The Kalagadi Manganese project is consistantly making headlines the world over. Investors and stakeholders will be thrilled to know that all areas of development are progressing steadily, despite the setbacks. Please follow the link below for a more detailed breakdown of infrastructure development.

RAIL LINK: 23% COMPLETE

Kalagadi is required to design and build a 19km railway siding that will connect to the Kudumane siding and ultimately to the main Manganese corridor line from Hotazel to Port Elizabeth.

An Engineering and Construction Management contractor for the railway project was appointed.

Detailed engineering design has been finalised allowing the company to go out on tender for the construction of the works. The work was awarded to a construction contractor in late October 2012 for an amount over R300 million.

All preparatory work for the construction of the rail spur has been done and the contractor has successfully established on site. The necessary permissions from the Railway Safety Regulator have been obtained.

Transnet Freight Rail has approved the design with the environmental authorities granting permission for the removal of protected vegetation along the planned route.

ELECTRICAL INFRASTRUCTURE: 85% COMPLETE

The Ferrum to Umtu Farm 132 kV line

The line design was amended to twin Tern conductor, single pole structure. Design has been completed; and Implementation contractors were appointed and construction has progressed extensively; Commissioning of the line is expected to be in April 2013.

The total power requirement for Kalagadi to sustain production is 35MVA. To support construction activities of the mine complex, Kalagadi requires about 10MVA. Eskom committed to make available only 3MVA to Kalagadi Manganese during the construction phase, while additional power could be made available only after the construction of the power infrastructure from the Ferrum substation. To access the 3MVa Kalagadi had to build a power line from the Hotazel substation to the Umtu substation. This installation was completed in March 2010, and the power was switched on in November 2010.

Kalagadi Manganese was also compelled to build power generation capacity to support construction activities, and subsequently installed diesel generators with a capacity of 9MVa. This installation was completed and commissioned in March 2010. Eskom is currently project managing the construction of the 70km line from Ferrum to Umtu to supply the 35MVa. The EIA process was concluded, with authorisation granted in September 2010.

Umtu to Ferrum - Substations:

  • Ferrum Transmission feeder bay has been completed;
  • Umtu Transformers have been delivered to the Umtu substation;
  • Construction on the Umtu substation is advancing as indicated below;
  • Platform earthworks have been completed and signed off by Eskom;
  • Both transformer runways have been completed;
  • Relay room construction is progressing and is nearing completion;
  • 11KV side plinths have been completed;
  • Earth mat is at 90% completion, only awaiting tails;
  • Steel erection is at 80%;

ROAD: 65% COMPLETE

Kalagadi Manganese is also building a road that connects the mine to the main road R380. The mine road is 9.5km long and is principally along the old R31 road to Van Zylsrus. The EPCM has completed the design engineering work, and the designs have been approved. Construction commenced in 2011 and has advanced considerably.

MINE: 68% COMPLETE

As part of the project, Kalagadi Manganese sank two shafts, the main shaft and a ventilation shaft. Head gears of both Main and ventilation shafts were completed in 2009 and good progress has been made in sinking operations.

Production level of the mine will be at ~280m, and sinking on the vent shaft has reached shaft bottom. Sinking on the Main shaft has also reached shaft bottom. The mine will be operational around end of quarter 4, 2013.

The expected completion of the surface infrastructure is October 2013.

SINTER: 98% COMPLETE

Engineering Design

Engineering design on the Sinter Plant has reached 100% completion. A final design package and as built drawings will be issued to Kalagadi once commissioning is complete.

SINTER

Construction

Overall completion of the Sinter Plant is 98%. This takes into consideration, the construction progress of 97% and Engineering completion of 100%. Electrical and Instrumentation installation has reached the 80% completion milestone. The commissioning process has commenced on the Sinter building albeit with minor snags on the electrical side. The Sinter plant will be ready to receive material feed by mid April 2013 pending the finalisation of Eskom full load power supply.

All construction works is expected to be completed by end of November 2013. The commissioning and handing over of the plant is scheduled for 12 December 2013

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