South African companies are known for their innovative approaches to challenges, and Cosira Tubular, a joint venture between the Cosira Group and Tubular Holdings, is no exception – having just achieved a major milestone in conveyor building on site at Potgietersrust Platinum mine.

This is according to John da Silva, Managing Director of the Cosira Group.

 “Our CAD/CAM division detailed an A-frame device which, once erected and put in place by our erectors was able to perform a major lift, involving seven individual lifts and 600 tons of steel, over a period of just twelve days,” da Silva comments.

“This achievement is a landmark in conveyor building, and will set a standard for structural steel erection in the mining industry. During an eight week period, the 430-strong on-site team erected an average of 280 tonnes per week, to deliver an impressive total of 5275 tonnes on the project, as at mid-October.

In addition, the off-site fabrication of all structural steel, platework and liners has taken just six months to complete,” continues da Silva.

He goes on to note:  “Besides the innovative ‘A’ frame device, a fleet of 27 cranes, ranging from just 8 tonnes to an impressive 500 tonne crawler, was used to deliver the higher than usual tonnage per week needed. This was due to the demanding erection schedule required, to bring in the ore flow from the new pit before exhaustion of the previous workings; and thereby to maintain the vital productivity of the platinum mine.”

No room for delays

Wayne Forman, Project Manager for Cosira, remarks on the close cooperation between parties, which allowed progressive access to follow-on trades, and contributed substantially towards achieving the tight deadlines.

Says Forman: “There was absolutely no room for delays of any kind in this high-speed project.  Because Cosira take ownership of all that they do, and possess the skills, organisation and capacity to handle a project from the ground upwards, we were able to rapidly adjust to changes as they occurred.”

Forman explains:  “When project scope changes arose, our CAD/CAM draughting office was able to deliver new drawings quickly. Supply and logistical challenges arising from ongoing changes in product and service availability were resolved, together with our client team, by original thinking, rapid strategic changes in sourcing and a broad supplier database. Four full-time Quality Control Inspectors worked tirelessly to ensure delivery of the high quality product Cosira is known for; and all project challenges were resolved by efficient organisation and the dedication and hard work of a committed team. “

375 000 accident-free manhours to date

Da Silva adds: “Despite the intense effort required to overcome scope changes and the time constraints involved, the project was brought in within acceptable parameters, and vital safety tenets were not neglected. We are very proud to have achieved 375 000 accident-free man hours to date.”

“The continued presence of five dedicated safety officers on-site ensures maintenance of safety protocols, and is partly responsible for our safety success. The other credit must go to the Cosira team, who are highly safety conscious, and shoulder the responsibility of safety in the workplace with enthusiasm. Their achievement has underlined the importance of ongoing site safety going forward.”

“Despite the size of our organisation, we have always maintained our dynamism and entrepreneurial spirit. Our project management staff are therefore empowered at an individual level, able to think on their feet and resolve challenges and demands proactively, as they arise. Ongoing in-house assessment and evaluation of our methods and procedures furthermore gives us the ability to adapt and improve to rapidly-changing industry conditions, and meet client requirements. At Cosira, we believe in quality, delivery and intelligent solutions,” concludes da Silva.