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 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   

 

Tubing

3CR12 CFLC Purlin and Girts 3CR12 Sag Angles

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

CLADDING
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.