Although lightweight steel structures and cold-formed sections manufacturer Robor Structural Solutions faces challenges in meeting State-owned power utility Eskom’s initial product-volume requirements, coupled with an erratic steel supply, the company worked with all of the supply-chain role-players to supply the utility’s new build projects.

Robor Structural Solutions MD and Energy division head Indiran Gounden tells Engineering News that the company, a division of steel, tube and pipe manufacturer Robor, is fulfilling its contract to provide several steel components for the dry-air cooling systems at the Medupi and Kusile coal-fired power stations, in Limpopo and Mpumalanga, respectively.

Medupi, which is expected to cost R91.2-billion, will be a dry-cooled coal-fired, baseload power-generating plant, comprising six 800 MW units, with a 4 800 MW installed capacity, which will reach full capacity by 2017, Creamer Media’s Research Channel Africa reported last month.

Kusile, also a dry-cooled coal-fired power station, is being developed at a cost of R118.5-billion and will consist of six units, each rated at about 800 MW installed capacity, giving a gross output of 4 800 MW.

Kusile’s first generating unit is scheduled to supply power to South Africa’s national grid by late 2014, with the subsequent five units being commissioned at eight and then 12-month intervals thereafter. The last unit is expected to be in commercial operation by 2018.

“Since starting its contract in 2008, Robor Structural Solutions has supplied 20 000 t of cold-formed steel sections, manufactured to the contractor’s specifications, for use at the Kusile and Medupi power stations, as well as at the power stations’ coal washing plants,” says Gounden.

In addition, the company has an extensive range of products and services for several applications in the power generation industry. These include the supply of steel sections, sidewall sections, pressure pipe, condensor tubing and electrostatic precipitator plates. The hot-dip galvanising service that provides corrosion protection for carbon steel and conveyor systems have been made available to Eskom through several contracts with the utility’s subcontractors.

The various contracts secured from Eskom and its subcontractors have enabled Robor Structural Solutions to gain exposure to the main project contractors and have helped the company establish itself as a reliable supplier to the power generation industry.

Robor Structural Solutions offers a complete solutions package that is tailor-made to customers’ requirements, with limited additional work required prior to installation, says Gounden.

The company also has access to numerous other divisions within Robor, which enables it to react to the ever-changing requirements and applications in the energy sector. This helps the division work with contractors to find the best possible solution, he says.

Robor Structural Solutions believes that Eskom’s construction of new coal-fired power stations presents suppliers with the opportunity to secure long-term supply contracts, creating a level of consistency in the manufacturing process, while creating employment opportunities for South Africa.

The company has supplied significant volumes of steel products for the utility’s power stations, including Medupi, Kusile, the 3 600 MW Duvha power station and the 3 600 MW Matla power station, both in Mpumalanga, as well as – for more than 50 years – the 3 990 MW Matimba power station in Limpopo.