Name of the Project
Dunnottar train manufacturing complex project.

Location
Gauteng, South Africa.

Client
Gibela Rail Transport Consortium, comprising Alstom (61%), Ubumbano Rail (30%) and New Africa Rail (9%).

Project Description
The project involves the construction of a 60 000 m2 factory at the Dunnottar industrial complex to manufacture trains for South African State-owned Passenger Rail Agency of South Africa (PRASA). This forms part of a R51-billion contract to supply 600 new trains over ten years and provide technical support, as well as spare parts over an 18-year period, to the rail agency.

The train manufacturing complex has a geographical footprint of 78 ha, comprising:
• the total built area of the factory of 51 ha, of which only 33 ha will be developed. The remaining land comprises an environmentally sensitive wetland, the preservation of which has necessitated the construction of a dam as part of the design and lay-out of the plant.
• twenty-seven hectares that has been reserved for the uBumbano Rail Park, which will house suppliers of equipment and components required for the new trains.

The factory will produce 580 coaches.

The plant will also be equipped with several kilometres of rail network, including a 1.2 km dynamic test track for the testing of completed trains.

The first trains are being manufactured in Brazil, while the remaining 580 units will be assembled at Dunnottar. At its peak, the manufacturing facility will produce 62 trains a year, in line with Alstom’s X’Trapolis Mega commuter train design.

To ensure that the contract’s 65% local-content stipulation is met, the complex will also accommodate local components suppliers.

Jobs to be Created
The project is expected to generate about 33 000 direct and indirect jobs.

Value
R1-billion.

Duration
Not stated.

Latest Developments
Gibela has made significant progress, together with its empowered partners, Trencon Construction and Black Jills Engineers, since site mobilisation for the construction of the Dunnottar train manufacturing complex started seven months ago.
 
Of the seven packages comprising the overall construction programme for the Dunnottar complex, two are in progress under the execution of Trencon.

Trencon was awarded Package 1 for site clearance and earthworks in January 2016.

In May 2016, Package 2, the largest of the overall construction programme including construction works for the five main buildings, was awarded to the Trencon and Black Jills Joint Venture.

Since May the following progress has been reported:
• concrete bases have been cast in the building where the body shells of the coaches will be assembled;
• the erection of the stub columns is nearing completion in preparation for structural steel;
• concrete bases are being laid, and the macropool area – the working platform that enables access on all sides of the train – is being excavated in the testing and coupling building;
• strip footings, which link the walls of the buildings upon erection, have been compacted for the filming building, in which the livery of the train is applied; and
• foundation slabs for the training centre have been laid and the access pit excavated.
 
Owing to continuous EHS training, audits and inspections, no days have been lost to injury since the start of construction work seven months ago, construction programme director at Gibela Vuyiswa Tlomatsane has said.

More than 400 people have been employed during the first two construction packages. The current complement of people on site, at 345, is set to increase significantly over the next few months as construction advances in several additional phases.
 
In accordance with the construction schedule, the training centre will be the first building to be completed to prioritise the training of South African artisans and operators in readiness for the start of local train manufacturing operations. Besides delivering to Gibela’s skilled employee needs as a priority, the training centre will also supply trained people to the broader South African railway sector in the years ahead.
 
It is planned that construction and equipping of all buildings on site will be completed by November 2017, when full-scale building and assembling of the first of the 580 South African-made trains for delivery to PRASA will begin. 

Key Contracts and Suppliers
None stated.

On Budget and on Time?
Construction of the factory was initially expected to start in early 2015, but delays in securing the site resulted in work falling behind schedule.

Contact Details for Project Information
Gibela communications director Pamella Radebe, email pamella.radebe@gibela-rail.com.
Alstom, Linda Huguet, tel +33 1 57 10 42 or email linda.huguet@transport.alstom.com.