SECTOR FOCUS

• MINING

  

  Key competencies		Key differentiators
  Multi-disciplinary international mine and process plant constructor Consortium partner in engineer, procure and construct (EPC) mine construction Contract crushing and hauling services On-site services contractor Supply chain logistics into remote sites		Experienced African mining and process plant constructor across 20 countries Strong repeat business client base Reputation for delivery of complex contracts in remote and difficult conditions

  
  

  Kinsevere – Democratic Republic of Congo The structural, mechanical, electrical, instrumentation and piping (SMEIP) supply, construct and commissioning of a copper plant to produce 60 000 tonnes per annum grade A copper. A site crew of 500 people achieved 1,35 million lost time injury free hours to complete the contract.		Kayelekera uranium contract – Malawi Erection of piping, structural and mechanical equipment, heavy lifts and electrical and instrumentation works. The plant consisted of 1 168 tonnes of steelwork, 711 tonnes of plate work, 27 kilometres of piping and 52 site-fabricated tanks.		Tenke Fungurume mining contract – Democratic Republic of Congo Supply, fabrication and installation of structural steel, platework, piping, electrical cabling and instrumentation, as well as installation of mechanical equipment.		Bogoso sulphide expansion contract – Ghana This brownfields project to increase output was the largest BIOX plant constructed at the date of completion.		Langer Heinrich uranium contract – Malawi Supply of 2 100 tonnes of tanking plate work, 4 414 tonnes of steelwork and 1 312 pieces of free issue mechanical equipment.

  
  

  CASE STUDY Ayanfuri Gold Development of an open-cast mining operation, process plant and related infrastructure – Ghana Group Five Projects and DRA, a South African mining process design group, is involved in this R480 million engineer, procure and construct (EPC) contract for AngloGold Ashanti’s process plant and related infrastructure at its open-cast gold mining operations. Due to Group Five’s local presence in Ghana since 1996, the group could ensure the availability of local skills and plant when the contract was awarded. The team was therefore able to start on time in March 2010 and expects to hand over to the client ahead of the contract deadline. Group Five is leading the logistics for the contract and controlled the shipping of items from Canada, China, Brazil, South Africa, Germany, Korea, Thailand, USA and Australia. With the group’s logistics experience, materials were cleared from the port in record time so that port demurrage charges were minimised. The access road from the port was in a very poor condition when the mill was due to be transported to site. The Group Five team repaired the public road to ensure that the mill shells could be safely transported to site. During the contract, 125 000 cubic metres of earthworks have been moved and 6 500 cubic metres of concrete and 1 100 tonnes of steel used. Platinum awards in safety, quality and project lifecycle audits have been achieved.

  
  
  

• INDUSTRIAL

  

  Key competencies		Key differentiators
  Multi-disciplinary industrial plant constructor Factory layout design and build Construction services, including civils and building works Resident multi-disciplinary maintenance and shutdown services contractor Supply of construction materials		Track record in civils, heavy mechanical, electrical and piping construction – Aluminium, steel, zinc and gold smelting – Gold process plants – Petrochemical – Oil and gas – Sugar – Paper – Cement

  
  

  Sasol FT wax expansion – South Africa Demolition of existing structures and the rerouting of services. Construction of bulk earthworks, access roads, underground drainage works, structural foundations and building extensions.		Matola cement mill – Mozambique Demolition of the existing concrete structures, constructing of new civil structures, installation of mill and associated items, structural steel, mechanical items and piping.		Emirates Aluminium Smelter – UAE Six packages ranging from a power plant and sub-station building to an anode bake furnace. We also constructed materials handling infrastructure.		Highveld induction furnace – South Africa Installation of a furnace and the supply of structural steel, handrailing, grating, piping and electrical and instrumentation works.		Mittal stockhouse – South Africa Installation and commissioning of 1 761 tonnes of structural steelwork, 440 tonnes of mechanical items, 56 tonnes of grating and hand railing, 404 tonnes of lining, 9 087 tonnes of sheeting and 44 tonnes of associated equipment.

  
  

  CASE STUDY Matola Cement Plant Installation of a new mill – Mozambique This R105 million brownfields contract for Cimentos de Mozambique started in March 2010 and involved mechanical, structural, electrical, civil and piling works. Group Five Projects worked in joint venture with two sub-contractors on this contract. This is a repeat client. The contract involved major demolition works on very old concrete structures, including two 45-metre chimneys, all very close to the operating plant. This required the team to work extremely carefully to ensure that safety and production was not compromised. The piling work was particularly challenging as the group worked from a platform very close to the sea level, with tides having to be accounted for. The civil works involved approximately 1 400 cubes of concrete which required an extremely high degree of accuracy. The 130 tonne mill was installed in December 2010 after which the rest of the process equipment and structural steel for the 43 metre high building was fitted. The group finished the contract without any labour disputes. The group managed the logistics on this contract, ensuring that materials were speedily cleared through customs for both road transport from South Africa and from the port of Maputo for the heavy mill and associated equipment sourced from Europe. Although numerous technical challenges were encountered due to amendments in design specification, the contract was handed over to the client after 13 months.

  
  
  

• POWER

  

  Key competencies		Key differentiators
  Power plant co-developer, equity participant and turnkey design and build contractor EPC for thermal, liquid and gas power plants Solar, wind and mini hydro power plant contractor Construction services in all disciplines Supply of construction materials		Dedicated power division within Engineering Track record in engineer, procure and construct (EPC) power plant delivery in Africa Approved EPC contractor to General Electric (GE) and other technology providers Capability to co-develop contracts to bankability Capability to execute across Africa and Middle East

  
  

  Kusile power station – South Africa Construction of site-wide civil works for a coal-fired power station using flue gas desulpherisation technology.		Sasol OCGT contract – South Africa Engineer, procure, construct and commission, including performance testing the open cycle gas turbines as part of the Combined Cycle Power Generation Project at Secunda.		Orapa Botswana IPP – Botswana Engineering and design work, including conceptual works, as well as the procurement of two GE LM6 000 gas turbines.		Aba power station – Nigeria Design, supply and installation of three gas turbines, with a combined output of 120 megawatt for the Aba power station.		Ibom gas-fired power station – Nigeria A multi-disciplinary contract for the design, supply and construction of a gas-fired power plant.

  
  

  CASE STUDY Sasol gas turbines and heat recovery steam generators – South Africa Group Five Engineering and Construction (E+C) was appointed in 2008 to design and build a power plant and install two 9E cycle gas turbines at Sasol’s Secunda petrochemical plant in Mpumalanga. It worked together with Group Five Projects, Civil Engineering and Housing during this contract. The two 120 megawatt turbines are the first privately-owned gas-fired units of its size in South Africa. During the construction of the first phase, Sasol extended Group Five’s scope of work to include the design, procurement, logistics, construction, installation and commissioning of two heat recovery steam generation (HRSG) boilers. The addition of the HRSGs enabled the exhaust gas heat from the turbines to be used to produce steam, which can be used in the Sasol manufacturing process. The installation of the HRSG units involved working alongside an operating plant whilst ensuring safety to employees and preventing damage to the operating turbines. Group Five handled the logistics of shipping the various components from global factories, as well as the planning of the heavy lifts on site in a very constricted construction area. No lost time injuries were experienced. The successful completion of this first major gas-fired combined cycle power plant illustrates that Group Five can undertake and successfully complete total EPC contracts by making use of the combined skills of its various business units and packaging them to offer an integrated solution to clients.

  
  
  

• OIL AND GAS

  

  Key competencies		Key differentiators
  Multi-disciplinary plant and infrastructure constructor Resident multi-disciplinary services contractor Refinery shutdown and turnaround contractor		Dedicated oil and gas business within Engineering Experienced shutdown and maintenance contractor to all oil and petrochemical majors Dedicated piping and steel fabrication facilities in line with ISO 3834 standards Tankage and pipeline technology constructor and services

  
  

  Sasol Alrode tanks – South Africa Construction of a new fuel storage facility for Sasol in Johannesburg using tank technology from HMT, our US-based liquid storage tank partner.		NMPP pipeline – South Africa New multi-products pipeline designed to convey various petroleum products between Durban and Johannesburg.		Engen maintenance shutdown – South Africa Planned plant maintenance and repair.		Chevron maintenance shutdown – South Africa Planned plant maintenance and repair		Cabinda gas plant – Angola Earthworks and piling concrete work for a new gas plant.

  
  

  CASE STUDY New Multi-products pipeline (NMPP), pump stations and terminals – South Africa Group Five is working in partnership with Spiecapag of France to build a new multi-products 610 mm diameter pipeline from KwaZulu-Natal to Gauteng for Transnet. In addition to the pipeline, Group Five is the sole contractor of associated pump stations along the pipeline, the construction of the terminals, valve network control blocks and other separately defined packages, as well as storage tanks and associated facilities in partnership with HMT, the group’s US tankage partner. The combined value constitutes one of the largest construction contracts undertaken by Group Five. Works on the contract started in May 2008. Group Five Coastal, Civil Engineering, Projects and the Oil and Gas business unit within Engineering and Construction (E+C) are involved in these contracts. Pipeline The pipeline is in its final stages before being commissioned along with the pump stations in September 2011. The pipeline involved a high-speed cross-country pipe laying method unfamiliar to South Africa. Terminal 1 and pump stations Construction of the five pump stations started as heavy civil construction contracts and will finish with the erection of major equipment and ancillary piping and electrical services. Although a late design change created significant pressure on the schedule, the contract is on track for completion in October 2011. The pump stations have achieved 1 million lost time injury-free hours. Terminal 2 Group Five begun construction in March 2010 and is on track for the scheduled completion in July 2012. The contract requires multi-disciplinary expertise involving civil, building, mechanical, electrical and instrumentation construction work. There has been no lost time injury to date.

  
  
  

• WATER AND ENVIRONMENT

  

  Key competencies		Key differentiators
  Multi-disciplinary constructor of bulk water transport, treatment and storage systems Engineer, procure and construct (EPC) delivery of bulk water systems Design and manufacture of large bore spiral wound water pipes		More than 35 years’ track record of delivery in water and marine civils sector, which includes some of the largest contracts in the SADC* region Dedicated pipe manufacture Strong African and Middle East capability

  * Southern African Development Community.

  BG3 pipeline – South Africa Group Five Pipe was awarded Rand Water’s R124 million BG3 pipeline in 2008. It completed the manufacture, coating and lining of the entire pipeline during this year. The pipes were the largest pipes with the thinnest walls ever to have been manufactured by the group, with new coating and lining technology used.		Olifantspoort water treatment works – South Africa Extension of existing water treatment works for Polokwane to increase capacity by 20 megalitres per day.		Vresap pipeline – South Africa Supply and installation of 126 kilometres of pipeline as a water supply system for Sasol between the Vaal dam and Secunda.		Berg River dam – South Africa 65 metres high, 990 metres long concrete faced rock fill dam near Franschhoek to augment water supply to Cape Town.		Lusip dam – Swaziland Construction of three dams, spillway and off-takes for the Lubovane irrigation project.

  
  

  CASE STUDY Spring Grove dam construction – South Africa The Spring Grove dam construction in KwaZulu- Natal started in April 2011 by the group’s Civil Engineering and Coastal businesses in joint venture with Pandev, one of the group’s long-standing enterprise development partners. In addition, certain parts of the works have been sub-contracted to local small and medium entities. Group Five has sound technical knowledge of dam construction and the seasonal impact and risks associated with dam construction. In the 1980s Group Five pioneered roller compacted concrete technology which allows for quicker dam construction. The group remains a leader in this niche market. The bulk excavation for the foundations of the dam wall is 60% complete, with work on the river bed for the diversion conduit having started. The foundation preparation for the intake tower is in progress and temporary access roads around the site are well advanced. The concrete batch plant has been erected and is ready for commissioning. The earth embankment core trench has also been fully excavated and the concrete aggregates are being crushed using our own plant and construction materials expertise. The contract is on track for completion in 2013.

  
  
  

• REAL ESTATE

  

  Key competencies		Key differentiators
  Developer, equity participant and turnkey design and build contractor in real estate developments Design to build contractor, with particular green building expertise Public private partnerships (PPPs)		Design to build capability In-house financial structuring capability for PPP delivery Large building capacity and track record International delivery capacity

  
  

  Khayelitsha District Hospital – South Africa Construction of a new 230-bed hospital in Cape Town for the Department of Public Works.		Brandvlei Prison – South Africa Demolition of an existing prison and construction of a new prison for 1 000 inmates.		Moses Mabhida soccer stadium – South Africa Construction of a 70 000-seater stadium, including hospitality boxes, an athletics track, sports field, basement parking and external works.		Bank of Tanzania – Zanzibar Construction of the 12 000 m2 branch office for the Bank of Tanzania, comprising a basement, ground floor and one tower.		Vodacom VI – South Africa The construction of a 15 000 m2 mobile switch centre was an addition to the Vodacom suite of buildings.

  
  

  CASE STUDY Levy Junction, mixed-use development – Zambia Levy Junction is the largest mixed-use development and the first multi-level retail development in Zambia. Group Five Building started this 94 000 m2 development in the capital of Lusaka in 2009. Delivery date is October 2011. The R820 million contract consists of a 30 000 m2 double-level retail centre, 25 000 m2 of parking, a 130-bedroom hotel, a 5 000 m2 commercial office block and the associated external works on parking and bulk services. Group Five Building supplied major plant, including tower cranes, concrete mixing and transportation plant from South Africa as availability in Zambia is extremely limited. Over 60 Group Five management members were relocated to Zambia for the duration of the contract. The safety performance has been excellent, with no lost time injuries experienced to date. On the back of its success with Levy Junction, the group is currently constructing two other commercial office developments in Lusaka. Group Five Housing has also started on a mine accommodation contract for one of the large mining companies on the copper belt. To service this country effectively, the group established an administration office in the capital, with a full suite of support services. This office, together with our established office in Chingola on the copper belt, has plant yards for the storage and servicing of construction materials and equipment.

  
  
  

• TRANSPORT

  

  Key competencies		Key differentiators
  Co-developer, equity participant and turnkey design and build contractor in transport concessions Engineer, procure and construct (EPC) delivery of transport infrastructure Multi-disciplinary constructor of roads, railways, ports, harbours and airports		International experience across Africa, Middle East and Europe Reputation for timeous and technically complex delivery Large contract capability EPC competence

  
  

  Gauteng Freeway Improvement Project – package E – South Africa Extensive lane additions and improvements to interchanges as part of SANRAL’s freeway improvements.		Gauteng Freeway Improvement Project – packages A and E – South Africa Packages included lane additions and improvements to interchanges as part of SANRAL’s freeway improvements.		King Shaka International Airport – South Africa Design and construction of an international airport in KwaZulu-Natal.		Durban harbour entrance widening – South Africa Durban harbour widening by 100 metres. Removal and replacement of existing northern breakwater, extension of southern breakwater and deepening of harbour entrance by three metres to a depth of 19 metres.		Western freeway upgrade phase 1 – South Africa Major upgrade and widening of a section of freeway between Khangella and tollgate bridges in KwaZulu-Natal.

  
  

  CASE STUDY New Doha International Airport (NDIA) passenger rail sub-terranean station complex – Middle East This R650 million contract for the New Doha International Airport is the first contract for the group in Qatar in line with its strategy of expanding its presence in the Middle East outside of Dubai. The contract forms part of the State of Qatar’s rail infrastructure system and complements other major infrastructure developments under construction in Qatar. The project management team within our Middle East business unit has extensive experience in terms of piling, excavation and “top-down” construction. The construction method involves the casting of vertical diaphragm walls into the ground from above and then excavating the material to create a cavern. The team is working in partnership with one of the world’s leading piling and diaphragm wall specialists. The construction of the sub-terranean station complex started in January 2010. The station complex represents roughly 70% of the construction site area and is constrained on three sides by existing structures. This presents many access and coordination issues. As the diaphragm wall’s typical panel is seven metres wide and 1,5 metres thick, very sophisticated and sizeable items of plant are required during the enabling works, further complicating the access. The group has achieved all its milestones on the contract and has received interest from a number of consultants and contractors within the region for similar future contracts. There are more than 60 further sub-terranean stations planned to be constructed in the State of Qatar. Group Five believes it is therefore well placed to secure further contracts.