Construction World December 2016

Winner

Civil Engineering Contractors A 1 MAJUBA RAIL

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 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 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.

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Construction WORLD

DECEMBER • 2016