Monthly Archives: May 2024

Client Focus

MINING SERVICES LEADER OFFERS THE FULL PACKAGE

A household name for shaft sinking in Africa’s mining sector, Murray & Roberts Cementation has over the decades developed a wide portfolio of mining services – some better known than others.

“Through our constant innovation across a range of fields, built on the expertise of our highly experienced staff, we keep developing very interesting responses to customer’s challenges,” says Pieter Oosthuysen, Senior Project Manager at Murray & Roberts Cementation.

Among the sector’s growing challenges has been the criminality associated with illegal mining activities. The company has developed solutions to prevent cable theft – including the encasing of cables in grout-filled pipes – and to seal off old areas using grout packs that create permanent barriers.

“Water management has also become a key issue for mines, especially in the mature deep-level gold mining sector,” says Oosthuysen. “Here, their issues are about ensuring responsible water management as well as reducing pumping costs from dormant or mined-out mining areas. This often requires that old underground areas be sealed off to contain the massive water pressures at depth.”

This is by no means a new issue, of course, but Murray & Roberts Cementation has been in this field for so long that they literally ‘wrote the book’, he notes. The company was part of the team that developed the Code of Practice for designing and constructing high pressure bulkhead plugs, and has a track record dating back decades with plugs and water doors.

“Our team collaborates with plug designers to guarantee that the plug’s design and placement are constructable,” he explains. “The successful construction and pumping of these plugs relies on the use of our mobile grout plants to overcome logistical obstacles.”

It demonstrated this capacity many years ago, when the company’s intervention saved the West Driefontein gold mine from flooding back in 1968. Since then, it has pushed the boundaries of technology to achieve a successful plug at over 2,800 m deep at ERPM’s 68 Level – where it also placed its longest plug segment at an impressive 24 m.

Managing water in the underground environment is not the only place where the company has excelled. As the public spotlight has focused on the safety of tailings dams, Murray & Roberts Cementation helps mines with the crucial task of draining water from these facilities.

“If drainage pipes from the penstocks are damaged over time, these need to be replaced to ensure proper drainage to support the stability of the dam,” he says. “While the mine installs new penstocks and drainage, we wash out these old pipes, install intrusion pipes and seal them off to ensure no leakage.”

Behind these achievements is Murray & Roberts Cementation’s pioneering role in the field of grout plants. It was the first to design and implement a high pressure pumping system that could convey grout from a surface plant to workings underground; the distances regularly covered by these systems have been between three and seven kilometres.

With further capability in aspects including raise drilling, silo and settler construction, blind hole boring, vent passes and ore and shaft rehabilitation, the company presents an unmatched portfolio, according to Dirk Visser, who is also a Senior Project Manager at Murray & Roberts Cementation.

“It is these additional support services that make us really unique in the market,” argues Visser. “Most other players will specialise in one or other aspect of this work, but we give customers the advantage of an integrated solution – allowing us to assume more project risk and relieving customers of significant coordination responsibility.”

For this reason, the company can manage projects that demand drilling and cementation, for instance, while also providing the raiseboring and remote shotcreting functions. The capacity to deliver these offerings, he emphasises, demands skills and experience which requires considerable investment.

“The core talent in our division has an average length of service between 12 and 18 years – with many employees reaching 30 to 40 years within the business,” he says. “We also continuously replenish our skills pipeline with up-to-date, relevant training which includes state-of-the-art training facilities including mock-ups for a grout plant, drop raise and raise drilling.”

The necessary hardware is also an important part of any successful project, and the investment by Murray & Roberts Cementation has also been significant. There is an extensive fleet of machines for the raiseboring part of the business, with more than 8 km of drill pipe available. “All that we do is underpinned by our comprehensive Murray & Roberts Cementation safety system, which has been developed by taking best practice and enhancing our own CRM systems,” he concludes. “The effectiveness is our safety commitment is demonstrated by our track record – with over seven million fatality-free shifts.”

Client Focus

SLURRYSUCKER PUTS SEWAGE WORKS BACK ON TRACK

Developed by local pump and dredging expert IPR, the SlurrySucker dredging system recently provided the ideal solution for getting the emergency water dams at a Gauteng wastewater treatment plant back to optimal condition.

Warren Spann, Business Development Manager at IPR, explains that the emergency dams had filled with sludge over time, and were presenting an operational risk to the plant. Dredging the dams with hydraulic excavators was not effective for a number of reasons, and the manual removal of sludge in trucks caused environmental challenges. The dams are vital sources of additional water for the treatment plant during times when insufficient volumes are flowing into the facility.

“IPR was contracted to conduct the dredging of these emergency water dams, and we put our new generation SlurrySucker Maxi onto the job,” says Spann. “This powerful dredging system is equipped with three Toyo K30 heavy-duty submersible slurry pumps, and was able to remove 50 dry tonnes per hour.”

Importantly, these specialised heavy duty 22kW Toyo pumps are capable of dealing with the wide variety of solids that accompany the wastewater to the plant including rags, nappies and even pillows. The pumps’ capacity allowed them to pump the sludge through 450 metres of pipeline on this contract, without the need for inline boosting.

Mounted on a purpose-designed pontoon, the SlurrySucker Maxi was drawn from across the 250 m long dams using ropes and a winching system. The operation was managed through remote controls in the hands of a trained and experienced technician, ensuring optimum safety.

“There were also two Atlas Copco WEDA D70H jetting pumps on the pontoon, to help stir up the sediment in the dams,” he says. “The first pump jets water down to the dredge head to agitate compacted sludge on the bottom of the dam, while the second pump jets water into sludge that is near – or even protruding from – the surface of the water. The latter is necessary as the pontoon needs 350 to 400 mm of water on which to float.”

To ensure that the discharge from the dredging activity complied with environmental standards, the dredged material was pumped into large dewatering bags. Each bag held 25,000 tonnes of material, and measured 30 m in circumference and was 60 m long.

These bags allowed water to weep out into a catchment pond, and IPR added a flocculant to the pipeline to help the solid materials to settle out. This strategy helped the wastewater plant to conserve water, as the filtrate was pumped back to the plant for re-use. The added flocculant in the filtrate assisted the plant further by contributing to the levels of flocculant that the plant would be adding as part of its normal process.

Lime was used to reduce the odour from the dewatering bags, giving the customer various options related to removing the material later including the provision of activated sludge to the agricultural sector.

“An added advantage of our dredging technique is that all our equipment is electrically powered, so it operates with hardly any noise,” says Spann. “This is in stark contrast to heavy mechanical equipment, and meant that we did not disturb the neighbouring residential estate.”

He adds that IPR’s advanced control panels on the SlurrySucker ensured that the power would trip if any oversize material threatened to damage the pumps. The panels convey an error message to the operators, so they can resolve the issue and return the system to work without risking any further harm to the equipment.

Client Focus

NEW BRANDING SECURES AUTHENTICITY OF LINATEX PREMIUM RUBBER

To reinforce the authenticity of its Linatex® premium rubber and protect its customers from inferior counterfeits, Weir Minerals has introduced new branding to its red iconic rubber recognised globally for its unrivalled wear life and lower total cost of ownership.

Exclusively manufactured by Weir Minerals for the past 100 years, Linatex® premium rubber has become the benchmark in protecting equipment against erosive damage. Over the years, copycats have tried to imitate Linatex® with substandard red rubber. To a regular consumer, it may seem like a bargain to buy the pirated product at an incredible price. However, it incurs massive adverse effects on almost every aspect of their operations.

Boitumelo Zimba, Rubber Product Manager at Weir Minerals Africa, says the distinctive red colour has traditionally been the major identifier of the Linatex® brand. Unfortunately, in recent years, there has been a marked influx of counterfeits that are made in the same red colour, which is confusing for unsuspecting end-users who may not be able to differentiate between the original Linatex® rubber and the pirated product.

“Customers across the world are aware of the value that Linatex rubber brings to their operations,” says Zimba. “It is only when that expected value is not achieved that they realise they have been sold inferior red rubber products under the Linatex name.”

To secure the authenticity of the brand, all Linatex® premium rubber is now branded with four rows of black Linatex® logos strategically placed along the length of the rubber roll. Extensive testing has confirmed that the black ink does not affect the unparalleled abrasion resistant properties of the rubber that has been the industry’s first line of defence against abrasion for a century.

The introduction of this new branding will enable customers to instantly, visually, verify the authenticity of their rubber products. The presence of the black Linatex® logos will be a guarantee of superior quality and performance.

Linatex® premium rubber is made from 95% natural latex using a unique liquid-phase process patented in 1923. Remarkably, its formulation and manufacturing process have remained unchanged for a century, with Weir Minerals Malaysia proudly serving as the sole manufacturer of Linatex® premium rubber in the world.

In contrast, says Zimba, most of these counterfeit products are produced in unregulated conditions that make use of low quality materials. During manufacturing of these products, there is no guarantee that the rubber goes through mandatory quality checks to ensure superior quality and performance.

“With Linatex premium rubber, quality is guaranteed through our single-source manufacturing process. Where necessary, we can also provide certification to indicate the authenticity of the product, especially when it is sold through our authorised resellers. However, the new branding will be extremely visible, allowing customers to easily identify that the product they are buying is indeed Linatex premium rubber,” concludes Zimba.

Client Focus

INNOVATIVE TRANSFORMER DESIGN FOR DATA CENTRE IN NIGERIA

The upgrade of a data centre in Nigeria has called for a custom-engineered dry-type transformer solution that can deal with, among other challenges, high level of voltage fluctuations.

According to Trafo Power Solutions Managing Director David Claassen, the contract followed successful past engagements with an existing data centre customer – who is now involved in Africa’s most populous state.

“In the context of an unstable power supply, this application required an unusual but effective solution,” says Claassen. “The challenge is that the voltage of the electrical supply in this area often fluctuates between plus and minus 10% of nominal voltage, so we designed our transformers to include an automatic on-load tap changer (OLTC).”

Further to this, the high level of total harmonic distortion, related to data centres, necessitated the need to design the transformer according to K-factor 13 to ensure maximum reliability and to compensate for the additional heat caused by these harmonics, as well as the associated voltage distortion.

The OLTC is installed on the transformer feet and fully integrated by Trafo Power Solutions. When there are fluctuations in voltage – up or down – this is sensed automatically and the secondary voltage of the transformer is adjusted accordingly by the OLTC, which ensures a stable secondary voltage reaches the data centre’s critical equipment. This specific design will allow the transformer to correct up to 10% under-voltage and up to 10% over-voltage in the power supply in four equal steps.

“It is important to realise that this level of fluctuation – if not corrected – would be extremely detrimental to electrical infrastructure,” Claassen continues. “In fact, some equipment would experience catastrophic failure under these conditions.”

Included in the project scope was also the control and protection of both the transformer and tap changer – as well as an automatic voltage regulator – making up a complete solution for the customer. The transformer supplied by Trafo Power Solutions is a 2,000 kVA unit which will step down the incoming voltage from 11 kV to 400 V. The company is also responsible for commissioning the solution on site.

“Cooling will be achieved in an air natural (AN) configuration, but fans have been included on the transformers to allow them to carry a 25% higher load, if necessary,” says Claassen. “The cooling aspect of the design is important in this context, as the higher harmonics can also lead to raised temperatures in the transformer.”

Trafo Power Solutions includes an electrostatic shield between the primary and secondary windings in this type of design to arrest any stray current that could be caused by the harmonic distortion. He highlights that there is no room for downtime in the data centre industry, so transformer design must be exacting and the manufacturing must be to the highest industry standards.

“A critical measure of any data centre is its level of uptime, so the customer needs stable voltage to underpin the reliability of all its infrastructure,” he says.

Claassen adds the company also offers modular solutions for data centres, an approach with particular benefits as customers can build up their medium voltage infrastructure gradually as their business grows. This facilitates a smooth and cost effective ramp up of operations, with the modular approach allowing the addition of new capacity without disruption.

Client Focus

SANDVIK BUILDS LOCAL PRODUCTION OF SCREENING MEDIA

As Sandvik Rock Processing makes significant investments in local screening media manufacturing capabilities, it is building the level of aftermarket support for its growing capital equipment portfolio.

According to Riaan Steinmann, EMEA Operations Director Screening Solutions at Sandvik Rock Processing, the company’s local and global R&D teams are developing exciting new product offerings.

“Our local screening media manufacturing operations at Crown Mines in Gauteng align with our global procurement focus on sourcing raw materials,” says Steinmann. “This makes it possible to use our own unique material formulations to manufacture world class screening media products.”

Together with its specialised materials, Sandvik Rock Processing also optimises each screening media panel design to maximise wear life and efficiency, he says. The company has developed panel load limit calculations to ensure structural integrity while avoiding over-designing.

“Optimising our screening media allows us to streamline our screen designs, leading to overall mass and cost reductions,” he explains. “As an essential part of our vibrating equipment offering, our screening media offer optimal performance at the lowest overall cost.”

He notes that the open-case polyurethane dispensing machine at Sandvik Rock Processing’s Crown Mines facility is specially designed in a flexible machine configuration – to produce a range of polyurethane products of the highest quality and at the most efficient rate.

“Various non-standard polyurethane parts can be made in an open-mould casting process,” says Steinmann. “This is achieved by placing moulds on a heated casting table, and then filling them with hot-coat polyurethane mixing systems using the dispenser casting hose.”

This allows the machine to produce parts such as non-standard-sized screening panels and sideliners, wedges, discharge liners and protector liners – providing flexibility in meeting a diverse range of products even at low volumes. He highlights that Sandvik Rock Processing regards innovation as a strategic cornerstone, using the discrete element method (DEM), for instance, to analyse material flow and optimise the selection of aperture size and type for each application.

“Our screening philosophy is that the optimal design and selection of screening media panel should cater to the distinctive characteristics of the ore being treated,” he explains. “This in turn needs to align with the vibrating machine’s physical and dynamic parameters. It is our strong portfolio in both vibrating screen equipment and screening media that puts us in the best position to provide tested solutions to the market.”

Sandvik Rock Processing R&D teams undertake continuous research using data from on-site performance. These studies investigate efficiencies and wear characteristics of screening media products under various operating conditions – and build the findings back into new designs and products. 

The local production of screening media by Sandvik Rock Processing promises to deliver shorter lead times and lower transportation costs for customers. Importantly, there is also a positive impact on the resilience of the supply chain. Steinmann adds, “There is also the environmental benefit of shorter transportation routes, which aligns with our own sustainability goals and those of our mining customers”

“We work towards finding the right balance between local and global sourcing, and are committed to supporting the local economy, skills development and job creation capability,” says Steinmann.

He acknowledges that, like all businesses in South Africa, the local screening media facility must meet the challenges of power disruptions from loadshedding, cable faults and cable theft. To prevent these issues from affecting the reliability of production and supply, Sandvik Rock Processing has invested significantly in sufficient backup power generating capacity to keep the plant running as required.

Client Focus

NEW TOWER LIGHT RANGE FROM PILOT CRUSHTEC

Crushing and screening operations frequently run on a 24/7 basis to meet demand and optimise productivity, so crushing specialist Pilot Crushtec is the ideal partner to introduce its own brand of mobile lighting towers for these and other applications.

According to Pilot Crushtec Sales and Marketing Executive Francois Marais, the company has supplied lighting products before, but this step will see the new range under its own brand – Mobi Light.

“Our own brand gives us the flexibility to source the right products internationally, and provide the high level of local support that customers have come to expect from us,” says Marais. “Owners of sites that operate after dark will benefit from this range, and we will also supply to plant hire companies who rent this equipment to mainly the construction and mining sectors.”

The range covers mobile lighting solutions at entry level right up to premium applications, he explains. On the smaller end, a unit with four 320 LED floodlights will achieve a lighting area up to 5,000 m2; at the other end of the scale, a mining unit with six 320 WLED floodlights will light up 7,800 m2.

Ben Armitage, Sales Engineer at Pilot Crushtec, explains that safety is a key consideration in the way the company has positioned its offering.

“Not only do you need sufficient lighting for the stationery crushing and screening equipment on a site, but there are typically several pieces of yellow metal equipment such as excavators, trucks and loaders moving around,” says Armitage. “Good lighting is therefore a critical element of the industry’s quest for Zero Harm.”

He notes that insufficient lighting also affects productivity. Where there is limited visual capacity, operators tend to reduce feed rates to plants – to avoid the risk of blockages and spillage. This can have a substantial effect on production and the resultant cost of operating the site.

“Other factors that the Mobi Lite tower range considers is the height of our masts,” he continues. “With our high masts at 8,5 metres, this ensures an increased lighting area while reducing operator fatigue, as the light is high enough to never shine in the operators’ eyes.”

The range takes advantage of developments in lighting technology – away from metal halide and toward light-emitting diode (LED) technology. LED lights offer a much longer lifespan, operate at low voltages and produce less heat.

“This has significant benefits for outdoor site operators,” he says. “LED lights light up the work area instantly and don’t require a cool-down period before the lighting plant can be relocated. These lights also consume less power, saving money especially when on-site power is diesel generated.”

Designed for demanding site conditions, the lighting units have a robust steel canopy to house the generating unit and start up panel. This strong structure prevents battery and diesel theft. Maintenance and inspection are also easier, as the steel doors on each side of the lighting plant can be opened for access to the large engine bay.

Client Focus

LATEST SA-DESIGNED HVAC FOR MILITARY VEHICLE

South Africa-based Booyco Engineering has upgraded the heating, ventilation and air conditioning (HVAC) system for a customer’s 8×8 armoured personnel carrier.

With almost 40 years of experience in custom designed robust HVAC solutions for the defence sector, the latest prototype is the third iteration of a bespoke unit for this longstanding export customer. According to Grant Miller, Executive Director at Booyco Engineering, the key advances in the latest system have been its integrated electronic control system and the addition of heating functionality.

“This version of the unit allows the driver two-way engagement with HVAC related information on the vehicle’s touchscreen dashboard consol, rather than via a standalone control panel,” says Miller. Using a controller area network (CAN bus) enabled controller, the HVAC’s control system is now fully integrated into the vehicle’s control communication network. The unit makes use of a micro-processor controller that was locally developed specifically for HVAC applications in military vehicles. The addition of heating to the system means that the vehicle can now be deployed in areas with colder climates.

Designed and manufactured in South Africa, the HVAC system is fully rated to stringent military standards. These include environmental specification MIL-STD-810G, MIL-STD-461C and MIL-STD-464C specifications on electromagnetic conformance and interference, and MIL-STD-1472F on general human engineering design. It was supplied to the customer in mid-2023 and has undergone extensive field testing under demanding conditions.

Ross Macphail, Engineering Manager at Booyco Engineering, highlights that the customer is also developing a hybrid electric-drive version of the same vehicle – in which the batteries will also require cooling.

“They intend to use our HVAC system for their new hybrid vehicle, where our equipment will be cooling not just the internal crew space but the batteries as well,” says Macphail. The large traction motor batteries on electric vehicles need to be actively cooled during operation.

He points out that this system also makes use of brushless DC compressors as opposed to a traditional engine driven compressor, which allows the HVAC system to be run independently of the vehicle engine.

Booyco Engineering’s HVAC equipment is designed to perform reliably in the high levels of shock, vibration and dust encountered in military applications. It also limits electromagnetic interference (EMI), which is unwanted electrical noise radiated and conducted from the equipment during operation. This aspect is particularly important in a military context, where EMI can negatively affect communication and other electronic equipment in the vehicle.

Client Focus

SEW-EURODRIVE TO SUPPLY ADVANCED DRIVE TECH FOR KEY AUTOMOTIVE PROJECT

Leading automation giant, SEW-EURODRIVE, is set to enhance a US-based vehicle manufacturing plant with its cutting-edge decentralised drive technology, specifically from their Generation C range.

This advanced technology will be incorporated into a brand-new storage and retrieval system at this automotive manufacturing facility. The primary objective is to streamline the supply of vehicle bodies to the existing manufacturing unit, in a bid to meet the soaring demand for vehicles and to bolster the plant’s production capacity.

Highlighting the significance of securing the order, Phillip Steyn, SEW-EURODRIVE South Africa Gqeberha Branch Manager, says the company has a solid track record in supplying drive technology solutions to the automotive industry.

“We have consistently demonstrated our commitment to innovation and our drive technology solutions continue to play a pivotal role in enhancing the efficiency, precision and reliability of manufacturing processes within the automotive sector,” he says. “Whether it’s providing advanced gearmotors, precision control systems or customised automation solutions, we contribute significantly to the industry’s ability to meet the demands of an ever-evolving market.”

Steyn points out the strong global support network of SEW-EURODRIVE, which offers unparalleled logistical flexibility. This ensures optimal shipping strategies including some drives being shipped directly from Germany to the US, while others are directed to the company’s facility in Gqeberha.

“We have strategically planned our deliveries in phases, tailored to the project’s requirements. Project completion is scheduled for September 2024,” adds Steyn.

“It’s noteworthy that this particular vehicle manufacturer relies consistently on SEW-EURODRIVE’s drive technology for all its global facilities. Specifically for this project, over 300 units from the Generation C range will be incorporated and this decentralised technology will facilitate independent and collaborative operations of the drives, either positioned on or near the motor in the field,” he explains.

“These units have been meticulously designed to resonate with the fast-paced dynamics of the automotive sector, ensuring a seamless process flow and top-tier production efficiency,” Steyn says. The decentralised drives will be integrated with SEW-EURODRIVE’s Digital Data Interface (DDI) platform and state-of-the-art servo technology for peak energy efficiency.

He elaborates on the advantages of decentralised tech over its centralised counterpart, underscoring its sustainability and consistency. “All products in our decentralised range share a uniform controller and interface, enhancing user experience and flexibility, with reduced spare parts inventory.”

The end-users stand to gain significantly as well. They can expect quicker and cost effective installations, faster maintenance response times and minimal disruptions, paving the way for uninterrupted productivity.

Client Focus

BOOYCO ELECTRONICS LEADS THE CHARGE IN QUARRYING & SURFACE MINING ELEVATING SAFETY WITH PDS

The continued focus on integrating Proximity Detection Systems (PDS) in South African quarries and surface mines highlights a significant shift towards enhanced safety and regulatory compliance. This move, directed by the Department of Mineral Resources and Energy (DMRE) regulations, underscores the critical nature of technology in mitigating workplace accidents. 

As the pioneer of PDS in South Africa and with more than eighteen year experience in the field, Booyco Electronics believes that the human factor is a crucial element in the successful deployment of such technologies.

Anton Lourens, CEO of Booyco Electronics, argues that beyond the technical installation, the acceptance and willingness of employees to embrace these tools and adopt them in their daily operations are fundamental to their effectiveness. He advocates for a comprehensive approach to change management that involves all organisational levels, from front-line workers to top executives, ensuring a unified understanding of the technology’s purpose, benefits and operational impact.

Lourens points out that the successful implementation of PDS technologies not only promises to enhance safety in quarries and surface mining operations but also influences other key operational aspects, such as equipment availability and productivity. He emphasises the importance of clear communication about the technology’s objectives to facilitate smoother adoption and minimise resistance among employees. 

Drawing from Booyco Electronics’ experience, Lourens highlights the setbacks in safety and productivity that can arise from inadequate change management, stressing the need for employee involvement in the process to foster a sense of ownership and understanding.

The change management strategy at Booyco Electronics begins with a technical readiness assessment to tailor the PDS technology to the unique conditions of each site. It encompasses educating stakeholders about the technology’s capabilities and limitations through specific deployments, managing expectations and providing training that explains the rationale behind the investment and its operational mechanics. 

Lourens also underscores the importance of ongoing training and system optimisation based on user feedback to ensure the continuous success and improvement of the PDS technology. Additionally, he cautions against the unintended consequences of technology dependence, advocating for proactive management and continuous education to maintain the safety benefits of PDS implementations.

Client Focus

CONCOR MOVES INTO HIGHLY TECHNICAL PHASES AT MSIKABA

The band is starting to play louder at the awe-inspiring Msikaba Bridge project, according to Concor’s Laurence Savage, Project Director of this pioneering structure. The Msikaba Bridge forms part of the South African National Roads Agency Limited’s (SANRAL) N2 Wild Coast project and is being constructed by the CME JV, a partnership between Concor and MECSA, both 100% black owned Grade 9CE South African construction companies.

“The last two years have been spent completing the four 21,000 t anchor blocks and progressing the elegant bridge pylons on each side of the gorge,” explains Savage. “We are now entering some exciting but technically challenging phases.”

The first of these is the post-stressing of the anchor blocks, to ensure the transfer of load exerted by the stay cables is well distributed through the blocks. Embedded 14 metres deep into each block, the post-stressing is profiled as a large ‘U’ shape to mobilise the dead mass of the anchor block being pulled up by the stay cable at the top.

He highlights that the post-stressing option is a modern and efficient strategy that reduces the need for reinforcement steel – which could have congested the blocks and made it difficult for the concrete to fill all the voids. The locally procured post tensioning strand cables at each of the 17 anchor points in each block are stressed up to around 500 t by a specialist company. The process is expected to take two to three weeks for each anchor point.

“The next major step will be installing pylon inserts into the pylon’s structure as it rises above the 86 metre mark,” he says. “There are 17 inserts for each pylon; these are steel rings weighing 8 to 10 t each, which are concreted into place one after the other until the pylon reaches a height of about 122 metres.”

The pylon inserts are used as the anchors from which the cables run as back-stays to the anchor blocks, and as fore-stays to the bridge deck. However, Savage notes that not all the inserts have to be in place before the launching of the deck can begin. Careful planning will allow the deck launching – itself a highly technical task – to commence after the first five inserts are installed, which is likely to be in the second half of 2024.

Another demanding aspect of the bridge’s latest phase will be the construction of the ladder deck. Being the first steel deck segment of the bridge, the ladder deck is to be cast in concrete into the foundation of the pylon and will be the largest continuous pour on site.

“We will cast 700 m3 of concrete in a single pour, with a very strong 65 MPa mix,” he says. “This will also demand a high density of reinforcement steel, weighing 160 t.”