M&D Construction Group continues to demonstrate that it can be relied upon to execute technically complex mining infrastructure projects according to scope, time and specification. This is facilitated by the Group’s ability to always “Find the Best Way”, a M&D core value that promotes continuous improvement; innovation; and problem-solving to eliminate inefficiencies and bolster productivity.
A sound example of “Find the Best Way” in practice is the Gamsberg Concentrator Project, for which M&D has provided world-class civil-engineering construction services. The company helped to fast-track the civils component of the first phase of the project, encompassing the flotation plant, as well as infrastructure in the milling zone and thickener area. Based on this strong performance, Vedanta Zinc International (VZI) entrusted M&D with the civil-engineering construction scope of the subsequent phase.
Located in Aggeneys, Gamsberg is the largest zinc project in the Northern Cape. Together with the mature Deeps and Swartberg mines, it is part of VZI’s Black Mountain Complex. Gamsberg Phase II Concentrator Project aims to double mining capacity from 4-million tonnes to 8-million tonnes annually and increase zinc-in-concentrate output from 300kt to 500kt per year. It is an extensive undertaking that has also entailed constructing complicated reinforced concrete structures. These are for the gyratory crusher; flotation plant; filter press; and thickener, in addition to the stockpile tunnel and milling infrastructure.
Furthermore, as per VZI’s request, they were built in monolithic pours to satisfy the design. This while also ensuring robust final structures that will be able to withstand the harsh mining applications and environmental conditions in which they operate. These include, among others, dynamic loading; fluctuating temperatures; and corrosive substances.
M&D achieved the first major 1 090 m3 concrete pour only eight weeks after contract award. Successfully navigating VZI’s onboarding requirements on a project site that is located 1 000 km from M&D’s headquarters in Johannesburg took extensive preplanning.
Gawie van der Merwe, the M&D Contracts Manager, says that built to the highest possible quality standards, these structures will continue to add value for many years and bear testament to the depth of the group’s concrete construction skills and expertise. “For example,
the pedestals of the semi-autogenous grinding and ball mill required various levels of formwork to a 13m maximum height. Furthermore, large items were cast into these structures to very high tolerances. A case in point is the 46 mm diameter bolts that were suspended in the air and held in place during the concrete pours, the largest of which was 750 m3,” Van der Merwe says.
M&D Divisional Head, Niekie Wagener, says the flagship structure, which will house the gyratory crusher, stands 30 m high and consists of six intermediate heavily reinforced decks. “Its internal and external walls between deck levels and the decks were cast in single lifts. Due to the size of each deck, back propping was required from ground to top level. All cast-in items were positioned to the highest tolerances to ensure that the mechanical equipment fits per design,” Wagener says.
An M&D batching plant was mainly used to produce the large quantities of concrete required for the construction of the structures. When required for the construction of the very large structures, additional concrete was supplied by a ready-mix company within the vicinity. Material for concrete production was sourced locally.
About 40 000m3 of concrete was placed to construct the structures, with extensive use made of a 40 MPa pump mix, which was developed by Concrete Proficiency.
High productivity was maintained despite extreme weather conditions in the area that vary between -2°C to 48°C. “Working in these conditions required careful planning especially considering the large quantities of concrete that we were placing. We poured and cast concrete in the late afternoon and evening when it was cooler and used the daylight hours to undertake finishings. This ensured optimal curing and prevented issues such as cracking and reduced strength,” Van der Merwe says.
The concrete was transported from the batching plants via six concrete mixer trucks, each with a capacity of 6 m3, and poured with a 42 m and 36 m concrete pump. They are part of the large fleet of equipment that M&D procured specifically for this project. This large investment made into critical plant and equipment has played an immense role in the impressive performance on this project thus far. M&D Plant has again provided robust technical support to ensure high equipment availability and fuel-efficient operation.
As another example of how M&D strives to always “Find The Best Way”, only material that complied with the group’s own ethical and sustainability practices were sourced for concrete production.
The more than 50 000 t of aggregate for concrete production was sourced from SPH Kundalila. This is considering the open-cast mining, as well as crushing and screening experts’ focus on reducing its carbon footprint by primarily using solar energy to power its quarrying operations.
Furthermore, SPH Kundalila is a licensed aggregate and sand producer, signalling to M&D that all materials sourced from this supply-chain partner have been mined legally. To be awarded aggregate and sand mining rights by the mining authorities, operators need to abide by strict environmental, as well as health and safety regulations
Cement was sourced from AfriSam, which is also committed to reducing the carbon footprint of its operations. This is by using recycled materials and energy-efficient processes in cement production. A significant portion of concrete’s embodied carbon is derived from cement production, including clinkering, which accounts for a large percentage of global CO2 emissions.
With the structures now practically complete according to schedule, the follow-on contractors have started to undertake the electrical, mechanical and structural mechanical piping installations. M&D worked closely with the client to accommodate its access and budget programme. As a flexible contractor, M&D was also willing and able to adjust its programme whenever required for follow-on contractors to start their preparatory work earlier. This also helped to nurture good team dynamics between the various project stakeholders.
M&D has since commenced constructing the plant road network. It consists of gravel access roads to the operation; paved roads within the plant for operations and maintenance; and heavy-vehicle haul roads with South African Roads Agency Limited-specification continuously reinforced concrete pavements. This is in addition to the vast drainage network, a complex system that separates stormwater and plant product for recovery, as well various secondary structures, including the electrical sub-stations.
These components of the project will be completed by mid-December 2025, bringing the 25-month civil-engineering construction contract to a close. Just under 400 people were employed to work on the project when it peaked. To optimise work and travel time on this remote construction site, they agreed to work seven consecutive weeks and followed by a week’s leave satisfying Department of Mineral and Resources and Energy’s (DMRE) oversight.
They have all made an invaluable contribution to the success of the project thus far. This includes undertaking their respective roles in a healthy and safe manner, in line with M&D’s first unwritten-ground rule (UGR), “Around here, Safety begins with Me”. Supported by M&D’s Safety Behavioural-Based system, this UGR makes all employees responsible for creating a safe working environment. They identify risks and safe practices which are documented, evaluated and then shared with all team members to constantly improve site health and safety practices.
This approach has once again been a resounding success. On 29 January 2025 at 10am, the M&D team achieved 1-million lost-time injury-free manhours on the Gamsberg Phase II Concentrator Project. By mid-April 2025, the team was only two weeks away from achieving 731 LTI-free days.
VZI achieved 824 LTI-free days, of which the M&D team contributed 655 LTI-free days, on 31 January 2025. This major milestone was celebrated at an event on the day that was also attended by DMRE acting Principal Inspector of the Northern Cape, Sifiso Gumede; VZI’s Chief Operating Officer, Jacques van Tonder; Rukesh Raghubir, Chief-Executive Officer of M&D; and Wagener. Van Tonder lauded the entire M&D team for its commitment to health and safety, with the following employees receiving accolades for their contribution to upholding the highest possible health and safety standards on the construction site:
- Van der Merwe for outstanding safety performance
- Rooksaar Singh for experiencing the most growth our of all the individuals working on the project
- Roxane Vece for being the best Contractor Safety Officer
- George Radebe for his top performance as Supervisor
- Eddie Makgeledise for his outstanding role as a SHE Representative
- Onele Pentene, a M&D Safety, Health and Environment Representative, for her responsible reporting of a Mine Health & Safety Act Section 23 and ordering work to stop at the crusher due to excessive dust.
“Our people are behind our success. They bring skills, experience and, just as importantly, the motivation needed to drive productivity and efficiency and ensure quality and safety. As a tight team, we have always been able to ‘Find the Best way’. And when we grow and prosper, our employees succeed in the true spirit of Khula Nathi!” Raghubir says.
