The Phase 1A and 1B project will increase the capacity of the heavy-haul freight railway, the Ore Line.
The objective of the project is to increase the ore-haulage capacity of the iron Ore Line between Sishen and Saldanha from 29 to 47 million tons per annum (Mtpa).
The project includes:
- Extension of loops to allow for the increase in train length from 228 wagons to 342 wagons including extension of passing lines on 19 loops, a new loop at 7a, and a maintenance line at Loop 10
- Salkor yard including earthworks, perway, sets, culverts, relay room/buildings, and services
- New electronic locomotive maintenance workshop at Salkor Yard including office and storage facilities; an effluent
treatment plant; sand drying and filling equipment; compressor and vacuum facilities for testing locomotives; water
and oil storage facilities; high-mast lighting; and hard-surface access roads within the depot
- Formation repairs at various sites throughout the ore line
- Power upgrade including a new feeder line for 860 km and feeder substations that expand across the entire ore line with approximately 11 000 new masts
A joint venture between Hatch, Mott Macdonald, and Goba acted in an EPCM role to manage the project. The scope of
services included extensive remodeling and expansion of an existing yard; extension of 19 passing loops; the provision of a complete new passing loop and maintenance facilities; formation repairs; and includes the provision of a new feeder line
along the 860 km length of the line.
Works were undertaken whilst achieving increases in the throughput on the line.
Interdisciplinary checking and hazard assessments were completed.
- 2008 shut completed with zero lost-time incidents (LTI) with more than 2 500 000 hours worked
- 18 loop extensions handed over for beneficial use by October 2008
- 100th 342 wagon train traveled down the line in July 2008
- Phase 1C (expansion 47-60 mtpa) approved November 2008
- Materials used: Rail - 132 km, Sleepers - 103 000, Ballast - 198 000 tonnes, Wiring - 1 300 km, Masts - 7 200
- Last LTI in October 2007; 12 months LTI-free (1 756 439 work-hours)
- Workforce peak: 1462 persons
