AFRICAN FUSION—MARCH2014
7
Genrec company profile
nent. “This helps throughput, because
the requirements are accessible to
inspectors anywhere at anytime. More
importantly, it helps to achieve consis-
tency,” he argues.
Asadirect result of theMedupi and
Kusile boiler structure contracts, Gen-
rec has completed an optimising and
expansion drive to increase the capac-
ity of its current facilities inWadeville.
The total undercover workshop area
has been increased to 55 000m
2
and
a further 19 500 m
2
of open area is
also under crane. Modern Computer
NumericallyControlled (CNC)andweld-
ing equipment as well as high volume
blasting and painting equipment have
been installed. The new resources,
equipment, training and logistics addi-
tions increase capacity from2000 t to
about 3 500 t per month, depending
on steel complexity.
One of the key factors of this
expansion drive has been the skills
development. The new training facility
provides development and training of
boiler-makers,detailers,CNCoperators,
welders, riggersand inspectionperson-
nel. “Over the past four years, we have
trained and qualified 11 Red Seal ap-
prentices and187 in-house artisans in
their respective trades. We are also in
discussions with SAISC about hosting
its drafting school on our premises,”
Mamotte reveals.
Quality certification
Genrec has ISO 9001: 2008, ISO
14001:2004,BSOHSAS18001:2007,
ISO/SANS3834Part 3 andAPI ISP/TS
29001 certifications. “These are all
‘must-haves’ foranycompanywishing to
compete on the international stage. All
clientswith global links require fabrica-
tors towork to international standards,
and certification gives clients the confi-
dence thatwecandeliver toanyquality
standards required.”
Mamotte says that ISO9001 is the
general quality management frame-
work formanufacturers. “Butwe
alsohaveAPI 29001accredita-
tion, the quality management
system for the design, develop-
ment, production, installation
and service of products for the
petroleum, petrochemical and
natural gas industriesalongwith
ISO 3834 that defines welding
specific quality requirements.
He sees ISO 3834 as “an
extension of ISO 9001”, with
regards to thecontrol ofwelding.
“While ISO 9001 is a company
wide quality management sys-
tem, ISO3834 is an addendum
that specifies how to achieve
quality fabrications and how to
control welding related activi-
ties,”Mamotte explains.
“We have always had a low
reject/repair rate on thewelding
side because of our extensive
useof submergedarcprocesses,
for example, but since adopting
ISO 3834, we have improved
that even further. By examining
all the activities necessary to
produce a weld, from contract-
ing to set-upand through to final
inspection, you tend to become
more aware of quality issues.
If, for example, you have to do
a full penetration weld, then
pre-work prior to welding is
important. ISO3834 insists that
the necessary process steps are
brought toattentionandproperly
implemented,” saysMamotte.
On theweldingprocess side,
he says that automatic or semi-
automatic submerged arc weld-
ing is preferred for heavy work,
while gas metal arc and flux-
cored arc welding predominate
for manual welding. “Some of
our boilermakers prefer to use
sticks for tacking, but for weld-
ing, we prefer more productive
processes,” he adds.
Critical welds are tested
ultrasonically, and all welds are
visually inspected, mostly with
the help of magnetic particle
testing. Inaddition to the inspec-
tion app, Genrec has also added an
app-based track-and-trace capability
to its offering. “Some fabricated steel
needs to be stored for long periods
before onsite construction begins. This
app allows any fabricated steel com-
ponent to be located, at any time, via
GPS co-ordinates thatwill direct one to
the exact lay-down location of an indi-
vidual structural component,”Mamotte
informs
African Fusion
.
“Because of the requirements of
theMedupi andKusileprojects,weare
Genrec capabilities
• Total project management.
• Design & detailing.
• Light,medium&heavystructural
fabrication.
• Planning & programming.
• Heavymachining.
• Blasting and painting.
• Trial & pre-assembly.
• Logistics and transport.
• Steel erection.
• Site services.
• Steel track and trace.
• Quality assurance, control and
inspection services.
On the welding process side, semi-automatic submerged arc
welding is preferred for heavy work.
One of the column base components for theMedupi Power
Station’s boxed column supports, which had to be fabricated to a
dimensional tolerance of 2,0mm.
Because of the very heavy section steel being welded, preheating
and interpass temperature control are essential components of
most welding procedures.
now geared up to do complex work to
the highest global quality standards.
We have generated some fantastic
systems and improved our capacity,
competitiveness and quality. We are
currently looking at a range of new
product opportunities and are excited
about the exploration work we have
done so far.
“Our company is synonymous with
fabricated structural steel and we be-
lieve it is time to expandanddiversify,”
Mamotte concludes.