Ngezi Portal 3 – 13000t Stockpile Cover

The structural design of the Ngezi Portal 3 was completed by FL Smidth. Appointed by the Client, Zimbabwe Platinum Mines (Pvt) Ltd. ZIMPLATS is one of the three Platinum mines in Zimbabwe with a total of five mines in production, and the sixth mine in the construction phase. 

The structure consisted of twelve main boxed gantries, 2.5m deep x 2m wide x 54m long. The twelve boxed gantries are welded to base plates on the concrete plinths at the base and bolted to a 7m dia center ring at the top.  This structure covered the Mine’s main ROM stockpile with a capacity of 13 000t. All work was carried out around the already-installed Stockpile Feed Conveyor. The Mine and Stockpile Feed Conveyor continued to operate during night shift operation throughout the installation period. Safety measures were of paramount importance as the Mine enjoys an excellent safety record. 

Shop Detailing 

Shop detailing was completed in Tekla. Detailing and model reviews were done at regular intervals to ensure the design intent was understood and carried into the shop detail drawings. 

Constructability Reviews 

During the shop detailing phase, numerous meetings were held to optimize the constructability of the structure. Safety of the site installation crew was of prime importance, with access walkways being added to ensure their safe transit up and down the structure during installation. 

Trial Assembly 

During the constructability reviews, a few concerns regarding the installation sequence were highlighted by the team. A decision was taken to trial assemble two main gantries with the lattice and infill steelwork between the two. The trial assembly was completed without a single modification having to be made. Trial assembly was assembled and disassembled in two weeks. Once the trial assembly was completed, the green light was given for full production to proceed. 


Manufacturing was done at Viva Engineering’s workshop in Spartan, Kempton Park.  

The CNC and preparation department cut their teeth on the structure and were excited to make use of the newly acquired FICEP SP16T6 CNC Anglematic which had been commissioned two weeks prior. This machine worked its way through the structure and resulted in the CNC department completing material preparation three weeks ahead of internal planning.  Repetitive gantry sides were assembled in jigs which were inspected and signed off by Viva’s Quality Department before assembly work started.  Welding Process utilized was GMAW and was done with the AMIGG 500PM pulse arch welding machines, resulting in superior weld quality with 90% less spatter and minimal cleaning. 

Cross-Border Exports and Logistics 

The structures were expertly packed by the Viva dispatch and logistics team, ensuring that the structures were safely secured and vehicles across the border were optimized. In total there were 31 vehicles dispatched to site. Vehicles were cleared through Beitbridge Border post and on average were on site within nine days from dispatch.  The center ring, whilst split, fell outside normal transport gauge and needed abnormal transport to site. 


Installation on site at Bimha Mine, Ngezi, Zimbabwe, was carried out by Hogarths Engineering; a Bulawayo based Structural/Mechanical Engineering Company. 

Erection Sequence 

Overall, three cranes were used during installation – 250t, 90t and 55t units.  Initially, large base plates were bolted onto the cast-in plates, on top of the concrete plinths. The erected gantries would be welded to these base plates once levels were checked and confirmed. The 12 main gantries were pre-assembled on the ground in positions convenient for lifting. The 90t lattice boom crane was positioned on top of the stockpile, where it lifted in and held the center ring in position ready to receive the main gantries. 

The twelve gantries were lifted into position by the 250t crane and bolted to the center ring being held by the 90t crane. This crane continued to hold the center ring whilst intermediate cross gantries, bracing and purlins were lifted in and fitted. Both the 150t and 55t cranes were in service feeding these members. Overall installation of steelwork took 3.5 months, with completion in early December 2019. No major site alterations or repairs were necessary.  Thankfully there were no safety incidents during the installation period. 


Roof Sheeting is 0.8 IBR Chromadek, Traffic Green colour. Total is 5500 square meters, with 8000 fixings. Sheeting installation started shortly after the first three bays of steelwork were completed. Completion of the sheeting was a week after completion of the steelwork. 

ISO 9001-2015 (Certification body – TUV) 

Viva Engineering obtained their ISO Certification in August 2019 and Hogarths in February 2020. Certification was at the same time as this work was being completed in our workshop and site, showing that simultaneous production and continuous improvement initiatives are possible. 

Key Points 

Structural mass – 380T 

Radius – 50.2m 

Diameter / Distance between supports – 100.4m 

Coverage – 7 914m2 

Top of structure height – 36.520m 


Northgate Dome – 11 000m2 

Viva Engineering and Hogarths Partnership 

The Viva-Hogarths partnership was formed in 2010. Since then, this partnership has developed into a dynamic and energetic partnership which has successfully completed a number of complex projects in Zimbabwe over the last 10 years. This partnership is of great value to clients looking to execute turnkey supply and installation work in Zimbabwe. 

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Completion date of steelwork Last load to site 01/07/2019
Completion date of full project December 2019
Tonnage and steel profiles used 380t 



Project Team Role Company
Nominator Viva Steelfab Engineering
Client/ Developer Zimbabwe Platinum Mines
Structural Engineer FLSmidth
Quantity Surveyor  
Project Manager  
Main Contractor Hogarths Engineering
Steelwork Contractor Viva Steelfab Engineering
Steel Erector Hogarths Engineering
Cladding Manufacturer ClassEcon Roofing & Tiles
Cladding Supplier ClassEcon Roofing & Tiles
Cladding Contractor PWR Roofing Services
Galvanising Monoweld Galvanizers
Paintwork Contractor  
Photographer, Photo competition  
Photographer, Other submitted images  

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Corruseal New Offices and Warehouse , Boksburg

Corruseal planned to build the new corrugated cardboard facility along similar lines to the facility it has in Cape Town. This Boksburg facility was planned to be a Phase 1 development with a view to adding to it at a later date.

This initial phase of the factory was built on a greenfield site and would cover an area of over 41 000m2 excluding the gatehouse. The factory required large minimally obstructed spaces to accommodate the production lines and to move materials. It was decided to have columns on a grid spacing of 25 x 13.5 metres throughout. The minimum clear height on the eaves of the production area was set at 9.0 metres. The clients brief included for 1.5 metre high roof monitors to incorporate translucent sheeting and smoke ventilation. Roof loading was required to support a future PV installation.

Why steel?

The project had a fast track construction program of some 6 months so the choice of a structural steel warehouse frame was the obvious choice. The detail of the roof configuration and type of columns was dictated by construction time pressures and practical constructability considerations.

A brief description of the structural framing

The main elements included 25 metre span trusses (or rafters) at 6.75 metre centres which were supported on girders spanning 13.5 metres. The internal footprint of the factory extended some 121 x 175 metres with no obstructing bracing in the production floor areas. All bracing was thus to be located in the perimeter walls. The lower portion of the perimeter walls were to have precast RC panels (varying between 1.5m and 2.1m high) with cladding above the precast walls to the eaves. Alternating translucent cladding strips were included   in the vertical walls to suit the architects’ requirements.

The design of the 25 meter spanning elements compared lattice trusses versus    cellular beam rafters. These elements also had to be fabricated with a 500 metre   “top chord” radius to suit the roof profile. The trusses designed with a 1.5m depth  (with continuity over the girder supports) proved to be a significantly more economical design. The trusses were designed with parallel chords and lacing. Sections selected were all various sizes of hot-rolled angles with gusset plates at  node connections. The 500m radiused chord was easily achieved in this form.

Cold formed lipped channel purlins at 1.562m centres were required to support the sprung effect of the curved roof cladding. The truss bottom chord was braced with hot rolled angle knee braces bolted to the purlins.

 The roof monitors stand 1.5 meters high x 6.75 metres wide (truss to truss). This sub-frame was constructed out of cold formed lipped channel sections (175 x 75 x 20 x 2.5) with knee bracing off the truss to control wind loading on the monitor.

The 13.5 metre spanning x 1.5 metre deep girders supporting every alternate truss were designed with hot-rolled channel sections on the top and bottom chords and hot rolled angles for the lacing. The selection of channel sections (with flat face horizontal) provided an efficient compression strut without requiring addition lateral bracing. The lacing was connected to the channels with welded gusset plates located on the channel centre line. The girders were designed to   be continuous over the supports thus providing further economy of section  weight.

Fabrication and erection

The main challenge on this project was the program.

In order to meet the required delivery dates the footprint of the roof structure was divided into a number of zones that matched the sequence that the structure was to be erected in and allowed for the envelope of the building to be closed in a phased manner. This ensured that all the steelwork in each zone was fabricated ready for delivery when required which allowed the installation to be completed and handed over for sheeting early in the program.

The erection process was also carefully looked at so as to pre-assemble as much of the steelwork onto the roof trusses at ground level before hoisting so as to minimise the installation of the smalls in the air which is always time consuming.

 This method of construction thus allowed the follow-on contractors access to the enclosed structure at an early stage in the construction and enabled the savings on the program to be maximised.


The roof sheets were rolled directly onto the roof using a scaffold tower ramp and due to their length required the attendance of a large number of workmen to handle the sheets.

To control the effect of thermal expansion / contraction, the 175m roof cladding length was divided into thirds with the upstream sheet riding over the downstream sheet with a double purlin detail as advised by the cladding specialist sub-contractor.

The skylight roofs however have full length sheets 150m. long which was also decided by the cladding specialist sub-contractor.

How the project team worked together

This project was built with such speed and efficiency that it required a team of professionals, contractors and specialist subcontractors who had experience with similar projects. This experience is critical in order to plan and execute all the activities to merge towards the phased completion dates of the different component parts of the project. The 3D structural shop drawings were very professionally undertaken by an experienced and dedicated operator. This set the critical structural steel component of the project onto a winning footing. 

How this project demonstrates the benefits of steel

The building of a roof structure of this size in the time that was allowed could have only been done in steel and shows that steel is the material of choice when it comes to factory and warehouse roofs. A curved roof of this size is really impressive when viewed from the outside and  is a testament to what can be achieved with steelwork when suitable planning is employed.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Physical address of the project    


Street Address  



Cnr. Atlas & Commissioner Roads , Boksburg. 
Google Maps link   

Completion date of steelwork  September 2019 
Completion date of full project  December 2019 
Tonnage and steel profiles used  820 ton : Hot rolled columns , beams , angles , tubes , Cold rolled purlins & girts. 

Project Team Role Company
Nominator TASS Engineering P/L
Client/ Developer Corruseal Group
Architect ZAARC
Structural Engineer Kantey & Templer
Engineer Kantey & Templer
Quantity Surveyor Corruseal Group
Project Manager Corruseal Group
Main Contractor Abbeydale Construction
Steelwork Contractor TASS Engineering P/L
Steel Erector THLN Construction
Cladding Manufacturer SAFAL Steel
Cladding Supplier SAFINTRA South Africa (Pty) Ltd
Cladding Contractor Tate & Nicholson
Corrosion Protection  
Corrosion Protection  
Paintwork Contractor DRAM Industrial Painters
Photographer, Photo competition Peter Hassall Photography

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

CLADDING (If applicable) 
Completion date of cladding  October 2019 
Cladding profile/ type used  Roof : Saflok Zincal AZ150 / Sides : Widedek Colorplus AZ150 
Cladding area coverage   Roof : 42,000m2  ,  Sides : 10,000m2 


ABinBEV in Sagamu

SAB Miller, prior to its takeover by ABInBev, identified the need for a new brewery in Nigeria and selected a site in Sagamu located approximately 60 km north-east of Lagos.  The initial brewery size was for 1.8 mega hectolitres, however, shortly after commencing with the design work, the decision was made by ABInBev to proceed with design work for a revised capacity of 3.2 mega hectolitres.   


Structural steel as choice of building material

The 3.2 mega hectolitre brewery is approximately 41 000 m² in building area consisting of a number of different buildings, e.g. packhall, brewhouse, engine room, CHP & boiler house, full-bottle store, administration buildings.

With the inherent flexibility that structural steel offers, combined with the main buildings all having requirements for large clear spans, some in excess of 32m, in order to accommodate the respective equipment, steel was the clear choice of construction material. Structural steel provided the various buildings on the project with an ability to absorb inevitable late design changes associated with a project of this type. In particular, the structural steel facades of four of the buildings, earmarked for future expansion at the outset of the project, provided the perfect flexibility required in the structure at the time of various expansions.

The steel grade that was available locally was 275 MPa and prior to commencement of the revised design, a list of section sizes available from the Nigeria market was obtained and utilised in the design.  During the review of shop drawings, some of the section sizes were no longer available requiring a design check of the structural elements to find suitable alternatives.  In most instances, the result was a heavier section having to be used. 

Value engineering was a key consideration in the design and fine-tuning was required wherever savings could be realised. For example, a decision was taken to provide additional columns in one section of the packhall building, which meant that instead of a girder with trusses connecting to the girder as per the main design rationale, the girder could be removed and the trusses then connected directly to the columns.  This resulted in a significant saving in the overall steel weight of the structure.

Other steel buildings and components include:

  • 240 m2 four-storey malt intake tower consisting of steel composite floors
  • 875 m2 five-storey sorghum intake tower consisting of steel composite floors
  • 2016 m2 seven-storey mill tower consisting of steel composite floors
  • Covered gatehouse entrance in steel approximately 890 m²
  • 600 m of steel pipe bridges
  • 400 m of covered pedestrian walkways
  • 56 m2 tyre store
  • 787.5 m2 keg Store
  • 387.5 m2 hops store
  • 2326 m2 generation and boiler warehouse
  • 4950 m2 brew house and cold block
  • 1575 m2 engine room
  • 480 m2 forklift workshop
  • 1335 m2 amenities building
  • 155 m2 induction building
  • 477 m2 empty bottle store canopy
  • 351 m2 water treatment plant
  • Steel supporting members for safety lines, which became a requirement from ABInBev during the construction stage of the project.


In spite of its limited local availability, structural steel was the ideal choice for the Sagamu Brewery project, providing the flexibility to deal with various design expansions and the solutions for large clear span elements.

The use of steel, combined with good collaboration between the architect, the structural engineer, the rest of the professional team and the contractor, has created a structure that will be economically efficient and meet the requirements of the client for resilient, sustainable design.  Aurecon is proud to be associated with a project of this calibre.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Physical address of the project
Street Address
Abeokuta-Sagamu Expressway
Ogun State
Google Maps link

Completion date of steelwork Feb 2019
Completion date of full project May 2019
Tonnage and steel profiles used 2900 tons
Cost of steelwork   NGN 1,795,735,245.00 = 4.9 Million USD

Project Team Role Company
Nominator Aurecon Consulting Engineers
Client/ Developer ABInBev
Architect PPS Architects (Pty) Ltd
Structural Engineer Aurecon Consulting Engineers
Quantity Surveyor De Leeuw Group
Main Contractor Vita Construction
Steelwork Contractor Vita Construction
Steel Erector Vita Construction
Cladding Manufacturer Vita Construction
Cladding Contractor Vita Construction
Galvanising Vita Construction
Paintwork Contractor Vita Construction

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Sappi Saiccor Woodyard Upgrade – Conveyor System

A complete woodchip conveying package supplied by TAKRAF Africa to Sappi’s Saiccor mill in Umkomaas, KwaZulu-Natal, South Africa, featured a unique four-conveyor, double-decker, walk-in type gallery, with the gantry bridge spanning 45 m, at a height of 24 m, over the existing Sulphur plant. The double-decker gantry houses the four conveyors in a 2 (top deck) + 2 (bottom deck) arrangement.

This double-decker design, together with other innovative design and technical features, enabled TAKRAF Africa to produce a successful solution within the severely confined space of the brownfields site and integrate it into the existing mill infrastructure.

The woodchip conveying package, the Sappi Saiccor Woodyard Upgrade (SSWU), handles increased production made possible by expansion to the Saiccor mill from 780 000 tpa to 890 000 tpa.

The package conveys woodchips from existing and new chipping lines to feed two new stockpiles at up to 680 tph. Using four screw reclaimers (from another OEM) and associated conveyors, woodchips are reclaimed from the stockpiles at a maximum 403 tph and conveyed to existing infeed digestor conveyors to feed existing silos.

The package covered design, engineering, installation and commissioning of 24 trough conveyors, 10 m to approximately 200 m long and some with incline angles of 19°; three Redler en-masse chain conveyors; transfer towers; and related systems. Conveying capacities range from 5 tph to 806 tph and belt speeds from 1.5 m/s to 2.8 m/s.

Technical and aesthetic highlights

The project incorporated ground-breaking steel structures, the most impressive being the double-decker gallery and large spanning stockpile gantries. Gantry G1 (weighing 72 tonnes), for example, spans 45 m over the plant. This is rarely done in conveying applications.

Consideration of structural framing and stability of gantries during engineering enabled lifting the double-decker gantries into position without interference with the existing plant. The head-end gantry G3, spanning over a Blower Building, was the largest lift, weighing over 85 tonnes.

The stockyard consists of A-frame support trestles, which transfer large forces from stockpile gantries to piled foundations. The trestle baseplates are considered as pinned connections to ensure that the A-frames only transfer axial forces to the foundations.

With reference to the cladding, while most of the 13 600 m2 used was fabricated from aluminium and painted blue to aesthetically match the existing plant, the double-decker conveyors were clad with stainless steel sheeting as protection from the corrosive environment. The structures were assembled, lifted and fixed into position without cladding to prevent damage to the latter. Most of the cladding was therefore installed at height, with structures reaching 35 m high.

Other innovative features include three reversible conveyors feeding two reversible shuttle conveyors to convey material to either of two stockpiles from the different chipping lines. Chutes were designed using DEM technology, as woodchips tend to exhibit airborne behaviour at certain velocities. Stockpile stacking is done by automated zone control with equal spreading of different wood species.

The bypass system from the stacking route to the reclaim conveyors, used if a reclaim machine is undergoing maintenance or in case of unplanned downtime, has a self-supported pipe design requiring no intermediate trestle support. A bypass plough mechanism diverts material temporarily from the existing chipping line to a newly supplied conveyor.

Redler conveyors convey fines generated by the screening system. Besides their ability to fit in with restricted layouts and space, their multiple discharges facilitate building of a “conshelled type” stockpile and assist in loading a truck evenly.


Structural steel fabrication is the norm in the bulk materials handling industry, providing conveying systems with the durability and strength to withstand harsh weather and heavy industrial use.

Structural steel also offers flexibility to the structural design engineer. This is evident in the various different framing systems that were utilized on the project to deliver intricate solutions in the restrictive constraints of the layouts and existing infrastructure.
Additionally, the strength per mass ratio of steel allows design of structures that can be lifted into position after pre-fabrication and assembly, as with the double-decker gallery and woodpile galleries.

In total, structural steel of approximately 1 700 tons was designed, fabricated and installed within a 12-month project duration. All hot-rolled structural steel profiles were rolled and fabricated in South Africa.

Due to the short timeline, fabrication was split between local South African fabricators. Structural detailing and fabrication companies were selected early in the project to assess their capabilities in manufacturing timelines and prevent ‘overloading’. Availability of certain section sizes was a key element, with four structural detailing, five structural fabrication and one dedicated flooring and hand railing company(ies) used.

Structural framing

Conveyor gantries and galleries have trussed sides and tops and bottoms. Each conveyor gantry is portalized at the trestles to transfer lateral forces in the top chords to the trestles.

Two types of trestles support the 45 m spanning woodpile galleries in the stockyard: Type A trestles resist vertical, horizontal and longitudinal forces on the galleries, while Type B trestles resist vertical and horizontal forces to reduce the effect of thermal movement.

Due to constrained interfaces and limited space, a conventional transfer tower at the head-end was not possible. A transfer gantry concept was therefore developed to ensure conveyor system stability by transferring all longitudinal belt and wind forces on the conveyor back to an anchor trestle. This is typical on the reclaim, double-decker and incline conveyors. The incline conveyors have sliding joints at the top trestle joining to the gallery to ensure longitudinal forces are transferred to the anchor trestle and not the gallery. The transfer towers are traditional braced and portalized structures.


As this was an operational plant, certain tie-ins had to be completed during limited shutdown windows, while also interfacing with new and existing Civils and LPS power supply services. Client involvement in construction meetings ensured access for pre-assembly and lifting with minimal disruption to other construction activities. More than 50 % of construction was completed next to existing plant operations. Some big lifts were completed early morning or late afternoon to reduce impact on other construction activities.


As the fast-track contract called for precise planning, the project team was aligned at the project start. Dedicated teams were set up for the basic design and the project was internally planned in three areas to allocate engineering responsibilities to mechanical and structural teams and drawing office section leaders. ‘Design base / criteria’ ensured that the structural team worked on the same baseline for the relevant loading criteria.

The quality assurance and control team provided effective communication with workshops to ensure no repeat inspections, while inclusion of the project manager in the engineering team’s daily meetings facilitated project scheduling.
Safety was a critical consideration from the start, and particularly so during execution, with challenges such as working at height and working in a very confined, brownfields site. Due to the project team’s safety focus, the project was closed out successfully with only one lost time injury (LTI).



Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Physical address of the project Street Address

Umkomanzi Drift
Google Maps link,30.7709497,15z/data=!4m5!3m4!1s0x0:0xf89ed4af015a3a0f!8m2!3d-30.180527!4d30.7709497  
Completion date of steelworkMARCH 2019
Completion date of full projectMAY 2019
Tonnage and steel profiles used1600
Project Team 
Client/ DeveloperSappi Pty Ltd – Saiccor Operations
Architect  / Clients Engineer / Owners EngineerSIVEST
Structural EngineerTAKRAF
Mechanical EngineerTAKRAF
Drawing OfficeTAKRAF
External Drawing officeAtomic Projects
External Drawing officeCad House
Quantity Surveyorn/a
Steelwork ContractorLouwill
Steelwork ContractorQR Steel
Steelwork ContractorImpact Engineering
Steelwork ContractorAvellini Brothers
Steelwork ContractorFP Engineering
Steelwork ContractorCoertzen Engineering Consultants
Steel ErectorTlotlo
Cladding ManufacturerGlobal Roofing Solutions – A division of Consolidated Steel Industries (Pty) Ltd
Cladding SupplierGlobal Roofing Solutions – A division of Consolidated Steel Industries (Pty) Ltd
Cladding ContractorTlotlo
Corrosion ProtectionRand Sandblasting Projects
Paintwork ContractorRand Sandblasting Projects
Paintwork ContractorLouwill Engineering (Pty) Ltd
Paintwork ContractorQR Steel
Paintwork ContractorImpact Engineering CC
Paintwork ContractorCoertzen Engineering Consultants
Photographer, Photo competitionUNPRECEDENTED Pictures
Photographer, Other submitted imagesUNPRECEDENTED Pictures
CLADDING (If applicable)
Completion date of claddingMARCH 2019
Cladding profile/ type usedIBR686
Cladding area coverage 13600m²
Cladding tonnage84,76 tonne

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Vamosem Semi Mobile Crushing Plant


The project entailed the fabrication of complete mobile crushing plant for a mine in Mozambique

Reason why steel (hot rolled/ lightweight/ tubular/ cellular/ Platework) was chosen:

Steel/Platework was chosen as the material of construction due to the industrial nature of the project.

What is special/ unusual/ innovative/ aesthetic about the steelwork/plate work/cladding in this project?

This SMC plant was detailed, fabricated by local South African companies which really showcases the level of experience and expertise that South Africa has.

Green building rating/environmental or sustainability considerations

At Betterect’s fabrication facility in Chamdor Krugersdorp, environmental concerns are kept in the forefront of our minds. All offcuts of steel are collected and recycled.

Special considerations such as the design process, fabrication, transport, and erection

The design of the SMC Plant was undertaken by ThyssenKrupp Germany, however, the detailing of the steelwork/plate work was undertaken by Betterect. The project included the fabrication of over 1 000 parts totaling to close to 950 tons of steelwork, plate work, grating, and hand railing and the pre-assembly thereof.

The fabrication of this steelwork/plate work was extremely labour intensive and required the strictest quality requirements as all welds required 100% non-destructive testing and needed to pass either radiographic or ultrasonic testing. The reason for such high-quality standards was due to the enormous loads/tonnages placed on the steelwork/plate work during operation at the mine in Mozambique.

There were many technical fabrication requirements which included preheating, welding of exotic materials, laser alignment, heavy lifts and more. The steelwork was painted with an industrial three-coat paint specification to withstand the grueling exposure to elements and operational requirements.

The hopper base frame weighed close to 45 tons and required abnormal transport loads to the site, which included police escorts in some area on route to the site due to the size of the equipment.

Challenges and solutions

The large number of loose parts and the uncompromising level of quality were challenges faced on the project.

Satisfaction/ testimony of the client

This was a technically challenging project due to the stringent NDT requirements and the quality level of the fabrication by Betterect was extremely high. Overall, it was a successful project with the equipment currently in operation.

What makes your entry special and different from other entries that may be in your category?

This project was truly a South African Engineering accomplishment and showed the world the capabilities of our fabricators and design houses.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Physical address of the project Street Address
Moatize Coal Mine,
Google Maps link  

Completion date of steelwork 12th December 2019
Completion date of full project 12th December 2019
Tonnage and steel profiles used 920 tons

Project Team Role Company
Nominator Betterect
Client/ Developer ThyssenKrupp Industrial Solutions
Structural Engineer  ThyssenKrupp Industrial Solutions
Steelwork Contractor Betterect
Cladding Manufacturer Global Roofing
Cladding Supplier Global Roofing
Cladding Contractor Global Roofing
Paintwork Contractor Betterect

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Wisium SA (Pty) Ltd – Relocation and extension of Mixing Plant in Brits Industrial

In the difficult financial climate that we as South Africans find ourselves, this is a brilliant example of how steel can innovatively be used to assist the growth of a company while keeping the costs much lower than expected.

Imagine a redundant feed plant standing in Pretoria West on Epol Dog Foods Plant. They have this 80t Tower Feed Mill Building which is no longer in use. On the other hand, you have Wisium SA an Animal Nutrition company who needs to build a state of the art new plant to accommodate their growth. Can you imagine buying a building in Pretoria West and bringing it to Brits? Well with Steel this was made possible!

Ferro Eleganza was appointed and given this exciting challange. But dismantling a building that was decades old was no easy task and safety was a huge concern for us. We began by removing all roof and then side cladding with its insulation. This was carefully done with cherrie pickers and mobile cranes to enable safe working. All steel members were then marked with item numbers according to a general arrangement to enable re-assembly later. Then according to well-planned method statements the steel structure was carefully dismantled in the opposite sequence that it would have been erected.All steel was then pressure cleaned to remove Epol’s food dust and transported to its new home in Wisium Brits.

Steelwork Contractor Interview:

This building needed to be modified in just a few places and also extended to accommodate the new feedmill design. Tekla Structures was the perfect tool to be able to do this detailing. Importing the existing building and adding the new extensions enabled minimum modifications to selected items of the building. Ready to receive the newly build steelwork from the factory.

Once the building was completely erected together with the additional extensions the entire building was given a final coat of paint. Giving the client a brand new steel structure.

The building was finally clad with new sheeting and the client boasted a beautiful new state of the art Feed Mill.

A very happy client celebrated this new plant with his industry in a grand opening.

Ferro Eleganza is privileged and proud to have been part of this innovative use of steel!

Completion date of steelwork June 2018
Completion date of full project June 2018
Tons of structural steel used Tons
Structural profiles used Hot Rolled Steel / C/R Lipped Channel


Completion date of cladding June 2018
Cladding profile/ type used IBR Chromadek®
Coil Manufacturer ArcelorMittal South Africa
Nominator Ferro Eleganza (Pty) Ltd
Main Contractor Techmach Technology (Pty) Ltd
Steelwork Contractor Ferro Eleganza (Pty) Ltd
Steel Erector Ferro Eleganza (Pty) Ltd
Cladding Contractor Ferro Eleganza (Pty) Ltd
Corrosion Protection
Paintwork Contractor
Dram Industrial Painting Contractors

Mafube Colliery Nooitgedacht Mine, Middelburg Relocation of EMV Workshop

The relocation of the EMV Workshop building, a large 280-ton industrial building, is a testament to the sustainability and reusability of structural steel. The structure, which was dismantled, moved over 100km and then reassembled, is made up of heavy hot-rolled sections and large “laced columns” carrying heavy 1.8m high plate girders which house a 200 ton overhead crane. This building is used to service and repair large tipper trucks and other large plant used on the mine. There is no way that the relocation of a building of this size could ever have taken place had it not been for the versatility of steel.

The building was situated in the highest Red Zone Safety area. Therefore, to strip off the roof and side cladding, dismantle a large steel structure, with all the highest of mine safety in place was truly a daunting task. The steelwork contractor put together risk assessments, method statements, fall protection plans, and planned that all safety requirements be met.

On this building, even the cladding had to be re-used, which presented a number of challenges. To replace each sheet in exactly the same position, using the same holes for the screws, otherwise, the roof would be full of holes and leak. Each sheet was marked and numbered in order to re-fit it to the same position.

Because there were no existing drawings for the structure, in order to enable marking up and dismantling the steelwork contractor drew the entire building on Tekla Structures. This enabled a marked up general arrangement which was used to mark every piece of steel with cherry pickers before dismantling the steel structure, reversing the sequence that would have been used to erect the building in the first place. The steel was then cleaned and transported to the new site where the mine wanted the building. The steelwork contractors were very proud of the entire relocation and that it took place 100% accident and incident-free. For this accomplishment, Anglo gave their entire team a bonus as recognition of their accomplishment and safe working practice.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Completion date of steelwork October 2018
Completion date of full project December 2018
Tons of structural steel used 280 Tons Relocated
Structural profiles used H/R sections / C/R Lipped channel
Completion date of cladding October 2018
Cladding profile/ type used IBR
Cladding area/ coverage and tonnage All cladding relocated
Nominator Ferro Eleganza (Pty) Ltd
Steelwork Contractor Ferro Eleganza (Pty) Ltd
Steel Erector Ferro Eleganza (Pty) Ltd
Cladding Contractor Ferro Eleganza (Pty) Ltd
Corrosion Protection Galvanising Armco Superlite (Pty) Ltd

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

SA Steel Mills

Steel is the backbone of our industry, and it follows suit as a backbone of infrastructure. Steel provides the strength to keep a building and its components standing from the ground up. SA STEEL MILLS –  I 00 000m2

Benefits achieved by using steel construction

Steel can be used in diverse arrays of applications, both domestic and industrial. The strength to weight ratio assists in cost savings and ensures that the structure will stand the test of time. Quick installation allows for time conservation and readily available labour. Quality is ensured with various guarantees and via the durable nature of steel. Steel is the very DNA of Strength.

Aesthetic appeal

Steel, dependent on the design and customer’s requirement, can be shaped to fit any mould. The versatility, design, and application can make a structural art piece that is appealing to the eye.

Environmental/ Sustainability consideration

Steel is a recyclable resource and can be recycled over and over. By observing the 3 R’s, we reduce, reuse and recycle steel and ensure that our activities are Green, which will, in turn, lower greenhouse gas emissions. Building design & process can harvest maximum sun / solar energy and rain & groundwater that will enable us to use transformative technology to produce steel differently from the global players and make SA Steel Mill the second player in the world to make green steel without (GHG ) greenhouse gases. The steel buildings are designed to create 90,000 sq meter rooftop to place photovoltaic panels on 24degrees to tap solar irradiation. The roof space is enough to produce 55 MVA lowest cost renewable solar power without any Carbon dioxide CO2. The renewable solar power can be stored in large environmentally friendly containerized batteries developed and commercialized by MIT professor. 55 MVA power will enable SA Steel Mill to produce 400,000 tons of green steel by using eco-friendly technology. The plant is operating off the grid for electricity and water supply, where we will ensure that energy is used conservatively and waste is managed by up to 75%.

Innovation in Design Fabrication or construction

Lightweight and high tensile sheeting have been used in the structure. The use of translucent sheeting harnesses daylight and reduces the need for artificial light sources. The total roof area spans across 66 000m2 which allows for rainwater harvesting into our reservoirs. The Plant is a redesign of a standard mill, such that logistical transfer of product converges at a common area of dispatch. This redesign has maintained functionality while lowering overall project costs.

Technical Process Required for Realising the Project

In the execution of construction, we have used LEAN principles from a process standpoint. We have been able to generate value, continually improve and manage our processes and waste, while optimising the entire project from a capital perspective. The Project will then yield a fully automated plant, which employs state of the art technology and reduces human error in the steel manufacturing process.In maximising efficiency, the mill utilises a central Melt Shop, where molten metal is transferred into four mills, obtaining their own applications.

What is the purpose of the structure/project?

This is a steel production plant. Used to house ovens, mills and finished goods.

What was the brief to the Architect?

Design a steel  mill  manufacturing  plant in the   most cost effective way.

Was   the   project  envisaged  in  steel from  the  start?  If  not, why was  it  built  in  steel  in  the end?

Yes, as we are a company grounded in the steel industry.

Give a  brief  description  of  the  structural  framing. What type  of  sections were  used I Beams of various weights have been used, namely the following:

  • 533 X 210 • 406 X 140 • 356 X 171 • 305 X 165 • 305 X I 02 • 254 X 146 • 203 X 133

305 x 305 H Beams • 203 x 203 H Beams • 152 x 152 H Beams

300 x  I 00     Channels  • 152 x 75 Channels

2000 x I 00 Lipped Channels • 150 x 75 Lipped channels • I 00 x 50 Lipped Channels

Give a brief description of the cladding process (complexity, difficulty, innovation etc).

All internal and light-framed buildings are built with a combination of brickwork and steel.

Were there any challenges in the fabrication of the project from the Engineer’s design

As we are a steel company, we have an inventory and supply of steel from other branches in house. We challenged the engineer to construct buildings using the inventory on hand. This task has allowed for us to repurpose old stock and really maximize existing materials. The challenge posed revolved around the load-bearing capacities of the steel from inventory. We have therefore designed the buildings stronger for their applications

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding in this project?

We have used lightweight, high tensile sheeting. We have made use of translucent roof sheeting, which allows for daylight to enter the plant

How did the project team work together (e.g. Contractor involved early, challenges/ease of communication etc.)?

We have a team of dedicated individuals who mind the time and cost constraints of the project. The team is sensitive to work ethic and commitment to doing what is right, rather than what is pleasing. Contractor involvement sought to source the best price, along with the best quality.No project is perfect, nor will they run smoothly, we have certainly had our share of project hiccups, however, we abide by the motto that: “teamwork makes the dream work”.

Completion date of steelwork September 2018 (Phase 1)
Completion date of full project December 2019
Tons of structural steel used 500 tons
Structural profiles used 254×146 I Beam, angles and Lip Channels
Completion date of cladding December 2018 (Phase 1)
Cladding profile/ type used 0.58mm G550 IBR 686 for Roof and Side Cladding
Cladding area/ coverage and tonnage 100 000m2 / 515 Tons
Developer Changing Tides
Architect Changing Tides Architects
Structural Engineer Cassiem Hanse and Associates
Main Contractor Changing Tides 74
Roof Sheeter Changing Tides 74
Quantity Surveyor Changing Tides 74
Cladding Supplier Pro Roof Steel & Tube
Structural Steel Erector Changing Tides 74

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Gamsberg Zinc Project

The Gamsberg Zinc Project is significant in that it will exploit one of the largest known, undeveloped zinc orebodies in the world. It was discovered almost 40 years ago and held undeveloped in the asset portfolios of various mining companies and subsequently, it was acquired from Anglo American by the Vedanta group in 2011. The Project comprises of an open pit mine and a dedicated processing plant.

ELB Engineering Services (Pty) Ltd were appointed as the EPC contractor for the engineering, procurement, construction and commissioning of the 4mtpa Zinc Concentrator, associated infrastructure and bulk infrastructure scope including a 20km overland power line and 30km overland water line and treatment facilities. 

A critical feature of Gamsberg’s development is its approach to biodiversity. The Project is being developed in the ecologically sensitive Succulent Karoo Biome, a designated biodiversity “hotspot” and one of just 35 “biodiversity hotspots” in the world. This has required extensive engagement with key stakeholders – government, NGOs and landowners, – which has resulted in a unique biodiversity offset agreement.

At peak, more than 3,400 people were employed by Vedanta Zinc International and business partners being the peak of Gamsberg’s construction. Around 700 people are currently employed permanently at the Gamsberg mine. Recruitment of local community members – in the first instance from local communities such as Pella, Pofadder and Onseepkans, and then from Namakwa District and the rest of the Northern Cape – was an obligation for all of the business partners working on Gamsberg and a priority for Zinc International itself. Of the people already deployed on the project, more than half are from local communities and the Northern Cape.

What was the brief to the architect?

No architect was involved or engaged on the project specifically for the industrial and mining structures. However, Von Bruun Architects were contracted for the LSFB portions of the project which were specifically the laboratory, change house, canteen and administrative buildings. The brief to the architect was to design and develop a system which could be largely fabricated in works off site, transported to the project works and erected with a minimum of on-site work. Given the high cost of skilled labour and erection on site, there was a material advantage to fabricating as much as possible in workshops off site and to limiting on-site work to the erection of modular units.

Was the project envisaged in steel from the start? If not – why was it built in steel in the end?

Preference was given to the use of structural steel as a structural commodity in the process plant design due to the remoteness of the site and limited construction resources available in the vicinity of the site.

This added value thus resulted in high standards of quality and delivery due to the works being undertaken in the controlled environment of the fabricator’s workshop and also reduced the requirement for site based resources.

Give a brief description of the structural framing. What type of sections were used (e.g. hollow, cellular, I beams etc) and why?

As the steelwork structures on this project covered the full spectrum from light lattice and trussed frames for cable and pipe racking to structures supporting large dynamic loads and overhead traveling cranes, from modular overland conveyor sections to a cantilevered stockpile feed conveyor, the project required the use of a very broad range of hot and cold rolled standard sections as well as made up plate girders.

Give a brief description of the cladding process (complexity, difficulty, innovation etc)

Cladding was used extensively to the roofs of substations, conveyor gantry doghouses, roofs and walls of the filter press building, compressor house and the like. In general, the cladding was conventionally applied IBR-profile 0.58mm.

Give a brief description of the Light Steel Frame Building element of the project. (Notable features/ achievements made possible by LSFB)

Due to the remoteness of the Gamsberg site in the Northern Cape and the limited access to construction materials, a clear strategy was adopted to consider alternative solutions for the construction of all non-process related buildings on the project. Through adopting the LSFB solution of the Assay Laboratory, Administration, Canteen and Changehouse, the site based resource requirements were significantly reduced during the construction period thereby improving the safety of the overall construction activities at the site through minimising congestion and interface management.

The LSFB design philosophy also proved to be more flexible in terms of accommodating late changes brought about by the fast track nature of the project. The inherent prefabricated nature of the LSFB reduced the construction time frame associated with the structural frames and opened up parallel working fronts for the installation of the services accommodated in the wall panels.

Were there any challenges in the fabrication of the project from the engineer’s design – if yes, please tell? Tell more about the fabrication and erection process if it was complex, difficult, innovative etc.

The Engineer designed all of the steel structures which was then issued to the various fabricators who also undertook the detailing work prior to manufacture.

It was incumbent on the Engineer and team to check that the detailing had been undertaken to the relevant codes and practices so as to produce complete shop-detailed fabrication drawings.

Close liaison with the fabricators afforded the Engineer greater control over the quantity and measure of steelwork.

Interfacing the details into the Tekla models resulted in significant time savings to the project.  Conceptual designs in-house, allowed the Engineer to tailor the fabrication of steelwork to suit the erection on site with specific emphasis on minimising small-piece assembly.

The two primary measures of the success of this process are the minimal requirement for site modification of fabricated steelwork and virtually zero interface errors to civil work and mechanical plant, then this process results unequivocally in success.

What is special/ unusual/ innovative/ aesthetic about the steelwork/cladding in this project?

 The project gave great scope to structural designers to carry out innovative and creative work. At the dictate of a somewhat fluid project schedule, designs often had to be adapted to retrofitting or to constructability with restricted access or to speed of fabrication and erection. One particular case in point being the design, detailing and erection (often retrofitting to structures already completed) of pipe and cable racks (latticed and framed or box trussed) as these were to a great extent site-run services which crossed already completed works or vehicle access ways.

How did the project team work together (e.g. contractor involved early, challenges/ ease of communication etc.)

The project setup was unique in that it comprised four distinct centres of execution across the subcontinent, including China, India and South Africa. The centre of gravity moved progressively from Beijing, where the process and basic engineering design was undertaken, Johannesburg where the detailed engineering to South African norms and standards was completed and all procurement undertaken, and finally to the Northern Cape during the construction phase. The engagement and involvement of the Owner’s Engineering team based in India formed an integral communication link throughout the project execution phase. The greatest lesson learnt in terms of communication across continents is the necessity of early engagement and team building across the broader project stakeholders, to gain a better understanding of cultural differences and approaches to engineering solutions and establish a common base of mutual respect and understand early on.   

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Completion date of steelwork Final installation of structural steelwork – September 2018.
Completion date of full project Operational Completion – 6 December 2018.
Tons of structural steel used 2 177t.
Structural profiles used SA hot-rolled sections S355JR:  

·           RSA, RSC, PFC, UB, UC

·           Plate Girders


Cold-formed sections:

·             CRLC purlins & girts


Platework S355JR

·             Chutes, bins, hoppers

Completion date of cladding Approximately October 2018
Cladding profile/ type used 0,56 / 0,8 IBR Chromadek®: Kingfisher Blue N01029
Cladding area/ coverage and tonnage 8 142 m²
Completion date of LSFB work Final building completed in October 2018.
Completion date of full project Operational Completion – 6 December 2018.
Tons of LSF used Approx. 60 tons.
Span of trusses and Kg/m2 (if applicable) Longest span 12m span  

Varies between 18 to 22kg/m2

Profiles used Z200 galvansied 550MPa 0.8mm flat sheet rolled on Framemaster profiler roll-former.
Type of cladding ·           Lamnaboard from Rigifoam with Terraco render  

·           15mm fIrec.heck boards from Knaus.

·           Internal 3mm rhinolite and washable paint.

·           Internal walls 102mm cavity batt from Isover.

·           Roof – 80mm polyurethane by Dalucon on 30mm purlins 0.58mm 550MPa.

Nominator ELB Engineering Services
Client/ Developer Vedanta Resources
Structural Engineer Consultauri
Engineer ELB Engineering Services
Quantity Surveyor CD Venter Land Surveyors
Project Manager ELB Engineering Services
Main Contractor ELB Construction (Pty) Ltd
Steelwork Contractor Louwill Lefa (Pty) Ltd
Steel Erector ELB Construction
Cladding Manufacturer ArcelorMittal South Africa
Cladding Supplier Global Roofing Solutions
Cladding Contractor Abraham Hansen
Corrosion Protection
Paintwork Contractor
Louwill Lefa (Pty) Ltd

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.

Omnia Nitrophosphate plant

Omnia is a diversified chemicals Group that supplies chemicals and specialised services and solutions for the agriculture, mining, and chemical application industries. Differentiation is ensured through using innovation combined with intellectual capital, whereby Omnia adds value for customers at every stage of the supply and service chain. With its vision of leaving a “better world” the Group’s solutions promote the responsible use of chemicals for health, safety and a lower environmental impact, with an increasing shift towards cleaner technologies.

A new Quality Control system was implemented internally at SE Steel Fabrication. All fabrication had to be done with a high level of accuracy, this was essential to prevent steelwork arriving on site and possibly requiring additional remedial work before installation, so a best-fit approach was adopted. Any remedial work may have placed the integrity of the anti-corrosive paintwork at risk in an already corrosive environment.

Limited space was available for steelwork, so a laydown area for steelwork was created approximately one kilometer from the actual site. This being the situation, we placed a 20-tonne crane and a horse and trailer permanently on site while the project was running, to ensure the correct sections and steelwork were being fed to the site. Ultimately to prevent delays, there was a need to plan for tomorrows erection, today, to avoid unnecessary standing time. Executing advanced planning on site allowed us to remain on program.

Full penetration welded, purpose made columns, were used on the Main Plant. 3CR12 was selected for the purlins and girts. The paint specification was a complex sand blasted, epoxy corrosion specification, to ensure the longevity of the steelwork on site.

Numerous safety challenges were faced during the tight deadline to complete erection on this 1200 tonne project. A dedicated Safety Officer was permanently placed on site to ensure all safety compliance was met on our part. This proved effective with a less than 1% accident rate during the entire span of the project, including all trades. This number needs to be taken into consideration, knowing, that there were numerous trades working on multiple levels of the structure, at the same time, the whole time. Up until the full height of +-46m.

Tight spaces as viewed in the pictures submitted, meant that cranes and cherry pickers had to be strategically placed in order to reach all necessary corners and the required heights, again often while other trades were working and the various levels of the structure. This also meant that work was halted while wind condition worsened during the erection process. In total, we had two 44m articulate boom cherry pickers, a 220-tonne, 160-tonne and a 50-tonne crane on site the full duration of the project (this excludes the laydown area machinery as listed above)

Planning, erection and project program was cast in stone with a strict deadline, regardless of the weather that there was no time to be wasted all had to be done in one year from design to fully operational. Installation crews and machinery from Europe were due to install their scope of work to ensure that this strict program was implemented, so we had no choice but to meet each deadline.

Project motivation editorials are provided by the project nominator. If any technical details, company names or product names are incorrect, please notify the SAISC so that the error can be corrected.

Completion date of steelworkFebruary 2019
Completion date of full projectMarch 2019
Tons of structural steel used1200 Tons
 Structural profiles usedUB/UC Columns and Beams Truss and Girder Systems Crane and Crawl Beams Channels   



3CR12 CFLC Purlin and Girts 3CR12 Sag Angles

304 S/S CFLC Girts 304 S/S Sag Angles

Completion date of claddingJanuary 2019
Cladding profile/ type used304 Stainless Steel
Cladding area/ coverage and tonnage± 18,000m²
Project Team RoleCompany
NominatorSE Steel Fabrication (PTY) Ltd
Client/ DeveloperOmnia Fertilizer a division of Omnia Group Pty Ltd
Structural EngineerOmnia Group Pty Ltd – Group Technical Projects
EngineerOmnia Group Pty Ltd – Group Technical Projects
Project ManagerOmnia Group Pty Ltd – Group Technical Projects
Project ManagerSE Steel Fabrication (Pty) Ltd
Main ContractorOmnia Fertilizer a division of Omnia Group Pty Ltd
Steelwork ContractorSE Steel Fabrication (Pty) Ltd
Steel ErectorSE Steel Fabrication (Pty) Ltd
Cladding SupplierM.R.G
Cladding ContractorM.R.G
Corrosion Protection Paintwork ContractorDram Trading
Corrosion Protection Paintwork ContractorRand Sandblasting Projects
Steel DetailerSSD Detailing & Engineering Services
Photographer, Photo competitionPhotography by Micaela
Photographer, Other submitted imagesCedric Brender-A-Brandis
VideographerCedric Brender-A-Brandis
Piping contractorGoss & Balfe

If you were a part of this project, and your company details are incorrect or missing – please notify the SAISC so that the error can be corrected.