Projects

Bucket And Bowl Workshop Multi-functional Workshop Facility
Sishen Mine, Kathu, Northern Cape

Bucket And Bowl Workshop Multi-functional Workshop Facility


The project is called the “Bucket and Bowl Workshop” because it became the metalwork workshop for mine machinery buckets and bowels at Kumba’s Sishen mine. The mine has identified the need for new haul truck maintenance and tyre handling facilities in Sishen due to the heavy Mining Equipment (HME) fleet expansion required for the Life of Mine (LOM). The workshop was designed to have the space and facilities for mechanical and tyre repairs and the maintenance of the new ultra Kumatso 960 and 860 E mining trucks.  The workshop, measuring 50 x 40 m, with a height of 27 m and internal footprint of 2 000 m², has been fitted with two 80 t overhead cranes, and the largest commercially installed tyre press (450 t) in the country. It also has four undercover bays and six apron bays outside. The scope of work for the ‘Bucket and Bowl’ workshop also incorporated a tyre yard for storing up to 280 tyres for the mega trucks, an adjacent administration building, compressor room, nitrogen tank storage slab, sewer pump station and 11 kV sub-station.

BVi was responsible for the electrical and mechanical design and contract management for various new buildings and workshops. 

Le Grand Chasseur New Grape Packhouse
Robertson, Western Cape

Le Grand Chasseur New Grape Packhouse


The project is a new Table Grape Packing and Cooling Facility that will be able to receive, grade, pack and cool to -0.5°C 100 tons of export table grapes per 9 hour shift.  Around 500 people will work in the facility and will use the latest imported productivity and tracking technology. 

Construction started in March 2019 and will be completed by the end of November 2019. 

Production will start in January 2020.

MAFA Packhouse 16, Noubaria, Egypt
Egypt

MAFA Packhouse 16, Noubaria, Egypt


Table Grapes for export markets, packing- and cooling facility.  

The facility is 10 500m² under roof with more than 500 people working in the facility.  The packhouse receives 180 tons of grapes which is then cooled to 16 °C and then sorted and packed into 360 000 x 500 g punnets accurately made to weight and then assembled into pallets.  The pallets is then cooled to -0.5 °C in 12 hours and then shipped in a total of 15 refrigerated shipping containers.  The project had very tight timescales and the approaching harvest date cannot be moved or negotiated.   A concurrent engineering approach was needed with designs and drawings being finalized for some disciplines after construction started.  The adaption to Egyptian standards and way of doing things  proved challenging together with language and distance from the site.  BVi Northern Cape (Springbok) also had a full-time representative on site, spending almost 5 months in Egypt. 

Letseng Diamond Mine - New Heavy Mining Equipment Workshop Facility
Lesotho

Letseng Diamond Mine - New Heavy Mining Equipment Workshop Facility


BVi is providing full EPCM Services at the Letseng Diamond Mine: Pre-feasibility Study, Feasibility Study, Detail Design, Project Management, Procurement, Contract Management and Construction Management

The project entails: Geotechnical Investigation, Bulk Earth Works, Terracing & Roads, Heavy Mining Equipment Workshop, Washbay and Quick Service Workshop. Water Supply Pipeline, Essential Services – Potable and Process Water Reticulation Network and Sewage Reticulation.  Water Storage Reservoirs and Compressed Air Installation.  Mining Haul Road Around the Workshop Facility.  Offices and Ablution Facilities for the Maintenance and Operational Staff.   Washbay Mechanicals Complete With Silt Trap, Water Circulation and Water Heating System.  Earthing and Lightning Protection for the Entire Facility, 11kv Reticulation, 11kv Transformers, Miniature Substations, 400/230V Distribution and the Control and Instrumentation for All Systems.  Area Lighting for the Facility and Internal Building Services (Small Power and Wet Works)

Assmang Iron Ore Beeshoek North and South Mines Structural Integrity Investigation
Northern Cape

Assmang Iron Ore Beeshoek North and South Mines Structural Integrity Investigation


Visual audit of steel structures and civil works at Beeshoek North and South Mines in the Northern Cape.

The North Mine previously supplied all of Assmang’s iron ore output since 1964. A series of large-scale infrastructure projects had maximized efficiency and productivity on site, which included a full washing and screening plant and a jig plant to beneficiate off-grade ore. Assmang commissioned Beeshoek South Mine in 1999.

The various structural elements were each allocated a condition category ranging from 0 to 5 (0 signifying excellent condition and 5 little to no useful residual strength), followed by priority level recommending the required remedial action.

Other common observed issues included faulty connections, removed and modified structural members, excessive spillage, missing grout below baseplates, vehicular and equipment impact damage, and general damage to walkways.

The combined inspections of Beeshoek North and South Mine covered over 51 conveyors, plant and buildings.

New Change House and Entrance Security Structure at Assmang Beeshoek Mine
Postmasburg Northern Cape

New Change House and Entrance Security Structure at Assmang Beeshoek Mine


Construction of the new change house and entrance security structure at Assmang Beeshoek South Mine.

Rehau Manufacturing Facility
Uitenhage, Eastern Cape

Rehau Manufacturing Facility


Development of the second phase of the manufacturing facility consisting of  8 000m² warehouse, 4 000m² paint line hall, 1000m² office extension, concrete hardstands.

Rapid Loadout Terminal – Storm Water Management Plan
Emalahleni, Mpumalanga

Rapid Loadout Terminal – Storm Water Management Plan


Formulation of Storm Water Management Plan: 

1 ) Identify clean and dirty water areas according to GN704
2) Build a numerical hydrological model of the RLT complex in PCSWMM to quantify the runoff volumes for a 50y storm event
3) Identify and design required infrastructure like pollution control dams on a conceptual design level
4) Define scope of work of the following phases that will be required for RLT to become GN704-compliant

Nkomati Mine JV – Stream Floodlines and SWMM Model Audit and Revision
Nkomati Mine, Machadodorp, Mpumulanga

Nkomati Mine JV – Stream Floodlines and SWMM Model Audit and Revision


The project consisted of four segments:

1) Audit Stream Flood line. 
2) Audit and revision of the Nkomati SWMM model.
3) Detailed design of Trench 52.  600m gabion mattress-lined canals, 2 gabion cascade drop structures (13m & 9m vertical cascades), 3 x 1 200mm haul road concrete pipe culverts with gabion head and wing walls
4) Formulation of conceptual solutions to address the GN704 compliance issues that was identified during the study

Thaba Metsi FEL 3 Study
Ellisras, Limpopo

Thaba Metsi FEL 3 Study


Infrastructure, roads, haul roads, storm water, workshop, washbay, fuel facility, offices and stock yard for the coal-handling plant.

Mpact – Paper Plant Upgrade
Richards Bay, KwaZulu-Natal

Mpact – Paper Plant Upgrade


Various areas of expertise were utilised for the upgrade of an existing paper manufacturing plant. The project required new foundations and structures surrounding the plant: conveyors, tanks, pulpers, thickeners, screens etc.

The project scope included the following:

  • Detailed Structural Steel Design: Crawl Beams, Support Structures and Platforms, Stairs and Walkways, Pipe Bridge.
  • Detailed Concrete Design: Foundations to conveyor structures, equipment and tanks (10m³, 600m³, 100m³), Columns, Concrete Tanks, Surface beds.
  • Re-routing of existing services
  • Location and re-routing of existing services
  • Demolition of existing structures, concrete and brick paving
  • Foundation and plinths for the new fibre-flow drum including bulk earthworks and safeguarding of excavations.
  • Dealing with ground water at excavations
  • Rock-fill mattresses for major equipment
  • New retaining wall
  • Foundation and plinths for a new conveyor and pit
  • Foundation and plinths for the new dump chest including bulk earthworks and the safeguarding of excavation
  • Foundation for dilution tanks 1 and 2
  • Foundation and plinths for new platforms
  • Small equipment foundations
  • Structural steel work including an access floor for the switch-room, equipment platform and hand railing
  • Foundation slab for a new refiner

Mayoko Mine Infrastructure
Democratic Republic of Congo

Mayoko Mine Infrastructure


Infrastructure for processing plant, haul roads, construction camp and new permanent housing complex.

G80 Canal and Relocation of Infrastructure
Kathu, Northern Cape

G80 Canal and Relocation of Infrastructure


Scope of Services:  New dewatering pipeline (Design and Construction Monitoring) and New Stormwater channel culverts.

Feasibility study, detail design and construction monitoring of total project.
Water pipes:  construction of 600mm diam (1.6 km long) and 350 mm diam (3.3 km long) above ground steel pipeline, complete with all fittings and specials.
Bulk earthworks design, haul roads, concrete silt traps, concrete canal access ramp. 
Construction of earthworks.
Construction of reinforced concrete (“trapezoidal” channel – 4.5 km long).
Construction of 3 No. reinforced concrete (cast-insitu) culverts and 1 No. reinforced concrete (precast culvert).
Construction of 4.8km steel pipeline above ground.

Xstrata Arthur Taylor Colliery Tip Station
Ogies, Mpumalanga

Xstrata Arthur Taylor Colliery Tip Station


11m-high reinforced concrete retaining wall, bulk earthworks, reinforced concrete foundations for conveyor and structural steel elements, storm water culverts, channels, silt traps, sleeves -- manholes, plinths. The tip station was for 1 000 tons.

Leeuwpan FEL 3 Study
Delmas, Mpumalanga

Leeuwpan FEL 3 Study


Infrastructure for new coal processing plant, haul roads, pollution A1:K66 system and dam, geotechnical investigation and design of water and electrical infrastructure.

Kolomela Mine Housing Project
Postmasburg, Northern Cape

Kolomela Mine Housing Project


Site monitoring of civil services for Kumba housing project. Total erven approximately 700. Design services investigation and reporting of Postmasburg sewer, water and storm water infrastructure.