DEPARTMENT OF WATER AFFAIRS

DW 149E

FORM FOR THE DAM SAFETY EVALUATION AND INSPECTION REPORT OF A SMALL
DAM
Name of dam:

Stormwater Dam 1____________________________________

Departmental file reference for dam: 12/2/X201-92______________________________________

Name of Approved Professional Person:

Marius Kolesky_________________________________

Name of Owner: Assmang Chrome____________

________________________________

Address of Owner: P.O. Box 152, Machadodorp 1170____________________________

Email: jonathanc@assmangchrome.co.za_______________________ Tel: 013 256 5137___
Notes: (i)
(ii)
(iii)
(iv)
(v)

Sections 1 to 8 should be completed prior to the dam safety inspection. Delete any
sections not applicable to the particular dam and insert extra lines where needed.
Survey instruments (at least a level and tape) should be taken along to survey the
relative heights of the non overspill crest, spillway crest, and embankment slopes.
Additional information may be included in annexures.
For a detailed checklist of the requirements for the dam safety evaluation of a Category
1, 2 or 3 dam, refer to Regulation 34 to 36 in the new dam safety regulations in
Government Notice No R. 139 of 24 February 2012.
Please also make the report available in electronic format.

SECTION 1: AVAILABLE INFORMATION

List all plans and reports that are available on the dam and which have been studied for the dam safety
inspection. Please enclose copies of plans with typical details. If no such plans exist, sketches must be
made. A copy of a 1:50 000 map showing the location must also be supplied. Photographs taken
during the inspection should also be enclosed and referred to in the report.
The 2010 Inspection Report refers to some drawings which were not available for this
evaluation but this is not considered a problem, with the Dam being rather straight forward.
SECTION 2: DESCRIPTION OF THE DAM
Wall type: Earth fill____________________

Wall height (maximum): 8 m_____________

Storage capacity: 99 670__m__________ Completion date: 2004________________

Crest length: 415 m__________
Contractor: Unknown______

__
____

Crest width: 3m______________________

Designer: Kwezi V3 Engineers______

Betterment works done after completion: None_____________________________________

Problems which occurred previously: Sedimentation of dam below the northern inlet canals, also
resulting in damage to the plastic liner at that point. This occurred before the 2010 inspection.
SECTION 3: GEOLOGY OF DAM SITE
General details (Rock types, quality, weathering, joint spacing, joint openings, joint filling, shear
zones)
Deeply weathered fine-grained shale and mudstone overlain by clayey silty sand with abundant fine to
coarse shale gravel.
Geological conditions and actual or potential problems such as sliding resistance, settlement,
seepage, erodability.
Left flank: Geological conditions as described above. No problems foreseen.
Right flank: As on left flank.
River section: Not applicable, off-channel
Spillway channel: No spillway at the moment. It will however be proposed that a spillway be
provided on right bank, just below the feeder canal from the west. This area is well grassed and
suitable for the purpose
Are the slopes around the dam basin stable? Yes
SECTION 4: DESCRIPTION OF DAM WALL MATERIAL
Dam was constructed through a cut and fill operation, with the material as described above being used
for embankment fill.
SECTION 5: CHECKING OF REGISTRATION INFORMATION
A computer printout of the registration information of the dam is available from the Dam Safety
Office. Please check whether all information is correct and complete. If there are any changes, please
indicate them on the computer printout and send it back with the report. Information corrected?
Yes, or No?

No

SECTION 6: EVALUATION OF THE HAZARD POTENTIAL

Any downstream development since the last dam safety inspection report? No____
Estimate of potential loss of life: 0
Estimate of potential economic loss: R 10 million_
Hazard potential rating as classified: Significant
Do you agree with the classification? Yes
If not, please apply for reclassification on the DW692E form.

SECTION 7: FLOOD ESTIMATES

Catchment area (km2): 0,6
Mean Annual Precipitation (mm): 800
Methods used for flood estimates: Rational Method. The catchment area is too small to use TR137
with any confidence at all
Flood estimates

1:20 (m3/s):
1:50 (m3/s):
1:100 (m3/s):
1:200 (m3/s):

6___
9__
12__
16__

Regional maximum flood (m3/s):

26__

Probable maximum flood (m3/s):

50__

Recommended design flood (m3/s): 12__

Safety evaluation flood (m3/s):

16 (1:200 year event) __

Motivation for choice of recommended design flood and safety evaluation flood (which guidelines
were used): SANCOLD Report No 4: Safety in Relation to Floods.
SECTION 8: EVALUATION OF SPILLWAY CAPACITY
Spillway type: No Spillway.
Spillway length: Not Applicable_ Critical spillway width: Not Applicable
Non overspill level: 1613,25
Full Supply Level or spillway level (m): 1612, 45(proposed)
Height of lowest point on non-overflow crest above spillway (m): 0,8
Spillway capacity with no freeboard (m3/s): Not Applicable
Will the incoming flood be significantly reduced by flood absorption? Yes.
Available freeboard during recommended design flood (m): Not Applicable
Will the dam fail if the non-overflow crest is overtopped? Yes, although the outside slope is quite
flat and well grassed, which may retard erosion. However, one of the pylons carrying the overhead
Eskom line, is positioned inside the downstream slope of the embankment, causing steeper slopes
around it. This may be a weak point, should overtopping occur. See photos 1 and 2.
What erosion could be expected during the recommended design flood? If a spillway is not
provided, the downstream slope may erode, particularly around the above pylon. Failure of the
embankment is possible.

And during the safety evaluation flood? Again, if no spillway is provided, erosion is certain and
failure quite likely.
Final evaluation of spillway capacity: The dams need to be provided with a spillway. A suitable
position is probably on the western side, just below the concrete canal that delivers dirty water from
that side to the dam.

SECTION 9: INSPECTION OF THE DAM

Date: 29 April 2016

Water level in dam: 2,5 m below crest

Did it rain recently? No

Describe: Not Applicable

Persons present at inspection: Jonathan Chunda, Willie Coetzee from AssMang Chrome, Marius
Kolesky(APP) and Mfundo Dlamini from the IUCMA.
EARTH WALLS
CREST OF EARTH WALLS
Crest width (m): 3

Has the crest width changed since construction? No____________

Is the crest still level or has settlement occurred? Impressively level, a line of levels was running
along the crest and it was shown to the very level, as indicated in the attached Appendix 2: Crest Long
Section. See photos 3,4 and 5
Are there signs of erosion? No_____________

Describe: -______________________________

Are there signs of cracks? No______________

Describe) -__

Is maintenance necessary on the crest? No

Are there signs of holes (ants, rats, Meercats, moles, crabs, etc.?) No__ Describe: -____________
UPSTREAM FACE OF EARTH WALLS
Slope (vertical: horizontal): 1:2,5
Slope protection measures (if any): Plastic lining.
Are there signs of erosion? _No________________

Describe: -________________________

Are there signs of cracks? No________________

Describe: The plastic lining has
developed tears and punctures over the years, generally having been repaired as is evidenced by the
number of repairs but also unrepaired tears/punctures. See photos number 6,7,8 and 9. Photo 9 shows a
very recent repair, but there are of course some others that should have been done at the same time.
Clearly the large tear at the sediment deposition is a special case and needs special attention. It is also
possible that some of the repairs may have separated over time and is recommended that all repairs
above water be inspected to ensure they are still competent. ________________________

Are there signs of settlement? No_____________

Describe: -_______________________

DOWNSTREAM FACE OF EARTH WALLS

Slope (vertical: horizontal): 1:4 to 1:5.

______________________________

Slope protection measures (if any): Well grassed.

Are there signs of erosion? No_________________

Describe: -_______________________

Are there signs of cracks? No__________________

Describe: -________________________

Are there signs of settlement? No__________________ Describe: -________________________

Are there signs of bulging/sliding? No__________________________________________________
Are there wet patches? No____________________

Describe: -_________________________

Are there signs of seepage/leaks? No____________

Describe: -________________________

Amount of leakage? N/A_____________________________________________________________

Is the leaking water clear or turbid? N/A_______________________________________________
Are there signs of holes (ants, rats, meercats, moles, crabs, etc.)? No____

Describe: -______

VEGETATION ON EARTH WALLS

Are there any trees or shrubs on the wall? No.
If so describe type, size, number and position: N/A
DRAINAGE SYSTEM IN EARTH WALL
Has a toe drain or internal drainage systems been provided? There is a drainage system below the
plastic lining which also serves as leak detection. Any leakage water is piped to a sump below the dam.
See photo 10.
Describe: Leakage water that reaches the sump is pumped back into the dam as it is polluted water.
_____________________________________________________________________
Amount of leakage (m3/s)? It is not possible to measure the leakage water inside the sump, but one
can clearly hear the dripping. It is suggested that the possibility of this leakage flow being measured,
should be investigated. If possible, the flow should be monitored to be aware of sudden variations.
_______________________________________________________
Is the water from the drains clear or turbid? The water appears clear.

DOWNSTREAM TOE AND FLANKS OF ANY DAM

Describe wet patches (position, size): None
Seepage/leaks (position, flow rate): None
Is the leakage water turbid /clear? None _______________________________________________
Are there trees within 5 meter of the dam wall? No____________________________________
Describe: -____________________________________
FLOOD OUTLETS (OF ANY DAM) / RETURN CHANNELS / TRAINING WALLS
Condition of structures in spillway channel (sills, retaining walls etc.) The dam does not have a
spillway and it is recommended that one be provided on the upper western side. The spillway can be
cut through the embankment just below the concrete canal discharge position. The plastic lining can be
extended through the spillway, up to where spillage is released down the well grassed slope.
Is the stability of the dam wall threatened by the spillway channel? N/A_______
Is there loose material in the spillway channel? N/A _______

Describe: -_______

Is there any erosion in the spillway channel? N/A ________

Describe: See above

Is there any erosion in the river? N/A ___________________

dam, a long distance from the nearest river.

Describe: This is an off-channel

Are the spillway length and freeboard still as shown on the drawings? N/A
STILLING BASINS / APRON
When was the stilling basin last emptied and inspected for scouring? N/A
Observations and Evaluation.
OUTLET WORKS (OF ANY DAM)
Number of outlet pipes: 2_______ Diameter: 200 mm_________

Type: Steel_________

Condition of outlet pipe foundation: The areas in the vicinity of the two pipes are completely dry, it
does not appear as if the outlet pipes are in any distress at all.
Is the control upstream or downstream? Downstream only_
Is there provision for an upstream emergency valve? No_
Are the valves used regularly? Yes
Are the valves in working condition?

Yes

Are there leaks alongside the outlet pipe? No

Any erosion downstream of the outlet works

No

Rust protection? Still in reasonable condition. _

Other observations: The 2 outlet pipes abstract from different levels inside the dam. The one shown
on photo 10 is at lowest level and can empty the dam. The other pipe takes off at a higher level and
serves the treatment works below the dam, not in use anymore. See photo 11
SECTION 10: EVALUATION OF STABILITY OF DAMWALL
The embankment appears perfectly stable.
SECTION 11: EVALUATION OF DRAINAGE SYSTEM
The leak detection system works well and appears to be able to deal with any leakage through the
plastic lining. An effort must be made however to monitor leakage rate, in order to note any
deviations.
SECTION 12: EVALUATION OF THE QUALITY OF OPERATION AND MAINTENANCE
Have the operating personnel been interviewed? Yes. The Assmang Chrome Plant has cut down
drastically on its operations. Water requirements from the dam has therefore reduced and the operation
thereof is affected. This needs to be recognised and allowed for in the Operations and Maintenance
Manual.
_________________________
Have there been any floods since the last dam safety inspection report? Yes
Were the Operation and Maintenance Manual / Emergency Preparedness Plan available; is it
used and up to date? It is available in 2 separate documents. There is one Operation, Maintenance
and Inspection Manual for the 2 dams, while dam failure and flooding are addressed as part of the
companys comprehensive Emergency Response Plan. These documents appear reasonably acceptable,
but they have probably not been approved by the Dam Safety Office. A major shortcoming of the
Operations Manual is the fact that it does not guide the operation in order to adhere to the requirements
of General Notice 704 of 4 June 1999, that stipulates that the dam should be operated at a level that
would prevent spillage during the 1:50 year flood event. A water balance that determines how excess
water is to be dealt with, must be carried out. Particularly now that the plant operations have been
reduced, less water is abstracted and therefore the means by which water level is maintained below the
critical 1:50 year available capacity, that must be spelled out. It is suggested that the Operation and
Maintenance Manual with Emergency Preparedness Plan, be updated (possibly combined) to allow for
the changed Operational Situation, now and into the future. There is a talk that Smelter Operations
may cease completely.
What routine inspection reports, monitoring records or maintenance records was available for
evaluation? There were no records available. __
Is everybody ready to implement the Emergency Plan? Probably not, as smelter operations are at
skeleton staff level.

SECTION 13: POLLUTIONCONTROL DAMS

How is ground water and surface water quality monitored around the dam? Groundwater
monitoring is not taking place.
How many times did the dam spill during the last five years? No spillage occurred.
Will the dam be able to hold a 1:50 year flood without spilling? Yes, if operated at the right level,
which it is not at the moment. There does however not appear to be a coherent plan in place to achieve
this.
Evaluation of the effectiveness of the dam to prevent pollution of ground and surface water
Under normal conditions there does not appear to be a problem, both ground and surface water. Under
extreme flooding, spillage is likely and surface water will be polluted. It is therefore necessary to
relook at the water balance and come up with proposals as to how this should be dealt with. This then
needs to be incorporated into the Operations and Maintenance Manual.
SECTION 14: OTHER FINDINGS
The deposition of sediment below the eastern stormwater canal brought down from the reworked ore
residue, has cause significance damage to the plastic lining at this point. See photo 6. It is likely that
this is still the same stuff, just added to by subsequent storms since the 2010 inspection. To remove this
sediment, means that a large area of plastic lining will have to be sacrificed, to be reinstated
afterwards. This work is now urgently required.
It is however quite clear that runoff from the discard ore dump now being reworked, will continue to
bring down excessive volumes of sediment. See photos 12 and 13. Once the ore has been remined and
the dumps rehabilitated, the situation will improve. It is also clear that the silt trap below this middle
canal is way too small for the sediment being carried down. Alternatively, some protection work must
be carried out at the ore dump to prevent excessive erosion there.
Looking at the silt trap for the eastern canal (Photo 14) it is clear that it is not being cleaned often
enough. It is too full, resulting in high velocity through it, causing only the coarser material to settle
and all fines to be washed into the dam. The visible silt deposition looks very coarse. It is
recommended that these silt traps be cleared more often, preferably a few times after rain in the rainy
season.
SECTION 15: LIST OF APPENDICES
Item
Appendix
Site plan / Locality plan
Recent Surveys as required by Regulation 35 (5)
Selected Design / Completion Drawings
Photos
Spillway discharge curve / table / formula
Area capacity curves / tables
Inflow / Outflow Hydrographs
Instrumentation graphs
Google Earth Dam Layout
Position and Direction of Photos

N Comments

Crest long section

X

X
X
X

SECTION 16: RECOMMENDATIONS OF PREVIOUS DAM SAFETY EVALUATION BY AN

APP
Date of previous evaluation _2010/08/31_____________ Name of APP __Mr G.P Steyn_______
List of previous recommendations and status of implementation.
No. Recommendations
Compile rules to ensure dam water level maintained at
3m or more below crest level.
1

Status
Not Done

Repair tears in HDPE Liner

Done

Repair Rodent Burrows

Done

Remove debris at northern canal inlet

Not Done

Repair/replace gratings covering silt traps in canals

Done

Compile Operation and Maintenance Manual

Done

SECTION 17: RECOMMENDATIONS OF THIS DAM SAFETY EVALUATION

Recommendations for maintenance, regular routine inspections, monitoring, further
investigations, rehabilitation must be included.
No. Recommendations
Perform water balance for current and future scenarios in order to determine dam operational
rules for compliance with the Regulation of Notice 704 of 4 June 1999.The possibility of
1
incorporating the River Dam across the valley in such operating rules, can be considered.
Include the operating rules determined above in the Operation and Maintenance Plan and
submit that with the existing Emergence Response Plan, to the Dam Safety Office for
2
approval.
3
Proceed to construct a spillway for the dam based on the results of the Operational Rules
determined above.
4
Repair all tears and punctures in the dam lines at the same time also inspecting and repairing
as necessary, the existing liner repairs.
5
Remove the sediment deposit below the northern stormwater canal. Afterwards repair/replace
the dam liner over the affected area.
6
Investigate means whereby the sediment ingress into the dam from the northern stormwater
canal can be reduced.
7
The silt traps should be cleaned of sediment more regularly.
8

Investigate means whereby the leakage rake into the drainage system can be measured and
monitored.

___________________________________________________
SIGNATURE (APPROVED PROFESSIONAL PERSON):

______________________
DATE: