Construction World December 2023

CONSULTING ENGINEERS

SKA MEERKAT EXTENSION PROJECT

U pon completion, the SKA (Square Kilometre Array) telescope will be the world's largest radio astronomy telescope, giving scientists the ability to map the universe with more sensitivity and speed and over a greater area and distance. This mega-science project is truly transformational and will change our understanding of the universe. It is no surprise then, that this project tests the limits of engineering and requires cutting edge technology and innovation. The MeerKat Extension project comprised the expansion of the existing MeerKAT array with 20 dishes and the establishment of the first four dishes for the SKA-MID Array. For this Design and Construct project, Zutari was appointed to conduct preliminary and detailed design, verification, and construction monitoring for the dish foundations, as well as the power and fibre needed to collect and relay data over vast distances. Zutari was also responsible for supportive access roads and platforms, buildings, a wastewater treatment plant and a construction camp with water supply and accommodation for 250 people, each requiring a vast array of expertise across disciplines. The project required each dish to point into space with extreme accuracy and stability. The dish foundations, therefore, were no ordinary structures, but had to meet exceedingly strict requirements with regards to stiffness and movement tolerances, as well as the orientation to true north; requirements which directly affected the larger telescope’s operation. In fact, the requirements for the foundations were so specific and strict that they could not be met using conventional design methods. In addition, the team encountered a significant challenge related to changing ground conditions across the vast site. This could radically impact the strict requirements regarding stability and orientation of the dish foundations, and required innovative solutions. In response, the design team utilised an innovative approach based on advanced technical theory. This approach utilised soil-structure assessment using strain in the ground and the resultant ground stiffness. Advanced 3D numerical modelling was also utilised by both the structural and geotechnical design teams. In order to analyse and understand realistic foundation behaviour the geotechnical and structural models needed to interface seamlessly.

where changes in ground conditions at dish foundation locations could impact the foundation meeting the client’s strict requirements or impact the type of foundation applied or result in a significant increase in works and quantities for the contractor. To model the geotechnical conditions on such a

vast site required creativity. Through this innovative work with data and modelling, the foundation team was able to derive expected ground conditions and rock level with improved accuracy, and to model effective solutions with greater confidence. The project made an important contribution to a radically innovative and prestigious project with diverse applications and far reaching positive consequences for South Africa and the world. • The project successfully met all the very stringent client requirements, despite complex challenges. • The project’s use of innovative, technically complex 3D modelling and advanced design approaches and other digital solutions radically improved project planning, analysis and design - ensuring the client’s strict performance requirements were achieved. • The project’s adaptive use of on-site materials, and unusual material and equipment solutions, in response to shortages and site restrictions. • The project’s excellent safety track record, despite several challenges. • The project’s inclusion of environmental considerations, including birds, protected species and existing river systems.

• Radical collaboration among the clients, contractors and designers, which ensured successful delivery of the project. 

PROJECT INFORMATION

• Company entering: Zutari • Client: COP Consortium (Consortium of Concor and OptiPower) • Civil Contractor: Concor-Optipower Consortium • Mechanical and Electrical Contractor: Optipower • Geotechnical Subcontractor: GeoCiv Group • Consulting Engineer: Zutari

The vast extent of the site created a challenge for the design and construction team. The available data for design was impacted due to the large distances between dish locations as well as access constraints to locations. This limitation in available data creates risk where changes on site during construction could relate to time delays and increases in cost. The available ground data was part of this associated risk

57

22 nd Best Projects Awards 2023