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DECEMBER • 2016
Construction
WORLD
16
Civil Engineering Contractors
A
1
MAJUBA RAIL
The 68 km corridor is the first large greenfield freight rail
infrastructure project to be carried out in South Africa since
1986 and will be operated by state-owned logistics provider
Transnet Freight Rail. The project was designed by Transnet
Capital Projects.
Aveng Grinaker-LTA was awarded the contract for construction
activities in January 2013. Construction of the line commenced in
March 2013, with the completion of the civils portion expected in
August 2016.
The objective of the project was to construct an electrified
heavy haul rail link line that ultimately links the Transnet Freight
Rail export coal line with the existing Majuba Power Station rail
yard. The construction of this dedicated railway came about when
Eskom launched an initiative to change the mode of transportation
of coal to a number of power stations, especially Majuba Power
Station, from road trucks to rail transportation, with resultant
positive economic, environmental and social benefits.
The rail line forms part of the Majuba Power Station coal supply
system and is to transport 21 million tons of coal in 100 jumbo
wagon trains per annum.
A major undertaking for the Majuba rail line was the
construction of the U-shaped table drains for surface drainage.
The scope of work required the construction of 63 km of
U-drains in every cut formation, on both sides of the rail line.
Aveng (Africa) Limited used three different methodologies for
this construction, with the third methodology being the most
effective and innovative.
Precast yards were erected at the batch plant sites. Quick
release precast moulds were used to manufacture the precast
units. The precast units were then transported to site where they
were installed where necessary.
The manufacturing of the precast units began in May 2014
and the project produced 30 000 units – enough for approximately
36 000 m – before a decision was made to change the
construction methodology. The teams producing the precast
were notable to produce enough in order to achieve the intended
programme and milestone dates.
Teams continued to manufacture and transport precast units to
site, but also incorporated the construction of in situ U-drains. The
logic behind this methodology was to place a 1,2 m precast unit,
leave a 2,8 m gap and then place another 1,2 m precast unit. The
2,8 m was then cast in situ. A total of 44 000 m was constructed
using methodology 1 and 2.
The third methodology involved slip forming of the remaining
19 km of U-drains, using volumetric concrete batching and a power
curber. A total of 19 000 m in 6 months (3 165 m/month) was
constructed using methodology 3.
Due to rigorous and demanding project milestones, the
teams involved in the construction of the U drains were required
to think out of the box, hence the change in methodology on
numerous occasions.
The methodology involved modern technology by using
a Power Curber slip form machine as well as Reimer self-
batching volumetric trucks. The introduction of fibre reinforced
concrete, although a known concept, had never been used in
conjunction with Reimer volumetric batching and slip form on
such a large scale before and thus a first in the South African
construction industry.
The third methodology involved a substantial amount of pre
planning prior to the methodology being approved by the client
as well as a massive effort from all teams involved during the
execution phase. The site construction teams excelled in many
aspects, such as detailed planning, management of logistics and
value engineered solutions.
The site also achieved 18 months LTI free and in excess of
4 000 000 hours LTI free, resulting in a LTIFR of zero.
The Majuba Rail project is a component of the
Eskom Road-to-Rail Initiative, with the
construction of a railway line that links the
Majuba Power Station to the main coal
railway hub in Ermelo, Mpumalanga.
Winner