Esor Pipelines has one of the most impressive track records in the South African pipeline industry, including several prestigious projects that required specialised expertise. These include the recent completion of sub-Saharan Africa’s largest water pipeline — the BG3 pipeline, a 3,5 metre diameter steel pipeline running from the Vaal dam to the Zoekfontein control works some 8,6 km away. The pipeline has a 10 mm thick wall and is epoxy-lined inside and outside and was commissioned to increase water distribution to Johannesburg and the surrounding areas.

One of the few companies capable of laying fuel and gas pipelines, Esor Pipelines was awarded the replacement of the Sapref fuel pipeline between Bayhead at the Port of Durban and the Sapref refinery in 2006. This showcase project was one of the biggest in South Africa at the time and involved placing seven steel pipelines ranging in diameter from 150 mm to 350 mm, over a distance of 84 km.

Earlier this year Esor Pipelines embarked on a relatively large project to install 29 km of 900 mm diameter continuously welded steel pipeline, between the Command Reservoir near Mandini and the Mvoti Reservoir at KwaDukuza-Stanger in KwaZulu-Natal. The pipeline has 6 mm and 7 mm wall thicknesses, with a polyurethane exterior coating and an epoxy internal lining. The project was awarded by state-owned water utility, Umgeni Water, and is part of the Lower Thukela Bulk Water Supply Scheme that will extend the utility’s bulk water infrastructure system along the KwaZulu-Natal North Coast area to meet the increasing water demands of the population in this area.

On the Western Aqueduct Project, the largest water supply project in Durban’s history, Esor Pipelines is installing 23 km of large bore pipe of varying diameters from 1 metre to 1,4 metres. In the same footprint, it is also installing 14 km of varying large bore pipe with diameters from 700 mm up to 1,2 metres on Durban's Northern Aqueduct Augmentation project, which will place urgently needed bulk water infrastructure for the rapidly developing northern areas of the city.

The division recently completed another project in Swaziland, which called for installation of 1,5 km of 1,9 metre diameter steel siphon between two existing canals in the Mhlume area. The Esor Pipelines division was established in 2008, after the acquisition of the Shearwater group of companies, introducing new and sustainable revenue streams for the group by expanding services from sub-surface foundation work to include above-surface civil engineering. “Since then we’ve enjoyed a great deal of success across a spectrum of projects that have included construction and rehabilitation of onshore pipelines primarily in the gas and petrochemical, water, stormwater and sewerage sectors,” Dave Gibbons, managing director of Esor Pipelines, says.

“Drawing on our specialist expertise in laying and welding of steel pipelines and in-situ pipeline refurbishment — including mechanical and linings and coatings — we’re able to serve both public and private sector customers from top mining and industrial groups to regional and municipal government authorities. We own a comprehensive fleet of equipment, including specialised pipe-laying machinery, and this is supported by a skilled technical team operating from a dedicated workshop and plant yard in Chloorkop, Gauteng.”

Esor Pipelines has a healthy order book for the current financial year and is actively pursuing several major opportunities in the SADEC region. The division employs more than 200 permanent personnel with the capability to work across a full range of pipelines, including those made from steel, glass fibre reinforced polyester, concrete, PVC, ductile iron, HDPE and fibre cement. It is one of only three local operations capable of performing in situ cement mortar lining, as well as epoxy and HDPE linings.

The division also provides world class pipe, culvert and bridge-jacking expertise to the market, based on more than three decades of expertise across southern Africa. Included in its “full package” offering, Esor Pipelines has established the skills to construct reinforced concrete and brick structures such as pump stations, reservoirs, chambers, telemetric structures and other ancillary structures.

As part of the Esor Group, Esor Pipelines is committed to a safe and healthy working environment, preservation of the environment and strict compliance with the Occupational Health and Safety Act, 85 of 1993 and the National Environmental Management Act. To this end, inspection and legal compliance audits are performed regularly, SHE policies are reviewed biennially and whenever changes in legislation occur. External audits are performed as required in compliance with OSHAS 18001 and ISO14001.

A Group SHEQ manager is supported by divisional managers and site safety officers. A detailed risk assessment is undertaken for each product type and specific tasks. These are then rated according to a matrix and mitigated accordingly. Site staff is trained and each site has a health, safety, environmental and quality plan.

Esor Pipelines operates from headquarters in Germiston and has successfully widened its geographic reach with a presence in KwaZulu-Natal, Eastern Cape, North West and Swaziland, as well as in Harare, Zimbabwe.