Flagship Projects

Infrastructure

Esorfranki were awarded the P26 Terrace Underground Facilities contract in February 2011 and mobilized to Site at Kusile Power Station in Ogies in March 2011. The contract consists of the installation of drainage systems and high pressure fire and water supply piping in a range of diameters from 150mm to 630mm for pressure lines and up to 2500mm for bulk stormwater lines. The total meterage to be installed in the contract period is in the order of 50 km of networked pipe. The balance of the contract is made up of the installation of 2 HDPE lined Holding Recycle Dams and 10 Km of insitu concrete networked Cable and Pipe Tunnels. Esorfranki employs over 750 laborers on this contract with an estimated completion in late 2015. The Contract value is in the order of R700m with Esorfranki being 65% complete to date.

In August 2011, Esorfranki were approached by Eskom to tender for the General Service piping contract at Kusile Power Station, which consisted of all the interface piping between the bulk supply systems and the terminations to the buildings on the power block. The Contract was awarded to Esorfranki in February 2012 with a mobilization date in April 2012. The Contract value is in the order of R340m with an estimated completion date of April 2015. A major element to the construction is the daily interfacing with the other Contractors on site for access and completion dates. The Contract is 70% complete to date and is progressing very well with little to no comebacks on pressure testing of the networks.

Esorfranki, together with their local JV partner Masibuyisane Services, embarked on the P29 Rock crushing contract in July of 2013. The Contract initially was to crush 537 000 cubes of spoil material to make a G7/8 sub 100 mm product in 6 months. The contract was extended for a further 1.5 million cubes with an estimated completion in June 2014. Esorfranki's Metso LT120 and LT110 Jaw Crushers are capable of producing 7500m3 per shift and run on a 22 hour cycle. The Product material is utilized by all contractors on the Power Station Site for general back filling of structures and civil works.

Kusile Power Station 1 Kusile Power Station 2 Kusile Power Station 3 Kusile Power Station 4

Esor Construction have been awarded the Hovercraft Project close to Burgersfort by LWUA (Lebalelo Water User Association) with a value of R25,2 million.

The contract comprises the construction of 40 air valve chambers and the upgrading of a 300 meter road in the Limpopo Province close to Burgersfort.  Esor will construct the new chambers stretching over a distance of about 15 km with some of them over 4 meters deep.

Construction commenced on the 15th March 2016 and is expected to be completed on the 20th January 2017.

Esor were awarded the P26 Terrace Underground Facilities contract in February 2011 and mobilised to Site at Kusile Power Station in Oogies in March 2011. The contract consists of the installation of drainage systems and high pressure fire and water supply piping in a range of diameters from 150mm to 630mm for pressure lines and up to 2500mm for bulk stormwater lines. The total meterage to be installed in the contract period is in the order of 50 km of networked pipe.

The balance of the contract is made up of the installation of 2 HDPE lined Holding Recycle Dams and 10 Km of insitu concrete networked Cable and Pipe Tunnels. Esor employs over 750 labourers on this contract with an estimated completion in late 2015. The Contract value is in the order of R700m with Esor being 65% complete to date.

In August 2011, Esor were approached by Eskom to tender for the General Service piping contract at Kusile Power Station, which consisted of all the interface piping between the bulk supply systems and the terminations to the buildings on the power block.

The Contract was awarded to Esor in February 2012 with a mobilization date in April 2012. The Contract value is in the order of R340m with an estimated completion date of December 2014. We employ 175 labourers and operators on this contract.

The contract scope comprioses of the installation of MPVC piping which was later changed to HDPE piping.  The piping networks is for the supply of potable water, fire water and sanitary drainage.

The contract was successfully completed with a gratified client and excellent quality work.

Building

Client   
Architect
Duration
Value
Laetma Props 16 Pty
Glh Architects
8 Months
25 Million

Annerley Road is a  refurbishment of an existing office block, consisting of two office levels, with a total of 1 500m2 floor area, as well as one basement level.

This includes a complete gut-out of the existing building and a new fit out, in the form of services and soft finishes, including facades and a double volume entrance.

7 Annerley Road 7 Annerley Road 7 Annerley Road 7 Annerley Road 7 Annerley Road
Client   
Architect
Duration
Value
Acsa
Shanbangu Architects
10 Months
65 Million

The contract comprises 4500sqm space of office refurbishment. The project consists of demolitions of the office areas, ablution blocks and common areas, and of building new spaces to suit client requirements.

The bulk of the work is in the form of soft finishes such as ceilings and partitions, shopfronts, tiling and paintwork. There are major HAVC , electrical works  and fire upgrades. All this work occurs in various phases and involves multiple tenants.

The major challenge on this contract is ensuring that there are no interruptions to the services, which could affect the entire airport.

ACSA East & West Wing Office Upgrade ACSA East & West Wing Office Upgrade ACSA East & West Wing Office Upgrade
Client   
Architect
Duration
Value
Otago Ivestments (Pty) Ltd
Impendula Design Architects
7 Months
32 Million

The construction of a new Builders Express and Rochester Furniture Stores, consisting of demolitions, bulk earthworks, retaining structures, semi basement and standard building wet trades, services and finishes. The building area consists of 5 200m2 floor area, as well as associated outer buildings, services and parking areas.

Craighall Park Builders Express Craighall Park Builders Express Craighall Park Builders Express Craighall Park Builders Express Craighall Park Builders Express
Client   
Architect
Duration
Value
Afcho
Afcho
6 Months
24 Million

The contract comprises the renovation of five existing inner city buildings into residential accommodation. Unlike most contracts,  Esor’s scope of work is limited to the wet works only, comprising demolition, structural changes, brickwork and plaster. All finishes are direct to the client.

The buildings are converted into 650 units of fourteen square metres and communal ablution blocks. The total floor area is 15 000m2 and 2 100 000 bricks have been laid during the contract.

Client    
Architect
Duration
Value
Roedean School
Tpsp Architects (Now Lyt)
8 Months
25 Million

Roedean Boarding House comprises of two floors of upmarket boarding school accommodation for 76 students, with a parking basement. The contract consists of earthworks, wet works, services and top grade finishes.

The design is based on the Herbert Baker architecture of the existing school. The contract incorporated cutting edge “Greening” construction technology such as specialist glazing, various components of insulation and underfloor heating.

Roedean Roedean Roedean Roedean Roedean
Client   
Architect
Duration
Value
West Ferry Developments
Glh Architects
9 Months
35 Million

The Rose is a “A” grade multi-storey office development, with 5 parking basements and 4 office floors. 
The architecture comprises a concrete framed structure, incorporating sandstone, glass, aluminium and terraline plastered facades. The main features are structural steel hanging balconies and double glazed curtain walls.

The Rose The Rose The Rose The Rose The Rose
Client   
Architect
Duration
Value
Unisa
Hmz Architects
8 Months
23 Million

The upgrade of the Eskia Mphalele Building at the Sunnyside Unisa Campus in Pretoria. The contract consists of the addition of four new ablution blocks, facades upgrades in the form of new sunscreens and louvres, AC and electrical upgrade throughout and new insulation and waterproofing to the existing 6 500m2 roof.

The refurbishment of the Westgate Shopping Centre was awarded to Esor & P Wise Joint Venture on 14/01/2016 with a contract value of R50 million subject to the BOQ finalization.

This is a refurbishment project of approximately 9000 m2 and is planned for 12 months.  It includes demolition and installation of new shopfronts, ceilings, tilling and ablution block refurbishment.  New lifts and new escalators will be included. New shops for new tenants are included as well as the involvement of tenant relocations.  Most of the work will be taking place after hours especially the noisy work.  The Mall will stay operational during the construction period. This Mall is buys and shoppers safety will have to be our main goal at all times.

With the project going as planned all participants are doing their fair share to get us to the planned practical completion date of 30/11/2016.

Although it was a difficult start to this project, it has armed us with knowledge and skill to work in this live environment.

Developments

Esor owns the development rights as the “turnkey developer/contractor” for an integrated housing development on approximately 237 ha of land that will ultimately yield approximately 7900 residential units as well as commercial, social, educational and medical facilities. 

  • 7900 residential units
  • 3 schools
  • 5 multi-functional community nodes
  • 3 shopping facilities
  • 5 neighbourhood parks
  • 1 hospital

Total project value is estimated at R1.5 billion.
We are currently constructing two pedestrian bridges to the value of R52 million which forms part of the bulk infrastructure of the development.

Diepsloot East 1 Diepsloot East 3 Diepsloot East 5 Diepsloot East 6 Diepsloot Bridge South Diepsloot Bridge

Soshanguve Ext 8 is a residential development in Tshwane. Esor have acquired the rights to develop Ext 8 in terms of a land availability agreement with the City of Tshwane Metropolitan Municipality for 839 residential stands.

Total project value excluding top structure opportunities is estimated at R 132 million.  
 

The Orchards is an integrated residential development in Akasia, Tshwane and 100% owned by Esor.

Comprising of 1373 stands.

  • 1 business site
  • Private open space
  • 2 x Educational sites and
  • 1373 residential stands

 

The Orchards The Orchards

Uitvlugt is an integrated residential development in Three Rivers East near Vereeniging and 100% owned by Esor.

Comprising of approximately 4200 proposed opportunities, of which Ext 1 (2242 units) is proclaimed and ready to be developed. 

Total project value excluding top structure opportunities is estimated at R 700 million.

Pipe Services

This project was awarded to Esor Pipejacking division in March 2013.  The project required 21 jackings within a 6 month period.  The J10 pipeline, replacing the outdated J8 pipeline, will be 14km long starting at Simon Bekker Rd in Germiston and ending at Reservoir Rd in Boksburg.  Our scope also includes 1 stormwater canal crossing, 2 rail road crossings, 1 un-utilised railroad cutting, and 17 road crossings.  The project was completed in December 2014.

J10 Pipeline 1 J10 Pipeline 2 J10 Pipeline railway J10 Pipeline 3 J10 Pipeline 4

Progress on the Wonderboom/Rooiwal bulk pipeline has advanced considerably with the recent completion of three important underground tunnels.

Pretoria motorists driving along Steve Biko Drive and Lavender Road over the past three months, would have been blissfully unaware that a team far beneath their wheels was digging one of the biggest underground precast culverts in South Africa.

According to project manager Anton Naude, each tunnel is 4,9 metres high and 2,7 metres wide, while the tunnel under Lavender Road is 40m in length supported by no fewer than 32 precast concrete structures, weighing 11 tonnes each.

"A hydraulic jack was used to push each structure into the tunnel which is wide enough to accommodate two small cars side by side.  A significant feature of the project was that the pipeline was laid without any disruption of traffic on the city's main arteries," he said.

The pipeline is a key component of Pretoria's 50-year development project and will supply water to Rainbow Junction and other industrial and residential growth areas to the north of the city.  The R130 million project began in 2013 and is scheduled for completion in 2015.

Wonderboom 1 Wonderboom 2 Wonderboom 3 Wonderboom 4 Wonderboom 5

The O6 project was awarded to Esor in May 2015 with a total of 9 jacks.

Since May 2015 we have finished three more jacks at Palmiet 06 line. These three jacks were handed over to the pipelines crew to push the steel pipe through the concrete sleeves. Our Original scope of work was to construct 9 pipe jacks on Portion B, but we were awarded an additional pipe jack on Portion A of the project. Progress to date on the remaining jacks is 7/91m at J8, 9/92m at J13 and 70/118m at J14. This means we still have adequate secured work on this line to keep us busy for the calendar year.

Typical of the area, we encountered a lot of mud and water at Jack 13 where we had to do piling to prevent mud slides and collapses. This however did not improve the conditions to prevent the mud slides and collapses. The soil was so saturated, that the 3m OD concrete pipe just dug into the soggy soil at the bottom and instead of jacking up, the pipe went down under its own weight.

We, as Esor, had to re-design the jack alignment and thinking on our feet it was decided to stop both jacks 13 and 14 than was planned to go under the N3 and Jack 14 under the secondary road.

The net effect resulted in an additional 20m VO approved, additional income and extended time in which to carry out the project.

In March 2016 we were awarded Jack 8 and right from the start we had difficulties with SANRAL and the Alberton Municipality. The jack was too close to the road and inside the SANRAL servitude and they wanted it moved. We then suggested 5 meters back and this was on a truck arrest road and the Municipality was not content on breaking up the arrest road in the event that it was needed during construction. We then requested for an open cut across the arrest road which was also denied. Eventually the jack went from a 53 meter jack to a 91 meter jack to satisfy every body’s needs.

This decision however brought additional problems that was not anticipated at the time. The pit and 15 meters of jacking is in backfilled ground conditions. With the heavy rains over the past few weeks we encountered numerous collapses in front of our pipe and every time we need to stop and make safe with nails and gunite before we can excavate further. The face of the jack is now under the arrest road and we have entered more solid rock and hopefully we will encounter no more collapses.

The Project's overall completion date is targeted for September 2016.

 

As we are targeting selected African countries, the award to Pipe Services of these 2 projects fits our strategy and reduce our risk and dependency on the South African market.

The Palapye Major Water Supply contract that include 6 pipe jack crossings below existing roads and railways.  The sleeves that will be used is 1800mm and 1500mm inside diameters with a total jack length of 217 meters.

The Mahalapye Major Water Supply contract include 4 pipe jack crossings below existing roads and railways.  1800mm and 1500mm diameter sleeves will also be used with a total jack length of 162 meters.

Treated Water will be running in the newly installed pipes from Water Treatment Plants.  The Palapye ring will be running from Botswana International University of Science and Technology water treatment plant whilst Mahalapye ring will run from Morale Hills water treatment works.

We have just completed the first crossing of 34m in Palapye, starting another crossing under a railway line to cover 20m and continuing with the 1st Mahalapye pipejack for the project running under neath A1 road covering 61m and expecting to complete by end March 2016.  The remaining pipejack crossings will all be completed by end of August 2016.

We completed site establishment in early December 2015 at the R59 Highway and Johan Le Roux corners.  The client is Midvaal Municipality with consulting engineers Gibb and Esor as the main contractor.

The R59 consist of 5 jacks of which 4 jacks are for sewer lines and one jack is for the water main line.  The 5 jacks consist of the following lenghts;  the Highway is 211m long and will have three inter jack sections to maintain an even pressure on the jacks and to prevent the pipe from seizing up.  The end of the jack will also be the start of the Johan le Roux jack that will start about 3m higher than what the Highway jack will end on.  The Johan le Roux crossing at 106m long willl end inside an existing sewer mainhole to be connected on the old line.  The third jack is the water main line and is situated about 5km from the other two jacks at Aandblom Street and is also jacked underneath the R59 highway for a total distance of 98m.  All three these jacks are currently in progress.

The 4th jack will be underneath the railway line at Meyerton and will be 84m long.  The 5th jack will be from the same pit as the Highway jack and is jacked underneath a property for 52m.  This jack will also end inside an existing hole within the sewer line to be connected with the existing sewer system.  All 5 jacks are spected as 1200mm IS pipe, making it very strenuous on the legs of the workers going to the front of the face.  Ventilation will be a big priority and hydration of the workers will be continuous.  Only two workers can be at the face at a time as the working space is so small.  As the main contractor on this project we will also be inserting a HDPE 500/600 OD pipe through the sleeve pipe and will build manholes at the jacking pits.

After spending over 12 months inside a 1200mm diameter pipe, we managed to complete the over 80m jack and see dayling on the 8 March 2017.

With our tireless efforts in mind, the Client has agreed to award some additional works to Esor which include additional manholes and installation that is successfully underway.

The project is estimated to be complete by the end of April 2017.

"The City of Cape Town approached Tuboseal in 2013 to investigate the possibility of rehabilitating the pipeline and utilising its much-needed capacity after many years of being degraded beyond use."

A CCTV inspection was the first and vital step in the rehabilitation process that ensued.  The city conducted several viability studies and finally appointed Aurecon Consulting Engineers to manage the trenchless rehabilitation project, comprising the CIPP lining of more than 3,300 metres of bulk sewer pipes ranging from 800mm to 1200mm in diametre, crossing underneath the N2 freeway and Baden Powell Drive.

Esor Tuboseal was awarded the project at a competitive rate and immediately began the careful logistical planning required in an environmentally sensitive and often inaccessible area.

The construction programme was expedited to ensure cleaning, final design, material manufacturing, shipping lead times and installation happened concurrently.  The dovetail effect of these activities placed the project firmly on track for completion well ahead of the programme and the (hopefully) rainy Cape Town winter.

The work itself was not without its challenges, but it did vindicate the depth of professionalism demonstrated by Esor Tuboseal and its commitment to preserving the natural environment.

"The rehabilitated pipeline runs alongside an ecologically sensitive wetland and the use of trenchless technology ensures that the ecological impact of the project is negligible.  Already 40% complete, we are on track to complete 3,300 metres of pipeline renewal without any significant excavations required."

Esor Tuboseal also adapted its hot water curing process to incorporate a high-performance water cooling system, which enables the recycling of process water and a saving of more than three million litres of drinking water amid critical water shortages in the Western Cape.

Apart from delivering a workd class product on this project, Esor Tuboseal set some audacious goals of 'safety first',  'first time right' and an unwavering resolve to maintain integrity with all stakeholders.

Pipelines

Our pipelines division is well on course to completing the installation of a pipeline connecting the Xonxa Dam to the Queenstown water treatment works.

This Eastern Cape project is a component of the greater Xonxa Dam transfer scheme and bulk water supply project commissioned by the Chris Hani Municipality to increase Queenstown’s bulk water supply.

The 22,3km DN 600 cement-lined steel conduit will not only help relieve present water shortages within the urban area but will provide a much needed supply of potable water to residents of underdeveloped rural areas.

An extensive range of tasks are associated with the project. Among these are site clearance, connections to the pump station delivery line and reservoir intakes as well as the execution of road and river crossings. The route also includes two above-ground sections, and traversing a ridge – a vertical gain in height from the pump station of 400m.

Important environmental and cultural considerations were the identification and protection of two very old trees and the preservation of bushman paintings and a site that was used to make stone tools.

The team, which is expected to complete the project by September, is made up of 30 core Esor Pipelines personnel, including operators, welders, foremen and supervisors. These numbers are augmented by 165 local recruits who have received training in pipeline construction.

The cooperation between contractor and client has been excellent, says Director Arné Rheeder.

"This is our first project for the Chris Hani District Council and we are delighted to be partnering with such a progressive and forward-thinking organisation on an important project like this."

We have been awarded the Construction of the F46 Pipeline:  Earthworks, Pipe laying and Associated works for the construction of a 4km long 1424mm ID (12mm thick) steel pipeline from Whiteridge Waterval to the Weltevreden Reservoir awarded by Rand Water.

The pipeline was awarded in two sections where Esor Construction will construct portion A and Maziya General Services will construction portion B.  Under Portion A, Esor Pipe Services have been awarded 4 road jackings of which 1 is complete and the remainder expected to be completed before the end of March 2017.  The Jacking at Maluti street was increased from 17m to 29m to pass existing structures which obstructed the pipeline route.  The jack closest to the Weltevreden Reservoir is being extended from 21m to 75m to mitigate the uprooting of a major storm water pipe.

Additional jacking of 30m is planned, next to a residential building where excavation for the pipeline cannot be done, but we can provide the solution.

Construction activities will start the 3rd May 2016 and the expected completion date will be 31st October 2017.

The Nandoni Bulk Pipeline project was awarded to Esor and started in December 2015.  This is our third project awarded in Limpopo following the opening of our office early 2015.

The contract comprises the construction of the bulk pipeline from Vuwani NR6 reservoir up to Majosi reservoir.

This involves the installation of a bulk water pipeline of 800 mm diameter continuously welded steel pipe, with a 3 layered coating and epoxy lining.  Major activities are :  construction of river and road crossings;  the connection at Vuwani pump station (NR6 reservoir);  connection to Majosi Reservoir and draw-off point provided for at Vyeboom/Kuruleni.

The project end date is set for August 2017 with a contract value of R231 million.