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.
Value
R1-billion.
Duration
Not stated.
Latest Developments
Visible progress is being made on the Dunnottar train manufacturing complex, with about 522 t of structural steel erected, 4 043 m3 of concrete cast, 5 km of piping installed and about 511 000 productive hours worked.
All structural steel for the training centre, complete with side cladding, has been erected. The concrete floor has also been cast and the exterior block work completed, with the building now ready for the installation of industrial fittings.
Meanwhile, the foundations are being cast for the static test and filming buildings, while the erection of the steel structure of the car body shell, fitting building and central offices is under way.
Gibela’s engineering, procurement and construction management contractor, Aecom, has appointed a further eight construction contractors for different work packages. The procurement for packages 5, 6 and 7, comprising electrical reticulation and equipment, mechanical and overhead cranes, besides others, has now been finalised.
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.
Alstom, Linda Huguet, tel +33 1 57 10 42 or email linda.huguet@transport.alstom.com.