Archive: October 30, 2024

Home without harm, everyone everyday: LTA Autecon prioritises safety and quality

October 30, 2024

“Any construction company can provide a product or a service, but consistently providing an excellent product on time without harm is something for which LTA Autecon is known. This is part of our history,” states Donavan Packaree, the company’s Safety Health Environment and Quality (SHEQ) Manager.

Packaree is passionate about safety and quality, regarding them as an inseparable combination – which has made LTA Autecon a market leader in SMEIPP (structural, mechanical, electrical and instrumentation, piping and platework) across a multitude of sectors, with a proud heritage spanning over 40 years.

The company’s safety pedigree and track record of project delivery and service excellence extends beyond its legal compliance requirements, and the codes and standards to which it subscribes. Rather, safety has become an integral part of its culture.

Safety and quality from the top down

Safety incidents lead to work stoppages – while poor quality and bad workmanship also result in delays. These are identified and mitigated through LTA Autecon’s Quality Management System (QMS), Packaree points out.

“When it comes to safety and quality, you cannot have one or the other. Good safety practices result in improved quality outputs and vice versa. We have leveraged this, with a checkpoint policy, which creates the framework for our QMS System. This considers safety, environment and quality. It was conceptualised in the early 2000s and has evolved into its current form,” he explains.

Although historically, this was a behaviour-based model, it has since evolved into a leadership model: “The best elements have been retained as building blocks and we have subsequently improved on them,” he comments.

The QMS includes plant task observations, visible leadership, daily inspections and data analysis to identify trends. Packaree explains that, while the behaviour-based model of old was based primarily on rules and regulations, the contemporary leadership model requires engagement with people at all levels. Consequently, safety officers are no longer seen as enforcers or ‘police officers’.

Home without harm, everyone everyday

As LTA Autecon know that knowledge is power, the company engages with employees at every level and its safety slogan of ‘home without harm, everyone everyday’ – which is at the heart of the business – represents an operational ethos which is taken very seriously, and has become an essential part of LTA Autecon’s organisational DNA – and its people development.

“Our people are the most important component of this business, and having them return home every day, unharmed, is paramount. This is reflected in our excellent statistical safety records,” says Packaree.

The same goes for clients, where a more inclusive approach also predominates.

Furthermore, as LTA Autecon operates at national key points, such as oil and gas refineries and pivotal private sector operations such as mines, safety and quality are very closely directed and monitored by its clients. This requires LTA Autecon to support its clients’ safety campaigns.

“These depend on trends. If a client observes that finger injuries or vehicle incidents are a problem, then we need to focus on these too,” Packaree explains.

In addition, as ISO 9001 and ISO 45001 certifications apply across all sectors, these form the  framework and structure for the QMS – and are also dynamic and flexible enough to encompass clients’ specific requirements.

“If we are working for example on a mine or a refinery, the expectations and the requirements will be different. Overall, safety is our highest priority, regardless of the environment in which we are operating,” he continues.

When it comes to the use of coded welders trained specifically for the high-risk and safety-intensive oil and gas environment – trained in ISO 3834: Part 2-certified welding processes and procedures – these requirements have become integrated into the company’s overall QMS. Annual audits are conducted by the certification body to verify compliance. Packaree says that this is done because welding is one of the core processes which form the backbone of the sector.

Prioritising Safety, Health, Environment and Quality (SHEQ)

Packaree believes that prioritising Safety, Health, Environment and Quality (SHEQ) makes LTA Autecon the SMEIPP company of choice for power, mining and oil and gas projects in South Africa: “Our clients understand and appreciate this commitment and dedication to SHEQ. This is paramount to the success of any SMEIPP project.”

SHEQ prioritisation also extends across borders into the SADC region and across Africa: “This is the way in which we operate. The location is irrelevant. By subscribing and conforming to international standards, we are able to deliver the same levels of excellence everywhere – and to meet the stringent standards of local and multi-national companies,” Packaree concludes.

Control systems and remote monitoring systems: partnering to ensure boiler safety and efficiency, says AES

October 28, 2024

Control systems, together with AES’s Remote Monitoring System (RMS) play a vital role in ensuring the safe and smooth operation of boilers. This is according to Dennis Williams, Commercial Director of Associated Energy Services (AES), a leading operations and maintenance service provider to the steam and boiler sector.

Although these systems operate independently, they combine to provide important technical and operational insights. Control systems ensure stable operation within dynamic systems and direct activities. AES’s RMS is a user interface that records, transmits and stores data from boilers for user analysis.

“It is easy to forget that the generation and use of steam from a boiler – a pressure vessel – is a potentially dangerous activity and that suitable care, skill and caution should be exercised. AES has over 25 years’ of operations and maintenance experience, as well as ISO certifications covering occupational health and safety (OHS) and the environment. However, this should be a space where we consistently mindful of new challenges to ensure complacency does not set in,” Williams advises.

The same goes for downtime: “Every input can have an impact on operations, so data is key – from the change in flue gas temperature to the variations in fan current draw. After an incident, the aim is to understand the root cause and prevent it from recurring,” he points out.

Steam pressure management

AES utilises its RMS on nearly all client sites. Each user has a unique steam demand profile, which is determined by the client’s particular operations.

Williams points out that RMS enables clients to get a full view of operations: “Unlike electricity, which is supplied instantaneously – allowing for very effective load following – there is an inherent delay in steam flow. A mismatch in steam demand versus supply manifests in a change in the steam system pressure. If less steam is generated and supplied than is demanded by the production process, then the steam pressure will drop.

“A better control system with advanced control philosophy will allow the boiler system to react quicker and with better combustion – and therefore supply the steam timeously, maintaining steam pressure while also achieving efficient use of fuel,” he explains.

If multiple boilers work together to meet the site steam demand, a strategy is needed to co-ordinate these, forming a balanced system.

Although control systems are required for every boiler – and manual intervention can be impractical, unsafe and illegal – the complexity and sophistication of control systems varies.

Williams maintains that a very stable, flat and consistent steam demand profile using a very uniform and stable fuel, could achieve good efficiencies and steam pressure management with a simple control system.

However, when steam demand fluctuates massively – and if fuel is highly variable and there are frequent equipment changes – a sophisticated control system allows the boiler to better manage that. Examples are food production facilities with multiple operating lines, beverage production facilities and batch manufacturing.

“Control is about minimising the variation between ideal operating parameters (% excess air, fuel delivery rate, feedwater temperature and flow) and the actual operating parameters achieved under operational loads.  This “delta” variance is essentially a measure of how far away from ideal operating conditions the boiler is. Inefficiencies need to be minimised to maximise stability of steam pressure and optimise combustion to minimise emissions,” Williams explains.

Steaming into the future

In older control systems, mechanical drives and linkages positioned control devices such as air / gas line control dampers, allowing for automation of flows and inputs. Latterly, digitisation of the overall control system has allowed for far more sophisticated boiler control and management.

”More accurate and faster controls could account for real-time changes to optimise system operation. On older mechanical control systems, there was often ‘mechanical drift’ on control linkages which needed to be frequently checked and reset. In addition, changes in the boiler plant, such as tube fouling, could not be accounted for – whereas electronically controlled systems measure these and automatically make adjustments,” Williams explains.

He cautions that, on solid fuel boiler control systems, certain aspects cannot be effectively measured instantaneously with instrumentation, and skilled operators continue to be imperative.

Today, AES’s RMS enables alarms and notifications to be transmitted via sms and even allows AES experts, operating remotely, to view site operations data and identify any actions which need to be taken. Furthermore, AES is continually expanding the capabilities of its systems. An example is the integration of stack camera feeds into the system to provide a record of emissions.

Williams observes that clients often have very sophisticated production management systems and visualisation tools recording and analysing production data on their plant – but rarely include the boiler plant in that system. AES’s remote monitoring system (RMS) provides a system to ensure measurement and even integrate the boilers into the wider production management system.

“We strongly recommend that all manufacturers maximise the use of control systems and remote monitoring system technology, as fuel costs, emissions controls and other pressures all benefit from better control, even on stable steam loads,” he concludes.

HDGASA: Hot Dip Galvanizers Association shines new light on renewable energy

October 21, 2024

The Hot Dip Galvanizers Association of Southern Africa (HDGASA) plays an important role in supporting the energy value chain – which spans clean, renewable and green energy – as it powers towards key sustainability targets, according to Executive Director, Robin Clarke.

After a nine year ‘teething period’, during which key energy sector stakeholders and local galvanizers found common ground, he says hot dip galvanizing is now the preferred corrosion control mechanism for this sector, enabling substantial return on investment for energy infrastructure projects and the industry as a whole.

“As an Association, we support the move to renewable energy. We are pleased that the sector has embraced hot dip galvanizing. What we do prolongs the life of the most essential element – steel,” Clarke points out.

Part of the transition

According to the International Trade Administration, 85 percent – or 42,000MW – of South Africa’s electricity is generated via coal-fired power stations. Coal will continue to provide most of the country’s power for the next decade, although the share from renewables is expected to develop faster than the market.

Clarke says that the HDGASA has always fostered a close, constructive relationship with Eskom:  “As an association, we have advised the parastatal regarding corrosion control of transmission lines and distribution equipment – and the relevant standards – over the past several decades. We expect this to continue with the 14 000 kilometres of transmission lines due to be provided under Eskom’s strategic development programme.”

The solar learning curve

This started with a rush to complete photovoltaic installations built according to generic European specifications in the Northern Cape.

Solar installations grew on the back of load shedding: “They were scattered across the length and the breadth of the country. We ran into headwinds related to corrosive environments that had not been factored into the original generic designs intended for the Northern Cape,” Clarke explains.

It has taken time for stakeholders to replace generic specifications with site- and location-specific alternatives. This means pre-approving a quality plan before accepting a design, to ensure that the corrosion control needed for each installation is correctly specified to meet the service life requirements. For example, a solar installation on the West Coast requires a different thought process and specification to an identical facility in Kakamas in the Northern Cape.

“We began working very hard as an Association to interface with key players to ensure that this was done – and that a thorough environmental assessment was completed to ensure that the specifications for corrosion control and the selection of the materials were correct,” Clarke advises.

Although this initially applied to large solar farms, it soon extended to far smaller installations on the roofs of commercial buildings such as shopping malls.

“We have been advising commercial property groups to not only correctly determine the corrosion control specifications for individual solar installations, but also to assess the baseline corrosion condition of the roof and the roof sheeting – on top of which PV panel installations will be installed. These roofs are predominantly galvanized or duplex-coated galvanized substrates. As such, the roofs need to have a service life equal to – or exceeding – that of the renewable energy installation, to ensure acceptable projected return-on-investment and sustainability targets,” he explains.

Bridging the gap

The HDGASA’s role has included highlighting the parallels between standards used in South Africa and those applied internationally, including the Americas, Europe, India, Australia and New Zealand. ‘We have provided solid proof to the renewables industry role players that our galvanizers can provide hot dip galvanizing equal to – or exceeding – the standards specified by designers of plants in Europe and in America,” he continues.

The Association also advises on other ranges of galvanized materials used for corrosion control. For example, where some designers have resorted to using thinner steel sections protected by continuous galvanizing coatings, the HDGASA has found several instances showing the articles to be incongruent with the projected service life of the renewable plant.

“Our advice has been to recommend that the designer specify batch dipping of fabricated steel elements,” Clarke says. This will inevitably provide greater service life from a coating that is  substantially thicker, thereby providing greater durability and service life – with a marginal cost variance when compared to the overall project cost.

Currently, he says that the HDGASA is working on two large remedial projects, resulting from poor storage and transportation: “Bundling, nesting of pre-galvanized steel components and strapping them together too tightly when importing such articles in a ship’s hold carries a disproportionate risk of damage to the corrosion control coating. Long periods when pregalvanized material is exposed to moisture and chlorides means that they have most likely begun to corrode at excessively high rates, by the time they arrive on site – affecting the service life of the renewable energy facility.”

The winds of change

Lessons learnt from the solar sector will also assist with the wind power sector which has, over a 10-year period, blown hot and cold – and only now seems to be gaining traction again as an alternative in the renewable energy arena.

Clarke says the HDGASA will continue to work closely both in-country and offshore with South African role players, championing the capacity and expertise of South African galvanizers to supply the solar, wind and developing renewable markets.

“The renewable energy sector provides a powerful growth opportunity for South Africa’s galvanizing fraternity, and the HDGASA will do all we can to support and facilitate this,” he concludes.

Malben Engineering: first to drive green steel transition in the SA automotive component manufacturing sector

October 17, 2024

Malben Engineering, an established Level 4 BBBEE supplier of stampings and welding components to local vehicle original equipment manufacturers (OEMs) for over five decades, is the first South African automotive component manufacturer to trial ‘green’, low-carbon steel. This distinguishes the company as a pioneering industry trailblazer, in the ongoing drive towards long-term environmental solutions, a key focus area for the automotive sector.

Speaking at the milestone handover of the first-ever green steel coil at the company’s Nigel manufacturing facility, Operational Director Luca Smargiasso points out that the increased use of green steel – and the decarbonisation of the local steel supply chain – will be game-changers for the steel and automotive sectors in the years to come.

The green steel coil delivered to Malben Engineering was produced by leading German steel and technology group Salzgitter AG as part of its SALCOS (Salzgitter Low Carbon Steelmaking) programme, and imported via local value-adding steel processor and merchant, Allied Steelrode.

Salzgitter Mannesmann International GmbH facilitates the supply of high-end steel coils from Salzgitter Flachstahl GmbH to core industries such as the automotive sector in overseas markets. The company also sees it as their responsibility to make decarbonised steel available to their international partners, including a calculation tool, to ensure the Co2 footprint traceability and transparency of products and logistics supplied.

Following Germany’s commitment to becoming carbon neutral by 2045 after signing the 2015 Paris Treaty with the European Union, Salzgitter AG achieved ‘first-mover’ status amongst its European counterparts, investing €1 billion of public funds and 1.3 billion of its own funds to become that country’s first steel mill to invest in a green plant, to supply the aggressively growing demand for green steel.

A ‘green’ partnership forged in steel

The three companies – Malben Engineering, Allied Steelrode and Salzgitter AG – have formed a strongly aligned, synergistic partnership over the past few years: “Malben Engineering was founded on a passion for supplying customers with a world-class product, through its agile decision-making and authentic, people-centric values – all of which are still hallmarks of the company today. In a nutshell, we strive to maintain our values while embracing innovation and new technologies. In Allied Steelrode and Salzgitter AG, we have found supply chain partners with a similar ethos and commitment,” Smargiasso comments.

“As pointed out in the Salzgitter AG strategy, decarbonisation of value chains will only succeed by joining forces. Our partnership with Allied Steelrode and Malben Engineering is a great example of exactly this,” explains local Salzgitter AG agent Shane Barnard of United Steel.

The partnership has worked tirelessly over the past 15 months, with its efforts culminating in the importation and processing of the first-ever green steel coil on the African continent.

This will afford all three partners the opportunity to evaluate the mechanical and chemical performance of green steel, to compare all the quality-related aspects – from formability to welding, and the identification of potential corrosion issues during transportation – with that of conventional ‘grey’ steel.

Smargiasso believes that any discrepancies are unlikely, as the steel-making process rather than the end-product is what changes, in order to reduce carbon emissions. According to Barnard, emissions vary from 2.2 to 2.4 tonnes of CO² emitted for every tonne of grey steel produced versus 0.48 tonnes of CO² for each tonne of green steel.

Another sustainability ‘first’

Smargiasso goes on to describe the decision to use green steel as “very serendipitous” given Malben Engineering’s increased focus on environmental sustainability and supply chain management.

The company recently scored an impressive 98% in an international Responsible Supply Chain Initiative (RSCI) supply chain audit initiated by Ford – another ‘first’ in South Africa.

Smargiasso believes that global demand for green steel will grow considerably, given the growth trajectory for steel consumption in the future. A recent study shows global steel usage increasing from 1,800 million tonnes per annum in 2020 to 2,800 million tonnes per annum by 2050. Barnard, however, believes that the growth will be far more aggressive than this:

“This exponential growth – factoring in the differences in CO² emissions between conventional steel and green steel – will fast track the uptake in demand for green steel,” he observes.

Furthermore, Barnard believes that the current price gap between grey and green steel will close in the near future, given the prevailing regulation landscape – a view firmly supported by Lee-Ann Geyser, Chief Marketing Officer (Automotive and Contracts) from Allied Steelrode:

“In Europe, which is South Africa’s main automotive trading partner, moves to tax consumers for goods – such as vehicles which have high carbon footprints – will ultimately negate any cost difference, and eventually see green steel being the more cost-effective solution,” Geyser comments.   

“Companies such as ours are at the forefront not only of understanding this change, but ensuring that we are a market leader in the usage of green steel, which in the future will be as sought after as white gold,” Smargiasso maintains.

Sustainable sourcing is here

“The road to sustainability has been shorter than initially expected! When we started looking at green steel, it was as a concept only – expected sometime during the next generation only. To the contrary, it has developed so fast – and we see the rising global demand for green steel impacting the entire supply chain,” comments Geyser.

She says local automotive (and other) exporters should view the inevitable carbon taxes and border taxes proactively: “This is no longer just a moral or environmental choice, but a strategic business decision, which incorporates sustainability mandates and corporate sustainability goals. International regulations are pushing all manufacturers, including OEMs, to actively seek more sustainable manufacturing materials.”

Geyser recommends early market engagement going forward – with the Malben Engineering, Allied Steelrode and Salzgitter AG partnership as industry forerunners: “As a ‘green steel partnership’, starting now puts us ahead of everyone else. Yes, the price of green steel is currently higher than conventional steel – however collectively, we decided to absorb this, so we could introduce green steel into the local supply chain. We know this will ultimately be beneficial for us and our customers.”

NAACAM commendation 

Renai Moothilal, CEO of NAACAM (National Association of Automotive Component and Allied Manufacturers), the custodian and voice of the South African automotive component industry, explains that the South African Automotive Masterplan 2035 (SAAM35) creates a future vision for the industry, setting specific development targets which include greater localisation, of which  decarbonisation and sustainable sourcing have become important deciding factors.

“All local OEMs have global commitments to reduce supply chain emissions in the next two decades. Carbon emissions will become an important element in sourcing decisions. First movers and early adopters such as Malben Engineering should be well placed when these  decisions are made – as their emission reduction strategies have been tried and tested, removing risk from sourcing. Beyond this, early adoption also demonstrates a level of proactiveness from the supplier to de-risk their own, as well as the OEM’s market strategies,” he adds.

“We commend Malben for procuring and trialling the automotive component sector’s first green steel. The company has demonstrated a firm commitment to technology innovation, investment and a new production approach – while successfully growing partnerships with its own supply and raw material chains. NAACAM is proud of our association with Malben Engineering!” Moothilal concludes.

Bolt and Engineering: Blazing a trail of innovation and excellence

October 15, 2024

Bolt and Engineering Distributors Group (B.E.D.) is proud to have been the Trailblazer sponsor of the 2024 Southern African Institute of Steel Construction (SAISC) Steel Awards, held in Johannesburg in early October.

“This reflects B.E.D.’s commitment to innovation, quality and excellence – and our values of working with the best suppliers and staff to deliver the latest products and solutions to our customers across many different sectors,” says Mike Giltrow, CEO of Bolt and Engineering Distributors Group (B.E.D.).

Giltrow presented the Export category award to Viva Engineering for successfully delivering 11 heavy-duty steel belt feeders for the Centinela copper mine project in Chile. The extensive use of structural steel in this project was very impressive, and showcased Viva Engineering’s excellent capabilities in meeting complex industrial challenges. This project was also the overall winner of the Steel Awards 2024.

Iconic trailblazers

B.E.D. sees itself as supplying the ‘nuts and bolts’ of industry, as a leading provider of high-quality products and services in sectors ranging from mining to general engineering, fabrication and agriculture, supplying welding equipment, fasteners and bearings to protective personal equipment (PPE) and more.

“In line with our ethos and tagline of ‘it’s our business to know your business’ we have worked hard to understand – and then supply – our customers’ businesses. As such, we have been closely linked to the steel industry since our inception in 1983, and our Trailblazer sponsorship underscores our commitment to fostering innovation in the industry. The ‘trailblazer’ concept really resonates with us, echoing inspirational trailblazers such as Nelson Mandela and Rassie Erasmus who made lasting impacts in our country.

We are proud to emulate these icons by blazing new trails with our innovative products and solutions, helping our customers to overcome their industrial challenges,” Giltrow advises.

Supporting megaprojects

B.E.D.’s range of products allow the company to operate as a ‘one-stop shop’, supplying to a variety of steel-related projects, including megaprojects such as enormous warehouses, mine conveyors and commercial sector structures, and ensuring their structural integrity and safety.

“We are very grateful for the opportunity to have supplied Steel Awards projects in the past and again this year. Our expertise in logistics, inventory management and product knowledge allows for seamless delivery and after-sales support,” Giltrow comments.

B.E.D.’s export division also extends its reach to across the continent, contributing to key infrastructure developments: “We have exported to Sub-Saharan Africa for over 15 years now. Aligning ourselves with similar-minded local in-country partners, who understand the local culture – as well as legal and trade-related requirements. In this way, we ensure that our high standards of quality and customer service are maintained, irrespective of the project location,” Giltrow adds.

Continually innovating

B.E.D. prides itself on understanding the challenges of contemporary steel projects, from industrial conveyors to high-precision architectural structures. The company’s adaptability has been a key factor in its continued success.

“We continually innovate, evolving our premium and medium-tier product offerings to meet the changing needs of industry. For instance, advancements in battery technology enable us to offer more efficient, portable power tools and welding equipment for construction sites, eliminating the need for generators and complex cabling,” Giltrow points out. B.E.D. is also undertaking initiatives such as welding training and state-of-the-art calibration.

Furthermore, B.E.D.’s partnerships with leading global brands such as Fronius, SKF and  Milwaukee ensure that the company remains at the forefront of technological advancements. This enables its customers to complete projects with precision and efficiency, all while maintaining the highest standards of safety and quality.

“Our increasingly successful export division and strategic partnerships with local businesses in Sub-Saharan Africa also demonstrate our innovative approach.

By forming strong relationships with companies which align with our values, we have been able to ensure that our products and services are exported and delivered into sub-Saharan Africa efficiently, maintaining high standards and avoiding unnecessary delays. This is essential when working on large, international steel projects,” he remarks.

Blazing a future trail

“This Trailblazer sponsorship demonstrates B.E.D.’s dedication to fostering progress, growth and excellence in the steel sector. We look forward to continuing our partnership with the SAISC, not only through sponsorship, but also through product training and skills development.

As a company, we are very enthusiastic about empowering the next generation of steel trailblazers and contributing to the long-term success of the industry,” Giltrow concludes.

Dekra Industrial scores 10 out of 10 for safety with 10th consecutive NOSCAR Award

October 11, 2024

Dekra Industrial is proud to announce its 10th consecutive NOSCAR Award, reflecting the company’s dedicated and consistent commitment to safety excellence. The NOSCAR award is only conferred after an extremely rigorous verification audit. The annual NOSA audit took place against the requirements of the CMB150 protocol. Scores obtained need to be above95%, with a disabling accident frequency rate of less than 0.8%, no fatal accidents, no occupational health issues and no major environmental incidents.

This significant milestone for Dekra Industrial coincides with the highest score the company has ever attained in all the time it has been audited by NOSA, alongside the successful completion of the company’s 2024 ISO 45001:2018 surveillance audit.

Johan Gerber, Managing Director of Dekra Industrial, expresses pride in this achievement: “Winning our 10th consecutive NOSCAR award is not just a number; it signifies our relentless pursuit of safety in all aspects of our operations. This achievement distinguishes us as a leader in industrial safety – and highlights our commitment to creating a safe working environment for our valued employees, suppliers and clients,” he states.

This year, Gerber was also honoured with an Excellence Award from NOSA as the winning Managing Director of the Year for the NOSA Mpumalanga region.

“This award is not about me, rather it reflects the hard work and dedication of our entire team,” Gerber points out. “I am very proud to be part of a company which prioritises safety and empowers its people to excel in their roles, growing in their careers and as individuals too! Dekra Industrial’s dynamic and ingrained safety culture provides an excellent foundation for this development,” he adds.

Six million serious-injury-free man-hours

Carina Kleinhans, Health, Safety, and Environment (HSE) Manager at Dekra Industrial elaborates on how the company’s safety culture has evolved over the years: “We started with a vision to unite our branches by means of a common safety ethos. Management commitment and leadership have played pivotal roles in this transformation,” Kleinhans enthuses.

“When our leaders really believe in safety, employees follow suit – creating a strongly cohesive, family-like culture which embraces Dekra’s Vision 2025 to be the ‘global partner for a safe, secure and sustainable world’.”

She emphasises the importance of the recent ISO 45001:2018 audit in enhancing Dekra Industrial’s health, safety and environmental goals. “ISO 45001:2018 is a global standard for occupational health and safety. As such, the audit not only confirms our compliance, but also provides us with recommendations for improvement, which we actively implement,” she notes.

The company’s impressive track record is further evidenced by the recent achievement of six million serious-injury-free man-hours, demonstrating the effectiveness of Dekra Industrial’s ingrained safety practices – even when working in space-constrained, challenging or dangerous industrial environments, which is often the case when doing non-destructive testing and inspection.

Dekra Industrial’s 0.00% Lost Time Injury Frequency Rates (LTIFR) and 0.00% Disabling Frequency Rate (DFR) further underscore its safety achievements. “You can never be complacent when it comes to safety: we continuously discuss and evaluate our performance to set new targets. Our ethos of continuous, incremental improvement ensures that we are always adapting to meet new challenges and achieve higher standards,” Kleinhans highlights.

Employee engagement

Gerber and Kleinhans both agree that individual employee engagement is crucial in fostering Dekra’s Industrial’s dynamic, ‘living’ safety culture. Initiatives such as the ‘#Why I Work Safe?’ internal campaign encourages employees to share their personal reasons for prioritising safety: “Employees develop their own slogans and posters for our walls,” Kleinhans explains. “When our people feel seen and valued, they are more likely to proactively and willingly engage in safety practices.”

Gerber echoes this sentiment: “Safety is not an ‘island’ or isolated department – it is an integral and integrated part of who we are as an organisation. By integrating safety into our daily discussions, we enhance morale and productivity.” He also compliments Kleinhans on her approach, noting that her daily, dedicated involvement alongside her team demonstrates true leadership.

Kleinhans shares a personal highlight from the 2024 NOSCAR Awards ceremony, noting the pride she felt as part of a diverse team, some members of which have been part of Dekra Industrial’s safety contingent since its first NOSCAR award ten years ago: “Being recognised by a respected external industry body for our achievements is a powerful demonstration that our commitment to safety truly pays off,” she says.

Focused and holistic

As Dekra Industrial celebrates these accolades, the company remains committed to and focused on its goals. The integration of health, safety and environmental practices is key to its future strategy. “We have digitised our safety systems, minimising time-consuming and wasteful paper trails, and allowing us to access information rapidly and improve efficiency,” Gerber explains. “This enhances our safety protocols and aligns with our environmental responsibilities.” This digitisation also assists Dekra Industrial with a holistic view of its employees, as safety and human resource information is integrated to provide a 360 degree picture, and creates on online repository of company culture and knowledge for the future.

Dekra Industrial’s commitment to safety and quality continues to set the standard for industry, ensuring that safety remains a core value and ‘golden thread’ underpinning and running through all its operations.

In closing, Gerber expresses gratitude to the entire Dekra Industrial team for their ongoing contributions to safety excellence: “Stringent safety, prudent financial management and meticulous quality control all make up the ‘glue’ and foundation that holds everything together in a successful business – and safety is certainly one of these essential foundational pillars at Dekra Industrial. I am incredibly proud of our team and look forward to continuing this journey together,” he concludes.

LTA Autecon celebrates 40 years of SMEIPP construction excellence

October 9, 2024

LTA Autecon, formerly known as Grinaker-LTA Mechanical & Electrical, has recently redefined its distinct identity and strategic positioning as a market leader in the structural, mechanical, electrical, instrumentation, piping and plate work (SMEIPP) construction sectors. With over 40 years of experience, LTA Autecon specialises in delivering an array of construction solutions tailored to the oil and gas and mining sectors. The company’s comprehensive service offerings range from procurement and fabrication to construction, commissioning and maintenance – underscoring its commitment to over four decades of industrial excellence and innovation.

Led by well-known SMEIPP sector stalwart Managing Director Bheki Mdlalose, the company is not only drawing on its heavyweight industry experience and capabilities in the oil and gas and mining sectors, but casting its net wider, to make an impact in several key vertical sectors.

Stalwart SMEIPP track record

Mdlalose began his engineering career with Murray and Roberts, playing a central role in many flagship projects. When he joined Grinaker-LTA in 2006, this upward trajectory continued with iconic construction projects such as the Moses Mabhida, Soccer City and Cape Town stadiums for the 2010 Soccer World Cup.

Shortly afterwards, Mdlalose opened his own project management company focusing on the power and mining industries. In 2015, he returned to Grinaker-LTA to lead the Mechanical & Electrical business, before taking the helm as Group Operating Managing Director (responsible for Grinaker-LTA and its subsidiaries) just 18 months later.

In 2019, Mdlalose led the restructuring of the then R8-billion per annum Grinaker-LTA Group, retaining just the Civils, Building and Mechanical and Electrical business units.

Thereafter, he set about reshaping the Mechanical and Electrical business for its transition into a standalone entity, which was re-established in 2023 and rebranded as LTA Autecon.

“This is where my key expertise lies. The SMEIPP space is totally different and relies on cyclical commodities – which constantly change and therefore dictate when and where companies invest. Previously, we had focused on the petrochemicals sector – and now wanted to re-enter the mining space – so the business needed to operate differently,” he explains.

“LTA Autecon was known for many years in the mechanical and electrical sectors, and the relaunching and rebranding move has been a positive one, intended to allow us to re-establish our own strong SMEIPP identity in the market,” he adds.

The end result is a business with a proud heritage spanning over 40 years and ISO 9001, 14001 and 45001 certification, which is perfectly positioned to manage projects for oil and gas, mining and resources clients – including many ‘blue chip’ companies – throughout Africa and the Southern African Development Community (SADC) region.

Refocused for the future

Being too strongly weighted towards South Africa’s petrochemical sector – which is in the midst of its own metamorphosis with several key refineries mothballed – was not ideal, Mdlalose admits.

“It was not sustainable for us to have all of our eggs in one basket – and therefore we needed to re-enter the mining space, tap into renewable energy and restructure our electrical and instrumentation business,” he says.

LTA Autecon now comprises three distinct business units: Oil & Gas, Metals & Minerals and Electrical & Instrumentation, which includes a wholly-owned, but completely independent subsidiary, Grunwald Manufacturing, manufacturing electrical and instrumentation equipment for a host of vertical sectors which are typically not serviced by a SMEIPP business.

  • The Metals & Minerals division is focused on the mining sector, leveraging the extensive construction opportunities available within South Africa and across Africa. As such, this division aims to support the growing demand for infrastructure related to mining activities,   focusing on projects which enhance operational efficiency and sustainability in the mining sector.
  • The Oil & Gas division specialises in the petrochemical and oil and gas sector, and is tailored to deliver a wide array of capital projects. These include services for turnarounds, shutdowns, and maintenance work – ensuring that clients in this sector can optimise their operations and maintain their compliance with industry standards.

“As we are actively involved in all refineries in this country, we understand the industry. In the short- to medium-term, South Africa will build a new refinery to replace those which have closed, so we must be strategically and operationally geared up for that opportunity,” Mdlalose points out.

  • The Electrical and Instrumentation business unit supports the other two business units – while also working alongside Grunwald Manufacturing.

Mdlalose believes this reorganised and reinvigorated operational structure will enable LTA Autecon to handle SMEIPP-specific projects – while also providing turnkey solutions through an integrated capabilities and resource base.

A business built on people

Referring to skills shortages in South Africa, Mdlalose observes that in order to retain experienced people, they need to be developed and recognised for their achievements.

“Our business is based on people. Some have been with the company for over 30 years and have amassed valuable institutional knowledge. They understand the SMEIPP environment – as well as our company identity and culture – and are invested in what we do,” he says, pointing out that this experience also translates into strong relationships with suppliers and clients within the SMEIPP space.

Mdlalose intends further developing skills within LTA Autecon by teaming up experienced individuals with incoming young professionals, through the company’s graduate development programme and project work on-site. This will ensure that the company has skills to take it forward.

Throughout, he focuses on leading by example: “My management style is very direct and straight-forward. I always lead from the front to create a sense of direction and inclusivity. I am an open-door, participative manager – but I also know that, when we promise something, we must deliver!”

Mdlalose’s people development ethos extends not only to his own workforce, but to the communities in which LTA Autecon works.

Although LTA Autecon profiles and promotes its impressive legacy over the past four decades, he says the company is also excited about the future and moving with the times: “As our people have worked in this space for a long time, they can innovate and do things differently. We think outside the box when it comes to SMEIPP project delivery – and will look at new construction methodologies and approaches which ensure that we stand out head and shoulders above our competitors – ensuring that our clients are happy, rewarding us with repeat business,” Mdlalose concludes.

Dekra’s heroes of safety: better than ever and better together! Co-located and closer to clients in Vaal Triangle and Secunda

October 1, 2024

Dekra Industrial and its training division, the Dekra Institute of Learning (IOL) are pleased to announce their move into impressive new premises in Naledi industrial park outside Sasolburg – and the expansion of their existing premises in Secunda – with a dynamic ‘one-stop’ shop offering encompassing non-destructive testing (NDT), inspection, lifting inspections, vendor certification and adult-based occupational training.

As such, the new and upgraded premises reflect Dekra Industrial’s focus on growth, as well as the company’s ongoing commitment to enhancing client relationships, operational efficiency and community engagement.

The expanded premises also mark a strategic shift away from DEKRA Industrial and the IOL operating as two separate entities, says Johan Gerber, Managing Director of Dekra Industrial.

“By co-locating under one roof and consolidating NDT, inspection services and training, the company can now offer a holistic, safe and seamless service to clients, as the ‘heroes of safety’ which we strive to be – in line with our parent company Dekra’s commitment to be a global partner for a safe and sustainable world by 2025,” Gerber explains.

This strategy has already proven successful, as the company is attracting new business and also further strengthening its relationships with longstanding clients in key target sectors.

Enhanced efficiency and proximity

Gerber furthermore highlights the operational benefits of the expansion, explaining that the move was essential to accommodate the company’s growing footprint and offerings: “The new premises in Sasolburg and expanded premises in Secunda have brought us physically closer to our clients, reducing our response time from 45 minutes to just 15 minutes. This leads to significant improvements in operational efficiency for Dekra Industrial and our clients.”

The new Sasolburg premises in the well-known Naledi industrial park positions both Dekra Industrial and the IOL within close proximity to key clients in the petrochemical and other sectors, offering enhanced accessibility and operational efficiency.

Gerber also notes that the consolidation of DEKRA Industrial and the IOL under one roof allows for the delivery of a stronger, all-encompassing service offering: “By combining our services, we can now offer a unified, comprehensive solution to our clients, which was previously not possible due to space constraints,” he adds.

The Secunda branch has also expanded its offerings and capabilities, particularly in the area of NDT replica services, which are crucial for assessing the structural integrity of components under stress.

A stronger community focus

Christopher Mörsner, Head of Training and Consulting at the Dekra IOL, explains that the move supports the IOL’s Vision 2028, which is centered on making a difference – and a sustainable impact – through adult-based occupational training and skills development. He points out that the consolidated services in Sasolburg will help to meet the needs of the local industry by bringing training services directly to clients in the Vaal Triangle region:

“Our ability to offer QCTO-accredited safety and occupational training, combined with a flexible, hybrid approach, allows us to provide tailored solutions which cater to our clients’ specific requirements,” says Mörsner.

He emphasises that this model not only supports local businesses: “It also fosters employment opportunities for the community by providing affordable, accessible training​ for those already in industry seeking to grow, and for school-leavers who cannot go to university,” he advises.

Excellent client engagement

The initiative to expand the premises is the brainchild of Donovan Vermeulen, Dekra Industrial Vaal Triangle Branch Manager, who recognised the strategic benefits of moving closer to key clients in the region.

Vermeulen is very enthusiastic about the positive impact the expanded premises will have on client engagement: “Being closer to our clients, especially those in Sasolburg and Secunda, allows us to provide faster response times and more efficient services, which ultimately saves them both time and money.”

Vermeulen also notes that the enhanced proximity means Dekra Industrial can respond to client requirements far more swiftly, particularly during critical situations such as breakdowns.

He points out the beneficial effect that the new premises in Sasolburg and expansion in Secunda has had on the company’s employees, stating that the move to larger premises has boosted morale and productivity. “The team is now more motivated, and the improved working environment has led to better service delivery, as happy employees work better! As the business grows, we also anticipate creating more local employment opportunities, further contributing to the community,” he enthuses.

Holistic industrial solutions 

Gerber explains that clients increasingly prefer working with a single provider that can meet all of their needs: “The new and expanded premises are a tangible demonstration of our serious commitment to offering a comprehensive, integrated NDT, inspections and training ‘one-stop shop’ service to our valued client base in the Vaal Triangle and in Secunda.

We remain dedicated to providing innovative solutions to the petrochemical and other high-risk industries – as well as to local industrial clients – while simultaneously fostering sustainable community development and employment opportunities,” he concludes​.