http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 14.59Change: -0.06
R/$ = 10.55Change: -0.03
Au 1300.41 $/ozChange: -3.54
Pt 1436.50 $/ozChange: -8.00
 
 
Note: Search is limited to the most recent 250 articles. Set date range to access earlier articles.
Where? With... When?








Start
 
End
 
 
And must exclude these words...
Close Main Search
Close Main Login
My Profile News Alerts Newsletters Logout Close Main Profile
 
Nelson Mandela 1918 - 2013   Agriculture   Automotive   Chemicals   Competition Policy   Construction   Defence   Economy   Electricity   Energy   Environment   ICT   Metals   Mining   Science & Technology   Services   Trade   Transport & Logistics   Water  
What's On Press Office Suppliers Directory Research Jobs Announcements Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Aug 10, 2012

Sephaku Cement saves 25% by using Chinese contractor

Back
Cogeneration|Eskom|Mining Weekly|Sephaku Cement|Sinoma International Engineering|China|South Africa|Delmas Plant|Kendal Power Station|Mine Health|Cement Producer|Cement Production Facility|Chemical Processing|Cogeneration|Mining|Steel|Steel Fixing Preparation Work|Tailor-made Tools|Cogeneration|Jacques Minnie|Pieter Fourie
cogeneration|eskom|mining-weekly-company|sephaku-cement|sinoma-international-engineering|china|south-africa|delmas-plant|kendal-power-station|mine-health-facility|cement-producer|cement-production-facility|chemical-processing|cogeneration-industry-term|mining|steel|steel-fixing-preparation-work|tailor-made-tools|cogeneration-person|jacques-minnie|pieter-fourie
© Reuse this



Five-hundred employees of Chinese company Sinoma International Engineering are currently working on site to construct cement producer Sephaku Cement’s new Aganang cement production facility, near Lichtenburg, in the North West, with 200 more to arrive within the next few weeks.

The Aganang operations will include limestone mining and the chemical processing of raw materials to produce clinker.

Sephaku did initially go out to tender for South African contractors, but realised that no South African contractor would be willing to take a turnkey risk on such a plant, Sephaku Cement CEO Pieter Fourie tells Mining Weekly.

“The fixed prices we received from the Chinese Sinoma saved us 25% on total development,” he says.

However, skills transfer and the use of local labour are provided for in the contract with Sinoma. One South African labourer is used for every three Chinese workers.

“I must reiterate that the Chinese workers will only be here during the construction of the plant; therefore, permanent jobs for South Africans will be created during the entire life of the plant, which is expected to be between 30 and 40 years,” he adds.

Meanwhile, the skills transfer between the Chinese and the South African workers is progressing well, especially with regard to the work ethic.

The Chinese building style does differ from the South African style in some practical ways, says Fourie.

“The concrete and steel are the same but concrete pumps and cranes are used more extensively for placing concrete. Other practical examples include their wheelbarrows that are properly balanced, the ways in which they rapidly fix the steel, using tailor-made tools rather than pliers and doing all steel fixing preparation work at a one-metre level above ground. These are minor differences that result in significant productivity improvements,” he explains.

Language did prove to be a challenge, but both companies have appointed translators to deal with this.

“We also experienced some challenges relating to safety management, as our safety culture is very different to theirs. Construction of the plant must be done in compliance with the requirements of the Mine Health and Safety Act (MHSA). As this is new to Sinoma, they have appointed knowledgeable South African safety persons to assist them and key Sinoma persons have been trained in the requirements of the MHSA.

We have, however, worked together on this and are proud to have more than one-million lost-time injury-free hours on this site,” Fourie points out.

Sephaku started construction on the R2.3-billion, 2.5-million-ton-a-year cement production facility late last year, with first production scheduled for September 2013, after the commissioning of the plant’s clinker in August 2013.

“We decided on this project because the average cement plant in South Africa is about 38 years old and we believe it is time to add capacity in preparation for the country’s future growth,” says Fourie.

Half of the clinker will be milled at Aganang to produce cement and the rest will be transported to the Delmas plant, where it will be further processed, using fly ash produced at the fly-ash classification plant at Kendal power station, as an extender to produce the final cement.

“Sephaku realises the future is in waste-heat recovery,” says Fourie.

To convert a normal cement plant for cogeneration is difficult and plants usually have to be shut down for about six months. However, Sephaku’s cooler was designed to make this possible future transition easier, he says.

“However, this is a future project which will only be considered once the current project is stable. We decided to keep this plant as basic and efficient as possible as we are still establishing ourselves in the cement business,” he adds.

Meanwhile, the construction of an Eskom substation was completed in March. A new 49 km 132 kV incoming powerline has also been erected from Watershed, near Lichtenburg, to the plant, says Aganang civil engineer Jacques Minnie.

Construction of a 4.2 km asphalt-surfaced access road from the existing Kapsteel road to the plant location is also under way. The road will consist of two 3.7-m-wide lanes, with two additional 0.8 m paved shoulders. It is expected to be completed in November, he concludes.
 

Edited by: Creamer Media Reporter
© Reuse this Comment Guidelines
 
 
 
 
 
 
 
 
Other Construction News
Updated 6 hours ago There is enough water in South Africa to supply communities and the economy, even if some activities may be constrained, such as agriculture in the Limpopo, says National Planning Commission commissioner Mike Muller. 
Muller was also the director-general from 1997...
South Africa’s infrastructure investment and roll-out ambitions face a significant capacity challenge as local government experiences a constraint in the availability of architects, engineers, project managers and financial managers. The nation’s pragmatic, but...
More
 
 
Latest News
Updated 48 minutes ago South Africa's drive to create a competitive and food-secure State was boosted on Tuesday with the launch of the Centre of Excellence (CoE) in Food Security, at the University of the Western Cape, which would bring together a cohort of experts and researchers from 19...
Updated 1 hour ago The City of Cape Town has entered into eight third-party service provider agreements licensing the take up of the spare infrastructure capacity generated through the city’s broadband network. Lease-agreement negotiations were progressing with another 20 third-party...
Updated 1 hour 13 minutes ago A 344.5 t wax reactor has arrived at petrochemicals giant Sasol’s Fisher-Tropsch wax expansion project, in Sasolsburg, in the Free State, after five weeks of road travel from Richards Bay, in KwaZulu-Natal. The reactor was transported through Pongola, in...
More
 
 
Recent Research Reports
Steel 2014: A review of South Africa's steel sector (PDF Report)
Creamer Media’s Steel 2014 report provides an overview of the global steel industry and particularly of South Africa’s steel sector over the past year, including details of production and consumption, as well as the country's primary carbon steel and stainless...
Projects in Progress 2014 - First Edition (PDF Report)
This publication contains insight into progress at the delayed Medupi and Kusile coal-fired projects, in Mpumalanga and Limpopo respectively, as well as at the Ingula pumped-storage scheme, which is under construction on the border between the Free State and...
Automotive 2014: A review of South Africa's automotive sector (PDF Report)
The report provides insight into the business environment, the key participants in the sector, local construction demand, geographic diversification, competition within the sector, corporate activity, skills, safety, environmental considerations and the challenges...
Construction 2014: A review of South Africa's construction sector (PDF Report)
Construction data released during 2013 hints at a halt to the decline in the industry during the last few years, with some commentators averring that the industry could be poised for recovery. However, others have urged caution, noting that the prospects for a...
Electricity 2014: A Review of South Africa's Electricity Sector (PDF Report)
This report provides an overview of the state of electricity generation and transmission in South Africa and examines electricity planning, investment in generation capacity, electricity tariffs, the role of independent power producers and demand-focused initiatives,...
Defence 2013: A review of South Africa's defence industry (PDF Report)
Creamer Media’s 2013 Defence Report examines South Africa’s defence industry, with particular focus on the key players in the sector, the innovations that have come out of the defence sector, local and export demand, South Africa’s controversial...
 
 
 
 
 
This Week's Magazine
Updated 6 hours ago There is enough water in South Africa to supply communities and the economy, even if some activities may be constrained, such as agriculture in the Limpopo, says National Planning Commission commissioner Mike Muller. 
Muller was also the director-general from 1997...
South African antenna designer and producer Poynting and provider of professional products, system integration and implementation and commissioning services for the broadcast and telecommunications markets in South Africa, African Union Communications (Aucom),...
Industrial automation giant Festo has been displaying some of the its ongoing research projects and latest automation developments and products at the Hannover industrial fair from April 7 to 11, as part of its Integrated Automation – The Next Steps theme. The...
South African retail companies are responding to the way in which e-commerce is changing their engagement model with customers by improving customer engagement channels and order fulfilment intelligence, says industrial and retail software company JDA Europe, Middle...
In support of the South African government’s mandate to create more jobs and promote sustainable development, multilevel marketing company Amway’ business model aims to assist government in easing the startup of business and encourage an entrepreneurial mindset...
 
 
 
 
 
 
 
 
 
Alert Close
Embed Code Close
content
Research Reports Close
Research Reports are a product of the
Research Channel Africa. Reports can be bought individually or you can gain full access to all reports as part of a Research Channel Africa subscription.
Find Out More Buy Report
 
 
Close
Engineering News
Completely Re-Engineered
Experience it now. Click here
*website to launch in a few weeks