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!

STRUCTURAL STEELWORK
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
CLADDING
Completion date of cladding June 2018
Cladding profile/ type used IBR Chromadeck
PROJECT TEAM COMPANY
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.

STRUCTURAL STEELWORK
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
CLADDING
Completion date of cladding October 2018
Cladding profile/ type used IBR
Cladding area/ coverage and tonnage All cladding relocated
PROJECT TEAM ROLE COMPANY
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”.

STRUCTURAL STEELWORK
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
CLADDING
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
PROJECT TEAM COMPANY
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.

STRUCTURAL STEELWORK
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

CLADDING
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
LSFB /  LIGHT STEEL FRAME BUILDING WORK
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.

PROJECT TEAM ROLE COMPANY
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 Arcelor Mittal 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.

STRUCTURAL STEELWORK
Completion date of steelwork February 2019
Completion date of full project March 2019
Tons of structural steel used 1200 Tons
 Structural profiles used UB/UC Columns and Beams Truss and Girder Systems Crane and Crawl Beams Channels   

Tubing

3CR12 CFLC Purlin and Girts 3CR12 Sag Angles

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

CLADDING
Completion date of cladding January 2019
Cladding profile/ type used 304 Stainless Steel
Cladding area/ coverage and tonnage ± 18,000m²

 

Project Team Role Company
Nominator SE Steel Fabrication (PTY) Ltd
Client/ Developer Omnia Fertilizer a division of Omnia Group Pty Ltd
Structural Engineer Omnia Group Pty Ltd – Group Technical Projects
Engineer Omnia Group Pty Ltd – Group Technical Projects
Project Manager Omnia Group Pty Ltd – Group Technical Projects
Project Manager SE Steel Fabrication (Pty) Ltd
Main Contractor Omnia Fertilizer a division of Omnia Group Pty Ltd
Steelwork Contractor SE Steel Fabrication (Pty) Ltd
Steel Erector SE Steel Fabrication (Pty) Ltd
Cladding Supplier M.R.G
Cladding Contractor M.R.G
Corrosion Protection Paintwork Contractor Dram Trading
Corrosion Protection Paintwork Contractor Rand Sandblasting Projects
Nomination Document Submission KRU Detailing CC
Structural Steel Detailer KRU Detailing CC
Photographer, Photo competition Photography by Micaela
Photographer, Other submitted images Cedric Brender-A-Brandis
Videographer Cedric Brender-A-Brandis
Piping contractor Goss & 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.

Kusile Coal Bridge from Kusile Boiler 5 to Kusile Boiler 6

Shanahan Engineering was successful in securing an erection only contract to erect Secondary and Tertiary Structural Steelwork for Kusile Boiler 3 for Mitsubishi Hitachi Power Systems Africa in 2013.

Shanahan delights in providing well supervised and productive construction crews for all of our customers. This positive attitude during the execution of our contract at Kusile quickly led to the company securing the erection contracts for Kusile Boilers 4 and 6 as well as the Primary Coal Feed Conveyor for Kusile Boiler units 4, 5 and 6, the Steel Erection contracts for PJFF units 4 to 6 and the Coal Bridge between Boilers 5 and 6.

The execution of our contract for the latter – the Coal Bridge between Boilers 5 and 6, is the reason for our contention at the 2019 Steel Awards.

As the name suggests, the Coal Bridge feeds coal into the Boiler Mills for use in the boiler combustion process. The coal travels up to Boiler 4 via the Primary Coal Feed Conveyor and then across two bridges from Boiler 4 to 5 and then from Boiler 5 to 6 before being fed into the Boiler Mills.

The bridge was assembled at Ground Level before being lifted as a single piece construction, to its final resting place, 50 m above ground level. The total weight of the bridge is 450 tons and is therefore too heavy to be lifted by means of a Mobile or Lattice Boom Crane.

The Engineers therefore designed a system of strand jacks comprising of a series of winches, and cables that are fixed to the 4 corners of the Coal Bridge. When all necessary load and safety checks have been checked and double-checked, the winches are activated in a controlled manner to lift the Coal Bridge up before being fixed by means of bolted connections, into position.

The lift can only be performed in near-perfect weather conditions. This is due to the large surface areas that are in play which would make windy and wet conditions more hazardous for the lift.

Prior to the Coal Bridge being ready to lift, the Shanahan Construction Team had to request for all the necessary components to be delivered to the erection site for the bridge to be assembled at Ground Level. The erection drawings are reviewed and a parts list was made that comprised 1556 steel sections and 11863 bolts and nuts. Some of the steel sections were quite light whilst others weighed tons. These parts lists were passed onto the Materials Handling Contractor who delivered the requested components to the erection site. On any mega – project like Kusile, there will be parts that are either incorrectly fabricated or missing, this invariably delays the process of erection due to the engineering queries that result. This process was managed closely by the Construction Team together with the Materials Handling Contractor and the Main Contractor so as to ensure the minimum possible impact to project schedule.

In this case, the Shanahan Construction team spent 10968 manhours to complete the assembly of bridge to be ready for lifting into position. The Strand Jacks were then fixed to the 4 corners of the coal bridge and the Construction Team were ready to erect by the afternoon on 7 December 2018. Weather conditions were checked and due to a favourable forecast (dry conditions and little wind), it was decided to perform the lift early the following day, 8 December 2018.

The lift started at 08h23 on 8 December 2018 following a special safety briefing which started at 06h30 earlier that morning. In the picture below you can see the 450 ton bridge section still on its trestles at Ground Level. By 15h40 on the same day, the Bridge had reached its final position. The lift took just under 7 hours and 20 minutes to complete which was just under 5 hours faster than any of the previous Coal Bridges.

Shanahan achieved a perfect Safety record during the Assembly and lifting of the Coal Bridge with no incidents having been recorded from start to finish.

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.

STRUCTURAL STEELWORK
Completion date of steelwork 08/12/2018
Completion date of full project In progress
Tons of structural steel used 450
Structural profiles used Miscellaneous
SA content – if this is an export project  
PROJECT TEAM COMPANY
Nominator Shanahan Engineering
Client/ Developer MHPSA
Structural Engineer Genrec
Main Contractor MHPSA
Steelwork Contractor MHPSA
Steel Erector Shanahan
Cladding Manufacturer Global Roofing Solutions
Cladding Supplier Global Roofing Solutions
Cladding and Roofing Global Roofing Solutions
Cladding Contractor Southey

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.

Kusile power station: absorber strakes: specialised fabrication and transportation

NATURE OF PROJECT

The purpose of the project was to decrease “Time to Site” as well as “Time on Site” as well as to ease onsite erection and improve quality of fabrication by manufacturing the Absorber Strakes to be installed at Kusile Power Station in the largest possible assemblies.The largest components to be moved were 120o segments of a 20m diameter, 9m high, circular absorber tower section, fabricated from 14mm steel plate.

The following considerations came into play when determining the feasibility of the “Large Assembly Transport”:

POSITIVE CONSIDERATIONS

Conditions inside the fabrication workshop at Genrec are controllable and assembly could take place without interference from the elements.Quality control is easier, and automated welding methods could be used.Time to/on site (read SITE COSTS) was drastically reduced.

NEGATIVE CONSIDERATIONS

Bespoke transport cradles, as well as lifting equipment would have to be designed and fabricated. This was mainly due to the flimsy nature of the 120o segmentsDue to the highly specialised nature of the design, specialist design expertise would have to be outsourced.It was decided that the positives outweighed the negatives and LSL Consulting Engineers were appointed to design the lifting and transportation equipment.

DESIGN PROCESS

Since the absorber towers are not constant in diameter, some sections were reducer sections and some were smaller sections. Therefore, a “one size fits all” system could not be used. All in all 4 different lifting arrangements and transportation cradles were used.However, due to a design process involving people from management right down to the factory floor, it was possible to design the different cradles and lifting beams in such a way that they could be disassembled and modified to suit the specific requirements of the particular component to be moved. Thus the same cradle components could be re-used.

As far as possible, standard hot-rolled structural sections were used (I-beams and H-profiles) due to ease of availability. Specialised spreader beams were however required to carry out the “top-and-tail” operations required to rotate the absorber segments from a vertical manufacturing position, to a horizontal transportation position. The spreader beams were manufactured using bespoke box girders due to considerations of lifting capacity.The most interesting” part of the process was that the spreader beams, as well as the lifting beams which clamped onto the shells, had to be positioned in such a way that the Centre of Gravity of each shell would act as the rotational pivot point.

FABRICATION & TRANSPORTATION

Fabrication of the cradles were done partly in-house and partly outsourced, and transportation and transport co-ordination was outsourced to a specialist contractor.

Tons of structural steel used 309
Structural profiles used Box Girders, I-beams, H-sections

Project Team

Project Team Role Company
Nominator GENREC
Client/ Developer GE (at time of project)
Structural Engineer LSL Consulting
Engineering Manager GENREC
Main Contractor GENREC
Steelwork Contractor Burger & Company
Steelwork Contractor Nessa Engineering
Steelwork Contractor One Steel

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.