A key player in construction in South Africa’s renewable energy sector, Concor is delivering its first fully wrapped Balance of Plant (BoP) contract at the TotalEnergies Renewables De Aar 2 South Wind Energy Facility, taking full responsibility for the engineering and construction of the civil and electrical BoP under its management. This benchmarks a new approach in the sector, to streamline delivery and reduce risk and it reinforces Concor’s position as a provider of turnkey BoP solutions.
Concor has embarked on its first fully wrapped Balance of Plant contract - covering both civil and electrical works - at the De Aar 2 South Wind Energy Facility.
As well as being the main contractor for the 25-turbine project which reaches across five farms near Philipstown, Concor is responsible for both the Civil BoP (CBoP) and Electrical BoP (EBoP) – from design and engineering to execution, including the Eskom Distribution self-build scope. This comprehensive approach moves beyond traditional contracting models, as Concor evolves to become a true turnkey BoP provider.
“With over 13 years’ experience in renewable energy infrastructure, more than 10 wind farms successfully completed since 2012 and a further six wind farms currently in various phases of construction, Concor is no stranger to the demands of this sector,” says Stephan Venter, Contract Director at Concor. “But this project sets a new benchmark. Taking full responsibility for both the engineering and construction elements, we are reducing interfaces, improving accountability and de-risking the process for our clients.”
This strategic shift positions Concor at the forefront of renewable energy project delivery in South Africa, offering clients a streamlined, single-source balance of plant solution that enhances coordination and delivery certainty.
Civil works
The 5 473 hectare facility is on a fast-track programme, with early works launched in November 2024 and completion scheduled by Q3 of 2026. The company’s scope includes 54 km of gravel road infrastructure, starting with the realignment and upgrading of 15 km of the existing Kranskop district road to accommodate heavy turbine components. Additionally, 41 km of new internal access roads are being constructed, supported by extensive blasting and cut-and-fill earthworks to adapt the local terrain.
A key innovation is in Concor’s design for the turbine foundations. A central pit, seven metres in diameter and filled with G7 material, has been incorporated to address the geological challenges of the region and reduce stress on the 22-metre diameter concrete bases. Each foundation uses 600 m³ of specially designed readymix concrete, batched on-site at two new modified 45 m3/hr Karoo plants to ensure consistency and quality. Smart rock sensors embedded in the foundations monitor internal temperatures, allowing real-time adjustments to mitigate the risk of thermal cracking.
Electrical works
As part of the electrical balance of plant (EBoP), Concor is responsible for trenching and laying 13 km of 33 kV medium voltage cabling from each turbine’s Power Transformer Kiosk (PTK) to a termination overhead line (OHL) structure. This is linked via an extensive 80 km 33 kV OHL network to the IPP substation, which steps up the voltage to 132 kV using a 165 MVA power transformer. The project also includes the construction of a new adjacent Eskom Distribution 132 kV Switching Station (SWS) and an extension of a 132 kV OHL to an upstream Eskom Main Transmission Substation (MTS).
The project has not been without challenges. A high water table impacted 11 of the 25 turbine bases, requiring the installation of subsoil drainage systems. In addition, heavy seasonal rainfall necessitated robust stormwater management to protect the access and internal roads.
Environmental compliance has remained central to Concor’s operations, guided by the Environmental Management Programme Report (EMPR). Teams receive regular training to uphold environmental protocols and safeguard heritage and biodiversity in this sensitive landscape.
“Our execution reflects Concor’s depth of experience in remote, large-scale projects,” says Project Manager, Gideon Niemand. “We are delivering to the highest standards, with environmental responsibility and engineering excellence at the core of what we do.”
With innovative engineering, efficient planning, and environmental stewardship, Concor is helping shape a more sustainable energy future.
For more information visit: www.concor.co.za