Engineering Capabilities & QA/QC
We do not guess; we compute. From LOD 500 finite-element analysis to automated HD plasma machining, submerged-arc welding and C5-I anti-corrosive systems — this is our end-to-end technical workflow.
Four disciplines, one accountable chain
Heavy mining & processing
Load-carrying welded plate girders, lattice screening trusses, crusher building frameworks, flotation cell supports and overland conveyor gantries engineered against severe dynamic harmonic vibration.
- ▹Concentrator and screening plant superstructures
- ▹Built-up plate girders to 2 000 mm web depth
- ▹Transfer towers, chutework supports and conveyor galleries
- ▹Tankhouse and electrowinning structures in C5-I service
Warehousing & commercial
Turnkey portal frames, clear-span distribution hubs to 80 m unsupported width, heavy crane runway beams and agricultural storage engineered for rapid bolted assembly.
- ▹Clear spans to 80 m with no internal columns
- ▹Crane runway beams to SANS 10160 duty classes
- ▹Cold-formed purlin and cladding rail packages
- ▹Mezzanine, racking-integrated and cold-store frames
Bridges & bespoke structural
Multi-span Warren and Pratt truss river crossings, architecturally exposed structural steelwork, pipe racks for petrochemical plant and explosion-proof access towers.
- ▹Road, rail and pedestrian bridge superstructures
- ▹Incremental launch and segmental erection methodology
- ▹Architecturally exposed structural steel (AESS categories 1–4)
- ▹Access towers, stairways and platform systems
Energy & petrochemical
Multi-tier pipe racks, distillation access structures, boiler and turbine hall framing, and solar-plant mounting systems built to hazardous-area detailing standards.
- ▹Zone 1 and Zone 2 hazardous-area structural detailing
- ▹Pipe racks held to ±1 mm tie-in tolerance
- ▹Boiler house, turbine hall and stack support framing
- ▹Utility-scale solar tracker and fixed-tilt substructures
Five stages, zero handover gaps
Digital engineering & LOD 500 BIM
Every project begins in our detailing bureau. We build a complete digital twin in Tekla Structures at LOD 400/500 before a single gram of steel is sawn, then run exhaustive clash detection against your mechanical, electrical and piping models so conveyor penetrations, pipe racks and crane gantries integrate on the first attempt.
- ⚡Tekla Structures 3D detailing with automated shop drawings
- ⚡Finite element analysis for dynamic mining, wind and crane load cases
- ⚡Clash detection against client MEP and process models
- ⚡Automated anchor-bolt layouts issued ahead of civils
- ⚡NC/DXF machine data generated directly from the model
Automated CNC machining
Our 45 000 m² yard runs Voortman and Ficep automated lines. Sections to 1 250 mm deep are loaded, sawn to length, drilled, slotted and hard-stamped without a human ever marking a hole position. Plate to 100 mm is processed on high-definition plasma and oxy-fuel tables using true-hole technology, so HSFG bolts slip through on site without reaming.
- ⚡High-definition CNC plasma cutting to 100 mm plate
- ⚡Automated 3-axis beam drilling and carbide sawing lines
- ⚡Robotic submerged-arc welding for built-up plate girders
- ⚡Section capacity to 1 250 mm depth and 30 m length
- ⚡Hard-stamped piece marks traceable to the model and heat number
Coded welding & NDT
Welding runs to ISO 3834-2 under qualified procedure specifications, executed by ASME Section IX coded welders. Inspection is not a formality: 100 % visual, 100 % ultrasonic on full-penetration butt welds, and 10 % magnetic particle inspection on primary fillets, witnessed by SGS or Bureau Veritas where the contract calls for it.
- ⚡ISO 3834-2 certified welding fabricator
- ⚡Submerged arc (SAW) and flux-cored (FCAW) processes
- ⚡100 % ultrasonic testing on full-penetration butt welds
- ⚡Third-party witness inspection by SGS / Bureau Veritas
- ⚡Full weld maps and traceable inspection release notes
Corrosion protection to ISO 12944
Coating is where African structures fail first. We blast to SA 2.5 cleanliness with a controlled 40–70 µm profile, then apply certified multi-coat systems — zinc-rich epoxy, MIO intermediate, aliphatic polyurethane — or total-immersion hot-dip galvanizing, matched to the actual C3 to C5-I environment rather than a generic specification.
- ⚡Abrasive blasting to SA 2.5 with profile verification
- ⚡ISO 12944 C3, C4, C5-M and C5-I certified systems
- ⚡Hot-dip galvanizing to ISO 1461 with duplex overcoat option
- ⚡Humidity-controlled paint hall with hold-point inspection
- ⚡DFT records and coating certificates issued per consignment
Cross-border logistics & erection
We do not hand you a stack of steel at the factory gate. Our in-house logistics desk manages SADC certificates of origin, customs clearance, abnormal-load road permitting, escort vehicles and convoy scheduling — then our erection crews bolt it together on your site, anywhere across 25+ African borders.
- ⚡SADC certificates of origin and pre-cleared customs documentation
- ⚡Abnormal-load permitting and escort vehicle coordination
- ⚡Consignments packed and marked in erection sequence
- ⚡EST Africa site supervision and full erection crews
- ⚡As-built survey and handover documentation pack
Facility & machine capacity
Material, welding & coating specifications
We adhere strictly to international and South African engineering standards (SANS 10162 · BS EN 10025 · AWS D1.1) to guarantee structural performance in severe industrial environments.
| Category | Standard / grade | Application & performance |
|---|---|---|
| Structural steel grades | S355JR / S355J2+N / S460MLBS EN 10025 / SANS 50025 | High-strength structural carbon steel for all primary load-bearing columns, beams, lattice trusses and crane gantries. S355J2+N is Charpy impact tested at −20 °C for dynamic shock loading. |
| Welding standards | AWS D1.1 / ISO 3834-2ASME Section IX coded welders | Full-penetration and fillet welds executed by coded welders using submerged arc (SAW) and flux-cored arc welding (FCAW) under qualified Welding Procedure Specifications. |
| Non-destructive testing | ISO 17640 / ISO 17638SGS / Bureau Veritas third-party | 100 % visual inspection by certified welding inspectors. 100 % ultrasonic testing on full-penetration butt welds. 10 % magnetic particle inspection on primary structural fillet welds. |
| Corrosion protection — C3 / C4 | ISO 12944 multi-coat epoxySA 2.5 surface cleanliness | Grit blast to SA 2.5 (40–70 µm profile), zinc-rich epoxy primer 75 µm, micaceous iron oxide intermediate 150 µm, aliphatic polyurethane topcoat 75 µm. Total DFT 300 µm. |
| Corrosion protection — C5 heavy | Hot-dip galvanizing to ISO 1461Duplex acid-resistant option | Total-immersion hot-dip galvanizing at 85–100 µm minimum zinc for coastal salinity, acid mining mist and electrowinning exposure. Optional duplex epoxy or vinyl-ester topcoat over swept-blast zinc. |
| Fasteners & structural bolting | Grade 8.8 / 10.9 HSFGEN 15048 / EN 14399 HRC | Hot-dip galvanized high-strength friction grip assemblies with hardened washers and direct tension indicators. Rated against shear and tension fatigue under vibrating screen loads. |
| Design codes | SANS 10162 / EN 1993 / AISC 360SANS 10160 loading | Limit-state design to South African, Eurocode or AISC frameworks depending on the client's engineer of record. Seismic and dynamic crane load cases modelled explicitly. |
| Dimensional tolerance | SANS 2001-CS1 / EN 1090-2 EXC3Trial assembly on critical spans | Fabrication to execution class EXC3 as standard, EXC4 on request. Critical tie-in spans are trial-assembled and dimensionally verified in the yard before release for shipment. |
Frequently asked
We deliver to 25+ African countries. Our highest-volume corridors run from our Germiston plant into Zambia, the DRC, Botswana, Zimbabwe, Mozambique and Namibia by road, with sea legs through Durban to Dar es Salaam and Mombasa for East African destinations. Our in-house logistics desk handles SADC certificates of origin, customs clearance, abnormal-load permits and escort coordination on every consignment.
Our 45 000 m² Germiston facility sustains 3 500 tons of fabricated structural steel per month across automated beam lines, plate processing and welding bays. We handle sections to 1 250 mm depth, plate to 100 mm thickness and single pieces to 30 m without splicing.
Yes. We accept Tekla, IFC, SDNF and CIS/2 models as well as AutoCAD DWG drawing sets. Our detailing bureau reviews the model, resolves connection design, runs clash detection against your MEP models and generates the NC data that drives our CNC lines directly — which removes the manual transcription step where most fabrication errors originate.
It depends on the actual micro-environment, not a generic classification. Flotation and electrowinning interiors are ISO 12944 C5-I and need a zinc-rich primer with a vinyl-ester or high-build epoxy topcoat at 400–500 µm total DFT. External mining structures usually sit at C4 and take a 300 µm three-coat system. Coastal and port work is C5-M, where we specify a duplex system — hot-dip galvanizing swept-blasted and overcoated with polysiloxane.
For a 2 000–3 500 ton mining or industrial structure, budget 6–8 weeks for detailing and approvals, 12–20 weeks for fabrication and coating, and 3–6 weeks for cross-border transit and site delivery depending on corridor. Fabrication overlaps with detailing once approved drawings are released area by area, so the critical path is usually shorter than the sum of those figures.
We are certified to ISO 9001:2015 for quality management and ISO 3834-2 for comprehensive quality requirements in fusion welding. Welders are coded to ASME Section IX and welding runs to AWS D1.1 procedures. Non-destructive testing is witnessed by third-party inspectors from SGS or Bureau Veritas where the contract requires it, and every consignment ships with its inspection release notes, DFT records and material certificates.
Both. Roughly two-thirds of our contracts are supply-and-erect, where our own site crews and supervision handle assembly, bolting and survey verification anywhere across the continent. We also supply fabrication-only where the client already has an erection contractor mobilised — in that case we pack and mark consignments in erection sequence and provide erection drawings and supervision on request.
At minimum: project location, approximate tonnage, structure type and target erection date. To price accurately we want general arrangement drawings or a 3D model, the design code and steel grades called for, the corrosion specification, and whether the scope is supply-only or supply-and-erect. Our estimation bureau responds to complete RFQs within 24 hours and issues a firm priced proposal within five working days.
Ready to build?
Let’s engineer your structural reality.
Send us your drawings, Tekla model or project scope. Our estimation bureau responds to complete RFQs within 24 hours.