Two of the seven construction packages for Gibela’s R1-billion train manufacturing complex at Dunnottar, in Gauteng, are under way.

The project, being undertaken by Gibela, Trencon Construction and Black Jills Engineers, will be completed by November 2017. The complex has a geographical footprint of 78 ha, with 51 ha making up the total built area.

Only 33 ha will be developed, as the remaining land is made up of an environmentally sensitive wetland, the preservation of which necessitated the building of a dam as part of the design and layout of the plant.

Twenty-seven hectares is reserved for the uBumbano rail park, which will house suppliers of equipment and components required for the 580 new trains that will be manufactured at the complex.

The first construction package, which was awarded in January, involves site clearance and earthworks.

The second package, which is also the largest of the overall construction programme and includes construction of the five main buildings, was awarded to the Trencon and Black Jills joint venture (JV) in May.

To date, the concrete bases in the building where the body shells of the coaches will be assembled have been cast; the erection of the stub columns is nearing completion in preparation for structural steel; the concrete bases are being laid and the macro-pool area – a working platform that enables access on all sides of the train – is being excavated in the testing and coupling building.

Further, strip footings that 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, in the training centre, foundation slabs have been laid and the access pit excavated.

“The dream of developing a world-class train manufacturing plant in the industrial heartland of Ekurhuleni is fast becoming a reality as we work hard towards physically transforming this greenfield site into one of the busiest train manufacturing plants in the world in just more than a year from now,” says Gibela CEO Marc Granger.

More than 400 people have already 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 when local train manufacturing operations start.

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.