M&D Construction Group (M&D), a leading multidisciplinary construction company, has earned a solid reputation for its ability to build world-class water supply infrastructure. This includes state-of-the-art water and wastewater treatment plants, as well as reservoirs and water towers.

Over the past six years, M&D’s Civils and Infrastructure Division has successfully delivered 10 reservoirs and two water towers of various sizes. The company has undertaken these projects on behalf of leading local municipalities and water authorities.

They include Magalies Water, Umgeni Water, Johannesburg Water, City of Ekurhuleni, and Breede River Municipality. This is in addition to two private sector client bodies, namely Heineken and Impala Platinum.

Reservoirs and water towers are very complex structures to construct, relying on specialist skills, experiences and capacities. They involve the design and application of high-specification water-retaining concrete mixes.

Moreover, this technical excellence often needs to be deployed effectively in very remote areas where many of these structures are built. This presents numerous logistical challenges that necessitate careful upfront planning to ensure that the construction programme proceeds
as planned.

Moreover, contractors need to be able to work well with communities located within the project footprint. This is to maximise community participation in these projects while also ensuring that local small, medium and micro enterprises (SMMEs) are able to maintain high-quality workmanship in line with that of the principal contractor.

There is very little scope for error when constructing water-retaining structures, with mistakes leading to costly delays.

The spirit of Kula Nathi

M&D has consistently excelled on these projects, which have always provided the perfect opportunity for the company to showcase its core values. These are also M&D’s key differentiators in the water infrastructure market. They include ‘be safe’, ‘do what you say’, ‘find the best way’ and ‘do it right’. This is in addition to Kula Nathi – isiZulu for ‘grow with us’.

Kula Nathi has enabled M&D to grow and develop a multi-skilled team that is needed to execute these projects very efficiently. Importantly, this team also comprises seasoned site managers and supervisors who have played a key role in successfully delivering this infrastructure.

Moreover, Kula Nathi has enabled the company to nurture strong professional relationships with subcontractors and suppliers with an impressive track record in water infrastructure. Certainly, the spirit of Kula Nathi is also applied when working with SMMEs and community members on these projects.

Lenasia reservoir development showcases excellence

M&D recently deployed these extensive skills and capabilities to construct a reservoir in Lenasia on behalf of Johannesburg Water. The company worked alongside Nyeleti Consulting, which was the design engineer and supervised the construction programme.

Niekie Wagener, head: Civils and Infrastructure, M&D, says that the project was a resounding success. He credits Nyeleti Consulting for having played a large role in the very positive outcome.

“This was certainly one of the best reservoir engineering designs M&D has had the opportunity to implement thus far. It was extremely well designed in terms of constructability. Certainly, the very strong team of engineers that Nyeleti Consulting deployed to the project also facilitated the efficient construction of this infrastructure. Furthermore, team dynamics between client, engineer and contractor were again very positive, creating an environment that was conducive to high levels of productivity and efficiency,” Wagener says.

This 15 Mℓ post-tensioned reservoir has a wall height of 8.5 m and a circumference of 157 m. Valued at more than R52 million, the new reservoir has brought an end to water supply interruptions in Lenasia and surrounding areas, which have been growing at a tremendous rate, placing significant pressure on existing water supply infrastructure. 

Opportunities for innovation

The project again provided M&D with an opportunity to innovate. The wall formwork was designed to be undertaken in a single 8.5 m lift – the first time a reservoir has been constructed in this manner in the country.

It was so designed by M&D to minimise construction joints in the wall, which was in line with Nyeleti Consulting’s design philosophy. By minimising the need for joint bandages, maintenance requirements have been significantly reduced over the entire life cycle of the infrastructure.

Considering the substantial long-term cost saving it will provide Johannesburg Water, the solution was very favourably received by the client.

However, constructing the reservoir wall in this manner was a steep learning curve for M&D and Nyeleti Consulting. A major challenge was the very thin reservoir wall, with the post-tensioning sleeves inside the formwork restricting space through which the concrete needed to flow.

To prevent honeycombing, the concrete mix was designed specifically for this application. Windows were also incorporated into the formwork design and experimental sleeves used to increase the space in which to vibrate the concrete.

Rukesh Raghubir, CEO of M&D, says that he is very impressed with the outcome. “I consider this project to be one of our many flagships, in terms of water-retaining structures. It demonstrates why we have remained a leader in the water infrastructure market.

“Our team that was deployed to site was able to ‘find the best way’, ‘do what we say’, ‘do it right’ and, importantly, ‘be safe’. Our spirit of Kula Nathi also prevailed throughout the project when working with subcontractors and suppliers, as well as SMMEs and community members. This also supported Johannesburg Water’s focus on ensuring that its infrastructure projects always start benefiting constituents as early as the construction phases,” Raghubir explains.

“The project met our client’s expectations in this regard by creating jobs, as well as training and development opportunities. We also delivered a world-class reservoir that will help to provide a reliable supply of water to residents of Lenasia and surrounding areas, and that will continue to add value over its entire life cycle,” Raghubir concludes.