In today’s challenging economic climate, achieving successful project delivery without cutting corners is not only possible but necessary for creating a sustainable future. Concor, a leading construction company, continues to demonstrate this ethos by adhering to fundamental principles and uplifting small to medium enterprises (SMMEs) in the construction industry. The company’s approach, founded on getting the basics right, has consistently enabled it to deliver projects on time and within budget, even in the most demanding environments.

A prime example of Concor’s successful project delivery model is the current construction of two new buildings, 10 Parks Boulevard and 55 Eastwood Road, within the prestigious Oxford Parks Precinct in Johannesburg. Known for its top-tier tenants, Oxford Parks is a highly sought-after commercial area, and the calibre of its developments is testament to the commitment of both Concor and the client, Intaprop, in enhancing the exclusive feel of the precinct.

Warren Mills, Contract Manager at Concor, says work on the project commenced in February 2024, with bulk earthworks completed by March and raft foundations following in April. “Once construction of the super-basement was underway, focus then shifted to the 10 Parks office tower and the project has progressed to the completion of level five on 10 Parks and activities on three for 55 Eastwood,” he explains. Both buildings are being constructed simultaneously, ensuring that timelines are met and that efficiencies are achieved throughout the process.

The common basement of 10 Parks Boulevard and 55 Eastwood Road is a substantial structure, utilising 15,350 cubic metres of concrete and 1,620 tonnes of rebar to ensure its strength and durability. With a footprint of 21,035m² spread over four levels, the basement also incorporates 520,000 bricks for internal brickwork, providing the foundational support needed for both buildings. 

The 10 Parks Boulevard office tower will require 4,250m³ of concrete, 510 tonnes of rebar, and 450,000 bricks to complete its structure, with a Gross Lettable Area (GLA) of 7,562m² spread across its five floors. Meanwhile, the 55 Eastwood Road building will use 3,250m³ of concrete, 370 tonnes of rebar, and 370,000 bricks for its four floors, with a total GLA of 4,734m². These materials reflect the scale and quality of the construction, ensuring both buildings meet high standards of durability and aesthetic appeal.

Despite some challenges, Concor’s 10 Parks project is currently ahead of schedule, highlighting the company’s ability to deliver quality work while adhering to tight timelines. This success can largely be attributed to Concor’s experienced project team, which has extensive knowledge of the Oxford Parks Precinct, having worked in the area for over seven years.

Central to Concor’s success in Oxford Parks is its commitment to uplifting SMMEs. “We have actively pursued a dedicated programme of mentoring small subcontractors from the start of our work within the Oxford Parks Precinct. One of our focuses has been to ensure they meet the high standards required for quality and safety, and this approach not only ensures that work is completed to our quality specifications but also helps develop a skilled and sustainable subcontracting workforce for the future.” 

Significantly, this Concor programme has seen many of these subcontractors become preferred partners, further ensuring that Concor’s projects remain ahead of schedule and exceed client expectations.

Mills stresses that it is important to note that Concor remains competitive by tendering out all subcontracting work, thereby giving a wide range of SMMEs the opportunity to participate. “By spreading these opportunities, we help foster a more inclusive and dynamic construction industry, ensuring that the benefits of projects are shared among a broader pool of businesses.”

The 10 Parks Boulevard and 55 Eastwood Road developments will be impressive additions to the Oxford Parks Precinct. 10 Parks offers five floors of office space and a retail floor totalling 7562m² GLA, while 55 Eastwood provides three floors of office space and a retail floor covering 4734m² GLA. The buildings share a four-level basement that includes parking and energy centres. Additionally, both buildings will feature rooftop solar installations, contributing to the sustainability of the project.

The ground floors of the buildings will house retail outlets, opening onto open terraces and pedestrian walkways. Terraces will also be available on the first and top floors, providing open spaces for social interaction. Both buildings are designed with curved east-facing facades to invite more natural light, and 10 Parks will feature a mechanically fixed tile façade, enhancing the aesthetic appeal of the development.

The Oxford Parks Block 2A Phase 1 project is targeting a Green Star V2 certification, reinforcing Intaprop and Concor’s commitment to sustainable construction. Achieving this certification requires a collective understanding and effort from the entire professional and construction team, including subcontractors and labourers. Communication and education are key in ensuring that every team member is aware of the requirements to minimise the project’s carbon footprint.

Concor’s operating model is centred on a back-to-basics approach, which focuses on executing the fundamental aspects of construction to the highest standard. Mills say that this attention to detail has proven time and again to be a formula for success. “When the basics are done right, everything falls into place, and the result is a successful, high-quality project.”

Agility also plays a critical role in Concor’s project delivery. The company’s ability to accommodate reasonable changes in design or programme allows it to remain competitive in a dynamic market, particularly when dealing with the ever-evolving demands of the property rental sector. Whether it’s adjusting to a tenant’s request for an earlier occupation date or modifying design elements, Concor’s agility ensures that its projects stay on track without sacrificing quality.

Concor’s continued success in delivering quality projects, even amid economic challenges, is a testament to its commitment to excellence, sustainability, and inclusivity. By focusing on the basics and uplifting small contractors, Concor ensures that each project is completed to the highest standard while contributing to a sustainable future for the construction industry. The 10 Parks Boulevard and 55 Eastwood Road developments are just the latest examples of how Concor’s tried-and-true approach continues to deliver remarkable results in the built environment.

Concor won two prestigious Construction World Best Projects 2024 Awards for its impressive work, undertaken in joint venture with Lubocon Construction, on the Ash Disposal Facility (ADF) expansion at Eskom’s Kendal Power Station near Ogies, Mpumalanga. Placed as the winner in the AfriSam Innovation Award for Sustainable Construction Category, the projects also secured a Highly Commended in the Civil Engineering Contractors Category. These awards highlight Concor’s commitment to environmentally responsible engineering and infrastructure innovation, especially within the power generation sector.

The project is notable for its sheer size and complexity, covering approximately 2.5km by 3km. The construction scope included a new 65 hectare ash disposal site, two lined dams for clean and polluted water, a 16km V-drain water channel system, silt traps, access roads and a significant 3km stream diversion. This expanded ADF enables Kendal Power Station to manage ash disposal sustainably, extending its operational life by almost another decade. The project’s comprehensive design ensures compliance with stringent environmental regulations, a critical aspect of maintaining energy production while safeguarding surrounding ecosystems.

The 3km stream diversion, a prominent element of the project, channels clean water around the ADF to prevent contamination. Designed to withstand extreme conditions, the diversion is built for 1-in-100-year flood levels and is reinforced with erosion control structures including gabion linings and Reno mattresses. The gabions alone required more than 4,100 hand-filled baskets, using over 42,000 tons of rock and employing 120 workers for 19 months. 

This diversion not only protects water resources but also aids in the restoration of a natural ecosystem as the gabions and river mattresses help stabilise the banks and encourage revegetation with wetland materials. A biodegradable blanket further prevents erosion on the banks, creating a supportive habitat for aquatic life and vegetation.

Environmental compliance was central to the ADF’s design, particularly the prevention of groundwater contamination. The facility was lined with a robust composite system, comprising two 150mm thick layers of low permeability clay sourced from on-site excavation. This clay layer, combined with an impermeable HDPE liner and a subsoil drainage system, forms a durable barrier that prevents seepage into the groundwater. Above this liner, a leachate collection system of HDPE pipes in a herringbone layout helps capture and manage potential contaminants, further safeguarding the environment.

The ADF project also included the construction of two strategically located dams—one for polluted water and the other for clean water. Dam 1, designated for polluted water, has a capacity of 130,000m³ while Dam 2, for clean water, can hold up to 257,000m³. These dams were compartmentalised for greater control and efficiency and included a 150mm concrete ballast layer for structural integrity. Concor applied a patented PVC formwork system during the dam construction allowing faster and more efficient casting of concrete panels, significantly reducing time and labour.

Facing a strict project timeline, Concor and Lubocon maintained continuous operations, leveraging around-the-clock shifts during dry months to make the most of favourable weather. This rigorous approach allowed the project to meet environmental licensing deadlines with construction commencing in June 2020 and completing in June 2024. 

Despite challenging timelines and complex requirements, Concor successfully maintained its Zero Lost Time Injury (LTI) rate across a total of 2.2 million hours worked. The company’s “Zero Harm” strategy and Visible Felt Leadership principle, involving active oversight by experienced safety officers, were instrumental in fostering a strong safety culture on-site.

The Kendal ADF project also set a high standard for community engagement and corporate social investment (CSI). Concor and Lubocon worked closely with Eskom to implement social initiatives in the surrounding communities. This included the addition of modular classrooms and a kitchen at a local primary school.

Furthermore, the project achieved 85% local content, sourcing materials, transport, security services, and other supplies from nearby towns, thereby boosting local economies. Over its lifecycle, the project employed around 450 local workers, including subcontractors, and partnered with community structures to ensure equitable access to employment. 

Skills development was also a priority, with training provided in fields such as civil engineering, safety, administration, and mobile plant operation. By the project’s end, over 850 locals had received valuable skills training, equipping them for future employment opportunities.

Concor’s approach to environmental management extended to on-site practices that minimised ecological impact. For instance, a subsoil drainage system captures clean groundwater and diverts it into the clean water dam, reducing reliance on municipal water sources and promoting water reuse. Additionally, the project’s stream diversion was lined with local wetland material to encourage natural vegetation growth. Regular maintenance will prevent alien plant invasion and protect the waterway from erosion.

This award-winning project is an exemplary model of sustainable construction, reinforcing Concor’s “Build to Last” philosophy, which emphasises longevity and value. The company’s commitment to quality was underscored by using innovative techniques, such as K Form shutters, which allowed the dam basins’ concrete work to be completed two months ahead of schedule. Every project component, from sluice gates to HDPE geomembranes, underwent stringent quality checks, ensuring a robust final product that would serve the community and environment effectively.

Concor’s achievements in the Kendal ADF project underscore the company’s capability to deliver on large-scale complex infrastructure projects with a strong emphasis on environmental stewardship, community engagement, and technical excellence. This project not only supports Eskom’s operational goals but also contributes significantly to South Africa’s broader energy security by ensuring a stable ash disposal solution aligned with environmental standards.

Two of Concor’s standout projects were recognised at this year’s Southern Africa Institute of Steel Construction (SAISC) Steel Awards, celebrating innovative and complex use of steel in the construction industry. SAISC CEO Amanuel Gebremeskel highlighted the growing complexity and creativity within the industry, and Concor’s projects were no exception, making significant impressions in two key categories.

The Eastgate Solar Phase 2 Project, which won the Innovation and Sustainability Category, is a prime example of Concor’s commitment to driving sustainable construction solutions. This project forms part of Liberty Two Degrees’ larger sustainability journey to achieve Net Zero, and it brought an additional 6.04MWp of solar power to the iconic Eastgate Shopping Centre in Johannesburg. The scale of the project was immense, covering an expansive 30,000 square metre rooftop area. The solar panel structure itself, which required over 560 tons of steel, was not only a technical feat but also an architectural highlight.

Nominated by steelwork contractor, Cadcon, the solar panel structure was constructed using circular and square hollow sections with the steel frame carefully designed to meet both functional and aesthetic demands. The use of tubular and square hollow sections allowed for the creation of a visually striking structure while ensuring the necessary strength and stability. These elements, including the trusses, columns, and edge plates, were fabricated to handle the load of the solar panels, while maintaining a lightweight and modern appearance. This careful balance between form and function was key to the project’s success. 

While Concor served as the main contractor, the steelwork contractor played a crucial role in delivering the detailed and precise work that was required for such an ambitious undertaking. The project was not only praised for its technical achievement but also received a commendation in the Tubular Category, further reinforcing its engineering excellence.

Another impressive project by Concor that garnered recognition was the West Chimney Repairs and Related Works at the Kusile Power Station, which received a commendation in the Mining & Industrial Category. This project involved the construction of three temporary 116 metre stacks and bypass ducts as part of critical repairs at the power station. Once again, the versatility and strength of steel were on full display, as these elements were essential in meeting the project’s demanding specifications and timeline.

The use of steel in this industrial application demonstrated its superior ability to withstand high temperatures, corrosion and structural load. Steel was the ideal material to ensure the durability and resilience of the temporary stacks, which had to be designed for long term stability despite their temporary nature. These structures were vital to keeping the power station operational while repairs were conducted, underscoring the importance of steel in critical infrastructure projects.

Both projects reflect the company’s ability to execute large scale, technically demanding projects with precision and innovation. Concor’s work on the Eastgate Solar Phase 2 Project and Kusile Power Station not only showcases the company’s expertise but also highlights the critical role that steel plays in modern construction, whether in sustainability-driven projects or essential industrial applications. Concor’s recognition at the SAISC Steel Awards reinforces its standing as a leader in the construction industry, particularly in projects that require the highest standards of engineering, sustainability and innovation.

Continued dedication to quality management allows Concor to raise the performance bar, thereby streamlining projects for customers and ensuring the highest levels of workmanship.

According to David Akinnusi, Senior Quality Assurance and Quality Control (QA/QC) Manager at Concor Construction, the quality journey has led to significant advances in the company’s key performance indicators (KPIs). For instance, there has been a 30% improvement in the company’s pass rate for first-time inspections in recent years. 

“Our continuous attention to quality is taking us from good to great,” explains Akinnusi. “An important factor driving this process has been our ‘Build to Last’ quality initiative, which we launched two years ago.”

This commitment, he says, means creating an enabling environment for high performance by all Concor employees – to build long lasting structures that satisfy clients. The quality philosophy drives this performance through excellent workmanship, delivered consistently in every project.

“By carefully managing our work processes, we ensure the quality of our outputs or end-results,” he says. “Our quality system also benchmarks these processes against world class standards; the system itself complies with ISO 9001:2015, while our workmanship meets both SA National Standards (SANS) and each project’s specifications.”

Concor’s quality assurance is therefore closely tied to established standards and procedures, which undergo internal auditing. This is followed by the quality control function, in which the necessary measures are applied through work area inspections and material testing, for example. 

“What is important is that we allocate designated QA/QC personnel to each project,” says Akinnusi. “They are dedicated to monitoring and ensuring compliance to both internal and external procedures and specifications.”

He notes that Concor’s quality philosophy extends beyond the physical structures that the company builds, to the people who build them. This relates to creating a culture of excellence where everyone feels proud, valued, respected and empowered to do their best work.  

“We believe the work done by every individual connects us as a team,” says Akinnusi. “This makes training and development paramount to our operations; it is vital that our employees are well equipped to champion excellence on every site.”

This staff development is done through a range of ongoing programmes to bring the latest knowledge and skills into each field of work. Among Concor’s development initiatives for employees are its study assistance programme, its engineer-to-project-manager programme for graduate engineers, its performance enhancement programme and its career path and succession planning for key functions.

Combining its systems with its depth of experience and skills, Concor is able to manage its quality at every stage of the project lifecycle. At planning stage, for instance, detailed tender reviews are undertaken by the project contract director and the estimating team. This helps to understand the detailed project requirements in relation to resourcing, scheduling and costing of projects. 

“When we get to the design stage, we use only professionally registered engineers to produce drawings for construction,” he explains. “Collaborative efforts are made to identify constructability concerns with the designers, both at the design and construction phases of a project.”

During execution, strict quality control plans are compiled and agreed between Concor and the client – which outline the specific testing and inspection requirements for different activity trades in the project.

“The handover of works is done progressively through trade data book reviews,” he says. “Clients are contractually allowed to snag the works, ensuring the handover is done to their satisfaction.”

There is also a post-handover stage when a contractual defects liability period is applied. Depending on the latent root cause of a defect, Concor remedies any defects that arise during this period. He notes that concreting, brickwork and waterproofing are fields in which contractors commonly experience quality challenges. Overcoming them demands proactive mitigation, with Concor using robust root cause analysis and lessons learnt to apply preventative measures. 

“We also allocate sufficient supervision to these specific high risk trades, and ensure that the personnel involved are competent and trained,” he says. “Our success in doing this is reflected in our non-conformance reporting (NCR) – another of our KPIs – and has direct cost benefits. In recent years, we have trimmed our NCR rates by 20%.”

A crucial outcome of all these quality efforts is the strengthening of relationships with clients, says Akinnusi, so Concor’s KPIs include regular feedback surveys to measure client satisfaction. An intensive 20-item questionnaire is conducted with clients each year to gauge this important factor, so any issues can be quickly identified, discussed and resolved. 

“This level of customer engagement helps to underpin the excellence we deliver, which leads to repeat business,” he says. “In the Oxford Parks Precinct developments, for instance, we have been engaged in five separate contracts over the years – a good sign of client trust in our ability.” 

Despite difficult market conditions in South Africa’s construction sector, Concor has never shied away from its commitment to social and economic transformation, which includes the strengthening of small businesses in areas where the company has projects underway.

According to Sheldon Mayet, Senior Transformation Manager at Concor, the procurement, skills development and recruitment process are valuable ways through which the company can empower small businesses in the communities where it works. This is particularly important in and around the country’s smaller towns, where business opportunities are more limited. 

“When we embark upon any project through or near a town, we always engage with local communities and businesses, firstly to inform them who we are and then to provide them with information about selected project requirements and opportunities which are available to them during the construction phase,” says Mayet. 

“In fact, the whole procurement process is carefully planned and managed, not only to give small businesses fair access to work but also to grow them with the relevant skills so they can become more viable in the long run.”

Among the first steps in each of these projects is for Concor to engage intensely with local structures of government and community members, to understand more about the area where the project will be located, he explains. This paves the way for compiling a database of skills availability, local businesses and for Concor to understand the dynamics of the community to ensure the company develops a trust relationship which is critical to the success of the project. 

“In addition to the small businesses from which we procure, we also draw our general workers for each project from the area we work in,” he says. “We talk to representatives from the nearby towns and villages to ensure that there is an equitable distribution of opportunities, while we also seek out the best available skills.”

At the same time, there is usually the need for work site training – such as health and safety, first aid and induction – which to a certain extent upskills these workers and makes them more employable when they seek their next jobs. 

In balancing its social contribution with its professional reputation and workmanship, Concor must ensure that the quality of its project deliverables is in no way compromised. Mayet highlights how the company focuses on the close and systematic supervision of all subcontractors, through its permanent team of experienced site managers, foremen and artisans. 

“Supervision is in fact an important aspect of the mentoring that we provide to small businesses who partner with us,” he says. “We help them to hone their construction-related skills, so they can participate more competitively in their markets.”

An important building block of any business in the construction sector, for instance, is its grading with the Construction Industry Development Board (CIDB). As a business moves up the nine CIDB grading levels, it can tender for projects of increasing value. Vital to any business’s progress to the next grade is its ability to improve its track record of actual projects competed. 

“We work constructively with emerging subcontractors to improve their profitability, systems and expertise, and to successfully complete their scope of work with us,” he says. “They are often able to achieve a better grading on the strength of our collaboration.”

Mayet emphasises the challenging but positive role of the Community Liaison Officer on each of its projects. The CLO is a community-based person appointed by Concor to help ensure that the company and community can work together and meet their common goals. 

“On every project, we upskill people and allow small businesses to gain more experience – which are the basic steps toward economic transformation,” he concludes.

Through its continuous investment in formalised training that delivers recognised qualifications, Concor Mining Services is helping build mining’s skills base from the ground up. 

Serving its blue chip mining customers with a range of contract mining services, the company leverages its recognised position for the benefit of the whole sector, according to Niel Fourie, Group Training Manager at Concor. The company is accredited as a training organisation by both the Mining Qualifications Authority (MQA). 

“This allows us to deliver the quality and level of training that not only ensures our customers a highly productive offering, but also gives employees portable qualifications as they progress their careers through the mining sector,” says Fourie. “The full qualifications, part qualifications and short courses are all vital to driving the minerals sector – which remains a key pillar of our economy. They are also important stepping stones for our employees, who use them to progress and often to study further.”

Among the roles on which the technical training is focused are dump truck operators, excavator and face shovel operators and support plant operators. There is also a focus on developing blasting assistants and foremen with rock breaking qualifications. Offered through the MQA framework, the training includes theoretical and practical elements, and Concor Mining Services ensures new operators become comfortable with site operations by having them work under the supervision of an experienced operators for a period of time. 

“The impact of the training can be clearly seen in our safety and performance indicators, which show employees really benefit from the skills development process,” he says. “We can also confirm the quality of the learning outcomes by the number of our trainees who move on to work for other employers in the sector – including our mining customers.”

He emphasises that Concor Mining Services sees this movement of people as an inevitable aspect of their career development – and the company is proud to have contributed to building the industry’s skills foundation. When a new employee joins the business, their competencies are analysed alongside the new roles they will be required to undertake – and a gap analysis is conducted. The necessary training interventions to fill those gaps are then defined and planned. 

“On this basis, we can develop an individual development plan for that employee, which could look forward one to five years,” he explains. “These individual plans are then aggregated into our Workplace Skills Plan for the business as a whole – which keeps us on track with the demands of the future.”

He points to the significance of a full qualification like the certificate in rock breaking, which enables a person to become an opencast blaster. This, he argues, is as important as a university degree – as it is a requirement for anyone seeking to achieve a blasting ticket. 

“The mining sector is highly regulated, especially in terms of health and safety, so there is no short cut to reach the required levels of awareness and expertise,” he says. “To comply with these regulations, the breadth and depth of knowledge that employees must learn and apply is both intensive and detailed.”

There is also considerable legal liability to be considered, especially in supervisory positions, making Concor Mining Service’s investment in health, safety and related training particularly valuable. The company’s skills matrix is therefore designed to balance employee’s needs for management, technology, operational and technical training. 

“These courses are recognised by the relevant authorities and structures, so they become ‘portable’ assets that raise the overall skill level of the mining sector,” says Fourie. “At the same time, courses we run such as first aid and firefighting add considerable value within our employees’ communities, as they empower individuals to respond to demanding situations outside of the workplace as well.”

The company’s investment in skills over the past five years or so now means that over 95% of surface mining operators employed by the company have earned their industry-recognised certification – enhancing their value to each project and to the safety and productivity of the mining sector more broadly. 

Concor has commenced construction on Oxford Parks Block 2A Phase I, located at the heart of Rosebank. The company is leveraging its expertise in project management and fast-paced programming for the construction of two office buildings integrated with basement parking and a retail development on the ground floor. 

Set to redefine the landscape of modern construction, Concor is implementing the Green Star V2 rating system for these buildings, aiming to surpass the already high benchmarks set within the Oxford Parks Precinct for green building practices. 

Martin Muller, Concor Contract Manager, says this initiative reflects the company’s dedication to integrating sustainable and eco-friendly practices into its projects, using green technologies and materials to minimise environmental impact.

The project, started in February 2024, is on a tight 17 month schedule with an anticipated completion in September 2025. The initial phases, including bulk earthworks, were swiftly completed in early March, with the construction team moving forward with raft foundation work. 

Each building, one spanning six storeys at 10 Parks Boulevard and the other four storeys at 55 Eastwood Road, is designed with distinctive architectural features including some round elements. These notable features enhance the aesthetic appeal and functionality of the structures. The common basement will accommodate four levels.

Concor is navigating several challenges inherent to the project’s scope and location. The proximity to the Gautrain servitude limits the use of piling, necessitating raft foundations that, while more time consuming, will ensure the project’s stability and durability. Additionally, the initiation of construction during the rainy season posed a challenge due to the area’s adverse soil conditions. 

Muller says that not unlike previous projects within this upmarket precinct, the Oxford Parks Block 2A Phase I project will showcase Concor’s ability to manage complex, fast track projects while maintaining an unwavering focus on quality, safety, and sustainability. 

“Our collaborative approach with subcontractors, coupled with our team’s comprehensive skillset, sets Concor apart in the construction industry. Communication remains key on all our projects ensuring that all team members are aligned with the project’s objectives, especially in terms of quality and safety,” Muller says. 

Through the projects previously completed and this new one, the company not only contributes to the urban development and aesthetic enhancement of Rosebank but also sets new standards for sustainable construction practices. The successful execution of Oxford Parks Block 2A Phase I will serve as a blueprint for future projects, promoting environmental responsibility, innovation, and excellence in construction.

Work is progressing well on the Wolf Wind Farm in South Africa’s Eastern Cape province, with Concor carrying out the civils balance of plant – including an innovative design for a steeply inclined concrete road to the site.

The contract, which is being tackled in a consortium with Murray & Roberts company OptiPower for developer Red Rocket, will see Concor building 17 foundation bases for wind turbine generators on a ridge in the Klein Winterhoek mountain range. Concor Contracts Manager and Lead Project Manager for the consortium, Stephan Nel, explains that the bases are for two sizes of turbine: there will be five 6,2 MW Vestas V162 turbines – the largest in South Africa – and twelve 4,5 MW V163 models.

“The foundation bases for V162 turbines measure 22,5 m in diameter, while the V163 foundations are 21,2 m,” says Nel. “The larger bases will consume over 650 m³ of concrete each, with the slightly smaller bases taking almost 600 m³.”

Concor is conducting over 180 000 m³ of bulk earthworks for the base excavations and roadways on site – which includes 15 km of access road to reach the 17 wind turbines.  A total of 100 000 m³ of rock will be blasted during the construction of the project. After cleaning, a concrete lining is applied and specially designed anchor cages of steel reinforcing bar – weighing either 64 t or 70 t dependent on the base size – are installed.

Concrete from the batch plant at the foot of the ridge will – like all other wind turbine components and related equipment – have to traverse a steep 18% incline gradient to reach the top of the ridge where the turbines will be located. He highlights that this challenge required an innovative solution that could be rapidly executed.

“In collaboration with the client, consultants and specialist service providers, we designed a concrete roadway that could be constructed using the slipform method,” he says. “The 1,100 m roadway, measuring 7 m wide, was completed in January this year, paving the way for the on-schedule execution of the project.”

Among the challenges in the road construction was designing a concrete mix with a 35 slump – to prevent the poured concrete from moving on the slope – that would still be workable for the required window period. Nel notes that high daytime temperatures of 36 degrees C and above aggravated this issue further.

“After considerable planning, investigation and trialling, a solution was developed to allow the slipform paver and the cement trucks to operate on the steep incline, and to lay down the concrete road as planned,” says Nel. “The road was continuously poured at an advance rate of about 200 m a day, consuming some 1,600 m³ of concrete – reinforced with anchor beams and intermittent steel bars.”

The Kendal Ash Disposal Facility expansion project, responsible for the storage of ash produced by Kendal Power Station until 2023, has successfully reached over 80% completion. With a projected completion date set for March 2024, this intricate venture is rapidly approaching its final stages.

Led by joint venture partners Concor and Lubocon Civils, the project accelerated its construction schedule over the winter, capitalising on the dry conditions. Concor’s Project Manager, Pierre Jansen van Vuuren, highlights the stellar productivity in June and July when the teams committed to continuous 24-hour shifts to gain momentum before the onset of the rainy season.

Spanning a massive area of 2.5 km by 3 km, the project’s components comprise the new 65 hectare Ash Disposal Facility (ADF), two dams each for both clean and polluted water storage, silt traps, an expansive 16 km V-drain system, a significant stream diversion and access road construction.

While the stream diversion and majority of the 14 km access roads have been completed, the principal focus now revolves around the ADF and the basins. 

The in-situ material is clay soils which calls for a specific construction methodology. Selected stockpiled excavated materials are being used in a double-layered low permeability clay for base protection, topped with carefully selected river sand to prevent liner damage. Cutting-edge drainage and leachate collection systems are incorporated to manage water flow efficiently, emphasising sustainability with dirty water reuse for dust suppression and other ADF activities.

Concor’s innovative approach in basin construction employs a patented PVC concrete formwork system, boosting efficiency by accelerating the casting panel process. This technique is not only time saving but also labour efficient.

Jansen van Vuuren accentuates the rigorous quality control measures in place. Leak prevention is paramount, with electronic leak detection ensuring construction integrity. “Our teams maintain open communication, emphasising the importance of the quality and structural integrity of the project,” he adds.

Challenges notwithstanding, the project is gearing up to finalise the liner system installation before the rainy season, with subcontractor Aquatan managing the basins and the ADF concurrently.

Highlighting the human element, Jansen van Vuuren praises the skilled workforce, noting that 852 locals have received training, and the project’s local procurement achievement stands at a remarkable 55%. 

He says this involvement extends beyond labour, and is aligned with Eskom and the Joint Venture’s CSI strategies, which are aimed at giving back to the local communities. By identifying local community recipients and working together with the contractors on its projects, Eskom ensures that the upliftment is extended beyond just employment opportunities. 

A good example associated with the Kendal Ash Dump Facility project was the adding of modular classrooms using containers and the fitting out of a kitchen at a local primary school, by the Joint Venture in conjunction with Eskom. This opportunity to give back addresses other needs within the community such as education and nutrition.

To allow Eastgate Shopping Centre in Gauteng to upgrade its heating, ventilation and air conditioning (HVAC) facilities for greater energy and water efficiency, Concor is carefully strengthening the structure on which the heavy new chillers will rest. 

Concor Contract Manager Martin Muller explains that the HVAC system is located on top of a building on the centre’s roof parking area, in which tenants are active – and who need to continue trading during the renovation. Aside from the technical elements of the contract, therefore, clear and ongoing communication with the client and the tenants is a crucial aspect of success. 

“The construction work includes the demolition of an existing roof, walls and slab above tenants,” says Muller. “The structure will then be strengthened to ensure it can safely carry the seven 10 tonne HVAC chillers which are to be installed on the roof top building.” 

Due to the presence of a tenant running a call centre in the adjacent building, demolition can only take place outside of normal working hours. He highlights the importance of Concor’s safety culture in ensuring safe working practices at night.

What is important is for the considerable load of the new installation to be effectively transferred into the centre’s existing concrete columns under the roof parking – and hence down into the foundations. This is being done through the construction of interlinking stub columns which will create a grid to support the chillers. These columns are being cast systematically, working in a direction of priority for the HVAC specialists – so they can start their installations on the network of support steelwork and grating that Concor will provide.

The new structure will also include a transformer room, and a perimeter louvre closure around the HVAC area. At about 3,5 metres high, the louvre will improve the roof top aesthetics by concealing the installation from view. Concor’s team and subcontractors receive working-at-height training and work strictly according to safety protocols – especially since the HVAC rooms are 8,5 metres above ground on one side of the structure and 20 metres high on the other. Completing the project will be a steel roof, louvres to allow fresh air to cool the installation, access doors and a steel staircase.