Transnet Expansion Program - Ore Line Expansion Rail - Phase 1A and 1B

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 ongoing 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
  
  • 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.

Scope of Services
A joint venture between Hatch, Mott Macdonald, and Goba is acting in an EPCM role to manage the project. The scope of services includes 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 861 km length of the line.

Works were undertaken whilst achieving increases in the throughput on the line.

Interdisciplinary checking and hazard assessments were completed.

Project Highlights

• 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
  
• Phase 1C (expansion 47-60 mtpa) approved November 2008
  
• Assisted the principal contractor, Concor, with its ISO 1800 accreditation
  
• Materials used: Rail - 132 km, Sleepers - 103 000, Ballast - 198 000 tonnes, Wiring - 1 300 km, Masts - 7 200

Project Safety

• Last LTI in October 2007; 12 months LTI free (1 756 439 work-hours)
  
• Workforce peak : 1462 persons