Pandemic partnerships: How COVID collaboration fuelled project success
ND Engineering showcased resilience and innovation through its involvement in Sappi Saiccor’s Project Vulindlela - despite the challenges of the COVID-19 pandemic.
The project, located in Umkomaas, KwaZulu-Natal, was primarily driven by the need for environmental improvements coupled with an increase in production. ND Engineering’s innovative use of duplex stainless steel and the on-site workshop were pivotal to the project’s success, which earned the team a runner-up spot in this category at the 2024 Sassda & Columbus Stainless Awards.
Strategic on-site workshop: a game changer
One of the most innovative aspects of ND Engineering’s involvement was the establishment of a 2 000 m² manufacturing workshop on Sappi’s premises. This decision allowed ND Engineering to expand production capacity to 12 000 m², combining this facility with an existing workshop in Hammarsdale, KwaZulu-Natal.
The on-site workshop not only increased capacity but also led to significant cost savings by reducing the need for abnormal road transport loads. The fully functional workshop, complete with two 20 tonne overhead cranes, was handed over to Sappi, reflecting ND Engineering’s commitment to long-term client relationships.
The workshop also facilitated local community involvement, allowing ND Engineering to offer comprehensive training programmes to local residents. Many trainees were later employed full-time, aligning with Sappi’s local training goals and enhancing the project’s overall impact.
The role of duplex stainless steel: engineering precision
Duplex stainless steel was central to Project Vulindlela. It was chosen for superior strength, corrosion resistance and cost-effectiveness. ND Engineering used 1,525 tonnes of duplex stainless steel throughout the project, demonstrating expertise in handling this specialised material. Using this grade enabled reduced vessel thickness without compromising structural integrity, which was critical for the high-pressure environments of the project.
One of the outstanding applications of duplex stainless steel was in the construction of large digesters, which are essential for pulp production. The material’s high strengthto- weight ratio enabled more efficient construction, reducing material costs and assembly time. This extensive use of duplex stainless steel also contributed to a significant increase in local stainless steel consumption, boosting the regional economy.
Overcoming challenges with innovation
Project Vulindlela began in 2019 and faced numerous challenges, especially the global COVID-19 pandemic. Despite these obstacles, ND Engineering’s innovative approach ensured it was the first large contractor to sign off and close out contracts without penalties. GM Mark Ackerman comments: “Navigating through the COVID-19 pandemic was one of our biggest challenges but our team’s dedication and the strong partnership with Sappi’s management made all the difference. Strategic decisions, like setting up the on-site workshop, were crucial to maintaining our timelines and delivering high-quality results”.
The on-site workshop allowed ND Engineering to construct most equipment in large sections transported to site using self-propelled modular trailers. This approach minimised the need for multiple transportation loads, enhancing safety and efficiency. ND Engineering also offered design expertise to address vacuum and pressure relief system challenges on larger vessels.
ND Engineering’s involvement in Project Vulindlela exemplifies its commitment to engineering excellence. Innovative use of duplex stainless steel, the strategic onsite workshop and ability to overcome pandemic-related challenges have set a new industry benchmark.