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 layout of the plant.
• 27 ha 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
Currently, about 528 workers are active on site – 322 of whom are from local communities – along with 35 plant vehicles and cranes.

At full capacity, the manufacturing facility will eventually employ about 1 500 people directly.

Value
R1-billion.

Duration
Not stated.

Latest Developments
The construction of the Dunnottar manufacturing facility is well under way and due to be completed by the end of 2017.

The on-site training centre has been completed and accepted its first intake of students in April 2017.

Gibela is expected to produce 62 trains this year.

A panel of 200 local suppliers will be manufacturing equipment and components for the 580 locally produced trains from 2018 onwards

Key Contracts and Suppliers
Aecom (engineering, procurement and construction management contractor); Trencon Construction (site clearance, bulk earthworks and civil infrastructure) and Trencon Construction and Black Jills Engineering (main site buildings, including the training centre).

On Budget and on Time?
The project is on schedule, following delays in initially securing the site.

Contact Details for Project Information
Gibela communications director Pamella Radebe, email pamella.radebe@gibela-rail.com.