By Tanya Olckers with technical input from Vic Ball Plumbers and Marnus Pretorius, Wet Services Engineer
A new 88-bed private hospital in Malmesbury in the Cape was designed to be as efficient as possible while keeping budget as well as operating costs in mind.

Tank levels for treated and potable water were also included in the dashboard. All images supplied by WFP Consulting Engineers
Crest Care is a group of private hospitals aiming to bring superior healthcare to their patients. With the building of their new Malmesbury facility, water and plumbing were high on their list as it related to water supply and pumping systems through to drainage, types of soil and waste drainage materials and systems to be used as well as hot water generation and hot water return circulation.
The work included a below ground drainage and a conventional stormwater system. Twin City Properties acted as the developer while Crest Care was the client. The initial site handover occurred on 14 November 2022, with the principal contractor’s final completion slated for 16 July 2024. The project scope included designing wet services covering plumbing, drainage, hot water generation, a deionised water treatment plant, domestic water storage and water booster pumps.
The above ground drainage was created with PVC while the water reticulation made use of CU Class ‘1’ pipe. All hot water and hot water return piping was insulated to prevent heat loss, and design was engineered to provide minimum lengths for hot water dead legs.
The hospital features medical suites, radiology, maternity, pediatrics, ICU, MRI, surgical facilities, pathology, and other services available on the website. Drainage systems utilised PVC-u piping, while domestic water supply used copper class 1. The deionised water supply, for specialised medical equipment such as scope and bottle washers, used Geberit Mepla multi-layer piping, with the DI water treatment plant installed by UCS Services. The hot water plant comprised two
6 500-litre heat accumulators supplied by IEES, with GreenBro 50kW heat pumps, and energy-efficient Wilo Stratos Pico/1-6 hot water return circulation pumps.
In a move that could be seen as counter-intuitive, the hot water loop did not follow the most direct path to the point of use. Instead, a ring feed was snaked through the building to minimise dead legs. This was also part of the overall spec provided for hot water delivery at point of use. This means that the waiting time for hot water at any draw-off point is less than eight seconds. The system maintains temperatures above 50°C at all draw-off points within the intended design waiting times.

Tank system.
A plant area that included the hot water generation plant was created and consists of heat pumps with thermocubes and circulation pumps. A water storage tank with booster pumps and deionising water treatment plant were also included. The cold water was separated into two ring feeds to feed the ground and first floors.
The architectural design and layout of fixtures, ablutions and kitchens guided the drainage system’s implementation. All waste fixtures were drained separately to the building’s perimeter, where they discharged into purpose-built brick gullies. These gullies were designed to accommodate multiple waste pipes at different invert levels and angles while complying with discharge and overflow gully regulations. No underground connections were made inside the hospital’s footprint, which increased the length of underground piping but reduced the risk of blockages. Special care was taken to ensure adequate venting and to enlarge waste discharge pipes where necessary and in accordance with SANS regulations.
Energy efficiency was prioritised in all pumping and heating systems, and design criteria were established based on occupancy class and client needs. Water demand was calculated based on fixture types and peak demand factors, as per SANS 10252 Part 1, and included domestic water storage and booster pump specifications. Drainage systems followed SANS 10252 Part 2 and incorporated local design regulations.

Closer view of the system.
Where ablutions were centrally located, special recessed plumbing ducts were designed to connect soil and waste fittings to a single accessible branch pipe. The ducts were filled with river sand to facilitate future maintenance without disrupting the concrete structure. Coordination between architectural design and other services was crucial, especially with limited ceiling void space for drainage, HVAC, water supply, rainwater and electrical systems.
Smart water meters were installed, linked to an online platform for real-time water usage monitoring. The system included irregular flow alarms to detect leaks, contributing to water conservation. Energy-efficient DAB Easybox Max booster pumps were specified, with integrated control panels and Wi-Fi for alarm monitoring. The booster pumps could adjust flow rates during peak demand times to optimise energy consumption.

Neatly wired.
The telemetry system provided comprehensive monitoring of the water treatment plant, including mains voltage, signal strength, water meter consumption, booster pump pressure and graphical representations of key equipment. Tank levels for treated and potable water were also included in the dashboard, allowing facilities management to monitor and manage the system efficiently.
The most challenging aspect of the project was the coordination of services in ceiling voids. This coordination was particularly challenging above the radiology department, as no services were allowed over this sensitive area.
The single greatest challenge the team encountered was time. However, because of a strong team and cohesive team work along with backing from suppliers, the building was completed in the designated timeframe.