overall awards 2014 - sassda steel... · you’ve earned your reward and long may you continue to...

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Fourth Quarter, 2014

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5 STAR STOVES

CONTENTSfourth quarter, 2014

FOURTH QUaRTeR, 2014 1

REGULARS

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50th ANNIVERSARY

2 Perspective

A message from the executive director, John Tarboton

34 History of the Stainless Steel awards

The awards were started in 1998

38 50 Years of Fabrication

In its many incarnations, the fabricator sector lives on

40 executive Director’s view: John Tarboton Then, now and into the future

Air LiquideColumbus StainlessCronimetEuro Steelfischer SAGeneral Profiling Gerhard Unger Dairy EquipmentMacsteel VRNND EngineeringNDERimexRPL EngineeringStalcorWeldamax

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Sassda awards 2014 OverviewND Engineering scoops top 2014 Award

Project - engineering: ND engineeringND Engineering’s fabrication of Sasol’s tar separators

Project - engineering: Gerhard Unger Manufacture of a mayonnaise plant for Tiger Brands (pictured left)

Project - art: Sway Fence The fence / art installation by Rina Stutzer

Innovation: ecostakeThe manufacture of stainless steel agricultural trellising

Innovation: Sello’s GuttersFilling the market gap with stainless steel guttering systems

Product: Rock Solid IndustriesThe manufacture of stainless steel automotive canopies

Product: Solar Primeg The move from using ferritic 444 to duplex 2304 in water heaters

Product: FrankeThe design and manufacture of a knee operated basin

achievement: Don MaxwellLifetime commitment and service to the industry

Student: Folorunso OmoniyiResearch into ceramic thermal barrier coatings

Sustainability: 5 Star StovesA truly green project for a worldwide problem

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Visit www.sassda.co.za for more information Tel +27 11 883 0119Fax +27 86 639 4277Email: [email protected]

A w a r m t h a n k y o u t o o u r s p o n s o r s a n d a l l w h o c o n t r i b u t e d t o t h e s u c c e s s of the Sassda 2014 Stainless Steel Awards. Here’s to celebrating this year’s winners! You’ve earned your reward and long may you continue to shine as captains of our industry.

WINNER Rock Solid Industries RUNNER UP Solar Primeg MERIT Franke Kitchen Systems

PRODUCT AWARD

SUSTAINABILITY AWARD

WINNER 5-Star Stoves

INNOVATION AWARD

WINNER Ecostake MERIT Sello’s Gutters

PROJECT ENGINEERING AWARD

WINNER ND Engineering RUNNER UP Gerhard Unger

PROJECT ART AWARD

WINNER Rina Stutzer

STUDENT AWARD WINNER Folorunso Omoniyi

ACHIEVEMENT AWARD

WINNER Don MaxwellND ENGINEERING

OVERALL WINNER

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pErSpECTivEfourth quarter, 2014

CONTACT USPublisher Maverick MarketingEditor / Melissa Rowlstonadvertising Tel: 011 440 5181 [email protected]

Letters, comments and subscription requests to [email protected]

SASSDAJohn Tarboton executive DirectorReuben Pillay Financial Manager: admin & HRMankabe More education & Training; architecture, Building & Construction SectorLesley Squires Market Intelligence; Membership; Consumerware, Hospitality & Catering Sector; Import Sector; africaMichel Basson Sassda Western/eastern CapeClive Phillpotts Sassda KwaZulu NatalKen Dewar Import Consultant; Technical- Fabrication & Welding Sector Kim Stevens events Co-ordinator

Tel: 011 883 0119 Fax: 011 883 0183

e-mail: [email protected]

Stainless Steel is published quarterly and is distributed to stockists, distributors, fabricators, specifiers, consulting engineers, architects, mining, petrochemical and chemical industries, food beverage and pharmaceutical

industries, consumer outlets, end-users, educational institutes and provincial and government departments. Maverick Marketing makes every effort to ensure the accuracy of the contents of its publications, but no warranty is

made as to such accuracy, and no responsibility will be borne by the publisher or Sassda for the consequences of any actions based on information so

published. all opinions, views and expressions contained in this publication are not necessarily those of the management of Sassda. The contents of this publication enjoy positive protection under the Copyright act and

therefore copyright thereof is expressly reserved. any copying,publication and distribution of part or whole of the publication is prohibited unless consent is

granted by Sassda.

For the record:air Products are a proud sponsor of the Stainless Steel awards. However, in the previous issue of Stainless Steel, we incorrectly

quoted Dustin Mulder from air Products, Mulder is no longer at air Products. We apologise for the error.

It is at this exciting event of the 50th Anniversary Stainless Steel Awards, that I am honoured to be appointed as Sassda’s executive director.

I would like to thank Bill Scurr as he passes the reins to me at this crucial point in Sassda’s history. Bill has spent the past two years putting Sassda firmly back on its feet and getting the ball rolling for what will take place in the foreseeable future.

As the year draws to a close, Sassda is furiously working on all its plans and projects for the coming year. I would like to thank the Sassda team for their support and hope we can continue to drive a member-focussed organisation that

delivers in its aim to support the local manufacture, specification and development of stainless steel.

Please continue to participate in Sassda; the courses, technical desk, magazine and other projects are here to serve the members.

There are many exciting projects on the go, but the culmination of a year’s work preparing for this year’s auspicious Stainless Steel Awards is foremost.

My congratulations to ND Engineering, a well deserved winner of this year’s highest accolade. I would also like to congratulate all the other winners and every single entrant to the awards. The calibre of the entries was of the highest standard and the judges worked hard and long, not always in agreement, to pick the best and the brightest for this year’s 50th Anniversary Stainless Steel Awards.

I would like to thank the judges for all their time and effort. A special thank you to the sponsors of the awards. Without these companies, all leaders in the industry, none of this would be possible.

This magazine is dedicated to the Stainless Steel Awards 2014. However, as it is the final issue of this year’s special 50th Anniversary issues, it is only fitting that we include something else special on Sassda’s past.

On page 34, we celebrate this history of the Stainless Steel Awards. The awards, as they are structured today, are the brainchild of Dave Slater and were first held in 1998. However, Sassda has been celebrating success in the industry since its inception.

As early as 1972, Sassda launched a Design in Stainless Steel Award to promote stainless steel design excellence. In 1981 Sassda acknowledged the meritorious service of Leo Melville and Albert Moore with the Stainless Steel Industry Awards and in 1985 the Stainless Steel “Loeries” were launched. The tradition continues today.

The Heavy Fabricators (HFA) have been an industry intrinsically linked to Sassda since the inception of Sassda. The HFA also celebrates its 50th anniversary this year, and on page 38 we pay homage to the members. Over the past 50 years the HFA have had very close ties to the association, and at various times even existed as part of Sassda. Today the fabricators still play a major part in Sassda and form the backbone of the stainless steel industry.

John TarbottonExecutive Director, Sassda

2014 marks the 50th anniversary of the Southern Africa Stainless Steel Development Association (Sassda).

To celebrate, Sassda is commemorating the development of stainless steel in South Africa at its 2014 Stainless Steel Awards Ceremony.

“We have seen some of the strongest entries in years for the 2014 Stainless Steel Awards,” says John Tarboton, the recently appointed executive director of Sassda. “I do not envy the formidable task of choosing the winners for these awards.”

Judging of the awards was conducted by a panel of 6 independent judges.

The judges were individually selected based on their experience and expertise in various sectors of the media, design and the stainless steel industry. The judges are all highly knowledgeable individuals with diverse expertise in stainless steel. “We thank them for their time and commitment judging these awards,” says Tarboton.

The panel is made up of stainless steel stalwart Diego Sella, architect Tom Steer, media representative Peter Middleton, engineers Nicolette Skjoldhammer and Dr Janet Cotton, and designer Luke Hartdegen. Sella and Steer have also participated as judges in previous years.

The award categories include: Best Stainless Steel Project, with sub categories in art, architecture, and engineering; Best Stainless Steel Product; Innovation Award; Achievement Award; Student Award; and the Stainless Steel Award.

Sassda has created a set of criteria for the judging panel to use when evaluating entries. The criteria include: excellence; innovation; sustainability; efficiency; quality; the impact on the environment and job creation.

The awards could not have been made possible without the generous support of the sponsors.

This year’s sponsors are Afrox, Air Products South Africa, Columbus Stainless, Euro Steel, fischer South Africa, Macsteel VRN,

NDE, ND Engineering, Rimex and Stalcor. They are all leaders in their fields and great supporters of stainless steel in South Africa.

Project Award - Engineering:This year there were 11 very strong

entries for the Engineering Project Award: RPL Engineering, Gerhard Unger Dairy Equipment, Conceptual Steel Engineering, HC Heat Exchangers, SAB Ltd, Rina Stutzer, Cloete Architects and ND Engineering with three massive projects.

ND Engineering’s massive tar separators project for Sasol scooped the Engineering Project Award as well as the overall Stainless Steel Award. “Congratulations ND Engineering, the project was an exemplary example of top notch South African engineering and fabrication at international standards,” said Tarboton.

Gerhard Unger scooped runner-up in this category for its Tiger Brands Mayonnaise Plant. The judges were particularly impressed with the fine attention to detail; proving South

African fabricators are world class.

Project Award – Art:The two entries for the art category

were Rina Strutzer with her design of the Sway fence at the Everard Read Gallery in Rosebank, Johannesburg and Cloete Architects for a stainless steel memorial. The judges were particularly taken with the form, implementation and choice of 3CR12 used by Rina Strutze, who won the Art Project Award.

Project Award – Architecture:There were two entries for the

architecture category. Conceptual Steel Engineering (CSE) entered its 3CR12 seven level helix spiral staircase for a water tower in Lanseria. Gutco Manufacturing submitted an entry for its mesh facade for Sanral in the Western Cape.

However, after much deliberation the judges decided not to award a winner in this category due to lack of sufficient information in the submissions.

wins 2014 Stainless Steel Award

AWARDS 2014STAINLESS STEEL

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Innovation Award:The judges awarded first place in

the innovation category to Ecostake for their agricultural trellising. “The trellis was very innovative,” said Tom Steer. “It was cleverly designed to satisfy a real problem and had many clever features such as a plastic wire and an anti-uproot feature to prevent theft. The manufacturers also realised that stainless steel was the best material for the job. Very innovative all round.”

The judges felt there were many innovative business solutions entered into the innovation category, even if the products themselves were not brand new. Sello’s Gutters was a great example of this. Although stainless steel gutters are not a new product, especially in the international market, Sello saw a gap in the South African market and grabbed it with both hands. His marketing and business model are truly innovative, filling a niche in the South African market. Sello’s Gutters earned a merit award in recognition of this.

Other entries included Ecovest for its Ecolite, Gerhard Unger for its mayonnaise plant, Rock Solid Industries for its canopies, HC Heat Exchangers, and Welfit Oddy for its innovation of many new products and solutions since its inception.

Product Award:This product category was the most

popular for submissions, with entries from 5 Star Stoves for its green stove; Solar Ray for its grade 444 solar tanks; Sello’s for its stainless steel gutters and facia boards; Rimex for its contribution in developing the stainless steel

gutters for Sello’s Gutters; Gerhard Unger Dairy Equipment for its mayonnaise plant; Bar Keeper’s Friend for its non-scratch stainless steel surface polish; Franke’s new cost saving autopsy tables; HC Heat Exchangers’ light weight heat exchangers; and ND Engineering for its stainless steel RDA units as well as its 60 ton acid cooler in Caledonia.

The winner was Rock Solid Industries for its revolutionary move from aluminium to stainless steel in the manufacture of automotive canopies. “This was a real winner with the judges,” said Tom Steer. “The canopies were extremely well made, high-quality, well researched and filled a market both locally and abroad.” The judges were also particularly taken with the clever flat-pack design.

Solar Primeg was awarded runner-up in the product category for its innovative development of making solar water heaters from duplex 2304, as opposed to the standard grade 444. “Solar Primeg is truly pushing the boundaries with this product,” said Tom Steer.

Franke Kitchen Systems scooped a merit award for its knee operated basin system. “This product is not exactly new,” said Steer, “but it has been rethought by Franke in such an innovative way that the final product is a great product for a multitude of industries.”

Achievement:In the achievement category there

were four entries, however, the two companies that entered were disqualified as the judges felt this award must be awarded to an individual. Don Maxwell of 3CR12 fame and John Cluett from SAB were both nominated. “Both the

entries deserve recognition,” said Diego Sella. However, there can only be one winner.

Don Maxwell scooped the Achievement Award for his commitment to stainless steel over the decades, over a multitude of projects and with an unrivalled enthusiasm and dedication.

Student:Five students entered this category.

Two were from Franke’s Design a Bathroom Competition; Murray Farquharson and Andrew Mboyi. Siphiwesihle Memela entered with the design of a multifunctional ottoman with arm and back rest. Ming Zhang entered with a paper on the use of chromium ore in the stainless steel alloying process.

The winner was Folorunso Omoniyi for his research paper on how to spray austenitic stainless steel with ceramic oxide to form a thermal barrier. The judges said they eagerly await the results of his research.

Sustainability:The sustainability category was

entered by Sello’s Gutters for its long lasting gutters; Ecovest for its Ecolite; Hazelton Pumps for its slurry pumps; HC Heat Exchangers; Rimex for its help developing stainless steel gutters; Welfit Oddy for its ISO stainless steel tank containers.

The winner was 5 Star Stoves. “5 Star Stoves created a truly sustainable product from stainless steel,” said the judges. “The stove and material used are eco-friendly and it is a great solution to many problems arising from other forms of informal cooking.”

THE JUDGES From left are Tom Steer, Peter Middleton, Nicolette Skjoldhammer, Dr Janet Cotton and Luke Hartdegen. Diego Sella, was not available for the photo.

ND ENgiNEERiNg - WinnerEntrant: Nolan Green The manufacture of 16 stainless steel tar separators for Sasol.

gERhaRD UNgER DaiRy EqUiPMENT - Runner upEntrant: Gary Crawford Gerhard Unger Dairy Equipment manufactured a mayonnaise plant for Tiger Brands, through WSP, providing design, engineering and management consulting services in the built and natural environment.

CoNCEPTUaL STEEL ENgiNEERiNg (CSE) CSE custom designed and built a seven level helix spiral staircase from 3CR12 stainless steel for the inside of the Lanseria water tower project.

hC hEaT ExChaNgERS Entrant: Hans Banza HC Heat Exchangers manufactured a stainless steel tubed heat exchanger for a 890kW spiral freezer, designed to provide the cooling capacity required to freeze over 10 tons of chickens per hour.

SaB LTD Entrant: John Cluett For the contribution made by the brewing industry in South Africa in the development and use of stainless steel through an in-depth investigation into the problems associated with corrosion of plants in the 1980s.

gUTCo MaNUFaCTURiNg Entrant: Laurence Gutridge A mesh façade application for Sanral in the Western Cape. (Pictured below)

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ND ENgiNEERiNg Entrant: Nolan Green The first CO2 Capture Project in southern Africa using Casolv Technology. The project included an absorption vessel, a stripper column and a vapour scrubber.

ND ENgiNEERiNg Entrant: Nolan Green The manufacture of six heat exchangers exported to Tunisia.

RPL ENgiNEERiNgEntrant: Ruland Munz Xstrata asked RPL Engineering to replace a corroded vessel made from 316 with one made from 904L. However, there was only enough 904L in South Africa to fulfil half the requirements. RPL therefore suggested 2205 be used as an alterative. This proposal was accepted and a duplex material tank was fabricated with much success.

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EVERaRD REaD gaLLERy - WinnerEntrant: Rina Stutzer The design of a stainless steel fence as an art installation for the Everard Read Gallery.

CLoETE aRChiTECTS Creating a memorial with the use of stainless steel sheeting.

CoNCEPTUaL STEEL ENgiNEERiNg (CSE) CSE custom designed and built a seven level helix spiral staircase from 3CR12 stainless steel for the inside of the Lanseria water tower project. (Pictured below)

gUTCo MaNUFaCTURiNg Entrant: Laurence Gutridge A mesh façade application for Sanral in the Western Cape.

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ND Engineering is this year’s overall winner of the Stainless Steel Awards. The Durban-based company is also the

winner of the Project Award in the subcategory: Engineering for its manufacture of 16 stainless steel tar separators for Sasol.

ND Engineering was awarded the order to design and manufacture 16 out of 24 tar separators in what was known as the Sasol Separator Replacement Project.

The procurement selection process for the manufacture of the separators was handled by Fluor SA and Sasol Technologies on behalf of Sasol and proved to be an exceptionally stringent process.

The willingness by Fluor SA and Sasol to keep this work local must be commended, especially since this was a high priority project within the organisation and, as it turned out, would prove an opportune time to prove the true capabilities of South African fabricators.

In short, the task that ND Engineering was faced with boiled down to the manufacture of 16 tar separator vessels within a 12-month period. This meant ordering, testing, preparing, forming, assembling, and welding more than 1 000 tons of 2205 duplex stainless steel.

To achieve this mammoth task, both ND Engineering’s main workshop and the Bayside workshop were utilised in a production line type process. The company’s main workshop assembled various components of the vessels in jigs with the completed sections being sent to the Bayside workshop for complete trial assembly, inspection and release for final assembly and welding on site in Secunda.

The resources in both of these workshops were fully committed to this project for 9 months.

Six months into manufacture, ND Engineering’s site team established operations in a specially designated site area in Secunda. At this point the company had over 300 resources working 7 days a week on the project across the 3 work areas.

An average of 91 000 hours were being worked on this project per month, and over the

12 month period, approximately 750 000 hours were clocked up without a single lost time injury being recorded. From the onset, this was a project like no other that ND Engineering had ever worked on.

Sasol and Fluor SA had a very specific goal that they set out to achieve with the fabrication of these separators. This was to extend the required inspection intervals on these vessels, thus reducing inspection and maintenance downtime and improving output.

To achieve this, they set up one of the

most advanced technical scopes and developed supplementary material standard requirements, making this project one of the most complex and advanced fabrication projects a South African company has ever had the privilege of working on.

“An absolute premium was placed on planning and scheduling and every step of the manufacturing and testing process was laid out in an extremely detailed execution plan,” says ND Engineering’s owner Elvis Green.

This plan was used as a daily tool to

Tar separator vessels for Sasol

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WINNER The sixteen tar separator vessels were built in Durban and then moved to Sasol in Secunda where final assembly and welding took place on site.

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As the pictures included with this submission show, these separators were highly complex in terms of the detailed internals and the multitude of cone, shell, and roof nozzles which had to be absolutely spot on in terms of their position and elevation.

They were replacement vessels that would be going into a live plant, so there was no room for errors in terms of the nozzle positions. The positions were verified by laser scanning of the completed vessel,. This included the staircases, ladders, and platforms. All were laser scanned and found to be in complete compliance.

In addition to the complexity of the separator vessels, there were also very complex welding standards that required an unprecedented number of Production Weld Test Plates (PTPs) over the period of the project.

A total of 128 PTPs were completed to ensure that the results achieved during shop and site welding were in line with the project approved welding procedures and required parameters.

Due to the complex features of the design, combinations of design standards were needed to evaluate the designs. Additional detailed FEA analysis was also conducted in order to assess each of the vessels’ specific

design parameters.In addition to having to meet the design

parameters, the 8 Tertiary Tar Separators had to be fully redesigned to operate as a part of a pressurised system, and the 8 Tertiary Tar Separators needed to be redesigned to include 9 access covers on the roof of the vessels to accommodate more access openings and the loading of the platforms on the roof.

Extending the life cycle costingThe existing separators were

fabricated from carbon steel and were required to be inspected annually. This entailed shutting down the plant to inspect and / or carry out the necessary repairs due to stress corrosion cracking.

The client used dual certified, duplex stainless steel with specific properties so as to extend the inspection intervals and reduce the impact of the product on the Separator shell and cones. The Risk Based Inspections (RBI) expectation is expected to be between 5 and 10 years.

Quality produced on timeTo meet the delivery deadlines set for

the project meant that ND Engineering needed to implement all of the carefully thought-out strategies to fast track the manufacturing process whilst maintaining the set quality objectives.

The client’s expectation and specific requirements far exceeded the standards listed above. To satisfy these requirements ND Engineering carried out extensive NDE testing on the welded components.

The site built for the project will now form part of a workshop extension of the pre-existing workshop.

Job creationIn order to meet the tight schedules

a total of approximately 320 people were actively involved in the fabrication either in the workshops or on site in Secunda. This overall project will continue to offer employment for the foreseeable future as the installation phases will run for another two years.

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S “This was an extraordinary project! It involved hundreds of weld test plates and ND Engineering was the only tendering company that passed all these tests, demonstrating world-class control of welding processes and quality.” - Peter Middleton


Acid Cooler for New Caledonia

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ND Engineering manufactured a replacement acid cooler (pictured right) for a large nickel mine in

New Caledonia. The project shows the benefits of using stainless steel and how only the world’s best fabricators can build these acid coolers due to the huge risks if these units fail in service. The shell and tube acid cooler weighed 58 tons and was manufactured in grade 316L stainless steel to meet the extreme process conditions.

ND Engineering has been extremely fortunate to have been successfully manufacturing acid coolers for the sulphuric acid industry for the past 20 years.

From the very beginning, its involvement with the MECS Acid Cooler Technology has proven to be most beneficial from a technological advancement point of view as well as from the business perspective.

Acid coolers are subjected to extremely harsh operating conditions and only the very best manufacturing and technological advancements will ensure that this vital piece of equipment can function properly in order to survive. Cooling hot sulphuric acid is always a challenge in any chemical operation. Anodic protection has been around for many years and became the technology of choice for

these types of applications. As with most processes, things are getting larger and larger to keep up with the world demand.

The circumstance surrounding this particular product replacement became so critical that during the final stages of manufacturing a decision was made to fly the unit to New Caledonia. With this unit being air freighted out of Durban it set new records for the Dube trade port as well as for a South African product manufactured in stainless steel.

ND Engineering had to ensure that very strict quality standards were met on this project.

RDA valve technology

ND Engineering provided its construction expertise and stainless steel manufacturing capabilities to the Tongaat Engineering Group, the initial

developers of the patented award-winning RDA valve technology.

ND Engineering has spent many years exploring and developing this technology with Tongaat Hullets, particularly from a fabrication and material selection point of view.

ND Engineering has also been selected by Ionex Separations Technologies, an American-based company, to manufacture this ground breaking RDA valve technology for its industrial applications.

This RDA Valve technology has many varying applications. Not only is it used extensively in the food industries, it is also used in applications with chemicals at high temperature, making stainless steel the natural choice.

ND Engineering has been involved in the development process from the initial concept valve units, through to the pilot valves and finally the production valves and maintained its partnership with Ionex as a strategic partner.

Even under great pressure to manufacture this technology in China, Ionex Separations Technologies, gave ND Engineering its full support in retaining the manufacturing in South Africa for the four units that are for a Chinese client.

This product allows the performance, cost effectiveness and environmental benefits through a reduction in process chemicals required, water used and waste eliminated. It also enhances aesthetic appeal, as only stainless steel can give the appearance needed for the food industry.


CO2 absorber column

ND Engineering manufactured a CO2 Absorption Column, which was transported to site in one piece. The

project also included a pre-vapour scrubber, a CO2 stripper column reboiler and an overhead condenser.

Process Plant Technology (PPTech) successfully completed the construction, commissioning and performance testing of this major project for German specialty chemicals group Lanxess to be constructed at their Newcastle facility in KwaZulu Natal in August 2013. Cansolv’s CO2 capture technology is used to remove carbon dioxide from the flue gas.

ND Engineering was approached by PPTech to fabricate and deliver the large vessels to site. The main absorption vessel was 3.5m in diameter and 32m long. This presented many challenges, both in manufacture and transport.

The vessels were manufactured in one piece in Durban for delivery to the Lanxess site in Newcastle. The deciding factor to fabricate and transport the main absorber in one piece was the major reduction in site work required. However, to make this simplified erection approach possible, the largest hydraulic crane in the country had to be sourced and utilised on site for installation.

Once the main columns were erected, the specialised structured packing was installed into the columns which had

been constructed within the required tight tolerances to allow satisfactory installation of the packing. The quality of the columns was well within specification with no modifications and or rework required on site for the fitment and / or installation of packing.

Since it would have been dangerous and expensive working at heights to make these ladders and platforms fit to the vessels on site, pre-assembly and welding of platform mounting cleats were an additional task undertaken in ND Engineering’s production facilities.

PPTech delivered the project on an EPC basis, assuming responsibility for design, engineering, procurement, construction, commissioning, and handover and were therefore very dependent on a reliable and cost effective fabrication partner, such as ND Engineering.

9 Sigma Road Germiston Johannesburg South Africa+27 (0)11 876 3740 www.gerhardunger.co.za

We’re not brewers, winemakers or cheese producers. Nor do we make juices, edible oils, soft drinks, sauces or mayonnaise.But, tell us what you want to produce and we’ll help you design or research and design a processing plant tailored to your specific needs.

For almost 40 years, Gerhard Unger has specialised in turnkey solutions for food and beverage processing plants.

Gerhard Unger’s ethos of craftmanship, professionalism, quality, design ability and site-work track record throughout Africa and the Indian Ocean islands has made it the supplier of choice for more than 300 clients, including a major quality mayonnaise producer.

Expertise, capability and an in-depth understanding of client needs ensures that we live up to the promise:

With Gerhard Unger on your side, consider it done!


Gerhard Unger manufactured a mayonnaise plant for Tiger Brands through WSP, one of the most diverse

engineering firms worldwide, providing design, engineering and management consulting services in the built and natural environment.

The plant is designed in a modular format that provides flexibility. In physical form, it comprises three ‘lines’ each of which have two ‘skids.’ One skid houses three stainless steel tanks (including pumps and instrumentation); the other skid contains six stainless steel tanks and ancillary equipment.

The tanks contain the ingredients, consisting of whole egg, edible oil, vinegar, and stabilisers, flavourants, etc.

The skid-mount design allowed for virtually total manufacture and assembly of the plant before it was delivered to the client’s premises.

For intellectual property reasons, the actual process detail is confidential. However, one may very easily understand the complexity of the manufacturing process in a plant that strongly states ‘fit for purpose’ in an environment of order. Attention has been very carefully given to placement of pumps, valves and other equipment requiring maintenance.

If there is one word more pertinent to pipework than any other, it is ‘simplicity.’ The same is true in many facets of life. “Simplicity is the ultimate sophistication,” said Leonardo da Vinci. Albert Einstein believed in the paring down of very complex concepts: “If you can’t explain it to a six year old, you don’t understand it yourself.” One of America’s greatest architects, Frank Lloyd Wright, put it another way: “Simplicity is the quality that measures the true value of any work of art.”

Le Corbusier sought to “realise a small masterpiece of simplicity.” Not only so-called great minds value simplicity. When a sculptor, who carved elephants out of tree trunks, was asked how he did it, he explained, “I cut away anything that doesn’t look like an elephant.”

So, to a professional pipework

Mayonnaise plant for Tiger Brands

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RUNNER-UP The mayonnaise plant Gerhard Unger built for Tiger Brands

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S “The pictures of this project really told a story of excellent quality, planning and the effective use of stainless steel. It is a great advertisement for South African quality.” - Nicolette Skjoldhammer “This project represents a complete (turn-key) project.” - Diego Sella

engineer, eloquence lies partly in simplicity. However, not the simple ‘straight line between two points’ philosophy. Pipework exists for the purpose of conveying, and such aspects as viscosity, temperature, emulsification, and high solids play important parts in the pipework design process. In the end, however, the pipework engineer will far prefer an harmonious pipe system to one resembling a rat’s nest, because, aesthetics aside, the former will allow excellent flow and CIP (cleaning in place) effectiveness, of paramount importance in food, beverage, pharmaceutical and cosmetics industries.

Since 1976, Gerhard Unger has provided specialised solutions for the above industries and others requiring a high level of stainless steel manufacture. That experience

and capability is to be seen in every plant and piece of equipment that leaves the Gerhard Unger facilities. So too, the mayonnaise plant in question.

‘You are only as good as your last job’ could be Gerhard Unger’s mantra … and this mayonnaise plant fits the bill perfectly. It displays high quality, advanced engineering, best practice design, efficiency, reliability and innovative manufacturing. And, it complies with the pragmatic approach of Gerhard Unger and WSP for pre-manufacture and factory testing to ensure that the plant can be re-assembled on site in the shortest time possible and with minimal disruption to the client.

There really is something special about equipment that does the job perfectly and looks great at the same time.


It’s been a good year for RPL. They’ve moved into new, much larger premises at 12 Foden Street, Aureus, in Randfontein, and have

stayed busy with a constant stream of large fabrication projects. Even the NUMSA strike didn’t impact their ability to deliver, since the majority of their staff were keen to work.

One aspect of their continuing success is Managing Director Ruland Munz’s passion for stainless steel. You would expect a company capable of manufacturing such large projects to consume a lot of 304L and 316L, staples of the industry, but over the last few months Munz’s team have being using an increasing amount of more exotic steels instead - like Alloy 600, 904L, 2507, 2205, and LDX 2101, among others.

“We’ve been attending seminars,” says Munz, “and we’ve learned a lot, particularly about duplex and super duplex stainless steels. There are some significant advantages to them that we hadn’t been aware of, that make a big impact, so we’ve started suggesting them to our clients.”

These stainless steels often have much higher corrosion resistance than their more conventional counterparts. Also, their strength profile means that it’s possible to fabricate projects with thinner gauge steels without compromising durability or structural integrity. Another advantage is that the stainless steels, in certain instances, cost less than the original steel used.

Significantly, a thinner gauge means achieving the same outcome with less material consumption, which will usually make a fabrication project more affordable.

“Stainless steel is expensive,” observes Munz, “and not everyone is prepared to try something new, especially when you’re talking about an item that will in any case cost a lot to fabricate. But we feel like we owe it to our customers to ensure they get the best value possible out of their project budgets.”

Their forays into the unconventional don’t end with materials - they’ve extended into techniques as well. When RPL took on a job from Smith Metallurgy and Quality Consulting, they were impressed by Marius

Smith’s depth of knowledge of exotic stainless steels. He also specified some unorthodox fabrication techniques which resulted in a product with a much longer life expectancy than they’d expected - techniques that RPL has now embraced in their own production.

Smith’s company has been in business since 2010, and offers specialist consulting services in many aspects of metal working. With more than 20 years experience in the field, many companies have found his input invaluable when decisions need to be made about what materials to use for particular applications, the best approaches to achieve specific quality outcomes, or to investigate why structures failed.

The companies have developed a mutually beneficial arrangement. RPL repair/refurbish items for clients and use Smith’s help to assess damage and generate reports on what he feels is the best way forward. Smith also employ RPL’s services to help build alternative

quotes when clients submit drawings.“We feel it gives our clients something

extra,” says Munz. “We don’t force these steels on anyone - we quote on drawings exactly as the client specifies - but our quotes are now more comprehensive, and include alternatives, simply to make our clients aware of their options.”

Working with less conventional stainless steels has not been without challenges though. Their biggest headache has been securing materials, because many current stockists of duplex stainless steels do not carry it in bulk.

With more and more of RPL’s clients showing interest in using these materials, supply can be a stumbling block, particularly since Munz prefers to shop local. “We do use substantial quantities of imported material, but we are a proudly South African company and we make a point of supporting our local industry whenever we can.”

RPL EngineeringCost effective solutions

The company is taking on more ambitious projects and recommending less conventional DUPLEx aND SUPER-DUPLEx stainless steels, which ultimately

perform better with longer life expectancies and thinner gauges

DUPLEX STAINLESS STEEL RPL’s Ruland Munz is using increasing amounts of duplex stainless steel for fabrication projects

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The Everard Read Gallery in Johannesburg was in need of a physical deterrent to secure their outside exhibition courtyard.

They had asked Rina Stutzer to design a functional but beautiful visual element that would fulfil the need, in harmony with all that already existed in the space.

The artist proposed a site-specific concept that visually merges the surrounding natural and architectural structures. The design had to consider the gallery context, especially aiming not to distract attention from the artworks on display. Knowing the scale and aesthetic importance of the fence, the process used had to be industrial and cost effective.

The development process included freehand concept sketches followed by the master made by hand utilising thin strips of natural wood. These were cut and carved into a 1/10 scale composition, also serving as a scale-model for the fence.

After the approval of the proposal, the fence was drawn into a 3-D digital realm, and transferred to the required format for the laser-cutting machinery. Fence parts were laser-cut and welded together at the engineering

“Sway” - a stainless steel fence

ARTWINNER

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“Wonderfully designed, superbly installed. High quality production and finish.” - Luke Hartdegen “The functionality and the beauty of this fence stood out. The gate was almost hidden and the changing ‘view’ was exciting.” - Nicolette Skjoldhammer

firm Certus. The welded fence segments were finally handed over to DSW art studio, a bronze foundry that also specializes in the finish of other metals. DSW managed the metal chasing, surface finishing and installation of the structure.

The combination of skilled people from different disciplines brought this design into being - the collaboration between

niche specialists creates more than what an individual might be able to. The specific project’s success is due to the merger of the artists and the engineers (engineers from Certus engineering in Midrand, Michele and Andreas Benassi) and a creative team of artists, namely Alex von Klitzing, Francois

Visser and Angus Taylor, from Dionysus Sculptures Gauteng (DSW art studio).

As the viewer moves around the creation, a dynamic visual impact is achieved by the structural appearance of the fence. From one vantage point the fence will appear purely linear, as if repeating Circa on Jellicoe’s exterior, but from another the animated quality of the design becomes clear.

Material enhancing form and aesthetic3CR12 stainless steel was the material

of choice, since this metal oxidizes slower than mild steel and it is also more cost effective when one compares it to other stainless steel types such as 304 and 316. The rigidity and strength of the chosen stainless steel, made it possible to design a pure vertical linear structure that is only fastened on floor level, with no other horizontal support. The reflective shimmer that is emitted by the material, when finely finished, adds a subtle luxurious characteristic to the structure. On all levels 3CR12 stainless steel was the most appropriate material to use for its ability to meet the challenges presented by the design process, as well as the budget.

The fence spans over 13 meters and includes 51 profile pairs, amounting to 102 individual units.

The fence cantilevers and for this reason the anchors had to extend deep into the floor. The base is a long stainless steel channel fastened on to a flat bar. The pedestrian and service gates, swing open by means of a swivel pipe cylinder hinge (a bespoke design for this project) which was sunken into the concrete foundation.

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SEcostake - WinnerEntrant: Jammie Hanlin Stainless steel agricultural trellising and fencing systems to replace wooden stakes.

Sello’s gutters Manufacturing - MeritEntrant: Sello Senyatsi Sello’s stainless steel fascia board, which has a unique design that allows it to be shaped and designed in any way. Stainless Steel guttering to fill a gap in the market. Ecovest holdings Entrant: Roland Meintjes The development of the EcoLite. The project used 10-ton fly presses in a unique metal forming process to manufacture off grid stainless steel components. (Pictured below)

Rock Solid industriesEntrant: Mike VossThe manufacturers of stainless steel canopies in the construction, transport, commercial and leisure sectors. h C heat Exchangers Entrant: Hans Banza The manufacture of stainless steel heat exchangers produced for the food industry. Welfit Oddy Entrant: Andrew Gardner The development of new products, accessories and industry solutions.

gerhard Unger Dairy EquipmentEntrant: Gary Crawford Manufacture of a mayonnaise plant for Tiger Brands, through WSP, providing design, engineering and management consulting services in the built and natural environment.



Wooden poles are predominately used for agricultural trellising in South Africa, while abroad the practice is

being phased out. This is because in many parts of the world wood supply has become scarce, while documented studies into the preservatives used to treat wooden poles have also raised alarm bells and been part of the motivation to curb the use of treated wooden poles.

Creosote has typically been used to treat wood. These preservatives contain toxins that in some instances have been known to leach into soil or ground water and could be associ ated with the contamination of grown produce quality, which in wine is referred to as cork taint.

Steel trellising has been widely accepted and used in Europe, USA and Australia.

Ecostake is a local company that produces the Vinestake as a sustainable solution for agricultural trellising and the Electrostake for fencing applications. The patented stainless steel system was accredited in 2007 with an SABS Design Excellence Award for the commercially viable advantages it provides.

Ecostake’s fencing includes durability and being ‘universal in application’ to pro-vide the user with great lifecycle cost savings benefits. The stakes can also be recycled and come with a ‘guaranteed for life’ benefit.

Jamii Hamlin, the founder and managing director, outlines the company’s vision saying, “Environomics is a term that best describes Ecostake’s objectives to equally deliver environmental sustain ability and an economically viable product offering to reverse the disposable consumer acceptance of planned obsolescence.”

He elaborates on the company’s innovative solution, “The user friendly benefits of the Vinestake system are holistic in their offer ing. The system is clinically appropriate for sensitive biological environments,

Alternative agricultural trellising

INNOVATIONWINNERECOSTAKE

WINNER Jamii Hamllin with his environmentally safe solution to vineyard trellising systems

biodynamic or organic applications, compatible with har vesting machinery, suitable for overhead trellising of table grapes or other stone fruit produce. It also yields greater cost efficiency, with tailored solutions specified according to farmers’ application requirements.

“Made from stainless steel, with a life expectancy of 25 years or more, Vinestake provides for excellent carbon footprint benefits and as a re-usable material it provides a residual return at the end of its service.”

Hartenberg Estate is a prime example of the migration to sustain able trellising in response to the concerns about cork taint asso ciated with the use of organic chlorate, or arsenic used in treating wooden poles, as well as the sustainability of alien forestry resources.

In 2005 the farm management decided to do a trial test of the Vinestake and since then all new plantings have been staked this way, despite the perception of the loss of traditional vineyard aesthetics.

Hartenberg’s acclaimed winemaker, Carl Schultz, had this to say about the aesthetic

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debate: “Vineyard aesthetics are a non-issue in the long-term, when weighed up against the advantages of this new technology.”

He said: “Growing trees (for, among other things, wooden poles), consumes 400 to 600 litres of water per day per tree in the growing season. In a country which is already water scarce, it does not make sense.

“The impact stemming from the preservatives used to treat vineyard poles is also an environmental concern. It is about preserving our natural resources by using a cleaner alternative that is re-usable and more durable,” he concluded.

While this tainting effect is difficult to

distinguish, it could have a negative impact on the desirability of the produce and ultimately discerning consumers might avoid purchasing or consuming produce that is considered to be tainted or associated with environmental malpractice.

To address the concern of wooden poles, Ecostake has under taken to produce a holistic and universally adaptable system for all agriculture trellising and fencing applications. They offer sterile and sustainable advantages for environmentally sensitive use. The product is durable, reusable and allows for recycling to provide a user with a viable solution for emerging environmen tal realities.



Senyatsi Home Improvements, trading as Sello’s Gutters Manufacturing, started in 1998 in Katlehong.

Sello Senyatsi got a job in 1996 as a metalworker for a steel fabricator in Germiston. While at this company he worked his way up to a foreman and built a strong relationship with his boss, Gerhard Van Schalkwyk. While working there as a factory foreman his sister spoke to him regarding gutters she had ordered over 6 months ago from a guy in Katlehong.

Sello decided to go have a look at her house and said he would do the gutters for her. He got permission to use the machinery at his current job and so began the gutters for his sister. Once he had completed the gutters and installed it he noticed that the gutters looked skew on the house.

That’s when he noticed the house was not built straight. Sello went back to work and decided to manufacture a cover to hide the slant of the gutters. This is where he developed the Sello’s Fascia board, which he has now patented.

Once the gutters and fascias were installed Sello got calls from his sister’s neighbours and other people in the community. Soon he was inundated with work in Katlehong.

His boss Gerhard Van Schalkwyk noticed this and told Sello to start his own business. His boss also provided him with a bending machine for free. Sello started his gutter company in 1998, however, he did not have all the machinery so had to buy certain things from a large company in Germiston. Soon this company became aware of the amount of work

Sello had and they started copying his work.Sello then decided that he had saved

enough to buy his own machinery and so began manufacturing everything by himself.

Sello Senyatsi started with galvanized and made it a huge success. However, Sello Senyatsi knew what his customers wanted, which is something that shines and adds bling to the house.

He approached Jason Naude from Rimex and asked him for stainless steel gutter coil that could be bent. Jason said to Sello that he will never sell stainless steel and it was not possible. However, Jason and Sello had a strong relationship and Jason decided to do research on a stainless steel guttering material that could be bent and formed.

Stainless Steel guttering systems

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“Recognition of Sello’s faith in stainless steel as a desirable and aesthetic material and for developing a brand new market, in spite of several cheaper alternatives.” - Peter Middleton“This award is definitely well deserved.” - Diego Sella

Sello started with 1 ton of stainless steel coil that took him over a year to sell. The following year he sold 2 tons and in 2014 Sello’s Gutters Manufacturing is selling up to 40 tons a month of stainless steel guttering systems.

Sello’s Gutters is the only company in South Africa that currently manufactures guttering systems in stainless steel.

Sello’s stainless steel fascia board has a unique design with seven unique bends and two stiffeners. The unique bends allowed the fascia board to be shaped and designed in a way that would be pleasing to any homeowner.

The two stiffeners were incorporated to ensure the fascia board would be stable during storms and keep its shape without bending but the most important reason for the stiffeners was so that one person could install the fascia board on their own without any trouble.

Stainless steel fascia boards have become such a hit in townships and rural areas that many competitors have tried to manufacture their own design but constantly fail as they are too weak and not easy to install. Sello Senyatsi realised this and ensured he got a patent for his fascia board design.

MERIT Sello’s facia boards are a massive hit in townships and rural areas


CUTTING, BENDING & ROLLINGTO YOUR SPECIFICATIONS!


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S Rock Solid industries - WinnerEntrant: Mike Voss Stainless steel canopies in the construction, transport, commercial and leisure sectors.

Solar Primeg - Runner-upEntrant: Megandren Moodley 2304 duplex high pressure solar water heaters as a replacement for ferritic 444 as the material of choice.

Franke Kitchen Systems - MeritEntrant: Debra Holmes A hands-free basin system that incorporates a built-in metering valve that is activated when applying pressure against the facia.

5 Star Stoves Entrant: Willem Malherbe The first of its kind micro gasification stove, which uses biomass as a clean cooking process.

Solar Ray Entrant: Manuela Stewart Solar water heaters using grade 444 stainless steel.

Sello’s gutters Manufacturing Entrant: Sello Senyatsi The guttering components needed to go with the Sello’s stainless steel fascia board. The only company in South Africa that offers stainless steel guttering systems.

gerhard Unger Dairy Equipment Entrant: Gary CrawfordThe mayonnaise plant manufactured for Tiger Brands, through WSP, providing design, engineering and management consulting services in the built and natural environment. (Pictured below) Franke Kitchen Systems

Entrant: Debra Holmes An autopsy table designed in co-operation with the KZN Department of health and an architect to provide a cost-effective solution. (Pictured above)

Bar Keepers Friend Entrant: Jamie van Schoor Bar Keepers Friend is a 130 year old established brand for cleaning stainless steel surfaces with its non-scratching abrasive acidic based formula.

hC heat Exchangers Entrant: Hans Banza Heat exchangers produced in stainless steel, which allow for lighter construction.

ND Engineering Entrant: Nolan Green Stainless steel RDA units.

ND Engineering Entrant: Nolan Green A 60 ton acid cooler that was flown by aircraft to a client in New Caledonia.

Rimex Sa Entrant: Jason Naude The development of a stainless steel product for Sello’s Gutters.

FOURTH QUaRTeR, 2014

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Rock Solid Industries has developed an industry first using stainless steel for the manufacture of canopies for

various construction, transport, commercial and leisure industries.

Rock Solid Industries (RSI) was established in 2007 as a polyurethane coating specialist, which, through its involvement in the mining industry, felt it could compete in the niche field of service as well as the commercial and leisure canopy market.

RSI in collaboration with RidgeBack Marketing conducted a four month market research on the canopy market. What was discovered was that aluminium is the most commonly used material for canopies.

However, RSI manufactured 17 units using aluminium and field tested each one in various field applications. Over the following 4 months, the units were returned for various failures, such as, weld fatigue cracking, draws bent out of shape, and units no longer water and dust tight.

Through a process of research and development, RSI discovered that grade 409 stainless steel was a much better option. Corrosion resistance is significantly improved using 409. The stainless steel grade can be readily cold-formed by all standard processes and forces needed are similar to those for low-alloyed carbon steels.

Sheets are double folded creating a safety edge, improving component strength.

409 has low carbon and nickel contents, stabilized with titanium, which reduces or prevents weld sensitation and formation of martensite. The stabilization thus gives this ferritic steel good weldability.

From the Swakopmund Coast through to the intense corrugations of the Savuti, grade 409 has undoubtedly been the reliable “Rock Solid” choice for RSI.

RSI canopies have recently achieved Ford Global Approval and become AA Fleet Specified.

Stainless steel vehicle canopies

PRODUCTWINNER

ROCK SOLID INDUSTRIES

Why does a magnet stick to an RSI SmartBox?It is not unusual for items made with the 400 series stainless steel to be magnetic. The 400 series, which contains iron and chromium, but with lower levels of nickel.

Why use steel when its heavier than aluminium?Stainless steel is nearly 3 times the weight of aluminium, however it is a lot stronger. RSI opted for a 1mm thick material, laser cut and structurally bent in strategic areas for optimised strength. RSI now produces a weight comparable product with superior strength and carrying capacity.

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SUPPLY - Our comprehensive product range

SUPPORT - Design, selection and application of appropriate grades and materials

www.nde.co.za

NDE • since 1952 • international sourcing • national stock holding • prompt & reliable delivery • knowledge & advice • technical support

SOUTH AFRICAN BUSINESSPROUD PARTNER TO FOR OVER 60 YEARS

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SOLAR PRIMEG

Solar PriMeg has been manufacturing Solar Water Heaters since 1993. It is one of the oldest solar manufacturers in

KwaZulu-Natal and in the country. It is based in Durban, which remains its target market, but has units throughout South Africa. The company has exported units to four other countries.

Solar PriMeg was the first company in South Africa to introduce the non-pressure flat panel collector system as a local competitor to the imported products. This won the company the Innovation Award in the 2012 Stainless Steel Awards.

Solar PriMeg manufactures flat plate collectors only. This is a 100% local content product and it believes that this technology should be used as an alternative to the imported product. Solar PriMeg uses the highest quality stainless steel to manufacture the non-pressure, semi pressure and the high pressure solar tanks. All the conversion and welding is also done within its factory.

Solar PriMeg’s systems have passed SABS standards. The company works closely with Test Africa and the SABS testing labs and has continuously improved its solar system on both a quality and performance basis.

Move from Ferritic to Duplex Stainless SteelSolar PriMeg has been experimenting

with lean duplex material since 2010. An opportunity in 2013 saw the company use grade 2304 duplex in the production of its high pressure solar water heaters and found many benefits as compared with ferritic 444.

Solar PriMeg is the first manufacturer in the solar / water heating industry in Africa that is using the duplex 2304.

Due to the higher yield strength of 2304 duplex, Solar PriMeg was able to down gauge the stainless steel thickness from 1.5mm to 1.0mm. Duplex is almost double the yield strength of the ferrittic material which means using the duplex material was the same as using 2.0mm 444 material. This is an advantage as

Duplex used for solar water heaters

PRODUCTRUNNER-UP

the pressure tank is stronger and will therefore last longer.

By down gauging, Solar PriMeg has benefitted from a cost reduction point of view over the past year. Duplex is more expensive than ferrittic material based on a R/kg basic, but due to the reduction of the mass, the company was able to reduce about 30% of the cost on the components they converted.

The pitting resistance equivalent (PRE) value of the duplex 2304 is better than the PRE for 444. This translates to a more resistant product that offers better quality. This further translates to a longer life span on the solar system, saving the end user.

Solar PriMeg was also able to achieve

more finished product or number of sheets from a coil of material than previously. Due to the down gauging, assuming the coil weight remains constant, we are able to get 30% more sheets than using 444 at standard gauge. This translates to increased productivity and further reduction in operational costs.

Due to the higher yield strength of the duplex material, even with the down gauging the total material strength of the vessel was increased as compared to ferrittic 444.

This was a win, win, win, win situation for Solar PriMeg. It was very rare that a project such as this offered cost effectiveness with improved quality across multiple aspects of design together with increased productivity.

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Hand hygiene is central to preventing the spread of infectious diseases in home and

everyday life settings. Arising from the demand from the food sector, Franke has produced the latest “hands-free” basin system.

The basin incorporates a built-in metering valve that is activated when applying pressure against the facia. Optional hygiene accessories such as a paper towel dispenser, a sensor operated soap dispenser and stainless steel waste bin from Franke completes the hygiene system solution.

The Knee Operated Basin is manufactured in grade 304 stainless steel, with an integrated splash back.

The built-in metering valve supplies water on demand. The adjustable metering provides the perfect amount of water needed and can reduce water consumption by as much as 75%.

Hands free solutions provide convenience and hygiene facilities with high traffic levels. That is why planners and operators are increasingly going for the touch-free option when fitting out institutional sanitary facilities. Franke Water Systems demonstrates its competence in this field too, with numerous new developments.

Franke Water Systems manufactures 90% of products in its own factories.

The demand for the new basin is ideally suited for export into Africa where hygiene is a very high priority.

“We anticipate this market will equal the South African market by 2020 and will create several direct and indirect job opportunities, from the stainless steel mill, through the factory and up to the shipping vessel,” says Franke.

FRANKEKnee operated hospital basin

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Don Maxwell - WinnerEntrant: Colin Barnes, Columbus StainlessFor the market development of 3CR12 worldwide. The market development of 3CR12 coal wagons, stainless steel tank containers and stainless steel wine tanks.

John Cluett The contribution made by John Cluett on behalf of the brewing industry in South Africa for the development and use of stainless steel in various applications within the food & beverage industry.

hazleton Pumps Entrant: Mathys Wehmeyer For the design, development and manufacture of slurry pumps for the past 20 years.

hC heat Exchangers Entrant: Hans Banza For the production of heat exchangers since 1973.

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Folorunso omoniyi - Winner For a paper exploring high temperature oxidation resistance of thermally sprayed ceramic oxide on austenitic stainless as thermal barrier coatings.

Debra holmes / Murray Farquharson Entrant: Franke Kitchen Systems The design of a 3D of a bathroom for the “Franke Design a Bathroom Competition”. (pictured above)

Debra holmes / andrew Mboyi Entrant: Franke Kitchen Systems The design of a bathroom for the “Franke Design a Bathroom Competition”.

Siphiwesihle Memela The design of a multi-functional product that includes an ottoman with arm and back rest.

Ming Zhang An innovative process for making stainless steel to directly alloy in the process with chromium ore instead of chromium (ferrochrome).

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Don Maxwell has been awarded the Achievement Award in the 2014 Stainless Steel Awards for the market development

of 3CR12, as well as his life time contribution to development in coal wagons, tank containers, wine tanks and the South African stainless steel industry.

Don worked for Anglo American as a metallurgist from 1958 to 1960. He then joined Iscor in Pretoria and worked in research from 1960 to 1964. In 1964 he joined Rand Mines. He was appointed Sassda’s acting part time honorary secretary.

In 1964 he was involved in the technology to ‘make low carbon stainless steel’ - direct from rock - from low cost chromite ores.

In 1965 he was presented with a Sandvik Saw by the Chairman of Sassda, Eric Stansfield, for his services to Sassda.

He joined RMB Alloys in 1969 and later Southern Cross Steel where he was assigned to Frank Bath to work on the Southern Cross project.

In 1969 he was sponsored by Rand Mines on an MBA programme and left to work for Elgin Metal Products as marketing manager.

He returned to Southern Cross in 1971 as Sales Manager until 1973 and then became Manager of Market Development at MS&A from 1973 to 1982. From 1983 until 1995 he was the Managing Director of 3CR12 International of MS&A and then Columbus Stainless. In 1995 until his retirement in 1998, he was the General Manager Market Development at Columbus Stainless.

In 1972 Don Maxwell initiated the wine industry development programme where he persuaded the wine industry to replace mild steel wine tanks with stainless steel tanks (KWV and Nederburg Estates adopted this and today stainless steel has become the standard material of choice)

430 ferritic stainless steel was also introduced into the sugar industry by Ian

Elsdon-Dew which was the first time that 430 was used in plate form anywhere in the world.

But 430 proved difficult to cut and became brittle when welded.

Don Maxwell together with Eric Smith decided to take a chance on developing a stable dual phase - or duplex 12 Cr steel but it would take too long via the laboratories - so together with Ian Elsdon-Dew they persuaded the sugar industry to accept a ‘fit for purpose’ steel with a Cr variation of 12% to 17% to allow them to experiment.

This got the team off the ground with full scale production trials - while Hannes

Hoffman, Ken Dewar and Dave Martin patiently hunted for the magical second phase martensite in the laboratory which led to the development of 3CR12.

The name was developed by Don Maxwell and Leo Melvill - 3CR (stood for chromium containing corrosion resisting) 12 (stood for 12% of chromium) and so the name 3CR12 was born.

In 1997, Don presented a paper at Marichem 97 on 316L Tank Containers which was well received and enabled South African Tank Container manufacturers to maintain a global leading role.

JUDGESCOMMENTS“3CR12 is possibly South Africa’s greatest development contribution to the international metals market and is now manufactured and used across the globe. As an early developer of the global market for this utility stainless, we felt that the recognition of Don Maxwell’s contribution was well overdue.” - Peter Middleton

DON MAXWELLMarket development of 3CR12

ACHIEVEMENTWINNER



Stainless steel is an attractive material and has established uses in industry for a variety of applications, usually due

to its corrosion resistance and strength. Even so, research is still being conducted on steels to further enhance their properties and optimize their performance. However, given the diversity of applications for which stainless steel is suitable, it is not surprising that producers are continually developing new grades to meet the needs of particularly demanding applications.

• Austenitic stainless steel is a choice that is extensively used in the power plant generation, gas turbine and aerospace industries for high temperature applications.

• The application of Austenitic stainless steel as the material for components operating in a severe high temperature environments has been a concern.

• There is a need for power efficiency and durability in aircraft propulsion and electricity generation and a need for higher hot section temperature resistance.

Research proposalFolorunso Omoniyi developed a

research paper to study the high temperature oxidation and corrosion resistance of thermally sprayed ceramic oxide powders on austenitic stainless steel 316L as thermal barrier coatings as the means of improving engineering properties and advancement in the nanotechnology materials industry.

His research aims to:• Assess the high temperature

oxidation and corrosion resistance of ceramic oxide impregnated on austenitic stainless steel 316L.

• Investigate the possible chemical interactions between the coating materials and austenitic stainless steel 316L.

• Determine the phase transformations and their impact on the overall thermal barrier coatings.

• Establish a compositional improved structured alloy.

Austenitic Stainless SteelThe material of focus throughout this

project is austenitic stainless steel AISI 316L. Austenitic stainless steels are widely

used and well-known for their exceptionally high toughness, good ductility, formability and excellent corrosion resistance.

Austenitic stainless steels generally have better corrosion resistance than ferritic and martensitic steels. AISI 316L, is very widely used for its corrosion resistance, and generally has better mechanical properties, and corrosion resistance in certain environments.

FOLORUNSO OMONIYIThermal barrier coating

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S “Excellent theory, good presentation and practical application.” - Diego Sella “This research submission was thoroughly thought through and the presentation left us in a state of anticipation with respect to the possible outcomes.” - Peter Middleton“If the student can reach a favourable outcome, I am certain that there are many industrial applications that will benefit from this research.” - Nicolette Skjoldhammer


Stainless Steel Tubing is our business.

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5 Star Stoves - Winner Entrant: Willem MalherbeThe first of its kind micro gasification stove, which uses biomass as a clean cooking process.

Sello’s gutters Manufacturing Entrant: Sello Senyatsi Sello’s Gutters produces stainless steel guttering that offers sustainability and a healthy working environment for employees.

Ecovest holdings Entrant: Roland Meintjes EcoLite utilises 10 ton fly presses in a unique metal forming process to manufacture off grid stainless steel components.

hazleton Pumps Entrant: Mathys Wehmeyer The design, development and manufacture of Hippo slurry pumps in duplex stainless steel or specialised alloys.

hC heat Exchangers Entrant: Hans Banza The use of ammonia-based stainless steel heat exchangers for massive energy savings compared to other refrigerants.

Rimex Sa Entrant: Jason Naude The development of a stainless steel product for Sello’s Gutters.

Welfit Oddy Entrant: Andrew Gardner Stainless steel ISO tank containers. (Pictured below)


5 Star Stoves is the first clean cookstove business that has mapped and developed the entire value chain into a

single business model. Bio energy franchises densifies biomass into pellets and distribute it to its best-of-breed clean cookstoves, giving the energy-poor household a cost effective value proposition.

2.5 billion people cook on open fires and rudimentary stoves. This contributes to deforestation fuelled by the thirst for firewood and charcoal, causing mudslides and reducing environmental resilience to cope with climate change adaptation.

Constant exposure to smoke from cooking is one of the world’s biggest unknown killers, causing respiratory tract infections and lung cancer. Women are the hardest hit, being caregivers supporting households with their cooking needs.

5 Star Stoves aims to provide a new cooking solution delivered via bio energy franchises to energy-poor households.

5 Star Stoves developed its own 2 plate, all stainless steel (grade 430), micro gasification stove as a best of breed adaptive technology and it is well known as the most efficient way to extract energy from biomass. It is the only 2 plate, uninsulated micro gasification stove in the market and the driver of the business.

The company is based in South Africa, where the first demonstration project was delivered and is now in process with the first commercial pilot. The rest of Africa and South East Asia is queuing up looking for development funding to introduce this clean cooking enterprise to their countries.

The household saves time, cooking with a high output stove; cleaner pots mean less washing time and saving water. The fuel pellets are conveniently located to pick up on the way home.

The household saves money. The average 5 person household uses an equivalent of 250kWhe to cook per month

5 Star StovesA clean cooking solution

SUSTAINABILITYWINNER

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S “This project by definition is sustainability. From the recyclability of the stainless steel to the fuel, really a great product.” - Nicolette Skjoldhammer “A very practical product, easy to use, affordable and a clever use of recycled waste.” - Diego Sella “A very clever product with straight forward design for use in informal settlements more safely than other products.” - Luke Hartdegen

costing an average of R360. 5 Star Stoves aims to half the cost to R180 per month.

Three tons of CO2 is saved every year from making a switch in fuel sources or making better use of biomass resources. Now with less household air pollution people are healthier. The stove poses no explosion risk and the pellets are not toxic.

“We see 5 Star Stoves becoming a new industry standard for base of pyramid clean cooking,” says 5 Star Stoves.

The concept was developed out of the need to find inventive ways to support

agro processing for small farmers as a higher revenue option. This, coupled with the need to create enterprising opportunities, paved the way for the development of the propriety technology clean cookstove. The stove parts are currently patent pending.

The company has won a SEED Award and also achieved first prize in the National Cleaner Councils Adaptive and Appropriate Technology Award and was a finalist for two other Climate Entrepreneurial Awards in 2013, and has been short listed for three awards so far for 2014.


NEWS50th anniversary

The history of the AwardsFostering innovation, recognising excellence

The very first Stainless Steel Awards ceremony was held in 1998, and almost instantly

gained international recognition - even today, it is the largest event of its kind in the world. Although on the surface it is a glamorous banquet affair, it has at its heart a much more practical purpose.

Publicly recognising extraordinary achievements in a wide range of stainless steel industry categories has the effect of encouraging entrepreneurship, excellence, and development. As it is the premier event of its kind, a Stainless Steel Award is coveted around the globe - and indeed, many international companies have been known to enter.

Since it was introduced it has been held every two years, with the exception of 2010, when the executive director at the time felt that economic conditions caused by the global recession made it impractical.

Early events had a larger number of awards spread over many areas, but over time, they have consolidated into clearer categories that speak to Sassda’s development vision for the project.

Each ceremony year, Sassda selects an independent panel to judge the entries. Its members are chosen based on their knowledge of the stainless steel industry, and their experience working with the material.

Project AwardsThe Stainless Steel Project awards

are intended to acknowledge innovative use of stainless steel in structures. It is currently split into three subcategories, recognising achievements in Art, Architecture and Engineering.

Project Awards - ArtAppreciation of art is subjective, but

this award is given to an art project that uses stainless steel as its primary material, and is beautiful.

Project Awards - ArchitectureAny type of building or renovation may

be entered in the architectural category, but the structure in question needs to have used stainless steel as a significant aspect, with a focus on pleasing aesthetics, environmental and user friendliness, and as near to zero maintenance as possible.

Project Awards - Engineering

A project being considered for this award will need to have used stainless steel in a substantial way, but that use must also in some way push boundaries.

Although the awards in this category have had different names in the past, what has not changed is the remarkable nature of the projects that received them.

Take, for example, the very first recipient of the Engineering Project award. It was won in 1998 by Sappi Saiccor for a 3.5km marine pipeline they extended into the Indian Ocean that had a surface area of 9 900m2 and consumed a colossal 810 ton s of stainless steel.

Delta Interior’s work on upgrading Vodacom’s head office in Midrand won them the Architectural Project Award in 2000, and Bryco-Gutco took the honors in 2002 for their striking work beautifying the Cape Town International

Airport, introducing many elements that had not been manufactured in South Africa before. Both of these projects are instantly recognisable, and iconic.

Easy Engineering took Best Project in 2004 with breathtaking stainless steel domes for the Sibiya Casino, structures that arguably qualify as Art, Architecture, and Engineering rolled into one. In 2006, it went to HG Molenaar, for a remarkable project in which they developed a submarine rescue system for Nato. And Rebcon Engineering’s work cladding the Timeball Tower in Durban earned them Best Project in 2008.


2012 saw the arrival of the current category splits, which went to Metso ND for Engineering, with Marco Cianfanelli & Steven Roger-Lund scooping up both the Arts and Architecture awards.

Product AwardsThe intention behind this category is to

honour achievements in new product design, and it goes without saying that entrants need to have used a significant amount of stainless steel. When selecting a recipient, judges will favour products that are entirely original, or provide significant improvement over something that already exists in the market.

Less direct factors also play a role in their decision. A product may replace one that was less environmentally friendly, for example. Or perhaps the method of its manufacture may provide upliftment to an underprivileged community. Its ability to promote competition in the market would also count in its favour.

NDE Process Flow Equipment snagged the first Product Award in 1998 for their range of stainless steel centrifugal pumps, but Hazelton Pumps took the crown from them in 2000 for an innovative high volume vertical spindle pump designed to shift acid slurry. It was the largest pump that the SABS had ever tested.

In 2002, Sol-E-Qual was recognised for a unique sample analysis machine they’d built in stainless steel to streamline quality control on food production lines. Veritech took the award in 2004 for inventing a unique stainless steel cartridge filter for use in kitchen fume extractors.

Remkor Technologies received Best Product in 2006 in recognition of the stainless steel chairs they designed and manufactured for the departure lounge at Lanseria International Airport. And Impala Platinum Holdings took the award in 2008 for fabricating some massive autoclaves from duplex stainless steel instead of carbon steel,

an achievement so impressive that they also landed the Overall Winner Award that year.

Finally, the 2012 Product Award went to Turnstar for their attractive yet functional Speedstile Express building access control system.

Innovation AwardsTo win an Innovation award, an

entrant must have made use of stainless steel in a particularly novel or ground breaking way. Unlike the previous category, this doesn’t need to be the creation of a product (although it could be), but rather any act of ingeniousness that involves stainless steel.

Abtech was the first company to receive this award, which they won for pioneering a container filling system for use on production lines. Tenneco Automotive took it in 2000 for developing a hot rolling process that was unique at the time. They extended the remarkable approach to an oval hot roll process for tubing which they

AWARD FEATURES The first Stainless Steel Awards was held in 1998 and has been celebrated biennially since (except in 2010 when it was shelved). Each year the winners have been profiled in a special Stainless Steel magazine Awards Issue. The first 1998 issue is pictured on opposite page. Above from left are the 2000 issue, the 2004 issue, the 2006 issue. Pictured left are the 2008 and 2012 issues. Unfortunately the 2002 magazine is no longer in Sassda’s archives.

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entered in 2002, but were trounced by Starke Industries, who invented a rotary washing machine called the Big Dipper for cleaning stainless steel tubes in the automotive industry.

The award was discontinued in 2006, but reintroduced in 2008, when it was promptly snapped up by Hazelton Pumps, for their impressive Hippo High Voltage Flameproof Submersible Pump, a product they designed for the mining industry. And in 2012, it was given to Rebcon, for their excellent work on Moses Mabhida Stadium in Durban, which required the invention of an entirely new cladding system.

Student AwardsPart of Sassda’s mandate is helping

the stainless steel industry to grow. It makes sense, therefore, to recognise the achievements of students who hope to enter the industry. Originally, there was also a related award that acknowledged excellence in company training programmes, but this was discontinued in 2002.

The first person to win a Student Award was Victoria Milner, for designing

a unique pair of stainless steel scissors specifically for preschool children, that caters to the size of their hands and their ability to grip. Ryan Korten received the award in 2000, for designing a coloured stainless steel spiral staircase which was installed outside Red Pepper Studios in Johannesburg.

The Student Award took a hiatus after 2000, but was reinstated at the 2008 Stainless Steel Awards, when it was presented to Boipuso Isaac for his environmentally sustainable design for a portable art gallery built of recycled stainless steel. And in 2012 Duncan Badabili took the honour for his design of a mixed use development structure.

Achievement AwardsThe Achievement Award is only

ever given to individuals, not companies, and recognises extraordinary contributions to the stainless steel industry. It’s unique in that more than one Achievement Award has been conferred at each ceremony in the past awards.

Rather than celebrating a specific development or invention, this award pays tribute to people who have stayed in the

industry for the long haul, and through hard toil have helped it grow - people whose steady work has made a difference to the South African landscape.

It was first introduced at the 2008 Stainless Steel Awards, where it was bestowed on Dave Rowlands, Jack Moody, and Sakkie Nel. It next appeared at the 2012 Awards, and was given to Ian Elsdon Dew, and Dave Slater.

The Stainless Steel AwardsUltimately, once all category prizes

have been given out, a single overall winner is selected. The Stainless Steel Award is the industry’s top honor, and its recipients must be exceptional. The companies and individuals who have achieved this prestigious recognition are:

1998 - Consani Engineering2000 - Sustech Manufacturing2002 - Southern African Stainless Tank

Container Association (SATCA)2004 - Veritech2006 - H G Molenaar2008 - Impala Platinum Holdings2012 - Rebcon Engineering


NEWS50th anniversary

The history of the HFA The HFA has been around almost as long

as Sassda itself, but has been frequently renamed. At its inception, it was the

Heavy Fabricators Association (HFA), a group that represented aspects of stainless steel manufacture unique to fabricators.

During the 1990s, there was a certain amount of uphill from fabricators who weren’t quite so “heavy”, so the organisation became known as the South African Stainless Steel Fabricators Association (Sassfa). That’s something of a mouthful, though, and it was ultimately shortened to a much more manageable “Fabricator Sector”.

Given the frequent rebranding, and the fact that its members are often in direct competition, an outsider might be forgiven for assuming that this is a group beset by politics and infighting. But had they been in attendance at the recent HFA Luncheon held at the Bryanston Country Club, they would have been left in no doubt that they were witnessing a meeting of old friends and allies.

Among those assembled were men who had been there at the start, who shaped the course of the stainless steel industry, and whose life’s work has had an immeasurable impact on the South African economic landscape. Whatever the official name of the group may be today, to men such as these, it will always be the Heavy Fabricator’s Association.

Over the decades that the HFA has been active, it has steadily grown in effectiveness to the point where it’s recognised by the government and able to work hand in hand with them on policies and legislation. In addition to sitting on the committees of numerous stainless steel related organisations, the HFA is also an active member of the South African Bureau of Standards’ technical committee, where it helps to revise and improve the legal standards that apply to stainless steel fabrication.

This success is remarkable, and the work that the association does has benefitted not only the fabrication sector, but South African industry as a whole. Events like this luncheon bring past and present members together to talk

about their achievements, and to reconnect. It is also a time for reminiscing.

When old friends meet and wine flows, not every tale told is suitable for print, but some are. For example, Jack Moody, a former chairman of the HFA, regaled the attendees with stories of the fabricators’ tour of Europe in the 1990s. Diego Sella, so the story goes, has a prosthetic leg, and carries a spare when travelling in case of emergencies. Moody insists they use this to smuggle emergency vodka.

But among the ribald tales, there were serious observations too. Marco Boekhout is one of the youngest member of the group, with 4 years as chairman under his belt. Something of a controversial character, he is nevertheless straight talking. In his view, the biggest future challenge is also the oldest one: how to bring new blood into the industry.

This is arguably true, but if the achievements of the last 50 years are anything to go by, a centenary luncheon seems assured.

The 1979 HFA committee from top left are J Kirkman, N Newmann, D Rowlands, Duncan Veale, PMD Howroyd, Leo Melvill, G Burrill, LS Fiander, LJ Lalor, W Carter, RS Hemphill, H Whitty, and front from left are E Smith, H Rink, A Goodwin, GP Brown, B Smaller, HGJ van Vuuren and E Stansfield

The Fabricators Today Standing from left are Diego Sella, Lambert Peterson, Jack Moody, Marco Boekhout, Martin Zechner, Bill Scurr, Jonty Kirkman, Ken Dewar and John Tarboton. Seated from left are Bob Stevens, Sakkie Nel, Malcolm Veale, George Whittle, Neil Barnes and Gary Crawford


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prOFiLE50th anniversary

“This year, Sassda looked back at its first fifty years and celebrated its

achievements as an association. Its history is inextricably linked with the South African stainless steel industry and thus it has celebrated the history, personalities and achievements that have made this great industry what it is today.

Sassda reinvented itself several times over the past five decades as it has adapted to a changing business and political environment. Mistakes have been made and lessons learnt, and so it is helpful to look back at how Sassda has been forged and what it is today.

Sassda was formed in 1964 to bring stockists and fabricators together. A year later, the two publications for which Sassda is best known – the Stainless Steel magazine and the Buyers’ Guide – were first published. Sassda then acquired its first permanent director and shortly after, the first technical director. By 1970, Sassda had a staff of four and was already focusing on increasing stainless steel consumption in Southern Africa.

The creation of sectors followed, along with government lobbying on behalf of the stainless steel industry. The first stainless steel design competition was launched in 1972 and technical enquiries reached about 100 per month, increasing in the next three years to nearly 500. Seminars started being held and the Heavy Fabricators Association (HFA) was formed – several years later merging with Sassda.

By the mid-1980s, Sassda was offering non-technical courses, relaunched the Buyers’ Guide and started to embark on export drives. In the late 1980s Sassda started getting involved in artisan training, Sassda Sports Days were introduced and Sassda got involved in education at universities and technikons.

In 1992, the Information Series was published and a 2000 Vision was formulated to plan for the political transition. 1996 saw

the start of compiling and maintaining industry statistics and Sassda worked closely with the dti and IDC to enhance manufacturing competitiveness. Member numbers and stainless steel consumption continued to show strong growth until the financial crisis in 2008.

Following the crisis, the strategy of Sassda resulted in an inward-focused association, the sectors were discontinued and Sassda arranged itself into functional silos and regions. Collapsing global demand resulted in low-priced finished product imports. The introduction of a roadshow using a fitted out pantechnicon was unsuccessful. The Stainless Steel magazine was terminated and training course costs increased to make them an income generator.

As a result of this change in strategy, Sassda lost sight of its original purpose and mission. It was time to examine what had made Sassda successful in the past. So, in 2012, Sassda adopted a back-to-basics programme with the 5Rs: Reinvigorate the sectors; Refresh education and training; Reinforce the technical profile; Rebalance

government interaction; and Resurrect Sassda’s visibility. The last issue of the magazine detailed how the 5R strategy has been successful implemented and has put Sassda back on solid ground.

Where does Sassda and the stainless steel industry find ourselves today? In a very different territory to the pre-crisis decades. Since 2008, administered price increases, especially electricity prices, have far outstripped inflation, while the ease of doing business in South Africa has become more onerous and difficult. Recent work by the dti has shown that South African industrialisation peaked in 1982 and deindustrialisation has accelerated in the last decade. This needs to be reversed. Wage increases need to be moderated, exports diversified, red tape cut and taxation tailored to increase investments. On the positive side the infrastructure investment

programme (the PICC and the SIPs) could act as a stimulus, as could exploitation of the Karoo shale gas reserves. Also, Africa is the next economic frontier and South Africa can and must capitalise on the opportunities that this presents.

Thus Sassda and the stainless steel industry find themselves in a new challenging space, but not unlike that of other metal industries in South Africa.

Sassda must build on the solid foundation that we have built, established by the implementation of the 5Rs, to take Sassda to the next level. To achieve this, the Sassda Main Committee will be holding a strategic review in November. Our plans, projects and programmes will then be developed, communicated and implemented.

To quote the most popular American poet of his day, Henry Wadsworth Longfellow: ‘Look not mournfully into the past, it comes not back again. Wisely improve the present, it is thine. Go forth to meet the shadowy future without fear and with a manly heart.’”

Executive director John Tarboton considers then, now and into the future

overall awards 2014 - sassda steel... · you’ve earned your reward and long may you continue to...

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