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Inanda Dam, KwaZulu-Natal
Pipeline Rehabilitation to Elevated Sections on Nagle Aqueducts 1 & 2
- Client: Umgeni Water
- Consulting Engineers: MSW / Ephakama
- Main Contractor: Esor Construction
- Subcontractor: Smart Civils
- Duration: 11 months (Jan 2025 – Feb 2026)
- Contract Value: R18 million
Project Overview
Umgeni Water’s Nagle Aqueducts form part of the bulk water supply system feeding the Durban Heights Water Treatment Plant. Decades of environmental exposure and corrosion had caused significant deterioration to the external pipeline structures. To ensure long-term reliability of this essential water supply infrastructure, Smart Civils was appointed by Esor Construction, under the supervision of MSW/Ephakama Consulting Engineers, to rehabilitate and protect the external surfaces of the aqueduct pipelines.
Scope of Work
Smart Civils’ scope included a full external rehabilitation programme involving:
- Cleaning and recoating of elevated pipeline sections.
- Rehabilitation of partially buried and eroded pipe areas.
- Application of protective coating systems to steel pipe supports and saddles.
- Repair and waterproofing of concrete pipe surfaces.
- Reinstatement of backfill and protective layers for long-term durability.
Project Challenges
The project required careful planning and technical expertise due to:
- Limited access: Elevated and steep terrain sections required scaffolding, rope access, and strict working-at-heights procedures.
- Adverse weather: High rainfall in the region impacted coating and curing schedules.
- Aging infrastructure: Advanced deterioration of coatings required extensive surface preparation.
- Environmental and safety constraints: Work was carried out under strict OHS and environmental management controls.
Execution Highlights
Smart Civils implemented specialised corrosion protection systems tailored to the site conditions:
- System 1: High-pressure cleaning, priming, and wrapping with Denso Acrylic Tape finished with a UV-protective topcoat.
- System 2: For buried and erosion-exposed pipelines – Densotherm HD wrapping, topcoating, and backfilling with soilcrete and Bidim protection.
- System 3: Steel supports coated with Denso ST HD epoxy and a polyurethane UV topcoat.
- Concrete surfaces: Waterproofed with SikaTop Seal 107.
Daily toolbox talks and risk assessments ensured continuous compliance with safety and environmental standards.
Outcome
The rehabilitation of the Nagle Aqueducts has extended the lifespan of this critical water supply infrastructure. Smart Civils’ precision execution and technical expertise ensured that the pipelines are now fully protected against corrosion and environmental damage — securing continued, reliable water delivery for years to come.
