Zutari was engaged as part of a joint venture of five consultants, Mokolo Crocodile Consultants (the JV), to deliver a comprehensive range of engineering services for Phase 1 of the project. These included:
- Tender design and documentation
- Detailed design
- Construction supervision
- Contract administration
- Preparation of an Environmental Management Plan (EMP)
- Risk and hazard assessments, including HAZOP studies
Resources from all five design companies were mobilised into a single project office, working collaboratively within a shared digital environment. Phase 1 comprised:
- A 4.5 MW pump station
- A 46 km pipeline with diameters of up to 1,100 mm
- Delivery of approximately 30 million cubic metres of water per annum
- Water abstraction from the Mokolo Dam in the mountains south of Lephalale
Fostering a culture of close collaboration within the JV was key to creating an optimised and innovative environment throughout the project. This led to several noteworthy innovations:
Blasting Predictably
To construct the MCWAP-1 pipeline, blasting was required in in-situ rock formations near an existing operational pipeline. This pipeline was the sole water supply for Eskom’s Matimba Power Station, Grootegeluk coal mine and a local municipality. The team developed a novel set of criteria for specifying and evaluating blasting loads, ensuring no structural damage or service interruptions occurred.
Saving Cost Through 3D Modelling
The project was an early adopter of 3D modelling and digital design applications. Operating within an integrated digital design environment significantly reduced the cost-per-drawing metric.
Saving Time With Robotics
Innovative processes and robotic equipment helped reduce construction time. A robotic crawler, developed specifically for the project, was used to inspect sections of an old pipeline. The contractor later refined and commercialised the design.
Opportunities for Upskilling
The project duration provided valuable opportunities for training and mentoring. Several junior engineers, including those from the client and contractor teams, achieved professional registration, while others advanced into management and contract administration roles.
Looking to the Future
The team developed a fully revised technical and performance specification for the project, modularised for flexible application in future projects and changing conditions.
