Rep Eng 01 Inception Report

REVIEW RECORD SHEET
Project Short Title: Expansion of Sludge Drying Beds at Khutsong and Kokosi Wastewater
Treatment Works..........................................................................................................................................
Project No: 12897 ..................................................... Document Ref. No: 12897-Rep-Eng-01 ................
Document Title: Project Implementation Plan ............................................................................................
Document Type: Report Draft Report

Letter Report Technical Memo
Other (specify) .....................................................................................................
Project Manager: Danie Jansen van Rensburg...... Project Director: Sugen Pillay ..............................
CHECKLIST
YES NO* N/A
1. Have you read the brief/scope/TOR ? x__ __ ______
2. Does the document meet the promised scope of works in the brief ? x __ ______ ______
3. Is the purpose and scope adequately stated? x__ ______ ______
4. Have the following been checked to the extent appropriate for this
project:
 data analyses x__ __ ______
 calculations x__ __ ______
 spreadsheets x__ __ ______
 field data ______ x _ ______
 drawings, figures, sketches x __ ______ ______
 tables x __ ___ ______
 data transfers x __ ______ ______
5. Has analytical uncertainty been adequately addressed? Yes
6. Are conclusions and recommendations logical and defensible? Yes
7. Are all necessary references identified? Yes
8. Are limitations or conditions in the use of the data, recommendations, Yes
or conclusions discussed where necessary, and have appropriate
disclaimers been included?
9. Has the Project Director been consulted about this report Yes
COMMENTS
All checklist items have been satisfactorily addressed

* Any ‘No’ answers must be explained
Reviewed by: Danie Jansen van Rensburg

Print Name Signature
Date: 12 April 2013
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Zitholele Consulting
Reg. No. 2000/000392/07
PO Box 6002 Halfway House 1685

South Africa
Thandanani Park, Matuka Close
Halfway Gardens, Midrand
Tel + (27) 11 207 2060
Fax + (27) 86 674 6121
E-mail : mail@zitholele.co.za
REPORT ON
Expansion of Sludge Drying Beds at

Khutsong and Kokosi Wastewater
Treatment Works:
Project Implementation Plan
Report No : 12897-Rep-Eng-01
Submitted to: Merafong City Local Municipality
Postal: PO Box 3, Carletonville, 2500

Physical: 3 Halite Street, Carletonville, 2499
DISTRIBUTION:
2 Copies - Merafong City Local Municipality

1 Copy - Zitholele Consulting (Pty) Ltd – Library
Directors : S Pillay (Managing Director); N Rajasakran (Director); Dr RGM Heath (Director)
i
EXECUTIVE SUMMARY
The sludge drying capacity urgently needs to be increased at the New Kokosi and Khutsong
WWTWs (Waste Water Treatment Works), because limited sludge drying capacity currently
has a major impact on the sewage treatment efficacy at these plants. Limited sludge drying
capacity has a knock on effect on the treatment process and leads to poor effluent quality.
All of the planned sludge drying beds were not constructed due to budgetary constraints
when the New Kokosi WWTW was built and when the Khutsong WWTW was upgraded
between 2007 and 2011. Funding is now available to proceed with this work.
The planned activities and deliverables of Zitholele to expand the sludge drying beds at the
two waste water treatment works are discussed in this report. This report also indicates a
projected programme for the execution of the project, and preliminary cost estimates.
It is expected that limited environmental inputs will be required to proceed with this project,
because the RODs (Record Of Decisions) are already in place. Legislation promulgated after
2007 will be scrutinised to verify whether it will have an impact on this project.
The positive impact that the expansion of the sludge drying beds will have on the operation
and performance of the waste water treatment works is expected to be significant.
ZITHOLELE CONSULTING
ii
TABLE OF CONTENTS
SECTION PAGE
1 INTRODUCTION ........................................................................................ 1
2 PROJECT OBJECTIVE .............................................................................. 1
3 LOCALITY .................................................................................................. 2
4 AERIAL PHOTOGRAPHS........................................................................... 3
5 SCOPE OF WORK ..................................................................................... 4
5.1 Engineering Design, Tender and Construction Monitoring ......................4
5.2 Construction ...........................................................................................4
6 PROJECT METHODOLOGY ...................................................................... 5
6.1 INCEPTION PHASE ...............................................................................5
6.1.1 Desktop Study...........................................................................5
6.1.2 Stage Deliverables ....................................................................6
6.2 Site inspections and Meetings with Operational Staff ..............................6
6.2.1 Activities....................................................................................6
6.2.2 Stage Deliverables ....................................................................6
6.3 DESIGN DEVELOPMENT PHASE .........................................................6
6.4 DOCUMENTATION AND PROCUREMENT ...........................................7
6.5 Contract Administration and Inspection ...................................................7
6.6 Close-Out ...............................................................................................8
7 ENVIRONMENTAL IMPACT ASSESSMENT .............................................. 8
8 OCCUPATIONAL HEALTH AND SAFETY.................................................. 9
8.1 Design Stage – Risk Assessment ...........................................................9
8.2 Prepare Health and Safety Specification .................................................9
8.3 Evaluation and Approval of the Health and Safety Plan ..........................9
8.4 Monitoring of the Health and Safety Plan during Construction ..............10
9 PRELIMINARY PROJECT COST ESTIMATE ........................................... 11
10 PROJECT PROGRAMME......................................................................... 12
11 CONCLUDING REMARKS ....................................................................... 13
LIST OF FIGURES
Figure 1: Localities of WWTWs ..........................................................................................2
Figure 2: Aerial view of the New Kokosi WWTW ................................................................3
Figure 3: Aerial view of the Khutsong WWTW ....................................................................4
LIST OF TABLES
Table 9.1: Project Cost Estimate ......................................................................................11
Table 10.1: Project Status Schedule ................................................................................12
LIST OF APPENDICES
Appendix A Record of Decisions
1
1 INTRODUCTION
Zitholele Consulting (in association with ProPlan) designed the New Kokosi WWTW (Waste
Water Treatment Works) and the upgrade of the existing Khutsong WWTW during 2006. The
New Kokosi WWTW has an average treatment capacity of 7.5 Ml/day. The Khutsong
WWTW was upgraded from 3.5Ml/day to 7.5Ml/day average treatment capacity.
Construction was started during 2007 and completed in 2011.
Due to budgetary constraints at that stage, only half of the planned sludge drying beds were
constructed at both Kokosi and Khutsong WWTWs. This project entails the implementation
of the remaining sludge drying beds. The current sludge drying capacities at the WWTWs
are not sufficient for effective operation of the plant.
2 PROJECT OBJECTIVE
The main project objective is to increase the sludge drying capacities at the two WWTWs.
The consequences of insufficient sludge drying capacities are relatively major, as follows:
 Poor effluent quality

 Non-compliance with regulations and licences
 Prosecution by the authorities
Other negative impacts include:
 Environmental impacts
 Difficulty in handling wet sludge when transferring the sludge from the drying beds to
trucks
 Non acceptance of wet sludge at landfill sites
 Wet sludge will generate more water generation at the landfill sites
 Knock-on effects on the sewage treatment process:
o Sludge digesters and fermenters cannot discharge sludge to the drying beds
o Sludge cannot be wasted from the biological reactors
o The MLSS (Mixed Liquor Suspended Solids) increases. If the MLSS
concentration is higher, then the sludge age is older, which may result in
sludge bulking and the growth of filamentous organisms. Higher
concentrations of MLSS also require more oxygen and aeration, which leads
to higher operating costs
o Sedimentation tanks and clarifiers cannot be de-sludged. Carry over occurs.
o Suspended solids are higher in the treated effluent
2
o The efficiency of the chlorine dosed for disinfection is reduced due to the
shielding effect that suspended solids have on micro-organisms.
3 LOCALITY
The localities of the two WWTWs are indicated in the figure below:
Figure 1: Localities of WWTWs
The New Kokosi WWTW is located approximately 5km south west of Fochville and receives
domestic sewage flow from Fochville, Kokosi and Greenspark suburbs.
The Khutsong WWTW is located approximately 9km west of Carletonville and receives
mainly domestic sewage from Khutsong North and Khutsong South.
3
4 AERIAL PHOTOGRAPHS
An aerial photograph of the New Kokosi WWTW is presented in the figure below:
Figure 2: Aerial view of the New Kokosi WWTW
An aerial photograph of the Khutsong WWTW is presented in the figure below:
4
Figure 3: Aerial view of the Khutsong WWTW
5 SCOPE OF WORK
5.1 Engineering Design, Tender and Construction Monitoring
The scope of work to be undertaken is as follows:
• Project inception
• Interaction with Operations staff of the WWTWs to ensure that the sludge drying beds
design will meet the needs of the Client. Site investigations and meetings on site are
planned.
• Final Designs for the sludge drying beds
• Prepare Tender Documentation for the appointment of the contractor(s), and submit
3 copies of the Tender Documents
• Prepare a brief letter to confirm that no additional environmental authorisations are
required. The RODs that were issued in 2006 are attached as Appendix A.
• Letting out of the contract to tender (for construction)
• Tender adjudication and preparing a Tender Adjudication Report
• Contract award and initiation
• Contract administration and inspection
• Construction Monitoring
• Preparation of As-built drawings and a Project Close-out Report.
It is expected that the following services will not be required:
• Geotechnical investigations
• Testing of sludge (physical, biological and chemical properties)
• Topographical surveys
• The construction of pilot dryings beds
• Preliminary designs, because it is expected that the final design will be similar to the
existing drying beds
5.2 Construction
The scope of construction work will be as follows:
At the New Kokosi WWTW:
5
 The construction of 4 sludge drying beds with a total area of 1219m2, which will
double the drying beds at the works.
o Earthworks and layer works
o Sloped concrete base slabs with watertight joints
o Concrete walls with heights of 1.5m and lower
o Sloped drainage channels for return water
 The supply and installation of sludge inlet pipework and valves for the drying beds
 The supply installation of mechanical sluice gates for return water from the sludge
The scope of construction work at Khutsong WWTW will consist of the following:
 The construction of 7 sludge drying beds with a total area of 2892m2, which will
double the drying beds at the works. This will mainly consist of the following:
o Earthworks and layer works
o Sloped concrete base slabs with watertight joints
o Concrete walls with heights of 1.5m and lower
o Sloped drainage channels for return water
 The supply and installation of sludge inlet pipework and valves for the drying beds
 The supply installation of mechanical sluice gates for return water from the sludge
6 PROJECT METHODOLOGY
A phased approach will be adopted in the implementation of this project, comprising the
following 6 distinct project stages:
 Inception
 Site inspections and site meetings with operating staff
 Design Development
 Documentation and Procurement
 Contract Administration and Inspection
 Close-out
6.1 INCEPTION PHASE
6.1.1 Desktop Study
Copies of the following documents were obtained and studies:
6
 Report No. 8098/7639/1/P: Kokosi Waste Water Treatment Plant – Process Design
Report, Zitholele (Feb. 2006)
 Report No. 8099/8267/1/W: Kokosi Waste Water Treatment Facilities
Scoping Report, Golder (March 2006)
 Report No. 5803///P: Khutsong Waste Water Treatment Plant – Process Design
Report, Zitholele (September 2003)
 Report No. 8098/8266/2/W: Khutsong Waste Water Treatment Facilities
Scoping Report, Golder (March 2006)
 The as-built drawings of the New Kokosi WWTW
 The as-built drawings of the Khutsong WWTW
6.1.2 Stage Deliverables
This report, the Project Implementation Plan, forms the deliverable for this stage of the
project.
6.2 Site inspections and Meetings with Operational Staff
6.2.1 Activities
A site inspection will be held to verify the performance of the existing sludge drying beds and
to familiarise ourselves with the site. At least one meeting will be held with the operating staff
to check whether any problems are being experienced with the previous design and to
identify opportunities to improve on the old design. Opportunities to facilitate the operation of
the drying beds will also be considered.
6.2.2 Stage Deliverables
A Technical Memo will be completed on completion of this stage of the project.
6.3 DESIGN DEVELOPMENT PHASE

 Check the process design and sludge loading calculations
 Calculate the theoretical range of drying times
 Finalise the operating philosophy
 Finalise the layout
 Finalise the general arrangement
 Concrete layouts, sections and details
7
 Structural designs of reinforced concrete

 Design concrete joint details
 Design for water-tightness, including rear guards and centre bulbs across joints for
concrete.
 Design piping and valves
 Design mechanical weirs
 Finalise working drawings and specifications
 Update budget and programme
 Client review and approval of design and drawings;
6.4 DOCUMENTATION AND PROCUREMENT
 Prepare tender specifications and documentation;

 Prepare a tender budget estimate;
 Prepare procurement documentation;
 Issue tender documentation to the Client for approval
 Tender advertisement
 Tender adjudication and preparing a Tender Adjudication Report
6.5 Contract Administration and Inspection
Manage, administer and monitor the construction contract and processes including
preparation and coordination of procedures and documentation to facilitate completion of the
Works, which will include the following:
 Attend site handover

 Issue construction documentation, including construction drawings and bending
schedules
 Carry out contract administration
 Attend regular site technical and progress meetings
 Inspect works for quality and conformity to contract documents
 Assist in the resolution of contractual claims by the contractor
 Clarify details and descriptions during construction as required
 Instruct, witness and review all tests on and off site
 Check and approve Contractor drawings
 Update and issue the drawing register
 Issue contract instructions as required
8
 Inspect the Works and issue practical completion and defects lists
 Deliver all test certificates, as built drawings and operating manuals
Deliverables will include:
 Construction documentation
 A drawing register
 Contract instructions
 Practical completion and defects list
6.6 Close-Out
Close-out will involve the following activities:
 Inspect and verify the rectification of defects

 Facilitate and/or procure final operations and maintenance manuals, guarantees and
warranties
 Prepare and/or procure as built drawings and documentation
Deliverables will include:
 Works and final completion lists

 Operation and maintenance manuals, guarantees and warranties
 As built drawings and documentation
7 ENVIRONMENTAL IMPACT ASSESSMENT
All authorisations are already in place and the Zitholele Environmental Team will just confirm
that no new legislation has an impact on the project. The current RODs are included as
Appendix A and do not specify a date for completion of construction.
9
8 OCCUPATIONAL HEALTH AND SAFETY
It is advised that Merafong contract the services of an independent sub-consultant

to act as the Occupational Health and Safety (OHS) Agent on the project. If
required, Zitholele can source and manage this sub-consultant on behalf of
Merafong.
The scope of the Safety Agent will include the following Occupational Health and
Safety (OHS) functions up to and including project close-out stage:
8.1 Design Stage – Risk Assessment
A site visit will be undertaken to conduct a risk assessment (based on probability,

severity and frequency) during the design stage to identify hazards and recommend
suitable mitigation measures to render the project safe. Risks will be incorporated
in the Health and Safety Specifications.
8.2 Prepare Health and Safety Specification
A Health and safety Specification will be prepared for the construction work to be
performed. The Specification will allow the Contractor to consider the necessary
health and safety requirements pertaining to the construction works so as to ensure
health and safety of affected persons.
The Health and Safety Specifications aims to discharge the Client’s responsibilities
in terms of the Occupational Health and safety Act (Act 85 of 1993) and the
attendant regulations. The most noteworthy of these regulations are the
Construction Regulations (2003), the General Administrative Regulations (2003)
and the General Safety Regulations (1986 and subsequent amendments).
8.3 Evaluation and Approval of the Health and Safety Plan
The Health and Safety Plan of the Principal Contractor will be reviewed in terms of
the Health and Safety Specification. Particular emphasis will be placed on the Risk
Assessment and the concomitant Safe Work procedures, OHS related
responsibilities, cost provisions and general OHS provisions to comply with
statutory requirements.
The Review of the Health and Safety Plan will be undertaken by completing a
detailed checklist and comments sheets, which will be distributed to the relevant
parties. All requisite amendments to the Health and Safety Plan will be facilitated.
The final Health and Safety Plan will be approved in writing.
10
8.4 Monitoring of the Health and Safety Plan during Construction
The Health and Safety Plan of the Principal Contractor will be monitored during construction.
Monthly audits will be conducted on site, and a monthly report will be produced. The
inspections will include amongst others, the use of protective equipment, documentation
audits, risk assessments, safe working practices, etc.
11
9 PRELIMINARY PROJECT COST ESTIMATE
A preliminary schedule of quantities was compiled and estimated rates were used to
estimate the total construction cost. The Guideline Scope of Services and Tariff of Fees
published by ECSA Notice 206 of 2011, Government Gazette No 34875 of 20 December
2011 was used to calculate the professional fees. An additional allowance of R 100 000.00
was added for the appointment of the Health and Safety Agent as well as a Geotechnical
Investigation. Furthermore an allowance of R 360 000.00 was made for full time construction
monitoring. The total project cost is R11 614 737.28 (excl. VAT). A summary of the total
project costs are presented below:
Table 9.1: Project Cost Estimate
PROJECT COST ESTIMATE
SECTION DESCRIPTION AMOUNT
SECTION 1 PRELIMINARY AND GENERAL R 1 659 250.00
SECTION 2 Kokosi Drying Beds R 1 968 000.00
SECTION 3 Khutsong Drying beds R 4 669 000.00
SUB-TOTAL 1 R 8 296 250.00
CONTINGENCIES (15% OF SUB-TOTAL 1) R 1 245 000.00
SUB-TOTAL 2 R 14 210 250.00
ESCALATION (10% OF SUB-TOTAL 2) R 1 422 000.00
TOTAL PROJECT CONSTRUCTION COST ESTIMATE (excl. VAT) R 9 541 250.00
PROFESSIONAL FEES (Based on ECSA 2012 Guidelines)
Primary and additional fee R 953 712.50
Additional fee for Reinforced Concrete R 264 013.75
SUB-TOTAL 1 R 1 217 726.25
Adjustment Factor for WWTW (1.25) R 1 522 157.81
Disbursements (6%) R 91 329.47
Allowance for H&S and Geotechnical Investigation R 100 000.00
Construction Monitoring (full time) R 360 000.00

TOTAL PROJECT FEE COST ESTIMATE (excl. VAT) R 2 073 487.28
TOTAL PROJECT COST ESTIMATE (excl. VAT) R 11 614 737.28
12
10 PROJECT PROGRAMME
A summary of milestone dates for the key phases of the project is shown in the table
below:
Table 10.1: Project Status Schedule

PHASE STATUS AND COMMENTS
Planning
Formalise project team Complete
Desktop study and site visit Complete
Investigations
Meeting with operators on site April 2013
Internal assessment April 2013
Investigation Report May 2013
Preliminary Design Phase
Preliminary Design Report May 2013
Approval (Merafong) June 2013
Detailed Design and Tender Phase
Detailed Design June 2013
Tender Documentation June 2013
Tender approval, advert and July 2013

tender period
Tender Adjudication Report August 2013
Tender Award October 2013
Construction and Monitoring Phase
Construction and monitoring Projected start October 2013 for 6 months

Phase
Project Close-out Phase
Project Close-out Projected May 2013
Project end date Projected May 2013
13
11 CONCLUDING REMARKS
This report re-confirms what was offered at proposal stage. The Merafong City Local
Municipality will need to approve this report prior to engaging in the next phase of the
project.
ZITHOLELE CONSULTING (PTY) LTD
1
APPENDIX A
RECORD OF DECISIONS

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REVIEW RECORD SHEET

Project No: 12897 ..................................................... Document Ref. No: 12897-Rep-Eng-01 ................

Document Title: Project Implementation Plan ............................................................................................

Document Type: Report Draft Report

All checklist items have been satisfactorily addressed

Reviewed by: Danie Jansen van Rensburg

Date: 12 April 2013

PO Box 6002 Halfway House 1685

Expansion of Sludge Drying Beds at

Submitted to: Merafong City Local Municipality

Postal: PO Box 3, Carletonville, 2500

2 Copies - Merafong City Local Municipality

Directors : S Pillay (Managing Director); N Rajasakran (Director); Dr RGM Heath (Director)

Construction was started during 2007 and completed in 2011.

 Poor effluent quality

Other negative impacts include:

Figure 1: Localities of WWTWs

Figure 2: Aerial view of the New Kokosi WWTW

An aerial photograph of the Khutsong WWTW is presented in the figure below:

Figure 3: Aerial view of the Khutsong WWTW

5.1 Engineering Design, Tender and Construction Monitoring

The scope of work to be undertaken is as follows:

It is expected that the following services will not be required:

The scope of construction work will be as follows:

At the New Kokosi WWTW:

6.1 INCEPTION PHASE

6.1.1 Desktop Study

Copies of the following documents were obtained and studies:

6.1.2 Stage Deliverables

6.2 Site inspections and Meetings with Operational Staff

6.2.2 Stage Deliverables

A Technical Memo will be completed on completion of this stage of the project.

6.3 DESIGN DEVELOPMENT PHASE

 Structural designs of reinforced concrete

6.4 DOCUMENTATION AND PROCUREMENT

 Prepare tender specifications and documentation;

6.5 Contract Administration and Inspection

 Attend site handover

Deliverables will include:

Close-out will involve the following activities:

 Inspect and verify the rectification of defects

Deliverables will include:

 Works and final completion lists

7 ENVIRONMENTAL IMPACT ASSESSMENT

8 OCCUPATIONAL HEALTH AND SAFETY

It is advised that Merafong contract the services of an independent sub-consultant

8.1 Design Stage – Risk Assessment

A site visit will be undertaken to conduct a risk assessment (based on probability,

8.2 Prepare Health and Safety Specification

8.3 Evaluation and Approval of the Health and Safety Plan

8.4 Monitoring of the Health and Safety Plan during Construction

9 PRELIMINARY PROJECT COST ESTIMATE

Table 9.1: Project Cost Estimate

PROJECT COST ESTIMATE

SECTION DESCRIPTION AMOUNT

SECTION 1 PRELIMINARY AND GENERAL R 1 659 250.00

SECTION 2 Kokosi Drying Beds R 1 968 000.00

SECTION 3 Khutsong Drying beds R 4 669 000.00

SUB-TOTAL 1 R 8 296 250.00

CONTINGENCIES (15% OF SUB-TOTAL 1) R 1 245 000.00

SUB-TOTAL 2 R 14 210 250.00

ESCALATION (10% OF SUB-TOTAL 2) R 1 422 000.00

TOTAL PROJECT CONSTRUCTION COST ESTIMATE (excl. VAT) R 9 541 250.00