PROJECT PROFILE - INDUSTRIAL

HEINEKEN BREWERIES

In July 2008 Omni Struct Nkosi (Pty) Ltd was awarded the construction of the Sedibeng Brewery situated between Alberton and Vanderbijl Park.

The initial contract was for the steel construction and erection of four buildings and various pipe-rack steelwork.

The buildings were: Brewhouse---232 tons of structural steel consisting of cell beams over a double volume area and trusses over a mezzanine area. This building also had to be sandblasted and painted with Plascon Interseal 670, due to the moisture content of the building once in operation. This building was the most difficult due to additional steel in the mezzanine area that had to be installed only once various other plant and machinery was in place. The use of cell beams in the double volume area gives this building a really "open" feel.

Utility building: Very much the same construction as the brew-house, this building is also constructed with cell beam rafters with monitor frames on the apex. Once the roof was on we had to install 150tons of piperacks inside.

Bright-beer and Fermentation building. These two buildings were constructed with lattice columns and girder and truss configuration steelwork. The biggest of these two buildings, the Fermentation cellar, was constructed with a central girder line supported by two lightweight towers, from the central girder, trusses spanning 30m flow back towards the lattice columns around the perimeter of the building. These two buildings with a height of 30m were constructed as big "fridges", and therefore had to be clad with isowall panels on the inside. To achieve this, numerous lines of angle was installed between the columns and cold rolled lipped channel fixed to the underside of the steel trusses for the panel support.

Pipe bridges---- External pipe bridges to a total of 650tons were erected for the transportation of beer in its different stages between buildings. These pipe racks with their different levels (sometimes up to 6) were fitted with various diameter tubes for this purpose.

What makes this project so unique is that a total of 1600 tons of structural steel had to be fabricated to a very high quality and the installation programme was only ten weeks. Sometimes this can surely only be accomplished when using steel.

In March 2009 we were awarded the Package 6 steelwork consisting of workshops, canteen, laboratory and various staircases, canopies, etc.

The joint venture of Tass eng, A.Leitta steel construction and Cadcon was awarded the construction of the bottling plant and logistics building.

I truly believe that these four companies combined have produced a world-class plant in record time!

Project handover to Heineken is expected in August 2009.

NCP CHLORCHEM

NCP Chlorchem was awarded to us based on our outstanding track record on projects with a similar nature. We constructed the electrolizer building, Brine filter plant, Chlorine cooling plant, pipe support structures as well as stainless steel sheeting and vents.

Project difficulties was access, but due to our large variety of mobile cranes, this problem was solved using different cranes for different buildings, ranging from a 1T truck mount crane to our 220T mobile crane.

DOORNFONTEIN STATION

Doorfontein station consists of a steel support structure for a 6750sq meter concrete slab, with a tubular roof on the upper level. This is a project part of the 2010 upgrade. The erection of the steel still has to be done to allow trains to use the tracks.

Project handover to Rainbow Construction is expected in March / April 2009.

CONSOL GLASS

Since January 2004, Omni Struct Nkosi has been involved in capital expenditure projects for Consol Glass. The projects have been fast track shutdown type projects as well as new plant projects.

Shutdown projects entail the turnkey. Detail supply, delivery and erection of structural steel buildings, bins, conveyer gantries, plate girder flooring with bond deck, mentis grating flooring, staircases, handrailing and specialized ventilators above Furnaces and all roof and sidecladding to structures etc.

The total scope of a typical shutdown would be the demolition of an existing 300 TON glass furnace and removal of the bottle making machines, temporing kilns and testing quality equipment. Existing structures normally require alterations and strengthening and then a new furnace, new bottle making machine are installed and commissioned. Time allocated for this type of project is normally 100 days and work is done on a continuous 24/7 basis. The end date is cast in stone and never changes irrespective. Total value ± 200 Million Rand, our part ranges 6 to 45 Million Rand.

Shutdowns Complete:

• 2004 Clayville C1 - R 6 000 000
• 2007 Bellville B1 - R 35 000 000
• 2008 Wadeville W1 - R 7 000 000

New plants constructed normally include the total fabrication of structures on a turn key basis. Also including all items listed in the "shutdown" scenario but on a Greenfields basis. We have also constructed a colour sorting plant at Clayville and were involved in the full installation and commissioning of all the mechanical equipment.

We also constructed extensions to the batch buildings in Wadeville and Clayville and did the onsite fabrication and erection of 8m X 40m high sand storage silos.

Part of our scope was for the erection of 60m high self supported chimney stacks at Clayville as wells as the fabrication and erection of 3CR12 stacks in Wadeville and Bellville plants.

Greenfields Projects:

• 2006 Clayville C3 - R 23 000 000
• 2006 Bellville Batch Plant - R 12 000 000
• 2007 Clayville C4 - R 30 000 000
• 2008 Clayville Batch Plant - R 10 000 000
• 2008 Clayville Colour Sort - R 5 000 000

JOHANNESBURG PARK STATION

Johannesburg Park Station is a project which was completed in 1998. It consists of 1000 Tones of Columns and Plate Girders. 10 000sq was constructed over 21 railway lines without any interruption to metro services. A tower crane with a specially designed base was continuously rolled over the new deck to facilitate construction.