Chimoio Water Supply Project FinalDesign

Chimoio Water Supply
Project
FinalDesignReport
ADVENTIST DEVELOPMENT AND RELIEF AGENCY

MAPUTO MOZAMBIQUE
1LZ 0f, 11
CHIMOIO WATER SUPPLY PROJECT
FINAL DESIGN REPORT
Financed by: On behalf of:

USAID National Directorate of Water
Rua Faria de Sousa 107 Ministry of Construction and Water
Maputo Republic of Mozambique
SHELADIA Associates Inc.

15825 Shady Grove Road, Suite 100
Rockville, Maryland 20850
USA
JULY 1994
Chimoio Water Supply Project
FinalDesign Report
TABLE OF CONTENTS
Page
1. INTRODUCTION I
1.1. Background I
1.2. Project Area 2
1.3. Climaiic Conditions 2
1.4. Project Objectives 2
1.5. Report Objectives 3
1.6. Report Structure 3
2. EXISTING DATA 4
2.1 Topographic Maps 4
2.2. Topographic Surveys and Wayleaves 4
2.3. Soil Surveys 4
2.4. Hydrology Information 5

2.4. 1. Storage Capacity of Chicamba Lake 5
2.4.2. Design Levels of Chicamba Lake 5
2.4.3. Historical Water Levels in Chicamba Lake 6
3. FIELD SURVEY 7
3.1. Topographical Survey 7
3.2. Soil Investigation 7

3.2.1. General 7
3.2.2. Soil Types 8
3.2.3. Test Results 8
3.2.3.1. Sieve analyses 8
3.2.3.2. Compaction analyses 8
3.2.4. Implications of Soil Types for Excavation and Structures 9
FinalDesignReport
4.COMPONENTS OF THE PROJECT 10
4.1. General 10
4.2. Intake Tower 10

4.2.1. Location and intake level 10
4.2.2. Civil work brief description 11
4.2.3. Structural calculation 11
4.2.4. Mechanical equipment 12
4.2.5. Electrical equipment 12
4.2.6. Alarms 13
4.3. Access Bridge to the Intake Tower 13

4.3.1. General 13
4.3.2. Method of construction 14
4.3.3. Structural calculation 14
4.3.4. Other ancillary 14
4.4. Transportable Punp 14

4.1.1. General 14
4.4.2. Civil work 14
4.4.3. Electro / mechanical work 15
4.5. Guard Store House 15

4.5.!. General 15
4.5.2. Civil work 15
4.6. Intake Site and Transformer Tower 16

4.6.1. Ganeral 16
4.6.2. Intake Site 16
4.6.3. Transformer Tower 16
4.6.3.1. Structural Calculation 16
4.6.3.2. Size of transformer 16
4.7. At ess Road 16

4.7.1. General 16
4.7.2. Method of Construction 17
4.7.3. Culverts 17
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4.8. Pressure Pipeline 17

4.8. 1.General 17
4.8.2. Earthworks 17
4.8.3. Pipe Laying 18
4.8.4. Concrete Works 18
4.8.4. 1. Valve Chamberr, 19
4.8.4.2. Anchor Blocks 19
4.8.4.3. Marker Posts 19
4.8.5. Valves and Accessories 19
4.8.6. Hydraulic analyses 20
4.8.6. 1. Water Hammer / Surge Pressure 20
4.8.7. Pipe MaterialSteel Pipes 22
4.8.8. Testing of the Pipelines 22
4.8.9. Cleansing and Disinfection of the Pipeline 22
4.9. Header Reservoir 23

4.9.1. General 23
4.9.2. Civil Work 23
4.9.3. Structural Calculation 23
4.9.4. ElectroMechanical work 23
4.10 Gravity Main 24

4. 10.1. General 24
4.10.2. Earthworks 24
4.10.2. 1. RiverStream Crossings 24
4.10.3. Pipe Laying 24
4.10.4. Concrete Works 24
4. 10.5. Valves and Accessories 24
4.10.6. Hydraulic analyses 24
4.10.6. 1. Water Hammer / Surge Pressure 26
4.10.7. Pipe Material uPVC Pipes and Fittings 28
4.10.8. Testing of the Pipelines 28
4.109. Cleansing and Disinfection of the Pipelines 28
5. OPERATION & MAINTENANCE 29
5.1 Present 0 & M Situation 29
5.2. 0 & M for Extended system 29
6. CONSTRUCTION PROGRAMME AND CASH FLOW 31
6.1. Construction Programe 31/1
6.2. Cash Flow 31/2
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7. CONFIDENTIAL COST ESTIMATE 32
7.1. Summary Cost EstimatePhase II 36
8. LIAISON 37
9. PROJECT RISKS AND CONST IAINTS 38
9.1. General 38
9.2. Major Risks 38

9.2. 1. Delays to Project Execution 38
9.2.1.1. Delay in obtaining finance on time 38
9.2.1.2. Delay in obtaining land acquisition approval 38
9.2.1.3. Delay due to possible presence of mines on the site 38
9.2.2. Unsustainabillity of the installed system 39
9.3. Minor Risks 39

9.3.1. Inability to construct system components as designed 39
9.3.2. Failure of the system to provide required capacity 39
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ABBREVIATIONS
The following general abbreviations are used in this Report:
F.D.R. Final Design Report

USAID United States Agency for Int,, national Development
AdC Agua d, Chimoio
DNA National Directorate of Water Affairs
DINAGECA National Directorate for Mapping
SIER Chimoio Energy Company
DNEP National Directorate for Roads and Bridges
DPCA Provincial Directorate for Construction and Water
CPMZ Companhia do Pipeline MocambiqueZimbabwe
masl Metres above sea level
m Metres
m3 Cubic metres
m3 Ih Cubic metres per hour
No. Number
Vs Litres per second
mm Millimetres
FinalDesign Report
CHAPTER 1
INTRODUCTIOY
Final Design Report
1. INTRODUCTION
1.1. Background
This report relates to Water Sector Study ( Draft Report, Sept. 93 ) by the
Consultant DHV and Feasibility analysis and cost estimate, Pipe line from
Chicamba Dam to Chimoio ( Apr. 94 ) by Consultant Sheladia Ass.
The city of Cumoio is the capital of Manica Province. In 1993 the Chimoio
City Council estimates the total urban / periurban population at about 190,000
inhabitants.
The normal source of raw water for the town of Chimoio is the Mezingaze
river where water is pumped out of two interconnected reservoirs to a water
treatment plant and then distributed through distribution network. The
upstream of these two reservoirs has been destroyed in a flash flood. The
distribution network is not a part of this F.D.R. but it is worth mentioning that
about 30% of total water pumped in distribution network is lost due to the
leakage's 'i the reticulation pipes through the City.
Only 50% of the 100,000 or so residents of the urbanised part of Chimoio are

connected to the water distribution network of "Agua de Chimoio". The
remainders, and some of periurban community, are served by public taps or
more often by a system of individual wells unrelated to the urban water supply
system.
Due to the drought of 1990/1991, the Mezingaze River has dried with hardly
any real storage capacity in the reservoir This situation is nov, repeated every
summer and AdC must completely cease operating six months a year.
During that period increasing pressure has been placed on boreholes wells to
support the entire community. Further attempts by the AdC to supply
additional water through drilled wells have not proved satisfactorily. Capacity
of these sources is very limited and in no way can be considered as having
potential to supply the entire City.
This drought has highlighted very clearly the extremely low security and the
insufficiency of the two present sources of water supply (Mezingaze River and
underground).
In response to this emergency, US Agency for International Development
(USAIDMozambique) agreed to provide finds to develop and construct an
alternative source of water supply which would better safeguard the water
supply of Chimo'o. The adequate source of raw water has been found in
Chicamba dam reservoir located 41 km from the City.
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1.2. Project Area
The town of Chimoio is located in the Beira corridor which contains major
infrastructures such as the railway and the EN6 national road that link the port
of Beira with Zimbabwe. The distance between Chimoio and the port of Beira
is approximately 200 km.
The town of Chimoio lies at an altitude of between 630 and 710. The treatment

plant, where the water must be discharged is located in the lowest part of
Chimoio at 635 m of altitude.
The project area is situated in the Province of Manica in Central Mozambique.

The installations will be constructed between the reservoir of the Chicamba
dam, where the intake is located, and the existing water treatment plant located
to the north of Chimoio.
1.3. Climatic Conditions
The minimum and maximum monthly average temperatures are 18 C and 25 C

respectively. Monthly average rainfall precipitations are:
January 240 mm
February 199 mm
March 183 mn
April 53 mm
May 14 mm
June 18 mnn
July 13 mm
August 15 mm
September 12 mm
October 36 mm
November 120 mm
December 218 mm
1.4. Project Objectives
The objectives of the Consultancy Services for phase I of the Project are:
To develop aconcept for the supply ofraw water to the city of

Chimoio
To prepare afinal design for the accepted alternative
To prepare and issue the tender documents
To prepare a tender evaluation and give recommendation to the client
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In developing the raw water supply concept, alternative sources have been
studied and the accepted alternative issupply from Chicamba dam.

1.5. Report Objectives
In particular the following engineering details shall be provided in this Report:
General layout ofthe scheme showing all main components
Longitudinal sections of the pipeline
Hydraulic analysis of the pipeline
Structural analysis of the structures
Plans and sections of important details and the dimensions of the

major components of the system such as intake tower, storage
reservoir, small structures on the pipeline, all necessary electrical
and mechanical equipment, etc.
1.6. Report Structure
This report issubmitted in three volumes, 9chapters in Volume I, Appendices

in Volume II,and drawings in Volume IIl.
Volume I:
Chapter 1. Introduction
Chapter 2. Existing data
Chapter 3. Field survey
Chapter 4. Components of the project
Chapter 5.' Operation & Maintenance
Chapter 6. Confidential cost estimate
Chapter 7. Construction programme and cash flow
Chapter 8. Liaison
Chapter 9. Project Risks and Constrains
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Tables and figures in this Report are numbered according to the Chapter in
which they appear. They are numbered consecutively according to mention hi
the text. Environmental and baseline studies are subjects of separate reports.
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CHAPTER 2
EXISTING DATA
Chimoio Water Suvply Project
Final Design Report
2. EXISTING DATA
2.1 Topographic Maps
Three principal series of topographic maps have been consulted. These are
available through the National Directorate of Water Affairs (DNA), the
National Directorate for Mapping (Dinageca), and the Chimoio Energy
Company (SHER/EdM).
1:50.000 (19581960), sheets 837 and 838

1:10.000 (1953), Bacia Hidrografica do Revue
1:10.000 (1980), DNGC, Chimoio
The 1:10.000 maps cover the whole project area, except for one section along
the EN6 road of about 8 km.
2.2. Topographic Surveys and Wayleaves
Both the National Directorate for Roads and Bridges (DNEP) in Maputo and
the Provincial Directorate for Construction and Water (DPCA) in Chimoio
have been consulted. Both organisations were most helpfiul. However, neither
were able to provide topographic surveys of the EN6 between Chimoio and the
Messica River nor of the road from the EN6 and the Chicamba Dam.
Apparently there was a serious fire in the technical archives of DNEP some
years ago which destroyed the records.
Services should be at least 15 metres from the centre line of a major road.
However, permission may be granted for closer passage in special cases.
Route of the pipeline is crossing the major road EN6 only one place, therefore
wayleave is required only for that road crossing.
The Companhia do Pipeline MocambiqueZimbabwe (CPMZ), were also most

helpful. They have provided copies of topographic survey carried out in
1964/65 along the pipeline between Chimoio and Messica River. The way-
leave of oil pipeline has a width of 60 m. CPMZ have indicated that it is not
acceptable to install the water pipeline within their way leave.
2.3. Soil Surveys
Relatively little information about soils along the pipe routes has been found.
The CPMZ topographic surveys carries some general notes about surface soil
conditions. Therefore it was necessary to execute the soil investigation along
the pipe route.
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2.4. Hydrology Information
The following information has been provided by the Hydrology Section of
SHER, Chimoio, the operators of Chicamba darn.
2.4.1. Storage Capacity of Chicamba Lake
Chicamba dam has storage capacity for full turbine operation (50 cubic metres
per second) during a period of three years. Water availability has not limited
power generation since the dam crest was increased in 1973, despite two
periods of serious drought. The water consumption of Chimoio is less than
0,5% of the turbine flow, a value which can be considered insignificant.
The long term plans for power generation in the Manica/Sofala region include
the construction of a substation on the Cahora Bassa power line to provide
power to the region. This will be cheaper than upgrading turbine capacity at
Chicamba/Mavuzi power scheme. There is therefore likely to be a lower water
consumption for electricity generation in the future and more storage capacity
will be available to secure the water supply for Chimoio.
2.4.2. Design Levels of Chicambu Lake
Important levels (metres above sea level, masl) relevant for the design of the
intake tower are:
Description Level (masl)
Dam crest 626
Maximum operational level 625
Flood protection level, January 622
Flood protection level, February 620
Designed minimum operational level 590
Actual minimum operational level 582
Bottom discharge 565
River bed 548
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2.4.3. Historical Water Levels in Chicamba Lake
The observed minimum in the Chicamba Lake since the dam crest was raised in
1973 are:
Yeal Level (masl)
1973/74 591
1974/75 613
1977/78 618
1984/85 615
1991/92 611
1992/93 609
1993/94 610
A study has been carried out of 'e probability of the occurrence of low water
levels in the Lake, this is included in the Environmental Study Report. A
resonable design level for the intake tower is 605msi.
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CHAPTER 3
FIELD SURVEY
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3. FIELD SURVEY
Field survey has been executed for the various aspects of the Project. Due to
lack of topographic and subsoil information both investigation were executed.
The Baseline study and Environmental study are subject of separate reports
3.1. Topographical Survey
The route of the transmission pipeline has been surveyed to establish
longitudinal sections for hydraulic design. The levels along the route of the
pipeline have been established on every 50 m, and along river and stream
crossings every 510 m. Site surveying on the locations of the structures
(reservoir, intake tower and bridge and intake site) established the levels on the
grid 5 m x 5 m. Concrete bench marks are established every 500 m along the
pipe route and on every bend.
The surveying carried out under the Project is sufficient for detailed design to
be prepared. The total quantities of topographical surveying are:
Longitudinal section levelling of transmission pipeline route 42 km

Bush clearing for longitudinal levelling 42 km
Site surveying (reservoir, intake site) 0,4 ha
Bench mark establishing 92 No.
All topographical survey work has been plotted and is shown on the drawings,
either as longitudinal section (transmission pipeline) or site plans (intake site,
reservoir).
3.2. Soil Investigation
3.2.1. General
The subsoil conditions for transmission pipeline route and major structures
have been investigated.
For the transmission pipeline, subsoil conditions have been investigated at a
frequency of roughly 500 m. On each river, stream crossing three trial pits have
been investigated, one in the middle and one on the each bank of the crossing.
Seismic investigation has been done on the intake sites. First location of the
intake site proved difficult for foundation construction. The alternative location
proved to be suitable for required type of structure
A total of 86 trial holes have been made, with the total excavation depth of 172
m. The full results of investigations are available in Volume II of this report.
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LnImoio water auppiy rrojecl
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3.2.2 Soil Types
The main soil and ground types encounterLd by the investigation are:
Sand
Silt
Gravel
Boulders
-Gneiss
The majority of trial holes encountered sand with varying degrees of
intermixed gravel and gneiss.
Rock outcrop has been encountered in only two holes, there will be some cases

where large boulders will have caused refusal and where such a boulder is
classified as rock.
Standing ground water has been encountered in all the holes at the river
crossings and some of the stream crossings.
3.2.3. Test Results
3.2.3.1. Sieve analyses
Sieve analyses were carried out on samples taken at sites for structures, and
additionally, for selected transmission pipeline route.
The results of the sieve analyses show acceptable material for backfilling pipes

and structures. Considering the presence of ground water on every river
crossing there is a need for special dewatering equipment during construction
and special protection of the pipes along the river and stream crossings.
3.2.3.2. Compaction analyses
Compaction analyses indicate a general suitability of all materials for

compaction.
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3.2.4. Implications of Soil Types for Excavation and Structures
An assessment has been made of the material to be excavated along the
transmission pipeline route , based on the analysis of the results of the trial
holes. The material to be excavated has been classified into:
normally excavatable material (soft material)

hard material, rippable
rock requiring blastirg
Based on typical trench dimensions of 600 mm width, and 1150 mn to 2500
mm depth, the following indicates the percentage of each type of material
required to be excavated for transmission pipeline and intake site:
Description Soft Hard Rock
Transmission pipeline 89% 90/0 2%
Intake site 410% 31% 28%
The above percentages have been used to estimate volumes of and cost 16r,
hard material and rock excavation. However, it must be stressed that the
frequency of test holes (every 500 m) prevents an accurate assessment and the
above percentages will vary during construction.
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CHAPTER 4
COMPONENTS OF THE PROJECT
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4.COMPONENTS OF THE PROJECT
4.1. General
Raw water will be pumped from C,'icamba Lake to header reservoir on the hill
overlcoking the Lake. From the reservoir the water will be transported by
gravity to the treatment plant of the Water Company of Chimoio. In
accordance with the originul Terms of Reference the rehabilitation of the
existing treatment plant was not in the scope of this Project. However it was
agreed that if the funds are available the rehabilitation of the plant will take
place pending on the available budget.
The following components are forming the system and will be built under this
Project:
Intake tower with high lifting pumps on the Chicamba Lake
Access bridge to the intake tower
Transportable pump, which will be used when the water level in the
Lake falls under 605 m
Guard, store house incorporating office, accommodation facilities and

storage
Fenced Intake site incorporated Guard, store house, transformer tower

etc.
Access road
Pressure pipeline including valves and fittings
Header reservoir of 100 m3 located on the hill overlooking the Lake
Gravity pipeline including valves and fittings
Radio communication
4.2. Intake Tower
4.2.1. Location and intake level
The location of the intake tower has been chosen in the bay of the Lake about
800m from the dam to reduce the impact of the power generation and waves.
Also it has been considered the subsoil conditions in order to minimise the
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Chimoio Water SupplyProject
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cost of foundation for the tower. Based on the available data about design
levels and historical water levels of Chicamba Lake the intake level for the
tower has been chosen to be 605 m.
4.2.2. Civil wo:k brief description
The dimensions of the tower are calculated to accommodate three submersible

pumps. One duty and one standby are in the scope of this Project, third one is
for future extension. The height of the tower from the bottom of the sump to
the top ofthe top slab is 23.20 m.
The material for construction of the tower will be reinforced concrete class 25

with high tensile bars as reinforcement. Construction of the tower can be
executed with sliding formwork, depending on the contractors equipment.
As a protection of the mechanical and electrical equipment a house will be
constructed on the top ofthe tower.
Material used for the cunstruction of the house will be 230 mm. bricks
plastered inside. Roof sheeting will be corrugated galvanised iron sheets.
Delivery pipes will be two steel pipes 300 mm Diameter encased in concrete to
prevent floating of the pipes . The slope of the pipes will be 3% in direction of
the Lake to enable back washing of the pipes. Back washing of the delivery
pipes can be executed whenever the water level in the lake is lower than
maximum level in the Lake by closing the valves on the delivery pipes, pumping
the water in the tower using a mobile pump and opening the valves on the
delivery pipes. Gate valve with 19 m mild steel spindle, gear box, bevel and
hand wheel shall be installed on the delivery pipes to allow opening and closing
from the top slab.
Minimum flow through two 300 mm steel pipes is 450m3,. Which is more than
adequate even for future extension.
Intake head structure isdesigned to allow required quantity of water in delivery

pipes. Material will be concrete class 15. To prevent debris, fishes and
crocodiles from entering the intake tower intake head structure will be
equipped with the grid 20 mm bars at 100 mm centres.
4.2.3. Structural calculation
Structural calculation are enclosed in Annex No. 1
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4.2.4. Mechanical equipment
The intake tower shall be equipped with two submersible pumps (I duty, 1
standby). The pumps shall be with the following characieristics:
Q=lOOm'1h, H=180m.
Calculation of the pump
Required capacity 2000 m' / day = 100 m3 /h (woridng time 20 hours/day)
level difference:
header reservoir 764 m
intake level 605 m
159 m
friction losses + 6.61 m

(L=2050 m, 250 mm dia steel pipe)" 165.61 m
The pumps were chosen KSB BPN 374/6+10A 733/2
The outlet pipe of each pump shall be provided with allnecessary nonreturn
and isolating valve. Pumps and vertical ID 250 mm steel double flanged pipes
3000 mm long will be supported with 600 mm plate welded support on the top
slab.
The intake tower house shall be equipped with a hand operated hoist, working

weight 2000 kg to permit removal of equipment from the tower.
Transportation of the equipment over the access bridge shall be by trolley.
4.2.5. Electrical equipment
The intake site will be electrically supplied from a distribution sub station to
be constructed by the Electricity Company. Electricity will be available with the
following characteristics:
380 V ; 50 Hz; 315 KVA
Distribution board and motor control panel will be installed inside the house.
The house will be equipped with 2 x 36 W 1200 mm long surface mounted
batten type fluorescent luminaires with single metal reflector.
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The lightning protection system will be installed with 4 earth electrodes to
protect the equipment from lightning.
Level switches shall be provided in the intake tower and header reservoir for
the following functions:
i) Water protection against dry running of pumpsintake tower
ii) High level cutoutheader reservoir
iii)Low level cutinheader reservoir
Level switches shall be floating mercury switches, enclosed in watertight plastic

casing, FLYGT Type ENH10. The switches shall be freely suspended and
adjustable to the required level.
A pressure switch shall be installed on the discharge manifold to provide cut-
out of the pumps. The pressure switch shall be adjustable and shall be set, on
commissioning, at the field established "closed valve" pressure for the pump
sets.
4.2.6. Alarms
The following visual and audible alarms shall be provided:
Electricity supplymains failure ( battery operated)
Header reservoiroverflow
Operation of any electrical protective device or safety cutout
Failure of any duty motor
Visual indication of alarms shall be located on the appropriate switchboard or
instrument panel. Audible indication of alarms shall be located both in the
Intake Tower and in the Office of the Guardstore house. A siren shall also be
installed on the outside of transformer tower.
4.3. Access Bridge to the Intake Tower
4.3.1. General
Access bridge shall be constructed as a link between intake site and the tower.
Material shall be reinforced concrete class 40. Reinforcement shall be high
tensile reinforcement bars.
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4.3.2. Method of construction
First, the I1 183 n embankment shall be constructed using excavated rock. On

the embankment shall bc placed precast concrete deck. Reinforced concrete
upstand restraint shall be constructed after next 11. 183 m. Upstand restraint
shall be based on natural stone masonry pier with class 20 concrete core. Next
precast concrete deck shall be placed between embankment and a pier. Third
precast concrete deck shall be placed between the pier and tower. After the
precast deck is placed in the position and to required level reinforced concrete
bridge deck shall be cast insitu. Every 11 Im movement joints shall be
constructed using Malthold DPC.
4.3.3. Structural calculation
Structural calculation are enclosed in Annex No. 2.
4.3.4. Other ancillary
Steel pipes I) 250 mm length 4000 mm internally lined and externally
protected shall be placed on the bridge fixed to bridge deck using brackets and
support brackets.
Electrical cables shall be fixed to a bridge beam on the galvanised cable tray.
Metal fence shall be constructed 700 mm high using 20 mm Dia. bars at 125
mm central. The handrail shall be protected with thermoplastic cover.
4.4. Transportable Pump
4.4.1. General
The water in the Chicamba Lake might fall below the elevation 605 m which
corresponds to the inlet of the intake tower. It might eventually reach 585 m,
the minimum level of operation of the hydroelectric plant.
4.4.2. Civil work
The reinforced ramp, on which the pump shall be transported will be
constructed from the store room to the existing ,,'ater level in the Lake while
the execution of the Project is going on. Any extension of the ramp will be
constructed separately from this Project according to necessity and when the
water falls below this level.
4.4.3. Electro /mechanical work
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The pump shall be mounted on the non roadworthy trailer. The pump shall be
following characteristics:
Q=110m3 /h, H=30m
The pump has been chosen KSR ELK/ELB 40.
Flexible reinforced rubber pipes 100 mm Dia shall be connected to the pump.
The pump shall pump the water from the Lake to the tower sump during low
water levels in the Lake. To enable operation of the pump a handwinch with
the stainless steel cable shall be mounted in the store room.
4.5. Guard Store House
4.5.1. General
The Guard, store house shall include the following facilities:
I office
2 bedrooms with the lounge for the guards off duty
I sl.,wer and toilet
I storage room for the transportable pump and pipes
The house shall be furnished with the hard furniture as follows:
Metallic cushioned armed chair No. 2

Metallic office desk No. I
4 tier steel file cabinet No. I
3 seater wooden settee with foamed cushions No. I
Metallic single bed with foam mattress No. 2
Storage cupboard No. 2
Kitchen table with 4 chairs No. 1
Storage cupboard ( lounge) No. 1
Key storage No. 1
4.5.2. Civil work
Material shall be brickwork plastered both sides. Roof shall be galvanised iron
sheeting. Sanitary waste from the toilet and shower shall be disposed in a septic
tank and soakaway. Water supply for the house shall be connected to the
Chicamba Township water main which crosses the intake site access road.
Sanitary wastes from the bathroom shall be disposed in a septic tank which is
connected to a soakaway.
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4.6. Intake Site and Transformer Tower
4.6.1. General
In order to provide efficient operation of the intake tower as well as security of

the equipment, an intake site shall be built at the entrance of the bridge.
4.6.2. Intake Site
Intake site shall consist of Guardstore house, transformer tower, sufficient

turning area for the truck in case of any operational or maintenance
requirements.
The level of the intake site shall be 625.20m. To prevent soil erosion due to
wave activity the edge of the site shall be protected with 500 mm free drainage
rockfill. The wire fence 1800 mm high shall be built around the site because of
security reasons. The erosion of the slope (if it isnot rock) shall be protected
with adequate vegetation.
4.6.3. Transformer Tower
To provide the adequate power supply transformer tower shall be built as per
requirements of EdM/SHER.
4.6.3.1. Structural Calculation
Structural calculation are enclosed in Annex No 3.
4.6.3.2. Size of transformer
The size of transformer has been calculated for the worst loading case. The
adequate transformer shall be 315KVA.
Detailed calculation of loading are enclosed in Annex No 4.
4.7. Access Road
4.7.1. General
Access road shall be constructed from existing road to Chicamba Dam to
Intake site. Total length shall be 1850 m.
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4.7.2. Method of Construction
The route of the road shall follow the existing dirt track to the "restaurante",
after that it shall follow a direct path to the intake site. The potholes on the
existing dirt track shall be filled with adequate material and compacted to 93%
MOD AASITO. Material for wearing course shall be selected gravel
compacted to 95% MOD AASHTO.
To prevent erosion of the road on the edge of the road shall be placed free
drainage rockfill 60250 mm compacted to 95% MOD AASHTO. Drainage
channels 100 nm deep shall protect the road from water flow on the slopes.
Ground slopes shall be protected from erosion uy vegetation.
4.7.3. Culverts
Water from the slopes shall be controlled by 4 culverts which shall be
constructed on every stream, crossing the road. Culverts shall be class S culvert
pipes with 100 mam. bed and haunch placed below subgrade layer with 1:100
fall.
4.8. Pressure Pipeline
4.8.1. General
First 2153 m of the transmission main from the intake to the header reservoir
shall be steel pipes longitudinal welded, internally lined, externally coated, 6 m
length, working pressure 22 bars.
4.8.2. Earthworks
The pipes shall be laid in the trenches 600 mm wide, with the minimum cover
of 800 mm above the top of the pipe. When crossing the streams, including the
portion of the pipe which is going to be laid under the maximum level of the
Lake, the invert level shall be 2.0 m deep. Below the invert of the pipe 100
mm of sand shall be placed. First 200 mm above the pipe shall be sand or
screened granular material compacted to 88% MOD AASHTO.
The reminder of trenches shall be backfilled with selected granular material
compacted to 96% MOD AASIITO. Excavation shall be protected with all
necessary planking and strutting to ensure the safety of workmen.
Material to be excavated shall be divided into three classes, Rock, Hard
Material and Soft Material.
Rock shall be defined as:
(i) Solid undecomposed boulders exceeding 0. 10 cubic metres; or
18
FinalDesign Report
(ii) Solid unweathered crystalline material in bulk or in banks or ledges,

which can ,ot be broken up or removed except by the use of
explosives.
Hard Material shall be defined as:
Material, not rock, which requires the use of pneumatic tools, mechanical

breakers, or special cutting tools to mechanical excavators for its practical
removal.
Excavation for concrete structures such as inspection chambers and for thrust

and anchor blocks shall be to required depth and as near as possible to the
external dimensions of the structure.
The excavation must be free of water at any time during the pipe laying and
construction of concrete structures.
Marker tape shall be placed 300 mm above the pipeline. The material for
Marker tape shall be blue PVC or polyethylene mesh or ribbon at least 50 mm
wide, incorporating a corrosion resistant tracing system.
4.8.3. Pipe Laying
Laying instruction of the manufacturer shall be explicitly followed. All pipes
shall be sound and clean before laying. When laying .j not in progress the open
ends of the pipes shall be closed by water tight plugs or other approved means.
Good alignment shall be preserved in laying.
4.8.4. Concrete Works
All coicrete and reinforced concrete works shall comply wit the following
standard specification as appropriate:
BS 8110 The structural use of concrete

BS 8007 Code of practice for "Design of concrete structures for retaining
aqueous liquids
BS 12 Ordinary Portland cement
BS 882 Aggregates for concrete
BS 812 Water absorption of aggregate
BS 3148 Water for washing aggregates
BS rj75 Admixtures of concrete
BS 1881 Strength test ofconcrete
BS 4449 Carbon steel bars
BS 4482 Cold reduced steel wires
BS 4483 Steel fabric
BS 1052 Finally annealed mild steel wire
19
Final Design Report
BS 4466 Cutting and bending of reinforcement

BS 8100 Tolerances of placement of reinforcement
BS 8110 The minimum concrete cover of reinforcement
BS 2499 Hot poured joint sealants
BS 5212 Cold poured polymerbased joint sealant
BS 4254 Twopart polysilphidebased sealants
BS 5889 Silicone based building sealants
BS 903 Rubber waterstops
4.8.4.1. Valve Chambers
Washout chamber's and air valve chambers shall be placed as per longitudinal
sections. The exack position shall be indicated on site. All concrete chambers
shall be painted outi;de with two layers of bitumen. All chambers shall be
lockable.
4.8.4.2. Anchor Blocks
Anchor, thrust blocks shall be placed on all the bends and at the slopes as
follows:
gradient spacing ( m)
up to I in 2 6
from 1:2 to 1:4 12
from l:4to 1:5 18
from 1:5 to 1:6 24
flatter than 1:6 not required
4.8.4.3. Marker Posts
Marker posts shall be made of precast reinforced concrete and placed 1.0 m
from central line of pipes. They shall be positioned on every bend of the
pipeline, on the straight portion every 500 m.
4.8.5. Valves and Accessories
All valves and accessories are designed for a pressure at least equal to two
times the normal working pressure where they will be installed. As far as
possible all equipment of the same type shall be from one manufacturer and
they must be clearly marked with the name of manufacturer, flow direction
arrows and the pressure for which they are designed. All valves shall be
manually operated and open left ( counter clockwise).
20
Chimoho Water Supply Project
Final Design Report
4.8.6. Hydraulic analyses
Hydraulic calculations of friction losses for the steel pipe have been calculated
based on HazenWilliams formula as follows:
4, 7
J= 10,708 x(Q LIS2XD
Where: J = Friction losses (m)

Q = Flow (/s)
C = 140 (HazenWilliams coefficient)
D = Pipe diameter (mm)
For the Q = 2000 m'/d ay; D =

250 mm and C = 140 =
J = 6,61 m
Water hammer / surge pressure is the crucial factor in the design of this
pressure pipeline, therefore the calculations are given below inclusive of water
hammer / surge pressure.
4.8.6.1. Water Hammer / Surge Pressure
This phenomenon occurs frequently in pressure pipelines and is defined as the
periodic pressure oscillation which move back and forth along a pipeline. The
phenomenon occurs when closing and opening valves, starting and stopping
pumps or when any other operating condition changes in the pipeline.
The example of calculation of water hammer / surge pressure is shown below.

The determining factor of the size of water hammer / surge pressure is the
speed with which the pressure wave travels along the pipeline. The following
formula has been used:
Cp=Cwx 1
1+I Ew dm
(Ep I/
Where Cp = Wave celerity (m/s)

Cw = Wave celerity in a column of water (1425 m/s)
Ew = Elasticity modus of water (2070 N/mm 2 )
Ep = Elasticity modus of pipe material (N/mm) uPVC Ep = 3000;
Steel Ep = 210000
dm = mean diameter of pipeline which is equal to internal pipe
diameter di plus pipe wall thickness t ( dm=di+t)
t = Pipe wall thickness ( mm)
21
FinalDesign Report
The size of pressure oscillation after a valve closure depends on the time it
takes to close the valve, and on the so called reflection time of the pipeline. If
the flow is cut during a period shorter than this reflection time the
maximum pressure increase may be calculated by use of the following formula:
H = Cp xx
g
Where:H = Maximum pressure increase (+) or decrease () (mhw)

Cp = Wave celerity as calculated by use ofthe above formula (m/s)
g = Acceleration of gravity (; 9,81 m/s')
Vo = Flow velocity just before valve closure (m/s)
The reflection time is calculated as follows:
To 2L
Cp
Where: To = Reflection time (s)

L = Length of pipeline (m)
Cp = Wave celerity (m/s)
In the case of having a longer valve closing time than the reflection time of
the pipeline, the pressure increase is lower than the calculated in the above
formula.
Calculation of water hammer / surge pressure:
Steel pipe ID 250 mm Wall thickness 4,8 mm; Q = 27,78 Vs;
Vo = 0,7 Js; Static head = 159 m; Friction losses = 6,61 m;
Length L = 2050 m =>
Cp = 1027,26 m/s

H = 73,30 m (mhw)
To = 4,00s
Ah = 159 + 6,61 + 73,30

Ah = 238,91 m
In order to avoid installation of some form of water hammer protective device
to reduce pressure, because of high operational and maintenance cost, steel
pipe is accepted. The reflection time is very short therefore the pressure
increase should be lower than calculated in the above formula.
22
FinalDesign Report
4.8.7. Pipe MaterialSteel Pipes
Due to high risk of water hammer and to avoid installation of water hammer
protective device to reduce pressure, the material for pressure main has been
designed to be GRW longitudinal welded pipe to SABS 719 Gr. B. 250 mm
internal diameter, wall thickness of 4.8 mm.
The main concern regarding the use of steel pipe is corrosion. The long
continuous lengths of welded steel pipelines increase the opportunities for
corrosion to develop. Welded joints are a potential source of increased
corrosion risk due to difficulty in applying protection after welding. Corrosion
of steel pipelines does not generally cause catastrophic failure, rather a
progressively increasing loss of water through leakage.
To protect steel pipe from corrosion pipes shall be internally lined with smooth,
dense, centrifugally spun cement mortar lining. External corrosion protection
shall be with fusion bonded low density polyethylene in thicknesses from 2.0 to
3.0 mm or similar approved by the Engineer on Site.
4.8.8. Testing of (he Pipelines
The pressure in the pipeline shall be raised steadily until a pressure of 1,5 times
the operating pressure is reached in the lowest part of the section, and the
pressure shall be maintained at this level for a period of one hour. The pumps
shall than be disconnected and no fuither water shall be permitted to enter the
pipeline for the further period of one hour. At the end of this period the original
pressure shall be restored by pumping and the loss measured.
The permissible loss in all welded steel pipeline shall not exceed 0.1 litres per
mm of pipe diameter per kilometre of pipe per 24 hours for each 30 m of test
head. In uPVC pipe the permissible loss shall not exceed 2.0 litres per metre
nominal bore per kilometre length per metre head ( calculated as the average
head applied to the section ) per 24 hours.
4.8.9. Cleansing and Disinfection of the Pipeline
At the conclusion of pipelaying flushing out of the pipeline shall be executed.
Disinfection of the pipeline shall be carried out using chlorinated raw water
from Chicamba Lake. Residual of not less than 20 mg/l of free chlorine shall be
acceptable for the structures. For the pipeline a residual of at least 20 mg/I for a
period of 2 hours shall be acceptable.
23
FinalDesign Report
4.9 Header Reservoir
4.9. 1. General
The header reservoir will be located on the hill overlooking the Chichamba
Lake at the elevation 762 m. The head will be enough to carry the water by
gravity to the treatment plant of Chimoio. It is not going to be a storage
3
reservoir only a pressure break tank, therefore the capacity will be 100 m .
The primary function of this reservoir is to protect the gravity main from
overpressure by breaking the head created by the submersible pumps in the
Intake Tower. This head depends on the water level in the Chicamba Lake,
which can vary by 20 m. The secondary function of the reservoir is to protect
the gravity main from water hammer caused by intake pumps and to reduce the
effect of water hammer at the pressure main.
4.9.2. Civil Work
The reservoir shall be built in the ground 1.0 m below original ground level. At
the bottom level of the reservoir sludge disposal pipe with the valve shall be
installed. Raw water has been taken from the Lake so settlement already took
place. The quantity of sludge will be minor. Sludge shall be disposed in the
channel filled with free drainage rockfill to allow soaking of the sludge in the
ground.
On the top slab three ventilation pipes shall be installed and entrance for
maintenance of the reservoir. Entrance shall be covered with cast iron manhole
lockable cover.
To prevent unauthorised entry in the reservoir area it shall be fenced with 1.8 m

high wire mesh fence with lockable gates. Access road to the reservoir area
shall be constructed as a dirt track 3.0 m wide.
4.9.3. Structural Calculation
Structural calculation are enclosed in Annex No. 5.
4.9.4. ElectroMechanical work
Level switches shall be installed in the reservoir to control the intake pumps.
Item 4.2.4. refers. The outlet pipe shall be equipped with the gate valve in case
of maintenance of the gravity main.
24
FinalDesign Report
4.10 Gravity Main
4.10.1. General
The pipeline between header reservoir and the treatment plant will be
constructed in 200 mm and 250 mm diameter unplasticized PVC pipe in class
6,9,12,16 and 20 according to hydraulic gradient and altitude.
4.10.2. Earthworks
Item 4.8.2. is applicable.
4.10.2.1. RiverStream Crossings
The banks of all the riverstream crossings shall be protected with wire mesh
gabions 400 mm thick. The pipes crossing the rivers and streams shall be
encased in concrete to prevent possible erosion during rainy season.
4.10.3. Pipe Laying
4.10.4. Concrete Works
Item 4.8.4. is applicable
4.10.5. Valves and Accessories
4.10.6. Hydraulic analyses
Hydraulic calculation are based on the formula first developed by Blasius for
smooth pipes, based on the premise that for smooth pipes the friction factor is
solely dependent on the Reynolds number. The formula is as follows:
p 158.2 L V,

Re D
Where P = Pressure loss in pascals (Pa) per metre of pipe

Re = Reynolds number
L = Pipe length in metres (m)
D = Pipe diameter in metres (m)
V = Velocity of flow in metres per second (m/s)
25
Final Design Report
Vxd
Re=-
q18
Where Re = Reynolds number

V = Velocity of flow in metres per second (m/s)
d = Inside pipe diameter (mm)
7l 8 = Kinematics fluid viscosity (m2 / s)
From the flow chart which is based on the above mentioned formula friction
losses for different classes of pipes for the required flow Q=27,78 Vs are as
follows:
pipe diameter classof the pipe friction losses

(ram) (m/100m)
250 6 0,15
250 9 0,17
250 12 0,19
250 16 0,24
250 20 0,32
200 9 0,46
200 _12 0,50
The highest point ( level 691.99 m ) on the gravity main is at km 28.675 from
the header reservoir. In the table below is shown the friction losses from the
reservoir to that critical point on the entire gravity main. When considering the
classes of the pipes in addition to the level difference between high and low
points on the pipeline the possible water hammer is taken into account.
pipe class of the length friction total friction

diameter pipe (M) losses losses (m)
(MM) (m/lOOm)
250 6 2678 0,15 4,05
250 9 5697 0,17 9,69
250 12 10500 0,19 19,95
250 16 9200 0,24 22,08
250 20 600 0,32 1,92
total friction 57,69
losses (m)
decrease of 2.88
characteristi
cs with age
+ 5%
TOTAL 60,57
26
Chinoio Water Supply Project
Final Design Report
of the header reservoir:

of the required level
Calculation
on the pipeline 691,99 m
Level of the highest point
752,56 m
Total friction losses,
pipeline, the
water supply, in case of some minor lekageS of the
To secure
minimeur water level in the reservoi
shall be 761,80 m.
inimum ater levl he resr tthe inlet at the treatment plant 3050 m of the
mm diameter. The pressure
be 200 ridioethe u re
reduct pressure at plant shall be 2'
in order to the treatment of the
gravity main before pipeline shall be 41,91 in. Depending on the quality
at the inlet
existing of the at the treatment
reservoir plant it might be necessay to construct
pressure break chamber before inlet to the existing reservoir. During the
necessry investigation of the existing reservoir
construction of the project
should be executed.
4.10.6.1. Water Hammer /Surge Pressure

pipelines
in pressure and and is defined
a pipeline. the
as The
This phenomenon occurs frequently moveback forth along
peiodic pressure oscillation which
closing and opening valves, starting and stopping
phenomenon occurs when operating condition changes in the pipeline.
pumps or when any other
due to level
through the pipeline by gravity
The example of
is transported
dn will be under pressure.
Although the water below for the biggest
cicull nc water h morlsurgO prelsure is show factor
The determining
on the gravity main between two points. speed with which the
level difference / surge pressure is the used:
of the size of water hammer pipeline. The following formula has been
along the
pressure wave travels
Cp=CWX
= Wave celerity (m/s)

Where Cp n/s)
Cw Wave celerity in a column ofwater (1425 2 )
Ew = Elasticity modus ofwater (2070 N/mm
material ( N mm ) uPVC Ep 3000;
I 2
Ep = Elasticity = modus of pipe
Steel Ep 210000
which is equal to internal pipe
dm= mean diameter of pipeline thickness t (dm = di+t)
diameter di plus pipe wall
t Pipe wall thickness ( mm ) on the time it
of pressure oscillation after a valve closure depends the pipeline. If
The size time of
and on the so called reflection
takes to close the valve,
27
Final Design Report
than this reflection time the

the flow is cut during a period shorter
by use of the following formula:
maximum pressure increase may be calculated
Vo
(±)Cp x
g
H
= Maximum pressure increase (+) or decrease () (mhw)

Where: H
ofthe above formula (m/s)
Cp = Wave celerity as calculated by use
closure (m/s)
Vo = Flow velocity just before valve
mis 2)
g = Acceleration ofgravity (= 9,81
The reflection time is calculated as follows:

2L
2
To =
Cp
Where:To = Reflection time (s)

L = Length of pipeline (m)
Cp = Wave celerity (m/s)
of
closing time than the reflection time
In the case of having a longer valve the above
lower than the calculated in
the pipeline, the pressure increase is
formula.
Calculation of water hammer/surge pressure:

= 27,78 /s ; Vo = 0.6 mis;
PVC 250 mm class 16 (assumption); Q
96 m;
Static head = 182,25 m; Friction losses = 32,
= 7 3 50m
Length L 1
Cp = 433,52 m/s

H = 26,51 m(mhw)
To = 80,04s
Ah = 182,25 32,96 + 26,51

Ah = 175,8 m
of a high pressure. Due to very

PVC class 20 is accepted for that area
pressure increase at the critical
long distance between two points the
sufficient, but because it is a
point will be lower even class 16 will be
the river crossing class 20 is
short section of the pipeline and in
designed.
Fittings
4.10.7. Pipe Material uPVC Pipes and
it to be used instead of steel, cast iron
The properties of uPVC pipes allow
highest stiffness per unit cost of the
asbestos cement, etc. pipes. It has the
28
FinalDesignReport
engineering plastics and is therefore most commonly used in load bearing
applications such as pressure pipes. !. has other features such as: low specific
gravity, good chemical and weather resistance, very smooth bores and the long
term flow characteristics vary very little from those of newly laid pipes.
Unplasticized polyvinyl chloride (uPVC) pressure pipes, joints and fittings shall

comply with relevant provisions of standards as set out below:
uPVC pipes: BS 3505

uPVC joints and fittings: BS 4346
uPVC solvent cements: BS 4346
Storage of pipes must be executed strictly in accordance with manufacturer
recommendation. It is essential that pipes are stacked with the socket and
spigot ends alternating and with the sockets projecting so that there is a barrel
to barrel contact along the lengths of pipe. During storage all pipes must be
protected from ultraviolet light.
4.10.8. Testing of the Pipelines
4.10.9. Cleansing and Disinfection of the Pipelines
Item 4.8.9. is applicable
29
FinalDesign Report
CHAPTER 5
OPERATION & MAINTENANCE
FinalDesign Report
5. OPERATION & MAINTENANCE
5.1 Present 0 & M Situation
Agua de Chimoio is responsible for all water supply system in Chimoio. The
water supply scheme is uncomplicated and easy to operate and little planning is
done. Even when there is enough raw water ( only 6 months a year ) operation
of existing equipment is complicated due to lack of spare parts and necessary
tools. The major problems for operation and maintenance can be summarised
as follows:
Shortage of skilled staff
Shortage of transport for staff and materials
Shortage of spare parts for the equipment
Purchasing procedures entail delays in the supply of spare parts and

materials and so prevent the prompt and efficient execution of
repairs
Missing system drawings, preventing proper maintenance planning

and execution
Lack of communication between intake, treatment plant, workshop
and main office
These and other problems are reflected in the actual condition of system. About
40 % of the pipe network is estimated to be in poor condition. Although the
distribution network is not in the scope of this Project rehabilitation work is
required.
5.2. 0 & M for Extended system
Based on the existing 0 & M problems proposal for efficient 0 & M for the
extended system relate mainly to:
More effective planning and execution of 0 &M activities;
The provision of necessary vehicles and equipment;
The adjustment of staffing requirements and working procedures to

match major features of the extended system notably:
Intake site at Chicamba Lake
Pressure main
30
Final Design Report
Head r reservoir site
Gravity main
Communication system to be established
Continuous monitoring of the efficient operation of the system
Change in emphasis from adhoc repairs to routine (preventive)

maintenance in order to lengthen service life of the system
Appropriate training to be provided, to operate the new equipment

Detailed operation and maintenance manuals shall be prepared by the
contractor. The manuals should cover the testing, operation,
maintenance, dismantling and repair of all equipment and should include
explanations of the function and purpose of each item supplied.
Long term training needs should be analysed and converted into long-

term training plans. Training plans for each job category should be
developed, including a plan for senior management. A consultant could
assist in developing the plans.
31
FinalDesign Report
CHAPTER 6
CONSTRUCTION PROGRAMME AND CASH FLOW

FinalDesign Report
6. CONSTRUCTION PROGRAVLME AND CASH FLOW
Construction programme and cash flow are based on the commencement date
15/09/1994. The Christmas Holidays have been included in the Construction
programme from 16/12/1994 to 02/01/1995. If the project implementation
starts on any later date the construction programme has to be modified.
32
6.1. Construction Programme
DESCRIPTION 15/09/94 15/10/94 15/11/94 16/12/94 02/01/95 15/01/95 15/02/95 15/03/95
Mobilisation
Access Road
Excavation Intake Site
Intake Tower
Access Bridge
Transformer Tower 0
GuardStore House
Excavation Pressure Mair a

0
Pipeloying Pressure Main
Reservoir Site
Excavation Gravity Main E

Pipelaying Gravity Main .
River Crossings
Structures on the Pipelines
ElectroMechanical Works
Testing
. LoCommisiorning
/
, .. : 31/11
6.2 Cash Flow iE m o n t hl yT
M cumulative
6000000-
5072013
5000000- 4566253
3790220
4000000- 3238330
3000000-
2000000-
97369 7741174779490 760
1000000- 46109251255
15.9.94 15.10.94 15.11.94 15.12.94 15.1.95 15.2.95 15.3.95
99 31/2
t7"Tc:
FinalDesign Report
CHAPTER 7
CONFIDENTIAL COST ESTIMATE
Final Design Report
7. CONFIDENTIAL COST ESTIMATE
item description unit provis. unit rate total

Iquant. (US$) (US$)
1. PRELIMNARY & GENERAL L.S. 1 505,000 505,000
total 1 505,000
item description unit provis, unit rate total

I quant. (US$) (US$)
2. PIPELNE
2.1. Excavation of trenches inany material
including backfill and removal of surplus
material. m 42,269 9.76 412,545
2.2. Supply steel pipes and fittings longitudinal
welded, internally coated, externally
protected, 6m length, working pressure 22 m 2153 70 150,710
bars.
2.3. Lay pips and fittings including testing,
flushing and disinfection m 2153 15 32,295
2.4. Supply uPVC pipes with rubber sealing
rings, 6m length all classes m 40,116 23.74 952,354
2.5. Supply fittings for uPVC pipes with rubber
rings No 235 138.83 32,625
2.6. Lay uPVC pipes and fittings including
testing, flushing and disinfection m 40,116 1.5 60,174
2.7. Construct all the chambers on the pipeline
including supply of all materials, valves and
fittings No 88 3,400 299,200
2.8. Provide all material and construct anchor
and trust blocks, marker posts, road and
railway crossings L.S. 1 41,950 41,950
2.9. Previde and construct all river and stream
crossings L.S. 1 46,080 46,080
total 2 2,027,933
33
FinalDesign Report

quant. (US$) (US$)
3. INTAKE TOWER AND BRIDGE
3.1. Excavation in any material and placement of
rock material L.S. 1 96,935 96,935
3.2. Grouting of all fractures L.S. 1 20,000 20,000
3.3. All concrete work for intake tower and
bridge including supply of all material for
concrete and reinforcement bars L.S. 1 231,441 231,441
3.4 Supply and installation of all
electromechanical work for intake tower
and bridge including all the testing and
commissioning L.S. 1 367,550 367,550
3.5. House on the intake tower L.S. 1 12,000 12,000
total 3 727,926
item description unit I provis.

quant. unit
(US$)
rate total
(US$)
4. TRANSFORMER TOWER L.S. 1 15,000 15,000
total 4 15,000
item description unit provis. unit rate I total

quant. (US$) (USS)
5. GUARD AND STORE HOUSE
5.1. Construction of guard, store house L.S. 1 75,000 75,000
5.2. Construction of septic tank and soakaway
including all drain pipes L.S. 1 8,075 8,075
5.3. Connection to existing water pipe m 1,200 12 14,400
5.4. Furniture L.S. 1 20,000 20,000
total 5 117,475
34
Final Design Report

quant. (US$) (US$)
6. INTAKE SITE AND ACCESS ROAD
6.1. Excavation in any material and backfill
around the structures for intake site L.S. 1 114,018 114.018
6.2. Construction of ramp, free drainage rockfill
and fence L.S. 1 7,756 7,756
6.3. Construction of access road L.S. 1 71,705 71,705
6.4. Supply and installation of all
electromechanical work at the intake site
including all testing and commissioning L.S. 1 84,200 84,200
total 6 277,679

quant. (US$) (USS)
7. STORAGE RESERVOIR
7.1. Excavation in any material, backfilling and
construction of dirt track L.S. 1 5,752 5,752
7.2. All concrete work for the reservoir
including supply of the material for concrete
and reinforcement bars L.S. 1 12,812 12,812
7.3. Supply and installation of all pipes and
fittings, wire fence and construction of
chambers L.S. 1 8,290 8,290
7.4. Supply and installation of float switches
including 2050m of cable L.S. 1 22,000 22,000
total 7 48,854

quant. (US$) (US)
8. SUNDRY ITEMS
8.1. Calculation, construction and asbuilt
drawings, operational manuals and 30 days
instruction period L.S. 1 36,800 36,800
8.2. Construction and removal of coffer dam L.S. 1 23,000 23,000
8.3. Notice boards No. 2 1,000 2,000
8.4. Spare pipes and fittings L.S. 1 28,044 28,044
8.5. Supply and install radio communication
including all permissions L.S. 1 35,000 35.000
total 8 124.844
35
Final Design Report

quant. (USS) CUSS)
9. PROVISIONAL SUMS
9.1. Additional soil investigation L.S. 1 9,280 9,280
9.2. Connection and installation of power supply L.S. 1 40,000 40,000
9.3. Miscellaneous plumbing and electrical
works, accounts certified by the Engineer L.S. 1 31,930 31,930
total 9 81,210

quant. _USS_ CUSS)
10. DAYWORK AND DEMINING
10.1. Daywork L.S. 1 10,000 10,000
10.2. Demining survey and demining L.S. 1 50.000 50,000
total 10 60,000

quant. (US$) (US)
1 I. MANAGEMENT, SUPERVISION AND
FACILITIES FOR ENGINEER L.S. 1 555,000 555,000
total 11 555,000

quant. (USS) (US$)
12 SUPPLY AND INSTALLATION OF
TREATMENT PLANT 2000m'/day L.S. 1 70,000 70,000
total 12 70,000
36
Final Design Report
7.1. Summary Cost EstimatePhase II
ITEM DESCRIPTON TOTAL

(USS)
1. Preliminary and General 505,000
2. Pipe line 2,027,933
3. Intake tower and bridge 727,926
4. Transformer tower 15,000
5. Guard and store house 117,475
6. Intake site and access road 277,679
7. Storage reservoir 48,854
8. Sundry items 124,844
9. Provisional sums 81,210
10. Daywork and Demining 60,000
11. Management, Supervision and facilities for Engineer 555,000
12. Supply and installation of treatment plant 70,000

SUBTOTAL item 1to item 12 4,610,921
Contingencies ( 10% or subtotal) 461,092
TOTAL 5,072,013
37
Final Design Report
CHAPTER 8
LIAISON
1?)
FinalDesignReport
8. LIAISON
During the design stage of the project (phase I) Consultant maintained close
contact with the relevant Officers of the following National and Provincial
Directorate:
National Directorate of Water Affairs (DNA)Maputo
National Directorate for Roads and Bridges (DNEP)Maputo
National Directorate for Mapping (DINAGECA)Maputo
Ministry of FinanceMaputo
Ministry of HealthMaputo
Provincial Directorate for Construction and Water (DPCA)Chimoio
Agua de ChimoioChimoio
Chimoio Energy Company (SHER)Chimoio
City CouncilChimoio
Companhia do Pipeline MocambiqueZimbabwe (CPMZ)Beira,

Mutare
Manica Provincial Government
Rural Water Programme, Manica
CFMCentro ( Central Region, Mozambican Railways)
Empresa de Tobaccos de Manica
SemocMozambique
38
FinalDesign Report
CHAPTER 9
PROJECT RISKS AND CONSTRAINS
Final Design Report
9. PROJECT RISKS AND CONSTRAINS
9.1. General
As apart of the services offered under this Project, the Consultant will assess
the possible risks to and constrains on Project execution and sustainability.
At this point in the Project some general risks and constrains are foreseen.
These are listed below and shown the reasons for the existence of the risk (or
constrain) ,ndthe measures for avoidance or reduction.
9.2. Major Risks
9.2.1. Delays to Project Execution
9.2.1.1. Delay in obtaining finance on time
Water level in the Chicamba Lake isat the moment the lowest for the last 20
years, therefore the construction of the intake tower, delivery channel and
intake head strutue will be cheaper and should be finished before the rainy
season starts.
To avoid this delay the finance construction should be closed as soon as
possible to enable the Contractor to start construction immediately after letter
of commencement isissued.
9.2.1.2. Delay in obtaining land acquisition approval
The Consultant strongly recommends that DNA, DPCA, AdC and Chimoio
Town Council acquaints itself with the respective sites and required wayleave,
and formally approaches the Land Boards with a view to securing the required
sites and wayleave.
9.2.1.3. Delay due to possible presence of mines on the site
Although no official information received by the Employer indicates the
presence ofmines on the Site, the Consultant recommends that due precautions
and investigation to be taken before commencement of work specially on the
hills overlooking the Lake where the header reservoir shall be built or in the
area around that location.
Such precaution and investigation may include obtaining local information,

carrying out a mine survey, demining, or clearance of the site by scoring the
surface with bulldozer equipped with a high blade as a protection in case of
blast (where it ispossible because ofthe high slope of the ground level).
39
FinalDesign Report
9.2.2. Unsustainability of the installed system
The inadequate system maintenance can cause the unsustainability of the
installed system.
To avoid that it is essential to establish the realistic operational and
maintenance requirements and appropriate tehnology.
9.3. Minor Risks
9.3.1. Inability to construct system components as designed
During soil investigation trial pits were excavated 500 m spaced, there is a
possibility of occurrence of the different material between the investigated trial
pits, which might caused the redesign of some components of the system.
Close monitoring of subsoil conditions is required by the Engineer on Site
during the excavation in order to do the necessary amendments of drawings if
conditions differs from original design.
9.3.2. Failure nfthe system to provide required capacity
The failure might occur if there is inadequate system maintenance leading to
high losses.
To reduce or avoid possible high losses of the system it is essential to establish
realistic operational and maintenance requirement as well as to equip the AdC
to fulfil their obligations.
40
FinalDesign Report
ANNEX No. 1
INTAKE TOWER
STRUCTURAL CALCULATION
/AZ
Consulting Engineers and Project Managers
Telephone +2634750775/9 Telefax +2634750780
Sheet NO: 4007194;C'104
Made by: AP
Bending Schedule Checked by: ,,P
CHIMOIO WATER SUPPLY PROJECT Date: JULY 1994
INTAKE TOWER Drawine Reference: 14007/94JC.2. 1.t
Bar Size N in Total Length Shape

Member/ Section Mark each M [mm Code A B C D E
INTAKE TOWER 01 ........
T12 .......
600 . . .....
600 ....... 1975 ..........
....... .......... ....... 38 915: ..............
200i,.............. , .............. .............
.
S02. T12 336 -- 336 2275 38 10151 300:
.. .
. .. .
...
. ..... ............... .............. .................... ........... I.......
............. .............. ,.............. .............. ..............
T2
103 ...........
....... ....
300 ......
.....
............. ........... .......... ....... ............... .............. .............. .............. i..............
300 4400 20 STRi
064 T12 300 300 3000 2O STR!
05 .... T12
....... 168
... ... ... .. ....... ... ...... ...... .. . ................ 20... . STR
168 ........... 4400 ...... . .............. , .............. .............. ...............
S06 T12 168 168 30001 20 STR i
S07 T16... ... ... .... ... ...180
.. ..
... . .. ...
.. .. ... ... .. ... .. ... .. ... .
180 5150 .. .. ... .. ...
37 .. 4340i
........ . . ........ :............... _.............................
08 ........ ................... 90............... 90 .....................

.. T16 2125 .............. 38 . ...................
965 : i.............. .............. i..............
0 T16 90 90 5950 41 1Q40
.....i'..i.. '..............
.. .......... .. .d................................. ............
.............. i.............. .............. i.............
0..
16
.......
i'
....... 90 90
........... 5925
' I .......... 20 STR:
......
6 6..........
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ii..............
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i....
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11 T16 180 180 8225 20 STR:
y'i.....
.... S2 T6 ' .........
i
i,...... 18 .. .... ..... ..... ' g i.............. i.............. i.............. ..............
.......
i.......i,............. 180.........
.......... ....
.. 7325 .. 20 ..............
.............
.. STR:
....
".i.
. ............. ........... ........ i
.......... 20 "6 3
T16 16 8225 STR:
1
......... . . ...... 16...
.............. . .... ' / ............ . ............ .............. i.......
14 T16 0 9 20 3 1065:
Intake Tower Top Slab 15 T12 38 38 3000 20 STR i
16 T12 63 63 1975 39 945; 160:
I# thus 17
i'T12
...
.. ...
. 44 44
'.......... 1925
Y
.f6............ 39 925
i6..........
f' 150
b...............
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i.............
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.......
.. ....
ST2
. .............
0 10 3 0 39 1505: 175:
T12 ...............
10 . ...............
10 .. . ...............
1600 .. . ................ .
82 495 . .125 . . . .............. .............. ,.... ... .
... .
ST2
....
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18
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4700
. . . . . . . i.............. {.. . . . . . . i.. . . . . . .
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20 STR:
21 ... .
....
...T12
..... ............. 8 ... ............ 8..............3425
..... ............... 20 . .STR
... . .............. {............... . ... ... ...........
... ........... b ............
6 ............
6 ...........205
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2 T1 2 9 9 1975 20 STR
...
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5
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10
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39 1005: 165:
Intake Tower 17 T12 23 69 1925 39 925:. 150::

Interm
C ediate
antilever ...... i'8.... ... ~{
..............' ............. 7 .5.................
.. .............. ..........
i'"i'7i..............{........
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Intermediate Cantilever 8 12 25 75 3100 39 1505: 175:
S~
b i...
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Slabs T2 .... 10 Y 30. 1600... 82' g~f~i..............
495
2......
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20.
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.............. i.............. {..............
S15..... 45 ...... 47-0 0 2 T
3 # thus 22 T12 25 75 1350 20 STR i
cont'd on next page
...'T12
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.. 1825 37 925
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.. ...
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Al . 16 8 24 2450 39 117566 05
All Bending Dimensions are in accordance with BS4466
* Consulting Engineers and Project Managers
* Telephone 2634750775i9 Telefax 2634750780
Sheet N*: 4007,94;C,'105
Made by: AP
Bending Schedule Checked by: A.,.
CHLIOIO WATER SUPPLY PROJECT Date: 1994
,TAIWE TOWER SLABS Drawine Reference: 4007,94,C.2.14
Bar Size W in Total Length Shape

Member/ Section Mark each N' [mm] Code A . B C D E
Intake Tower 27 T16 8 24 4500 20 str;
Inter. Cantilever 28 T6 8 24 3400 20 sr..............
.idiate
Slabs (Conc'd from 29 R8 116 348 1250 61 210: 360:
previous page)
............... ........ ................... .......... .... .................... .................. ........................... ............................. .............

................ .............. .............. ............... .................... .................. ............ ............... .............. ............... ,..............
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• ] Telephone +263475077519 Telefax +2634750780
Sheet NI: BS 106
Bending Schedule Made by:
Checked by:
R.S.B.
RSB.
AP.
CH.IJOIO WATER SUPPLY PROJECT
Date: JUNE 1994
INTAWE HOUSE ABOVE INTAKE TOWER
Drawing Reference: 007,94,C :.13
Bar Size N' in Total Length Shape

Member/ Section Mark each N' [mmJ Code A B i C : D i E
BEAM 2 19 T16 3 6 3150 20 S'rRf
2# THUS2#THS 20 T12 2
20 I2
............... ............................ 2 4 3150
315U 2'0 STR:
20.........................................................
......
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21 "............
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8
..................
1950 39 86 43
22 R8 54 108 1400 61 195
.............. ............... 45
............. ...................................................
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BEAM 3 21 TI6 4 8 1950 39 865: 430 !
2# THUS 23 T16 2 4 4550
24...........0........................................................ 20 SrR.
.....
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2 4 ...........
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..............
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COLUMN 29 T16 4 16 4825 37 4700iU
4# THUS 30 RB 32 128 775 60 150: 150:
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Telephone 702531.5 Made By ......................
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Page :
Job No.:
10.1/20
Chimoio Water Supply project Made by: ap
rc cant. slab Date
30 /07/94
rc design checked:
beam/slab design acc. BS 81:0
REINFORCEMENT DESIGN for a slab

for Cross Section: SUPPORT - cantilever
Width: b = 1000 mm, bw = 1000 mm

Depth: h = 200 mm, hf = 0 mm
d = 144 mm, d' = 60 mm
Cover: top 40 mm, bot. 50 mm, sides 0 mm
Span: 1 = 1.600 m, Width of Support 300 mm
Materials:
Concrete fcu = 40 N/mxn2, Steel fy = 460 N/mm2
Moments and Forces:
Bending: M = 26.6 kNm

Shear: V = 33.2 kN, UDL = 0.00 kN/m
REINFORCEMENT:
Bending:
Bottom:
requ.: As = 485 mm 2 >

provide 8 T12 at 200 mm c/c with As = 904 mm 2 (0.28%)
Shear:
Shear Stress: v = 0.23 N/mm2, vc = 0.82 N/mm 2
No Shear reinforcement required !
Design at 294 mm from Cl for 0.0 kN, v = 0.00 N/mm2
Asv = 0 mm2/m
Provide 0 legs R 0 at 0 mm --> Asv = 0 mm2/mCurtailment:
j< 0 mm >j<--- 0 Links R 0 --->
0 mm ----------- >1
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2 Rober Mugabe Road Sheet No .... ................................

P.O Box UA 424. Un,on Avenue. Harare
Telephone 702531.5 Made By ........... .......
Teleiex. 702536
Telex: 22345 COOWYR ZW Checked By .................................. .
JOB .. .................................. ...... .... ...... ...... ... .................. . . . ...... ......
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P 0. Box UA 424. U.,en Avenue Hlrae
Telephone 702531.5 Made By
Telefsx: 702536
Telex: 22345 COOWYR ZW . . Chcka. ...................................
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2 Robert Mugabe Rood Shee No .........................................

P0. Box UA 424. Union Avenue. Harare
Telephone 7025315 M ade By .........................................
Telefax: 702536
Telex: 22345 CODW YR ZW Checked By .......................................
J O B 0.............................................................
...... ............
...............
..............
........... Date ...............
... ..............................
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2 Rober Mugabe Road Sheel No .........................................

P 0 Box UA 424. Union Avenue. Harare
Telephone 702531.5 Made By ........................
Telefax. 702536
Teiex: 22345 CODWYR ZW Checked Bv ..........................................
JOB ...... .. ..................................... .............. .... ........ ......................................

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2 Roben Mugabe Road SICe No .. ....................................

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Telephone 702531.5 ;Aade By ...............
...........................
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Tle x 22345 COOWYR ZW h d By ......................................
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2 Robert Mugabe Road Sheet No ....................................................
P.O. Boe UA 424. Union Avenue, Harare
Telephone 702531S
Made By ...........................................
Telefax: 702536
Telex: 2345 COOWYR ZW Cheded By .........................................
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Chimoio WaterSupply Project
FinalDesignReport
ANNEX No. 2
ACCESS BRIDGE
Telephone +263.475M75S9Tclefu +263475750
Sheet N2: BS 103

Bending Schedule Made by:
Checked by:
S.B.
R.
A.P.
CHIMOIO WATER SUPPLY PROJECT
Date: JUNE
BRIDGE & INTAKE HOUSE R.C. DETAILS.
Drawing Reference: 4007/94/C/2.13
Bar Size W In Total Length Shape

Member/ Section Mark each N [mm] Code A B C i D E
BRIDGE 06 T16 4 12 11000 20 STR!
3# SE'TIONS 07 T12 4 12 11000 20 SI'R !
(IN 11# PANELS OF 08 ........
......
SIZE 1017mm)
RIO .......
138 .........
414.........
.......
....
................... 6
2000 6. ........
. ..... .......
220 .. . . .
09 RI2 238 714 2000 60 670, 2001....
22# IN EACH PANEL ...................
10 ..RI2 ......... .
122 366 . 050 81 3351 351
11 R12 242 726 1125 83 900! 150
.....
... 6151
" ...... ......
12
................. 2.."... ..
R ... . . 39 . 750.
5.....0.... 9.0 . . .......... i
....... ................. ...................... .
13 T25 10 30 11000 20OSTR
. ..... ........ ............. ....................... ............................... ............ ............................
15 T12 162 486 1975 20 STR
. ... -.........
. . ......... ................ ...
1 T16 32 972 2200 2 STR I
........ ..................... . ... .
F .....
..
. ...
.iii .......
.. .......
6. .. .... ..................
I I. ................... ...........
STR ...... ..... . ".............. .............. .. . .
18 T12 22 66 2050 39 1015i 751
CORBEL STUB COLUMN 01 T25 3 6 3375 99A

2#TIIUS.. . . ............... ...... .............
. .
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. ".............:........4 ........ .............
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S. . . . . . .. ....................
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..... ................
2 4 1900
.....................................
...
60 200 50......:

.
.
:.................
...... ....
.............
03 ... . ..........................
T12 4 8... .....................................
1650 60 "'200:"'500......1'.......i....
~....... ............. .............. ...............
........ ................... ....
.....
........ ............. .........
......... . ...........
MAIN CORBEL 04 T20 21 21 3375 99B

.... ............. ..................
....... ........
. . ....................
...............
......... . ................ ............. ..... ..
..
................
.............
.............
...............
....................
..................
............
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..
* .................
. ..........
05 2 7 7C 5
60 33
. ..........
.......................................... ....... .
" .
JO X5X4SU 05 T20 6 6 350 .38 84 30 ['
COLUM AT MVEA
M ETH 314
............... ....RIO 20
......... .............. ..... ........ 20 ...................
•.......................................................... 25009 ................ 60 ...........
300 84i 400
......................
..
OINT. " .... .:.
32 RI0 6 6 2400
2...TH U S................. 6..840......
.. ... ".. ... .........
T.U .......
.......
.......
I....
....
.. ... ........... .... . ............... ...... ... . ... :... .
All Bending Dimensions are In accordance ivth BS4466

Mop= Nicholas O'Dwyer & Partners
2 Robert Mugabe Road Sheet No ...................................

P.O. Box UA 424, Union Avenue, Herare
Telephone 702531.5 Made By .........................
..............
Telefax: 702536
.....
o,.....
.......
.............
Telex: 22345 CODWYR ZV
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F Consulting Engineers
2 Robet Mugsb Rood

Hirer.
Sheet No .. >
:...
P.O. Box UA 424. Union Avenue,
Telephone 7025315 d.B* -
Te::ex: 2
Telefx: 36
7253CO Y W Wl*LeIB MaWd By ........................
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2 Robert Mugabe Ro4.d No .......
.;I,!el .................................
P.O. Box UA 424. Union Avenue. Herare
Telephone 702531.5 Made By ... ......................................
Telefax: 702538
Telex: 22345 CODWYR ZW Ch,.thedBV ... ..................................
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2 Robert Mugabe Road Sheet No ............................ .............

P.O. Box UA 424, Union Avenue, Harare
Telephone 702531.5 MadeB V.........................................
Telefax: 702536
Telex: 22345 COOW YRZW Checked By ........ . ................................
JOB ....... . ............................... ......................................................................... ... . e ........... ....................
SECTION .................................................. .............
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________________________
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eir Nicholas O'Dwyer & Partners
2 Roben Mugeb. Rood Sheet No .......................................................

P 0. Box UA 424. Union Avenue, HireSe
Telephone 702531.5 ade y ...............
Telefax: 702530 ..........
Telex: 22345 CODWrYR ZW Checked By ...............................................
JOB ........ ................. ae..............

SECTION .. .. ........... ................ .
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LAMONT Consulting Engineers
Page
.11,) No. : 1031/20
Chimoio Water Project Made by: jf
Bridge Date : 06/07/94
nax field moment checked:
bemelab d.aign .cc. 9J oil*
REINFORCEMENT DESIGN for a rectangular beam

for Cross Section: SPAN - simply supported
Width: b - 300 mm, bw - 300 mm
Depth: h 750 mm, hf 0 mm
td - 698 mm, d' - 60 mm
Cover: top 40 mM, bot. 40 mm, si des 41) mm
Span: 1 .12.000 m, Width of Support 300 ,nm
matrials :
Concrete fcu - 25 N/mm', Steel fy - 410 N/mm'
Moments and Forces;

Bending: M 504.0 kNm
Shear: V 168.0 kN, UDL = 28.00 kN/m
REINFORCEMENT:
Bending:
Bottom: requ.: As 2529 mm' -
provide 5 X25 with As * 3125 am' (1.39%)
Shear:
Shear Stress: v = 0.81 N/mm', vc 0.72 N/mm'
Design at %6000 mm from Cl for 144.4 kN, v 0.7U {1/mrO'
Minimum Links:' Asv = 552 mm'/m
Provide 2 legs RI0 at 275 mm Asv = 571 mm'/m
2 ..
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7-S !/
Jimicnolas u'uwyer & Fartners
2 Robert Mugabe Road
Shevl No ...........................................
P.O. Box 702531.5
Telephone
Telephon UA 424. Union Avenue, Haaie
70253 1. aM,e B ....
. .......................................
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Talefax 702536
Telem 22345 CODWYR ZW
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........... ...... Date ............ ............ ....................... .
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2 Roben Mugabe Road Shee No ...........................................

PO. Box UA 424. Union Avenue. HariSe
T e:Phone 702531.5 Made By .... ..........................................
TlOefa., 702536
Tele. 22345 COOWYR ZW Chpcked By .. ........................................
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* INicholas O'Dwyer & Partners Consulting Engineers
2 Robert Mugabe Road Sheet No.

P.O. Box UA 424, Union Avenue, Harare
Telephone 702531.5 Made By .............. .. .........................
Telefax: 702536
Telex: 22345 CODVYR ZW Checked By ....................................................
JOB ....... ........................................................................... . ........................ . . . . . . . O ................... ....... .....................................
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2 Rob n Mugabe Road SheuoNo ..........................................

P.O. Box UA 424. Union Avenue, Hrre ....................
.....
Telephone 702531 5 M ide By .........................
Telefax: 702536
Telex: 22345 COOWYR ZW Chocked By ........................................
...... Date.......................................
.......................
JO B .................................................................................................
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S EC TION ......................................... .
.................................
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Final Design Report
ANINEX No. 3
TRANSFORMER TOWER
- Telephone +2634750775/9 Telefax +2634750780
Shcul NO: 4007/94/C/lu2
Bending Schedule %lade by:

Chucked by:
R.S.B.
A.P.
CHIMOIO WATER SUPPLY PROJECT Date: JULY 1994
TRANSFORIER TOWER Drawing Reference: 4007/941C/2.12
Bar Size N in Total Length Shape

Member/ Section Mark each NO [mm] Code A B C D E
BASES 01 T16 10 40 1025 38 215: 670:
BEAM 1 02 TI2 4 24 1900 38 865i 230i

.... ...............
..
.............
..............
....
..........
........
...........
......
............
o............
,.......
..
..............
.. .............
;
6# 03 T16 2 12 2000 20 2000;:
04 .....
.........
T12 .......
2 ............
12 2000 ...... 20
.............
"."...................
2000: ................
....................
..............
...............
05 ...............
..............
..............
............
R8 ........
..........
.......
.....
,.. 11 66 1000 60 230; 180::
BEAM 2 02 TI2 4 24 1900 38 865i 230:

6#
......
.....
.....
....
05
....
...........
..............
................
R8
,..
.......
....
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...........
i.......
......
14
!...84 10OW 60 230: 180.
06 TI2 2 12 2500) 2(0 25o00
7 .............
............... .......
..........
.......... . ...
....... ..............
..............
..............
..........
SLAB I !1 TI2 18 18 3025 33 2830:"

i....... i.....
......
... ...
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.. ...............
.... ... .. 6..............
.................
......... i...........
i.....
........
1#12 TI?
....... I.
i........
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.. I5 4025
i6.............
............ 33 ............
...........
.....'...
..............
3830:.............
i..........
I........
.....
13 TIO 18 ..............
18 ..................
3025 ......
33 ..
2830: .............
..
!....
..
.
i .....
.....
:.....
....... ................ ....... ...
.........
....i
..
14 TIO I5 15 4025 33 3830:.
COLUMN 1 08 T16 4 16 60001 42 690: 305: 4885i 65i

4# 4 . .
09 ...............
T16 ............
............... 16
....
.. 2250 51 .............
.................
... 265i...
2030: ............
.................. :............
.............. 100
........
...............
..............
10....
..
...
..
............
..
...
...........
R8...........
...
.........
..........
i.......
36i.....
i...
144 9001 60 180 1801
...............
..............
..............
...............
...............
........
........
...........
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.......
........
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..
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........ .
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......
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..............
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............ .............
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.................. :......
All Bending Dimeiois are in accordance %i%h J|S4466

. .................................
Sheet No .............
2 Rober Mugabe Road
P.O. Box UA 424. Union Avenue. Harare
Made By ...........................................
Telephone 7025315
T lelax: 702536
CheckefBy ........................................
Telex: 22345 CODW YR Z W
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FinalDesign Report
ANNEX No. 4
CALCULATION FOR SIZE OF TRANSFORMER
"L',
i
r , :. ,v
L, WJ,
o , . .,. .
Chimoio Water Supply Projec!
FinalDesign Report
ANNEX No. 5
HEADER RESERVOIR
i Consulting Engineers and Project Managers
Telephone +2634750775/9 Telefax 2634750780
Sheet NO: 4007/94iC/l0l
Made by: R.S.B.
Bending Schedule Checked by: A.P.
C010 WATER PROJECT Date: JULY 1994

RESERVOIR Drawing Reference: 4007,'94,C'4.2
Bar Size W in Total Length , Shape i
Member/ Section Mark each N [mm] Code A B C D E

RESERVOIR 01 T12 152 152 2400 39 l170: 125::
S02 T12 307 307 2925i 20 STRi
.. ....
. . .. . .. .
. .. . . ..... ........... ............. .... . ............... . . . . . . .............. ............... .............. ..............
03
.. .. Tl2
. . ..... ..... 253 , . . ..........................
...... .............. 253 1525 ........... ....... 51
...... 440
..... ".
............. .............. .............. ..............
04 ... ....
. T12 172 .......... 172
........... . .. . . 2525
....... ............. . . ... .. .52
. . . . 950i
. . . .:. .. .3751
. . . .. .950:
. ... .............. ..............
05 T12 190 190 5675 65 5675.....
...' 06.i ............ 6.............
fT2
..... 6 16 ........... 325
i ; ............. 4 i 6...
10:i ..............
305; ................ 60: .......... .
2240; ............
. . . . . T12.............
.....
07 16 ..........
.....
....
16 ..........
........37......
1425 16 ..............
................
...1
....i
... .......
SR8
. . . . . I
5.. ............... 88 ................ 775..
....
88
............... 61."'.....
... .............. ............... . . . . . . . i..............
165: 165:
S ~ 12 48 8 00 35 700:
10 T12 96 96 15%0 61 46i 210
11 T12 15 15 2650 61 695 550. :
....
.. .. . ... ..
12 T12.. ............
........ 15
... 15................
............... 2875
.... ................ 61 ......
4001 .......
.........
960 .... ............ ..............
. . .
. ...
...
.Tl2.. 14 ...............
13................... 14 ....................
3100 .................. 39 ............
1775i;..............
150:.............. ,.............. ..............
....... 14 ....... ..............
T12
..............
28
...............
28
.....................
6975
.. ....20 .................
STR
. .. .. . . . .. ..............
. .. .......... .
15 . .. . ... .. . TI2
..... ... .......... .I ............... .................... .................. .. .......... .............. , . . .
96 96 1725 39 810! 175:: .... .............. .............
....... 16....... . ......
T12. ...... ...........
96 I..............
96 ... .............
2475 .. . ............... ..........
82 810 . .;. . . . . .
210. . . . . . . . .i.. . . . . . IF . . . . . .
........ 17....... ....
......... . .............
T12 16 ....................
16 ............... 2050 ........ ..........
35 ............
1850:: ;.............. ............. i ............. .............
18.......
... .. .. ... ...
T12 ............. ............... ... ..................
7 7 2700 ..............
38 . . . . . . ....... .. ..... .............. .............. ..............
44 51850
....i...
9 T12
... .............. g......
....... ..................
............. ..... . ~ ............. ............ ..............
15 15 3200 61 685 83
... "'...................
S2 12
.. 16 ...............:..........
16
............ 38
.'......
2400
'"'
" '..
.. .....
'..
"i'..
305: 1850:
........... i...
... ........... i...
..... .
.......
.. f.....
.. ..............
.... ....... ..................
' .................
............ '6
i ..
..
................................
...........
.. 12 14 14 3700 55 1350 . 1910;.
150:; . 150 .
22 T12 24 24 2150 33 1860
... 3...
. T .......
2 .............. 90................
90 ....................
2 0. ...................... ... ...... . ..... ..... ...... " ............... o .........
2 T12
.... .... . T12 190 190 2000
...................56............... 56.................... 65
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Chimoio Water Supply

ADVENTIST DEVELOPMENT AND RELIEF AGENCY

1LZ ­0f,­ 11

CHIMOIO WATER SUPPLY PROJECT

Financed by: On behalf of:

SHELADIA Associates Inc.

1.1. Background I

1.2. Project Area 2

1.3. Climaiic Conditions 2

1.4. Project Objectives 2

1.5. Report Objectives 3

1.6. Report Structure 3

2. EXISTING DATA 4

2.1 Topographic Maps 4

2.2. Topographic Surveys and Way­leaves 4

2.3. Soil Surveys 4

2.4. Hydrology Information 5

3. FIELD SURVEY 7

3.1. Topographical Survey 7

3.2. Soil Investigation 7

4.2. Intake Tower 10

4.3. Access Bridge to the Intake Tower 13

4.4. Transportable Punp 14

4.5. Guard ­ Store House 15

4.6. Intake Site and Transformer Tower 16

4.7. At ess Road 16

4.8. Pressure Pipeline 17

4.9. Header Reservoir 23

4.10 Gravity Main 24

5. OPERATION & MAINTENANCE 29

5.1 Present 0 & M Situation 29

5.2. 0 & M for Extended system 29

6. CONSTRUCTION PROGRAMME AND CASH FLOW 31

6.1. Construction Programe 31/1

6.2. Cash Flow 31/2

7. CONFIDENTIAL COST ESTIMATE 32

7.1. Summary Cost Estimate­Phase II 36

9. PROJECT RISKS AND CONST IAINTS 38

9.1. General 38

9.2. Major Risks 38

9.3. Minor Risks 39

The following general abbreviations are used in this Report:

F.D.R. Final Design Report

Only 50% of the 100,000 or so residents of the urbanised part of Chimoio are

The town of Chimoio lies at an altitude of between 630 and 710. The treatment

The project area is situated in the Province of Manica in Central Mozambique.

1.3. Climatic Conditions

The minimum and maximum monthly average temperatures are 18 C and 25 C

The objectives of the Consultancy Services for phase I of the Project are:

­ To develop aconcept for the supply ofraw water to the city of

studied and the accepted alternative issupply from Chicamba dam.

In particular the following engineering details shall be provided in this Report:

­ General layout ofthe scheme showing all main components

­ Plans and sections of important details and the dimensions of the

1.6. Report Structure

This report issubmitted in three volumes, 9chapters in Volume I, Appendices

Chapter 1. Introduction

Chapter 2. Existing data

Chapter 5.' Operation & Maintenance

Chapter 6. Confidential cost estimate

1LZ 0f, 11

2.2. Topographic Surveys and Wayleaves 4

4.5. Guard Store House 15

7.1. Summary Cost EstimatePhase II 36

To develop aconcept for the supply ofraw water to the city of

General layout ofthe scheme showing all main components

Plans and sections of important details and the dimensions of the

1:50.000 (19581960), sheets 837 and 838

2.2. Topographic Surveys and Wayleaves

The Companhia do Pipeline MocambiqueZimbabwe (CPMZ), were also most

normally excavatable material (soft material)

Intake tower with high lifting pumps on the Chicamba Lake

Access bridge to the intake tower

Guard, store house incorporating office, accommodation facilities and

Fenced Intake site incorporated Guard, store house, transformer tower

Pressure pipeline including valves and fittings

Header reservoir of 100 m3 located on the hill overlooking the Lake

Gravity pipeline including valves and fittings

i) Water protection against dry running of pumpsintake tower

ii) High level cutoutheader reservoir

iii)Low level cutinheader reservoir

Electricity supplymains failure ( battery operated)

Operation of any electrical protective device or safety cutout