at the required height, because of the fast setting time.

“We have designed SupaSet to be excep-tionally easy for DIY and small contrac-tors to use. In addition, while maximising convenience, it virtually eliminates costly wastage,” comments Lafarge South Africa’s Maria Sazeides, national sales and marketing manager. “On-site manual mixing of a traditional concrete mix, is associated with wastage of surplus ingredients and made-up mix, contamination and variable results. We are delighted to see customers enjoying the rapid consistent results and cost-effectiveness benefits that SupaSet can provide.”

INNOVATIVE SOLUTION FOR pOLE SETTINg SupaSet, a remarkable ready-to-use product for quickly setting poles in position has been launched by lafarge South africa, the local presence of the international lafarge group, the world leader in building materials.

Ready-to-use SupaSet in a convenient 25 kg pack.

Lafarge South Africa’s SupaSet, the quick and easy solution for setting poles in position.

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www.pmsa.com

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FibresFor the effective use of fibres in hardened concrete:• Fibres should be significantly stiffer

than the matrix, i.e. have a higher modulus of elasticity than the matrix,

• Fibre content by volume must be adequate,

• There must be a good fibre-matrix bond,• Fibre length must be sufficient, and• Fibres must have a high aspect ratio,

i.e. they must be long relative to their diameter.

For the quantities of fibres typically used (less than 1% by volume for steel), the fibres will not have a significant effect on the strength or modulus of elasticity of the composite. It is therefore important to evaluate published test data and manufacturers’ claims carefully.

Types of fibreThere are natural and synthetic types of fibre. In this article, let us look at the most commonly used stiff fibre types:

GlassIn the form first used, glass fibres were found to be alkali reactive and products in which they were used deteriorated rapidly. Alka-li-resistant glass containing 16% zirconia was successfully formulated in the 1960s and by 1971 was in commercial production in the UK. Other sources of alkali-resistant glass were developed during the 1970s and 1980s in other parts of the world, with higher zirconia contents. Alkali-resistant glass fibre is used in the manufacture of glass-reinforced cement (GRC) products, which have a wide range of applications.

Glass fibre is available in continuous or chopped lengths. Fibre lengths of up to 35 mm are used in spray applications and 25 mm lengths are used in premix applica-tions. GRC products are used extensively in agriculture; for architectural cladding and components; and for small containers.

SteelSteel fibres have been used in concrete since the early 1900s. The early fibres were round and smooth and the wire was cut or chopped to the required lengths. The use of straight, smooth fibres has largely disappeared and modern fibres have either rough surfaces, hooked ends or are crimped or undulated through their length.

Modern commercially available steel fibres are manufactured from drawn steel wire, from slit sheet steel or by the melt-ex-traction process which produces fibres that have a crescent-shaped cross section.

Typically steel fibres have equivalent diameters (based on cross sectional area) of from 0,15 mm to 2 mm and lengths from 7 to 75 mm. Aspect ratios generally range from 20 to 100. (Aspect ratio is defined as the ratio between fibre length and its equivalent diameter, which is the diameter of a circle with an area equal to the cross-sectional area of the fibre).

Carbon steels are most commonly used to produce fibres but fibres made from corro-sion-resistant alloys are available. Stainless steel fibres have been used for high-temper-ature applications.

in concrete

STIFF FIBRES

The role of

By Bryan Perrie, MD of The Concrete Institute

Concrete made with portland cement is relatively strong

in compression but weak in tension and tends to be

brittle. The weakness in tension can be overcome by the use of conventional rod reinforcement and to some

extent by the inclusion of a sufficient volume of stiff

fibres. The use of fibres also alters the behaviour of the fibre-matrix composite

after it has cracked, thereby improving its toughness.

Some fibres are collated into bundles using water-soluble glue to facilitate handling and mixing. Steel fibres have high tensile strength (0,5 – 2 GPa) and modulus of elasticity (200 GPa), a ductile/plastic stress-strain char-acteristic and low creep.

Steel fibres have been used in conven-tional concrete mixes, shotcrete and slurry-infiltrated fibre concrete. Typically, content of steel fibre ranges from 0,25% to 2% by volume. Fibre contents in excess of 2% by volume generally result in poor work-ability and fibre distribution, but can be used successfully where the paste content of the mix is increased and the size of coarse aggre-gate is not larger than about 10 mm.

Steel fibre-reinforced concrete containing up to 1,5% fibre by volume has been pumped successfully using pipelines of 125 to 150 mm diameter. Steel fibre contents up to 2% by volume have been used in shotcrete applica-tions using both the wet and dry processes.

Steel fibre contents of up to 25% by volume have been obtained in slurry-infil-trated fibre concrete. Concretes containing steel fibre have been shown to have substan-tially improved resistance to impact and greater ductility of failure in compression, flexure and torsion. Similarly, it is reported that the elastic modulus in compression and modulus of rigidity in torsion are no different before cracking when compared with plain concrete tested under similar conditions.

It has been reported that steel fibre-re-inforced concrete, because of the improved ductility, could find applications where impact resistance is important. Fatigue resistance of the concrete is reported to be increased by up to 70%.

It is thought that the inclusion of steel fibre as supplementary reinforcement in concrete could assist in the reduction of spalling due to thermal shock and thermal gradients. The lack of corrosion resistance of normal steel fibres could be a disadvantage in exposed concrete situations where spalling and surface staining are likely to occur.

For further information, contact The Concrete Institute on 011-315-0300 or

visit www.theconcreteinstitute.org.za

Concrete structures, crafted by master designers, can be creations of awesome beauty. But to combine beauty and durability calls for a myriad of other factors. Fibre-reinforcement is just one.

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“Sponsoring an event of this nature not only enhances our leadership position in the industry, but it also shows our true commitment to delivering on our promise of strength

beyond the bag. As a company, we remain passionate about investing in initiatives and projects that advance excellence in concrete. We also look forward to strengthening our partnership with the CSSA,” says Richard Tomes, the managing director of cement sales at PPC.

The Fulton Awards have been associated with the celebration of achievements in the South African building industry for decades. It is also an indication of the high standards of the skills and creativity found in both the local construction professionals and contractors.

“These awards are also synonymous with the recognition of excel-lence in construction, and of excellence in concrete in our country,” says Daniel van der Merwe, architectural concrete specialist at PPC.

“The Fulton Awards began as a tribute to the late Dr Sandy Fulton for his outstanding contribution to the understanding of concrete, its development and improvement. The first Fulton Awards were held in 1979 and has grown to be one of the highlights on the industry’s calendar,” says John Sheath, chief executive officer of CSSA.

SpONSOR FOR 2015 FULTON AWARdS

South africa’s leading cement supplier, ppC, has decided to be the anchor sponsor of the Concrete Society of Southern africa’s (CSSa) fulton awards in 2015. Considered as the ‘Oscars’ of the concrete industry, the fulton awards event is arguably the most prestigious award that a project team can receive in the built environment.

At the last Fulton Awards in 2013, two of PPC’s clients were presented with awards in the ‘Civil Engineering Structure’ and ‘Sustainable Concrete’ categories for its work on the De Hoop Dam project in the Limpopo Province.

The judging panel said the work at the De Hoop Dam project led to significant simplification of the construction process and al lowed one of the highest construction rates achieved in South Africa, with a peak of more than 130 000 cubic metres of Roller Compacted Concrete (RCC) placed in one month. The De Hoop Dam is a flag-ship project for the Depart-ment of Water Affairs and will address a significant portion of future water needs in the Limpopo Province.

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www.wackerneuson.com

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A consortium providing civils and electrical infrastructure to one of the continent’s largest wind farms was formed by Murray & Roberts

Construction companies, Concor Civils and Concor Roads & Earthworks, in a joint venture with Consolidated Power Projects (Conco) with a contract start date of November 2012.

Murray & Roberts Construction’s were responsible for the construction of 50 km of gravel road, 60 concrete foundations for the wind turbines, route modifications on the N2 highway, building an operations and main-tenance building, as well as trenching for 200 km of MV cabling to the substation.

Project detailEach of the turbine foundations required approximately 335 m3 of concrete and the selection of a suitable cement supplier was based on a number of factors. “We chose AfriSam due to our longstanding relationship with the company, the quality of the cement, its suitability for the project, the pricing and their ability to deliver timeously,” Joe Nell, project manager for the consortium, says.

Globeleq is the majority shareholder and is jointly managing the construction of Jeffreys Bay Wind Farm. The company is an independent power industry leader in the emerging markets participating in nearly

14 000 megawatts (MW) of generation capa-city in more than 25 countries. The project’s consortium partners include Old Mutual, Thebe Investment Corporation, Mainstream Renewable Power South Africa, Jeffreys Bay Community Trust, Enzani Technologies and Usizo Engineering.

The wind farm’s civils and electrical infrastructure consortium selected AfriSam’s HSC 52.5N cement due to its early strength properties. “The customer required cement that was not only able to provide the high strengths required for the turbine founda-tions, but that would also expedite the fast track construction programme due to its rapid hardening properties. This versatile cement is cost effective due to its workability, strength and durability properties,” Meredith Jordan, AfriSam sales manager:Building, Civil and Manufacturing (BCM), explains.

Efficient delivery crucial“Delivery of the 4 000 tons of cement began in March 2013 and the last consignment was delivered in December the same year before the annual building and construction shutdown. The bulk of the product was sent from our Ulco factory, some 80 km outside of Kimberley. This equates to a lead distance in the order of 1 000 km each time we made a delivery. Our depots in Queenstown and East London were placed on standby as a backup and we were able to meet all our deadlines,” Jordan points out.

Nell says that the civils and electrical infrastructure project consortium was given 10 milestone dates with which they needed to comply. “We were under extreme pressure but we have managed to meet the first nine milestones timeously and we are on track to achieve the final milestone in the first quarter of 2014. The seamless and expeditious delivery of cement by AfriSam has played a

large role in the successful attainment of the turbine foundation deadlines”.

Murray & Roberts’ Concrete Centre of Excellence was tasked with developing the optimum concrete mix for the high temper-atures generated beneath the turbines. The mix also needed to be extremely durable, so the concrete had a fair quantity of fly ash added to accommodate the demands of the end application.

“We established a concrete batching plant at a commercial quarry close to the project and the concrete was transported to various locations on this 3 800 ha site. It was critical to micro manage the interface with all parties, including AfriSam, Conco and Siemens, to ensure that the specified delivery periods were concluded without incident. Apart from the huge physical extent of the project’s footprint, at peak we had 650 people on site from the civil and electrical consortium and Siemens, leading to complex logistical planning,” Nell adds.

Nell points out that all the roads and the foundations are now completed and the environmental rehabilitation process is underway. “97% of the cabling installation has been completed and the substation was energised on 6 December 2013. Siemens erected 70% of the turbines and the first two circuits were commissioned prior to the December 2013 shutdown. All component deliveries will be completed in February 2014 and the erection of the remaining turbines will be completed before the handover in April 2014.”

“Joe Nell and his team made the logistics very easy for AfriSam by having all the neces-sary documentation in place prior to deliv-eries. The healthy and collaborative rela-tionship we developed with the project team was a huge enabler in the smooth workflow process,” Jordan concludes.

EFFICIENT delivery The 138 MW Jeffreys Bay

Wind Farm in the Eastern Cape is characterised by the extremely fast track

nature of the project. 44


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mAIN: Each of the turbine foundations at the Jeffreys Bay Wind Farm project required approximately 335 m3 of concrete and AfriSam was selected as the supplier of choice for this project. top: AfriSam was selected to supply the cement for the Jeffrey Bay Wind Farm where its quality product was used the turbine foundations. AboVE: The Jeffreys Bay Wind Farm project required cement that was able to provide the high strengths required for the turbine foundations.

what is the project?

Holiday Inn Hotel Refurbishment, both external and external.

who is the client?

Tsogo Sun would be the client, however Form Force Scaffolding was appointed as a subcon-tractor be appointed by Gamma Zenith.

what is the scope of the project?

Form Force's scope of works is to supply and erect access scaffolding to all external façades of building.

when did the project start and when is it likely to be completed (the subcontracted part)?

The project started in February 2014, and is expected to be completed in April 2014.

how many people does form force Scaf-folding have on site?

While we are erecting scaffolding we would have approximated 15 labourers on site – this includes supervisors.

what have been the major challenges of the project?

There have been one major one: due to hotel still being open, our workers had to be extra cautious when handling material and had to keep noise levels down as guests were in the hotel.

what is form force Scaffolding?

I am the managing director of the company. Form Force Scaffolding opened its doors in 2008 with the vision of becoming the market leader in providing superior scaffolding and access solutions to the construction, mining,

and events and media industries. It is a turnkey scaffolding provider, specialising in supplying, erecting, modification and dismantling of access scaffolding. Form Force Scaffolding is involved in a number of projects countrywide, with clients ranging from small construction companies, to some of the leading construc-tion firms in the country.

why did you decide to use layher products for this project?

Form Force opted to use Layher because of the extreme pressure and timeline faced on project. Layher – being a much lighter scaffold which is easier to erect – allowed Form Force Scaffolding to erect each façade in record time.

what products did layher provide?

Layher provided the complete systems for the Allround Scaffolding.

what is your experience of the company?

We have received a personalised service from both staff, as well as management. The entire Layher team takes a personal interest in the project and some of the staff was present while Form Force was erecting scaffolding. Material was always available on request. Our Layher experience was great ‘all-round’.

LIghTER ANd FASTERform force Scaffolding is currently busy with the supply and erection of access scaffolding to all external façades of the holiday inn in milpark, Johannesburg. Construction world had a on-on-one interview with hassan Suleman, the company’s md.

Form Force Scaffolding was responsible for the supply and erection of access scaffolding to all external façades of the holiday Inn in Milpark.

hassan Suleman.

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Bayferrox pigments are imported by Chryso Southern Africa from Lanxess in Germany, one of the largest pigment supp-

liers to the global construction industry. Chryso SA is the sole distributor of Bayferrox range of pigments for the Southern African construction industry.

Dumaine Els, Chryso SA’s technical sales representative based in Jet Park, says Netrac Investments, the developers of the upmarket and strategically situated new convenience and lifestyle shopping facility, had no hesitation in opting for concrete roads to handle the heavy vehicular traffic expected to visit the 27 stores spread over 17 000 m2 on the corner of Kingfisher and Trichard roads. The roads inside the shopping centre grounds lead to over 1 000 parking bays constructed from interlocking concrete blocks without pigmentation.

“The developers were seeking the exceptional durability and long-life that concrete roads can provide for a shopping complex that has over 340 000 people living in its catchment area and therefore can expect to carry far above normal vehicular traffic. Bayferrox 330 black pigment was selected so that future tyre marks and oil spills on the dark concrete surfaces would not be too conspicuous.”

Large quantities of Bayferrox 330 black pigmentation were also used recently to conceal spillage staining on the bunded concrete areas surrounding the fuel storage tanks on Transnet’s new Multi-Product Pipe-line (NMPP) project which runs between Durban and Heidelberg, Gauteng.

A dosage of 16,6 kg Bayferrox pigmen-

tation per cubic metre of concrete was used for the mix for the concrete roads at Sunward Lifestyle Centre. In total, 47 tons of pigments were used to achieve the required black shading of the roads constructed by main contractor, Mikon Construction of Boksburg.

The mix for the 3 000 m3 of pigmented concrete used to construct the roads was designed by AfriSam’s Technical Department and supplied from the company’s Wadeville operations. Matthews Setlhodi, Afrisam team production leader in charge of the concrete requirements for the project, says 80 to 100 m3 of ready mix concrete were delivered daily to the Sunward Lifestyle Centre construction site by AfriSam over a period of about eight months. “Roughly 500 concrete mixer loads were required for the road building,” he adds.

Lanxess manufactures Bayferrox 330 pigment using the 85-year-old patented Laux


Process which offers high quality and appli-cation advantages such as colour intensity and colour consistency.

“Bayferrox pigments are also weath-er-stable and light-fast, and not toxic or irri-tating to the skin or mucous membranes,” Els adds. “In line with the Chryso Southern Africa Group’s emphatic move towards dust-less product technology, the free-flowing iron oxide pigmentation is supplied in granular form which is virtually dustless.”

Sunward Lifestyle Centre is anchored by a 4 100 m2 Checkers ‘Blue Label’ store, and a 3 000 m2 Food Lover’s Market. The new high-quality retail mall will con- centrate on upmarket food and lifestyle retailing and will cater for one of the most

affluent areas in Ekurhuleni. The mall is managed

by Retail Network Services, which also manages Pan Africa Shopping Centre in Alexandra, Edendale Mall in Pietermaritzburg, Heming-ways Mall in East London, Grayston Shopping Centre in Sandton, and Jabulani Mall in Soweto.

Bryan Perrie, MD of The Concrete Institute, and a global authority on concrete roads and pave-ments, says the decision to opt for pigmented concrete roads at Sunward Lifestyle Centre is commendable and somewhat of a pioneering move for the South African commercial sector. “There certainly seems to be potential for further similar designs at shopping malls as concrete roads undoubtedly offer exceptional long life for

such heavy traffic situations. And the use of quality colour pigmentation would augment the design possibilities even further.”

The Concrete Institute provides training courses on a wide variety of concrete techno-logical subjects including concrete roads at its School of Concrete Technology in Midrand where many Chryso SA staff members have studied over the years.

for luxury centrePIGMENTED ROADSConcrete roads, coloured black

with a Bayferrox inorganic pigment, were selected ahead of asphalt or other alternative road

surfaces for the extensive road network in the new R220-million

major Sunward Lifestyle Centre shopping complex in Sunward

Park, Boksburg.

Chryso SA has installed a colour labo-ratory at its head office in Jet Park that can measure the colour strengths of pigmentation, and provide customers with specifications to colour match available concrete masonry produc-tion lines. Chryso S.A. has also produced an informative free leaflet ‘Pigmented Concrete’, containing essential advice for members of the construction industry involved in the pigmented colouring of concrete. Copies of the leaflet can be obtained by phoning Dumaine Els on 011-395-9700, or sending an email to [email protected]. Also visit the Chryso SA website, www.chryso.com for more information about coloured concrete.

“Bayferrox pigments are also weather-stable

and light-fast, and not toxic or irritating to the

skin or mucous membranes.”

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www.sephakucement.co.za

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Growth markets are anticipated across sub-Saharan Africa, spurring rapid infrastructure development

and the construction business opportuni-ties that come with it.

With myriad building and construction projects underway, the prospect of high returns from project tenders is bringing thousands of industry stakeholders to the Totally Concrete Expo.

The delivery of timely and sustainable infrastructure in Africa requires effective industry collaboration both domestically and across borders, next generation building technology, and innovative materials. Historically, it has been a very real challenge to complete construction projects on budget and on time in Africa and the injection of new practices and technologies is vital to fast-track devel-opment. Many of the latest innovations in engineering and building technologies are arriving in Africa for the first time at Totally Concrete, taking place from 26 to 28 May in Johannesburg, South Africa.

Industry growth estimates have sky-rocketed and it is now estimated that USD940-million will be invested into the cement industries of South Africa, Zambia, and Zimbabwe alone by 2018. New cement plants also being built in a number of other African countries. Happy-Girl Buthelezi, head of business development at PPC South Africa will outline how PPC is helping build Africa to the apex of its economic potential through its cement

plant construction projects in the sub- Saharan region and. Wolfram Schmidt from the BAM Federal Institute for Materials Research and Testing in Germany will share findings from the first ever Africa-wide cement competency testing programme.

Totally Concrete provides a crystal clear picture of where the industry is headed, recognising that next generation tools and technology are required to enhance the local and regional built environment. Clem Sunter, chair of the Anglo American Chair-man’s Fund and renowned conversational model strategist, will deliver the keynote address and Daniel Silke, leading political analyst and futurist, will give a presen-tation that sets the stage for shaping the future of Africa and defining the role that the construction industry will play therein.

Incorporating both strategic and tech-nical elements, Totally Concrete has practical tools and techniques for all professionals active in the construction sector. Stakeholders from over 40 countries worldwide will have an opportunity to access cutting edge technology as it arrives for the first time on African soil. Totally Concrete is endorsed by over 60 industry associations and sponsored by PPC, Lafarge, AfriSam, CCS, PMSA and Nyeleti Consulting. Martin S. Owuor, First Secretary of the High Commission of Kenya, says of the event, “Totally Concrete is very informative and very important at this critical time when Africa is trying to improve infrastructure necessary for development.”

Since October 2013, the company has supplied coil coatings to Roofings Rolling Mills (RRM), located in Uganda.

BASF and its technical service were on hand when the new coil coating lines were put into operation.

RRM is part of the Roofings Group, East Africa’s largest steel producer. At its site in Namanve Industrial Park, RRM operates three production lines with an annual capacity of 240 000 metric tons. BASF has supplied a Pevicoat® mixing unit, based on site at RRM. The Pevicoat® unit is a computer-assisted paint mixing system that can mix any colour and gloss level within a very short time.

“With RRM, we have an important long term partner, which will allow us to continue to grow in this key region. Africa is an attractive market for our industrial coatings,” explained Phil Green, business development Manager BASF´s Coatings division. “For RRM, robust products with high quality and excel-lent service are crucial.” The coatings and the service are provided from BASF’s site in South Africa.

“The African market plays a key role in the BASF strategy, but also in the future growth plans of our Industrial Coatings Solutions unit, ” explains Nils Lessmann, BASF business manager precoatings EMEA.

Coil coatings are used to coat aluminium and steel coils before they are processed further into different products in the construc-tion, household appliance and automotive industries. Products range from refrigerators to building façades. As the panels are stamped, rolled and joined, the coating has to be flex-ible and elastic so that it does not flake off. At the same time, however, it has to meet the requirements for scratch resistance.

INNOVATIVE TEChNOLOgy pLATFORMnot only does 2014 mark a time of growth for africa, but also a time of distinct development for the

26 to 28 May 2014 at the Sandton Convention Centre.

COATINgS IN UgANdAbaSf is expanding its business in industrial coatings in the growth market of africa.

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>cement, concrete and construction industries.

www.alliedcranehire.co.za

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EQuIPMENT

National sales manager Nicolan Govender gives his take on what to expect just in 2014: “In our experience,

one of the most reliable indicators of potential demand is the level of enquiries we receive from established customers, the people who are in business for the long haul and are constantly alert to developments within their own local markets,” he says.

Govender continues that the interest received from this core group over the last few months would suggest an imminent resurgence in recycling and construction work. The former in Gauteng, while there has been a noticeable upswing in demand for infrastructural growth in KwaZulu-Natal and the Eastern Cape provinces.

Govender’s cautious optimism stems from a continuous flow of new products are being dispatched to customers and certain sectors

Power, performance, durability, ergonomics, maintenance and serviceability provide across-the-

board superiority throughout the product range which includes the S510, S530, S550, S570, S590 and T590. “Nothing escaped our re-engineering; these loaders do more, better and faster,” says Michael Burns, national sales and marketing manager at Bobcat Equipment South Africa.

The new M-series will run up produc-tion and run down total cost of ownership on any site. The re-engineered hydraulics system which consists of a higher standard flow, combined with lower backpressure and high hydraulic pressure, results in 20% improved hydraulic efficiency. Improved attachment performance increases overall functionality by working faster and more

efficiently. The increased tractive effort enables operators to push more and dig harder than ever before. Stronger hydraulics and better tractive effort also results in faster cycle times.

“With operator safety and comfort always taking precedence, cab space has been increased by 10%, giving more room all around. The cab is not only bigger but quieter with a 60% noise reduction which improves the working environment, jobsite communica-tions and subsequently leads to better produc-tion. Noise and vibration are further isolated by the new engine mounts,” continues Burns.

The intelligent full-colour deluxe instru-mentation panel with optional keyless start as well as monitoring and interactive func-tions further improve operation. Operation levels are clearly displayed on the new 7" (full-colour LED screen with easy-to-read virtual sweep gauges. Important controls like engine speed control and operator switches are located right in front of the operator, giving superior visibility to raised lift arms through the larger top window. The 14% larger window also increases visibility.

The new cab-forward moves the oper-

gEARINg Up FOR 2014South african crushing and screening leader pilot Crushtec international is upbeat about prospects for the new year despite the trials and tribulations that beset local and international economies during 2013.

Nicolan govender, national sales manager, pilot Crushtec International.

within the mining industry displaying a higher degree of confidence than was apparent six months ago.

“This is particularly encouraging, especially as a number of larger operators are taking a close look at the range of Sandvik heavy duty mobile crushers, screens and scalpers which were added to our product offering last year. One product in particular, the UJ540i, attracted a great deal of interest at bauma Africa which, due to renewed activity within the contract market, is now reflected in our order book.”

He explains that the majority of orders received have been for mobile equipment; however enquiries continue to be received for modular plants in anticipation of future large volume contracts.

Bauma Africa was also the setting for the announcement of Pilot Crushtec Internation-al’s sole Africa distributorship of EDGE Innovate mobile materials handling equipment – an additional product line not only attractive to existing customers but which is also expected to gain the company important access to a wide variety of industries.

One of the attendant problems following a trading downturn is the hangover effect of reduced inventories restricting the supply of finished products and spare parts as the business cycle accelerates. As distributor of key brands like Sandvik, Rubble Master, TRIO

MORE. BETTER. FASTER bobcat Equipment South africa, part of the goscor group of Companies, an imperial Comp-any, proudly introduces the completely re-engineered, new generation compact m-series.

and its own highly successful TwisterTrac and Pilot Modular semi-mobile products, Govender is confident that Pilot Crushtec International has the ability to provide the turnaround times and after sales service to meet customer expectations.

“Not only do we offer a comprehensive range of machinery ex-stock but we have increased the volume and breadth of our spares offering in recognition of the growing importance of our PartsLink division.

“We believe in the resilience of our industry, so much so that we will be increasing our regional sales footprint into areas like the Northern Cape, Eastern Cape and KwaZu-lu-Natal. Another development will be the introduction of more localised service centres following the success of last year’s pilot project in the Eastern Cape.”

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EQuIPMENT

At 32 metres high – roughly the height of a nine-storey building – the cylindrical steel cold box will add a

distinctive landmark to the Coega landscape once it is lifted into position with multiple heavy-duty cranes.

Air Products remains firmly on schedule for completion of the plant in the third quarter, followed by commissioning and the flowing of gas in the fourth quarter of 2014, said Air Prod-ucts general manager, On-sites, Robert Rich-ardson. He said the cold box was the ‘heart of the plant’ and was probably the most distinctive feature of every cryogenic air separation plant.

The cold box’s arrival on site, transported by a self-propelled modular transporter from the Port of Ngqura, signalled the successful completion of a complex chain of behind-the-scenes processes in engineering, design, procurement, manufacturing and logistics.

“Together with the arrival of other high-tech components from America and Europe, this means the construction of the plant now moves from the major civil and building works stage into the mechanical phase of the installation,” said Richardson.

The cold box houses and insulates the cryogenic equipment for the refrigeration and distillation of atmospheric air into liquid oxygen and nitrogen. Several heavy-duty cranes will lift and fit the cold box into its final position on a massive concrete foundation, Richardson said.

He said the concrete foundation, together with lay down areas and support trestles where the cold box will rest horizontally for inspection and preparation prior to lifting, were constructed well in advance to allow time for the concrete to cure.

After inspection for possible shipping damage and quality control, the cold box will be fitted with valves and safety equipment, and ladders and platforms will be welded into place along with the application of corporate branding.

Air Products’ engineering team has conducted a rigging study and developed a lifting plan to determine the placement of the lay down areas, the cold box’s posi-tion in the lay down areas, as well as the number and size of the cranes, and health and safety issues.

“The project has been injury-free thus far. Air Products has supervised and conducted many of these lifts before, and this lift will once again be supervised by our experienced team with a key aim of sending everyone home safely, every day,” Richardson said.

The Coega Development Corporation (CDC) said the arrival of the cold box was not only a milestone for Air Products but also for Coega, adding that it would become a new

MILESTONEaiR products’ new air separation plant in the Coega industrial development Zone (idZ) has moved another step closer to its opening target with the arrival this week of a key piece of equipment that will tower over the Coega idZ and form the heart of the R300-million plant.

Coega IDZ icon for Eastern Cape businesses using industrial and speciality gases.

“The arrival of this essential component means that Air Products is one step closer to completing and opening their plant, which means they will be servicing their clients in the IDZ and across the Eastern Cape at a higher level, bringing security of gas supply both to the city and the province,” said Ayanda Vilakazi, CDC head of marketing and communications.

“The CDC welcomes the speed at which Air Products is working and looks forward to the plant coming online.”

Air Products managing director Mike Hellyar said the company took a strategic decision to build the new air separation unit in order to provide its Eastern Cape customers with improved security of supply, against the background of positive economic and indus-trial growth in the province, particularly in the Coega IDZ. “The location of a plant in the Eastern Cape reduces the need for expensive and risky cross-country trucking of products from Gauteng,” said Hellyar.

“Market analysis conducted by Air Products showed high demand for industrial gas across the province’s automotive sector, as well as the agro-processing, food and beverage, and renewable energy sectors.

“In addition to servicing existing customers and traditional users of industrial and speciality gases, Air Products has identified strong potential to stimulate demand and move into new markets,” Hellyar added.

The construction phase of the plant has created approximately 120 jobs and Air Products has directed the majority of the project investment into the Eastern Cape by engaging local consultants and contractors in the design, engineering and construction of the facility.

By creating security of supply, the new air separation unit will unlock business opportu-nities and support employment through the entire value chain of the industries it services, including the automotive, food and beverage, agro-processing, pharmaceutical and renew-able energy sectors.

AboVE: The 32-metre cold box, the central component for Air Products’ new Eastern Cape air separation unit, is transported to the Air Products site in the Coega Industrial Development Zone, after arriving in the Port of Ngqura on Sunday, 16 February.

MAJOR

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ator area closer to the attachment, giving a better working vantage point. Bobcat loaders with enclosed cabs are air-conditioned and have a pressurised interior space that helps keep dust to a minimum. Increased light output of over 50% provides greater comfort and safety.

Burns says: “The new M-Series has many cost saving features; the performance of the cooling system has been improved and extended machine life while increased fuel capacity extends operation time.

“The M-series is unsurpassed when it comes to ease and speed of maintenance. With easy access to routine maintenance points, daily maintenance can be done quickly,” says Burns. “The swing open tailgate and the transverse mounted engine provide one-sided serviceability. The cab tilt provides

straightforward access to the hydraulics as well as to routine and long term maintenance points. Burns adds that these loaders do not require any belt adjustments, including the drive and alternator belts.

According to Burns, the rugged Bobcat chaincase is the only maintenance free chaincase in the industry, with an exclusive bow-tie drive train design, fixed axle tubes, stronger axles and fully sealed bearings. The pre-stressed #80 high-strength oval chains (HSOC) with no master link, thick side-link plates and hardened pins are 38% stronger than other products currently available on the market. Burns also points out that the chains never require adjustment. “The permanently sealed and lubricated Bobcat rollers and idlers do not require routine maintenance, saving the end user more time and money.”

www.esor.co.za

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EQuIPMENT

n ongoing roll-out will extend to include coverage across the Southern African region during 2014 as successive machines are ‘switched on’. GSM

technology coverage is available throughout southern Africa, with satellite catering for remote connections outside the cellular grid. GSM provides the best platform for near real-time tracking, providing imme-diate and/or hourly reporting on machine health, location and utilisation, whereas satellite is generally limited to daily reports.

A comprehensive remote monitoring and asset management service offered in five levels, Cat EMSolutions meets every operational scope requirement, from plant hire and construction fleets to full-scale mine sites. Cat EMSolutions levels range from information access to full service and maintenance support options.

“The introduction of Cat EMSolutions places Caterpillar at the forefront of orig-inal equipment manufacturers in the field of advanced conditioning monitoring,” explains Barloworld Equipment Bureau manager, JP Briggs. “Research confirms that customers are seeking consistency and standardisation, areas where Cat EMSolu-tions is designed to deliver.”

Product Link's intuitive web-based browser interface is Vision Link®, accessed via a PC or through Smartphones (an

example being a proprietary Cat device), making it easy for users to zoom in from any location globally for a detailed look at indi-vidual assets.

Supporting tools include Cat S•O•SSM

Services fuel and oil analysis programmes, housed at the Barloworld Conditioning Monitoring Centre, which are in turn acces-sible via Vision Link and optional or inclusive on all Cat EMSolutions options (depending on the level selected). Cat S•O•S Services are an essential component in machine life cycle costing, predictive and preventative maintenance strategies.

Key EMSolutions features include near real-time fuel level information; machine filtering by job site/geographical location; multiple machine tracking; payload displays on medium and large wheel loaders; and geo fencing capabilities.

Meanwhile, at the Equipment Moni-toring Bureau, a dedicated Barloworld Equipment team tracks individual machine data feeds downloaded via their onboard ECM (Electronic Control Module) computers.

Alerts received via the Equipment Moni-toring Bureau provide location and utili-sation updates, with more detailed infor-mation transmitted depending on the Cat EMSolutions level selected. Alerts sent via Cat ECM systems notify fleet owners when standard protocols have been exceeded. Examples of typical alerts are ‘engine over speed’, ‘high torque converter oil temper-ature’, ‘machine abuse’, and ‘implement hydraulic oil temperature high’.

There are degrees of alerts, depending on the severity of the outcome. A Red ‘Level 3’ alert status, for example, would indicate the need for an immediate mechanical shut-down and service support. “Planned and well-managed maintenance programmes provide the best assurance of high machine availability within budget, which is where routine use of Cat S•O•S Services provides a high degree of certainty,” says Briggs.

All S•O•S sample results and reports for each machine are easily accessible via Vision Link.

The five optionsThe five Cat EMSolutions packaged options are Level 1 Access; Level 2 Inform; Level 3

Machine health and location:

On 15 January 2014, Barloworld’s Equipment Monitoring Bureau officially came on stream,

automatically connecting to and interacting with a diverse construction and mining Cat machine population spread across South Africa that are

‘Product Link™ ready’, communicating via GSM or satellite technology to a dedicated control room at the

Barloworld Condition Monitoring Centre in Boksburg, Johannesburg. Product Link is Caterpillar’s onboard

transmitting hardware.

IT PAYS TO KNOW

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EMSolutions forms an integral part of scheduled and preventative maintenance planning, which includes S•O•SSM Services fuel and oil analysis programmes housed at the Barloworld Condition Monitoring Centre.

EMSolutions SOS Laboratory technician.

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EQuIPMENT

Advise; Level 4 Support; and Level 5 Manage. In terms of summary overview, Level 1

Access, enables users to access the Vision Link portal to know where their equipment is and what it is doing with remote, near real-time information.

Level 2 Inform enables users to manage equipment health and utilisation trends compared to benchmarks via automated reporting. These reports show a range of parameters such as fuel burn trends by machine and site application; fault codes that indicate a need for operator training or repairs; the amount of time units spend idling as opposed to earning; and confirmation on individual machine hours recorded in order to schedule prescribed maintenance.

The Equipment Monitoring Bureau generates a monthly fleet summary report for the customer, highlighting areas for potential improvement.

With Level 3 Advise, the package moves beyond pure reporting to include expert dealer recommendations. A Barloworld Equipment condition monitoring adviser provides valuable advice about mainte-nance, utilisation and repair, drawing from the data trend analysis generated.

These recommendations work hand-in-hand with a conditioning monitoring programme that can include in-field machine inspections, and fluid analysis via the Cat S•O•S Services programme.

Level 4 Support builds on Level 3 and caters for larger fleet owners, entailing the outsourcing of fleet maintenance, parts or repairs to a dedicated Barloworld Equip-ment technical services team, backed by the full EMSolutions and S•O•S suite, plus a dedicated conditioning monitoring adviser.

For mining customers, Level 5 Manage is in turn a negotiated maintenance and repair contract option where Barloworld

Equipment has sole responsibility within predetermined maintenance pricing struc-tures for agreed machine rolling avail-ability targets.

“Level 3 offers the best overall advan-tage for fleet owners seeking the bene-fits of mutual-monitoring, S•O•S analysis and constant on-line remote tracking and reporting by Barloworld’s Equipment Moni-toring Bureau,” adds Briggs.

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EMSolutions quality control.

VisionLink Mobile Home Screen – Cat Phone.

rIGHt: EMSolutions engine maintenance.

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> PRODuCTS AND SERVICES

Feedback from customers allows the company to develop products that provide cost effective solu-

tions for specific applications. The compa-ny’s stainless steel handrailing systems and floor grating are perfect examples of innova-tion at work.

“The wastewater, mining, petrochemical and chemical industries are very harsh envi-ronments for handrailing and floor grating. Chemicals and saltwater provide the perfect breeding ground for structural damage through corrosion. This, in turn, compro-mises the safety of the installation and can result not only in costly downtime, but more critically in slips and falls. The introduction of stainless steel products was an absolute necessity from both an occupational health & safety (OHS) as well as a productivity perspective,” Elaine van Rooyen, marketing manager of Andrew Mentis, points out.

Andrew Mentis’ corrosion resistant RS40 40 x 40 floor grating and handrailing in 304, 316 and 3CR12 stainless steel is ideally suited to the extreme conditions found in harsh environments. The products are designed and engineered to suit situations where the strength to weight ratio is impor-tant and where the integrity of the structure is not negotiable.

Not only is the use of stainless steel in applications such as these a safe and cost

effective option, but it does not compro-mise the aesthetics of the environment. The stainless steel handrailing systems boast clean modern lines and the stanchions offer a variety of standard angles and matching accessories. Bends and closures common to mild steel systems are also available for the stainless steel system.

Floor gratingAndrew Mentis’ stainless steel Rectagrid RS40 floor grating is considered to have the highest load bearing capacity. Manufactured using a pressure locking system pioneered by the company, the round transversals are perma-nently locked to the bearer bars enabling the use of the full depth of the bearer bars when calculating loads. It also guarantees the structural integrity of the product and further enhances its reliability and longevity in corro-sive environments.

Stainless steel Rectagrid RS40 is corro-sion resistant and non-sparking, so it is perfectly suited to situations where strength to weight ratio is important, such as waste-water treatment plants, petrochemical and chemical plants and mining operations. Stainless steel grating is particularly suitable for areas with elevated temperatures.

The compressive pressure locking of the bearer bars and transversals forms an exact pitch of 40 mm by 40 mm, which results in the bearer bars maintaining a perfectly upright position. In addition, as a result of the strong intersection locking, banding is unnecessary. Facilities are, however, available to provide banded and tailored grating where this is required,” says Van Rooyen.

HandrailingMentis stainless steel handrailing is aesthet-ically pleasing and offers scratch and stain resistant properties. The stainless steel tubular handrailing system is complemented by a range of standard angles and matching accessories, with different bends and end closures to provide versatility. The stan-chions and bends form part of a system of interlinking components that can be installed without the need for special tools, thus making installation quick and easy.

“Safety plays a large role in the selection of construction materials for handrailing. Weakened handrailings, caused by corrosion and damp, can result in accidents as well as raise maintenance costs. Mentis’ stainless steel handrailings are engineered and manu-factured to improve safety and reduce main-tenance,” says Van Rooyen.

She adds that the stanchion base plates are designed to allow moisture to drain from the stanchion itself. “Hand and knee rails and

bends are manufactured from 31,8 mm diam-eter tube with a 1,5 mm wall thickness. Bends and closures have swaged ends, improving speed of installation and preventing mois-ture from penetrating into the joints. This is particularly important in environments where corrosion is common due to the pres-ence of water and chemicals.”

The stanchions have a 45 mm diameter and a wall thickness of 2 mm specifications and are available in 316, 304 and 3CR12 stain-less steel. The centre hole for the knee rail is drilled and then flared on both sides. The top is also flared and a half round cap is welded into place. The base plate is 8 mm thick and welded to the tube.

Flatex and Mentex expanded metalsExpanded metals in the Mentex range up to and including 4,5 mm thick and the Flatex range up to and including 3 mm thick are available in 304 stainless steel. Expanded metal has a wide range of applications in industry as well as the domestic market.

SafetyVan Rooyen explains that Andrew Mentis has spared no effort or expense in ensuring that its stainless steel products conform to the highest possible safety and quality standards. Andrew Mentis satisfies the requirements of ISO 9001:2008 Quality Management Systems in respect of the design, development and manufacture of all its products.

“Attention to detail and an intimate knowledge of the specific requirements of each industry are factors that play a large role in Andrew Mentis’ ongoing success and have ensured that we continue to grow our footprint throughout Africa,” Van Rooyen concludes.

Mentis stainless steel handrailing is aesthetically pleasing and offers scratch and stain resistant properties.

Safety plays a large role in the selection of construction materials for Mentis stainless steel handrailing.

The stanchions and bends form part of a system of interlinking components that can be installed without the need for special tools, thus making installation quick and easy.

The Mentis stainless steel stanchions have a 45 mm diameter and a wall thickness of 2 mm specifications and are available in 316, 304 and 3CR12 stainless steel.

The hand and knee rails and bends of Mentis stainless steel handrailings are from 31,8 mm diameter tube with a 1,5 mm wall thickness.

Corrosion and chemical RESISTANCEAndrew Mentis was first

formed in 1950 as a precision engineering

works and subsequently went into the development

and manufacture of steel grating. Extensive research

and market experience has resulted in the growth

of the range of products to encompass expanded

metal, Mentrail (guardrails for roads), industrial

handrailing systems, steel floor tiles and Mendrill (automatic drilling and

boring machines).

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2.

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4.

5.

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PRODuCTS AND SERVICES >

1. 2.

3. 4.5.

BOOSTINg EThIOpIAN CEMENT pLANT playing an important role to Ethiopia’s much celebrated grand Ethiopian Renaissance dam construction – africa’s largest hydroelectric power plant yet – is South african Transport software business Cargoware.

CargoWare – the logistics software division of JSE listed Cargo Carriers – has in the past year installed

fleet management software to manage a staggering fleet of 1 000 Volvo

trucks, whose initial aim was to collect imported cement from a seaside port in Djibouti and transport it to an Ethiopian

Cement plant construc-tion site just 70 km from Addis Ababa.

The new Ethiopian Cement plant – sole cement provider of the USD4,8-billion Grand Ethiopian Renaissance Dam pro jec t – i s backed by Ethiopian multinational Derba MIDROC, whose owner,

S h e i k h M o h a m m e d Al Amoudi, ranks 62nd on the Forbes richest men list and 2nd on the continent. CargoWare is contracted to Derba MIDROC’s subsidiary, Derba Transport, where the

FleetLogiX software system has been installed. Fleet operators typically use the FleetLogiX

system to schedule their vehicle movements, manage dispatch and driver allocation, order processing, trip documentation management and invoicing and proof of delivery amongst a host of other productivity and profit-geared features. The first group of 750 trucks are fully operational and the balance of the initial order of 1 000 trucks is being fulfilled in the next few months.

CargoWare’s target ahead of Phase I, beginning last October, was to help Derba Transport move 3 million tons of cement within its first year – the 1st phase production capacity of the Ethiopian Cement plant – mainly to supply the Grand Renaissance Dam projects with cement, while still responding to domestic and neighbouring country demand.

In addition to the FleetLogiX system deployment, the 2nd phase of CargoWare’s involvement will be the implementation of Onkey – CargoWare’s maintenance manage-ment system that gives transport operators control over the maintenance of all assets, management of service and repair schedules. “Our history tells us that companies that utilise our full suite of transport solutions can

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shave in excess of 10% off their operational costs, of course this falls to the bottom line”, says Charel Schickerling, general manager at CargoWare and executive responsible for the Ethiopian project.

Per Ljungstrand, general manager – Derba Transport says: “The challenges managing such a large fleet can not be addressed without a computerised fleet management system. Such a system should not only deal with day-to-day driver and vehicle manage-ment issues but also ensure that transactional data is accurately recorded and reported. The FleetLogiX and OnKey systems will provide us with these controls to ensure the scalability to allow us to grow in future.”

A map showing the location of the grand Ethiopian Renaissance dam.

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"Inter-Africa Irrigation has been making use of Ultraflo mPVC piping at its Zambian irrigation projects, due to the fact that the range boasts

higher impact resistance and improved ductility. It also features increased hydraulic capacity and a more reliable performance, when compared to standard PVC piping prod-ucts," he states.

DPI Plastics exports manager Rajesh Naval states that the Ultraflo mPVC pipes were supplied to the Kapinga project in diameters ranging between 110 mm and 450 mm. "The pipes supplied to the project are manufac-tured in accordance with SABS 966 specifica-tions, which guarantees an operating pressure of up to 18 MPa. Its lighter mass ensures that the Ultraflo range is easier and more cost-ef-fective to transport, which is a major benefit in a remote area such as Kapinga."

Rawlinson points out that Inter-Africa Irrigation makes use of predominantly locally sourced staff on its Zambia projects. "We have total of about 70 local residents working on the Kapinga project. Sourcing local staff is important, as it leads to job creation and skills

development. This leaves a lasting and meaningful impres-

sion on the commu-

nity, together with the new irrigation system."According to Rawlinson, the Kapinga

project has been running smoothly, with no major challenges encountered to date. "DPI Plastics has proven to be a reliable and trust-worthy supplier, and that has gone a long way in ensuring that everything remains on schedule. DPI Plastics also boasts a highly competitive cost-to-performance ratio, which is an important aspect in this industry."

Inter-Africa Irrigation specialises in the supply and installation of full scale solutions for drip, micro-jet and centre pivot irrigation projects in Southern Africa. Rawlinson points out that the company has developed a strong market share in Zambia. "Our high quality workmanship has ensured significant growth in Zambia, an emerging market that hold tremendous promise, due to the high demand for continued infrastructural development."

Looking to the future, Naval is confident that DPI Plastics will continue to gain meas-urable market share through its Ultraflo range, particularly within the exports market. "There has been a steady increase in demand for mPVC piping, particularly from emerging African economies such as Zambia, the DRC and Mozambique. DPI Plastics has already established a good reputation in these regions, and is well positioned to satisfy this rise in demand," he concludes.

LEFt: DPI Plastics export manger, Rajesh Naval, and rIGHt: technical and product manager, Renier Snyman. bELoW: PVC pipes ready for export.

IRRIGATIONPipes for Zambian projectDPI Plastics' proprietary

Ultraflo mPVC pressure pipes were supplied in

standard 6 m lengths to the Kapinga Irrigation

Project in Zambia, which was established in mid-

2013. The appointed contractor, Inter-Africa Irrigation, selected the

Ultraflo range of pressure pipes for the project

due to its high-strength characteristics, notes IAIS manager Craig Rawlinson.

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This three year sponsorship is one that goes far beyond the simple branding of a building – it is an important partnership of support, training and skills development. “We at Lafarge are very

proud to partner with the University of Johannesburg (UJ) in contrib-uting to creating highly valuable human capital. Today’s students are tomorrow’s leaders and engineers, who help to shape our country and ultimately build better cities,” says Desmond Maharaj, general manager: cement, Lafarge South Africa.

Lafarge South Africa is the local presence of the international Lafarge Group. The company will provide a deeper insight into the world of civil engineering to the UJ-Civil Engineering Society, a student organisation for engineering students. This will be achieved through technical presentations, the supply of products for students to help complete practical applications as per their course requirements, and to raise funds through events such as the upcoming Annual UJ-Civil Golf Day in April.

The UJ-Civil Engineering Society will visit other universities that offer engineering courses in order to experience their facilities and to learn more about their courses. Lafarge will be supporting these initiatives wherever possible.

The first will be a site visit for final year students to the Lafarge plant based in Moscow, Russia, later this year. This destination has been chosen because of the significant civil engineering work being undertaken in the city. As a member of BRICS (Brazil, Russia, India,

China and South Africa) Russia is one of the world’s major emerging economies and, as such, offers a wide range of infrastructure devel-opment, which will be of great academic interest. These students will gain insight into the manufacture of cement, aggregates and concrete at the Lafarge plant in Russia.

Lafarge’s objective is to make a positive contribution to society and this is just one of the many Lafarge projects that are currently underway to support skills development and partner with educational institutions to build a better South Africa for all.

NEW ENgINEERINg INITIATIVElafarge South africa, the world leader in building materials is proud to announce that they are the new sponsor of the university of Johannesburg’s Civil Engineering Student Society.

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Lafarge and UJ personnel attending the announcement of Lafarge South Africa’s sponsorship of the UJ-Civil Engineering Society.

www.viinstruments.co.za

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SAISC education director Spencer Erling says that this programme will revolutionise the steel construction

industry. “Imagine a digital tool on your laptop, tablet or smart phone, that is so intuitive you will be up and running in a minute and within a few ‘clicks’ the capacity of the connection is displayed,” Erling says.

The entire process is as simple as it gets. • Click on the SAISC standard connection

you want to use (there are five major groups, from which you can choose your particular requirement with sub groups e.g. major group, moment connections, sub group, with a haunch etc.)

• Select the member sizes you wish to join (a full data base of sections is available to choose from).

• Select the bolt diameters, number of rows of bolts and the plate thickness.

• Push the calculate button and instantaneously the capacity of the connection is displayed.

But there is a lot more to this programme says Erling. “By placing your cursor on the box you are told what “the weak link in the connection is”, allowing you to refine the connection design. This is really a ‘jackpot’ feature of the programme,” he says.

Once you know the weak link the process is just as simple:• Enter all the loads from the analysis (axial,

moment and shear) and a design check is performed.

• Click to see a to-scale sketch of your connection with all stiffeners, dimensions and weld sizes specified, which you will be able to transfer to the construction drawings.

• Click to open examples, discussions and commentaries relating to your design so you can refresh your memory at an instant as to what was said in the SAISC Green Book about your particular design.

• Save and or print out summary of the connection design and file

TOOL UShERS IN NEW ERA

SAISC education director, Spencer Erling.

The Southern african institute of Steel Construction has developed a digital tool that enables the structural engineer to design the appropriate structural steel connection at the ‘press of a button’.

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this in logical paper and/or electronic traceable manner.

background Connection design is a critical part of the structural steel construction process. The late Bernard (Tommy) Thompson of Dorman Long Africa famously said: “Steel structures do not fail because of inadequate member design; they fail because of inadequate connection design”.

SANS10162:2005 sets down the rules for designing steel structures. To simplify the designer’s life, the SAISC publishes The South african Steel Construction handbook, popu-larly known as the Red Book, which turns the code formulae into tables. This ‘bible’ of the industry also provides guidance and general information to help the steel designer.

In 2013, to complement updated versions of the Red Book, the SAISC published a new hard copy version of the Green Book, which brought connection design up to date. The book is notable for its guidance and includes a plethora of simplifications, where appropriate.

“Once again, there is a great deal of text to explain ‘what and how’ but also examples to guide the designer through the maze of formulae and methods,” says Erling. The book has become a desktop companion to those involved in connection design and more than 300 designers have attended the SAISC courses on connection design based on the Green Book.

Notwithstanding the simplifications, connection design done by hand can be a laborious task, especially if the designer desires to optimise the efficiency (i.e. cost in Rands and Cents) of connections. “The net result is that too many steel structure designs are issued for construction with inadequate attention paid to the connections and their details. This is a serious concern for the SAISC and the industry and, so, after a tremendous effort by the SAISC team the new digital connection design tool was developed,” Erling says.

“A tool of this type has been dreamt about for years and in April 2014 it will be publicly launched and the dream will become a reality,” Erling concludes.

The new range includes the PWS 700-115 and the PWS 850-125 model angle grinders. Bosch Power Tools SA

senior manager Juergen Lauer notes that the new range of angle grinders have a smaller grip circumference and a lightweight design. "Weighing just 1,7 kg and 1,8 kg respectively, the new PWS angle grinders offer improved user comfort in a number of applications."

Lauer adds that the PWS range of angle grinders fall within the Universal class of Bosch’s Compact Generation. “They have an adjustable protective guard, which can be adjusted without the use of a wrench, and a spindle lock allowing for easy disc change. The PWS range of angle grinders also come

with a new patented sealing at the rear bearing, which reduces vibrations."

The PWS 700-115 angle grinder boasts 700 watts of power and is suitable for small to medium tasks, such as cutting, grinding and brushing metal and stainless steel. “The PWS 700-115 uses a 115 mm disc, and has 180 degree turnable gear housing which makes it suitable for right and left handed handling. The PWS 850-125 angle grinder uses a 125 mm disc and is powered by an 850 watt motor. Its anti-vibration handle ensures that the operator can carry out more demanding tasks with ease."

Lauer comments that Bosch's proprietary dust protection system comes standard on both angle grinders. “The dust protection system protects the ball bearing against dirt

to ensure extended maintenance intervals. This, combined with regular maintenance of the air vents, will ensure

a significant increase in the lifespan of the angle grinder,"

he concludes.

ANgLE gRINdER RANgE The South african division of bosch power Tools – a world leader in portable electric power tools and accessories – has expanded its Compact generation line of diY tools, by launching a new range of pwS angle grinders to the local market.

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Access to tall structures such as cooling towers and silos is often limited and dangerous. In order to gain access to these types of structures, Skyriders makes use of various industrial rope

access techniques such as bolting and aiding, which enables its rope access technicians to safely and easily ascend or descend the structure.

Skyriders marketing manager Mike Zinn notes that once access has been established, temporary or permanent platforms can be set up allowing Skyriders to carry out a wide range of concrete testing services. “This testing provides industries ranging from power generation to sugar processing with significant savings in terms of cost and time, as scaffolding can be costly and time consuming, and the cost can be disproportionate to the work that needs to be carried out.”

Skyriders offers three primary concrete-related rope access services, including; inspections, maintenance and repairs. Zinn reveals that concrete inspection comprises internal and external visual inspec-tion, cover metal surveys, carbonation testing, core drilling, structural integrity surveys and protective coating surveys.

"Working closely with engineers, Skyriders rope access technicians conduct structural integrity and protective coating surveys. These determine the extent of any damage to the concrete, reinforced steel, paint or any other coatings that cover the structure. Once a problem has been identified, Skyriders will carry out the required repairs in order to prevent further deterioration," he says.

In addition to inspecting and repairing concrete structures, Zinn explains that Skyriders provides a strengthening and maintenance service too. Concrete maintenance includes the application of corro-


The company, which designs, manu-factures and distributes building mate-rials, began local production in 1929

with the establishment of Rhino products, to manufacture plasterboard by hand. Branded then as Rhinoboard, this innovative product still today provides versatile, distinctive aesthetics to enhance the interior styling of any building, from hospitals and schools to homes and leisure centres.

Over the next 40 years, the company underwent various structural changes, intro-ducing new products and building systems along the way. In 1996 the company was renamed BPB Gypsum, a move which enabled the South African operation to achieve inter-national status.

The new millennium saw fthe formation

of LBS (Lightweight Building Solutions), now Gyproc Service Centers. In December 2005, the French multinational corporation Saint-Gobain purchased BPB Gypsum. The local team chose the company name Gyproc because it emphasised the use of gypsum elements used in the company’s products.

Saint-Gobain Gyproc has since then grown from strength to strength with over 12 new innovative products being introduced to the market over the last two years.

2014, the company’s 85th year in South Africa, will be another exciting year with more innovative solutions being introduced to the market to enhance energy efficiency and environmental protection.

In delivering his address at the gala evening, regional managing director of Saint-Gobain,

for inspection and repair ROpE ACCESS

leading rope access specialist Skyriders has developed a reputation for being an industry-leader in the provision of concrete inspection, repairs and maintenance for a variety of industrial applications, thanks to its unrivalled track record in africa.

Skyriders provides a strengthening and maintenance service too.

sion inhibitors, barrier coatings systems and expansion joint sealing. "Once the inspection is complete and it is determined how much reinforcing steel must be treated, maintenance can begin. Any rust is removed and corroded sections are replaced, before the steel is coated with epoxy and covered with cement. To protect the reinforcing steel from the effects of carbonation, barrier coating and corrosion mitigating inhibitors are applied to the structure."

“We are looking to market our services and capabilities to South Africa’s water authorities, as a number of local dam walls and reservoirs are currently in poor condition, and we have the ability and resources to help improve this situation – by inspecting every millimetre of the walls in less time than it takes for scaffolding to be installed,” he concludes.

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Regional managing director of Saint-gobain, Steve du Toit.

85 yEARS IN SAThis year, leading interior building solutions group gyproc a division of Saint-gobain, celebrates 85 years of successful trade in South africa. loyal customers and key stakeholders joined the senior executives of the company for a gala dinner to commemorate and celebrate the company’s milestone, held at monte Casino.

Steve du Toit emphasised the point that as a company Gyproc, while celebrating 85 years are continually evolving as a business. “The business launched 18 new products in the past 18 months and has 10 more innovative product launches planned for this year. In the coming five years we plan to launch more new prod-ucts than the business has introduced in the past 85,” announced Du Toit. “Our core focus will be on our customers, their experience in dealing with us, and how best we can service their needs. In addition, we are looking beyond our immediate borders with expansion plans into Africa, so there are many more exciting years ahead,” he said.

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success factors of this MOU. “This exchange benefits both countries as the engineers across both South Africa and Palestine have now been given the opportunity to glean from each other and cross-pollinate ideas and strengths across the nations. We have much to learn from each other, I am hoping that this will change the face of engineering in both countries,” said Sabela.

ECSA aims to ensure that this agree-ment will be completely leveraged through the effective delivery of technical training and mentoring programmes for engineers in both nations.

The Engineering Council of South africa (ECSa) recently signed a memorandum of understanding (mOu) with the palestinian Engineering association (pEa), The institute of municipal Engineering of Southern africa (imESa), and municipal infrastructure Support agency (miSa) to address the skills shortages in the engineering fields from a national perspective and to facilitate training opportunities for engineering practitioners from both countries.

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AppOINTMENTS

DIARY AND APPOINTMENTS

The MBA North

In collaboration with the South African government, this partnership is aimed at developing capacity in local govern-

ment through sharing best practices between the two nations, and providing a platform for an engineering exchange programme aimed at driving economic growth and development.

“ECSA is pleased to form this alliance to launch the exchange and cooperation programme between the State of Palestine and the Republic of South Africa with specific focus on Local Governance and Municipal Development,” said Edgar Sabela, acting CEO for ECSA at the signing of the memorandums of understanding between ECSA, PEA, IMESA and MISA, which took place at The Sheraton in Pretoria.

ECSA has, as one of its priorities, a mandate to cultivate partnerships that are geared towards up-skilling engineering practitioners

INCREASEd COLLABORATION

and capacitating local government. ECSA is looking to increase its pool of competent local government engineering practitioners, and meeting this objective will be one of the

Engineering Council of South Africa (ECSA) recently signed a Memorandum of Understanding with the palestinian Engineering Association. Edgar Sabela, acting CEO for ECSA, is seated on the right.

The first event was held under the name of bauma Africa, and it celebrated a successful premiere with 754 exhibitors from 38 countries and 14 700 visitors from over 100 coun-

tries. As part of their co-operation on international construction machinery events, Messe München and AEM announced at bauma in 2013 their intention to set up a joint venture in Africa.

This joint venture will be organising the upcoming trade show as BAUMA CONEXPO AFRICA. The event will retain the current successful exhibition team and its CEO Elaine Crewe. Eugen Egetenmeir, managing director of Messe München, explains: "Both partners have agreed on the new event name of BAUMA CONEXPO AFRICA. This new, joint name reflects the close and trusting cooperation between Messe München and AEM."

Dennis Slater, president of AEM, comments: "Africa offers tremendous opportunities for North American companies in particular. We are pleased to be supporting our members as they enter or expand in this market."

The next edition of the International Trade Fair for Construction Machinery, Building Material Machines, Mining Machines and Construction Vehicles will be held from 15 to 18 September, 2015, in Johannesburg. The event venue will be announced soon.

STRONg pARTNERShIpbauma africa is renamed bauma COnEXpO afRiCa.

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Centre for Sustainability in Mining and Industry

at the university of the Witwatersrand

Professor Caroline Digby, director.

Basil ReadBruce Morton, executive director: construction.

Charl Venter, re-elected as MBA

North vice-president.

Lea Smith, has been elected president of Master Builders Association North.

www.layher.co.za

www.mapei.co.za

april 2014 constructionworld - crown publications · economy’ thela stated that the national...

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