Monthly Archives: June 2022

Client Focus

AFRISAM’S COMPOSITE CEMENTS LEAD IN SUSTAINABILITY DRIVE 

Leading the market in reducing clinker content in its composite cements, AfriSam has been a trailblazer in cutting carbon emissions in one of the economy’s most energy-intensive sectors.

Hannes Meyer, executive cementitious at AfriSam, highlights that the energy consumed in producing ordinary Portland cement (OPC) can be 20 to 25% higher than a composite cement, of the same strength class, containing a cementitious extender. 

“This results from the added cost of producing a higher percentage clinker at high temperatures used per tonne of composite cement manufactured,” says Meyer. “Extenders like fly-ash or ground granulated blast furnace slag (GGBFS) can be blended into the mix, reducing the amount of clinker milling required per tonne of cement.”

This has more recently become a focus for other players in the market, even those who had previously not embraced the concept of composite cement, he notes. AfriSam has in the meantime become the benchmark for these cement innovations, along with a range of sustainability initiatives to monitor and reduce carbon emissions. 

Leading the market in reducing clinker content in its composite cements, AfriSam has been a trailblazer in cutting carbon emissions.
Leading the market in reducing clinker content in its composite cements, AfriSam has been a trailblazer in cutting carbon emissions.

“A vital aspect of our use of extenders has been our ability to activate these materials for greater reactivity,” he says. “Through evolving our chemical and mechanical activation methods, we achieve a more reactive product – allowing us to progressively replace more and more clinker while retaining high cementitious quality and strength performance.”

In another stream of the company’s research, it has taken strides in developing the reactivity of clinker itself. By changing the mineralogy of clinker, its reactivity can be improved. Meyer points out that cement blending companies have already recognised the high reactivity of AfriSam cement, with many of them preferring AfriSam’s products as they ‘go further’ in a blending application.

“We have also had great success in the use of grinding aids in our milling processes, collaborating closely with specialist firms to address our exacting requirements,” says Meyer. “These grinding aids are specific to the extenders we use, helping to improve reactivity and in some instances adding 10% to 15% early strength enhancement.”

The end result is that less clinker needs to be produced per tonne of final product, he emphasises, leading to less carbon dioxide being generated. The company has also become more efficient in the use of thermal and electrical energy in its processes. Whereas electricity used to be a minor cost in cement plants, it is now a major factor in cement manufacture. In this context, AfriSam has explored alternative fuels, which have become a major focus for many cement producers globally. 

“We have made progress with responsibly disposing of waste products in our energy generation strategies, and we hope that government will take the necessary steps to allow us to expand these initiatives,” he says. 

This includes the combustion of waste tyres and industrial carbon sludge, using high-efficiency multi-channel burners that reduce hazardous emissions. He says the employment of increasingly sophisticated process control technology is also part of the ‘AfriSam Way’ towards a sustainable planet. 

Client Focus

ADDING ENGINEERING VALUE TO GRINDEX PUMP SOLUTIONS

Pumping solutions are all about adding value through the right technical expertise and resources, including design, engineering and construction capability, according to Integrated Pump Technology general manager Jordan Marsh. 

“Customers don’t come to us for a pump-in-a-box; rather, they have a specific application that must be served, and are looking for a cost effective solution,” says Marsh. “Our experienced technical team and well-equipped workshop give us the capability to develop such solutions in-house.”

The company has developed pump flotation devices (PFDs), for example, which are suitable for the range of Grindex submersible pumps. In another application, customers faced an issue with pumps being damaged underground by moving equipment; Integrated Pump Technology designed and produced fit-for-purpose protective cages for these units.

Assembly of a Grindex Mega pump underway at Integrated Pump Technology.
Assembly of a Grindex Mega pump underway at Integrated Pump Technology.

“For our large 90 kW pumps, we have even developed sturdy pump stands which allow them to sit above the slurry line and avoid sinking into mud,” he says. “We also have a trolley solution for submersible pumps that customers need to move often over rough terrain around their sites – allowing these to become easy plug-and-play units.”

The experienced staff under the workshop manager includes qualified technicians and apprentices, with a qualified draughtsman drawing up the detailed plans for new innovations. The company’s recent move to new premises allowed the workshop facilities to be upgraded with a new sand blasting unit, stator dropper, spray booth and wash bay.

“Integrated Pump Technology’s experience of the Grindex range since 2014 has given us plenty of insight into how we can enhance the application of these quality products,” he says. “By adding our engineering capability to these quality products, we have been able to generate valuable solutions for customers.”

With the combined experience of management and staff running into many decades, customers can feel confident of finding a solution when bringing their specific challenge to Integrated Pump Technology, concludes Marsh. 

Client Focus

SCREENING ACROSS APPLICATIONS 

A key attribute of Metso Outotec’s Lokotrack® ST2.3™ scalping screen is not its compact design but its ability to be deployed in several applications and process various feed materials. Leveraging the machine’s unique versatility, contractors can transfer productivity from one jobsite to the next despite the changing conditions.

Contractors know that every jobsite is different. However, they are also aware that they don’t have the comfort of purchasing specific pieces of equipment to match the needs of every project. With a growing requirement to do more with less, contractors can take advantage of the Lokotrack® ST2.3™ scalping screen’s versatility, which allows it to be adapted and deliver the desired results on a broad range of applications.

Newly launched and now available locally from Pilot Crushtec International, the Lokotrack® ST2.3™ scalping screen is a multi-use scalping screen perfectly suited to heavy duty scalping, fine screening and recycling. Dubbed the ‘Swiss Army Knife’ of screening, the machine is designed to process a range of materials, from topsoil and recycled concrete waste, to road base material and fine aggregates. 

The machine can be used as a standalone unit or as part of a multi-stage crushing and screening process. Its versatility is enhanced by the various screen media options, including grizzly, punch plate, finger grizzly and wire mesh. 

Despite its compact build, the machine punches above its weight with a 4.6 m² screening area, the widest in its class. This is complemented by an aggressive stroke up to 13 mm with 5G acceleration, resulting in a high screening performance. 

Contract crushing is a nomadic venture by its nature, which often calls for moving of machines from one site to the other. With that in mind, Metso Outotec paid particular attention to ease of transportation during the development of the Lokotrack® ST2.3™ scalping screen. With its compact screen box size (3,040mm x 1,520 mm) and optimised weight (17 000 kg), the machine can be moved from one site to another using a standard trailer, thus helping contractors cut back on transportation costs. 

Amid record high fuel prices, fleet owners will benefit from the machine’s fuel efficiency. Powered by a CAT® C3.6 diesel engine, the machine consumes as low as seven litres of fuel per hour, translating into lower total cost of operation. 

With Metso Outotec’s IC automation system, fleet managers can monitor, control remotely and automate the screening process for better performance. With information on upcoming maintenance needs, fleet managers can plan their maintenance breaks effectively to reduce machine downtime. IC automation also makes the work of operators safer with the remote-control features.

Talking points 

  • The machine sets new standards in versatility with its ability to process various feed materials across primary scalping and fine screening applications
  • With its compact screen box size (3,040mm x 1,520 mm) and optimised weight (17 000 kg), the machine can be easily transported in one piece using a standard trailer
  • With a 4.6 m² screening area, the Lokotrack® ST2.3™ has the widest screen in its size class
  • An aggressive stroke up to 13 mm with 5G acceleration results in high screening performance 
  • The machine’s fuel economy helps fleet owners reduce their operating costs
Client Focus

CONCOR AT THE FOREFRONT OF ‘GREEN’ CONSTRUCTION

When it comes to care for the environment, there can be few contractors around with the track record of Concor, which has shown its commitment to ‘green’ construction on literally scores of building, construction and civil engineering projects, some of which have won top industry awards.

“Our excellent track record is not a matter of chance,” says Bruce Paul, group environmental manager at Concor. “Care for the environment and a concern for sustainability is ingrained in our company culture. Quite apart from this, we also need to measure up to the high expectations of all our stakeholders.” 

He adds that clients increasingly have ambitious goals when it comes to sustainability and environmental care and Concor takes cognisance of this. Additionally, the company – like any other contractor –has to comply with the National Environmental Management Act (NEMA), which constitutes an entire family of laws, as well as other relevant legislation.

“Basically, any reputable contractor these days will have to show a high level of environmental awareness and have a real commitment to sustainability in order to operate successfully, so the business case for being strong in these areas is overwhelming,” he says. 

Concor, of course, is a member of the Green Building Council South Africa (GBCSA) and has been responsible for many high-profile green building projects, both in South Africa and across border, which have been recognised under the GBCSA’s Green Star certification system.

Examples include the phase 1 refurbishment and expansion of the Menlyn Park Mall in Pretoria, the first retail building in South Africa to achieve Green Star SA status; the Aurecon Century City building in Cape Town, the first building in South Africa to be awarded a 5 Star Green Star SA – Office Design v1 rating; and FNB@Parkside in Windhoek, which ranks as Namibia’s first green building.

According to Paul, the Menlyn Park refurbishment – completed several years ago – exemplifies what green building means in practice. “As regards materials, post-consumer recycled reinforced steel was used while the ordinary cement in the concrete was reduced by 30 % through substitution with fly ash,” he says. “Also noteworthy was a reduction of potable water consumption of around 30 % compared to what would normally have been expected on a project of this size and type. 

“Recycling, of course, is an important principle of the green approach and a high level of recycling was achieved at Menlyn Park with more than 70 % of waste being repurposed.”

Further afield, in Qatar, Concor built the Qatar Science & Technology Park, which achieved a LEED Green Building under the Core and Shell Gold award. LEED (Leadership in Energy and Environmental Design) which is the US equivalent of South Africa’s Green Star certification system. 

Commenting generally on green buildings, Paul says they cost less to run, produce less greenhouse gas emissions, use energy optimally and are easier to insure and hold value longer. “These factors appeal to developers and building owners, and we are seeing more clients insisting on their buildings being green. My own view is that the future of large projects in the construction industry really depends on designers and contractors being knowledgeable about green construction processes.”

More recently, Concor completed several phases of the Oxford Park precinct construction with buildings achieving various Green Star certifications; the latest is the recently completed Ikusasa which achieved a 6 Star Green Star certification in terms of the GBCSA Green Star rating. 

Green construction principles can, of course, be applied outside the commercial building field and Paul says Concor is particularly proud of the work it has done on wind farms around the country which are generally situated in environmentally sensitive locations. He points to the Roggeveld Wind farm in the Western Cape – which recently entered commercial production – as a particularly fine example of what can be achieved.

“We were responsible for a portion of the civils work, which included turbine bases spread over a construction footprint of 40 ha,” he says. “The site is situated on Central Mountain Renosterveld, which is home to unique species such as Brunsvigia josephinae and other red data species. The design footprint of the project mapped the localities and accommodated them. Where this was not feasible, search and rescue exercises were conducted and retrieved plants were relocated elsewhere on the property.”

Protecting and translocating protected species was also to the fore on the Loeriesfontein, Khobab and De Aar Wind Farms in the Northern Cape and the Jeffrey’s Bay Wind Farm in the Eastern Cape, among others. An interesting feature of the Khobab project was the use of specially designed concrete mixes which reduced the site’s construction carbon footprint from approximately 300 kg of CO2 per cubic metre to just 90,7 kg of CO2 per cubic metre, dropping the project’s overall carbon footprint by 31 %.

Many high-profile bridge and road projects have also provided platforms for Concor to display its skills in environmental care. It was the main contractor, for example, on the Mtunzini N2 road upgrade, which was opened in 2019. This involved the construction of a new highway crossing the uMhlathuze and the uMlalazi rivers and traversing 22 wetland systems. All wetland aspects affected such as unique plants and soils were either temporarily sealed off from the works and removed for later reinstatement.

Finally, no mention of Concor’s skills in the environmental field would be complete without reference to one of its most prestigious current contracts – the construction (in joint venture with Mota-Engil) of SANRAL’s Msikaba Bridge in the Eastern Cape which will span the 220 metre deep Msikaba Gorge.

The civil engineering challenges on the project, which include working at heights of up to 128 metres (the maximum height of the bridge pylons), are formidable but Concor and its partners have also been responsible for rescuing nearly 15 000 threatened and protected plant species and translocating them to on-site holding nurseries. The plants have subsequently been replanted at carefully selected sites near the bridge.

“We have also had to consider the sensitivities of a colony of rare Cape vultures,” says Paul. “The Cape vulture, also known as the Cape Griffon, was listed in 2015 as a regionally endangered species. Measures included paying careful attention to blasting operations to limit disturbance to the colony, particularly in the breeding season.” 

Paul believes the attention to environmental concerns displayed on the Msikaba Bridge project will become a benchmark for the civil engineering industry. “The engineering that’s going into the bridge is amazing but the project is also a landmark in terms of the environmental care that is accompanying construction activities. It shows that construction can be carried out very successfully and with low impact in even the most sensitive of environments,” he concludes.

Client Focus

MURRAY & ROBERTS’ MINING BUSINESS MAKES STRONG RECOVERY

The Mining Platform of Murray & Roberts, one of the world’s leading mining contracting businesses, is fast putting the economic effects of the COVID pandemic behind it and its order book has now recovered to pre-pandemic levels.

“Our order book was eroded in the immediate aftermath of the global economic shutdown caused by the pandemic but has now recovered nicely,” says Mike da Costa, who is CEO of the Mining Platform. “It now totals R22,2 billion which is sharply up on the R17,9 billion of a year ago. Future prospects also look good as there is a significant pipeline of new projects that we’re bidding on.”

The Murray & Roberts Mining Platform consists of three regional businesses. These are Murray & Roberts Cementation, headquartered in Johannesburg but with branches in Kitwe in Zambia and Accra in Ghana; Cementation Americas (which incorporates Cementation USA), based in Salt Lake City, which handles the Americas; and RUC Cementation, which operates out of Perth in Australia and works throughout Australasia and south-east Asia.

“We’re active in virtually every major mining jurisdiction,” says da Costa. “Notable mines and projects where we are currently working include the Venetia Underground Project in South Africa, the Jansen potash project in Canada, the Kennecott Utah Copper Keystone project in the US, the Oyu Tolgoi copper/gold mine in Mongolia, the Grasberg copper/gold mine in Indonesia and the Tanami gold mine in Australia.”

The Mining Platform, which in Murray & Roberts’ 2021 financial year generated revenues totalling approximately R9,5 billion, offers services spanning every aspect of underground mining, including feasibility studies, specialist engineering, vertical and decline shaft construction, mine development, specialist mining services such as raise boring and grouting, and contract mining.

While Murray & Roberts Cementation, the African arm of the global Mining Platform, may not be the biggest contributor to revenues currently (this title is held by Cementation Americas), it is probably fair to say that it has spearheaded the platform’s rise to a position of global pre-eminence in mining contracting. Over decades it has been noted for its technical capabilities and, in particular, its shaft-sinking expertise, which has played a vital role in the development of South Africa’s deep level gold mining industry. It is currently turning over approximately R3,5 billion a year but is aiming to lift this to R4,5 billion.

Commenting on the current performance of Murray & Roberts Cementation, its managing director, Mike Wells, says the bulk of its work is in South Africa. “Historically, we’ve worked all over Africa but at the moment our African presence – outside of South Africa – is largely confined to some raiseboring contracts we have in Zimbabwe, Burkina Faso and Tanzania, as well as a contract at the Navachab gold mine in Namibia where the client is developing a trial underground mine. In South Africa, however, we are extremely busy. We’ve definitely put the impact of the pandemic behind us.”

Wells says that a particular highlight for Murray & Roberts Cementation at the moment is the coal sector. “We’re working at New Clydesdale colliery through our Boipelo joint venture,” he notes. “We’re also at Matla 1, where we are doing stonework tore-establish the mine in a new location. Another opportunity in the coal sector is to do stonework by the method of road-heading and we’re actively pursuing work of this type.”

Murray & Roberts Cementation’s flagship contract is the Venetia Underground Project, where the company’s work on the sinking and equipping of the two vertical shafts the project requires is now well advanced, with the shaft sinking phase nearing completion. Although Murray & Roberts Cementation’s current scope of work runs through to about 2024, Wells believes there is a reasonable prospect of the company remaining active at the mine for years to come, given the scale of the VUP.

In the PGM field, Murray & Roberts Cementation has worked for several years on various aspects of the giant Platreef project near Mokopane and is just starting its latest contract at the site, which will see it carrying out development for the initial Phase 1 mine. An interesting feature here is that the contract will see Murray & Roberts Cementation using a battery-powered mining fleet – owned by the client, Ivanplats – for the first time.

Moving to safety, Wells says Murray & Roberts Cementation’s safety record is outstanding. “We notched up five million fatality-free shifts just over a year ago, which was a major milestone, and we should hit the 6 million mark shortly. We’ve now been fatality free for around six-and-half years, which is a truly exceptional run. We attribute our success to our Major Accident Prevention (MAP) programme, as well as the excellent training we provide at our world-class Training Academy at our Bentley Park premises near Carletonville.”

The task of bringing new business into Murray & Roberts Cementation is the responsibility of Allan Widlake, new business director, who says there is plenty of scope for the company to grow both in South Africa and the rest of Africa. “Clients across the board are starting to put out new tenders and projects that were previously on hold are now coming to the market,” he states. “This is particularly the case in South Africa but we’re encouraged by developments in other parts of Africa. In Zambia, for example, there are definitely some opportunities emerging on the Copperbelt.”

Widlake says Murray & Roberts Cementation is differentiated from most other players in the market by the breadth of its offering, its procurement ability, its balance sheet, its HR skills, its safety record and the training facilities at Bentley Park. As he says, “Our Training Academy is a huge asset and is particularly important now that localisation of employment opportunities is a requirement on virtually all contracts. We can take people with no mining experience and bring them up to an impressive level of competence very quickly by putting them through Bentley Park.”

Moving back to the global perspective, Mike da Costa says that the relatively recent acquisition by Murray & Roberts of Terra Nova Technologies in the US and Insig Technologies in Australia will significantly expand the Mining Platform’s capabilities. 

San Diego-based Terra Nova has given the platform a strong foothold in the materials handling market. The company designs, supplies and commissions overland conveyors, crushing/conveying systems, mobile stacking systems and in-pit crushing and conveying systems. 

“Terra Nova is a perfect fit for Murray & Roberts’ Mining Platform and gives us the capability of delivering, for example, conveying systems of up to 12 000 t/h capacity,” observes da Costa. “Its biggest market is North America but it is also active in South America and has an office in Santiago in Chile. It has, in fact, just won a major contract in Chile. Our intention is to grow the business by leveraging our global footprint.”

Commenting on the Insig acquisition, da Costa says it takes Murray & Roberts into high-tech territory, as the company specialises in developing IoT (Internet of Things) systems and remote control solutions in the mining field.

“We’ve been working on a digital strategy for the Mining Platform for some time now and the acquisition of Insig is central to our digital journey,” concludes da Costa. “We will be using Insig’s systems in house initially but will ultimately market them to the wider mining industry. We see them as being vital in our move to increase efficiencies, cut costs and increase safety through digitisation.”

Client Focus

TECHNOLOGY TO REMOTELY MONITOR, MANAGE PUMPS

Digital technology is taking the reliability of water pump solutions to another level, with remote monitoring and control now giving users more insight into operations than ever before. 

The result, according to Nicolette Gomes, senior service sales specialist at Grundfos, is that users have the ability to assess their equipment performance at all times – and to plan well in advance for the necessary servicing interventions.

“We facilitate this process with our Grundfos Remote Management (GRM) system, which is a cloud-based portal that users can log in to from anywhere,” says Gomes. “The required module just has to be installed onto a pump controller We can even install GRM on other pump brands, after updating the controller on their system.”

She explains that GRM provides a real time overview of the pump system, generating valuable data on key performance indices and transmitting that to the portal. The user can view the data and monitor exactly how the pumps are performing at any given time. 

“The benefits of this portal include the ability to track energy consumption and flow volumes  and to generate reports on this activity,” she says. “A range of alarms can be activated to alert operators to issues such as over-voltage or under-voltage, as well as water shortages and other problems.”

The GRM will also send a notification to Grundfos and the customer when the pre-determined service intervals have been reached, ensuring that regular maintenance is conducted to optimise pump longevity and performance. 

“This gives us the opportunity to order in the necessary spares, to have them available as soon as the customer’s operation provides the opportunity to conduct the work,” she says. “Even the details of each maintenance intervention – including the parts replaced – can be logged on the system, so that a good record is maintained.”

There is even an element of remote control in the GRM, which allows the user to manage the equipment – for instance, stopping and starting the pumps – without having to physically stand in front of the machinery, she notes. This can help to avoid catastrophic failure from conditions like dry-running.

“We can connect this to a Grundfos MGE motor with an integrated frequency converter or CUE external frequency converter, to monitor operational data,” she says. “This includes the power consumption, speed and set points, so that customers can see how their systems behave over time, and can use these insights to minimise downtime.”

Gomes concludes that customers gain inestimable value from these technology tools, as they not only ensure optimal performance but also avoid costly repairs and unscheduled downtime.