Archive: August 29, 2024

Empowering communities and transforming lives – Dekra IOL’s Community Development Facilitator skills programme

August 29, 2024

Dekra IOL has expanded its Community Development Facilitator skills programme, which is focused on empowering community leaders and transforming lives, to feature an insightful substance abuse counselling component. The result is that the programme very effectively integrates substance abuse education and counselling into the broader context of community development.

Community upliftment

One of the primary goals of the programme is to uplift communities by equipping individuals with skills to support those struggling with substance abuse. Christopher Mörsner, Head of Training and Consulting at Dekra IOL explains: “We aim to enable community leaders to provide crucial support in areas where private healthcare is inaccessible, helping people to recover from the scourge of addiction and rebuild their lives.”

The curriculum provides a deep understanding of the impact of drug and alcohol abuse. Key components include facilitating education and awareness on substance abuse, staging interventions with those suffering from addiction and promoting public awareness of substance addiction and its negative impact on individuals, families and the broader community.

Quality and Effectiveness

DEKRA IOL collaborates closely with the South African Depression and Anxiety Group (SADAG) to provide real-world insights and best practices from experienced community leaders and mental health professionals.

Sias Esterhuizen, Team Leader at DEKRA IOL notes: “Our trainers are respected community leaders and life coaches, who are dedicated to raising awareness and promoting positive change. Their real-world experience ensures that the training is practical and impactful.”

In-person and personal

Mörsner underlines the importance of the ‘in-person and personal’ aspect of Dekra IOL’s community development facilitator skills programme. This approach ensures that participants receive hands-on, face-to-face instruction and support, which is crucial for dealing with sensitive issues such as substance abuse.

“While we do offer hybrid training, the nature of this course allows for a vital personal interaction between our trainers and students. This fosters a deeper understanding and a stronger commitment to the programme’s community development and empowerment-related objectives,” he emphasises.

Practical preparation

The programme prepares participants to handle real-world challenges by teaching integrity-based leadership skills and ethical practices. Furthermore, by prioritising in-person training and interactions, Dekra IOL ensures that attendees are well-prepared to handle the challenges of community development and substance abuse counselling with empathy, and a robust range of practical skills. Students learn how to arrange community awareness raising events, promote mental health and effectively manage substance abuse challenges.

“We equip our participants with the necessary skills to create positive and tangible outcomes, in community settings and formal workplaces,” Mörsner points out.

DEKRA IOL also remains committed to remaining abreast of the latest developments in community development facilitation, continually reviewing policies and procedures – and learning from experience – to ensure the programme remains relevant and effective.

Since its launch, the first group of students have already enrolled in the programme, and Dekra IOL has received positive feedback for its comprehensive and practical approach: “Partnering with SADAG is a success story in itself!” enthuses Esterhuizen. “The feedback from participants highlights the programme’s value – and the new perspectives it provides on handling cases of depression, anxiety, and substance abuse.”

The Community Development Facilitator skills programme is more than just a training initiative: it embodies the Dekra IOL’s commitment to making a tangible difference. By equipping individuals with the skills required to effectively address substance abuse, DEKRA IOL is empowering community leaders to foster healthier, more resilient communities: “In line with our ethos and tagline, we are ‘expanding our roots for a brighter future,’ and this includes transforming how people think about substance abuse and the community support offered to those affected.

Our commitment to holistic community development – together with SADAG’s input and guidance – ensures that this distinctive skills programme not only transforms lives but also builds stronger, more sustainable communities in the long term,” Mörsner concludes.

Investment in standards ensures South Africa is at the forefront of steel sector development says the SAISC

August 23, 2024

Standards development has significant benefits according to Amanuel Gebremeskel, CEO of The Southern African Institute of Steel Construction (SAISC), which is the custodian of steel industry development and knowledge across Africa.

“The ultimate reason that the SAISC exists is to develop and write standards, bringing the South African steel industry to the forefront of development and making it competitive,” Gebremeskel explains.

He and colleague Dennis White of the SAISC’s sub-association, SAMCRA (SA Metal Cladding and Roofing Association) – are assisting with redrafting the South African Bureau of Standards (SABS) specifications for steel. Completion is imminent – which, in standard-setting terms, means these are likely to be published within the next two to three years.

This timescale is not always beneficial for the steel industry, which does not always receive the much-needed updates as quickly as they are needed.

Again, though, the SAISC plays a proactive role: “People who are trying to do something that is not in the current standards, call us. We then source the information relating to more advanced standards required to get the job done,” he says.

Investing in standards

One of the SAISC’s historical mandates has been the development of steel sector standards, in partnership with the SABS.

The SABS relies on various technical committees – comprising experts in different areas – to compile the necessary standards documentation, to which it holds the copyright.

As Chairperson of the committee that recently began redrafting the new steel standards, Gebremeskel attributes a pause of several years to organisational changes within the SABS  as well as to the need to comply with new Pan-continental trade agreements.

Gebremeskel explains that standards typically work in cycles. In the US, for example, they follow six-year cycles, which reflect those of building regulations. In South Africa, these extend for 10 to 15 years – and are not only influenced by local industry developments but international changes, including new WTO (World Trade Organisation) rules.

“Therefore, standards are long-term investments – and require quite a sustained effort. That is why people who are involved in steel construction stay on standards committees for several years,” he remarks.

Keeping pace with international steel standards

Gebremeskel says that the SAISC has considerable exposure to steel standards around the world: “We choose which types to adopt and how to modify them for local conditions. We understand our industry relatively well, and what kind of capabilities we have.”

SAISC members have direct access to other standards-setting bodies including the  International Standards Organisation (ISO), of which the SABS is a member. Members of the SAISC also chair or serve on sister institutes and standards organisations.

“We are highly integrated into global standard setting. I used to work at the American Institute of Steel Construction (AISC) which sets that country’s standards for steel construction. We have many people who sit on committees in Europe. We use very similar, if not identical, formats. There has been a high degree of standardisation,” he continues.

Because standards are a very important component of world trade, Gebremeskel explains that harmonising them is important: “If you want to make a car in China and sell it in the US, there has to be a minimum set of standards with which to comply. However, there is also still a legacy issue in different parts of the world, which have their own standards development histories. So, regional and in-country standards bodies are still very key.”

He adds that, because South Africa has been industrialised for many decades, its standards are accepted globally. “When we do structures in other jurisdictions, many clients accept the use of our standards. When it comes to mining, standards used in other countries – including ISO – were developed here in South Africa as we are the leaders in steel standards development for mining.”

South Africa has built up considerable expertise in drafting standards and many countries – including developed nations – actually request assistance with writing standards from South Africa.

A new set of standards

Gebremeskel says that while the new steel standards are founded on existing ones, they also incorporate new products and developments: ”The bulk of what we do is to introduce new developments in steel construction, better ways of design, new and different materials, new construction techniques – and even new ways of producing steel. The use of software in design is evolving. To integrate that into standards means people can start using it.”

The new standards will also cover harsher weather conditions. Despite having had earthquakes of magnitudes between 3 and 6.2 locally, there was initially no South African standard for how to design steel to withstand them.

“Now, we have provided a standard that people can use to design steel structures that may be exposed to earthquake loading in South Africa. I have been involved in this for almost a decade.

“Many studies have been published and are being used. This approach also applies to other weather conditions such as wind, flooding and hurricanes. For example, we have invested a lot of time and effort into developing standards to counteract the impact of fires on steel structures –  which is why we have the national centre for fire research at Stellenbosch University,” Gebremeskel concludes.

Hot dip galvanizing: adding to architectural appeal by successfully combining functionality with aesthetics

August 20, 2024

Hot dip galvanized steel is elegant, low-maintenance, durable, sustainable – and is becoming increasingly popular in contemporary architecture – according to Executive Director of the Hot Dip Galvanizers Association of South Africa (HDGASA), Robin Clarke.

Because galvanized steel has the unique ability to marry functionality with aesthetics, it has not only become an architectural feature in itself, but created a developing market for the galvanizing sector, which the HDGASA represents.

Form and function

Over the past 20 years, architects have used galvanized steel to create steel frames, skeletons and steel facades, designing so that structural steel is left exposed, highlighting the internal elements of buildings.

“The Glass House in Parktown North is an example of this. Designed by architect Karlien Thomashoff and artist / owner Roelof Petrus van Wyk, it was inspired by Johannesburg’s rich gold mining history. The surrounding buildings – and the hot dip galvanized steel electricity pylons located a few metres away from the site – add to this industrial aesthetic,” Clarke explains.

Architecture has also embraced sustainability, smart construction and the reuse of building materials: “Architects have followed trends such as the optimal utilisation of space, and the ability to reuse materials. All of these elements have come together and sparked a move towards designing for sustainability,” Clarke adds.

Steel also highlights other natural materials. Referring to the New Tram Street Offices in Pretoria, Clarke says custom-designed galvanized planters and drain pipes integrated with softer textures and green foliage. A sun control structure on the northern and southern facades of the building was also made out of hot dip galvanized steel.

The highlight, however, is the entrance canopy of the office block: “This is framed with a horizontal hot dip galvanized channel supported from the building, giving the illusion of a floating roof. The design is distinctive in the way that galvanized steel has been used to improve the architectural environmental impact as a modular building element in a soft suburban node. Hot dip galvanized steel – due to its unique properties – is used to bind other materials such as concrete, brick and glass into a coherent whole.”

Steel supply chain collaboration

Clarke and HDGASA Marketing Manager, Anthony Botha, agree that practicality will continue to drive design.

However, achieving the best outcomes requires innovative collaboration across the steel supply chain. Clarke explains that existing standards SANS  121 cover baseline hot dip galvanizing (for corrosion control) requirements. Architects requiring an aesthetic beyond this need to work closely with the fabricator and galvanizer, and the steel sections fabricated need to comply with SANS 14713 Parts 1 and 2.

This is where the HDGASA also fulfils a valuable role in providing guidance, thereby also ensuring that the responsibility to fabricate in a compliant manner is shared responsibly across the supply chain.

This includes advising architects and designers on the correct quality of steel selected for galvanizing:  “In this regard, support from a fabricator working to a high standard will ensure that a galvanizer can deliver extra smoothness, with no lumps and bumps around the bolt holes, no oxide lines and also adequate provision for drainage holes,” Clarke advises.

He furthermore points out that steel supply chain collaboration between architects, fabricators and galvanizers has produced some impressive results. The Military Health Base Depot, located on an existing military property in Thaba Tshwane municipality, is an excellent example.

This award-winning project was designed by architect Jeremy Malan, tasked with creating a new facility for the improvement and centralising of the SA National Defence Force’s medical supply base. This incorporated and integrated five buildings of significant heritage value. Malan therefore created an eclectic, campus-type development which included the restored and creatively repurposed original structures. The historic hanger building – that was originally constructed out of structural steel – provided stark characteristic elements and strong aesthetics for this composite structure.

“All the major structural steel members – as well as a plethora of steel fittings and components intrinsic to the design – were hot dip galvanized. Colour-coated galvanized sheeting was also used on the roof and the side cladding of the large warehouse. A key element of the success of this project was an excellent surface finish.  Careful detailing of all the steel work, braces, joints and footing was done in accordance with international best practice. This – together with close liaison between the architect, engineer, building contractor, fabricator and galvanizer – produced the desired results,” Clarke reveals.

Award-wining, landmark projects

He remarks that in South Africa, galvanized steel has amassed some “tremendous hot dip galvanizing disciples” in the local architectural and design sector, who have created landmark projects.

The HDGASA has accordingly recognised many of these through the Architectural category of its Hot Dip Galvanizing Awards events. One such award-winning project was the redevelopment of the 116-year-old Tramways Building, which triggered the rejuvenation of Gqeberha’s (Port Elizabeth’s) central business district (CBD).

Existing steel structures were hot dip galvanized and re-used. As the building was close to the harbour, corrosion control was improved through the use of a duplex paint system, adding the colour and texture which contributed to the visual aesthetic of the building.

“Spangling is another element that can be optimised in design. “Galvanizing is a living coating. Architects can use specific elements including the spangle (or ‘flowers of zinc’ as it is referred to) that develops during the cooling process. In very large spaces – such as the Nelson Mandela Metropolitan University’s South Campus Living and Learning Student Housing project designed by Matrix Urban Design – this can very effectively merge with architectural detailing,” Botha comments.

A large amount of hot dip galvanized steel was used throughout this project – from structural columns to balustrades, staircases, bridges, balconies and pergolas. The patina of the natural hot dip galvanized surface finish was aesthetically noticeable, contrasting with the light-coloured wall finish of the buildings.

“In this manner, hot dip galvanizing very successfully blends elements such as steel, glass and concrete into a strong architectural statement: coherent, appealing and sustainable; and also fulfils an accentuating and framing function – over and above its inherent properties of corrosion control and long service life,” Clarke concludes.

The ‘torque’ of the town: Bolt and Engineering Distributors and Bolt Torque’s new distribution agreement to boost bolting

August 19, 2024

Bolt and Engineering Distributors (B.E.D.) Group is very pleased to announce its new distribution agreement with torque and tensioning company Bolt Torque, which has a comprehensive range of manual, hydraulic, electric and battery bolt torque and bolt tensioning solutions. This strategic partnership, announced just ahead of Electra Mining 2024, where Bolt Torque and their principals, PLARAD® Torque and Tension Systems from Germany, will be exhibiting – marks a significant addition to B.E.D.’s industrial product and solutions portfolio, enhancing its ability to provide cutting-edge bolting solutions to a diverse range of industry sectors, including ship repair, wind farms, oil and gas, and mining.

Mike Giltrow, CEO of B.E.D. expresses his enthusiasm for this exciting collaboration: “As a leading fastener supplier to industry for the past 4 decades, we have naturally always recognised the importance of bolt torqueing and tensioning. However, without the right supplier expertise, we were cautious. Fortunately, Bolt Torque fits the bill perfectly, and is willing and able to work with us, leveraging our mutual bolt-related strengths and synergies.”

Angus Houston, Sales Director and Project Manager at Bolt Torque, shares Giltrow’s enthusiasm: “We have been searching for a legitimate national distributor for some time, and this collaboration with B.E.D. is a match made in heaven! With 9 established branches and an excellent existing customer base – which aligns perfectly with our key target markets in mining, energy, power, oil, and gas – it is ideal. The clear customer service orientation and passion B.E.D.’s nationwide team also fits our own operational ethos and approach perfectly,” says Houston.

Enhancing service offerings and capabilities

This new distribution agreement is set to significantly enhance B.E.D.’s service offerings and capabilities. Giltrow elaborates: “When bolting or fastening becomes specialised, involving for example larger diameters, high tensile materials, stainless steel and other complex materials or criteria, we can now ensure that bolts or fasteners are properly tightened. We can also offer customers rental equipment with certification, providing a turnkey solution from supplying bolts, torque values: a real ‘turn-bolt’ service.”

Existing and potential customers can expect several specific benefits from B.E.D.’s distribution of Bolt Torque’s offerings: “B.E.D.’s reputation for quality and service will now extend to torqueing and tensioning opportunities nationwide,” says Giltrow. “We will therefore be adding to the quality of our fasteners by ensuring they are correctly tightened – avoiding problems like overtightening – which can lead to failures. Factors such as lubrication and galvanizing can also affect torque values, and our experts will guide customers through these considerations.”

Strategic importance at Electra Mining

Regarding the strategic importance of this collaboration for B.E.D. in the context of the upcoming Electra Mining exhibition, Giltrow notes: “The focus will be on the mining sector, but it is also an excellent opportunity to introduce Bolt Torque – and our collaboration with them – to a wider industrial target market.”

Looking to the future, Giltrow sees significant growth in B.E.D.’s bolting-related products and solutions. “We will ensure seamless integration of Bolt Torque’s products into our portfolio and distribution network, including proactively educating our Area Sales Managers (ASMs) in terms of Bolt Torque’s product portfolio, and its many applications for our customers.”

Giltrow observes that such future opportunities could extend – amongst others – to the bearings sector, where B.E.D. is already a very well-known supplier of SKF quality bearings and solutions to a wide variety of industries.

Houston adds: “Electra Mining 2024 will certainly be a pivotal event for us. Appointing B.E.D. as our nationwide distributor allows us to leverage their extensive established customer network and relationships to expand our reach and accessibility across South Africa.”

Having Angus Houston representative of Bolt Torque and PLARAD® Torque and Tension Systems on our stand at Electra Mining will be great and provide the ideal platform to familiarise the B.E.D. ASM`s and other key staff with the PLARAD® product range!

B.E.D. customers can now benefit from calibration services, SANAS-certified contracted calibration laboratory in Cape Town. B.E.D. can supply and calibrate torque tools and tensioners of any brand, not just the ones supplied by B.E.D. This includes force calibration for torque tools up to 20,000Nm, as well as single-stage and multi-stage tensioners, measuring gauges, and a wide range of electronic and measuring devices.

‘Bolting on’ to opportunities

“Specific projects and industries that will benefit from this distribution agreement include upcoming renewable energy projects, refineries, and mining,” highlights Angus Houston. “Our products have several key advantages, such as attractive daily rental offerings and the high-quality, globally-recognised PLARAD®  Torque and Tension Systems from Germany. Our long-term rental pricing is also very cost-effective for companies which do not wish to invest capex but require the service.

Houston adds that Bolt Torque’s new tooling options are among the world’s leading brands, particularly for wind, power, and oil and gas sectors.

Bolt Torque ensures the quality and reliability of its equipment and services through rigorous standards and experience. “With over 30 years of expertise in bolt torqueing and tensioning technology, we ensure that only the highest quality tools are rented out. We will also have spare equipment available at B.E.D. offices to ensure readiness in case of an urgent customer requirement,” he says.

Great expectations

Houston concludes with high expectations for Electra Mining 2024 and Bolt Torque’s collaboration with B.E.D.: “We will have rental tools and key PLARAD®  tools on display, including the latest Technology PLARAD®  Battery Tools wind turbine tensioners.

We are excited to showcase our products and solutions to visitors and potential customers – and that these will now be available from all of B.E.D.’s branches going forward. The sky is the limit!”

Cousins Steel International makes KwaZulu-Natal a retail and logistics hub of steel

August 15, 2024

As reported by the Business Research Institute at the University of KZN for Q2 2024, business confidence in KwaZulu-Natal is currently surging. Dynamic structural steel company Cousins Steel International (CSI) is strategically positioned to take full advantage of this positive upswing in positive sentiment, and will continue to build on its strong record of delivering the massive warehouses and distribution centres which line the highways into the port city of Durban.

Cousins Steel International (CSI) Director Adam Oldfield, acknowledges that within a short space of time KZN has developed into an important logistics and retail hub featuring substantial investment by private sector retail and logistics companies in warehouses and distribution centres within key developments nodes to the north and south of the city.

“With continued space opening up for development to the north of Durban, due to the recent launch of the Dube TradeZone 2, the upcoming launch of The Brickworks phase 2 and the establishment of logistics hubs inland (pending the development of Transnet’s proposed dry port at Cato Ridge), we expect CSI to have a strong pipeline of work for the next three to five years,” Oldfield says.

Already, the company has a sound track record of successfully delivering iconic logistics and retail structures, including the the Takealot warehouse at The Brickworks in Riverhorse Valley, a major beverage retail warehouse in Phoenix Industrial Park and a number of projects within Dube TradePort Trade Zone 1.

Building an exciting future

Oldfield points out that the majority of CSI’s structural steel project work (tonnage and volume-wise) is currently in the logistics and retail sectors, from consumer goods to food and beverage.

He adds that steel is the ideal material for the construction of large warehouses and distribution centres due to its flexibility, sustainability and faster rate of construction when compared with other materials such as concrete.

He also believes that the port of Durban – Africa’s busiest and largest container port – continues to drive the growth of logistics, despite the widely publicised delays and congestion of recent years. Evidently, while many companies are filling large warehouses to create stockholding buffers against this infamous port congestion, the problem is expected to ultimately right itself, paving the way for future growth.

“We know that the Durban port is a gateway: not only into the rest of the country, but also into the rest of the continent. Hammarsdale and inland development have eased the congestion out of Durban. There is definitely continued movement to the north – both residential and industrial. We know that mini-warehouses and conventional logistics facilities continue to move in this direction,” Oldfield comments.

However, he adds that the larger projects and developments are likely to take shape to the south.

While long-awaited projects such as the automotive supplier park remain entangled in bureaucratic red tape, he says that there is plenty of activity in the South Durban basin – with major investors buying up whole city blocks in ageing industrial areas such as Mobeni and Jacobs, demolishing the dated buildings and replacing them with large new state-of-the-art warehousing.

More efficient use of space

Oldfield admits that there is still a shortage of space close to the Durban port. However, he says that older buildings in Durban’s long-established industrial areas to the south – which were not only unsuitable for modern use but have sometimes been poorly maintained – are now being replaced with structures which are double their height and equipped with high-tech mobile racking. This not only trebles their storage capacity, but enables them to operate far more efficiently.

Given the calibre of projects that are now emerging, Oldfield says that CSI can be more strategic in its selection of projects to minimise potential challenges.

“For example, extensive roadworks on the N3 leading out of Durban currently create significant logistical problems as vehicles delivering steel to site are forced to wait for hours in traffic jams. As a result, it just makes more sense for us to focus on projects which are closer to our base,” he comments.

A strong development trajectory

That being said, CSI also stands to benefit from future projects once the upgraded highways open. Once the Transnet dry port development – with its associated rail infrastructure from the main port – is operational, Oldfield expects a logistics and retail boom heading inland towards Pietermaritzburg.

“There are still areas in and around Durban which are hampered by development bottlenecks. Whether these will continue for two or even five years, we cannot say. However, we firmly believe that the development trajectory will continue – and that more will happen. There is a lot of positive sentiment and potential in KwaZulu-Natal,” he enthuses.

“Currently and moving forward, we are strongly positioned, and are focusing on the construction of the larger warehouses, delivering the high-level quality and client service required on these projects. At the same time, we are also proactively pursuing other avenues, such as exports. As a company, we have a long track record in building structures for export into Africa and internationally.

We are very confident about how we are positioned for the future. The sky is the limit!” Oldfield concludes.

Hot dip galvanizing solutions to corrosive challenges stand the test of time and safely extend life-of-mine

August 14, 2024

The Hot Dip Galvanizers Association of South Africa (HDGASA) spends a significant amount of time liaising with the mining sector where the tough environment – characterised by acidic fissure waters, humidity, fumes and gases, as well as dust and abrasion – takes its toll on pivotal steel infrastructure.

HDGASA Executive Director Robin Clarke advises that, although hot dip galvanizing is primarily favoured for economic reasons, the collateral outcome is improved mine safety:

“The design criteria are largely economical: how long will a mine last and be safely serviceable? The key elements are cost to build, cost to operate and cost to maintain. Hot dip galvanizing is competitive across all these criteria,” Clarke points out.

The mining sector faces many challenges, including economic turbulence, fluctuating commodity prices, the entrance of new investors and skills scarcity.

“We can never assume that knowledge and experience are embedded. Much of what we do is informative and educational,” Clarke says.

Lessons from the past

While it has now really taken hold in the sector, hot dip galvanizing only began to gain traction within South Africa’s deep-level mining sector comparatively recently. During the 1990s, Clarke’s HDGASA predecessors set out to demonstrate that this was the best corrosion control mechanism for mining.

A forward-thinking engineer at a large mining house collaborated with the HDGASA and the South African Bureau of Standards (SABS) to scientifically investigate the impact of hot dip galvanizing over a 10 period.

Up until then, a tendency to over-design steel sections to compensate for probable levels of corrosion prevailed.

“During 1995 and 1996, various tests and simulations were performed to establish probable real- world performance outcomes for hot dip galvanized steel in deep-level mining applications. The South African Bureau of Standards (SABS) performed tests with both natural and service mine water, extracted from shafts in service.

Outperforming expectations and safely operating beyond LOM

The testing process occurred over a 500-day period. Steel test pieces, with a hot dip galvanized coating averaging 200µm thickness were used. The loss of zinc on the test pieces exposed to natural water equated to 4µm/per annum, which equated to a probable coating life of 50 years. The test pieces subjected to typical mine service water suffered a loss in the order of 8µm per annum, which translates into a probable service life of 25 years, easily meeting the 25 year life-of-mine (LOM) estimate which the design engineer was briefed to achieved,” he explains.

In January 2003 and 2006, further tests verified these original predictions. Corrosion levels remained low, with only some isolated spots (where the galvanized coating had been mechanically damaged during installation) showing marginal deterioration.

“On these spots, no corrosion creep was evident and a portion of the zinc-iron alloy – still at about 24 µm – provided corrosion protection. The bottom line was, that 10 years after being applied, the corrosion control of zinc had outperformed expectations – except for a very particular application, where the vertically-oriented steel buntons had eroded, after being subjected to direct impingement of water droplets, dust and debris at high velocity.”

Mining engineers undertook either to minimise this falling material, or redesign shields over the buntons.

The HDGASA has subsequently published papers addressing corrosion challenges in deep-level mining, particularly in instances where corrosion cells develop due to the accumulation of debris at catch points in crevices, and surfaces of various hollow section components. However, even these illustrated the positive impact of utilising a corrosion control hot dip galvanized coating.

Clarke says lower levels of corrosion mean that many mines are now safely operating beyond their originally envisaged LOM. At feasibility level, design engineers are even considering designing for durability beyond the original LOM specification – which is even more reason to hot dip galvanise.

“It is very gratifying that hot dip galvanizing has now gained traction to the extent that it has, with virtually all steel work either being galvanized or considered for galvanizing,” he says.

‘Hot’ solutions to corrosive challenges

The HDGASA’s role in the mining sector did not stop there: the Association recently addressed challenges in coal washing, due to the presence of high levels of extremely corrosive sulphur.  The solution extended beyond merely galvanizing, with the HDGASA proposing a combination of galvanizing and paint, known as a duplex system.

“Pioneering work was done in response to engineering requests for solutions to extremely corrosive challenges. We therefore compiled operating procedures for preparation and  painting, and we also collaborated with paint manufacturers.  After 10 years, the duplex system which we recommended remains in exceptional condition – and is expected to provide another 15 years’ service life,” he advises.

“The HDGASA will continue to play an important role in mining, supporting what is now widely accepted in the sector as an embedded corrosion protection technology backed by sound science, and with a proven ability to extend life-of-mine and improve return-on-investment,” Clarke concludes.

Green taxes increase the need for load-balanced, smarter steam says AES

August 12, 2024

Whether it is the South African government’s recently signed carbon tax legislation, or the advent of ‘green’ import taxes imposed by the European Union (EU), South Africa’s manufacturing sector faces considerable sustainability challenges, according to Dennis Williams, Commercial Director of Associated Energy Services (AES), a leading operations and maintenance service provider to the steam and boiler sector.

As the debate around emissions, affordability and ‘green’ taxes on exports to the EU scales up, Williams points out that it is not yet certain how emissions will be measured, whether improvements made to existing energy plant will be recognised by the relevant authorities – or if manufacturing companies will find themselves forced to make a complete switch-over to alternative fuels.

“This would certainly come as a blow to South African manufacturers that still rely on fossil fuels,” he observes.

Solid debate around energy efficiencies

AES believes that a company’s sustainability journey begins with maximising what can be achieved with existing energy plant.

“By managing combustion and ensuring that this is ultra-responsive to the changing requirements of each manufacturing plant, both costs and emissions can be optimised.  However, different fuel types react differently to fluctuating steam demands. For example, as gas combustion systems provide a high range of turndown, they respond extremely quickly. Solid fuel combustion systems such as coal and biomass react more slowly to changes in steam demand,” he explains.

He adds that because there is a given amount of solid fuel in the combustion furnace at any one time, whatever changes in steam demand occur will require a change in the amount of fuel being fed into the furnace – together with the amount of oxygen required to maintain effective combustion.

“The problem arises where there are multiple boilers online and suddenly, there is a substantial steam demand peak. On regular auto-control, they ramp up to follow that peak and eventually catch up. However, when it subsides, there is a massive amount of thermal inertia in these boilers. It is very difficult to quickly counteract this, and this is wasteful in terms of one’s ability to burn coal effectively.”

Balancing the load

AES‘s load balancing system enables multiple solid-fuel boilers to work together to effectively and efficiently deliver steam on demand. Key to this is understanding a company’s steam load. If it is flat with only gradual changes, loads can easily be followed. Sudden spikes and drops in steam demand are unfortunately more difficult to control.

A co-ordinated approach, using the overarching load-balancing control system, effectively coordinates steam demand across the multiple boilers and ensures optimisation of the online capacity to deliver the demand efficiently and effectively, Williams advises: “We control how each of those boilers is synchronised to follow the load – and reduce when the load reduces. This system achieves optimised efficiency and improves the assets’ ability to maintain pressure control by applying analysis to demand changes to sequence boiler loads effectively.”

The era of ‘smart’, data-driven steam

These systems are very much data driven. Setpoint inputs are carefully adjusted to ensure the narrowest steam pressure control band possible is achieved, so that steam pressure remains stable.  The key metrics within the operating model can be adjusted to meet the unique requirements of each site – and accommodate the number of boilers that need to be load-balanced.

Furthermore, instrumentation really comes to the fore in measuring the efficiency of combustion based on the constituents of the flue gas coming out of the boiler: “We rely on levels of carbon dioxide and oxygen to tell us if we have too much or too little fuel or oxygen to achieve the right reaction. That is all data-driven,” Williams explains

AES’s remote monitoring system (RMS) works hand-in-hand with its load-balancing module, he adds.

“The two share some instrumentation and data streams. Through the RMS and its web interface, AES and our clients can see what is happening from an operational perspective.”

Although components such as variable speed drives (VSDs) provide more accurate control of elements such as the boiler stoker and fans than previously – and data is also widely used to manage these systems on an ongoing basis – human intervention also remains important.

“You still need someone with an acute understanding of what you are trying to achieve to set up the system. An element of intervention and oversight by skilled and experienced operations and maintenance personnel in certain circumstances is still needed. An example is having the knowledge to ensure the correct bed depth on the stoker, which other automated systems have failed to do successfully”  Williams maintains.

A better balanced future

The benefits of load-balancing include better control over combustion processes and steam quality – as well as using less fuel and, ultimately, paying lower carbon or green tax.

Going forward, Williams believes that AES and its clients will need to work even more closely together to achieve sustainability targets, whilst increasing efficiencies and minimising costs:

“The imposition of green taxes – whether they are by European or local authorities – will drive an increasing requirement from our clients for accurate monitoring and load-balancing, and the data or metrics which make this possible. We are already conducting various assessments for different fuel types and load-balancing options for clients,” he concludes.

Cousins Steel International provides a refreshing warehousing and distribution centre solution for leading beverage manufacturer

August 7, 2024

An invaluable relationship-building opportunity and a successfully completed project is how Cousins Steel International (CSI) Director, Adam Oldfield, describes a warehouse and distribution centre that was recently completed for a popular beverage manufacturer at Phoenix Industrial Park to the north of Durban.

A natural progression from significant upgrades to this plant in 2016, the project got underway in 2021. From the outset, it was unfortunately plagued by hold-ups and non-delivery resulting in little progress.

In 2023, a leading consulting engineering company, with which CSI collaborates closely, was awarded the contract. CSI was a perfect fit to work with this well-respected company due to its dedication to both quality and safety.

“We were approached by the management of the consulting engineers to come on board with them to complete the project – which, for various reasons, the original contractor could not complete. We were appointed in mid-2023 to do structural steel supply and installation. There were multiple challenges from the start,” Oldfield recalls.

Recounting the first visit to site with the consulting engineers, he recalls that only 160 tons of the 800 tons of steel required for the project had been delivered: “Furthermore, only 2 bays out of the 36 in the plans were up. Just 20 percent of the requisite steel was on site – and less than 5 percent of the structure had been completed. There were also major concerns about what was had been constructed. None of the foundations were in line, the structural alignment and heights were wrong, and many structural elements were incorrect. We had to work very closely with consulting engineering company to find solutions to rectify all of this.”

The value of teamwork

Oldfield credits the ingenuity and dedication of the team – including CSI with its in-house  design, engineering and fabrication expertise,  the consulting engineers, project engineers  – as well as the client’s project manager and MJC Industrial Roofing – for the successful delivery of the 25 000 sq/m facility.

“In terms of innovation, there were for example a significant number of issues when it came to the initial groundwork. We had to find a balance between how costly and how effective each proposed solution was going to be,” he explains.

The faulty foundation was ultimately rectified through the redesign of base plates, which had to be individually marked and placed.

The next challenge hinged on whether or not to dismantle the existing bays. “Initially, we decided to leave them and to start working at the other end of the warehouse. By the time we had progressed 200 metres, it was obvious that the structures were not going to line up. When you have alignment issues, the knock-on effect reverberates throughout the building from foundation to roof. The gutters do not align and the brick walls which tie into the steel work are too far out,” he notes.

For CSI, this challenge meant spending long hours on site and combining the flexibility of structural steel with smart engineering insights, to offer the client viable but also cost-effective and speedy solutions. Finally, when fabrication issues also emerged, a decision was taken to dismantle the original two bays.

However, the challenges on-site did not end here: “The client has a very stringent working environment, particularly regarding health and safety procedures and standards. In addition, this was a working site with delivery vehicles constantly moving in and out of it, resulting in very tight space and movement constraints from a structural steel perspective,” Oldfield explains.

Reaching the finishing line

At the end of the day, it was with great relief and pride that the team reached the project finish line, he adds.

“Looking back, when compared to a greenfield project, this probably took twice as long to complete. We are still adding some finishing touches and extras,” he points out.

Oldfield, who also heads up the SAISC’s technical committee – which is strongly focused on quality within South Africa’s steel sector – says that despite an ultimately rewarding outcome, this project once again emphasises the need for meticulous background checks to determine service providers’ true capacity and standard of work, ahead of making appointments.

Overall, he says the beverage manufacturer, which had faced ongoing challenges since project commencement, has been very appreciative of the end result: “This was a particularly challenging project to complete, given we were all drafted in part-way through and taking over a less-than-ideal situation on site. The end-client knew that the current team was doing its best, considering the substantial challenges. We are really proud to have worked alongside the consulting engineers – as well as the rest of the project team – to achieve what at the end of the day has been a fantastic result! ” Oldfield concludes.

Ensuring a quality legacy for South African steel – SAISC invests in quality, skills and sustainability

August 2, 2024

While the Southern African Institute of Steel Construction (SAISC) is closely monitoring seismic changes happening upstream, it has taken a strategic decision to focus on ensuring a steady supply of good quality steel for downstream steel businesses, says Chief Executive Officer (CEO) Amanuel Gebremeskel.

Against a backdrop of economic and policy uncertainty and potential facility closures – albeit that, for now, these have been deferred – Gebremeskel says the SAISC will concentrate on supporting the steel supply chain rather than on the struggles of specific mills.

“While a steel mill might employ around 2 500 people, the downstream sector, which includes the automotive, construction, energy and mining sectors, is the far larger employer, supporting more than 600 000 jobs.

Therefore, the SAISC must prioritise building a dynamic sector similar to Canada’s, where downstream fabricators remain strong, despite the absence of large steel mills – rather than following Australia – where the closure of large mills has virtually incapacitated the downstream sector,” he explains.

Two streams of investment

As the custodian and sole representative of South Africa’s downstream steel industry, Gebremeskel says the SAISC is prioritising quality and availability: “We are most concerned about ensuring a steady supply and good diversity of steel in our market. This must be predicated on quality and not where steel comes from.”

He says the SAISC has identified two important areas for investment – the development of stringent quality standards through the South African Bureau of Standards (SABS) and the implementation of a sound quality regime.

“This includes the development of a SAISC ‘quality certification stamp’- signifying that companies with the stamp have voluntarily completed SAISC quality training. The quality regime will also include the development of a database by the SAISC’s technical committee, which will allow designers to understand – and design around – the particular products which fabricators can access.

He notes that the SAISC’s input into contributing to SABS standards and then providing supporting literature which explains these standards – and illustrates how companies can comply with them – necessitates a considerable investment of time, technical expertise and related resources.

Strengthening sustainability

Another pivotal area where both the upstream and downstream industry needs to improve is sustainability – both from a business and an environmental perspective. While steel may be one of the most widely used – as well as the ‘greenest’ and most widely recycled materials of construction – it has a rather poor environmental record:

“Older mills which rely on dated technology – known as legacy mills – cannot compete with new mills in Asia and Europe that rely on modern technology. These newer mills use more energy- efficient arc furnaces, as opposed to dated oxygen furnaces which require large amounts of coking coal.

Although many newer steel mills across the world have also invested in renewable and cleaner energy – in contrast to the carbon-intensive coal-fired energy used locally – such investments are yet to reach South Africa,” he advises.

According to Gebremeskel, even though the so-called ‘mini’ (or smaller) mills which have sprung up to process scrap metal are using more energy-efficient induction furnaces, there is still some way to go.

“As they are relatively new – and because they rely on scrap that is often of poor quality – the mini-mills need to elevate themselves to meet the higher standards to which we are accustomed in the market – and that does take time,” he admits.

While some of these mini-mills have invested considerably to increase volumes, additional spend is now also required to expand product ranges if they are to effectively take up the slack should the ArcelorMittal long products facilities ultimately lose capacity, he adds.

Building a digital ‘skills bridge’

The South African steel sector is also navigating the loss of key skills to retirement and emigration.

The SAISC needs to respond by retaining the knowledge that is lost to the sector. The ‘silver bullet’ solution would be to upload much of the accumulated expertise onto a digital platform for SAISC members, according to Gebremeskel.

“Through our website and online learning platform, we are aiming to link the older generation of steel professionals with future generations. Hopefully, in this way, we can build a digital ‘skills bridge’ and make this invaluable information readily accessible,” he says.

The SAISC is also reaching out to engineers. Those who attended the Institute’s breakfast discussion earlier this year – which focused on challenges to the availability and quality of steel – reported that the event was extremely beneficial, and an important opportunity to engage with the steel sector. Other events, including the annual SAISC Steel Awards, are similarly well attended by a wide range of SAISC members and steel supply chain participants – from designers and consulting engineers, to fabricators and construction contractors.

In addition, engineers are now being included on the SAISC Board.

Quality engagement

Gebremeskel concludes with a firm commitment that the SAISC will provide further opportunities for stakeholders to engage: “We would like to energise everyone to work together to solve the problems that can be solved. The SAISC needs to set the tone for the steel sector, so that people do not give up and lose out on important opportunities to further the skills, quality and sustainability of the steel industry.”